High fidelity insert earphones and methods of making same

Abstract

An insert earphone is provided in which a piece of foam material is used to resiliently mount a receiver within a chamber portion of a one-piece plastic housing member. The receiver has an output port extending through a central aperture of the piece of foam material and into one end of a passage defined by a tubular portion of the housing member with a damper being disposed in the other end of the passage. The tubular portion is inserted into an ear tip or other coupling device and has an enlarged diameter end section to achieve a locking action. Two such insert earphones may be coupled through cables to a junction unit and filters are provided for enhancing the drive of the earphones at high frequencies, the filters being preferably mounted in the junction unit.

1. An insert earphone comprising:
 a unitary housing having a hollow body portion, the hollow body portion having an end wall and an open end disposed opposite the end wall and a hollow elongated tubular portion extending from the end wall;    an end cap;    a cable including a plurality of electrical conductors extending from an electrical audio signal source external to the housing, the cable being secured with the end cap, the end cap connected to cover the open end of the hollow body portion;    a receiver for transducing electrical energy received along the plurality of electrical conductors to sound energy, the receiver being supported within the hollow body portion of the housing and having a sound outlet port extending partially into the hollow elongated tubular portion of the housing in a closely conforming manner;    an insert formed from a resilient material, the insert being disposed between the receiver and at least one interior wall of the unitary housing to inhibit movement of the receiver within the hollow body portion and assisting to provide an acoustic seal between the hollow body portion and the elongated tubular portion;    a damper supported within the hollow elongated tubular portion of the housing at a position opposite the sound outlet port of the receiver, sound from the sound outlet port of the receiver being conducted to the damper by the hollow elongated tubular portion;    a resilient sealing member disposed over the hollow elongated tubular portion for sealing with an ear canal of a wearer;    the earphone extending into and substantially acoustically sealing the ear canal of the wearer where inserted, the damper and receiver response compensating for loss of external ear resonance and coupling resonance that otherwise would occur when the insert earphone is inserted into the ear canal of the wearer to thereby assist in providing a high fidelity response.    
     
     
       2. An insert earphone comprising:
 a unitary housing having a hollow body portion, the hollow body portion having an end wall, at least one interior wall, and an open end disposed opposite the end wall, and a hollow elongated tubular portion extending from the end wall;    a receiver for transducing electrical energy received into sound energy, the receiver having a sound outlet port extending from an end thereof;    an insert formed of resilient material, the insert having a substantially central opening therein; and wherein, during assembly, the outlet port of the receiver is placed in the opening of the insert and the receiver and insert are inserted as a unit into the open end of the hollow body portion until the outlet port engages and extends partially into the hollow elongated tubular portion such that a portion of the insert is compressed between the end of the receiver and the end wall, and other portions of the insert are compressed between the receiver and the at least one interior wall, thereby mounting the receiver within the hollow body portion and assisting to provide an acoustic seal between the hollow body portion and the elongated tubular portion while providing for transmission of sound energy from the sound outlet port through the hollow elongated tubular portion into the ear canal of a wearer.    
     
     
       3. A high-fidelity insert earphone comprising:
 a unitary housing having a hollow body portion, the hollow body portion having an end wall, and a hollow elongated tubular portion extending from the end wall;    a receiver for transducing electrical energy received into sound energy, the receiver having a sound outlet port extending from an end thereof, the sound outlet port having a first end and a second end; and    an insert formed from a resilient material, the insert being disposed between the end of the receiver and the end wall and flanking on the second end of the sound outlet port, the first end of the sound output port mating with, directly contacting a surface of, and extending into the hollow elongated tubular portion.    
     
     
       4. The high fidelity insert earphone of  claim 3  wherein the insert mounts and inhibits movement of the receiver within the hollow body portion of the unitary housing. 
     
     
       5. The high-fidelity insert earphone of  claim 3  further comprising a damper supported within the hollow elongated tubular portion of the housing at a position opposite the sound outlet port of the receiver, sound from the sound outlet port of the receiver being conducted to the damper by the hollow elongated tubular portion. 
     
     
       6. The high-fidelity insert earphone of  claim 5  further comprising a resilient sealing member disposed over the hollow elongated tubular portion for sealing with an ear canal of a wearer. 
     
     
       7. The high fidelity insert earphone of  claim 6  wherein the earphone extends into and substantially acoustically seals the ear canal of a wearer. 
     
     
       8. The high fidelity insert earphone of  claim 7  wherein the earphone emulates a human ear's natural diffuse field response to sound energy received. 
     
     
       9. The high fidelity insert earphone of  claim 6  wherein the resilient sealing member has a plurality of outwardly projecting flange portions of generally conical form and of progressively increasing diameters. 
     
     
       10. The high fidelity insert earphone of  claim 9  wherein the earphone extends into and substantially acoustically seals the ear canal of a wearer. 
     
     
       11. The high fidelity insert earphone of  claim 10  wherein the earphone emulates a human ear's natural diffuse field response to sound energy received. 
     
     
       12. An insert earphone comprising:
 a receiver for transducing electrical energy received from sound energy, the receiver having a sound outlet port extending from an end thereof, the sound outlet port having a first end and a second end, the receiver having a radial dimension and at least one outer surface;    an insert formed from a resilient material, and having an uncompressed thickness; and    a unitary housing having a hollow body portion, the hollow body portion having at least one inner surface, a radial dimension, and an end wall, and a hollow elongated tubular portion extending from the end wall, the radial dimension of at least a portion of hollow body portion being less than the sum of the radial dimension of the receiver and the uncompressed thickness of the insert, and open assembly, a final portion of the insert being disposed and compressed between the end of the receiver and the end wall, second and third portions of the insert being disposed and compressed between the at least one outer surface of the receiver and the at least one inner surface of the hollow body portion, the first end of the sound outlet port directly contacting a surface of the hollow elongated tubular portion and extending into the hollow elongated tubular portion, and only the second end of the sound outlet port being flanked by the insert, the insert thereby mounting the receiver in the hollow body portion and assisting to provide an acoustic seal between the hollow body portion and the elongated tubular portion of the housing.    
     
     
       13. A method of assembling an insert earphone comprising a receiver having a sound outlet port extending from an end thereof, a unitary housing having a hollow body portion, the hollow body portion having an end wall and an open end disposed opposite the end wall, and a hollow elongated tubular portion, and a resilient insert having a substantially central opening therein, the method comprising the steps of:
 placing the sound outlet port of the receiver through the opening of the resilient insert;    inserting the receiver, sound outlet port first, and the resilient insert as a unit into the open end of the hollow body portion;    moving the inserted receiver toward the end wall such that first and second portions of the resilient insert are folded back in a direction toward the open end and compressed between the receiver and at least one inner surface of the hollow body portion; and    matings engaging the sound outlet port of the receiver with the hollow elongated tubular portion such that a third portion of the resilient insert is compressed between the end of the receiver and the end wall.    
     
     
       14. The method of  claim 13  further comprising the step of operatively coupling an electrical energy source to the receiver. 
     
     
       15. The method of  claim 14  wherein the insert earphone further comprises an end cap, and further comprising the step of securing the end cap to the open end of the hollow body portion. 
     
     
       16. An insert earphone comprising:
   a housing including a hollow tubular portion;        a cable including a plurality of electrical conductors from an electrical audio signal source external to the housing;        a receiver mounted with the housing for transducing electrical energy received into sound energy, the receiver communicating sound energy to the hollow tubular portion of the housing;        an acoustic damper disposed in the hollow tubular portion of the housing, sound energy being propagated between the receiver and the acoustic damper through the hollow tubular portion of the housing;        a resilient sealing member coupled with and extending from the hollow tubular portion of the housing for sealing with and passing sound energy through an ear canal of a wearer; and        the insert earphone extending into and substantially acoustically sealing the ear canal of the wearer when inserted such that the insert earphone is supported by the ear of the wearer, the acoustic damper and receiver response compensating for loss of external ear resonance and coupling resonance that otherwise would occur, when the insert earphone is inserted into the ear canal of the wearer to thereby assist in providing a high fidelity response while the receiver is in close proximity to the ear canal without requiring a long flexible tube between the hollow tubular portion of the housing and the resilient sealing member.     
     
     
       17. The insert earphone of  claim 16  further comprising a resilient material, wherein the housing further includes an end wall and at least one interior wall, wherein the tubular portion extends from the end wall, and wherein the resilient material is disposed between the receiver and at least one wall of the housing. 
     
     
       18. The insert earphone of  claim 17  wherein the resilient material comprises a resilient insert. 
     
     
       19. The insert earphone of  claim 18  wherein the resilient insert assists in providing an acoustical seal between a hollow body portion of the housing and the hollow tubular portion of the housing. 
     
     
       20. The insert earphone of  claim 18 , wherein the resilient insert includes a first portion and a second portion, and wherein the first and second portions are folded back and compressed between the receiver and at least one interior wall of the housing when the receiver is inserted toward the end wall of the housing. 
     
     
       21. The insert earphone of  claim 17  wherein the resilient material inhibits movement of the receiver relative to the housing. 
     
     
       22. The insert earphone of  claim 16  wherein the receiver is supported within the housing. 
     
     
       23. The insert earphone of  claim 16  wherein the receiver is supported within the housing and has a sound outlet port extending partially into the hollow tubular portion of the housing in a closely conforming manner. 
     
     
       24. The insert earphone of  claim 23  wherein the sound outlet port extending partially into the hollow tubular portion directly contacts a surface of the hollow tubular portion. 
     
     
       25. The insert earphone of  claim 24 , wherein the housing further includes an end wall, wherein the tubular portion extends from the end wall, wherein the sound outlet port extends from an end of the receiver and includes a first end and a second end, wherein the first end extends partially into the hollow tubular portion and directly contacts a surface of the hollow tubular portion, and wherein the resilient material is disposed between the end of the receiver and the end wall of the housing and flanks only the second end of the sound outlet port. 
     
     
       26. The insert earphone of  claim 16  wherein the resilient sealing member has at least one outwardly projecting flange portion. 
     
     
       27. The insert earphone of  claim 26 , wherein the resilient sealing member includes a plurality of outwardly projecting flange portions of generally conical form and of progressively increasing diameters. 
     
     
       28. The insert earphone of  claim 16  further comprising a filter electrically coupled to an electrical audio signal source external to the housing, the filter for receiving electrical signals from the audio signal source and for modifying frequency components of the electrical signals received. 
     
     
       29. The insert earphone of  claim 28  wherein modifying frequency components of the electrical signals received comprises increasing high frequency components of the electrical signals received. 
     
     
       30. The insert earphone of  claim 28  wherein the filter is located in a junction box external to the housing. 
     
     
       31. The insert earphone of  claim 28  wherein the filter is located in the housing. 
     
     
       32. A dual earphone assembly comprising:
   a connector configured to be connected to an output of a stereophonic amplifier;        a pair of cables configured to connect the connector to a pair of insert earphones configured to produce high fidelity stereophonic reproduction based on the output of a stereophonic amplifier and substantially acoustically seal both ear canals of a wearer, each insert earphone comprising:      a housing having a hollow tubular portion;        a receiver mounted with the housing for transducing electrical energy received into sound energy, the receiver communicating sound energy to the hollow tubular portion of the housing;        an acoustic damper disposed in the hollow tubular portion of the housing, sound energy being propagated between the receiver and the acoustic damper through the hollow tubular portion of the housing;        a resilient sealing member coupled with and extending from the hollow tubular portion of the housing for sealing with and passing sound energy through an ear canal of a wearer; and        the insert earphones extending into and substantially acoustically sealing the ear canals of the wearer when inserted such that each insert earphone is supported by an ear of the wearer, the acoustic damper and receiver response compensating for loss of external ear resonance and coupling resonance that otherwise would occur, when the insert earphones are inserted into the ear canals of the wearer to thereby assist in providing a high fidelity stereophonic response while the receivers are in close proximity to the ear canals without either insert earphone requiring a long flexible tube between the hollow tubular portion of the housing and the resilient sealing member.       
     
     
       33. The dual earphone assembly of  claim 32 , wherein each insert earphone further includes a resilient material, wherein the housing further includes an end wall and at least one interior wall, wherein the tubular portion extends from the end wall, and wherein the resilient material is disposed between the receiver and at least one wall of the housing. 
     
     
       34. The dual earphone assembly of  claim 33 , wherein the resilient material comprises a resilient insert. 
     
     
       35. The dual earphone assembly of  claim 34 , wherein the resilient insert assists in providing an acoustical seal between a hollow body portion of the housing and the hollow tubular portion of the housing. 
     
     
       36. The dual earphone assembly of  claim 34 , wherein the resilient insert of each insert earphone includes a first portion and a second portion, and wherein the first and second portions are folded back and compressed between the receiver and at least one interior wall of the housing when the receiver is inserted toward the end wall of the housing. 
     
     
       37. The dual earphone assembly of  claim 33 , wherein the resilient material inhibits movement of the receiver relative to the housing. 
     
     
       38. The dual earphone assembly of  claim 32 , wherein the receiver of each insert earphone is supported within the housing. 
     
     
       39. The dual earphone assembly of  claim 32 , wherein the receiver of each insert earphone is supported within the housing and has a sound outlet port extending partially into the hollow tubular portion of the housing in a closely conforming manner. 
     
     
       40. The dual earphone assembly of  claim 39 , wherein the sound outlet port extending partially into the hollow tubular portion directly contacts a surface of the hollow tubular portion. 
     
     
       41. The dual earphone assembly of  claim 40 , wherein the housing of each insert earphone further includes an end wall, wherein the tubular portion extends from the end wall, wherein the sound outlet port extends from an end of the receiver and includes a first end and a second end, wherein the first end extends partially into the hollow tubular portion and directly contacts a surface of the hollow tubular portion, and wherein the resilient material is disposed between the end of the receiver and the end wall of the housing and flanks only the second end of the sound outlet port. 
     
     
       42. The dual earphone assembly of  claim 32 , wherein the resilient sealing member of each insert earphone has at least one outwardly projecting flange portion. 
     
     
       43. The dual earphone assembly of  claim 42 , wherein the resilient sealing member of each insert earphone includes a plurality of outwardly projecting flange portions of generally conical form and of progressively increasing diameters. 
     
     
       44. The dual earphone assembly of  claim 32 , further comprising a filter configured to be electrically coupled to a stereophonic amplifier external to the housings of the insert earphones, the filter for receiving electrical signals from the stereophonic amplifier and for modifying frequency components of the electrical signals received. 
     
     
       45. The dual earphone assembly of  claim 44 , wherein modifying frequency components of the electrical signals received comprises increasing high frequency components of the electrical signals received. 
     
     
       46. The dual earphone assembly of  claim 44 , wherein the filter is located in a junction box external to the housings of the insert earphones. 
     
     
       47. The dual earphone assembly of  claim 44 , wherein the filter is located in each of the housings of the insert earphones.