WO2014107712A1

WO2014107712A1 - Adaptive component

Info

Publication number: WO2014107712A1
Application number: PCT/US2014/010460
Authority: WO
Inventors: Randy GRANOVETTER; Stephan Roundtree; Medford Alan Dyer; Alan Kraemer
Original assignee: Taida Company, Llc
Priority date: 2013-01-07
Filing date: 2014-01-07
Publication date: 2014-07-10

Abstract

An adaptive component is provided. The adaptive component includes a first end and an exterior surface extending from the first end to a second end. The exterior surface has at least one contour configured to seat against at least one contour of an inner passage of an earpuff. An inner passage extends from the first end to the second end. The inner passage is configured to seat against a nozzle of a speaker housing. The adaptive component is configured to support the earpuff and further configured to connect the earpuff to the speaker housing.

Description

ADAPTIVE COMPONENT

RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/749,566, filed January 7, 2013, the disclosure of which is incorporated herein by reference.

BACKGROUND

[0002] Wireless and mobile electronic devices are increasingly popular. Non- limiting examples of wireless and mobile electronic devices include MP3-style players, cellular phones, laptop and tablet-style computers, game controls, personal digital assistants, embedded connected devices in an automobile, embedded connected devices in a home or office, embedded connected devices in a

commercial building such as a hotel or factory, embedded connected devices in a transportation facility such as an airport or train station, digital cameras, DVD players and internet protocol television (IPTV).

[0003] These wireless and mobile electronic devices often include interactive display screens, controls and sound capabilities. In some instances, the audio signals generated by the wireless and mobile electronic devices are transmitted through wires to one or more small speakers that are positioned adjacent to, or in portions of the ears of the user. In other instances, the generated audio signals can be transmitted to speakers via wireless transmission devices. A non-limiting example of a speaker system positioned adjacent to the ears of the user is

headphones. Non-limiting examples of headphones include "Jbuds" marketed by JLab Audio, "Xtreme Xplosives in Ear" marketed by JVC, "Skullcandy INK'd Earbuds" marketed by Skullcandy, "Image S4" marketed by Klipsch, "MDR- EX57LP" marketed by Sony, "AH-C360" marketed by Denon and the "CX 300 II" marketed by Sennheiser. Non-limiting examples of a speaker system positioned within portions of the ears of the user are earbuds and earphones.

[0004] Earbuds and earphones refer to very small headphones that are fitted directly in portions of the user's outer ear and are positioned to face the user's ear canal without being inserted in the ear canal. In some instances earbuds and earphones can be uncomfortable and prone to falling out of the ear. It would be advantageous earbuds and earphones could be improved.

SUMMARY

[0005] The above objects as well as other objects not specifically enumerated are achieved by an adaptive component. The adaptive component includes a first end and an exterior surface extending from the first end to a second end. The exterior surface has at least one contour configured to seat against at least one contour of an inner passage of an earpuff. An inner passage extends from the first end to the second end. The inner passage is configured to seat against a nozzle of a speaker housing. The adaptive component is configured to support the earpuff and further configured to connect the earpuff to the speaker housing.

[0006] According to this invention there is also provided an earpuff assembly. The earpuff assembly includes an earpuff having an inner passage. The inner passage has at least one contour. An adaptive component has a first end and an exterior surface extending from the first end to a second end. The exterior surface has at least one contour configured to seat against a contour of the inner passage of the earpuff. The adaptive component further includes an inner passage extending from the first end to the second end and having at least one contour. A speaker housing has a nozzle configured to seat against the inner passage of the adaptive component. The adaptive component is configured to support the earpuff and further configured to connect the earpuff to the speaker housing.

[0007] According to this invention there is also provided a method of tuning an earpuff assembly. The method includes the steps of providing an earpuff having an inner passage, the inner passage having at least one contour, connecting the earpuff to an adaptive component thereby forming an earpuff assembly, the earpuff assembly having a leading edge, the adaptive component having a first end and an exterior surface extending from the first end to a second end, the exterior surface having at least one contour configured to seat against the contour of the inner passage of the earpuff, the adaptive component further including an inner passage extending from the first end to the second end and having at least one contour, connecting the earpuff assembly to a nozzle of a speaker housing and varying the leading edge of the earpuff assembly such as to provide a desired audio spectral response.

[0008] Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure la is an exploded perspective view of a first embodiment of an earpuff structure incorporating an adaptive component.

[0010] Figure lb is an exploded perspective view of the earpuff structure of Figure la. [0011] Figure lc is an exploded cross-sectional perspective view of the earpuff structure of Figure la.

[0012] Figure 2 is an exploded side view, in elevation, of the earpuff assembly and speaker housing of Figure la.

[0013] Figure 3 a is a side view, in elevation, of a first embodiment of an assembled earpuff structure.

[0014] Figure 3b is a cross-sectional view, in elevation, of the assembled earpuff structure of Figure 3 a.

[0015] Figure 4a is an exploded perspective view of a second embodiment of an earpuff structure incorporating an adaptive component.

[0016] Figure 4b is an exploded cross-sectional perspective view of the earpuff structure of Figure 4a.

[0017] Figure 5a is an exploded perspective view of a third embodiment of an earpuff structure incorporating an adaptive component.

[0018] Figure 5b is an exploded side view, in elevation, of the earpuff structure of Figure 5a.

[0019] Figure 6a is a perspective view of the assembled earpuff structure of Figure 5 a.

[0020] Figure 6b is a cross-sectional view, in elevation, of the assembled earpuff structure of Figure 5a.

[0021] Figure 7a is a perspective view of the adaptive component of the earpuff structure of Figure 5 a.

[0022] Figure 7b is a side view, in elevation, of the adaptive component of the earpuff structure of Figure 5 a.

[0023] Figure 8a is a cross-sectional view, in elevation, of the earpuff of Figure 5 a illustrated prior to assembly with the adaptive component. [0024] Figure 8b is a cross-sectional view, in elevation, of the earpuff of Figure 5 a illustrated after assembly with the adaptive component.

[0025] Figure 9a is a cross- sectional view of one embodiment of an earpuff illustrating a leading edge formed with a conical segment and an end segment.

[0026] Figure 9b is a cross-sectional view of another embodiment of an earpuff illustrating a leading edge formed with a radiused segment and an end segment.

[0027] Figure 9c is a cross-sectional view of another embodiment of an earpuff illustrating a leading edge formed with a radiused segment and an end segment.

[0028] Figure 9d is a cross- sectional view of another embodiment of an earpuff illustrating a leading edge formed with a conical segment and an end segment.

[0029] Figure 10a is a graph comparing the audio spectral responses of the earpuffs of Figs. 9a and 9b.

[0030] Figure 10b is a graph comparing the audio spectral responses of the earpuffs of Figs. 9a and 9c.

[0031] Figure 10c is a graph comparing the audio spectral responses of the earpuffs of Figs. 9a and 9d.

DETAILED DESCRIPTION OF THE INVENTION

[0032] The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0033] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0034] Unless otherwise indicated, all numbers expressing quantities of dimensions such as length, width, height, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term "about." Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

[0035] The description and figures disclose an adaptive component for use in supporting an earpuff and connecting an earpuff to portions of a speaker housing. Generally, the adaptive component connects the earpuff to portions of the speaker housing such that the earpuff can form a temporary earmold that allows a user to comfortably wear the earpuff for extended periods of time while substantially preventing the earpuff from falling out of the ear. While the term "earpuff, as used herein, is defined to generically mean any soft, pliable material used to cover a portion of a speaker housing and configured to seat within a portion of an ear canal, it should be understood that the term "Earpuff is a registered trademark currently in use by the Taida Corporation, headquartered in La Jolla, California and has U.S. Trademark Registration No. 4418796. The term "portions of a speaker housing", as used herein, is defined to mean a portion of any very small headphone that may be fitted into portions of a user's ear.

[0036] Referring now to Figs, la, lb, lc and 2, a first embodiment of an adaptive component is shown generally at 10. As will be explained in more detail below, the adaptive component 10 (hereafter "adapter") is combined with an earpuff 12 to form an earpuff assembly 14. The earpuff assembly 14 is configured to securely connect to a portion of a speaker housing 16 (hereafter "housing"), thereby forming an earpuff structure 18. The earpuff assembly 14 is configured to form a temporary earmold that allows a user to comfortably wear the earpuff assembly 14 for extended periods of time.

[0037] Referring again to Figs, la, lb and lc, the housing 16 can be any portion of a small headphone. The small headphone can be any of the commercially available non-limiting examples noted above. In the embodiment illustrated in Figs, la, lb, and lc, the housing 16 is provided without an installed eartip. The term "eartip", as used herein, is defined to mean any soft, pliable material used to cover a portion of the housing 16 and comfortably seat within a portion of a user's ear canal. Typically, eartips are made from materials such as soft foam, rubber or gel-like materials. However, it should be appreciated that in other embodiments, the housing 16 can be provided with an eartip and the eartip can be removed prior to connection to the earpuff assembly 14.

[0038] Referring again to Figs, la, lb and lc, the housing 16 includes a housing shell 20, an extended segment 22, and a nozzle 24. The housing shell 20 is configured to contain a sound generating device (not shown), such as, for example, a speaker and further configured to connect to the earpuff assembly 14. The sound generating device can be activated by either wired or wireless devices. Any desired sound generating device can be used. In the illustrated embodiment, the housing shell 20 is formed from a polymer-based material. However it should be appreciated that the housing shell 20 can be formed from any desired material sufficient to contain a sound generating device and connect to the earpuff assembly 14.

[0039] The extended segment 22 extends from the housing shell 20 to the nozzle 24. The extended segment 22 can have any desired length, diameter and

configuration sufficient to connect the nozzle 24 to the housing shell 20.

[0040] Referring again to Figs, la, lb and lc, the nozzle 24 includes a circumferential portion 26. Portions of the circumferential portion 26 extend radially from the nozzle 24. The circumferential portion 26 of the nozzle 24 is configured as a retention structure and combines with associated structures in the adapter 10 to secure the earpuff assembly 14 to the housing shell 20. The nozzle 24 and the circumferential portion 26 will be discussed in more detail below. In the illustrated embodiment, the nozzle 24 has a conical shape. However, in other embodiments, the nozzle 24 can have other shapes sufficient to form a retention structure to secure the earpuff assembly 14 to the housing shell 20.

[0041] Referring now to Fig. lc, a housing passage 28 extends through the housing shell 20, through the extended segment 22 and through the nozzle 24. The housing passage 28 is configured as a conduit for sound generated within the housing shell 20 by a speaker (not shown) positioned within the housing shell 20. The housing passage 28 can have any configuration sufficient to convey sound generated within the housing shell 20.

[0042] Referring again to Figs, la, lb and lc, the earpuff 12 is illustrated. As discussed above, the earpuff 12 attaches to the adapter 10, thereby forming an earpuff assembly 14. The earpuff 12 is configured to comfortably seat within a portion of a user's ear canal. The earpuff 12 can have different shapes and configurations dependent upon the shape and configuration of the adapter 10 and the housing 16. One non-limiting example of an earpuff is illustrated in U.S.

Provisional Patent Application No. 61/451895, filed March 11, 2011, and PCT Application No. PCT/US2012/028463, filed March 9, 2012, the disclosures of which are incorporated herewith in their entireties.

[0043] In certain embodiments, the earpuff 12 is formed as an integral one-piece structure. The term "integral", as used herein, is defined to mean the earpuff 12 is formed as a single, homogenous body. However, it is within the contemplation of this invention that the earpuff 12 can be fonned from separate and distinct segments that are joined together.

[0044] In the embodiment illustrated in Figs, la, lb and lc, the earpuff 12 is fonned from a biodegradable, visco-elastic, low resilience, polymeric-based open- cell foam material. However, it is within the contemplation of this invention that the earpuff 12 can be made from other desired materials.

[0045] Referring again to Figs, la, lb and lc, the earpuff 12 has a first end 30, a second end 32 and an inner passage 34 extending therethrough. The inner passage 34 has a circumferential inner passage wall 36 as shown in Fig. lc. Generally, the inner passage wall 36 has various diameters and contours that are configured to mate with the various diameters and contours forming an exterior surface 38 of the adapter 10 such that the earpuff 12 seats securely on the adapter 10.

[0046] Referring again to Figs, la, lb and lc, the adapter 10 is configured to support the earpuff 12 and further configured as a structure to connect the earpuff 12 to portions of the speaker housing 20. The adapter 10 has a first end 40, a second end 42, an inner adapter passage 44 defined by an inner passage wall 46 and the exterior surface 38. [0047] The second end 42 of the adapter 10 has a circumferential projection 48 that extends radially from the adapter 10. The circumferential projection 48 has a first portion 50 and a second portion 52. The first portion 50 and the second portion 52 cooperate to form a bowl-like structure with the first portion 50 having a concave cross-sectional shape and the second portion 52 having a convex cross-sectional shape. The second portion 52 forms a leading edge 53 having a desired geometry. The circumferential projection 48 is configured for several functions. First, the first portion 50 is configured to receive and seat with the second end 32 of the earpuff 12 as the earpuff 12 is formed on the adapter 10. Second, the second portion 52 is configured to comfortably seat within the user's ear canal. Third, the geometry of the leading edge 53 allows tuning of the earpuff assembly 14, such as to provide desired sound characteristics of the sound provided by the earpuff structure 18. In certain instances, the desired sound characteristics of the sound provided by the earpuff structure 18 can also be achieved by the combination of the geometry of the leading edge 53 and the material forming the adapter 10. The tuning capabilities of the earpuff structure 18 will be discussed in more detail below. While the illustrated embodiment shows the bowl-like structure of the circumferential projection 48, it should be appreciated that in other embodiments the second end of the adapter 10 can have different shapes and structures sufficient to receive and seat with the second end 32 of the earpuff 12 and comfortably seat within the user's ear canal.

[0048] Referring again to Fig. lc, the inner passage wall 46 of the adapter 10 provides several functions. First, the inner passage wall 46 forms a retention segment 54 configured to receive and seat the circumferential portion 26 of the nozzle 24 of the housing 16. While the retention segment 54 illustrated in Fig. lc has the general cross-sectional shape of an inverse funnel, in other embodiments the retention segment 54 of the adapter 10 can have any desired shape sufficient to receive and seat the circumferential portion 26 of the nozzle 24 of the housing 16. Second, the inner passage wall 46 forms a conduit segment 56 for sound generated within the housing shell 20. The conduit segment 56 can have any configuration sufficient to convey sound generated within the housing shell 20.

[0049] In certain embodiments, the adapter 10 is formed as an integral one-piece structure. The term "integral", as used herein, is defined to mean the adapter 10 is fonned as a single, homogenous body. However, it is within the contemplation of this invention that the adapter 10 can be fonned from separate and distinct segments that are joined together.

[0050] In the embodiment illustrated in Figs, la, lb and lc, the adapter 10 can be formed from the same biodegradable, visco-elastic, low resilience, flexible and pliable, polymeric-based open-cell foam material that forms the earpuff 12.

However, in other embodiments, adapter 10 can be formed from other materials compatible with the material fonriing the earpuff 12. In the illustrated embodiment, the material forming the adapter 10 has a durometer hardness rating in a range of from about 30 to about 50 as measured by the ASTM D2240 Type A scale. In other embodiments, the adapter 10 can be formed from materials having a durometer rating less than about 30 or more than about 50 provided the material is flexible and compatible with the material forming the earpuff 12.

[0051] In certain embodiments, the earpuff assembly 14 can be fonned by a two- step molding process. The first step of the molding process involves fonning the adapter 10 by conventional injection molding processes. The second step of the forming process involves molding an earpuff 12 over a formed adapter 10 such that a chemical bond is formed between the adapter 10 and the earpuff 12. In this process, the various mating diameters and contours of the exterior surface 38 of the adapter 10 and the inner passage wall 36 cooperate to provide additional retention and anti-rotation properties to the earpuff assembly 14. However, in other embodiments, the adapter 10 and the earpuff 12 can be formed separately and can be subsequently joined together at any desired time and by any desired joining process, thereby forming the earpuff assembly 14. The various mating diameters and contours of the exterior surface 38 of the adapter 10 and the inner passage wall 36 can be configured in any desired manner.

[0052] As discussed above in the illustrated embodiment, the earpuff assembly 14 is formed by molding the earpuff 12 over a previously formed adapter 10. The earpuff assembly 14 is then urged onto the housing 16 such that the circumferential portion 26 of the nozzle 24 is received by and seats within the retention segment 54 of the adapter 10, thereby forming the earpuff structure 18 as shown in Figs. 3 and 3b.

[0053] Referring now to Fig. 2, the adapter 10 has a length that is substantially the same as a length of the earpuff 12, such that when the adapter 10 and the earpuff 12 are combined to form the earpuff assembly 14, the first end 40 of the adapter 10 is substantially flush with the first end 30 of the earpuff 12 and the second end 32 of the earpuff 12 is received within the first portion 50 of the circumferential projection 48 of the adapter 10. The arrangement of the second end 32 of the earpuff 12 and the circumferential projection 48 is such that an outer rim 58 of the circumferential projection 48 is substantially flush with an outer surface 60 of the earpuff 12.

[0054] Referring again to Figs, la, lb and lc, the earpuff assembly 14 utilizing the adapter 10 provides significant benefits over conventional earbuds, although all benefits may not be present in all embodiments and circumstances. First, the adapter 10 allows various earpuffs 12, having certain shapes and configurations, to be easily connected to housings also having certain shapes and configurations. Second, the secure attachment of the earpuff 12 to the adapter 10 substantially prevents the earpuff 12 from becoming separated from the housing 16. Third, as discussed above, the secure attachment of the earpuff 12 to the adapter 10 substantially prevents rotation of the earpuff 12, thereby contributing to the comfort of wearing the earpuff structure 18. Fourth, the leading edge 53 of the adapter 10 can be shaped to provide a tuned earpuff structure, thereby providing desired sound characteristics.

[0055] While Figs, la-lc, 2 and 3a-3b illustrate one embodiment of the earpuff structure 18 formed by the adapter 10, earpuff 12 and housing 16, it should be appreciated that an earpuff structure can be assembled with other embodiments of an adapter, earpuff and housing. Referring now to Figs. 4a and 4b, a second embodiment of an earpuff structure is shown generally at 118. The earpuff structure 118 includes an adapter 100, earpuff 112 and speaker housing 116 (hereafter "housing").

[0056] In a manner similar to the earpuff assembly 14 discussed above and shown in Figs, la-lc, the adapter 100 is combined with the earpuff 112 to form an earpuff assembly 114. The earpuff assembly 114 is configured to securely connect to a portion of the housing 116, thereby forming the earpuff structure 18. The earpuff assembly 1 14 is configured to form a temporary earmold that allows a user to comfortably wear the earpuff assembly 114 for extended periods of time.

[0057] While the adapter 100, earpuff 112 and speaker housing 116 can be the same as, or similar to, the adapter 10, earpuff 12 and speaker housing 16 illustrated in Figs, la-lc and discussed above, the earpuff structure 118 can be accomplished with the adapter 100, earpuff 112 and speaker housing 116 having different configurations and structures as illustrated in Figs. 4a and 4b.

[0058] Referring again to Figs. 4a and 4b, the housing 116 can be any portion of a small headphone. The housing 116 includes a housing shell 120, an extended segment 122, and a nozzle 124. In the embodiment illustrated in Figs. 4a and 4b, the housing shell 120 and the extended segment 122 are the same as, or similar to, the housing shell 20 and the extended segment 22 shown in Figs, la-lc and discussed above. However, it should be appreciated that in other embodiments the housmg shell 120 and the extended segment 122 can be different from the housmg shell 20 and the extended segment 22.

[0059] The nozzle 124 includes a circumferential portion 126 that extends radially from the nozzle 124. The circumferential portion 126 of the nozzle 24 is configured as a retention structure and combines with associated structures in the adapter 100 to secure the earpuff assembly 114 to the housing shell 120. The nozzle 124 and the circumferential portion 126 will be discussed in more detail below. In the illustrated embodiment, the circumferential portion 126 has a rectangular cross- sectional shape. However, in other embodiments, the circumferential portion 126 can have other shapes sufficient as a retention structure to secure the earpuff assembly 1 14 to the housmg shell 120.

[0060] Referring again to Figs. 4a and 4b, a housing passage 128 extends through the housing shell 120, through the extended segment 122 and through the nozzle 124. In the embodiment illustrated in Figs. 4a and 4b, the housing passage 128 is the same as, or similar to, the housing passage 18 shown in Figs, la-lc and discussed above. However, it should be appreciated that in other embodiments the housing passage 128 can be different from the housing passage 18.

[0061] Referring again to Figs. 4a and 4b, the earpuff 112 is illustrated. As discussed above, the earpuff 112 attaches to the adapter 100 thereby forming an earpuff assembly 114.

[0062] In the embodiment illustrated in Figs. 4a and 4b, the earpuff 112 is formed from the same materials and with the same forming processes as discussed above. However, it is within the contemplation of this invention that the earpuff 1 12 can be made from other desired materials and with other desired processes.

[0063] Referring again to Figs. 4a and 4b, the earpuff 112 has a first end 130, a second end 132 and an inner passage 134 extending therethrough. The inner passage 134 has a circumferential inner passage wall 136 as shown in Fig. 4b. Generally, the inner passage wall 136 has various diameters and contours that are configured to mate with the various diameters and contours forming an exterior surface 138 of the adapter 100 such that the earpuff 112 seats securely on the adapter 100.

[0064] Referring again to Figs. 4a and 4b, the adapter 100 is configured to support the earpuff 112 and further configured as a structure to connect the earpuff 112 to portions of the speaker housing 116. The adapter 100 has a first end 140, a second end 142, an inner adapter passage 144 defined by an inner passage wall 146 and the exterior surface 138.

[0065] The first end 140 of the adapter 100 has a circumferential projection 148 that extends radially from the adapter 100. The circumferential projection 148 has a first portion 150 and a second portion 152. The first portion 150 forms a

substantially flat surface and the second portion 152 has various contours finally forming a conical cross-sectional shape. When the earpuff 1 12 is positioned over the adapter 100 to form the earpuff assembly 114, the first end of the earpuff 130 seats against the substantially flat surface of the first portion 150 of the

circumferential projection 148. When the earpuff assembly 114 is connected to the nozzle 124 of the housing 1 16 to form the earpuff structure 118, the conical portion of the second portion 152 extends over the extended segment 122 of the housing 116. While the illustrated embodiment shows the structure of the circumferential projection 148, it should be appreciated that in other embodiments the circumferential projection 148 can have different shapes and structures.

[0066] Referring again to Fig. 4b, the inner passage wall 146 provides several functions. First, the inner passage wall 146 forms a retention segment 154 configured to receive and seat the circumferential portion 126 of the nozzle 124 of the housing 120. While the retention segment 154 illustrated in Fig. 4b has the general cross-sectional shape of a rectangle, in other embodiments the retention segment 154 of the adapter 100 can have any desired shape sufficient to receive and seat the circumferential portion 126 of the nozzle 124 of the housing 11 . Second, the inner passage wall 146 forms a conduit segment 156 for sound generated within the housing 1 16. The conduit segment 156 can have any configuration sufficient to convey sound generated within the housing 11 .

[0067 j In the embodiment illustrated in Figs. 4a and 4b, the adapter 100 is formed from the same materials and with the same forming processes as discussed above for the adapter 10. However, it is within the contemplation of this invention that the adapter 100 can be made from other desired materials and with other desired processes.

[0068] In a manner similar to that described above, the earpuff assembly 114 is formed by molding the earpuff 1 12 over a previously formed adapter 100. The earpuff assembly 1 14 is then urged onto the housing 116 such that the

circumferential portion 126 of the nozzle 124 is received by and seats within the retention segment 154 of the adapter 100, thereby forming the earpuff structure 118.

[0069] Referring now to Fig. 4b, the adapter 100 has a length that is substantially the same as a length of the earpuff 112, such that when the adapter 100 and the earpuff 112 are combined to form the earpuff assembly 118, the first end 130 of the earpuff 112 seats against the substantially flat surface 150 of the circumferential projection 148 and the second end 132 of the earpuff 112 is substantially flush with the second end 142 of the adapter 100.

[0070] Referring again to Fig. 4b, the second end 132 of the earpuff 112 forms a leading edge 153 having a desired geometry. As discussed above, the geometry of the leading edge 153 can be combined with the material forming the earpuff 112 to allow tuning of the earpuff assembly 1 14, such as to provide desired sound characteristics of the sound provided by the earpuff structure 118.

[0071] Referring now to Figs. 5a and 5b, a third embodiment of an earpuff structure is shown generally at 218. The earpuff structure 218 includes an adapter 200, earpuff 212 and speaker housing 216 (hereafter "housing").

[0072] In a manner similar to the earpuff assembly 14 discussed above and shown in Figs, la-lc, the adapter 200 is combined with the earpuff 212 to form an earpuff assembly 214. The earpuff assembly 214 is configured to securely connect to a portion of the housing 216, thereby forming the earpuff structure 218. The earpuff assembly 214 is configured to form a temporary earmold that allows a user to comfortably wear the earpuff assembly 214 for extended periods of time.

[0073] Referring again to Figs. 5a and 5b, the housing 216 can be any portion of a small headphone. The housing 216 includes a housing shell 220, an extended segment 222, and a nozzle 224. The nozzle 224 includes a circumferential portion 226 that extends radially from the nozzle 224. A housing passage 228 extends through the housing shell 220, through the extended segment 222 and through the nozzle 224. In the embodiment illustrated in Figs. 5a and 5b, the housing shell 220, extended segment 222, nozzle 224, circumferential portion 226 and housing passage 228 are the same as, or similar to, the housing shell 20, extended segment 22, nozzle 24, circumferential portion 26 and housing passage 28 shown in Figs, la-lc and discussed above. However, it should be appreciated that in other embodiments the housing shell 220, extended segment 222, nozzle 224, circumferential portion 226 and housing passage 228 can be different from the housing shell 20, extended segment 22, nozzle 24, circumferential portion 26 and housing passage 28.

[0074] Referring again to Figs. 5a and 5b, the earpuff 212 is illustrated. As discussed above, the earpuff 212 attaches to the adapter 200 thereby forming an earpuff assembly 214. The earpuff assembly 214 is configured to comfortably seat within a portion of a user's ear canal. The earpuff 212 can have different shapes and configurations dependent upon the shape and configuration of the adapter 200 and the housing 216. One non-limiting example of an earpuff is illustrated in U.S. Provisional Patent Application No. 61/451895, filed March 11, 2011, and PCT Application No. PCT US2012/028463, filed March 9, 2012, the disclosures of which are incorporated herewith in their entireties.

[0075] In the embodiment illustrated in Figs. 5a and 5b, the earpuff 212 is formed from the same materials and with the same forming processes as discussed above. However, it is within the contemplation of this invention that the earpuff 212 can be made from other desired materials and with other desired processes.

[0076] Referring now to Figs. 5a, 5b, 8a and 8b, the earpuff 212 has a first end 230, a second end 232 and an inner passage 234 extending therethrough. The inner passage 234 has a circumferential inner passage wall 236. Generally, the inner passage wall 236 has various diameters, contours and structures that are configured to mate with various diameters, contours and structures forming an exterior surface 238 of the adapter 200 such that the earpuff 212 seats securely over the adapter 200.

[0077] In certain embodiments, the earpuff assembly 214 can be formed by the same two-step molding process described above for the earpuff assembly 14.

However, in other embodiments, the adapter 200 and the earpuff 212 can be formed separately and can be subsequently joined together at any desired time and by any desired joining process, thereby forming the earpuff assembly 214. The various mating diameters, contours and structures of the exterior surface 238 of the adapter 200 will be discussed in more detail below.

[0078] Referring now to Figs. 5 a, 5b, 7a and 7b the adapter 200 is configured to support the earpuff 212 and further configured as a structure to connect the earpuff 212 to portions of the speaker housing 216. The adapter 200 has a first adapter end 240, a second adapter end 242, an inner adapter passage 244 defined by an inner passage wall 246, and the exterior surface 238.

[0079] Referring now to Figs. 7a and 7b, the adapter 200 includes a plurality of spaced apart connector segments 264a-264d extending from an adapter housing 266 and configured to form the first adapter end 240. The adapter 200 also includes a plurality of reinforced, spaced apart support segments 270a-270d extending from the adapter housing 266 to form the second adapter end 242. The connector segments 264a-264d, adapter housing 266 and support segments 270a-270d cooperate to form the inner adapter passage 244 that extends from the first adapter end 240 to the second adapter end 242 therethrough. The inner adapter passage 244 is configured as a conduit for sound passing through the housing 266.

[0080] Each of the connector segments 264a-264d includes a connector tab 272 as illustrated in Fig. 7a. The connector tabs 272 are configured to releaseably mate with the nozzle 224 of the housing 216 such that the adapter 200 is connected to the housing 216. The connector tabs 272 can have any desired configuration sufficient to releaseably mate with the nozzle 224 and connect the adapter 200 to the housing 216.

[0081] Referring again to Fig. 7a, the support segments 270a-270d are configured for several functions. First, the support segments 270a-270d are configured to provide structural support for the earpuff 212 as the earpuff 212 is positioned adjacent to or within portions of the user's ears. Second, the support segments 270a-270d are configured as release levers, such that pressure applied to the support segments 270a-270d at the second adapter end 242 acts to pivot the connector tabs 272 away from the nozzle 224, thereby allowing the adapter 200 to be disconnected from the housing 216. In this manner, the connector tabs 272 disengage the nozzle 224 and the adaptor 224 can be removed from the housing 216 with the earpuff 212 installed over the adapter 200 or with the earpuff 212 removed from the adapter 200.

[0082] Optionally, each of the support segments 270a-270d can include a reinforcing member 274. The reinforcing members 274 are configured to provide structural reinforcement to the support segments 270a-270d such that pressure can be applied to the support members 270a-270d at the second adapter end 242 while minimizing breakage of the support segments 270a-270d. While the embodiment illustrated in Figs. 7a and 7b illustrates the reinforcing members 274 as having the cross-sectional shape of a four-sided structure, it should be appreciated that in other embodiments the reinforcing members 274 can have other cross-sectional shapes sufficient such that pressure can be applied to the support members 270a-270d at the second adapter end 242 while minimizing breakage of the support segments 270a- 270d.

[0083] While the embodiment of the adapter 200 illustrated in Figs. 7a and 7b shows a quantity of four connector segments 264a-264d and a quantity of four support segments 270a-270d, it should be appreciated that more or less than four connector segments or support segments can be used.

[0084] Referring again to Figs. 7a and 7b, the adaptor housing 266 includes a plurality of circumferential projections 276. With the earpuff 212 in an seated position substantially covering the adapter 200 as shown in Figs. 6a and 6b, the projections 276 are configured to engage the soft material forming the earpuff 212 such as to substantially prevent rotation of the seated earpuff 212. While the projections 276 shown in Figs. 7a and 7b have the shape of a saw tooth, it should be appreciated that the projections 276 can have any desired shape or configuration sufficient to engage the soft material forming the earpuff 212 such as to

substantially prevent rotation of the seated earpuff 212. In still other embodiments, other structures mechanisms or devices, such as for example clips or clamps, can be incorporated into the adapter 200 and configured to prevent rotation of the seated earpuff 212.

[0085] Referring again to Figs. 7a and 7b, the circumferential projections 276 are spaced apart from the adapter housing 266 such as to form a circumferential recess 278. The recess 278 will be discussed in more detail below,

[0086] In a manner similar to the adapter 10 illustrated in Figs, la-lc, the adapter 200 is formed as an integral one-piece structure. However, it is within the contemplation of this invention that the adapter 200 can be formed from separate and distinct segments that are joined together.

[0087] In the embodiment illustrated in Figs. 4a and 4b, the adapter 200 is formed from the same materials and with the same forming processes as discussed above for the adapter 10. However, it is within the contemplation of this invention that the adapter 100 can be made from other desired materials and with other desired processes.

[0088] Referring again to Fig. 5a, the adapter 200 has a length that is

substantially the same as a length of the earpuff 212, such that when the adapter 200 and the earpuff 212 are combined to form the earpuff structure 218, the first end 230 of the earpuff 212 seats substantially adjacent to the first end 240 of the adapter 200 and the second end 232 of the earpuff 212 is substantially flush with the second end 242 of the adapter 200.

[0089] Referring now to Fig. 8a, the inner passage 234 has a first contour 280a, a second contour 280b and a third contour 280c. As will be explained in more detail below, the first, second and third contours, 280a-280c of the inner passage 234 are configured to closely approximate various exterior contours of the adapter 200, such as to securely attach the earpuff 212 to the adapter 200.

[0090] Referring again to Fig. 8a, the first contour 280a of the inner passage 234 of the earpuff 212 has a generally conical cross-sectional shape and is configured to seat against the generally conical exterior surfaces of the connecter segments 264a- 264d of the adapter 200. The second contour 280b of the inner passage 234 of the earpuff 212 includes a circumferential void 282. The circumferential void 282 forms an annular tip 284 in a direction toward the first earpuff end 230. The annular tip 284 of the earpuff 212 is configured to seat within and against the recess 278 formed by the spaced apart projections 276 of the adapter 200. The third contour 280c of the inner passage 234 of the earpuff 212 has a generally cylindrical cross- sectional shape and is configured to seat against the generally cylindrical exterior surfaces of the support segments 270a-270d of the adapter 200. In this position, the reinforcing members 274 of the adapter 200 are configured to engage the soft material forming the earpuff 212, thereby further preventing rotation of the earpuff 212.

[0091] While the embodiment of the earpuff 212 illustrated in Fig. 8a shows a quantity of three interior contours 280a-280c, it should be appreciated that in other embodiments, more or less than three interior contours can be used sufficient to closely approximate the exterior contours of the adapter 200.

[0092] In a manner similar to that described above, the earpuff assembly 214 is formed by molding the earpuff 212 over a previously formed adapter 200. The earpuff assembly 214 is then urged onto the nozzle 224 of the housing 216 such that connecter tabs 272 of the adapter 200 seat against the nozzle shoulder 224 of the nozzle, thereby forming the earpuff structure 118. In this position, the adapter 200 is securely attached to the housing 216 such that the various contours 280a-280c of the inner passage 234 align with the various exterior surfaces of the adapter 200 as described above. In this position, the earpuff 212 is securely retained on the adapter 200 and the earpuff structure 218 is formed.

[0093] The earpuff assembly 218 is inserted into portions of the ear canal of the user such that the foam material of the earpuff 212 compresses and subsequently expands to the approximate shape and dimensions of the portions of the user's ear canal. In this manner, the foam material of the earpuff 212 is self-adjusting and form fitting, thereby creating an original personal fit to the exact shape of the user's ear.

[0094] Referring again to Fig. 8a, earpuff 212 is shown prior to installation over the adapter (not shown). The inner passage 234 of the earpuff 212 has a first diameter Dl at the first earpuff end 230. Refemng now to Fig. 8b, the earpuff 212' is shown after installation over the adapter (not shown). As a result of enlarging the inner passage 234' to accommodate the various diameters of the adapter, the inner passage 234' now has a second diameter D2 at the first earpuff end 230 that is considerably larger than the first diameter Dl. Without being held to the theory, it is believed that the resulting compressive forces within the stretched earpuff 212' contribute to the retention of the earpuff 212' on the adapter.

[0095] Referring again to Fig. 5b, the second end 232 of the earpuff 212 forms a leading edge 253 having a desired geometry. As discussed above, the geometry of the leading edge 253 can be combined with the material forming the earpuff 212 to allow tuning of the earpuff assembly 214, such as to provide desired sound characteristics of the sound provided by the earpuff structure 218.

[0096] Referring again to Fig. 2, portions of the adapter 10 and portions of the earpuff 12 cooperate to form the leading edge 53. In use, the leading edge 53 is positioned within the user's ear canal. As discussed above, the geometry of the leading edge 53 allows tuning of the earpuff assembly 14, such as to provide desired sound characteristics of the sound provided by the earpuff structure 18. The desired sound characteristics can be quantified as an audio spectral response (also known as frequency response). The term "audio spectral response", as used herein, is defined to mean the overall tonal characteristics of the audio device, and can be shown as a plot of audio amplitude (in decibels) vs frequency. It has been found that varying the shape of the leading edge 53 can vary an audio spectral response of the earpuff assembly 14.

[0097] Referring now to Figs. 9a-9d, various earpuffs 312, 412, 512 and 612 are illustrated. The earpuffs 312, 412, 512 and 612 have leading edges 353, 453, 553 and 653 respectively. The leading edges 353, 453, 553 and 653 each have a different cross-sectional profile. As will be discussed below in more detail, the different cross- sectional profiles of the leading edges 353, 453, 553 and 653 result in different audio spectral responses of the earpuff assemblies. While Figs. 9a-9d illustrate leading edges formed solely by earpuffs, it should be appreciated that in other embodiments, leading edges can be formed by a combination of an eaipuff and an adapter, such as the non-limiting example of the leading edge 53 shown in Fig. 2. Consistent with the leading edges shown in Figs. 9a-9d, the leading edges formed by the combination of an earpuff and an adapter can have different cross- sectional profiles resulting in different audio spectral responses of the earpuff assemblies.

[0098] Referring now to Fig. 9a, the leading edge 353 of the earpuff 312 is formed by a conical segment 390 and an end segment 392. In the illustrated embodiment, the end segment 392 has a substantially flat surface. However, in other embodiments, the end segment 392 can have other desired surfaces, such as for example, an irregular surface.

[0099] Referring now to Fig. 10a, a graph depicting the audio spectral response of the earpuff 312 is illustrated. The audio spectral response can be measured by various test methods. In one traditional test method, a single tone is swept from the lowest frequency of interest to the highest and the output amplitude is plotted.

Another test method uses an impulse response, where a very short pulse is applied to the sound device and Fast Fourier Transforms are used to obtain the audio spectral response. In another test method, broadband (10Hz to 20Khz) pink noise is applied to the device. Pink nose is broadband audio noise that declines in energy at a rate of 3db/octave. An audio spectrum analyzer is then used to plot the amplitude vs.

frequency response in real time. Averaging can be used to minimize instantaneous variations in the pink noise signal. In practice, an ear simulator such as model 43AC-S1 from G.R.A.S. Sound and Vibration, headquartered in Denmark, can be used. The ear simulator includes a coupler and a calibrated microphone. During the test, an earbud is inserted into the coupler and optionally clamped. The microphone is then interfaced to a computer using a USB microphone preamplifier. The audio signal is routed to software (such as that provided by AudioMulch Software, headquartered in Melbourne, Australia) that allows dynamic creation of any audio configuration. A spectrum analyzer (such as that provided by Blue Cat Audio, headquartered in Paris, France) can be installed and connected to the software.

Using this software approach allows creation of any desired test configuration.

[00100] Referring again to Fig. 10a, a graph of the audio amplitude and the resulting frequency of the earpuff 312 is illustrated as the "red" curve and identified as reference character 394. The graph of Fig. 10a has a vertical axis of audio amplitude, decibels (db), and a horizontal axis of frequency, measured in Hz. As will be discussed in more detail below, the curve 394 is used as a baseline, and other audio amplitude vs resulting frequency curves, stemming from different leading edge shapes, will be compared against the curve 394.

[00101] Referring now to Fig. 9b, the leading edge 453 of the earpuff 412 is formed by a rad used segment 490 and an end segment 492. In the illustrated embodiment, the end segment 492 has an indented or concave section. However, in other embodiments, the end segment 492 can have other desired shapes, such as for example, a beveled section.

[00102] Referring again to Fig. 10a, a graph of the audio amplitude and the resulting frequency of the earpuff 412 is illustrated as the "orange" curve and identified as reference character 494. As can be seen by comparing the curve 394 and the curve 494, the curve 494 illustrates a shift in the frequency of the lower peak as well as an attenuation of the higher peak. The changes in the curves 394 and 494 stem from the changes in the cross-sectional profiles of the earpuffs 312 and 412 respectively. In this manner, the cross-sectional profiles of the earpuffs can be arranged such as to provide a desired audio spectral response.

]00103] Referring now to Fig. 9c, the leading edge 553 of the earpuff 512 is formed by a radiused segment 590 and an end segment 592. In the illustrated embodiment, the end segment 592 has an indented substantially flat surface.

However, in other embodiments, the end segment 592 can have other desired surfaces, such as for example, an irregular surface.

[00104] Referring now to Fig. 10b, a graph of the audio amplitude and the resulting frequency of the earpuff 512 is illustrated as the "green" curve and identified as reference character 594. As can be seen by comparing the curve 394 and the curve 594, the curve 594 illustrates a new peak in the curve 594 occurring at a frequency of 3800 Hz and a second peak shifted higher in frequency while the high frequency peak is virtually eliminated. The changes in the curves 394 and 594 stem from the changes in the cross-sectional profiles of the earpuffs 312 and 512 respectively. As discussed above, the cross-sectional profiles of the earpuffs can be arranged such as to provide a desired audio spectral response.

[00105J Referring now to Fig. 9d, the leading edge 653 of the earpuff 612 is formed by a conical segment 690 and an end segment 692. In the illustrated embodiment, the end segment 692 has an indented or concave section. However, in other embodiments, the end segment 692 can have other desired shapes, such as for example, a beveled section.

[00106] Referring now to Fig. 10c, a graph of the audio amplitude and the resulting frequency of the earpuff 612 is illustrated as the "white" curve and identified as reference character 694. As can be seen by comparing the curve 394 and the curve 694, the curve 694 illustrates a reduction of the peak in the curve 594 occurring at a frequency of 3800 Hz and a shift in the frequency of the second peak with restoration of the higher frequency peak. The changes in the curves 394 and 694 stem from the changes in the cross-sectional profiles of the earpuffs 312 and 612 respectively. As discussed above, the cross- sectional profiles of the earpuffs can be arranged such as to provide a desired audio spectral response.

[00107] While Figs. 10a- 10c illustrated the tuning of earpuff assemblies by varying the geometry of the leading edges, it should be appreciated that in other embodiments, the earpuff assemblies can be tuned by varying the materials used to form the leading edges. As discussed above, the embodiment illustrated in Fig. 2 has a durometer hardness rating in a range of from about 30 to about 50 as measured by the ASTM D2240 Type A scale, it has been found that the earpuff assemblies will provide different audio spectral responses for different hardness ratings within the range of 30 to 50, as well as different audio spectral responses for hardness ratings less than about 30 or more than about 50. In summary, the material forming the leading edge of the earpuff can be configured such as to provide a desired audio spectral response.

[00108] It should be appreciated that in still other embodiments, the earpuff assemblies can be tuned by varying a combination of the cross-sectional shape of the leading edge and the materials used to form the leading edge. It has been found that the earpuff assemblies will provide different audio spectral responses for different combinations of the cross-sectional shape of the leading edge and the materials forming the leading edge.

[00109] In accordance with the provisions of the patent statutes, the principle and mode of operation of the adaptive component has been explained and illustrated in its preferred embodiments. However, it must be understood that the adaptive component may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.

Claims

CLAIMS What is claimed is:

1. An adaptive component comprising:

a first end;

an exterior surface extending from the first end to a second end, the exterior surface having at least one contour configured to seat against at least one contour of an inner passage of an earpuff;

an inner passage extending from the first end to the second end, the inner passage configured to seat against a nozzle of a speaker housing;

wherein the adaptive component is configured to support the earpuff and further configured to connect the earpuff to the speaker housing.

2. The adaptive component of claim 1, wherein a circumferential projection is formed at the second end.

3. The adaptive component of claim 2, wherein the circumferential projection forms a leading edge configured for insertion into an ear of a user.

4. The adaptive component of claim 2, wherein the circumferential projection includes a first portion configured to receive a second end of the earpuff.

5. The adaptive component of claim 3, wherein the leading edge is formed by a conical segment and an end segment.

6. The adaptive component of claim 1, wherein a material forming the adaptive component has a durometer hardness rating in a range of from about 30 to about 50 as measured by the ASTM D2240 Type A scale.

7. The adaptive component of claim 1, wherein a circumferential projection is formed at the first end.

8. The adaptive component of claim 7, wherein the second end of the adaptive component is positioned within the inner passage of the earpuff.

9. The adaptive component of claim 7, wherein circumferential projection includes an inner portion configured to seat against a first end of the earpuff.

10. The adaptive component of claim 1, wherein the adaptive component includes a plurality of connector segments configured to seat against a nozzle of a speaker housing.

11. An earpuff structure comprising:

an earpuff having an inner passage, the inner passage having at least one contour;

an adaptive component having a first end and an exterior surface extending from the first end to a second end, the exterior surface having at least one contour configured to seat against the contour of the inner passage of the earpuff, the adaptive component further including an inner passage extending from the first end to the second end and having at least one contour;

a speaker housing having a nozzle configured to seat against the inner passage of the adaptive component;

12. The earpuff structure of claim 11 , wherein a circumferential projection is formed at the second end of the adaptive component.

13. The earpuff structure of claim 12, wherein the circumferential projection forms a leading edge configured for insertion into an ear of a user.

14. The earpuff structure of claim 12, wherein the circumferential projection includes a first portion configured to receive a second end of the earpuff.

15. The earpuff structure of claim 13, wherein the leading edge is formed by a conical segment and an end segment.

16. The earpuff structure of claim 11, wherein the earpuff and the adaptive component are tune such as to provide desired sound characteristics.

17. A method of tuning an earpuff assembly, the method comprising the steps of:

providing an earpuff having an inner passage, the inner passage having at least one contour;

connecting the earpuff to an adaptive component thereby forming an earpuff assembly, the earpuff assembly having a leading edge, the adaptive component having a first end and an exterior surface extending from the first end to a second end, the exterior surface having at least one contour configured to seat against the contour of the inner passage of the earpuff, the adaptive component further including an inner passage extending from the first end to the second end and having at least one contour;

connecting the earpuff assembly to a nozzle of a speaker housing; and varying the leading edge of the earpuff assembly such as to provide a desired audio spectral response.

18. The method of claim 17, wherein the leading edge of the earpuff assembly has a cross-sectional shape, and wherein the cross- sectional shape is configured to provide a desired audio spectral response.

19. The method of claim 17, wherein the leading edge of the earpuff assembly is formed from a material having a desired hardness, and wherein the material is configured to provide a desired audio spectral response.

20. The method of claim 17, wherein the leading edge of the earpuff assembly has a cross -sectional shape and is formed from a material having a desired hardness, and wherein the cross-sectional shape and the material are configured to provide a desired audio spectral response.