Abstract: An improved EarTip may result from the distribution of PTFE throughout a slow recovery foam. Such an EarTip may have a finer, more uniform cell structure that aids in insertion within a user's ear canal. It may also have a smoother skin, with a lower kinetic coefficient of friction, and may provide improved sound attenuation.

Abstract: An earbud (10) for carrying sound from a source (16) to a person's ear canal, includes a soft foam body (20) and a sleeve (26) of stiffer material lying within the body. The body is molded around the sleeve and is chemically bonded to the sleeve without an adhesive between them. The earbud is molded around the sleeve by placing the sleeve on a mandrel pin (42) within a mold cavity (32) placing foamable material in the mold and closing the mold. The mold has shoulders with one mold shoulder (52) that abuts one end (46) of the sleeve and another mold shoulder (60) that lies within 0.1 millimeter of the other sleeve end (62), to prevent foaming material from leaking into the space (64) between the mandrel pin and the sleeve passage.

Abstract: A headphone that is especially useful to test the efficacy of an earplug installed in an ear canal, by using the headphone to produce sound and by sensing sound pressure at the ear drum despite the presence of the earplug. Applicant uses the speaker (42) in the headphone to produce a smooth and reasonably “flat” frequency response by reversing the speaker orientation. In the reversed orientation, the front side of the speaker diaphragm (50) faces into the headphone cup and away from the ear. The rear side of the speaker that has a circle of holes (52), faces toward the ear. The headphone frame has a cylindrical passage (40) for carrying sound to the person's ear, which has an outer end (78) that is tapered to encompass the holes in the speaker back side (44). The axial distance (L) from the speaker rear side to the ear, is at least 0.6 inch to accommodate the protruding end of an earplug.

Abstract: An earbud (10) for carrying sound from a source (16) to a person's ear canal, includes a soft foam body (20) and a sleeve (26) of stiffer material lying within the body. The body is molded around the sleeve and is chemically bonded to the sleeve without an adhesive between them. The earbud is molded around the sleeve by placing the sleeve on a mandrel pin (42) within a mold cavity (32) placing foamable material in the mold and closing the mold. The mold has shoulders with one mold shoulder (52) that abuts one end (46) of the sleeve and another mold shoulder (60) that lies within 0.1 millimeter of the other sleeve end (62), to prevent foaming material from leaking into the space (64) between the mandrel pin and the sleeve passage.

Abstract: An earbud (10) for carrying sound from a source (16) to a person's ear canal, includes a soft foam body (20) and a sleeve (26) of stiffer material lying within the body. The body is molded around the sleeve and is chemically bonded to the sleeve without an adhesive between them. The earbud is molded around the sleeve by placing the sleeve on a mandrel pin (42) within a mold cavity (32), placing foamable material in the mold and closing the mold. The mold has shoulders with one mold shoulder (52) that abuts one end (46) of the sleeve and another mold shoulder (60) that lies within 0.1 millimeter of the other sleeve end (62), to prevent foaming material from leaking into the space (64) between the mandrel pin and the sleeve passage.

Abstract: An earpiece of flexible foam construction which incorporates recycled pulverized polyurethane foam (RPPF). RPPF constituting 5% to 30% of the improved foam has been found to be useful. The novel and unique nature of RPPF allows for the replacement of a higher cost component with a lower cost component while maintaining or improving physical properties, such as sound attenuation, sound control, comfort and fit.

Abstract: A method for making antimicrobial rebonded carpet pad includes mixing zinc pyrithione with a polyol to form an antimicrobial polyol mixture concentrate, blending the antimicrobial polyol mixture concentrate with a binder stream, mixing the binder with foam particles and curing the binder. The percentage of zinc pyrithione mixed with the polyol and the addition ratio of the antimicrobial polyol mixture concentrate with the binder stream are selected to provide an overall concentration of zinc pyrithione in the binder of at least about 7500 ppm. The particles and binder are cured into a block and sliced to form carpet pad.

Abstract: An improved EarTip may result from the distribution of PTFE throughout a slow recovery foam. Such an EarTip may have a finer, more uniform cell structure that aids in insertion within a user's ear canal. It may also have a smoother skin, with a lower kinetic coefficient of friction, and may provide improved sound attenuation.

Abstract: A method for making antimicrobial rebonded carpet pad includes mixing zinc pyrithione with a polyol to form an antimicrobial polyol mixture concentrate, blending the antimicrobial polyol mixture concentrate with a binder stream, mixing the binder with foam particles and curing the binder. The percentage of zinc pyrithione mixed with the polyol and the addition ratio of the antimicrobial polyol mixture concentrate with the binder stream are selected to provide an overall concentration of zinc pyrithione in the binder of at least about 7500 ppm. The particles and binder are cured into a block and sliced to form carpet pad.

Abstract: A method for making antimicrobial rebonded carpet pad includes mixing zinc pyrithione with a polyol to form an antimicrobial polyol mixture concentrate, blending the antimicrobial polyol mixture concentrate with a binder stream, mixing the binder with foam particles and curing the binder. The percentage of zinc pyrithione mixed with the polyol and the addition ratio of the antimicrobial polyol mixture concentrate with the binder stream are selected to provide an overall concentration of zinc pyrithione in the binder of at least about 7500 ppm. The particles and binder are cured into a block and sliced to form carpet pad.

Abstract: A polyurethane foam produced from a formulation comprising a polyol, an isocyanate, a strut reinforcing agent and a VOC reducing agent. The isocyanate reacts with the polyol to produce the polyurethane foam. By including the strut reinforcing and VOC adsorption agents in the formulation during the reaction between the isocyanate and the polyol, the air permeability and firmness of the polyurethane foam are enhanced while the amount of VOCs within and the level of VOCs emitted by the polyurethane foam are reduced relative to a polyurethane foam produced by reacting the isocyanate and the polyol in the absence of the strut reinforcing or VOC reducing agents.

Abstract: A bonded foam product manufactured with a vegetable oil polyol is herein disclosed. The pre-polymer for use as a binder in the manufacture of a bonded foam product comprises an isocyanate and a vegetable oil polyol, wherein the pre-polymer is substantially free of any petrochemical polyol. In another aspect, the invention is method for making a bonded foam product, the method comprising coating a plurality of foam pieces with a pre-polymer, the pre-polymer comprising an isocyanate and a vegetable oil polyol, wherein the pre-polymer is substantially free of any petrochemical polyol, compressing the foam pieces into a foam log of a desired density, and steaming the foam log to cure the pre-polymer. If desired, a process oil may be added to the pre-polymer to modify the viscosity of the pre-polymer.

Abstract: An earplug of the type that includes a shell (12) that fits tightly in a human ear canal and a stem (20) that lies in the shell and can be pushed forward to push the shell into an ear canal, which reduces the possibility of loss of the stem, and provides better blocking of noise. The shell and stem have front ends that are integrally molded and that merge to avoid loss of the stem, although the molding leaves gaps between the shell and stem. The stem has a passage (62), and an insert (60) is inserted into the passage and expands the stem to cause the stem to closely slidably fit in a guide flange (44) of the shell and to press the stem into contact with an inside flange (46) of the shell to form a seal thereat to better block sound. An additional inside front flange (62) is formed in a front portion of the shell, so when the shell front portion is compressed by the walls of the ear canal the front flange engages the stem to provide another sealed chamber that blocks sound.

Abstract: An earbud (10) for carrying sound from a source (16) to a person's ear canal, includes a soft foam body (20) and a sleeve (26) of stiffer material lying within the body. The body is molded around the sleeve and is chemically bonded to the sleeve without an adhesive between them. The earbud is molded around the sleeve by placing the sleeve on a mandrel pin (42) within a mold cavity (32), placing foamable material in the mold and closing the mold. The mold has shoulders with one mold shoulder (52) that abuts one end (46) of the sleeve and another mold shoulder (60) that lies within 0.1 millimeter of the other sleeve end (62), to prevent foaming material from leaking into the space (64) between the mandrel pin and the sleeve passage.