Abstract: An earplug comprises a core and a sound-attenuating body attached to the core, the sound-attenuating body comprising a tip cavity extending proximally from the tip of the sound-attenuating body and comprising a distal opening. The tip cavity side wall includes a plurality of protrusions extending inwardly toward the longitudinal axis of the core. The plurality of protrusions may include from 2 to 12 protrusions. A method of making an earplug includes covering at least a portion of a core with a material including unactivated foaming agent; inserting an end of the core and at least a portion of the material into a mold cavity; and activating the foaming agent to create a sound-attenuating body. The sound-attenuating body has a base, tip, and tip cavity with a plurality of protrusions. The mold cavity may include a boss with a cup and plurality of cut-outs on the cup for forming the protrusions.

Abstract: A method of making personal protective equipment, such as a push-in earplug, is disclosed. The method includes the steps of covering a substrate with an outer layer that includes an unactivated foaming agent, positioning at least a portion of the outer layer in a mold, and activating the foaming agent such that a portion of the outer layer expands.

Abstract: A push-in earplug including an elongate core and outer layer is disclosed. The outer layer includes a sound attenuating portion having a first average density and a stem portion having a second average density, and the second average density is greater than the first average density.

Abstract: An earplug assembly includes a first earplug, a second earplug, and a cord including a first end, a second end, each earplug including a stem and a sound attenuating body. A method for preparing the earplug assembly includes attaching the first and second ends of the cord to the first and second earplugs, respectively, by contacting a hot tip to the proximal end of the stem of the earplug to form an attachment point, removing the hot tip, and contacting or inserting the end of the cord to the attachment point to thermally bond the end of the cord to the stem of the earplug.

Abstract: An earplug comprises a core and a sound-attenuating body attached to the core, the sound-attenuating body comprising a tip cavity extending proximally from the tip of the sound-attenuating body and comprising a distal opening. The tip cavity side wall includes a plurality of protrusions extending inwardly toward the longitudinal axis of the core. The plurality of protrusions may include from 2 to 12 protrusions. A method of making an earplug includes covering at least a portion of a core with a material including unactivated foaming agent; inserting an end of the core and at least a portion of the material into a mold cavity; and activating the foaming agent to create a sound-attenuating body. The sound-attenuating body has a base, tip, and tip cavity with a plurality of protrusions. The mold cavity may include a boss with a cup and plurality of cut-outs on the cup for forming the protrusions.

Abstract: The present description provides an earplug. One exemplary earplug described herein includes a stem and a sound attenuating body attached to the stem. The sound attenuating body includes a leading end, a base end, a tip region positioned rearward of the leading end, and a longitudinal axis extending between the leading end and the base end. An array of cavities is positioned within the tip region and spaced around the longitudinal axis and provides a collapsible volume.

Abstract: A push-in earplug including an elongate core and outer layer is disclosed. The outer layer includes a sound attenuating portion having a first average density and a stem portion having a second average density, and the second average density is greater than the first average density.

Abstract: Hearing protection devices, e.g., push-to-fit earplugs, having a tip cavity in the sound attenuating body and methods of manufacturing the hearing protection devices are described herein.

Abstract: A method of making personal protective equipment, such as a push-in earplug, is disclosed. The method includes the steps of covering a substrate with an outer layer that includes an unactivated foaming agent, positioning at least a portion of the outer layer in a mold, and activating the foaming agent such that a portion of the outer layer expands.

Abstract: A method of making personal protective equipment, such as a push-in earplug, is disclosed. The method includes the steps of covering a substrate with an outer layer that includes an unactivated foaming agent, positioning at least a portion of the outer layer in a mold, and activating the foaming agent such that a portion of the outer layer expands.

Abstract: A push-in earplug including an elongate core and outer layer is disclosed. The outer layer includes a sound attenuating portion having a first average density and a stem portion having a second average density, and the second average density is greater than the first average density.

Abstract: A push-in earplug including an elongate core and outer layer is disclosed. The outer layer includes a sound attenuating portion having a first average density and a stem portion having a second average density, and the second average density is greater than the first average density.

Abstract: A push-in earplug including an elongate core and outer layer is disclosed. The outer layer includes a sound attenuating portion having a first average density and a stem portion having a second average density, and the second average density is greater than the first average density.

Abstract: Hearing protection devices, e.g., push-to-fit earplugs, having a tip cavity in the sound attenuating body and methods of manufacturing the hearing protection devices are described herein.

Abstract: Hearing protection devices, e.g., push-to-fit earplugs, having a tip cavity in the sound attenuating body and methods of manufacturing the hearing protection devices are described herein.

Abstract: A push-to-fit type earplug (100) including a sound attenuating portion (113) and a semi-rigid stem portion (114) having a relatively greater stiffness than the sound attenuating portion is disclosed. The sound attenuating portion and stem portion are made of a closed-cell, slow-recovery foam.