A custom-fit in-ear-monitor (IEM) is provided that utilizes a plurality of drivers and a single piece driver module that significantly simplifies fabrication while insuring that the completed IEM achieves the desired acoustic performance. The driver module, which is fit within a custom-fit ear mold shell, includes a plurality of driver ports to which the drivers are coupled. The driver module also includes an acoustic output member that includes one or more sound bores that acoustically couple the acoustic output surface of the custom-fit ear mold shell to the plurality of driver ports via a plurality of sound ducts within the driver module.
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0. 65. A custom-fit in-ear-monitor (IEM), comprising:
a custom-fit ear mold shell having an external surface that is shaped to match the contours of an end user's ear;
a pre-tuned single piece driver module disposed within the custom-fit ear mold shell and positioned to deliver an acoustic output through a first opening formed in an end of the custom-fit ear mold shell, wherein the single piece driver module comprises:
a plurality of driver ports formed in the single piece driver module; and
an acoustic output member that includes a first sound bore that is acoustically coupled to a first driver port of the plurality of driver ports and a second sound bore that is acoustically coupled to a second driver port of the plurality of driver ports, wherein the first and second sound bores are formed through an output face of the acoustic output member which is positioned at the first opening formed in the end of the custom-fit ear mold shell; and
a plurality of drivers disposed within the custom-fit ear mold shell, wherein each of the plurality of drivers is coupled to one of the plurality of driver ports; and
a removable faceplate configured to close a second opening in the custom-fit ear mold shell, wherein the single piece driver module and the plurality of drivers are configured to be inserted while separated from the faceplate through the second opening in the custom-fit ear mold shell prior to closing the second opening with the faceplate.
28. An A custom-fit in-ear-monitor (IEM) driver component configured to fit within an IEM comprising: a custom-fit ear mold shell , comprising: and a pre-tuned single piece driver module configured to fit within said custom-fit ear mold shell, said single piece driver module comprising:
a plurality of driver ports, each of the driver ports of the plurality of driver ports configured to be coupled to a plurality of a driver of one or more drivers,
a central body portion, wherein:
at least one a first of said plurality of driver ports is comprised of a first hollow member that extends away from a the central body portion of said single piece driver module, and wherein
at least one a second of said plurality of driver ports is comprised of a cavity formed within said central body portion of said single piece driver module and configured to accept at least a portion of at least one a first of said plurality of the one or more drivers; and
an acoustic output member, wherein
said acoustic output member extends away from said central body portion of said single piece driver module, wherein
said acoustic output member includes at least one sound bore one or more sound bores each configured to be acoustically coupled to have an end disposed at an acoustic output surface of said IEM custom-fit ear mold shell, and wherein
said at least one sound bore is one or more sound bores are each acoustically coupled via a plurality of sound ducts within said body portion of said single piece driver module to at least one of said plurality of driver ports; and
a removable faceplate configured to close an opening in the custom-fit ear mold shell, wherein the single piece driver module and the one or more drivers are configured to be inserted while separated from the faceplate through said opening in said custom-fit ear mold shell prior to closing said opening with the faceplate.
2. A custom-fit in-ear-monitor (IEM), comprising;
a custom-fit ear mold shell having an external surface that is shaped to match the contours of an end user's ear;
a single piece driver module configurable to fit within said custom-fit ear mold shell, said single piece driver module comprising:
a body portion;
a plurality of driver ports, wherein at least one of said plurality of driver ports is comprised of a first hollow member that extends away from a the body portion of said single piece driver module; and
an acoustic output member, wherein said acoustic output member extends away from said body portion of said single piece driver module, wherein said acoustic output member includes at least one sound bore one or more sound bores that is acoustically coupled to an acoustic output surface of said custom-fit ear mold shell, and wherein
said at least one sound bore is one or more sound bores are each acoustically coupled via a plurality of sound ducts within said single piece driver module to at least one of said plurality of driver ports; and
a plurality of drivers disposed within said custom-fit ear mold shell, wherein one of each of said plurality of drivers is coupled to a corresponding one of each of said plurality of driver ports;
a crossover circuit disposed within said custom-fit ear mold shell and electrically coupled to said plurality of drivers, wherein said crossover circuit is configured to receive an electrical signal from an audio source that is external to said custom-fit IEM and to provide separate input signals to each of said plurality of drivers based on said electrical signal; and
a removable faceplate configured to close an opening in said custom-fit ear mold shell, wherein said single piece driver module and said plurality of drivers are configured to be inserted while separated from the faceplate through said opening in said custom-fit ear mold shell prior to closing said opening with said faceplate.
1. A custom-fit in-ear-monitor (IEM), comprising:
a custom-fit ear mold shell having an external surface that is shaped to match the contours of an end user's ear;
a pre-tuned single piece driver module configurable configured to fit be positioned entirely within said custom-fit ear mold shell, said single piece driver module comprising:
a central body portion;
a plurality of driver ports, wherein at least one of said plurality of driver ports is comprised of a first hollow member that extends away from a the central body portion of said single piece driver module; and
an acoustic output member, wherein said acoustic output member extends away from said central body portion of said single piece driver module, wherein said acoustic output member includes at least one sound bore having an end that is acoustically coupled to disposed at an acoustic output surface of said custom-fit ear mold shell, and wherein
said at least one sound bore is acoustically coupled via a plurality of sound ducts, within said single piece driver module, to one or more driver ports of said plurality of driver ports; and
a plurality of drivers disposed within said custom-fit ear mold shell, wherein one of each of said plurality of drivers is coupled to a corresponding one of each of said plurality of driver ports;
a crossover circuit disposed within said custom-fit ear mold shell and electrically coupled to said plurality of drivers, wherein said crossover circuit is configured to receive an electrical signal from an audio source that is external to said custom-fit IEM and to provide separate input signals to each of said plurality of drivers based on said electrical signal; and
a filler disposed within said custom-fit ear mold shell, wherein said filler is disposed within said custom-fit ear mold shell after said single piece driver module and said plurality of drivers and said crossover circuit have been installed within said custom-fit ear mold shell, and wherein said filler captures and holds said single piece driver module and said plurality of drivers and said crossover circuit within said custom-fit ear mold shell; and
a removable faceplate configured to close an opening in said custom-fit ear mold shell, wherein said single piece driver module and said plurality of drivers are configured to be inserted while separated from the faceplate through said opening in said custom-fit ear mold shell prior to closing said opening with said faceplate.
3. The custom-fit IEM of
4. The custom-fit IEM of
5. The custom-fit IEM of
further comprising a cable socket integrated into said custom-fit ear mold shell, wherein a source input cable coupleable to said audio source is attached to said custom-fit IEM and to said crossover circuit via said cable socket.
6. The custom-fit IEM of
wherein said crossover circuit is integrated into said cable socket.
7. The custom-fit IEM of
9. The custom-fit IEM of
10. The custom-fit IEM of
11. The custom-fit IEM of
12. The custom-fit IEM of
13. The custom-fit IEM of
14. The custom-fit IEM of
said single piece driver module further comprising comprises a PCB cavity, wherein said PCB and said crossover circuit are at least partially housed within said PCB cavity.
15. The custom-fit IEM of
16. The custom-fit IEM of
17. The custom-fit IEM of
said single piece driver module further comprising comprises at least one locking feature configured to capture and hold said single piece driver module within said custom-fit ear mold shell.
18. The custom-fit IEM of
19. The custom-fit IEM of
wherein said acoustic output member the at least one sound bore includes a first sound bore acoustically coupled to a first of said plurality of driver ports via a first duct of said a plurality of sound ducts within said single piece driver module, and wherein said acoustic output member the at least one sound bore includes a second sound bore acoustically coupled to a second of said plurality of driver ports via a second duct of said plurality of sound ducts within said single piece driver module.
20. The custom-fit IEM of
21. The custom-fit IEM of
a first driver of said plurality of drivers is coupled to said first driver port, wherein
a second driver of said plurality of drivers is coupled to said second driver port, wherein
a third driver of said plurality of drivers is coupled to said third driver port, wherein
said first driver is a high-frequency driver, wherein
said second driver is a mid-frequency driver, and wherein
said third driver is a low-frequency driver.
22. The custom-fit IEM of
23. The custom-fit IEM of
24. The custom-fit IEM of
25. The custom-fit IEM of
26. The custom-fit IEM of
27. The custom-fit IEM of
29. The IEM driver component custom-fit in-ear-monitor (IEM) of
wherein a second third driver port of said plurality of driver ports is comprised of a second hollow member that extends away from said body portion of said single piece driver module.
30. The IEM driver component custom-fit in-ear-monitor (IEM) of
wherein said body portion of said single piece driver module is fabricated from a rigid material and wherein said first hollow member and said acoustic output member are fabricated from a pliable material.
31. The IEM driver component custom-fit in-ear-monitor (IEM) of
wherein said rigid material is comprised of a plastic material and said pliable material is selected from the group of elastomeric materials consisting of silicone, neoprene, ethylene propylene diene monomer, nitrile rubber, nitrile, polyvinyl chloride, nitrile/PVC blends, and urethane.
32. The IEM driver component custom-fit in-ear-monitor (IEM) of
wherein said single piece driver module including said body portion, said plurality of driver ports and said acoustic output member are fabricated from a pliable material.
33. The IEM driver component custom-fit in-ear-monitor (IEM) of
wherein said pliable material is selected from the group of elastomeric materials consisting of silicone, neoprene, ethylene propylene diene monomer, nitrile rubber, nitrile, polyvinyl chloride, nitrile/PVC blends, and urethane.
34. The IEM driver component custom-fit in-ear-monitor (IEM) of
said single piece driver module further comprising at least one locking feature integrated onto an outer surface of said single piece driver module and configured to capture and hold said single piece driver module within said IEM custom-fit ear mold shell.
35. The IEM driver component custom-fit in-ear-monitor (IEM) of
wherein said acoustic output member includes the one or more sound bores include a first sound bore acoustically coupled to a first of said plurality of driver ports via a first duct of said a plurality of sound ducts within said single piece driver module, and wherein said acoustic output member includes the one or more sound bores include a second sound bore acoustically coupled to a second of said plurality of driver ports via a second duct of said plurality of sound ducts within said single piece driver module.
36. The IEM driver component custom-fit in-ear-monitor (IEM) of
further comprising an acoustic output extension, wherein said acoustic output extension is slidably mounted to said acoustic output member, and wherein said acoustic output extension is adjustable between a non-extended position and an extended position.
37. The IEM driver component custom-fit in-ear-monitor (IEM) of
wherein said single piece driver module is configurable by blocking off one of said plurality of driver ports of said single piece driver module.
38. The custom-fit IEM of
39. The custom-fit IEM of
40. The custom-fit IEM of
41. The custom-fit IEM of
42. The custom-fit IEM of
44. The custom-fit IEM of
45. The custom-fit IEM of
46. The custom-fit IEM of
47. The custom-fit IEM of
48. The custom-fit IEM of
49. The custom-fit IEM of
50. The custom-fit IEM of
51. The custom-fit IEM of
52. The custom-fit IEM of
53. The custom-fit IEM of
54. The custom-fit IEM of
wherein said acoustic output member includes the one or more sound bores include a first sound bore acoustically coupled to a first of said plurality of driver ports via a first duct of said a plurality of sound ducts within said single piece driver module, and wherein said acoustic output member includes the one or more sound bores include a second sound bore acoustically coupled to a second of said plurality of driver ports via a second duct of said plurality of sound ducts within said single piece driver module.
55. The custom-fit IEM of
56. The custom-fit IEM of
57. The custom-fit IEM of
58. The custom-fit IEM of
59. The custom-fit IEM of claim 48 58,
wherein said first circular cross-section is larger than said second circular cross-section.
60. The custom-fit IEM of
61. The custom-fit IEM of
62. The custom-fit IEM of
0. 63. The custom-fit IEM of claim 1, wherein an output of the acoustic output member is disposed inside the custom-fit ear mold shell.
0. 64. The custom-fit IEM of claim 1, wherein
the body of the single piece driver module is directly coupled to the first hollow member, and
the body of the single piece driver module is directly coupled to the one or more sound bores.
0. 66. The custom-fit in-ear-monitor (IEM) of claim 65, wherein a cross-sectional area of the first sound bore at the output face of the acoustic output member is greater than a cross-sectional area of the second sound bore at the output face of the acoustic output member.
0. 67. The custom-fit in-ear-monitor (IEM) of claim 66, wherein two or more of the plurality of drivers are coupled to the first sound bore and only one of the plurality of drivers are coupled to the second sound bore.
0. 68. The custom-fit in-ear-monitor (IEM) of claim 66, wherein the plurality of drivers comprise a first driver that is coupled to the first sound bore and a second driver that is coupled to the second sound bore, and the first driver is a high frequency driver and the second driver is a mid or a low frequency driver.
0. 69. The custom-fit in-ear-monitor (IEM) of claim 66, wherein the first sound bore is substantially straight between a first driver port of the plurality of driver ports and the output face.
0. 70. The custom-fit in-ear-monitor (IEM) of claim 69, wherein the plurality of drivers comprise a first driver that is coupled to the first sound bore and a second driver that is coupled to the second sound bore, and the first driver is a high frequency driver and the second driver is a mid or a low frequency driver.
0. 71. The custom-fit in-ear-monitor (IEM) of claim 65, wherein the single piece driver module comprises an elastomeric material.
0. 72. The custom-fit in-ear-monitor (IEM) of claim 65, wherein only one of the plurality of drivers are coupled to the first sound bore and only one of the plurality of drivers are coupled to the second sound bore.
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In addition to simplifying IEM fabrication, the single piece driver module of the present invention also provides a single component that can be used in a variety of IEM configurations by simply varying the number and type of drivers coupled to the driver ports. For example, in the configuration illustrated in
In the configuration described above in which single piece driver module 400 is separate from the custom-fit ear mold, preferably one or more of the various members that extend away from body 407, e.g., output member 405 and driver port members 409 and 411, are fabricated from a pliable material so that they may be moved out of plane as required by the specific geometry of each particular user's ear mold. The body 407 of the module may be fabricated from the same pliable material or from a rigid material such as a plastic. Preferably the pliable portions of module 400 are fabricated from silicone, although other elastomeric materials that allow out-of-plane positioning of members 405, 409 and 411 may be used (e.g., neoprene, ethylene propylene diene monomer (EPDM), nitrile rubber, nitrile, polyvinyl chloride (PVC), nitrile/PVC blends, urethane, etc.).
The IEM's crossover circuit, which provides a means of dividing the input electrical signal among the plurality of IEM drivers (e.g., drivers 703, 705 and 707), may be integrated into the IEM in a variety of ways without affecting the invention. For example, in IEM 900 shown in
In some embodiments of the invention, driver module 400 includes one or more external features that aid in positioning and/or maintaining the module within the custom-fit ear mold. For example, IEM 1300 shown in
As previously noted, sound output member 405 preferably includes a pair of sound bores although it may be configured to use a single sound bore or more than two sound bores. Additionally, and as described below, the present invention is not limited to a specific cross-sectional shape for either the acoustic output member or the sound bores contained therein.
In at least one embodiment of the invention, driver module 400 includes an extension 1901 fitted onto the acoustic output member 405.
One of the benefits of the present invention is that it allows a pre-tuned driver assembly which utilizes the acoustically optimized driver module described above to be inserted into a custom-fit IEM shell, thereby greatly simplifying custom-fit IEM fabrication and assembly. While the driver assembly and the crossover circuit may be sealed within the IEM shell using a filler, an alternative approach is to use a faceplate to seal the IEM shell after the components have been inserted. In this approach, the IEM components may be held in place by an adhesive, padding, filler or an interference fit with the internal features of the IEM shell. By using the same size cutout for each custom IEM shell, the same faceplate can be used, thereby further reducing IEM fabrication complexity.
As noted above, the use of a pre-tuned, single piece driver module simplifies the fabrication of a custom-fit IEM, thereby reducing cost, while insuring that the performance consistently meets the acoustic goals for the device.
By eliminating the necessity of tuning each IEM prior to finalization, the present invention allows the manufacturing process to be substantially altered from the traditional, more labor intensive process typically used to manufacture custom-fit IEMs. For example,
As a result of simplifying the manufacturing and assembly process, the present invention allows portions of the process to be performed remotely and off-site. For example and as illustrated in
In the process described above, the use of a single piece, pre-tuned driver module not only simplifies IEM construction, but it also allows relatively un-trained personnel to assemble the final IEM. To further simplify the process entire driver assemblies, i.e., single piece driver module, drivers and crossover circuit, may be pre-assembled, thereby further minimizing the tasks that must be performed on-site (e.g., within the store).
In order to further expand the usefulness of the single piece driver module of the invention, it is possible to block off one or more of the driver ports during assembly. As a result, the same single piece driver module can be modified to use a fewer number of drivers, thereby lowering IEM cost.
Systems and methods have been described in general terms as an aid to understanding details of the invention. In some instances, well-known structures, materials, and/or operations have not been specifically shown or described in detail to avoid obscuring aspects of the invention. In other instances, specific details have been given in order to provide a thorough understanding of the invention. One skilled in the relevant art will recognize that the invention may be embodied in other specific forms, for example to adapt to a particular system or apparatus or situation or material or component, without departing from the spirit or essential characteristics thereof. Therefore the disclosures and descriptions herein are intended to be illustrative, but not limiting, of the scope of the invention.
Depallens, Philippe, Saggio, Jr., Joseph A.
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