Earplus assembly and method for forming the same

An earplug assembly comprising:

• a first earplug and a second earplug, each earplug comprising:
• a stem comprising a proximal end, a distal end, and a longitudinal axis extending from the proximal end to the distal end;
• and
• a sound attenuating body disposed at the distal end of the stem;
• and
• a cord comprising a first end, a second end, and a length extending between the first and second ends, the first and second ends thermally bonded to and extending to a depth into the proximal ends of the stems of the first and second earplugs, the stem comprising a first material selected from polypropylene, polyethylene terephthalate, polybutylene terephthalate, nylon, polycarbonate, and mixtures thereof and the cord comprising a second material selected from thermoplastic polyolefins, thermoplastic elastomers, ethylene vinyl acetate, flexible polyvinyl chloride, styrene-butadiene copolymer, polypropylene-based elastomers, and mixtures thereof.

An earplug assembly comprising:

• a first earplug and a second earplug, each earplug comprising:
• a stem comprising a proximal end, a distal end, and a longitudinal axis extending from the proximal end to the distal end;
• and
• a sound attenuating body disposed at the distal end of the stem;
• and
• a cord comprising a first end, a second end, and a length extending between the first and second ends, the first and second ends thermally bonded to and extending to a depth into the proximal ends of the stems of the first and second earplugs by thermal bonding, the stem comprising a first thermoplastic having a first melting temperature and the cord comprising a second thermoplastic having a second melting temperature that is lower than the first melting temperature by at least 30° C.