A device includes an electromagnetic radiation delivery system such as a laser of light emitting diode infrared emitter configured for delivery of electromagnetic radiation within a sealed canal such as an ear canal, a fiber optic cable configured for delivering or capturing the electromagnetic radiation within the sealed canal, and a photo detector coupled to the fiber optic cable forming a portion of a voice communication system. Other embodiments are disclosed.

An article of manufacture and a method are disclosed including a multi-layered knee pad including an outer shell and other layers forming high sidewalls, the height of which depends on the internal width of the knee pad. The outer shell may also have an array of recesses on its outer convex surface. The other knee pad layers include one or more foam layers on the concave side of the outer shell, one or more gel layers surrounded by the foam layers, and a fabric sheet covering the foam layers on the concave side of the outer shell. The knee pad is manufactured using an injection mold to form the foam layers. The knee pad is customizable with respect to size, firmness, and structure. The knee pad may be customized by varying the layer's characteristics such as material and dimensions as well as the size and location of the recesses.

A method for making a foam component is provided and includes inserting a foam material into a cavity of a mold having a top plate and a bottom plate, heating the foam material to cause the foam material to expand, and moving one of the top plate and the bottom plate relative to the other of the top plate and the bottom plate as the foam material expands and contacts the one of the top plate and the bottom plate to cause the foam material to fold over on itself within the cavity.

An in-mold foam molded article has a foam body made from olefin-based resin pre-expanded beads and an insert member having an elongated connecting portion and movement resisting portions provided apart from one another in the elongated connecting portion. The insert member is subjected to insert molding upon in-mold foam molding using the olefin-based resin pre-expanded beads. The foam body has a movement facilitating structure that facilitates relative movement between the insert member and the foam body during shrinkage of the in-mold foam molded article after release from a mold.

A method for improving the production of a cased device (1), wherein a casing component (2) of the cased device (1) is produced, which production of the casing component (2) comprises injecting a polymer mixture (4) for creating a solid foam interior into a cavity, which cavity is formed by the casing component (2), which injecting is done by an injection apparatus (3) and which injecting is based on injection control data (5) input to the injection apparatus (3), wherein during the injection of the polymer mixture (4) into the cavity forming data (6) for describing the injection process is recorded, wherein after injecting the polymer mixture (4) into the cavity at least one image of the casing component (2) is recorded and wherein based on the forming data (6), the at least one image and the injection control data (5) a prediction model (8) for generating new injection control data (10) for inputting to the injection apparatus (3) is updated.

A push-in earplug is provided. The push-in earplug comprises an elongate core comprising a core material. The push-in earplug also comprises an outer layer comprising a foam material, the outer layer covering at least a portion of an outer surface of the elongate core. The push-in earplug also comprises a channel extending through the elongate core from a first end of the elongate core to the second end of the elongate core.

A push-in earplug is provided. The push-in earplug comprises an elongate core comprising a core material. The push-in earplug also comprises an outer layer comprising a foam material, the outer layer covering at least a portion of an outer surface of the elongate core. The push-in earplug also comprises a channel extending through the elongate core from a first end of the elongate core to the second end of the elongate core.

Manufacturing systems for expandable components may include a controller, a heat and/or pressure source, and a transfer line. For example, the expandable components may be configured to transform from a compressed configuration to an expanded configuration upon application of heat and/or pressure. In addition, the controller may activate the heat and/or pressure source to release heat and/or gases that are directed to the expandable components via the transfer line. Further, the manufacturing system may also include an igniter, a manifold, and a valve to further control the release of heat and/or gases. Moreover, at least a portion of the heat and/or gases may be recaptured in a closed chamber and redirected to additional expandable components in other closed chambers. Furthermore, various post-processing may be performed on the components in their expanded configurations.

An in-mold foam molded article has a foam body made from olefin-based resin pre-expanded beads and an insert member having an elongated connecting portion and movement resisting portions provided apart from one another in the elongated connecting portion. The insert member is subjected to insert molding upon in-mold foam molding using the olefin-based resin pre-expanded beads. The foam body has a movement facilitating structure that facilitates relative movement between the insert member and the foam body during shrinkage of the in-mold foam molded article after release from a mold.

A device includes an electromagnetic radiation delivery system such as a laser of light emitting diode infrared emitter configured for delivery of electromagnetic radiation within a sealed canal such as an ear canal, a fiber optic cable configured for delivering or capturing the electromagnetic radiation within the sealed canal, and a photo detector coupled to the fiber optic cable forming a portion of a voice communication system. Other embodiments are disclosed.