Abstract: A method for forming a device (10) that fits into a person's ear canal, that carries sound from a pipe (B) of a speaker assembly (A) into the person's ear canal, and that blocks environmental noise. A first elastomeric material (14) is molded around an elongated core (16) to form a device body (12) with an outer surface that can seal to a person's ear canal. In one method, the first elastomeric material of the body is a soft foamable material and the core is a previously-formed tube (16) of a stiffer second elastomeric material, with the body bonded to the tube by being molded around it, either in a mold cavity or by extrusion through an extrusion head. In another method, the elastomeric material of the body is a non-foam, and the core (96) is a rigid pin that is removed from the earplug body after the earplug body has at least partially solidified.

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.

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.