Advanced Hearing Protection for High Noise Areas

Introduction

This innovative hearing protection device is designed to provide superior sound attenuation, making it essential for industries where employees or users are frequently exposed to high noise levels. The technology combines comfort and protection, ensuring that individuals can perform their tasks in loud environments while reducing the risk of long-term hearing damage. For companies in the safety, construction, manufacturing, or military sectors, this technology offers a valuable tool for enhancing worker safety and meeting regulatory requirements for hearing protection.

The Challenge: Balancing Comfort and Hearing Protection

In high-noise industries, hearing protection is not just a recommendation—it’s a necessity. However, many traditional hearing protection devices fail to offer the right balance of comfort and protection, leading to low compliance rates among workers. Devices that are too bulky or uncomfortable may not be worn consistently, putting employees at risk of exposure to harmful noise levels. At the same time, devices that do not offer sufficient attenuation fail to protect hearing effectively. Companies are looking for solutions that provide robust sound attenuation without sacrificing user comfort or functionality.

High Sound Attenuation with Unmatched Comfort

This high sound attenuating hearing protection device addresses these concerns by delivering both advanced noise reduction and enhanced comfort for long-term use. The device is designed to provide significant attenuation across a broad range of frequencies, making it ideal for environments with extreme noise levels, such as construction sites, factories, or military operations. Its ergonomic design ensures a secure and comfortable fit, even during extended periods of use. By reducing unwanted noise while allowing for clear communication, this device supports both safety and productivity.

Key Benefits for Safety and Industrial Sectors

For companies in construction, manufacturing, and other high-noise industries, this technology provides a reliable way to protect workers from the damaging effects of prolonged noise exposure. By integrating this hearing protection device into safety protocols, businesses can reduce the risk of hearing loss, lower incidents of noise-related health issues, and improve overall worker safety. Military and defense applications will also benefit from the device’s ability to offer sound attenuation without compromising situational awareness, providing personnel with protection in critical environments. Consumer electronics companies can explore this technology for high-performance ear protection products aimed at recreational or professional users in noisy settings.

Investing in Enhanced Hearing Protection

Licensing this advanced hearing protection technology positions your company at the forefront of occupational safety and personal protective equipment innovation. With increasing awareness of the importance of hearing health and stricter regulatory requirements, providing a high-performance device that combines protection, comfort, and usability is a strategic move. This technology offers a smart, effective solution to noise exposure challenges across various industries, helping companies protect their workforce while maintaining productivity and safety. It’s an essential tool for organizations dedicated to safeguarding their employees and meeting the highest standards in hearing protection.

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Abstract
Claims

A hearing protection device insertable into an ear canal is provided, the device generally including a stem portion, a sound attenuating portion affixed to and extending at least partially over the stem portion, and a volume of space disposed between and delimited by the sound attenuating portion and the stem portion, where at least a part of the sound attenuating portion is collapsible into the volume of space during insertion of the hearing protection device into the ear canal.

1. A hearing protection device insertable into an earcanal, comprising:

a stem portion;

a sound attenuating portion affixed to the stem portion and including:

a sleeve for receiving and retaining the stem, and

a single flange extending over and beyond the sleeve and extending at least partially over the stem portion; and

a continuous, unobstructed volume of space disposed between and delimited by the single flange, the sleeve, and the stem portion;

wherein the sound attenuating portion extends at least approximately half of a length of the hearing protection device and less than approximately an entire length of the hearing protection device;

wherein the single flange extends approximately half of the length of the sound attenuating portion; and

wherein the single flange is fully collapsible into the volume of space during insertion of the hearing protection device into the ear canal.

2. The hearing protection device of claim 1, wherein the stem portion includes a front portion which is inserted and retained within the sound attenuating portion at the sleeve and an opposite rear portion which extends from the sound attenuating portion and the sleeve through the volume of space.

3. The hearing protection device of claim 2, wherein the front of the stem portion is affixed to the sound attenuating portion at the sleeve by an adhesive agent.

4. The hearing protection device of claim 2, wherein the rear of the stem portion extends from the sound attenuating portion, through the volume of space, and includes features for facilitating handling of the device.

5. The hearing protection device of claim 4, wherein the features comprise at least one of a projection and a recess formed in an outer surface of the stem portion.

6. The hearing protection device of claim 2, further comprising a cavity formed in the stem portion along a longitudinal axis thereof for receiving and retaining a cord, the cavity including an opening at the rear portion of the stem.

7. The hearing protection device of claim 1, further comprising a bulbous portion disposed at a front of the sound attenuating portion.

8. The hearing protection device of claim 7, wherein the bulbous portion includes a partially spherical shape.

9. The hearing protection device of claim 1, further comprising a flared portion disposed at a rear of the sound attenuating portion.

10. The hearing protection device of claim 9, wherein the flared portion comprises an annular shaped element which extends in a smooth curve outwardly from a longitudinal axis of the device.

11. The hearing protection device of claim 1, wherein the sound attenuating portion includes a substantially circular cross-section which varies in area from the front to the rear thereof such that the sound attenuating portion includes a smallest cross-section at a front end and a largest cross-section at the rear end.

12. The hearing protection device of claim 1, wherein the sound attenuating portion is substantially bell-shaped and includes a partially spherical bulbous portion at a front end and a flared portion at a rear end, the flared end extending outwardly from a longitudinal axis of the sound attenuating portion.

13. The hearing protection device of claim 12, wherein the single elongated flange element extends between the bulbous portion and the flared portion, the elongated flange element including a plurality of concentric rings on an outer surface thereof of serially increasing diameters from the front to the rear of the sound attenuating portion.

14. The hearing protection device of claim 13, wherein the rings form a plurality of corresponding steps along a profile of the sound attenuating portion.

15. The hearing protection device of claim 1, further comprising a plurality of concentric circular ridges formed about the sound attenuating portion between a front end and an opposing rear end to facilitate handling of the device and retention of the device within the ear canal.

16. The hearing protection device of claim 1, wherein the sleeve extends into the volume of space along a longitudinal axis of the sound attenuating portion toward a rear thereof and includes a cavity for receiving the stem portion.

17. The hearing protection device of claim 16, further comprising a plurality of ribs disposed on the sound attenuating portion at the interior thereof extending from the sleeve to the rear of the sound attenuating portion.

18. The hearing protection device of claim 17, wherein the ribs taper in cross-sectional area in a direction toward the rear of the sound attenuating portion.

19. The hearing protection device of claim 17, wherein the plurality of ribs comprises four ribs equally spaced about an interior surface of the sound attenuating portion.

20. The hearing protection device of claim 1, wherein the sound attenuating portion is composed of a foam material having a Shore OO durometer of approximately 20 to 40.

21. The hearing protection device of claim 1, wherein the sound attenuating portion is composed of a foam material having a Shore OO durometer of approximately 30.

22. The hearing protection device of claim 20, wherein the stem portion is formed of a material having a Shore A durometer of approximately 60 to 100.

23. The hearing protection device of claim 22, wherein the stem portion is formed of a material having a Shore A durometer of approximately 80.

24. The hearing protection device of claim 1, wherein the volume of space is substantially frustoconical in shape.

25. The hearing protection device of claim 1, wherein the sound attenuating portion is formed a compressible resilient material.

26. The hearing protection device of claim 25, wherein the compressible resilient material is a foam.

27. The hearing protection device of claim 26, wherein the foam comprises at least one of a polyurethane, an acrylic blend, a PVC, a silicone, and a nitrile foam.

28. The hearing protection device of claim 25, wherein the compressible resilient material is a plastic or a rubber material or a composition thereof.

29. The hearing protection device of claim 28, wherein the compressible resilient material is a thermoplastic elastomer.

30. The hearing protection device of claim 1, wherein the sound attenuating portion includes a rounded front end.

31. The hearing protection device of claim 30, wherein the sound attenuating portion includes a substantially cylindrical shape.

32. The hearing protection device of claim 30, wherein the sound attenuating portion includes a partially spherical shape.

33. The hearing protection device of claim 1, wherein the sound attenuating portion includes a single flange extending over the stem toward a rear of the device to form the volume of space, the flange collapsible into the space.

34. The hearing protection device of claim 1, wherein the front of the stem portion is affixed to the sound attenuating portion at the sleeve by a chemical bonding.

35. The device of claim 1, wherein the stem portion extends from the volume of space to an exterior of the device at an angle of approximately 0-60° related to a longitudinal axis of the earplug.

36. The device of claim 35, wherein the angle is approximately 0-30°.

37. The device of claim 35, wherein the stem portion is an elongated curved element.

38. The device of claim 35 wherein, the sound attenuating portion includes an opening to the exterior of the device, the stem portion extending from the device through a center of the opening.

39. The device of claim 35 wherein, the sound attenuating portion includes an opening to the exterior of the device, the stem portion extending from the device through the opening between a center of the opening and an outer edge of the opening.

40. The device of claim 35, wherein the sound attenuation portion includes an irregular shape.

41. The device of claim 1, wherein the sound attenuation portion includes an irregular shape.

42. The hearing protection device of claim 1, wherein the single elongated flange element that includes a plurality of concentric rings on an outer surface thereof, the rings being of serially increasing diameters from a front to a rear of the sound attenuating portion.

43. The hearing protection device of claim 42, wherein the rings form a plurality of corresponding steps along a profile of the sound attenuating portion.

44. A hearing protection device insertable into an ear canal, comprising:

a stem portion having a front end and an opposite rear end;

a single flange element fixed to the front end of the stem portion and extending over at least a portion of the stem portion toward the rear of the stem portion, said flange element extending at least approximately half of a length of the hearing protection device and less than approximately an entire length of the hearing protection device;

a sleeve configured to receive and retain the stem portion, the sleeve extending at least partially over the stem portion, the single flange disposed to extend over and beyond the sleeve;

a volume of space delimited by the stem portion, the sleeve, and the single flange element;

wherein the flange element is formed of a compressible resilient material and the flange element is fully collapsible into the volume of space during insertion of the earplug into the ear canal.

45. The hearing protection device of claim 44, wherein the single flange element includes an elongated conical shape and is composed of a foam having a Shore OO durometer of approximately 20 to 40.

46. A sound attenuating portion of a hearing protection device, the sound attenuating portion being configured for insertion into an ear canal, comprising:

a front insertable portion formed of a compressible resilient material;

a flange portion extending rearwardly from the front insertable portion and

a volume of space formed at an interior of the flange portion rearward of the front insertable portion;

wherein the flange portion extends out of contact from a remainder of the hearing protection device and at least approximately half of a length of the sound attenuating portion and less than approximately an entire length of the hearing protection device,

and wherein the flange portion is fully collapsible into the volume of space.

47. The device-portion of claim 46, further comprising a bulbous portion at a front end thereof.

48. The portion of claim 47, further comprising a flared portion at a rear end thereof extending outwardly from a longitudinal axis of the device.

49. The portion of claim 48, wherein the bulbous portion includes a partially spherical shape and the flared portion is formed of a smooth curve extending from a body portion of the device outwardly from the longitudinal axis.

50. The portion of claim 46, further comprising a substantially circular cross-section which varies in area from a front to a rear thereof such that the portion includes a smallest cross-section at a front end and a largest cross-section at the rear end.

51. The portion of claim 46, wherein the sound attenuating portion is substantially bell-shaped and includes a partially spherical bulbous portion at a front end and a flared portion at a rear end, the flared end extending outwardly from a longitudinal axis of the sound attenuating portion.

52. The portion of claim 46, further comprising a plurality of concentric circular ridges formed about the portion between a front end and an opposing rear end to facilitate handling of the portion and retention of the portion within the ear canal.

53. The hearing protection portion of claim 46, wherein the sound attenuating portion is formed a compressible resilient material.

54. The hearing protection portion of claim 53 wherein the compressible resilient material is at least one of a polyurethane, an acrylic blend, a PVC, a silicone, and a nitrile foam.

55. The hearing protection portion of claim 53, wherein the compressible resilient material is a plastic or a rubber material or a composition thereof.

56. The portion of claim 46, further comprising a shape of at least one of frustoconical, conical, partially spherical, and cylindrical.

57. The portion of claim 46 wherein the volume of space is substantially conical in shape.

58. The device of claim 46, wherein the compressible resilient material comprises a foam and wherein the volume of space formed thereby is partially spherical in shape.

59. The device of claim 46, wherein a length of a part of the flange portion which extends over the volume of space is approximately less than half of an overall longitudinal length of the flange portion.

60. The device of claim 46, wherein a length of a part of the flange portion which extends over the volume of space is approximately less than one-quarter of an overall longitudinal length of the flange portion.

Title

High sound attenuating hearing protection device

Inventor(s)

Robert N. Falco, Richard Knauer, Alan R. Seville

Assignee(s)

3M Innovative Properties Co

Patent #

7464786

Patent Date

December 16, 2008