(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY(PCT)
`
`(19) World Intellectual Property Organization
`International Bureau
`
`(43) International Publication Date
`9 July 2009 (09.07.2009)
`
`
`2 ; UTAVATAUA
`
`(10) International Publication Number
`WO 2009/086555_ Al
`
`(51) International Patent Classification:
`HOAR 25/00 (2006.01)
`(21) International Application Number:
`PCT/US2008/088656
`
`(22) International Filing Date:
`31 December 2008 (31.12.2008)
`
`(25) Filing Language:
`(26) Publication Language:
`
`English
`English
`
`(30) Priority Data:
`61/009,690
`
`31 December 2007 (31.12.2007)
`
`US
`
`(71) Applicant (for all designated States except US): KOSS
`CORPORATION[US/US]; 4129 North Port Washington
`Road, Milwaukee, WI 53212 (US).
`(72) Inventors; and
`only):
`US
`(for
`(75) Inventors/Applicants
`[US/US]; S104 W21015
`MLODZIKOWSKI, Allan
`Cindy Drive, Muskego, WI 53150 (US). ROBERTS,
`Lain
`[GB/US]; Chicago,
`IL (US). AYE, George
`[GB/US]; Chicago, IL (US). O LEARY,Jerry [GB/US];
`
`(74)
`
`(81)
`
`Chicago, IL (US). KOSS, Michael [US/US]; River Hills,
`WI (US). THALER, Martin [US/US]; Chicago, IL (US).
`PELLAND, Michael
`[US/US]; N4626 Wildwood Ln.,
`Princeton, WI 54968 (US).
`
`Agents: LAVENDER, Mark,D. et al; K & L Gates LLP,
`Henry W Oliver Building, 535 Smithfield Street, Pitts
`burgh, PA 15222-2312 (US).
`
`Designated States (unless otherwise indicated, for every
`kind of nationalprotection available): AE, AG, AL, AM,
`AO, AT, AU, AZ, BA, BB, BG, BH, BR, BW, BY, BZ, CA,
`CH,CN, CO, CR, CU, CZ, DE, DK, DM, DO, DZ, EC,EE,
`EG,ES, FI, GB, GD, GE, GH, GM, GT, HN, HR, HU,ID,
`IL, IN,IS, JP, KE, KG, KM, KN, KP, KR, KZ, LA, LC, LK,
`LR, LS, LT, LU, LY, MA, MD, ME, MG, MK, MN, Mw,
`MX, MY, MZ, NA, NG,NI, NO, NZ, OM,PG,PH, PL, PT,
`RO, RS, RU, SC, SD, SE, SG, SK, SL, SM, ST, SV, SY, TJ,
`TM,TN, TR, TT, TZ, UA, UG, US, UZ, VC, VN, ZA, ZM,
`ZW
`
`(84)
`
`Designated States (unless otherwise indicated, for every
`kind of regionalprotection available): ARIPO (BW, GH,
`
`[Continued on nextpage]
`
`(54) Title: ADJUSTABLE SHAPE EARPHONE
`
`
`
`FIG.
`
`1A
`
`disclosure
`This
`(57) Abstract:
`relates to an adjustable ear insert,
`such as an earbud style earphone,
`that may be inserted in a user's ear
`canal
`in a compact configuration
`and adjusted by a user to expand
`and fit snugly against the ear canal.
`
`Bose Exhibit 1015
`Bose v. Koss
`
`
`
`
`
`WO2009/086555A.IIMITIMNNMININNINNINIINTINEMLOATRINMAI
`
`

`

`WO 2009/086555 Ad
`
`IDMTNININNTIIIIN MTNIINN MKUTARM
`
`GM, KE, LS, MW, MZ, NA, SD, SL, SZ, TZ, UG, ZM, — asto the applicant's entitlement to claim thepriority of the
`ZW), Eurasian (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM),
`earlier application (Rule 4.17(Hi))
`European (AT, BE, BG, CH, CY, CZ, DE, DK,EE, ES,FI,
`Published:
`FR, GB, GR, HR,HU,IE, IS, IT, LT,LU, LV,MC, MT,NL,
`NO,PL, PT, RO, SE, SI, SK, TR), OAPI (BF, BJ, CF,CG, — with international search report
`CI, CM, GA, GN, GQ, GW, ML, MR, NE, SN, TD, TG). —__with amendedclaims
`Declarations under Rule 4.17:
`
`—_as to applicant's entitlement to applyfor and be granted a
`patent (Rule 4.17(U))
`
`

`

`WO 2009/086555
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`PCT/US2008/088656
`
`TITLE
`
`ADJUSTABLE SHAPE EARPHONE
`
`PRIORITY CLAIM
`
`Lay
`
`The present application claims priority to U.S. provisional application
`
`Serial No. 61/009,690,
`
`titled "ADJUSTABLE FIT EARBUD, CLOTH COVERED
`
`CORD AND CORDCLIP ZIPPER," filed December 31, 2007, which is
`
`incorporated herein by referencein its entirety.
`
`BACKGROUND
`
`The present disclosure generally relates to adjustable ear inserts and
`
`more particularly to earphones for listening to audio media, such as that which
`
`may be played from portable audio devices.
`
`Earphones are usually a pair of small loudspeakers that are provided
`
`with a mechanism to hold them close to a user's ears and a means of
`
`?
`
`connecting them to a signal source such as an audio amplifier, radio, or
`
`portable audio device, such as a CD or MP3player.
`
`Earbuds are earphones of a small size that are placed directly outside or
`
`in the ear canal. Some earbuds, called external-canal earbuds, are designed to
`
`sit outside the ear canal. These are generally inexpensive and are favored for
`
`al)
`
`their portability and convenience. However, due to their inability to provide
`
`sound isolation, they are incapable of delivering the same dynamic range
`
`offered by manyfull-sized headphones and ear-canal earbuds (described
`
`below) for a given volume level. As a result, they are often used at higher
`
`volumesin order to drown out noise from the user's surroundings. Overtime,
`
`earbuds became a commontype of earphone bundled with portable audio
`
`devices.
`
`Internal-canal earbuds are earbudsthat are inserted directly into the ear
`
`canal. These offer portability similar to external-canal earbuds, and also act like
`
`earplugs to block out environmental noise. There are two main typesof internal-
`
`30
`
`canal earbuds: universal and custom. Universal internal-canal earphones
`
`provide one or more stock sleeve size(s) to fit various ear canals, which are
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`commonly made out of silicone rubber, elastomer, or foam, for noise isolation.
`
`Universal internal-canal earbuds are marketedtypically to casual listeners and
`
`are relatively inexpensive,
`
`though some offer very high audio quality.
`
`Custom internal-canal earbuds are fitted to individuals. Castings of the
`
`"4H
`
`ear canals are made, usually by an audiologist. The manufacturer uses the
`
`castings to create custom-molded silicone rubber or elastomer plugs that
`
`provide added comfort and noise isolation. Because of the individualized labor
`
`involved, custom internal-canal earbuds are more expensive than universal
`
`internal-canal earbuds.
`
`Consequently,
`
`there is a need for improved internal-canal earbuds. The
`
`foregoing discussion is intended onlytoillustrate some of the shortcomings
`
`presentin the field of the invention at the time, and should not be taken as a
`
`disavowal of claim scope.
`
`SUMMARY
`
`The present invention includes,
`
`in various embodiments, an adjustable
`
`shape earphone.
`
`In at least one embodiment,
`
`the earphone includes:
`
`(i) a
`
`housing having a first side and a secondside; (ii) a resilient cushion attached to
`
`the first side of the housing, the resilient cushion having a compact shape and
`
`an opening; (iii) at least one cantilever arm protruding from thefirst side of the
`
`a)
`
`housing, where at least part of the cantilever arm is located within the opening
`
`of the resilient cushion;
`
`(iv) a dial rotatably mounted in the housing, where at
`
`least part of the dial extends from the second side of the housing and where the
`
`dial includes threads; and (v) an actuator comprising a first portion and a
`
`second portion, where the second portion has threads. The actuatoris
`
`mounted slidably in the housing, and the actuator threads operably engage the
`
`dial threads suchthat rotation of the dial
`
`in a first direction translates the first
`
`portion of the rigid actuator into contact with the cantilever arm. Further, the
`
`first portion of the actuator is configured to bend the cantilever arm into the
`
`resilient cushion as the actuator contacts the arm, and the cantilever arm is
`
`Al)
`
`subsequently configured to force the resilient cushion to have an expanded
`
`shape as the cantilever arm bends into the cushion.
`
`i2
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`WO 2009/086555
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`In another embodiment,
`
`the adjustable earphone includes:
`
`(i) a housing
`
`having a first side and a second side, wherethefirst side of the housing is
`
`configured to attach to a cushion;
`
`(ii) at least one cantilever arm protruding from
`
`the first side of the housing, where at least part of the cantilever arm is
`
`"4H
`
`configured to be located within an opening of the cushion when the cushion is
`
`attached to the housing; (iii) a dial rotatably mounted in the housing, where at
`
`least part of the dial extends from the second side of the housing, and where
`
`the dial includes threads; and (iv) an actuator comprising a first portion and a
`
`second portion, the second portion having threads. The actuator is slidably
`
`mounted in the housing, with the actuator threads operably engaging the dial
`
`threads such that rotation of the dial in a first direction translates the first portion
`
`of the rigid actuator into contact with the cantilever arm.
`
`In addition,
`
`thefirst
`
`portion of the actuator is configured to bend the cantilever arm as the actuator
`
`contacts the arm.
`
`In yet another embodiment,
`
`the adjustable earphone includes: (i) a
`
`housing;
`
`(ii) an ear canal portion adjacent to the housing, the ear canal portion
`
`having a first shape; (iii) and an adjustment assembly operably coupled to the
`
`housing. The adjustment assembly includes:
`
`(i) a movable member movable
`
`with respect to the housing between a first position and at least a second
`
`position;
`
`(ii) an expansion assembly configured to receive the movable member;
`
`and(iii) a control member configured to move the movable membersuch that
`
`actuation of the control member causes the movable member to move from a
`
`first position to at least a second position. Further, the movable memberis
`
`configured to cause the expansion assembly to expand in at least one direction
`
`|
`
`when the movable memberis moved to the second position. Subsequently,
`
`the
`
`expansion assembly is configured to force the ear canal portion to have atleast
`
`a second shape when the expansion assembly is expanded.
`
`In yet other embodiments,
`
`the adjustable earphone includes:
`
`(i) an ear
`
`canal portion having a shape, where the ear canal portion is operable for
`
`AV
`
`placement in a user's ear canal; and (ii) means for adjusting the shape of the
`
`ear canal portion by a user when the ear canal portion is positioned in the user's
`
`ear.
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`In yet other embodiments,
`
`the present invention provides an adjustable
`
`ear insert including:
`
`(i) an ear canal portion configured for insertion in a user's
`
`ear canal, the ear canal portion having a first shape; and(ii) an adjustment
`
`assembly at least partially located within the ear canal portion, where the
`
`"4H
`
`adjustment assembly is operable to cause the ear canal portion to have at least
`
`a second shape.
`
`In yet other embodiments,
`
`the adjustable ear insert includes:
`
`(i) an inner
`
`end having an eartip, where the inner end is configured to be placed within an
`
`ear canal of a user; (ii) and an outer end having a control feature, where the
`
`outer end is configured to remain outside the ear canal, and where the control
`
`feature is accessible by the user to expand or compactthe eartip.
`
`In these and other various embodiments, an adjustable ear insert is
`
`capable of insertion into a user's ear canal and then may be adjusted by the
`
`user to create a snug fit between the ear canal and an ear canal portion of the
`
`adjustable ear insert.
`
`In other words, the ear canal portion is capable of being
`
`adjusted to substantially seal the ear canal portion against the user's ear canal.
`
`Where the adjustable ear insert is an earphone, such a snugfit or seal provides,
`
`among other things, enhanced noise isolation from external noises other than
`
`those produced by the earphone, and sound enhancement for sound produced
`
`2()
`
`by the earphone. Where the adjustable ear insert is an earplug, such a snug fit
`
`or seal provides, among other things, enhanced noiseisolation from external
`
`noises. Further, the in-ear adjustability of the ear canal portion provides an ear
`
`insert that should not require different sized ear canal portions for different
`
`users.
`
`BRIEF DESCRIPTION OF THE FIGURES
`
`The features of the various embodiments are set forth with particularity in
`
`the appended claims. The various embodiments, however, both as to
`
`organization and methods of operation, may best be understood by way of
`
`example with reference to the following description,
`
`taken in conjunction with
`
`the accompanying drawings as follows.
`
`FIG. 1A is a perspective view of a wired adjustable earphone according
`
`to one non-limiting embodiment.
`
`

`

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`FIG. 1B is a is a perspective view of a wireless adjustable earphone
`
`according to one non-limiting embodiment
`
`FIGS. 2A-2B are diagrams showing compact and expanded shapes of
`
`various ear canal portions of adjustable earphones according to various
`
`"4H
`
`embodiments.
`
`FIGS. 3A-3D are several top views of adjustable earphones using a
`
`variety of user controls and actuator mechanisms to provide an adjustable
`
`earphone according to various embodiments.
`
`FIG. 4 is a side cross-sectional view of one non-limiting embodiment of
`
`an adjustable earphone.
`
`FIGS. 5A-5G are several
`
`illustrations of some of the various ear canal
`
`portion shapes made possible by the adjustable earphone of FIG. 4.
`
`FIG. 6 is an exploded view of the adjustable earphone ofFIG. 4.
`
`FIG. 7 is a side cross-sectional view of one non-limiting embodiment of
`
`an adjustable earphone.
`
`FIGS. 8A-8G are several illustrations of some of the various ear canal
`
`portion shapes made possible by the adjustable earphone of FIG. 7.
`
`FIG. 9 is an exploded view of the adjustable earphone of FIG. 7.
`
`FIG. 10 is a top cross-sectional view of one non-limiting embodiment of
`
`an adjustable earphone.
`
`FIGS. 11A-1 1H are several illustrations of some of the various ear canal
`
`portion shapes madepossible by the adjustable earphone of FIG. 10.
`
`FIG. 12 is an exploded view of the adjustable earphone of FIG. 10.
`
`FIG. 13 is a top cross-sectional view of one non-limiting embodiment of
`
`|
`
`an adjustable earphone.
`
`FIGS. 14A-14C are several
`
`illustrations of some of the various ear canal
`
`portion shapes made possible by the adjustable earphone of FIG. 13.
`
`FIG. 15 is an exploded view of the adjustable earphone of FIG. 13.
`
`FIG. 16 is a cross-sectional view of one non-limiting embodiment of an
`
`A
`
`adjustable earphone inserted and expanded in a user's ear canal.
`
`FIGS. 17A-1 7B are perspective views of a non-limiting embodiment of an
`
`eartip cushion and a base housing element of an adjustable earphone.
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`FIG. 18A is a perspective view of an earphone assembly including a cord
`
`wrapped around an audio device.
`
`FIG. 18B is a perspective view of a portion of an earphone assembly
`
`including a cord only partially wrapped around an audio device.
`
`"4H
`
`FIG. 19A is a perspective view of an adjustable earphone from the
`
`earphone assembly of FIG. 18A and 18B.
`
`FIG.
`
`19B is an illustration of a spring clip from the earphone assembly of
`
`FIGS. 18A and 18B.
`
`FIG. 19C is an illustration of the spring clip of FIG. 19B being used to
`
`hold in place the wrapped cord of the earphone assembly of FIG. 18A.
`
`FIG. 20 is a perspective view of one non-limiting embodiment of an
`
`adjustable earphone having a rotatable dial.
`
`FIG. 21A is an exploded view of the adjustable earphone of FIG. 21A.
`
`FIG. 21B is an exploded view of an ear canal cushion and part of a
`
`housing of the adjustable earphone of FIG. 21A.
`
`FIG. 22 is a front view of the adjustable earphone of FIG. 21A.
`
`FIG. 23 is a side view of the adjustable earphone of FIG. 21A.
`
`FIG. 24 is a perspective cross-sectional view, taken along line 24-24 in
`
`FIG. 22, of the adjustable earphone of FIG. 21A.
`
`FIG. 25 is a top cross-sectional view, taken along line 25-25 in FIG. 22,
`
`of the adjustable earphone of FIG. 21A, with an ear canal portion shown having
`
`a compact, first shape.
`
`FIG. 26 is a top cross-sectional view, taken along line 26-26 in FIG. 22,
`
`of the adjustable earphone of FIG. 21A, with the ear canal portion shown having
`
`|
`
`an expanded, second shape.
`
`FIG. 27 is a side cross-sectional view of the adjustable earphone of FIG.
`
`21A inserted and expanded in a user's ear canal.
`
`FIG. 28 is a top cross-sectional view of one non-limiting embodiment of
`
`an adjustable earphone having a push button.
`
`AV
`
`_f-
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`DETAILED DESCRIPTION
`
`Certain exemplary embodiments will now be described to provide an
`
`overall understanding of the principles of the structure, function, manufacture,
`
`and use of the devices and methods disclosed herein. One or more examples
`
`"4H
`
`of these embodiments areillustrated in the accompanying drawings. Those of
`
`ordinary skill
`
`in the art will understand that the devices and methods specifically
`
`described herein and illustrated in the accompanying drawings are non-limiting
`
`exemplary embodiments and that the scope of the various embodiments of the
`
`presentinvention is defined solely by the claims. The featuresillustrated or
`
`described in connection with one exemplary embodiment may be combined with
`
`the features of other embodiments. Such modifications and variations are
`
`intended to be included within the scope of the present invention.
`
`In the following description,
`
`like reference characters designate like or
`
`corresponding parts throughout the several views. In addition,
`
`in the following
`
`description,
`
`it is to be understood that such terms as "forward," "rearward,"
`
`“front,” "back," "right," "left," "upwardly," "downwardly," and the like are words of
`
`convenience and are not to be construed as limiting terms. The description
`
`below is for the purpose of describing various embodiments of the invention and
`
`is not intended to limit the invention thereto.
`
`The various embodiments described herein are directed to devices
`
`intended to be placed in an ear canal, such as an earphone assembly usable
`
`with an audio device. Referring to FIGS. 18A and 18B, an earphone assembly
`
`5 includes a cord 10 and a pair of earphones 100. The cord 10 hasafirst end
`
`11, a second end 12, and an electrical connector 13 located at the first end 11.
`
`|
`
`The electrical connector 13 connects the earphone assembly 5 to an audio
`
`device 1 such that electrical signals may be conveyed through the cord 10, to
`
`each earphone 100, where theelectrical signal may be converted to audible
`
`sounds bya transducer (see, e.g., FIGS. 24 and 27). As is knownin thefield, a
`
`transducer is a device, usually electrical, electronic, electro-mechanical,
`
`AV
`
`electromagnetic, photonic, or photovoltaic, that converts one type of energy or
`
`physical attribute to another for various purposes,
`
`including producing audible
`
`sounds. The term transducer may be usedto refer to an audio loudspeaker,
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`

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`WO 2009/086555
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`which converts electrical voltage variations representing music or speech, to
`
`mechanical cone vibration, and hence vibrates air molecules creating sound.
`
`Each earphone 100 is located at the second end 12 of the cord. The
`
`cord 10 further includes a first portion 16 adjacent to the first end 11 of the cord
`
`"4H
`
`10 and a second portion 17 adjacent to the second end 12 of the cord 10. The
`
`first portion 16 includes a single strand and the second portion 17 includes two
`
`strands such that the two earphones 100 maybe placed in the ears of a user,
`
`with one strand of the second portion 17 on eachside of the users head.
`
`As shown in FIGS. 1A and 1B, awired (FIG. 1A) or wireless (FIG. 1B)
`
`earbud style earphone (100, 50 respectively) according to an aspect of the
`
`present disclosure includes an eartip cushion 121 that may be inserted ina
`
`user's ear canal in a compact configuration, or first shape 122, and, oncein the
`
`ear canal, expanded to an expanded configuration, or second shape 123 (see
`
`FIG. 26), to fit snugly against all sides of the ear canal (see, e.g., FIG. 27). The
`
`resulting customized fit provides improved audio isolation by blocking external
`
`sounds from reaching the user's eardrum, as well as improved comfort by
`
`allowing the user to determine the amount of pressure exerted by the eartip, or
`
`ear canal portion 120, on the interior of the ear canal. Further, forming a near
`
`airtight seal between the ear canal portion 120 and the user's ear canal should
`
`not only reduce the outside ambient noise that reaches the user's eardrum, but
`
`should also provide a sound transducer (see FIGS. 24 and 27) of the earphone
`
`120 with a 1:1 acoustic coupling with the user's eardrum, thus enhancing the
`
`audible sound perceived by the user. The eartip cushion 121 may be
`
`fabricated from a foam material. While the earphone of FIGS. 1A or 1B will
`
`typically be returned to its compact configuration, or first shape 122, prior to
`
`removal from the user's ears, the compressible material of the eartip, or ear
`
`canal portion 120, may allow the earbud to be removed whilestill in its
`
`expanded configuration.
`
`Still referring to FIGS. 1A and 1B, expansion of the eartip may be
`
`AV
`
`achieved by twisting or pressing on acontrol 180 on an exterior surface of the
`
`earbud. Where expansion is achieved by twisting a control 180 about
`
`longitudinal axis L in the direction of arrow A and/or B, a manufacturer's logo
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`189 displayed on the control 180 may be attached to the control by a
`
`mechanism (described below) that allows the logo 189 to remain substantially
`
`upright and readable regardless of the rotation of the control 180.
`
`In various embodiments,
`
`referring now to FIGS. 20-27, an adjustable
`
`"4H
`
`earphone, such as adjustable earphone 100, for example, can comprise a
`
`housing 110, an ear canal portion 120, and an adjustment assembly 130. The
`
`housing may havea first side 111 and a second side 112 (see FIG. 21A and
`
`24). Adjacent to and attached tothe first side 111 of the housing is the ear
`
`canal portion 120. Ear canal portion 120 generally defines longitudinal axis L
`
`(see FIG. 20) and is operable for placement in a user's ear canal (see, e.g.,
`
`FIG. 27). Ear canal portion 120 is shown in FIG. 20 having a shapethat
`
`includes a compact, first shape 122 to facilitate initial placement of the ear canal
`
`portion 120 in the user's ear canal and mayinclude a cushion 121 (see FIGS.
`
`21A and 21B). Cushion 121 generally has an opening 125 that, as is described
`
`in more detail below, may receive part of an expansion assembly 160. Further,
`
`cushion 121 includes a housing groove 127 (FIG. 24) designed to receive or
`
`snap onaprotruding ring 118 of the housing 110 such that cushion 121 may
`
`attach releasably to the housing 110. Cushion 121 may be stretchable and
`
`madeof a resilient, compressible material. The resilient material may include a
`
`foam, a memory foam, a closed-cell foam, an open-cell foam, an elastomer, an
`
`elastomeric foam, silicone, and/or rubber. The ear canal portion 120,
`
`including
`
`cushion 121, may be capable of being adjusted to have an expanded, second
`
`shape 123 (see FIG. 26). Further, ear canal portion 120,
`
`including cushion 121,
`
`may also be capable of being adjusted to have intermediate shapes, or at least
`
`a third shape (not shown).
`
`In other words, the shape of the ear canal portion
`
`120 may be changed to have any number of shapes,
`
`including a continuum of
`
`shapes betweenthe first shape 122 and the second shape 123. The purpose of
`
`adjusting the shape of the ear canal portion 120 is to allow a user to change the
`
`shape of the ear canal portion 120, after insertion in the user's ear canal, to
`
`A
`
`have a snug fit between the ear canal and a substantial part of the ear canal
`
`portion 120. Such a snugfit provides noise isolation (from external noises other
`
`than those produced by the earphone 100) and sound enhancement
`
`(for sound
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`produced by the earphone 100), among other things. Further, the in-ear
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`adjustability of the ear canal portion 120 provides an earphone 100 that should
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`not require different sized ear canal portions 120 or cushions 1271 for different
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`users; in other words, the adjustable earphone 100 mayprovide a one-size-fits-
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`"4H
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`all device owing to the customized fit offered by the adjustability of the ear canal
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`portion.
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`In various embodiments,
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`referring again to FIGS. 20-27, the adjustable
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`earphone 100 may include meansfor adjusting the shape of the ear canal
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`portion 120 by a user when the ear canal portion 120 is positioned in the user's
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`ear canal. Means for adjusting the shape of the ear canal portion 120 may be
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`provided in at least one embodiment by adjustment assembly 130. Adjustment
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`assembly 130 may be operably coupled to the housing 110 and/or to the ear
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`canal portion 120 such that actuation of the adjustment assembly 130 causes
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`the ear canal portion 120 to have at least a second shape 123.
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`Generally, according to various non-limiting embodiments,
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`the
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`adjustment assembly 130 may include a movable member 140, an expansion
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`assembly 160, and a control member 180. The movable member 140 may be
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`movable with respect to the housing 110 betweena first position (see FIG. 25)
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`and at least a second position (see FIG. 26). The expansion assembly 160
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`may be configured to receive the movable member 140, and the control
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`member 180 may be configured to move the movable member 140 with respect
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`to the housing 110. Actuation of the control member 180 may cause the
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`movable member 140 to movefrom the first position (see FIG. 25) to the
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`second position (see FIG. 26). The movable member may be configured to
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`cause the expansion assembly 160 to expandin at least one direction when the
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`movable member is moved to the second position (FIG. 26). Relatedly, the
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`expansion assembly may be configured to force the ear canal portion 120 to
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`have at least a second shape 123 when the expansion assembly 160 is
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`expanded. Conversely, the expansion assembly 160 may be configured to
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`3)
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`retract in at least one direction when the movable member is movedtothe first
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`position (FIG. 25), thus resulting in the ear canal portion returning tothefirst
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`shape 122 when the expansion assembly 160 is retracted.
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`movable member 140 mayincludeafirst portion 150 and a second portion 142
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`In more detail, according to at least one non-limiting embodiment,
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`the
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`that together serve as an actuator (see FIGS. 21A and 24), as explained in
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`more detail below. Generally, the movable member movesalong longitudinal
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`"4H
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`axis L (see FIG. 20) and is designed to moverelative to the housing such that
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`the first portion 150 of the movable member 140 may engage the expandable
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`member 160 when moved accordingly. Such relative movement is caused by
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`force exerted on the movable memberby a user adjusting control member 180,
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`as described below. This force may be provided by any number of mechanical
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`mechanisms; here the movable member 140 receives a moving force from a
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`threaded engagement between the control member 180 and the second portion
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`142 of the movable member 140 at threads 143 (see FIGS. 21A and 25).
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`Threads 143 of the movable member 140 are designed to remain rotationally
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`stationary relative to the housing 110 such that rotation of the control member
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`180 forces the movable member to translate with respect to the housing 110.
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`This rotational stability is provided by guide protrusions 146 (FIG. 21A) on the
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`second portion 142 of the movable member 140. Guide protrusions 146 are
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`received slideably in guide recesses 114 (FIG. 21B) of the first side 111 of the
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`housing 110 such that the second portion 142 of the movable member 140 may
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`()
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`translate but will not substantially rotate with respect to the housing 110 owing
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`to the interface between the protrusions 146 and the recesses 114.
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`Further, referring to FIGS. 21A, 24, 25 and 27, the second portion 142
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`may include a cavity 141 that is configured to support a transducer 190, part of
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`the cord 10 electrically coupled to the transducer 190 (see FIG. 27), and thefirst
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`portion 150 of the movable member 140. The second portion 142 mayalso
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`include a slot 149 for passing the cord 10 into the cavity 141. Additionally,
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`the
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`second portion 142 may include locking grooves 147 and transducer supports
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`148. Thefirst portion 150 of the movable member 140 mayinclude locking
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`protrusions 152 that are designed to be inserted and twisted into the locking
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`30)
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`grooves 147 of the second portion 142 such that transducer 190 is held in
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`place, or sandwiched, between the first portion 150 and the second portion 142
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`of the movable member. Friction between the first portion 150, the transducer
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`190, and the supports 148 of the second portion 142 may provide sufficient
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`force to prevent the protrusions 152 ofthe first portion 150 from freely
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`decoupling from the locking grooves 147 of the second portion 142.
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`Accordingly,
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`the movably member 140,
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`including the first and second portions
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`"4H
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`150, 142,
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`is designed to move as a single rigid body relative to housing 110.
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`Thus, while shown in at least one embodiment as two separable components,
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`first and second portions 150, 142 could also be one unitary and integral
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`component.
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`Thefirst portion 150 of the movable member 140 is designed,
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`in at least
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`11)
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`one non-limiting embodiment,
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`to actuate expansion assembly 160 asthefirst
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`portion 150 is moved fromafirst position (FIG. 25) to at least a second position
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`(FIG. 26). The first portion 150 thus includes an actuating surface 155 (see,
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`e.g. FIG. 24) that may be shaped and positioned such that the actuating surface
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`155 engages operably the expansion assembly 160, as explained in more detail
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`below. Thefirst portion 150 of the movable member 140 also may include a
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`sound passageway 151 (FIG. 21A) oriented along longitudinal axis L. Sound
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`passageway 151 provides a channel along which sound produced by the
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`transducer 190 maytravel freely toward an inner end 101 (FIG. 20) of the
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`earphone 100 and into opening 125 (FIGS. 21A-26) of the cushion 121. Also,
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`()
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`the first portion 150 includes an O-ring groove 153 (FIG. 21A) configured to hold
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`an elastic O-ring 154. O-ring 154 seals the movable memberagainst thefirst
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`side 111 of the housing 110 and/or against the expansion assembly 160 (see
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`FIGS. 25-26). Accordingly, audible sound waves produced bythe transducer
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`190 only are allowed to travel toward the inner end 101 of the earphone 100,
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`and, subsequently, a user's ear drum, via sound passageway 151 of the
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`movable member 140.
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`According at least one non-limiting embodiment,
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`referring now to FIGS.
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`21A-21 B and 25-26, the expansion assembly 160 is designed to expand in at
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`least one direction when actuated by the movable member 140. The expansion
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`assembly 160 may be designed to expand in a direction substantially transverse
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`to the longitudinal axis L (see FIG. 20). Here, this is accomplished by using a
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`set of cantilever arms 161. The cantilever arms 161 protrude from the first side
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`111 of the housing and, whentheresilient cushion 121 is attached to the
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`housing, are at least partially located within the opening 125 of the cushion 121.
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`Arm recesses 126 (FIG. 21B) formed in the cushion 121 receive the cantilever
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`arms 161 such that the cushion 121 does not rotate freely thereon. The
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`"4H
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`cantilever arms 161 are uniformly spaced around longitudinal axis L to form an
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`opening 164 configured to receive thefirst portion 150 of the movable member.
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`Cantilever arms 161 each include an inner surface 163 and an outer surface
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`162.
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`Inner surface 163 is curved at least partially toward longitudinal axis L so
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`that at least part of the inner surface 163 will make contact with the movable
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`member's actuating surface 155 when the movable member 140 is advanced
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`toward the inner end 101 of the earphone 100. The actuating surface 155 of
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`the movable member 140 is curved correspondingly to meet the inner surface
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`163 of each cantilever arm 161. As the movable member 140 is moved toward
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`the inner end 101 of the earphone 100, the actuating surface 155 ofthefirst
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`portion 150 of the movable member 140 makes contact with one or more of the
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`cantilever arms 161 at inner surface 163. Further movement of the movable
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`member 140 in the same direction pushes on the inner surface 163, thus forcing
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`the cantilever arm 161 to bend away from longitudinal axis L (see FIG. 26).
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`Because the cantilever arms 161 are received insertably in the opening 125 of
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`the resilient cushion 121, the cantilever arm is bent into the cushion 121 as the
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`movable member 140 contacts and pushes the cantilever arm 161.
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`Consequently, as the cantilever arm is continually bent away from longitudinal
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`axis L, the cushion 121 is forced to have an expanded, second shape 123 (see
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`FIG. 26). Thus, the ear canal portion 120 may be expanded after insertion ina
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`user's ear canal, substantially sealing the cushion 121 against the user's ear
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`canal to form a snugfit.
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`Note that, while a plurality of cantilever arms 161 are described above as
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`providing the expansion assembly 160 with the ability to expand, it is
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`contemplated that any numberof cantilever arms,
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`including one, could perform
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`A
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`the same or similar function.
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`According at least one non-limiting embodiment,
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`the control member 180
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`is designed to actuat