Custom fit in-ear monitors utilizing a single piece driver module

Abstract

A custom-fit in-ear-monitor (IEM) is provided that utilizes a plurality of drivers and a single piece driver module that significantly simplifies fabrication while insuring that the completed IEM achieves the desired acoustic performance. The driver module, which is fit within a custom-fit ear mold shell, includes a plurality of driver ports to which the drivers are coupled. The driver module also includes an acoustic output member that includes one or more sound bores that acoustically couple the acoustic output surface of the custom-fit ear mold shell to the plurality of driver ports via a plurality of sound ducts within the driver module.

What is claimed is: 
     
       1. A custom-fit in-ear-monitor (IEM), comprising:
 a custom-fit ear mold shell having an external surface that is shaped to match the contours of an end user's ear; 
 a pre-tuned single piece driver module configurable configured to fit be positioned entirely within said custom-fit ear mold shell, said single piece driver module comprising:
 a central body portion; 
 a plurality of driver ports, wherein at least one of said plurality of driver ports is comprised of a first hollow member that extends away from a the central body portion of said single piece driver module; and 
 an acoustic output member, wherein said acoustic output member extends away from said central body portion of said single piece driver module, wherein said acoustic output member includes at least one sound bore having an end that is acoustically coupled to disposed at an acoustic output surface of said custom-fit ear mold shell, and wherein 
 said at least one sound bore is acoustically coupled via a plurality of sound ducts, within said single piece driver module, to one or more driver ports of said plurality of driver ports; and 
 
 a plurality of drivers disposed within said custom-fit ear mold shell, wherein one of each of said plurality of drivers is coupled to a corresponding one of each of said plurality of driver ports; 
 a crossover circuit disposed within said custom-fit ear mold shell and electrically coupled to said plurality of drivers, wherein said crossover circuit is configured to receive an electrical signal from an audio source that is external to said custom-fit IEM and to provide separate input signals to each of said plurality of drivers based on said electrical signal; and 
 a filler disposed within said custom-fit ear mold shell, wherein said filler is disposed within said custom-fit ear mold shell after said single piece driver module and said plurality of drivers and said crossover circuit have been installed within said custom-fit ear mold shell, and wherein said filler captures and holds said single piece driver module and said plurality of drivers and said crossover circuit within said custom-fit ear mold shell; and 
 a removable faceplate configured to close an opening in said custom-fit ear mold shell, wherein said single piece driver module and said plurality of drivers are configured to be inserted while separated from the faceplate through said opening in said custom-fit ear mold shell prior to closing said opening with said faceplate. 
 
     
     
       2. A custom-fit in-ear-monitor (IEM), comprising;
 a custom-fit ear mold shell having an external surface that is shaped to match the contours of an end user's ear; 
 a single piece driver module configurable to fit within said custom-fit ear mold shell, said single piece driver module comprising:
 a body portion; 
 a plurality of driver ports, wherein at least one of said plurality of driver ports is comprised of a first hollow member that extends away from a the body portion of said single piece driver module; and 
 an acoustic output member, wherein said acoustic output member extends away from said body portion of said single piece driver module, wherein said acoustic output member includes at least one sound bore one or more sound bores that is acoustically coupled to an acoustic output surface of said custom-fit ear mold shell, and wherein 
 said at least one sound bore is one or more sound bores are each acoustically coupled via a plurality of sound ducts within said single piece driver module to at least one of said plurality of driver ports; and 
 
 a plurality of drivers disposed within said custom-fit ear mold shell, wherein one of each of said plurality of drivers is coupled to a corresponding one of each of said plurality of driver ports; 
 a crossover circuit disposed within said custom-fit ear mold shell and electrically coupled to said plurality of drivers, wherein said crossover circuit is configured to receive an electrical signal from an audio source that is external to said custom-fit IEM and to provide separate input signals to each of said plurality of drivers based on said electrical signal; and 
 a removable faceplate configured to close an opening in said custom-fit ear mold shell, wherein said single piece driver module and said plurality of drivers are configured to be inserted while separated from the faceplate through said opening in said custom-fit ear mold shell prior to closing said opening with said faceplate. 
 
     
     
       3. The custom-fit IEM of  claim 1 , wherein a second driver port of said plurality of driver ports is comprised of a second hollow member that extends away from said body portion of said single piece driver module. 
     
     
       4. The custom-fit IEM of  claim 1 , wherein at least one of said plurality of driver ports is comprised of a cavity formed within said body portion of said single piece driver module, and wherein at least one of said plurality of drivers is at least partially disposed within said cavity. 
     
     
       5. The custom-fit IEM of  claim 1 ,
 further comprising a cable socket integrated into said custom-fit ear mold shell, wherein a source input cable coupleable to said audio source is attached to said custom-fit IEM and to said crossover circuit via said cable socket. 
 
     
     
       6. The custom-fit IEM of  claim 5 ,
 wherein said crossover circuit is integrated into said cable socket. 
 
     
     
       7. The custom-fit IEM of  claim 1 , wherein said body portion of said single piece driver module is fabricated from a rigid material and wherein said first hollow member and said acoustic output member are fabricated from a pliable material. 
     
     
       8. The custom-fit IEM of  claim 7 , wherein said rigid material is comprised of a plastic material. 
     
     
       9. The custom-fit IEM of  claim 7 , wherein said pliable material is selected from the group of elastomeric materials consisting of silicone, neoprene, ethylene propylene diene monomer, nitrile rubber, nitrile, polyvinyl chloride, nitrile/PVC blends, and urethane. 
     
     
       10. The custom-fit IEM of  claim 1 , wherein said single piece driver module including said body portion, said plurality of driver ports and said acoustic output member are fabricated from a pliable material. 
     
     
       11. The custom-fit IEM of  claim 10 , wherein said pliable material is selected from the group of elastomeric materials consisting of silicone, neoprene, ethylene propylene diene monomer, nitrile rubber, nitrile, polyvinyl chloride, nitrile/PVC blends, and urethane. 
     
     
       12. The custom-fit IEM of  claim 1 , wherein a second driver port of said plurality of driver ports is comprised of a second hollow member that extends away from said body portion of said single piece driver module and is acoustically coupled to an ambient environment. 
     
     
       13. The custom-fit IEM of  claim 1 , further comprising a printed circuit board (PCB), wherein said crossover circuit is contained on said PCB. 
     
     
       14. The custom-fit IEM of  claim 13 , wherein 
 said single piece driver module further comprising comprises a PCB cavity, wherein said PCB and said crossover circuit are at least partially housed within said PCB cavity. 
 
     
     
       15. The custom-fit IEM of  claim 13 , further comprising a plurality of barbed stand-offs attached to a surface of said single piece driver module, wherein said PCB and said crossover circuit are mounted to said single piece driver module by said plurality of barbed stand-offs. 
     
     
       16. The custom-fit IEM of  claim 13 , further comprising a plurality of PCB mounting clips attached to a surface of said single piece driver module, wherein said PCB and said crossover circuit are mounted to said single piece driver module by said plurality of PCB mounting clips. 
     
     
       17. The custom-fit IEM of  claim 1 , wherein 
 said single piece driver module further comprising comprises at least one locking feature configured to capture and hold said single piece driver module within said custom-fit ear mold shell. 
 
     
     
       18. The custom-fit IEM of  claim 17 , wherein said at least one locking feature is comprised of a locking barb integrated onto an outer surface of said acoustic output member. 
     
     
       19. The custom-fit IEM of  claim 1 ,
 wherein said acoustic output member the at least one sound bore includes a first sound bore acoustically coupled to a first of said plurality of driver ports via a first duct of said a plurality of sound ducts within said single piece driver module, and wherein said acoustic output member the at least one sound bore includes a second sound bore acoustically coupled to a second of said plurality of driver ports via a second duct of said plurality of sound ducts within said single piece driver module. 
 
     
     
       20. The custom-fit IEM of  claim 19 , wherein said second sound bore of said acoustic output member is acoustically coupled to a third of said plurality of driver ports via a third duct of said plurality of sound ducts within said single piece driver module. 
     
     
       21. The custom-fit IEM of  claim 20 , wherein
 a first driver of said plurality of drivers is coupled to said first driver port, wherein 
 a second driver of said plurality of drivers is coupled to said second driver port, wherein 
 a third driver of said plurality of drivers is coupled to said third driver port, wherein 
 said first driver is a high-frequency driver, wherein 
 said second driver is a mid-frequency driver, and wherein 
 said third driver is a low-frequency driver. 
 
     
     
       22. The custom-fit IEM of  claim 19 , wherein said first sound bore and said second sound bore are concentric. 
     
     
       23. The custom-fit IEM of  claim 19 , wherein said first sound bore has a first circular cross-section and said second sound bore has a second circular cross-section. 
     
     
       24. The custom-fit IEM of  claim 23 , wherein said first circular cross-section is larger than said second circular cross-section. 
     
     
       25. The custom-fit IEM of  claim 19 , wherein said first sound bore has a shaped, non-circular cross-section and said second sound bore has a circular cross-section. 
     
     
       26. The custom-fit IEM of  claim 19 , wherein said first sound bore has a first shaped, non-circular cross-section and said second sound bore has a second shaped, non-circular cross-section. 
     
     
       27. The custom-fit IEM of  claim 1 , further comprising an acoustic output extension, wherein said acoustic output extension is slidably mounted to said acoustic output member, and wherein said acoustic output extension is adjustable between a non-extended position and an extended position. 
     
     
       28. An A custom-fit in-ear-monitor (IEM) driver component configured to fit within an IEM comprising: a custom-fit ear mold shell , comprising: and a pre-tuned single piece driver module configured to fit within said custom-fit ear mold shell, said single piece driver module comprising:
 a plurality of driver ports, each of the driver ports of the plurality of driver ports configured to be coupled to a plurality of a driver of one or more drivers, 
 a central body portion, wherein: at least onea first of said plurality of driver ports is comprised of a first hollow member that extends away from athe central body portion of said single piece driver module, and wherein   at least one a second of said plurality of driver ports is comprised of a cavity formed within said central body portion of said single piece driver module and configured to accept at least a portion of at least one a first of said plurality of the one or more drivers; and   
 an acoustic output member, wherein
 said acoustic output member extends away from said central body portion of said single piece driver module, wherein 
 said acoustic output member includes at least one sound bore one or more sound bores each configured to be acoustically coupled to have an end disposed at an acoustic output surface of said IEM custom-fit ear mold shell, and wherein 
 said at least one sound bore is one or more sound bores are each acoustically coupled via a plurality of sound ducts within said body portion of said single piece driver module to at least one of said plurality of driver ports; and 
 
 a removable faceplate configured to close an opening in the custom-fit ear mold shell, wherein the single piece driver module and the one or more drivers are configured to be inserted while separated from the faceplate through said opening in said custom-fit ear mold shell prior to closing said opening with the faceplate. 
 
     
     
       29. The IEM driver component custom-fit in-ear-monitor (IEM) of  claim 28 ,
 wherein a second third driver port of said plurality of driver ports is comprised of a second hollow member that extends away from said body portion of said single piece driver module. 
 
     
     
       30. The IEM driver component custom-fit in-ear-monitor (IEM) of  claim 28 ,
 wherein said body portion of said single piece driver module is fabricated from a rigid material and wherein said first hollow member and said acoustic output member are fabricated from a pliable material. 
 
     
     
       31. The IEM driver component custom-fit in-ear-monitor (IEM) of  claim 30 ,
 wherein said rigid material is comprised of a plastic material and said pliable material is selected from the group of elastomeric materials consisting of silicone, neoprene, ethylene propylene diene monomer, nitrile rubber, nitrile, polyvinyl chloride, nitrile/PVC blends, and urethane. 
 
     
     
       32. The IEM driver component custom-fit in-ear-monitor (IEM) of  claim 28 ,
 wherein said single piece driver module including said body portion, said plurality of driver ports and said acoustic output member are fabricated from a pliable material. 
 
     
     
       33. The IEM driver component custom-fit in-ear-monitor (IEM) of  claim 32 ,
 wherein said pliable material is selected from the group of elastomeric materials consisting of silicone, neoprene, ethylene propylene diene monomer, nitrile rubber, nitrile, polyvinyl chloride, nitrile/PVC blends, and urethane. 
 
     
     
       34. The IEM driver component custom-fit in-ear-monitor (IEM) of  claim 28 ,
 said single piece driver module further comprising at least one locking feature integrated onto an outer surface of said single piece driver module and configured to capture and hold said single piece driver module within said IEM custom-fit ear mold shell. 
 
     
     
       35. The IEM driver component custom-fit in-ear-monitor (IEM) of  claim 28 ,
 wherein said acoustic output member includes the one or more sound bores include a first sound bore acoustically coupled to a first of said plurality of driver ports via a first duct of said a plurality of sound ducts within said single piece driver module, and wherein said acoustic output member includes the one or more sound bores include a second sound bore acoustically coupled to a second of said plurality of driver ports via a second duct of said plurality of sound ducts within said single piece driver module. 
 
     
     
       36. The IEM driver component custom-fit in-ear-monitor (IEM) of  claim 28 ,
 further comprising an acoustic output extension, wherein said acoustic output extension is slidably mounted to said acoustic output member, and wherein said acoustic output extension is adjustable between a non-extended position and an extended position. 
 
     
     
       37. The IEM driver component custom-fit in-ear-monitor (IEM) of  claim 28 ,
 wherein said single piece driver module is configurable by blocking off one of said plurality of driver ports of said single piece driver module. 
 
     
     
       38. The custom-fit IEM of  claim 2 , wherein a second driver port of said plurality of driver ports is comprised of a second hollow member that extends away from said body portion of said single piece driver module. 
     
     
       39. The custom-fit IEM of  claim 2 , wherein at least one of said plurality of driver ports is comprised of a cavity formed within said body portion of said single piece driver module, and wherein at least one of said plurality of drivers is at least partially disposed within said cavity. 
     
     
       40. The custom-fit IEM of  claim 2 , further comprising a cable socket integrated into said custom-fit ear mold shell, wherein a source input cable coupleable to said audio source is attached to said custom-fit IEM and to said crossover circuit via said cable socket. 
     
     
       41. The custom-fit IEM of  claim 40 , wherein said crossover circuit is integrated into said cable socket. 
     
     
       42. The custom-fit IEM of  claim 2 , wherein said body portion of said single piece driver module is fabricated from a rigid material and wherein said first hollow member and said acoustic output member are fabricated from a pliable material. 
     
     
       43. The custom-fit IEM of  claim 42 , wherein said rigid material is comprised of a plastic material. 
     
     
       44. The custom-fit IEM of  claim 42 , wherein said pliable material is selected from the group of elastomeric materials consisting of silicone, neoprene, ethylene propylene diene monomer, nitrile rubber, nitrile, polyvinyl chloride, nitrile/PVC blends, and urethane. 
     
     
       45. The custom-fit IEM of  claim 2 , wherein said single piece driver module including said body portion, said plurality of driver ports and said acoustic output member are fabricated from a pliable material. 
     
     
       46. The custom-fit IEM of  claim 45 , wherein said pliable material is selected from the group of elastomeric materials consisting of silicone, neoprene, ethylene propylene diene monomer, nitrile rubber, nitrile, polyvinyl chloride, nitrile/PVC blends, and urethane. 
     
     
       47. The custom-fit IEM of  claim 2 , wherein a second driver port of said plurality of driver ports is comprised of a second hollow member that extends away from said body portion of said single piece driver module and is acoustically coupled to an ambient environment. 
     
     
       48. The custom-fit IEM of  claim 2 , further comprising a printed circuit board (PCB), wherein said crossover circuit is contained on said PCB. 
     
     
       49. The custom-fit IEM of  claim 48 , said single piece driver module further comprising a PCB cavity, wherein said PCB and said crossover circuit are at least partially housed within said PCB cavity. 
     
     
       50. The custom-fit IEM of  claim 48 , further comprising a plurality of barbed stand-offs attached to a surface of said single piece driver module, wherein said PCB and said crossover circuit are mounted to said single piece driver module by said plurality of barbed stand-offs. 
     
     
       51. The custom-fit IEM of  claim 48 , further comprising a plurality of PCB mounting clips attached to a surface of said single piece driver module, wherein said PCB and said crossover circuit are mounted to said single piece driver module by said plurality of PCB mounting clips. 
     
     
       52. The custom-fit IEM of  claim 2 , said single piece driver module further comprising at least one locking feature configured to capture and hold said single piece driver module within said custom-fit ear mold shell. 
     
     
       53. The custom-fit IEM of  claim 52 , wherein said at least one locking feature is comprised of a locking barb integrated onto an outer surface of said acoustic output member. 
     
     
       54. The custom-fit IEM of  claim 2 ,
 wherein said acoustic output member includes the one or more sound bores include a first sound bore acoustically coupled to a first of said plurality of driver ports via a first duct of said a plurality of sound ducts within said single piece driver module, and wherein said acoustic output member includes the one or more sound bores include a second sound bore acoustically coupled to a second of said plurality of driver ports via a second duct of said plurality of sound ducts within said single piece driver module. 
 
     
     
       55. The custom-fit IEM of  claim 54 , wherein said second sound bore of said acoustic output member is acoustically coupled to a third of said plurality of driver ports via a third duct of said plurality of sound ducts within said single piece driver module. 
     
     
       56. The custom-fit IEM of  claim 55 , wherein a first driver of said plurality of drivers is coupled to said first driver port, wherein a second driver of said plurality of drivers is coupled to said second driver port, wherein a third driver of said plurality of drivers is coupled to said third driver port, wherein said first driver is a high-frequency driver, wherein said second driver is a mid-frequency driver, and wherein said third driver is a low-frequency driver. 
     
     
       57. The custom-fit IEM of  claim 54 , wherein said first sound bore and said second sound bore are concentric. 
     
     
       58. The custom-fit IEM of  claim 54 , wherein said first sound bore has a first circular cross-section and said second sound bore has a second circular cross-section. 
     
     
       59. The custom-fit IEM of claim  48  58,
 wherein said first circular cross-section is larger than said second circular cross-section. 
 
     
     
       60. The custom-fit IEM of  claim 54 , wherein said first sound bore has a shaped, non-circular cross-section and said second sound bore has a circular cross-section. 
     
     
       61. The custom-fit IEM of  claim 54 , wherein said first sound bore has a first shaped, non-circular cross-section and said second sound bore has a second shaped, non-circular cross-section. 
     
     
       62. The custom-fit IEM of  claim 2 , further comprising an acoustic output extension, wherein said acoustic output extension is slidably mounted to said acoustic output member, and wherein said acoustic output extension is adjustable between a non-extended position and an extended position. 
     
     
       63. The custom-fit IEM of claim 1, wherein an output of the acoustic output member is disposed inside the custom-fit ear mold shell. 
     
     
       64. The custom-fit IEM of claim 1, wherein
 the body of the single piece driver module is directly coupled to the first hollow member, and   the body of the single piece driver module is directly coupled to the one or more sound bores.   
     
     
       65. A custom-fit in-ear-monitor (IEM), comprising:
 a custom-fit ear mold shell having an external surface that is shaped to match the contours of an end user's ear;   a pre-tuned single piece driver module disposed within the custom-fit ear mold shell and positioned to deliver an acoustic output through a first opening formed in an end of the custom-fit ear mold shell, wherein the single piece driver module comprises:
 a plurality of driver ports formed in the single piece driver module; and 
 an acoustic output member that includes a first sound bore that is acoustically coupled to a first driver port of the plurality of driver ports and a second sound bore that is acoustically coupled to a second driver port of the plurality of driver ports, wherein the first and second sound bores are formed through an output face of the acoustic output member which is positioned at the first opening formed in the end of the custom-fit ear mold shell; and 
   a plurality of drivers disposed within the custom-fit ear mold shell, wherein each of the plurality of drivers is coupled to one of the plurality of driver ports; and   a removable faceplate configured to close a second opening in the custom-fit ear mold shell, wherein the single piece driver module and the plurality of drivers are configured to be inserted while separated from the faceplate through the second opening in the custom-fit ear mold shell prior to closing the second opening with the faceplate.   
     
     
       66. The custom-fit in-ear-monitor (IEM) of claim 65, wherein a cross-sectional area of the first sound bore at the output face of the acoustic output member is greater than a cross-sectional area of the second sound bore at the output face of the acoustic output member. 
     
     
       67. The custom-fit in-ear-monitor (IEM) of claim 66, wherein two or more of the plurality of drivers are coupled to the first sound bore and only one of the plurality of drivers are coupled to the second sound bore. 
     
     
       68. The custom-fit in-ear-monitor (IEM) of claim 66, wherein the plurality of drivers comprise a first driver that is coupled to the first sound bore and a second driver that is coupled to the second sound bore, and the first driver is a high frequency driver and the second driver is a mid or a low frequency driver. 
     
     
       69. The custom-fit in-ear-monitor (IEM) of claim 66, wherein the first sound bore is substantially straight between a first driver port of the plurality of driver ports and the output face. 
     
     
       70. The custom-fit in-ear-monitor (IEM) of claim 69, wherein the plurality of drivers comprise a first driver that is coupled to the first sound bore and a second driver that is coupled to the second sound bore, and the first driver is a high frequency driver and the second driver is a mid or a low frequency driver. 
     
     
       71. The custom-fit in-ear-monitor (IEM) of claim 65, wherein the single piece driver module comprises an elastomeric material. 
     
     
       72. The custom-fit in-ear-monitor (IEM) of claim 65, wherein only one of the plurality of drivers are coupled to the first sound bore and only one of the plurality of drivers are coupled to the second sound bore.