Earmold for improved retention of coupled device

FIELD OF THE INVENTION

[0001] The present invention relates to the field of devices used to hold audio devices at the opening of a user's ear.

BACKGROUND OF THE INVENTION

[0002] Various types of earmolds are manufactured in the prior art, primarily for use with hearing aids, communication devices and portable audio systems. Most existing earmolds rely on a deep and tight insertion into the ear canal for providing stability of the device in the ear. This type of deep and tight insertion tends to cause painful rubbing of the insert against the ear canal and also can have the effect of sealing the ear canal. As a result, the user experiences irritation and discomfort, particularly after many consecutive hours or days of use. Sealing the ear canal has dangerous implications to the wearer. It will also affect a person's ability to hear ambient sound by reducing the intensity of the sound. It will alter a person's ability to localize sound, particularly in the high frequencies where interaural sound pressure differences are the primary cue for localization.

[0003] U.S. Pat. No. 5,659,156 (“the '156 patent”) solves most of the foregoing problems of such prior art devices. However, the earmolds disclosed in the '156 patent sometimes come loose from the speaker, communication device, hearing aid, etc. (referred to herein as an “audio device”) to which they are coupled.

SUMMARY OF THE INVENTION

[0004] The present invention addresses numerous shortcomings of prior art earmolds. Preferred earmolds according to the invention include a first protrusion to secure the earmold to a user's ear, a cavity shaped on a first side to receive an audio device and shaped on a second side to fit within the user's outer ear (a “second protrusion”), and at least one retention flap for securely retaining the audio device.

[0005] Preferred embodiments include two or more retention flaps disposed around the perimeter of the first side of the cavity. Preferably, the retention flaps do not extend around the entire perimeter of the cavity, but instead are discontinuous. Such discontinuity allows for easier insertion and removal of the audio device, while holding the audio device more securely than earmolds of the prior art. These retention flaps may be formed in a variety of shapes, including but not limited to arcuate shapes, triangular shapes and trapezoidal shapes.

[0006] In some preferred embodiments, a user engages the first protrusion of the earmold by inserting the earmold into the ear and then rotating the mold so that this first protrusion rests under the crus of the helix of the ear. In other embodiments, the first protrusion contacts a different portion of the outer ear.

[0007] The second protrusion conveys sound from the speaker into the user's ear canal. Preferred embodiments of the second protrusion require only a very shallow insertion (approximately ⅛ inch in some embodiments) into the user's ear canal. In some embodiments, the earmold is held in place by the first protrusion and/or other features such that the second protrusion does not contact the ear canal. In other embodiments, the second protrusion lightly contacts a portion of the ear canal. In yet other embodiments, the second protrusion contacts opposing sides of the ear canal.

[0008] Preferably, no seal is formed between the second protrusion and the ear canal. Accordingly, some preferred embodiments of the second protrusion include an ear canal insert vent on the second side to prevent a pneumatic seal from being formed in the ear. Some preferred embodiments include a sound bore which penetrates from the first side through to the second side. Accordingly, when these embodiments of the invented earmold are used, complete occlusion of the ear canal is prevented, thereby minimizing the amount by which a person's ability to hear ambient sound is diminished when wearing the inventive earmold. As a result, a person's ability to localize sound is maintained.

[0009] The invented earmold's profile follows the curvature of the ear canal. By following the curvature of the ear canal, the user's comfort is greatly improved. Moreover, preferred embodiments of the present invention include a notch in the earmold which provides relief to a user's antitragus. Relief to the antitragus is important to prevent compression of tissue at the antitragus and to avoid associated discomfort.

[0010] Some preferred embodiments include markings for reference by the wearer to ensure proper orientation of an audio device.

[0011] Some preferred earmolds are composed of soft plastic material and others are composed of an elastomeric material or other material. Some preferred earmolds are composed of polyvinyl and/or silicone.

[0012] Some embodiments of the present invention provide an earmold for holding an audio device near a user's ear, the user's ear comprising an ear canal and an outer ear, the earmold including: a cavity formed in a first side of the earmold, the cavity configured to receive at least a portion of the audio device; a first protrusion extending from a second side of the earmold and configured to engage a portion of the user's outer ear; a second protrusion extending from the second side of the earmold and configured to be positioned proximate the user's ear canal; and a plurality of retention flaps extending from an edge of the cavity towards an interior of the cavity to secure at least a portion of the audio device within the cavity, the retention flaps extending around only a portion of a circumference of the cavity. The inventive earmold preferably includes a sound bore having a first end inside the cavity and a second end proximate a tip of the second protrusion.

[0013] Some such earmolds include a vent disposed along a portion of the second protrusion. Some such vents extend from the edge of the cavity to a point proximate a tip of the second protrusion. In some embodiments, the first protrusion is configured to engage under a crus of a helix of the outer ear.

[0014] Some embodiments include an alignment notch which allows a user to orient the audio device with respect to the earmold. The retention flaps may be formed on opposing sides of the edge of the cavity or may have other configurations. An alignment notch may be formed in a retention flap.

[0015] In some embodiments, a notch is provided which is configured to provide contact relief to an antitragus of the user. In some embodiments, the earmold is configured to prevent the second protrusion from touching the ear canal and in other embodiments the earmold is configured to hold the second protrusion in contact with the ear canal.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]FIG. 1 depicts one preferred embodiment of a left earmold of the present invention installed in a human ear.

[0017]FIG. 2 depicts one preferred embodiment of a left earmold of the present invention installed in a human ear.

[0018]FIG. 3 depicts an embodiment of a left earmold of the present invention.

[0019]FIG. 4 depicts an embodiment of a right earmold of the present invention.

[0020]FIG. 5 depicts an embodiment of a left earmold with an earphone installed therein.

[0021]FIG. 6 depicts a side view of one embodiment of the invented earmold.

[0022]FIG. 7 depicts a top view of one embodiment of the invented earmold.

[0023]FIG. 8 depicts a cross-section of one embodiment of the invented earmold.

[0024]FIG. 9 depicts another embodiment of the invented earmold.

[0025]FIG. 10 depicts an embodiment of the invented earmold attached to a two-way communication device.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS

[0026]FIG. 1 shows one preferred embodiment of left earmold <b>101</b> inserted at the opening of a human ear. Left earmold <b>101</b> is disposed within concha <b>108</b>, which is the largest cavity in the outer ear, and between tragus <b>110</b> and antitragus <b>115</b>. Helix <b>120</b> begins at crus <b>125</b> and wraps around most of the outer ear.

[0027] Left earmold <b>101</b> is held in place in the ear, at least in part, by first protrusion <b>103</b>. Left earmold <b>101</b> includes receptacle or cavity <b>104</b> to accommodate at least a portion of an audio device.

[0028] Optional vent or notch <b>105</b> prevents a pneumatic seal from forming in the ear canal. Vent <b>105</b> also accommodates the transmission of sound into the ear canal from the user's surroundings.

[0029] Optional antitragus notch <b>130</b> spreads out the surface area over which the weight of left earmold <b>101</b> bears upon antitragus <b>115</b>. Accordingly, antitragus notch <b>130</b> causes less pressure on antitragus <b>115</b> and results in greater comfort to the user. In some preferred embodiments, antitragus notch <b>130</b> is generally smooth and slightly concave in shape, as depicted in FIG. 1. However, antitragus notch <b>130</b> has different shapes in various embodiments of the inventive earmold, and may be, for example, only a subtle change in curvature of a convex portion of the earmold.

[0030] The embodiment illustrated in FIG. 1 includes optional labels <b>135</b> and <b>140</b> to indicate the intended ear (left ear) and the size of the mold (large), respectively.

[0031]FIG. 2 shows a preferred right earmold <b>102</b> inserted at the opening of a human ear. Right earmold <b>102</b> generally corresponds to left earmold <b>101</b> of FIG. 1. Right earmold <b>102</b> includes first protrusion <b>103</b> for holding right earmold <b>102</b> in the ear, receptacle <b>104</b> to accommodate at least a portion of an audio device, optional antitragus notch <b>130</b>, optional vent <b>105</b> and optional labels <b>135</b> and <b>140</b>. It can be seen from FIGS. 1 and 2 that the shape and size of the invented earmold is selected to match and fit within the user's outer ear, including the shape of the user's tragus, antitragus, concha and crus.

[0032]FIG. 3 shows a first side of left earmold <b>101</b>. The bottom <b>320</b> of left earmold <b>101</b> and antitragus notch <b>130</b> are shown. In this embodiment, antitragus notch <b>130</b> is not concave, but instead is a slightly flattened portion of an otherwise convex surface.

[0033] Cavity or receptacle <b>104</b> is provided to accommodate at least a portion of an audio device. In some embodiments, receptacle <b>104</b> is located on the approximate center of the first side of earmold <b>101</b>, the second side of the earmold being defined as the side of the earmold adjacent to the user's ear. In one preferred embodiment of the invention, cavity <b>104</b> is dome-shaped, with the shallowest part of cavity <b>104</b> being 0.1050 inches deep at the outer edge and the crest of the dome extending another 0.070 inches in the center of cavity <b>104</b>. One preferred cavity <b>104</b> is circular in shape and approximately 0.5 inches in diameter.

[0034] Sound bore <b>340</b> extends from cavity <b>104</b> to the tip of second protrusion <b>360</b> (not shown). Sound bore <b>340</b> provides a port through which sound can travel from the speaker part of the audio device to the ear canal of the user. Sound bore <b>340</b> also allows air to pass between cavity <b>104</b> and the wearer's ear canal. In one preferred embodiment, sound bore <b>340</b> is 0.10 inches in diameter and is close to the center of second protrusion <b>360</b>. The center of one such bore <b>340</b> is 0.090±0.030 inches from the edge of cavity <b>104</b>.

[0035]FIG. 3 illustrates an embodiment of retention flaps <b>350</b> according to the present invention. Retention flaps <b>350</b> protrude from the edges of cavity <b>104</b> in order to retain more securely an audio device (not shown) which has been disposed within cavity <b>104</b>. This feature will be more fully appreciated with reference to FIGS. 5, 8 and <b>10</b>. In this example, retention flaps <b>350</b> are arcuate in shape. In other embodiments, retention flaps <b>350</b> are formed in a variety of shapes, including but not limited to the shapes indicated in FIGS. <b>4</b>-<b>6</b> and <b>8</b>-<b>10</b>.

[0036] The embodiment shown in FIG. 3 illustrates optional notch <b>105</b>, which is gas-communicative with a user's ear canal. Notch <b>105</b> prevents a pneumatic seal from being formed in the ear canal and allows a user to hear ambient sounds.

[0037] Also shown is lower lobe <b>310</b> and first protrusion <b>103</b>. Left earmold <b>101</b> is kept in place in the ear by the combination of first protrusion <b>103</b> and features found on the second side of left earmold <b>101</b>, preferably with the assistance of contact, even if slight, by lower lobe <b>310</b>, bottom <b>320</b> and antitragus notch <b>130</b>.

[0038] The description of FIG. 4 parallels that of FIG. 3, but for a right earmold with different retention flaps <b>350</b>. FIG. 4 shows a first side of right earmold <b>102</b>. Bottom <b>320</b> of right earmold <b>102</b> and antitragus notch <b>130</b> are shown.

[0039] Cavity or receptacle <b>104</b> accommodates at least a portion of an audio device. Receptacle <b>104</b> is located on a first side of earmold <b>102</b>. A second side of earmold <b>102</b> is adjacent to the user's ear. A portion of second protrusion <b>360</b> and optional vent <b>105</b> may be seen on the second side of earmold <b>102</b>. In some preferred embodiments of the invention, cavity <b>104</b> is a truncated cylinder, with the walls of the cylinder being between ⅛ and ¼ inches deep.

[0040] In the embodiment shown in FIG. 4, retention flaps <b>350</b> extend from opposing sides of cavity <b>104</b> to hold an audio device more securely within cavity <b>104</b>. In this embodiment, retention flaps <b>350</b> include sides <b>410</b> which project towards the interior of cavity <b>104</b> and sides <b>415</b> which roughly parallel edge <b>420</b> of cavity <b>104</b>.

[0041] Optional alignment mark <b>405</b> has been formed in one retention flap <b>350</b> to indicate to a user the proper orientation of an audio device in right earmold <b>102</b>. Preferably, alignment mark <b>405</b> may easily be detected by touch, so that a user may orient an audio device with reference to alignment mark <b>405</b> after the earmold is secured within the user's ear. Some audio devices manufactured by Jabra Corporation, the present assignee, are made with a tab, notch or similar structure which corresponds to the position of alignment mark <b>405</b>.

[0042] Optional notch <b>105</b> prevents a pneumatic seal from being formed in the ear canal and allows a user to hear more ambient sounds than would be possible if a seal were formed.

[0043] Also shown in FIG. 4 are lower lobe <b>310</b> and first protrusion <b>103</b>. Right earmold <b>102</b> is kept in place in the ear by the combination of first protrusion <b>103</b> and features found on the second side of right earmold <b>102</b>, preferably with the assistance of contact, even if slight, by lower lobe <b>310</b>, antitragus notch <b>130</b> and bottom <b>320</b>. Preferred embodiments require only a very shallow insertion (approximately ⅛ inch in some embodiments) of the second protrusion into the user's ear canal.

[0044] In some embodiments, the earmold is held in place by the first protrusion and/or other features such that the second protrusion does not contact the ear canal. In other embodiments, the second protrusion lightly contacts a portion of the ear canal, e.g., a lower side edge of the ear canal. In yet other embodiments, the second protrusion contacts opposing sides of the ear canal and/or contacts most or all of the circumference of the ear canal.

[0045] Optional labels <b>325</b> and <b>330</b> indicate the intended ear (the right ear) and the size of the mold (large), respectively.

[0046]FIG. 5 shows left earmold <b>101</b> with audio device <b>505</b> installed. In this embodiment, retention flaps <b>350</b> are roughly triangular in shape, with the free vertex of each triangle extending towards the approximate center of cavity <b>104</b>. Cord <b>510</b> provides power and/or a signal for audio device <b>505</b>. Notch <b>105</b>, first protrusion <b>103</b>, lower lobe <b>310</b>, bottom <b>320</b>, and antitragus notch <b>130</b> are shown.

[0047]FIG. 6 is a side view of one preferred earmold. Second protrusion <b>360</b> extends upward from the base of second side <b>610</b> of the earmold. In some embodiments, second protrusion <b>360</b> extends upward at an angle of approximately <b>115</b> degrees from the horizontal, to closely match the curvature of the user's ear canal. In preferred embodiments, the insertion depth of second protrusion <b>360</b> is shallow, for the purpose of minimizing or eliminating physical contact with the inner ear canal. In some such embodiments, the insertion depth of second protrusion <b>360</b> is kept to ⅛ inch or less.

[0048] As noted above, vent <b>105</b> is provided to prevent a pneumatic seal from forming in the ear. In one preferred embodiment, vent <b>105</b> is 0.090 inches wide and 0.045 inches deep with curved edges inside and outside the vent. Vent <b>105</b> extends from the first side of the earmold up the side of second protrusion <b>360</b>. In some preferred embodiments, vent <b>105</b> ends no less than 0.10 inches from the end of the second protrusion <b>360</b>.

[0049] Second protrusion <b>360</b> is angled back or curved by an amount approximating the concha angle of the a user's ear. The purpose of this angle <b>615</b> is to permit a closer, more comfortable fit with the ear.

[0050] In the embodiment shown in FIG. 6, retention flaps <b>350</b> are similar in shape to those depicted in FIG. 4. Retention flaps <b>350</b> extend only part of the way around the circumference of cavity <b>104</b>, in order to allow an audio device to be more easily inserted into, or removed from, cavity <b>104</b>.

[0051] Referring to FIG. 7, a top view of a preferred earmold is shown. First protrusion <b>103</b> is designed to fit comfortably under the crus of helix of a user's outer ear. Valley <b>705</b> exists between first protrusion <b>103</b> and second protrusion <b>360</b>. The purpose of valley <b>705</b> is to more naturally fit the contours of the outer ear and to achieve user comfort.

[0052] Optional concha dehump <b>710</b> is included in the lower center of the second side to permit a close fit with the outer ear. Optional antitragus notch <b>130</b> is also included in the design of the earmold to relieve pressure on the user's antitragus. Shoulder <b>720</b> is also provided in the region of the lower lobe <b>725</b> for a better fit with the edge of a user's concha. Also depicted is the bottom <b>730</b>. Retention flaps <b>350</b> are present, but are not visible in FIG. 7.

[0053]FIG. 8 is a cut-away view of a preferred earmold and an audio device. Audio device <b>505</b> includes speaker <b>820</b> and magnet <b>825</b>, enclosed within case <b>815</b>. Depending on the embodiment, cord <b>830</b> may conduct signals to control speaker <b>820</b> and/or supply power to audio device <b>505</b>.

[0054] In this embodiment, audio device <b>505</b> fits snugly into cavity <b>104</b>, with very little space remaining around the edges. Front portion <b>835</b>, top portion <b>840</b> and bottom portion <b>850</b> of audio device <b>505</b> preferably conform with the corresponding inner surfaces of cavity <b>104</b>. It is convenient, though not necessary, for at least a portion of audio device <b>505</b> to fit closely with the interior of cavity <b>104</b>. If only top portion <b>840</b> and bottom portion <b>850</b> of audio device <b>505</b> fit snugly within cavity <b>104</b>, audio device <b>505</b> should be adequately secured by the friction between these portions and cavity <b>104</b> and by retention flaps <b>350</b>.

[0055] Retention flaps <b>350</b> extend towards the center of back portion <b>845</b> of audio device <b>505</b> and towards the interior of cavity <b>104</b>. Here, retention flaps <b>350</b> do not extend as far towards the interior of cavity <b>104</b> as in other embodiments described in the previous paragraphs. Nonetheless, even the relatively short retention flaps <b>350</b> illustrated in FIG. 8 can hold audio device <b>505</b> firmly in place. There is a tradeoff with respect to the length of retention flaps <b>350</b>: other factors being equal, the longer retention flaps <b>350</b> are made, the more securely they can hold an audio device. However, longer retention flaps <b>350</b> tend to interfere more with the processes of inserting audio device <b>505</b> into cavity <b>104</b> and extracting audio device <b>505</b> from cavity <b>104</b>.

[0056] As illustrated in FIG. 8, sound from speaker <b>820</b> is conducted from a first end of sound bore <b>340</b> within cavity <b>104</b> to a second end of sound bore <b>340</b> at or near the tip of second protrusion <b>360</b>. As noted above, the tip of second protrusion <b>360</b> is disposed at the opening of a user's ear canal. Accordingly, sound bore <b>340</b> facilitates the transmission of sound from speaker <b>820</b> to a user's ear canal.

[0057]FIG. 9 depicts another embodiment of an earmold according to the present invention. Retention flaps <b>350</b> are formed along opposing sides of cavity <b>104</b> on the first side of earmold <b>900</b>. Alignment mark <b>905</b> is formed in one of retention flaps <b>350</b> and extends into cavity <b>104</b>. Alignment mark <b>905</b> allows a user to orient an audio device within cavity <b>104</b> by “feel” as well as by inspection of earmold <b>900</b>.

[0058] Vent <b>105</b> extends from the edge of the first side of earmold <b>900</b> to a point near the tip of second protrusion <b>360</b> on the second side of earmold <b>900</b>. In this embodiment, vent <b>105</b> extends part of the way around the circumference of the first side of earmold <b>900</b>.

[0059]FIG. 10 illustrates how some embodiments of the present invention may be formed to accommodate a portion of an audio device having a speaker and a boom microphone. Earmold <b>1000</b> is shown engaged with two-way communication device <b>1001</b>. Speaker <b>1005</b>, shown in phantom, is disposed within cavity <b>104</b>. Microphone <b>1010</b> is supported by boom <b>1015</b>, which fits into support <b>1020</b>. Retention flaps <b>350</b> extend past speaker <b>1005</b> to engage a portion of support <b>1020</b>.

[0060] First protrusion <b>103</b> engages with a portion of a user's outer ear and second protrusion <b>360</b> fits into a user's ear canal. Sound bore <b>340</b> extends from cavity <b>104</b> in the first side of earmold <b>1000</b> to the tip of second protrusion <b>360</b> on the second side of earmold <b>1000</b>. Sound bore <b>340</b> provides a port through which sound can travel from speaker <b>1005</b> to the user's ear canal. Sound bore <b>340</b> also allows air to pass between cavity <b>104</b> and the wearer's ear canal.

[0061] In some embodiments, cord <b>1020</b> supplies power to two-way communication device <b>1001</b>. In some such embodiments, two-way communication device <b>1001</b> includes a transceiver (not shown) which receives first signals from microphone <b>1010</b> and transmits the first signals to an external device, and which receives second signals from an external device and transmits the second signals to speaker <b>1005</b>. In other embodiments, cord <b>1020</b> transmits first signals from microphone <b>1010</b> to an external device and transmits second signals from an external device to speaker <b>1005</b>. In some preferred embodiments, the external device is a telephone, such as a cellular telephone. In other embodiments, the external device is a personal digital assistant, a computer, or a similar device.

[0062] While the best mode for practicing the invention has been described in detail, those of skill in the art will recognize that there are numerous alternative designs, embodiments, modifications and applied examples that are within the scope of the present invention. For example, in some alternative embodiments of the invention, the earmold does not include the second protrusion which penetrates (although not deeply) the ear canal. The second protrusion can be omitted and secure mounting to an ear can still be achieved. Accordingly, the scope of this invention is not limited to the previously described embodiments.