(12) United States Patent
`US 6,856,690 B1
`(10) Patent N0.:
`
`Skulley Feb. 15, 2005
`(45) Date of Patent:
`
`USOO6856690B1
`
`(54)
`
`(75)
`
`COMFORTABLE EARPHONE CUSHIONS
`
`Inventor:
`
`Gerald W. Skulley, Aptos, CA (US)
`
`(73)
`
`Assignee: Plantronis, Inc., Santa Cruz, CA (US)
`
`(*)
`
`Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 258 days.
`
`Appl. No.: 10/043,613
`
`Filed:
`
`Jan. 9, 2002
`
`4,160,135 A
`4,170,275 A
`4,239,945 A
`4,278,852 A
`4,302,635 A
`4,389,542 A
`4,437,538 A
`4,523,661 A *
`4,529,058 A
`
`7/1979 Gorike ....................... 179/182
`10/1979
`...... 181/129
`
`12/1980 Atoji et al.
`................. 179/182
`7/1981 Gorike ....................... 179/182
`11/1981 Jacobsen et al.
`.. 179/156
`
`6/1983 Gorike ................... 179/1
`.. 181/129
`3/1984 Ohlsson et al.
`
`............... 181/129
`6/1985 Scalzo et al.
`7/1985 Emery ........................ 181/129
`
`(List continued on next page.)
`FOREIGN PATENT DOCUMENTS
`
`JP
`
`2001309478 A * 11/2001
`
`............ H04R/U10
`
`(21)
`
`(22)
`
`(51)
`(52)
`(58)
`
`(56)
`
`Int. Cl.7 ................................................ H04R 25/00
`US. Cl.
`........................................ 381/371; 381/367
`Field of Search ................................. 381/370, 371,
`381/375, 376, 380, 189, 361, 367, 368,
`374, 2/209, 279/430, 181/129, 130, 135
`
`Primary Examiner—Huyen Le
`Assistant Examiner—Brian Ensey
`(74) Attorney, Agent, or Firm—Peter Hsieh
`
`(57)
`
`ABSTRACT
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`1,368,307
`2,235,372
`2,408,494
`2,468,721
`2,856,469
`2,989,598
`3,030,458
`3,051,961
`3,073,410
`3,134,456
`3,160,717
`3,220,505
`3,456,263
`3,571,813
`3,602,329
`3,645,354
`3,798,393
`4,005,278
`4,041,256
`4,058,688
`4,071,717
`4,087,653
`4,156,118
`
`>>>>>>>>>>>>>>>>>>>>>>>
`
`2/1921
`3/1941
`10/1946
`4/1949
`10/1958
`6/1961
`4/1962
`9/1962
`1/1963
`5/1964
`* 12/1964
`11/1965
`7/1969
`3/1971
`8/1971
`2/1972
`3/1974
`1/1977
`8/1977
`11/1977
`1/1978
`5/1978
`5/1979
`
`*
`
`2:15:13?....................... 179/156
`..... 179/182
`Veneklasen ..
`
`..... 179/182
`Volkmann
`
`Morse .................. 179/182
`
`..... 179/182
`Touger et al.
`Gongoll ................ 179/182
`
`Clark ~~~~~~~~~~~~~~~~~~~ 2/209
`
`Gongoll et a1: "
`181/23
`
`Wadsworth """
`181/23
`Beguin ............. 381/372
`
`Hargrave ..................... 181/23
`A1160
`Allen ............... 2/209
`..
`Bauer et a1.
`181/23
`
`Kliewer .......
`181/23
`
`
`Gorike ~~~~~~~~~~ 179/182
`Gorike ~~~~~~~~~~~~~~~~~~~~~~~ 381/373
`09”.“ a1: """"""""" 179/182
`filinggfa etal 33%;;
`..... 179/156
`Frieder, Jr. et al.
`.
`
`Hargrave .................... 179/182
`
`A cushion for a headset earphone comprises a resilient ring
`having opposite input and output faces, and a through-
`opening defining an interior surface between the two faces.
`The input face has structure for acoustically coupling the
`opening to an output face of an audio speaker, and the output
`face is resiliently conformable to a lateral face of an external
`ear of a listener, thereby acoustically coupling the opening,
`and hence, the speaker,
`to the listener’s ear. The interior
`surface of the cushion can be configured to effectively match
`the acoustical impedance at the output face of the speaker to
`the acoustical impedance at the entrance of the listener’s ear.
`In one possible embodiment,
`the ring is formed of an
`1
`t
`filled with microca sules containin
`a material
`g
`6 as omer
`.
`p
`capable of an endothermic phase changes at a constant
`temperature, such that the cushion more effectively conducts
`heat away from the ear, thereby providing long term listen-
`ing comfort. In another embodiment, the through-opening is
`acoustically coupled to the output of the transducer with an
`acoustic plug such that the cushion is flexibly articulated
`about the plug relative to the speaker, thereby enabling the
`cushion to comply more easily to the listener’s ear using
`lower contact forces between the cushion and the ear.
`
`26 Claims, 2 Drawing Sheets
`
`310
`
`'
`
`I?
`
`.
`
`
`
`320
`
`33°
`3M
`
`’
`
`'
`
`goo 302 322
`
`, / 5K5
`\‘
`\fl‘L--
`‘i é
`30*
`
`336
`342 m
` .17.},_~
`
`
`
`
`
`,- -.31"
`
`
`
`
`
`ll
`
`Bose Exhibit 1017
`
`Bose V. Koss
`
`

`

`US 6,856,690 B1
`
`Page 2
`
`US. PATENT DOCUMENTS
`.
`.
`2/1986 F1f11 et al.
`................... 181/129
`
`313:; gh’ééuey 6‘ ‘1
`~ 373/333
`
`u“ m “““““
`/
`/
`8/1987 Houng
`381/183
`.
`
`.
`9/1988 Wllcox, Jr.
`379/430
`.
`.
`.
`8/1989 Saplejewskl
`2/209
`
`10/1989 Derhaag et al.
`. 379/430
`.
`.
`.
`
`381/187
`5/1990 Saplejewskl
`9/1990 Moody .............
`. 181/129
`.
`.
`.
`
`2/1991 Saplejewskl et al.
`.
`2/209
`.
`
`4/1991 Rlchardson ............... 2/6
`..
`. 181/129
`5/1991 Dohi et al.
`
`................... 2/209
`8/1992 Urella et al.
`9/1996 Hofer et al.
`................ 381/183
`
`4,572,324 A
`232%: 2
`7
`7
`4,689,822 A
`4,771,454 A
`4,856,118 A
`4,875,233 A
`4,922,542 A
`4,958,697 A
`4,989,271 A
`
`5,003,631 A
`5,018,599 A
`5,138,722 A
`5,555,554 A
`
`5,677,964 A
`D391,575 S
`5,736,785 A
`5,761,298 A
`5,821,468 A
`5,911,314 A
`5,960,094 A
`6,097,809 A
`6,099,894 A *
`6,101,260 A
`6,163,615 A
`6,252,970 B1
`6295 366 B1
`7
`7
`
`10/1997 Sun ............................ 381/187
`.
`. D14/223
`3/1998 Bergin et al.
`
`.. 257/712
`4/1998 Chiang et a1.
`
`................ 379/430
`6/1998 Davis et al.
`10/1998 Urella etal. ................ 181/129
`..
`.. 2/209
`6/1999 Urella et al.
`
`.
`.. 381/381
`9/1999 Jensen et al.
`
`.. 379/430
`8/2000 Lucey et al.
`
`427/126.3
`8/2000 Holman
`
`
`.. 381/381
`8/2000 Jensen et al
`
`12/2000 Callahan
`381/371
`
`.. 381/374
`6/2001 Poon et al.
`1
`9/2001 H 11
`_
`t
`381/374
`a 6‘ e a‘ ““““““““
`
`* cited by examiner
`
`

`

`US. Patent
`
`Feb. 15, 2005
`
`Sheet 1 0f 2
`
`US 6,856,690 B1
`
`
`
`

`

`US. Patent
`
`Feb. 15, 2005
`
`Sheet 2 0f 2
`
`US 6,856,690 B1
`
`
`
`
` “I\\\‘\!.—.‘.\\\76—”.I——
`
`
`
`
`
`
`
`
`
`
`W 5
`
`24
`
`32‘ Fig. 7
`
`

`

`US 6,856,690 B1
`
`1
`COMFORTABLE EARPHONE CUSHIONS
`
`BACKGROUND
`
`1. Technical Field
`
`This invention generally pertains to communication head-
`sets containing earphones, and more particularly, to cushions
`for the earphones that provide enhanced wearing comfort.
`2. Related Art
`
`Headsets with earphones, and optionally, associated
`microphones, are well known and widely used in broadcast
`and two-way communications. Headsets provide the advan-
`tages of a hands-free listening that is isolated to the listener,
`i.e., the earphones closely couple the sounds they produce to
`the listener’s ear such that, on the one hand, the sounds are
`relatively free from interference from other sounds present
`in the listener’s environment, and on the other hand, such
`that the sounds do not escape to the listener’s environment
`to be overheard by, or
`interfere with,
`the listening of
`bystanders.
`Headsets, which can incorporate one or two earphones for
`monaural or stereo listening, can be classified into three
`general types in accordance with the type of ear-phone that
`they employ: 1) “In-the-ear” type earphones, sometimes
`referred to as “ear buds,” which fit
`into the concha, or
`entrance to a wearer’s middle ear, such as that described in
`US. Pat. No. 5,761,298 to M. Davis, et al.; 2) “On-the-ear”
`types that couple against a lateral face of the auricle, or
`external ear, of the wearer, such as that described in US. Pat.
`No. 5,960,094 to W. Jensen, et al.; and, 3) “Over-the-ear”
`types that surround and form a closed chamber over the
`auricle of the listener, such as that described in US. Pat. No.
`6,295,366 to L. Haller, et al.
`Headsets, particularly those of the two latter types, typi-
`cally incorporate some structure, such as a yoke or
`headband, for forcefully maintaining the output face of the
`earphone in, against, or over the ear of the wearer. As a
`consequence, the force exerted by the earphones against the
`ear or head of the wearer can become uncomfortable after
`
`extended periods of wear. Additionally, the wearer’s body
`heat can also build up in the interface between the earphone
`and the ear or the head of the wearer to an uncomfortable
`level.
`
`SUMMARY
`
`In accordance with the invention, a cushion for an ear-
`phone of a headset affords a wearer of the headset improved,
`long-term wearing comfort, including enhanced cooling of
`the wearer’s ears and a reduction in the force needed to
`acoustically couple the ear-phone to the wearer’s ear.
`In one possible embodiment,
`the cushion comprises a
`resilient ring having opposite input and output faces, a
`thickness between the faces, and a through-opening defining
`an interior surface. The ring may be variously shaped. The
`interior surface of the ring may flare out between the input
`faces and output faces, like a horn, to match the acoustic
`impedance at
`the output
`face of an electro-acoustic
`transducer, or speaker, to that at the entrance of a listener’s
`ear. The ring includes structure associated with the input
`face for acoustically coupling the through-opening of the
`ring to the output face of the speaker, and the output face of
`the ring is made resiliently conformable to the lateral face of
`the listener’s external ear to acoustically couple the through-
`opening, and thus, the speaker, to the listener’s ear.
`In another advantageous embodiment,
`the cushion can
`comprise a foamed elastomer incorporating microcapsules
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`of a proprietary “phase change” material that is capable of
`an endothermic phase change at a substantially constant
`temperature, which can be “pre-set,” or fixed, at a particular
`value at the time the microcapsules are made, and before
`they are incorporated into the elastomer. The phase-change
`material imbues the cushion with a substantially enhanced
`specific heat and thermal conductivity, and thereby enables
`an earphone incorporating the cushion to be worn against the
`ear for longer periods of time without an uncomfortable
`buildup of heat.
`In yet another advantageous embodiment, the output face
`of the speaker is provided with a flange, and the interior
`surface of the ring of the cushion is provided with a
`complementary recess located inside of the input
`face
`thereof and configured to resiliently receive the flange of the
`speaker in a complementary, over-center engagement. The
`through-opening of the ring is acoustically coupled to the
`output face of the speaker by inserting the output face of the
`speaker into the through-opening at the input face until the
`flange on the speaker is received and retained in the recess.
`In this one—piece cushion embodiment, the cushion ring
`may also be provided with an exterior circumferential recess
`located between the output face of the ring and the interior,
`flange-receiving recess. The circumferential recess serves to
`resiliently articulate an output face portion of the cushion
`relative to an input face portion thereof, thereby: rendering
`the output face of the cushion more easily compliable to the
`lateral face of the listener’s ear without requiring uncom-
`fortably high contact forces between the cushion and the ear.
`The circumferential recess also increases the external sur-
`face area of the cushion, thereby enabling it to transfer more
`heat away from the interface with the listener’s ear.
`In still yet another advantageous embodiment, the cushion
`ring may be acoustically coupled to the output face of a
`speaker by a second resilient ring having a recess into which
`a flange on the speaker is resiliently inserted and retained in
`a manner similar to that described above. A third, rigid
`retainer ring is captivated within the recess in the second
`ring along with the flange on the speaker. A first end of an
`acoustic plug is inserted though the respective openings of
`the cushion ring, the second ring, and the third ring, and
`retained therein by the third ring. The plug has a flange on
`an end opposite to the first end that presses a first portion of
`the input face of the cushion ring against a corresponding
`portion of an output face of the second ring.
`In this multi-piece cushion embodiment, a second portion
`of the input face of the cushion ring circumscribing the
`flange of the plug may be spaced apart from a corresponding
`portion of the output face of the second ring to resiliently
`articulate the cushion ring relative to the second ring and
`speaker, thereby increasing the external surface area of the
`cushion for
`improved heat
`transfer from the interface
`between the cushion and the ear, and rendering the output
`face of the cushion more easily compliable to the lateral face
`of the listener’s ear without requiring uncomfortably high
`contact forces between the cushion and the ear.
`
`By equipping a headset with at least one earphone incor-
`porating one of the novel cushions of the present invention,
`a wearer of the headset can experience improved, long-term
`wearing comfort, including enhanced cooling of the wear-
`er’s ear and a reduction in the force required to couple the
`earphone to the wearer’s ear.
`Abetter understanding of the above and other features and
`advantages of the invention may be had from a consideration
`of the following detailed description of some exemplary
`embodiments thereof, particularly if such consideration is
`made in conjunction with the figures of the accompanying
`drawings.
`
`

`

`US 6,856,690 B1
`
`3
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is an expanded isometric view of a headset having
`an earphone incorporating a cushion in accordance with the
`present invention;
`FIG. 2 is a front elevation view of the output face of a first
`embodiment of an ear-phone cushion in accordance with the
`present invention;
`FIG. 3 is a cross-sectional, side elevation view of the
`earphone cushion of FIG. 2, showing a speaker in phaitom
`lines extracted and spaced apart from an input face of the
`cushion;
`FIG. 4. is a front elevation view of the output face of a
`second embodiment of an earphone cushion in accorc ance
`with the present invention;
`FIG. 5 is a cross-sectional, side elevation view of the
`earphone cushion of FIG. 4, showing a speaker in phaitom
`lines extracted and spaced apart from an input face of the
`cushion;
`FIG. 6. is a front elevation view of the output face of a
`third embodiment of an earphone cushion in accorcance
`with the present invention;
`FIG. 7 is a cross-sectional, side elevation view of the
`earphone cushion of FIG. 6, showing a speaker in phaitom
`lines extracted and spaced apart from an input face of the
`cushion; and,
`FIGS. 8—10 are respective cross-sectional, side elevation
`views of three embodiments of an acoustic plug in accor-
`dance with the present invention.
`DETAILED DESCRIPTION
`
`
`
`FIG. 1 is a partially expanded isometric view of a headset
`10 incorporating an earphone assembly 12, comprising an
`electro-acoustic transducer, or “speaker” 14 (shown in phan-
`tom outline), a comfort-enhancing earphone cushion 16 in
`accordance with one embodiment of the present invention,
`and structure 18 for acoustically coupling a through-opening
`20 of the cushion 16 to a sound output face 22 of the speaker.
`In the particular exemplary embodiment illustrated in FIG.
`1, the acoustical coupling structure 18 comprises a second
`resilient ring 24, a third ring (not visible in the figure)
`captivated within the second ring, and an acoustic plug 28,
`and is described in more detail below in connection with
`
`FIGS. 6—10. However, other structures for acoustically
`coupling the cushion 16 to the speaker 14 are also possible,
`as described in more detail below.
`
`The headset 10 may optionally include other elements,
`such as a means for acoustically coupling an output face of
`the cushion 16, and hence, the earphone 12 and speaker 14,
`to a lateral face of an external ear, or auricle, of a listener
`(not illustrated), which, in the particular embodiment illus-
`trated in FIG. 1, comprises a resilient, arcuate head-band
`having a first end 32 attached to a housing 34 for the
`earphone assembly 12, and a second end 36 that includes a
`pad 38 for pressing against the side of the listener’s head
`opposite to that on which the listening ear and earphone 12
`are located. Other means for coupling the earphone 12 to the
`listener’s ear are also known, including resilient, U-shaped
`yokes that hang below the listener’s head of a type familiar
`to airline travelers, and hook-like hangars that suspend the
`earphone from the top edge of the external ear, and which
`include a resilient hinging mechanism that presses the
`earphone against the ear.
`the headset 10 may
`In addition to the head-band 30,
`incorporate a microphone 40 to enable two-way voice
`communication by the wearer. In the embodiment illustrated
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`4
`in FIG. 1, the microphone may be mounted at the end of a
`boom 42 that is movably attached at a second end to the
`earphone housing 34 for adjustment relative to the wearer’s
`mouth. Alternatively,
`the microphone may comprise an
`omnidirectional microphone 44 that is suspended below the
`earphone housing 34 by one or more headset input wires 46,
`as shown by the dashed outlines in FIG. 1.
`A first embodiment of a comfort-enhancing cushion 100
`for an earphone in accordance with the present invention is
`illustrated in the front elevation and cross-sectional, side
`elevation views of FIGS. 2 and 3, respectively. As may be
`seen in the figures, the cushion 100 comprises a first resilient
`ring 102 having opposite input and output faces 104, 106, a
`thickness 108 between the two faces, and an opening 110
`extending therethrough and defining an interior surface 112
`of the ring. Although the first ring 102 of the cushion 100 is
`shown as substantially annular in shape, the cushions of this
`invention are not limited to this particular shape, but may
`incorporate other, differently shaped rings, e. g., they may be
`oval, elliptical, heart—shaped, or auricular in shape.
`The material of the ring 102 may vary widely, so long as
`it is both resilient and, as discussed below, somewhat elastic.
`Thus,
`in one possible embodiment,
`the ring 102 of the
`cushion 100 may comprise an elastomer, e.g.,
`a
`polyurethane, which may be “foamed” with either open or
`closed cells. Thus, in only one of many possible exemplary
`manufacturing embodiments, the ring 102 of the cushion
`100 is procured in the form of a sheet of elastomer, die-cut
`from the sheet, and pressed in heated molds (i.e.,
`“thermoformed”)
`into the various ring configurations
`described herein. Of course, many other manufacturing
`techniques are also possible.
`The input face 104 of the ring 102 has means for acous-
`tically coupling the through-opening 110 of the ring to an
`output face 114 of a speaker 116, shown in phantom lines in
`FIG. 2, and the output face 106 of the ring is resiliently
`conformable to a lateral face of a listener’s external ear, or
`auricle. The speaker 116 may comprise a known type of
`electromagnetic, piezoelectric, or electrostatic type of driv-
`ing element, or a combination thereof, or even some other
`form of driving element, for generating sound waves from
`the output face of the speaker and in the direction of the
`arrow shown in FIG. 3.
`
`In the first exemplary embodiment of the cushion 100
`illustrated in FIGS. 1 and 2, the acoustical coupling means
`includes a circumferential flange 118 provided at the output
`face 114 of the speaker 116. The through-opening 110 at the
`input face 104 of the ring 102 is configured in size and shape
`to receive the speaker’s output face 114 in a resilient,
`complementary, slide-in engagement in the direction of the
`arrow in FIG. 3. Additionally, the interior surface 112 of the
`ring 102 is provided with a complementary, flange-retaining
`recess 120 located adjacent to the input face 104 of the ring
`that is configured to resiliently receive the flange 118 of the
`speaker in an elastic, “over-center” engagement. That is, the
`opening 110 at the input face 104 of the ring 102 is stretched
`out and over the output face 114 end flange 118 of the
`speaker 116, then allowed to return elastically such that the
`flange is retained in the recess 120, and the speaker’s output
`face 114 abuts the portion of the interior surface of the ring
`102 circumscribing the through-opening 110. A bead of a
`resilient adhesive (not illustrated) can be dispensed in the
`recess 120 between the ring 102 and the speaker flange 118
`to secure and render the coupling more permanent.
`As may be seen in the cross-sectional view of FIG. 3, the
`interior surface 112 of the ring 102 flares out smoothly
`
`

`

`US 6,856,690 B1
`
`5
`between the output face 114 of the speaker, when it is
`coupled to the ring, and to the output face 106 of the ring,
`thereby smoothly increasing the cross sectional area of the
`through-opening 110 between the two output faces. This
`change in the cross-sectional area of the opening 110 permits
`the cushion 100 to act as an “acoustical transformer” that
`
`matches the acoustical impedances at the two respective
`cushion and speaker output faces 114 and 106, for more
`efficient
`transmission of sound from the speaker to the
`listener’s ear.
`In one possible embodiment,
`the interior
`surface 102 of the opening 10 can flare out uniformly, like
`a frusto-conical megaphone, and in another embodiment, the
`interior surface can flare out exponentially, like a horn.
`As discussed above, one of the problems associated with
`wearing headsets for extended periods is the discomfort
`caused by the build-up of body heat, and hence, temperature,
`at the interface between the earphone and the ear. It has been
`discovered that this problem can be significantly reduced by
`increasing the ability of the earphone, or at least the portion
`thereof in direct contact with the ear, viz., the cushion, to
`conduct heat away from the interface, which can be effected
`by, among other ways, 1) increasing the thermal conductiv-
`ity of the material of the cushion, and 2) increasing the
`exterior surface area of the cushion exposed to cooler
`ambient air.
`
`The first effect above is achieved in an earphone cushion
`in accordance with the present invention by “filling” or
`loading the resilient material of the cushion ring, e.g., an
`elastomer, with microcapsules of a “phase change”
`substance, i.e., a substance capable of an endothermic, i.e.,
`heat-absorbing, and an exothermic,
`i.e., heat releasing,
`change of phase, e. g., from a solid to a liquid and vice-versa,
`at
`a substantially constant
`temperature. Several such
`substances, and the microcapsules for containing them, are
`described in US. Pat. No. 6,099,894 to M. Holman,
`assigned to Frisby Technologies, Inc., of Bay Shore, NY,
`and the teachings of which are incorporated herein by this
`reference.
`
`The temperature at which the encapsulated substance
`undergoes a phase change can be programmed, or “pre-set,”
`at a particular value, e.g., body temperature, at the time the
`microcapsules are made, and before they are incorporated
`into the “host,” e.g., the elastomer of the ring. Thus, filling
`the material of the cushion ring with phase—change micro—
`capsules that are pre-set to change phase at a temperature
`slightly greater than body temperature has two effects: 1)
`The effective specific heat of the cushion is increased
`substantially,
`thereby rendering the cushion capable of
`absorbing a substantially greater amount of heat from the
`interface with the ear than are ordinary materials, and 2) The
`effective thermal conductivity of the cushion material is
`substantially increased,
`thereby enabling the cushion to
`conduct a greater amount of heat away from the ear interface
`and to the surrounding ambient air. This latter effect is
`enhanced even more if the elastomer of the ring is foamed
`with open cells, which permit circulation of the ambient into
`the host material and into direct contact with the microcap-
`sules.
`
`The phase-change microcapsule additives are commer-
`cially available under the name “Thermasorb” from licens-
`ees of Frisby Technologies, Inc., such as 3M, Inc., St. Paul
`Minn., and open-celled foamed elastomers containing the
`microcapsules are available under the name “Comfortemp”
`from other licensees thereof.
`A second embodiment of an ear cushion 200 in accor-
`
`dance with the present invention is illustrated in the front
`
`6
`and cross-sectional side elevation views of FIGS. 4 and 5,
`respectively, wherein elements that are the same or similar
`to those in the first embodiment of cushion 100 illustrated in
`
`FIGS. 2 and 3 are labeled with corresponding reference
`numerals in which the most significant digit has been
`incremented by one. By reference to FIGS. 4 and 5, it may
`be seen that the cushion 200 of the second embodiment is
`
`substantially similar to the first embodiment 100, and differs
`therefrom only by the provision of at least one circumfer-
`ential recess 222 in the exterior surface of the ring 202 of the
`cushion between the output face 206 thereof and the flange-
`retaining recess 220 in the interior surface 212 thereof.
`The at least one circumferential recess 222 of the second
`
`exemplary embodiment serves at least two desirable comfort
`functions. First, the recess 222 substantially increases the
`external surface area of the cushion 200, thereby enabling
`the cushion to transfer more heat away from the interface
`with the listener’s ear to the ambient air. Second, the recess
`222 serves to resiliently articulate an output face portion 224
`of the cushion 200 relative to an input face portion 226
`thereof, thereby rendering the output face 206 of the cushion
`more easily compliable to the lateral face of the listener’s
`external ear, without: requiring uncomfortably high contact
`forces between the cushion and the ear for effective acoustic
`
`coupling thereof. The resulting reduction in the required
`contact force translates directly into enhanced, long-term
`headset wearer comfort.
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`A third exemplary embodiment of an ear cushion 300 in
`accordance with the present invention is illustrated in the
`front and cross-sectional side elevation views of FIGS. 6 and
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`7, respectively, wherein elements that are the same or similar
`to those in the first and second embodiments of cushion 100
`
`and 200 respectively illustrated in FIGS. 2—5 are labeled
`with corresponding reference numerals in which the most
`significant digit has been incremented by two or one,
`respectively, as above.
`As may be seen from the figures, the third embodiment of
`the cushion 300 comprises a multi-piece structure wherein
`the structure associated with the input face 304 of the first
`resilient ring 310 for acoustically coupling the through-
`opening 310 of the ring 302 to the output face 314 of the
`speaker 316 includes the provision of a coupling flange 318
`on the output face of the speaker, as described above in the
`first two exemplary embodiments 100 and 200.
`Further, a second resilient ring 330 is also provided that
`has many of the features of the first rings 102 and 202
`described above, including opposite input and output faces
`332 and 334 and an opening 336 therethrough corresponding
`to the through-opening 310 in the first ring 302. The opening
`336 defines an interior surface in the second ring 330
`between the input and output faces 332 and 334, and is
`configured at the input face to resiliently receive the output
`face 314 of the speaker 316 in a complementary, slide-in
`engagement. The interior surface of the second ring 302 is
`also provided with a flange-retaining recess 320, which is
`located adjacent to the input face 334 and configured to
`resiliently receive the flange 318 of the speaker 316, together
`with a third, rigid retainer ring 340 described below, in a
`complementary, over-center, elastic engagement.
`The third, rigid retainer ring 340 has an opening 342
`through it corresponding to the respective openings 310 and
`336 of the first and second rings 302 and 330, and an outer
`periphery configured to be resiliently received in the flange-
`retaining recess 320 of the second ring in a complementary,
`over-center engagement, together with the flange 318 of the
`speaker 316. The third ring 340 cooperates with an acoustic
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`

`

`US 6,856,690 B1
`
`7
`plug 350, described below, to acoustically couple the input
`face 304 of the first ring 302 to the output face 334 of the
`second ring 330, and thus, to the output face 314 of the
`speaker 316, in the manner described below.
`The acoustic plug 350 of the third embodiment of cushion
`300, which is shown in the enlarged, cross-section elevation
`views of FIGS. 8—10, includes an input end 352 correspond-
`ing to, and configured to be received through, the respective
`through-openings 310, 336, and 342 of the first, second and
`third rings 302, 330, 340, and to be retained therein by the
`retainer ring 340. The plug 350 further includes an output
`end 354, a flange 356 circumscribing the output end, and at
`least one aperture 358 extending through it. The at least one
`aperture 358 can comprise a single,
`large bore (not
`illustrated) that extends completely through both ends of the
`plug 350, or alternatively, a large counterbore that termi-
`nates behind an output face 360 of the plug, as shown in
`FIGS. 8—10, together with one or more smaller aperture
`extending through the output face, as shown in FIG. 6,
`which can be configured in terms of their size, shape,
`number and distribution on the output face to acoustically
`“tune” the earphone.
`In use,
`the input end 352 of the plug 350 is inserted
`through the respective openings 310, 336, and 342 of the
`first, second and third rings 302, 330, 340, and is retained
`therein by the third ring such that the flange 356 on the plug
`presses a first portion of the input face 304 of the first ring
`302 tightly against a corresponding portion of the output
`face 334 of the second ring 330, thereby acoustically cou-
`pling the input face of the first ring to the output face 314 of
`the speaker 316.
`As shown in FIG. 7, means 362 use provided for retaining
`the input end 352 of the plug 350 in the third retainer ring
`340. As illustrated in FIG. 8, the retaining means 362 may
`comprise a bead of an adhesive 364 between the input end
`352 of the plug 350 and the third ring 340. Alternatively, a
`plurality of cams 366 may be supported on the plug’s input
`end 352 and made resiliently deflectable thereat by, e.g., a
`plurality of elongated slots 368 formed in the input end of
`tile plug, such that the input end and the cams can snap into
`the opening 342 of the third ring 340 with an over-center
`locking engagement, as shown in FIG. 9. In yet another
`alternative, the retaining means 362 can comprise comple-
`mentary screw threads 370 on respective ones of the input
`end of the plug and in the opening 342 of the third ng, in
`which instance, the plug 350 screws into the opening 342, as
`illustrated in FIG. 10.
`An additional feature of the third embodiment of cushion
`
`300 is illustrated in FIG. 7, viz., that the first ring 302 can
`be configured such that a second portion of the input face
`304 of the first ring circumscribing the flange 356 of the
`acoustic plug 350 is spaced apart from a corresponding
`portion of the output face 334 of the second ring 330. The
`circumferential recess 322 thereby defined affords the cush-
`ion 300 with substantially the same comfort benefits that the
`at least one circumferential recess 222 affords to the second
`
`embodiment of cushion 200 described above, viz., improved
`heat transfer and enhanced compliance with the external ear.
`By now, those of skill in the art will appreciate that many
`modifications, substitutions and alterations can be made to
`the present invention in terms of its materials, elements and
`methods without departing from its scope. For example, the
`output face of the acoustic plug can be faceted and plated
`with, e.g., a precious metal, to serve as decorative trim. The
`second ring of the third embodiment can be made of a
`resilient material having a different texture and/or color for
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`8
`ornamental purposes, or covered with a simulated leather
`called “leatherette,” to lend a rich look and feel to the
`cushion. A plurality of circumferential recesses can be
`provided the exterior cushion of the second embodiment to
`improve its comfort benefits even further.
`In light of the foregoing examples,
`the scope of the
`present
`invention should not be limited to that of the
`particular embodiments thereof described and illustrated
`herein, as these are merely exemplary in nature, but rather,
`should be commensurate with that of the claims appended
`hereafter, and the functional equivalents thereof.
`What is claimed is:
`
`1. An earphone cushion, comprising a first resilient ring
`having opposite input and output faces, a thickness between
`the faces, and an opening therethrough defining an interior
`surface between the faces, the input face having associated
`structure for acoustically coupling the opening to an output
`face of a speaker, the output face of the first resilient ring
`being resiliently conformable to a lateral face of an auricle,
`and the interior surface flaring unidirectionally outwardly
`for at least a portion of the thickness, the first ring compris-
`ing an elas