CROSS-REFERENCE TO RELATED APPLICATIONSThis application is a continuation of the reissue application Ser. No.09/489,441 filed Jan.21,2000, now U.S. Pat. No. Re.38,351, which is a reissue of U.S. application Ser. No.08/770,647 filed Dec.19,1996, U.S. Pat. No.5,887,070 issued Mar.23,1999, which is a continuation of U.S. application Ser. No.08/597,940 filed Feb.7,1996, now abandoned, which is a continuation of U.S. application Ser. No.08/430,698 filed Apr.27,1995, now abandoned, which is a continuation of U.S. application Ser. No.07/880,244 filed May8,1992, now abandoned.
This is a continuation of application Ser. No. 08/597,940, filed Feb. 7, 1996, now abandoned, which is a continuation of application Ser. 08/430,698, filed Apr. 27, 1995, now abandoned, which is a continuation of Ser. No. 07/880,244 filed May 8, 1992, now abandoned.
BACKGROUND OF THE INVENTION1. Field of the Invention
This invention relates to earphones and methods of making the same to obtain earphones and earphone assemblies which reproduce sounds with very high fidelity and with minimum noise and which are suitable for use by the most discriminating listeners. The earphones and assemblies of the invention are very compact and light in weight, are highly reliable and are readily and economically manufacturable.
2. Background of the Prior Art
“Audiophile” earphones have been marketed for use by audiophiles or discriminating listeners interested in the highest possible sound reproduction. Such audiophile earphones have been ostensibly capable of effecting high fidelity sound reproduction although it has been recognized by many users as well as the makers of such earphones that they have left much to be desired with respect to fidelity of reproduction. It has apparently been assumed by such users and makers that deficiencies in quality of sound reproduction are an unavoidable result of the use of earphones.
In a separate audiometry art, earphones have also been developed and marketed in limited quantities for use in specialized audiometry applications to measure the responses of a patient's ear and having features for obtaining desired response characteristics, one disclosure being contained in the Killion U.S. Pat. No. 4,763,753, issued Aug. 16, 1988. Another separate art, the hearing aid art, also contains many disclosures related to the achievement of improved response characteristics, including a paper entitled “SMOOTHING THE ITE RESPONSE: THE BF-1743 DAMPED COUPLING ASSEMBLY” by Mead C. Killion and William J. Murphy, first published in April 1981 and revised June 1982, by Industrial Research Products, Inc. Elk Grove Village, Ill. Such disclosures in the audiometry and hearing aid art relate to devices of relatively expensive construction which are designed for specialized applications and marketed in limited quantities. The applicability of the audiometry and hearing aid arts to the making of earphones for use in high fidelity sound reproduction has apparently gone unrecognized.
SUMMARY OF THE INVENTIONThis invention was evolved after learning of the deficiencies of earphones marketed for use by audiophiles and with the general object of providing earphones which have improved high fidelity response characteristics and which are readily and economically manufacturable.
Important aspects of the invention relate to the recognition and discovery of problems with prior art arrangements and their causes and to an analysis of what is necessary to overcome such problems and otherwise provide improved earphones. It was discovered that one serious problem with audiophile earphones has been related to the failure to recognize the need to compensate for loss of external-ear resonance when using an earphone and the failure to provide compensating acoustic characteristics between the ear canal of a user and the transducer or receiver used to develop an audio signal from an applied electrical signal. It was further discovered that features of a damped coupling assembly of the hearing aid disclosed in the aforementioned Killion and Murphy paper might be applied with advantage to the construction of an audiophile earphone. With a damped coupling assembly as disclosed in that paper, a damper is coupled through a tube to an output port of a receiver and is disposed within the tip of an earmold. The arrangement produces a frequency response which will compensate for the loss of external ear resonance and which is largely independent of the total length of the coupling between the receiver and the earmold tip.
In accordance with the invention, an audiophile insert earphone is provided which uses a damped coupling assembly similar to that disclosed in the above-mentioned Killion and Murphy paper and operative to provide compensation for the loss of external-ear resonance. In accordance with one important feature of the invention, a pair of such earphones are combined in a dual earphone assembly usable for stereophonic reproduction.
Additional important features of the invention relate to features of construction which facilitate manufacture of insert earphones and which at the same time achieve reproduction of sounds with very high fidelity and with a high degree of reliability. Certain of such features relate to the provision of a housing member which can be readily molded from plastic in one piece and which serves the functions of connecting to an outlet port of a receiver, supporting a damper and providing a sound passage. The housing member also serves to releasably connect to a coupling device such as an earmold or ear tip and it performs all of such functions with a high degree of accuracy and reliability. Others such features relate to the provision of a resilient support for the receiver to minimize the effects of vibration and noise and to methods of making the earphone to facilitate manufacture at low cost.
Another feature relates to the combination of electrical filters with the earphone and its damped coupling assembly to achieve optimum overall results.
Still another feature relates to a construction to facilitate removal and replacement of a damper and to the provision of a tool for that purpose.
This invention contemplates other objects, features and advantages which will become more fully apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 illustrates a high fidelity insert earphone assembly of the invention;
FIG. 2 is a cross-sectional view of one earphone of the assembly ofFIG. 1, taken substantially along line2—2 ofFIG. 1;
FIG. 3 shows a piece of resilient material used in construction of the earphone ofFIG. 1;
FIG. 4 is a cross-sectional view taken substantially alongline4—4 ofFIG. 2;
FIG. 5 is a circuit diagram of a electrical filter unit of the assembly ofFIG. 1; and
FIG. 6 is a side elevational view, partly in section, illustrating a device usable for removal of dampers of the earphones of the invention.
DESCRIPTION OF A PREFERRED EMBODIMENTInFIG. 1,reference numeral10 generally designates an earphone assembly which is constructed in accordance with the principles of this invention and which is suitable for use by an audiophile, for example. It will be understood, however, that a number of features of the invention are not limited to any particular use. Certain features may be used, for example, in the construction of hearing aids for use by persons having a hearing impairment.
The illustratedassembly10 includes a pair ofearphones11 and12 for insertion into the entrances of the ear canals of a user. A pair ofcables13 and14 connectearphones11 and12 to ajunction unit15 and acommon cable16 connects thejunction unit15 to aplug connector17 which may be connected to an output jack of a stereophonic amplifier, for example.
FIG. 2 is a cross-sectional view of theearphone11, the construction of theother earphone12 being preferably identical to that of theearphone11. Theearphone11 comprises areceiver18 which is mounted in achamber portion19 of ahousing member20. Thereceiver18 has an acoustic output port and haselectrical input terminals23 and24 and is operative for generating an acoustic output signal at theoutput port22 as a function of an electrical signal applied to theterminals23 and24. Theterminals23 and24 are connected throughwires25 and26 to conductors of thecable13 and anouter sheath27 of thecable13 is bonded to astrain relief member28.Member28 is secured in an opening of anend cap29 which is secured to one end of thehousing member20 to close one end of thechamber portion19.
Thehousing member20 includes awall32 at an opposite end of thechamber portion19 and anouter wall34 of thechamber portion19 which is in surrounding relation to thereceiver18 and which may preferably be of generally cylindrical form.
Thehousing member20 further includes atubular portion35 which projects from theend wall32 of the chamber portion of the housing member and which is inserted in anopening37 of anacoustic coupling device38 arranged to be inserted into the entrance of an ear canal of a user. As shown, thecoupling device38 is in the form of an eartip of a soft compliant material and has three outwardly projectingflange portions39,40 and41 which are of generally conical form and of progressively increasing diameters, arranged to conform to the inner surface portions of the entrance of the ear canal of the user and to provide a seal limiting transmission of sound to the ear canal.
In accordance with a releasable lock feature of the invention, anend section42 of thetubular portion35 is of increased cross-sectional size to provide anexternal shoulder43 in facing relation to thewall32. In assembly, aportion44 of the compliant material of thedevice38 is stretched over theend section42 and then expands into the space between theshoulder43 and thewall32 as shown, so as to lock thedevice38 andhousing member20 together while permitting disassembly when desired.
Custom earmolds or other types of coupling devices may be substituted for the illustrateddevice38, the subassembly of thehousing member20,receiver18 and other parts being thus usable with various types of coupling devices.
In accordance with further important features of the invention, thetubular portion35 defines apassage46 which has anoutlet end portion47 for propagation of acoustic energy into the earcanal of a user and aninlet end portion48 in communication with theoutlet port20 of thereceiver18. Theoutlet port22 is preferably in the form of a tubular member which is fitted into theinlet end portion47 of thepassage46 as shown. Anacoustic damper50 is fitted in theoutlet end portion47 of thepassage46 and, as illustrated, includes a cup-shapedscreen member51 secured in acylindrical support member52. Theoutlet end portion47 preferably has an enlarged diameter to provide ashoulder53 operative to limit movement of thedamper50 toward thereceiver18 during assembly and to accurately fix its position. As shown, the portion of thescreen member51 which is transverse to the direction of sound transmission is in recessed relation to the end of thetubular housing portion22 and the terminal end of the tubular housing portion is spaced a substantial distance from the terminal end of the coupling device, the result being that problems with wax accumulations on the screen are minimized. However, should such accumulations occur, a special removal tool as hereinafter described may be used to remove a cloggeddamper50 which can then be replaced with a new damper.
With the construction as thus far described, thehousing member20 can be readily molded from plastic in one piece and it serves the functions of connecting to the outlet port of the receiver, supporting the damper, providing a sound passage and releasably connecting to a coupling device which may be of various possible types, such functions being performed with a high degree of accuracy and reliability.
Additional important features relate to the provision of a resilient support for thereceiver18 to minimize problems with noise and vibrations while facilitating assembly of the earphone. A piece offoam material54 is provided having a generally rectangular form and acentral opening55 as depicted in FIG.3. In assembly,strain relief member28 at the end of thecable13 is installed in an opening in theend cap29 and the conductors of the cable are connected directly or through theseparate wires25 and26 as illustrated to theterminals23 and24 of thereceiver18, being optionally extended through aresilient foam element56, as shown. Then theoutput port22 of the receiver is inserted in theopening55 of thepiece54 and the receiver is inserted into thechamber portion19 and moved toward thewall32 to press fit theoutput port22 into theinlet end portion48 of thepassage46. During this assembly step, aportion58 of thepiece54 is compressed between the end of thereceiver18 and thewall32 andportions59 and60 of thepiece54 are folded back and compressed between the receiver and theouter wall34 of thechamber portion19. As shown in the cross-sectional view ofFIG. 4, parts of the folded-back portions59 and60 extend along the sides of thereceiver18 as well as along the top and bottom of thereceiver18. This assembly step is readily and quickly performed and results in a resilient support of thereceiver18 within thehousing member20 in a manner such as to minimize transmission of noise and vibrations thereto, functioning with a high degree of reliability. It also results in an acoustic seal between theoutput port22 and theinlet end48 ofpassage46. As a final assembly step, an epoxy or equivalent bonding means is used to secure theend cap29 to the end of thehousing member20.
FIG. 5 is a schematic diagram of the configuration of thejunction unit15 which connects theearphone cables13 and14 to thecommon cable16 and which includes special electrical filters for enhancing the performance of theearphones11 and12. Oneconductor63 and oneconductor64 of thecables13 and14 are directly connected to aground conductor65 of thecommon cable16. Asecond conductor67 of thecable13, asecond conductor68 of thecable14, andconductors69 and70 ofcable16 are respectively connected topads71,72,73 and74 of acircuit board76 which is formed with two circuits operative to increase the signal applied to the receivers of theearphones11 and12 as a function of increasing frequency.
As shown, a capacitor77 and aresistor78 are connected in series directly betweenpads71 and73 while aresistor80 is connected directly betweenpads71 and73, in parallel with the series combination of capacitor77 andresistor78. Similarly, acapacitor81 and aresistor82 are connected in series betweenpads72 and74 while aresistor84 is connected directly betweenpads71 and73. It will be apparent that at very low frequencies, when the capacitive reactance is high, the series impedances are determined primarily by the value of theresistors80 and84. As the frequency increases, the series impedances are reduced, increasing the amplitudes of higher frequency components of the applied signals.
This electrical filtering operation is found to be highly desirable, permitting the use of an amount of acoustic damping sufficient to smooth out peaks in the acoustic responses of theearphones11 and12 while obtaining optimum frequency response characteristics. By way of example, the value of each of theresistors78,80,82 and84 may be 100 ohms and the value of each of thecapacitors77 and81 may be 0.22 microfarads. Thecircuit board76 and the parts thereon preferably have quite small dimensions. Each of the resistor and capacitor parts preferably has maximum dimensions of 0.150″×0.300″×0.100″. These dimensions are desirable to obtain a compact junction unit and are such that if desired, as when a single earphone is to be used, the filter for each filter might be located within the earphone, e.g. between thereceiver18 and theend cap29. In a two earphone assembly such as the illustratedassembly10, however, it is generally preferable to locate the filters in thejunction unit15.
FIG. 6 illustrates a tool usable for removal and replacement of a damper which has become clogged with wax or otherwise defective. Asupport rod86 carries a threadedelement87 which has apointed end88 to be pushed into the screen of a defective damper while therod86 is rotated to engage the threads of theelement87 with a lip of thecylindrical support52 of thedamper50; therod86 being then retracted to withdraw the defective damper.Replacement dampers89 may be contained in achamber90 within thesupport rod86 and may be accessed by removal of anextension91 of therod86, theextension91 having a reduced diameter threadedend portion92 which is screwed into an internally threaded end portion of thereplacement damper chamber90.
It will be understood that modifications and variations may be effected without departing from the spirit and scope of the novel concepts of this invention.