(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY(PCT)
`
`
`
`ANONACA
`
`(10) International Publication Number
`WO 2009/086555 Al
`
`(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 ofnational protection 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, FL, GB, GD, GE, GH, GM, GT, HN, HR, HU, ID,
`IL, IN, IS, JP, KE, KG, KM, KN, KP, KR, K%, 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 regional protection available): ARIPO (BW, GH,
`
`[Continued on next page]
`
`(19) World Intellectual Property Organization
`International Bureau
`
`(43) International Publication Date
`9 July 2009 (09.07.2009)
`
`International Patent Classification:
`HO4R 25/00 (2006.01)
`
`International Application Number:
`PCT/US2008/088656
`
`International Filing Date:
`31 December 2008 (31.12.2008)
`
`Filing Language:
`Publication Language:
`
`English
`English
`
`Priority Data:
`61/009,690
`
`31 December 2007 (31.12.2007)
`
`US
`
`Applicant (for all designated States except US): KOSS
`CORPORATION [US/US]; 4129 North Port Washington
`Road, Milwaukee, WI 53212 (US).
`Inventors; and
`only):
`US
`(for
`Inventors/Applicants
`MLODZIKOWSKI, Allan [US/US]; S104 W21015
`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];
`
`(51)
`
`(21)
`
`(22)
`
`(25)
`
`(26)
`(30)
`
`(71)
`
`(72)
`(75)
`
`
`
`WO2009/086555A1_IIMATUTAITTAMMCATA
`
`(54) Titles ADJUSTABLE SHAPE EARPHONE
`
`FIG.
`
`1A
`
`This disclosure
`(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.
`
`APPLE 1141
`APPLE1141
`
`1
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`

`

`WO 2009/086555 AX
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`_[IMTIITTIIUINTMINANIT TAMAKITMMMT
`
`GM, KE, LS, MW, MZ, NA, SD, SL, SZ, TZ, UG, ZM, ——astothe applicant's entitlement to claimthe priorityof the
`ZW), Eurasian (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM),
`earlier application (Rule 4.17(iii))
`European (AT, BE, BG, CH, CY, CZ, DE, DK, EE, ES,FI,
`FR, GB, GR, HR, HU, IE, 1S, IT, LT, LU, LV, MC, MT,NL,—Published:
`NO, PL, PT, RO, SE, SI, SK, TR), OAPI (BF, BJ,CF,CG, — with international search report
`Cl, CM, GA, GN, GQ, GW, ML, MR, NE, SN, TD, TG). — with amended claims
`Declarations under Rule 4.17:
`
`— asto applicant's entitlement to apply for and be granted a
`patent (Rule 4.17(ti))
`
`2
`
`

`

`WO 2009/086555
`
`PCT/US2008/088656
`
`ULE
`
`ADJUSTABLE SHAPE EARPHONE
`
`PRIORITY CLAIM
`
`The present application claims priority to U.S. provisional application
`
`Serial No. 61/009,690, titled “ADJUSTABLE FIT EARBUD, CLOTH COVERED
`
`CORD AND CORD CLIP 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 earphonesfor listening to audio media, such as that which
`
`may be played from portable audio devices.
`
`Earphonesare usually a pair of small loudspeakers that are provided
`
`with a mechanism to hold them closeto 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 MP3 player.
`
`Earbuds are earphonesof 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
`
`their portability and convenience. However, due to their inability to provide
`
`sound isolation, they are incapable of delivering the same dynamic range
`
`offered by many full-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. Over time,
`
`earbuds became a commontype of earphone bundledwith portable audio
`
`devices.
`
`Internal-canal earbuds are earbuds that are inserted directly into the ear
`
`canal. Theseoffer portability similar to external-canal earbuds, and also actlike
`
`earplugs to block out environmental noise. There are two main types of internal-
`
`30
`
`canal earbuds: universal and custom. Universal internal-canal earphones
`
`provide one or morestocksleeve size(s) to fit various ear canals, which are
`
`3
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`WO 2009/086555
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`PCT/US2008/088656
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`commonly made outofsilicone rubber, elastomer, or foam, for noise isolation.
`
`Universal internal-canal earbuds are marketed typically to casual listeners and
`
`are relatively inexpensive, though some offer very high audio quality.
`
`Custom internal-canal earbudsarefitted to individuals. Castings of the
`
`ear canals are made, usually by an audiologist. The manufacturer uses the
`
`castings to create custom-moldedsilicone rubber or elastomerplugsthat
`
`provide added comfort and noiseisolation. Because of the individualized labor
`
`involved, custom internal-canal earbuds are more expensivethan universal
`
`internal-canal earbuds.
`
`Consequently, there is a need for improved internal-canal earbuds. The
`
`foregoing discussion is intended only toillustrate 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 presentinvention 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 the first side of the
`
`20
`
`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, whereat
`
`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 actuator is
`
`mounted slidably in the housing, and the actuator threads operably engage the
`
`dial threads suchthatrotation of the dial in a first direction translatesthefirst
`
`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
`
`30
`
`subsequently configured to force the resilient cushion to have an expanded
`
`shape asthe cantilever arm bendsinto the cushion.
`
`to
`
`4
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`In another embodiment, the adjustable earphoneincludes: (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
`
`configured to be located within an opening of the cushion whenthe cushion is
`
`attached to the housing; (ili) 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 comprisingafirst portion and a
`
`secondportion, the second portion having threads. The actuatoris slidably
`
`10
`
`mountedin the housing, with the actuator threads operably engaging the dial
`
`threads suchthat rotation of the dialinafirst 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 earphoneincludes: (i) a
`
`housing; (ii) an ear canal portion adjacent to the housing, the ear canal portion
`
`havingafirst 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 betweena 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 member suchthat
`
`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 expandin at least one direction
`
`25
`
`when the movable memberis moved to the second position. Subsequently, the
`
`expansion assembly is configured to force the ear canal portion to haveat least
`
`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
`
`30
`
`placementin a user’s ear canal; and (ii) means for adjusting the shapeof the
`
`ear canal portion by a user whenthe ear canalportion is positioned in the user’s
`
`ear.
`
`5
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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
`
`adjustment assembly is operable to cause the ear canal portion to have atleast
`
`a second shape.
`
`In yet other embodiments, the adjustable earinsert includes: (i) an inner
`
`end having an eartip, where the inner end is configured to be placed within an
`
`ear canalof a user; (ii) and an outer end having a control feature, where the
`
`10
`
`outer end is configured to remain outside the ear canal, and wherethe control
`
`feature is accessible by the user to expand or compactthe eartip.
`
`In these and other various embodiments, an adjustable earinsert 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.
`
`Wherethe 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 enhancementfor sound produced
`
`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 embodimentsare setforth with particularity in
`
`the appendedclaims. 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
`
`30
`
`the accompanying drawingsasfollows.
`
`FIG. 1A is a perspective view of a wired adjustable earphone according
`
`to one non-limiting embodiment.
`
`6
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`FIG. 1B is ais a perspective view of a wireless adjustable earphone
`
`according to one non-limiting embodiment
`
`FIGS. 2A-2B are diagrams showing compact and expanded shapesof
`
`various ear canal portions of adjustable earphones according to various
`
`embodiments.
`
`FIGS. 3A-3D are several top views of adjustable earphones using a
`
`variety of user controls and actuator mechanismsto provide an adjustable
`
`earphone according to various embodiments.
`
`FIG. 4 is a side cross-sectional view of one non-limiting embodimentof
`
`10
`
`an adjustable earphone.
`
`FIGS. 5A-5G are severalillustrations of someof the various ear canal
`
`portion shapes madepossible by the adjustable earphone of FIG. 4.
`
`FIG. 6 is an exploded viewof the adjustable earphoneof FIG. 4.
`
`FIG. 7 is a side cross-sectional view of one non-limiting embodimentof
`
`an adjustable earphone.
`
`FIGS. 8A-8G are severalillustrations of some of the various ear canal
`
`portion shapes madepossible by the adjustable earphone of FIG. 7.
`
`FIG. 9 is an exploded view of the adjustable earphoneof FIG. 7.
`
`FIG. 10 is a top cross-sectional view of one non-limiting embodiment of
`
`an adjustable earphone.
`
`FIGS. 11A-11H 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
`
`25
`
`an adjustable earphone.
`
`FIGS. 14A-14C are several illustrations of some of the various ear canal
`
`portion shapes madepossible by the adjustable earphone of FIG. 13.
`
`FIG. 15 is an exploded view of the adjustable earphoneof FIG. 13.
`
`FIG. 16 is a cross-sectional view of one non-limiting embodiment of an
`
`30
`
`adjustable earphone inserted and expanded in a user’s ear canal.
`
`FIGS. 17A-17B are perspective views of a non-limiting embodiment of an
`
`eartip cushion and a base housing element of an adjustable earphone.
`
`7
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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.
`
`FIG. 19A is a perspective view of an adjustable earphone from the
`
`earphone assembly of FIG. 18A and 18B.
`
`FIG. 198is anillustration of a spring clip from the earphone assembly of
`
`FIGS. 18A and 18B.
`
`FIG. 19Cis anillustration of the spring clip of FIG. 19B being used to
`
`10
`
`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 viewof 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
`
`25
`
`an expanded, second shape.
`
`FIG. 27 is a side cross-sectional view of the adjustable earphoneof FIG.
`
`21A inserted and expandedin a user’s ear canal.
`
`FIG. 28 is a top cross-sectional view of one non-limiting embodiment of
`
`an adjustable earphone having a pushbutton.
`
`30
`
`-6-
`
`8
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`DETAILED DESCRIPTION
`
`Certain exemplary embodimentswill now be described to provide an
`
`overall understanding of the principles of the structure, function, manufacture,
`
`and use of the devices and methodsdisclosed herein. One or more examples
`
`of these embodimentsareillustrated in the accompanying drawings. Those of
`
`ordinary skill in the art will understand that the devices and methods specifically
`
`described herein andillustrated in the accompanying drawings are non-limiting
`
`exemplary embodiments and that the scope of the various embodimentsof the
`
`present invention is defined solely by the claims. The featuresillustrated or
`
`10
`
`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
`wow
`
`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 arenot to be construed aslimiting terms. The description
`
`below is for the purpose of describing various embodimentsof the invention and
`
`is not intendedto 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 hasa first end
`
`11, asecond end 12, and an electrical connector 13 located atthe first end 11.
`
`25
`
`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, wherethe electrical signal may be converted to audible
`
`soundsby a transducer(see, e.g., FIGS. 24 and 27). As is known in thefield, a
`
`transduceris a device, usually electrical, electronic, electro-mechanical,
`
`30
`
`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,
`
`9
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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 includesa first portion 16 adjacentto the first end 11 of the cord
`
`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 placedin the ears of a user,
`
`with one strand of the secondportion 17 on eachside of the users head.
`
`As shown in FIGS. 1A and 1B, a wired (FIG. 1A) or wireless (FIG. 1B)
`
`10
`
`earbud style earphone (100, 50 respectively) according to an aspectof the
`
`present disclosure includes an eartip cushion 121 that may be inserted ina
`
`user’s ear canal in a compact configuration, orfirst shape 122, and, oncein the
`
`ear canal, expanded to an expandedconfiguration, or second shape 123 (see
`
`FIG. 26), to fit snugly againstall sides of the ear canal (see, e.g., FIG. 27). The
`
`resulting customizedfit 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
`
`25
`
`typically be returned to its compact configuration, orfirst 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 while still in its
`
`expanded configuration.
`
`Still referring to FIGS. 1A and 1B, expansionof the eartip may be
`
`30
`
`achieved by twisting or pressing on a control 180 on an exterior surface of the
`
`earbud. Where expansion is achieved by twisting a contro! 180 about
`
`longitudinal axis L in the direction of arrow A and/or B, a manufacturer’s logo
`
`10
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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 regardlessof the rotation of the control 180.
`
`In various embodiments, referring now to FIGS. 20-27, an adjustable
`
`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 attachedto the first side 111 of the housing is the ear
`
`canal portion 120. Ear canal portion 120 generally defines longitudinal axis L
`
`10
`
`(see FIG. 20) and is operable for placement in a user’s ear canal (see, e.g.,
`
`FIG. 27). Ear canal portion 120 is shownin 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 may include 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 on a protruding ring 118 of the housing 110 such that cushion 121 may
`
`attach releasably to the housing 110. Cushion 121 maybe stretchable and
`
`made of 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
`
`25
`
`a third shape (not shown).
`
`In other words, the shape of the ear canal portion
`
`120 may be changed to have any numberof shapes, including a continuum of
`
`shapes betweenthefirst shape 122 and the second shape 123. The purposeof
`
`adjusting the shape of the ear canal portion 120 is to allow a user to change the
`
`shapeof the ear canal portion 120, after insertion in the user’s ear canal, to
`
`30
`
`have a snug fit between the ear canal and a substantial part of the ear canal
`
`portion 120. Such a snug fit provides noise isolation (from external noises other
`
`than those producedby the earphone 100) and sound enhancement (for sound
`
`AS,
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`11
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`produced by the earphone 100), among other things. Further, the in-ear
`
`adjustability of the ear canal portion 120 provides an earphone 100 that should
`
`not require different sized ear canal portions 120 or cushions 121 for different
`
`users; in other words, the adjustable earphone 100 mayprovide a one-size-fits-
`
`all device owing to the customizedfit offered by the adjustability of the ear canal
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`portion.
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`In various embodiments, referring again to FIGS. 20-27, the adjustable
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`earphone 100 mayinclude meansfor adjusting the shape of the ear canal
`
`portion 120 by a user when the ear canal portion 120 is positioned in the user’s
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`10
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`ear canal. Means for adjusting the shape of the ear canal portion 120 may be
`
`provided in at least one embodiment by adjustment assembly 130. Adjustment
`
`assembly 130 may be operably coupled to the housing 110 and/or to the ear
`
`canal portion 120 suchthat 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, the
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`adjustment assembly 130 may include a movable member 140, an expansion
`
`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 member140, and the control
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`member 180 maybe configured to move the movable member140 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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`25
`
`cause the expansion assembly 160 to expandin at least one direction when the
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`movable memberis 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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`30
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`retract in at least one direction when the movable member is movedto the first
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`position (FIG. 25), thus resulting in the ear canal portion returning to the first
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`shape 122 when the expansion assembly 160 is retracted.
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`12
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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, 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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`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 movedaccordingly. Such relative movement is caused by
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`force exerted on the movable member by 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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`10
`
`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 secondportion
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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 memberto 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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`translate but will not substantially rotate with respect to the housing 110 owing
`
`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 the first
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`25
`
`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, the
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`second portion 142 may include locking grooves 147 and transducer supports
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`148. The first 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 suchthat transducer 190 is held in
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`place, or sandwiched, between the first portion 150 and the secondportion 142
`
`of the movable member. Friction betweenthe first portion 150, the transducer
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`-l1-
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`190, and the supports 148 of the secondportion 142 mayprovide sufficient
`
`force to preventthe protrusions 152 of the first portion 150 from freely
`
`decoupling from the locking grooves 147 of the second portion 142.
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`Accordingly, the movably member140, including the first and second portions
`
`150, 142, is designed to move as a single rigid body relative to housing 110.
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`Thus, while shownin at least one embodiment as two separable components,
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`first and second portions 150, 142 could also be one unitary andintegral
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`component.
`
`The first portion 150 of the movable member 140 is designed, in at least
`
`one non-limiting embodiment, to actuate expansion assembly 160 asthe first
`
`portion 150 is moved fromafirst position (FIG. 25) to at least a second position
`
`(FIG. 26). The first portion 150 thus includes an actuating surface 155 (see,
`
`e.g. FIG. 24) that may be shaped andpositioned such that the actuating surface
`
`155 engages operably the expansion assembly 160, as explained in moredetail
`
`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
`
`passageway 151 provides a channel along which sound producedbythe
`
`transducer 190 maytravel freely toward an inner end 101 (FIG. 20) of the
`
`earphone 100 andinto opening 125 (FIGS. 21A-26) of the cushion 121. Also,
`
`the first portion 150 includes an O-ring groove 153 (FIG. 21A) configured to hold
`
`an elastic O-ring 154. O-ring 154 seals the movable member againstthe first
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`side 111 of the housing 110 and/or against the expansion assembly 160 (see
`
`FIGS. 25-26). Accordingly, audible sound waves producedbythe transducer
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`190 only are allowedto travel toward the inner end 101 of the earphone 100,
`
`25
`
`and, subsequently, a user’s ear drum, via sound passageway 151 of the
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`movable member 140.
`
`According at least one non-limiting embodiment, referring now to FIGS.
`
`21A-21B and 25-26, the expansion assembly 160 is designed to expandin at
`
`least one direction when actuated by the movable member 140. The expansion
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`30
`
`assembly 160 may be designed to expand in a direction substantially transverse
`
`to the longitudinal axis L (see FIG. 20). Here, this is accomplished by using a
`
`set of cantilever arms 161. The cantilever arms 161 protrude from the first side
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`111 of the housing and, when theresilient cushion 121 is attached to the
`
`housing, are at least partially located within the opening 125 of the cushion 121.
`
`Arm recesses 126 (FIG. 21B) formed in the cushion 121 receive the cantilever
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`arms 161 such that the cushion 121 doesnotrotate freely thereon. The
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`cantilever arms 161 are uniformly spaced around longitudinal axis L to form an
`
`opening 164 configured to receive thefirst portion 150 of the movable member.
`
`Cantilever arms 161 each include an inner surface 163 and an outer surface
`
`162.
`
`Inner surface 163 is curved at least partially toward longitudinal axis L so
`
`that at least part of the inner surface 163 will make contact with the movable
`
`10
`
`member’s actuating surface 155 when the movable member 140 is advanced
`
`toward the inner end 101 of the earphone 100. The actuating surface 155 of
`
`the movable member140 is curved correspondingly to meet the inner surface
`
`163 of each cantilever arm 161. As the movable member 140 is moved toward
`
`the inner end 101 of the earphone 100, the actuating surface 155 ofthefirst
`
`portion 150 of the movable member 140 makescontact with one or moreof the
`
`cantilever arms 161 at inner surface 163. Further movement of the movable
`
`member140 in the same direction pushes on the inner surface 163, thus forcing
`
`the cantilever arm 161 to bend away from longitudinal axis L (see FIG. 26).
`
`Because the cantilever arms 161 are received insertably in the opening 125 of
`
`the resilient cushion 121, the cantilever arm is bent into the cushion 121 as the
`
`movable member 140 contacts and pushesthe cantilever arm 161.
`
`Consequently, as the cantilever arm is continually bent away from longitudinal
`
`axis L, the cushion 121 is forced to have an expanded, second shape 123 (see
`
`FIG. 26). Thus, the ear canal portion 120 may be expandedafter insertion in a
`
`25
`
`user’s ear canal, substantially sealing the cushion 121 against the user’s ear
`
`canal to form a snug fit.
`
`Note that, while a plurality of cantilever arms 161 are described above as
`
`providing the expansion assembly 160 with the ability to expand, it is
`
`contemplated that any numberof cantilever arms, including one, could perform
`
`30
`
`the same or similar function.
`
`According at least one non-limiting embodiment, the control member 180
`
`is designed to actuate the movable member140 such that the movable member
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`=| 3:
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`15
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`15
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`WO 2009/086555
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`PCT/US2008/088656
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`140 moves to cause