Deformable ear tip for earphone and method therefor

A method for forming ear tips, the method comprising:

• configuring a molding station having top and bottom molding plates;
• first compression molding an inner structure using a first moldable material;
• curing the formed inner structure;
• reconfiguring the molding station by replacing one of the top and bottom molding plates;
• second compression molding at least a portion of an outer structure using a second moldable material;
• curing the at least a portion of the outer structure that has been formed by the second compression molding;
• and
• removing a resulting ear tip from the molding station;
• and
• applying an outer coating to the at least a portion of the outer structure,
• wherein the first moldable material comprises an elastomer of a first hardness and wherein the second moldable material comprises an elastomer of a second hardness, the second hardness being less than the first hardness.

A method for forming ear tips, the method comprising:

• configuring a molding station having top and bottom molding plates;
• first compression molding an outer structure using a first moldable material;
• curing the formed outer structure;
• reconfiguring the molding station by replacing at least one of the top and bottom molding plates;
• second compression molding at least a portion of an inner structure using a second moldable material;
• curing the at least a portion of the inner structure that has been formed by the second compression molding;
• and
• removing a resulting ear tip from the molding station,
• wherein the first moldable material comprises an elastomer of a first hardness and wherein the second moldable material comprises an elastomer of a second hardness, the second hardness being less than the first hardness, and
• wherein said inner structure includes at least one feature to mechanically secure said inner structure to the headphone.

An ear tip for a headphone, comprising:

• an inner cylindrical structure configured to removably attach to the headphone;
• and
• an outer spherical structure integral with or adhered to at least sides of said inner cylindrical structure, said outer spherical structure being formed at least partially from a deformable material,
• wherein said inner cylindrical structure extends substantially through the ear tip,
• wherein said outer spherical structure is sealed against the top end of said inner cylindrical structure,
• wherein said inner cylindrical structure comprises an elastomer of a first hardness and said outer spherical structure comprises an elastomer of a second hardness, wherein the second hardness is less than the first hardness, and
• wherein said inner cylindrical structure includes at least one feature to mechanically secure said inner cylindrical structure to the headphone.

An ear tip for a headphone, comprising:

• an inner cylindrical structure configured to removably attach to the headphone;
• an outer rounded structure integral with or adhered to said inner cylindrical structure, said outer rounded structure being formed at least partially from a deformable material;
• and
• an outer film provided around said outer rounded structure, thereby providing an outer surface for the ear tip,
• wherein said inner cylindrical structure comprises an elastomer of a first hardness and said outer rounded structure comprises an elastomer of a second hardness, wherein the second hardness is less than the first hardness, and
• wherein the outer film has a thickness of less than 2.0 mm.

A method for forming an ear tip, the method comprising:

• providing an inner structure for an ear tip;
• providing a top mold having at least one protrusion;
• providing a bottom mold having an ear tip cavity;
• depositing a quantity of a second material into and/or adjacent the ear tip cavity so as to form an outer structure;
• coupling the top and bottom molds together with the protrusion being inserted into the ear tip cavity;
• curing the ear tip being formed within the ear tip cavity;
• after the curing, removing the to mold;
• removing excess portions of the first material and the second material from the formed ear tip;
• and
• removing the formed ear tip from the bottom mold,
• wherein the inner structure of the formed ear tip comprises an elastomer of a first hardness and wherein the outer structure of the formed ear tip comprises an elastomer of a second hardness, the second hardness being less than the first hardness.

A method for forming an ear tip, the method comprising:

• forming an inner structure for an ear tip;
• providing a top mold having at least one protrusion;
• providing a porous bottom mold having an ear tip cavity;
• placing a sheet of a first material over the cavity, the sheet being used to form an outer film for the ear tip;
• depositing a quantity of a second material on the sheet and adjacent the cavity so as to form an outer structure;
• applying a vacuum to the porous bottom mold to draw the sheet of the first material and the at least a portion of the deposited second material into the cavity;
• placing the molded inner structure onto the protrusion;
• heating the cavity;
• coupling the top and bottom molds together with the protrusion being inserted into the cavity;
• curing the ear tip being formed within the cavity;
• subsequently removing the top mold;
• removing excess portions of the first material and the second material;
• and
• removing the formed ear tip from the bottom mold,
• wherein the inner structure of the formed ear tip comprises an elastomer of a first hardness and wherein the outer structure of the formed ear tip comprises an elastomer of a second hardness, the second hardness being less than the first hardness.