Abstract: An earplug of the type that has a stem (12) and a plurality of flanges (21–23), is constructed to be stiff enough to be easily inserted into the ear canal, and to thereafter press with minimal force against the walls of the ear canal for comfort. The earplug is molded of an elastomeric material whose stiffness decreases considerably, such as at least 4%, when it is warmed from room temperature (about 72° F.) to ear canal temperature (about 100° F.). Each flange has a radially inner portion (52) that extends straight at an angle (B) that is within 15° of a radial direction (62) (a direction perpendicular to the stem axis), and has a radially outer portion (54) that extends straight and at an angle (C) that is within 20° of an axial direction (66).

Abstract: An earplug (10) that includes a soft foam body (12) and a stiffener (14) in the body, is produced by a method that has minimum steps and that results in an earplug of attractive design and that uses a minimum of material. One method includes molding an earplug body in a body cavity (52) while a mandrel (56) lies in the body cavity. After the foam material in the body cavity has at least partially solidified, the mandrel is removed, leaving an empty stiffener cavity (60) in the foam body (12). With the body remaining in the body mold (54), flowable stiffener material (14A) is poured into the stiffener cavity of the body and allowed to solidify, to produce an earplug with a molded-in stiffener (14). Another method, results in an earplug (90) with a stem (95) having a rearwardly-projecting stem portion (96). This method includes molding a stem rear portion (96) in a stiffener cavity (110) while allowing stiffener material to project forward of the rear portion to form a stem free front portion (120).

Abstract: An earplug (10) with a body front portion (22) for insertion into a person's ear canal, has a pocket (30) to increase comfort and is constructed to enhance noise attenuation. The pocket, which allows easier compression of the body front portion for increased comfort, has a plurality of baffles (50) that attenuate sound better than a pocket without baffles. The pocket with baffles is formed by a core pin (80) that lies in an injection mold (82) and that forms the pocket, the core pin having a plurality of slots (81) that form the baffles. The pocket includes a rear portion (36) that forms a wide passage, and the earplug includes a blocker portion (90) that partially or completely closes off the rear pocket passage.

Abstract: Earplugs with soft foam bodies and with stiffeners in the bodies, are molded by suspending the stiffener in the body mold cavity using a pin (60) that extends into a passage (56) at the rear of the body. Each stiffener is tapered in diameter, with a rear end (34) of greatest diameter.

Abstract: An earplug is provided for use by an airplane passenger, which more slowly increases the pressure of air in the passenger's ear canal than the rate of increase in cabin air pressure as the airplane descends near the end of a flight. The earplug has a cavity (30) that is open to the front end (20) of the earplug, and with a restrictor (24) at the front end of the cavity that allows air to pass between the cavity and ear canal, and the cavity to collapse, only at a very slow rate. As the environmental air pressure increases near the end of a flight, the earplug is slowly compressed in diameter and compresses the cavity.