FOAM EARPLUG WITH TRANSDERMAL MATERIAL

Abstract

A foam earplug for reception at least partially within the ear canal and including a body portion formed of resilient foam plastic material having a multiple open cell structure and having a size and shape for at least partial reception within the ear canal. A transdermal material having a particular beneficial action, and with an outer layer of the foam earplug infused with the transdermal material so that the benefits of the transdermal material is in transdermal contact with the ear canal. One example is a humectant material and, specifically, a moisturizer/lubricating material, for providing an increase to the lubrication and moisturizing in the ear canal. A second example is where the beneficial action is provided by systemic distribution such as a sleep aid, i.e., Melatonin, so that when the earplugs arm worn during sleep, the earplugs will provide a sleep aid to the wearer.

Claims

1. A foam earplug for reception at least partially within an ear canal of a user, including, a body portion formed of resilient foam plastic material having a multiple open cell structure and having a size and shape for at least partial reception within the ear canal of the user, a transdermal material having a particular beneficial effect for the user of the earplug, and an outer layer of the foam earplug infused with the transdermal material so that the transdermal material is in transdermal contact with the ear canal when the foam earplug is received at least partially within the ear canal, and wherein the transdermal material provides the beneficial effect and has at least one active ingredient that is transferred systemically to the ear canal of the user by transdermal contact with the ear canal by the outer layer of foam infused with the at least one active ingredient to provide the beneficial effect to the user of the earplug as compared to the resilient foam plastic material without the outer layer of foam infused with the at least one active ingredient, and wherein the body portion has a size and shape to be received substantially within exterior and interior portions of the ear canal, and wherein the outer layer infused with a transdermal material has a thickness in the range of 0.1 to 40 mils.

2. The earplug of claim 1 wherein the transdermal material is a humectant material and a moisturizer/lubricating material, received within the ear canal for providing an increase in the lubrication and moisturizing in the ear canal as compared to the resilient foam plastic material without the outer layer infused with the humectant material

3. The earplug of claim 1 wherein the transdermal material is Melatonin and received within the ear canal for providing the outer layer of foam infused with Melatonin to provide an aid in sleep as compared to the resilient foam plastic material without the outer layer infused with the Melatonin.

4. The earplug of claim 1 wherein the foamable plastic material is provided to be a slow recovery foamable material.

5. The earplug of claim 1 wherein the transdermal material is a humectant material and is glycerin.

6. The earplug of claim 1 wherein the earplug has a bullet shape with a flared back end.

7. The earplug of claim 1 wherein the ear plug is molded into a desired shape for insertion into the air ear canal.

8. The earplug of claim 1 wherein the outer layer infused with a transdermal material has a thickness in the range of 0.1 to 20 mils.

9. A method of making a foam earplug having an outer layer infused with a humectant material and specifically, a transdermal material having a particular beneficial effect, including the following steps: providing a mold having at least one cavity to form an earplug having a size and shape to fit at least partially within an ear canal, providing a transdermal material having a particular beneficial effect, costing the interior of the cavity with the transdermal material, providing a foamable plastic material, and placing the foamable plastic material within the coated cavity to foam to the size and shape of the cavity to form a resilient foam plastic earplug having an outer layer infused with the transdermal material.

10. The method of claim 9 wherein the foamable plastic material is provided to be a slow recovery foamable material.

11. The method of claim 9 wherein the transdermal material infused in the outer layer of foam is a humectant material and, specifically, a moisturizer/lubricating material to form an earplug having the outer layer infused with the humectant material.

12. The method of claim 11 wherein the humectant material is, specifically, glycerin.

13. The method of claim 9 wherein the transdermal material of the outer layer of foam is infused with a sleep aid material and, specifically, Melatonin to form an earplug having the outer layer infused with the Melatonin material.

14. The method claim 9 wherein the transdermal material provides the beneficial effect and has at least one active ingredient that is transferred systemically to the body of the wearer by transdermal contact with the ear canal by the outer layer of foam infused with the at least one active ingredient to provide the beneficial effect to the wearer of the earplug as compared to the resilient foam plastic material without outer layer of foam infused with the at least one active ingredient.

15. The method of claim 9 wherein the cavity is provided with a size and shape to produce an earplug to be received substantially within exterior and interior portions of the ear canal.

16. The method of claim 9 wherein the cavity is provided with a size and shape to produce an earplug to be received only within an exterior portion of the ear canal.

17. The method of claim 9 wherein the outer layer infused with humectant material is to a thickness in the range of 0.1 to 40 mils.

18. The method of claim 9 including the additional step of removing the coated earplug from the cavity and coating any portions of the earplug not coated in the cavity by spraying.

19. A method of making a foam earplug having an outer layer infused with a humectant material and specifically, a transdermal material-having a particular beneficial effect, including the following steps: providing a mold having at least one cavity to form an earplug having a size and shape to fit at least partially within an ear canal, providing a foamable plastic material, placing the foamable plastic material within the cavity to foam to the size and shape of the cavity to form a resilient foam plastic earplug, removing the earplug from the cavity, providing a transdermal material having a particular beneficial effect, and coating the earplug with the transdermal material to form a resilient foam plastic earplug having an outer layer infused with a transdermal material.

20. The method of claim 19 wherein the foamable plastic material is provided to be a slow recovery foamable material.

21. The method of claim 19 wherein the transdermal material infused in the outer layer is a humectant material and specifically, a moisturizer/lubricating material to form an earplug having the outer layer infused with the humectant material.

22. The method of claim 20 wherein the humectant material is, specifically, glycerin.

23. The method of claim 19 wherein the transdermal material of the outer layer is a sleep aid material and, specifically, Melatonin to form an earplug having the outer layer infused with the Melatonin material.

24. The method of claim 19 wherein the transdermal material provides the beneficial effect and has at least one active ingredient that is transferred systemically to the body of the wearer by transdermal contact with the ear canal by the outer layer of foam infused with the at least one active ingredient to provide the beneficial effect to the wearer of the earplug as compared to the resilient foam plastic material without outer layer of foam infused with the at least one active ingredient.

25. The method of claim 19 wherein the cavity is provided with a size and shape to produce an earplug to be received substantially within exterior and interior portions of the ear canal.

26. The method of claim 19 wherein the cavity is provided with a size and shape to produce an earplug to be received only within an exterior portion of the ear canal.

27. The method of claim 19 wherein the outer layer infused with humectant material is to a thickness in the range of 0.1 to 40 mils.

28. The method of claim 19 wherein the coating is applied by spraying.

29. A method of making a foam earplug having an outer layer infused with a humectant material and, specifically, a transdermal material having a particular beneficial effect, including the following steps: providing a foamable plastic material, providing a mold having a size and shape to form an elongated flat sheet of foamed plastic material, placing the foamable plastic material within the cavity to foam to the size and shape of the cavity, providing a punch having an interior size of an earplug to fit at least partially within an ear canal, repeatedly punching the elongated flat sheet of foamed plastic material to form multiple earplugs each having a size and shape to fit at least partially within an ear canal, providing a transdermal material having a particular beneficial effect, and coating the carplug with the transdermal material to form a resilient foam plastic earplug having an outer layer infused with a transdermal material.

30. The method of claim 29 wherein the foamable plastic material is provided to be a slow recovery foamable material.

31. The method of claim 29 wherein the transdermal material infused in the outer layer is a humectant material and, specifically, a moisturizer/lubricating material to form an earplug having the outer layer infused with the humectant material.

32. The method of claim 31 wherein the humectant material is, specifically, glycerin.

33. The method of claim 29 wherein the transdermal material the outer layer is a sleep aid material and, specifically, Melatonin to form an earplug having the outer layer infused with the Melatonin material.

34. The method of claim 29 wherein the transdermal material provides the beneficial effect and has at least one active ingredient that is transferred systemically to the body of the wearer by transdermal contact with the ear canal by the outer layer of foam infused with the at least one active ingredient to provide the beneficial effect to the wearer of the earplug as compared to the resilient foam plastic material without outer layer of foam infused with the at least one active ingredient.

35. The method of claim 29 wherein the cavity is provided with a size and shape to produce an earplug to be received substantially within exterior and interior portions of the ear canal.

36. The method of claim 29 wherein the cavity is provided with a size and shape to produce an earplug to be received only within an exterior portion of the ear canal.

37. The method of claim 29 wherein the outer layer infused with humectant material is to a thickness in the range of 0.1 to 40 mils.

38. The method of claim 29 wherein the coating is applied by spraying.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 is an illustration of a foam earplug of the prior art;

[0025] FIG. 2 is an illustration of a coated foam earplug in accordance with the present invention;

[0026] FIG. 3 is a cross-sectional view of the earplug taken along lines 3-3 in FIG. 2;

[0027] FIG. 4 is an illustration of a semi-aural headband type of earplug using ear protectors in accordance with the present invention;

[0028] FIG. 5 is a cross-sectional view of ear protectors taken along lines 5-5 of FIG. 4;

[0029] FIG. 6 is an illustration of a method of producing the earplug of the present invention including using coating inside the earplug mold cavity;

[0030] FIG. 7 is an illustration of a first step of a method of making an earplug of the present invention using a spray top-coat coating; and

[0031] FIG. 8 is an illustration of a step of providing a spray top-coat coating which either completes the method of FIG. 7 or may provide an additional step for the method of FIG. 6.

[0032] FIG. 1 illustrates a prior art earplug 10 typically molded from a slow recovery foam material. As can be seen, the earplug has a generally bullet-shape main body 12 with a flared outer end 14. This type of earplug would have the cells on the outer surface of the earplug typically being smaller at the outer surface and with larger cells in the center of the earplug. In this type of molded foam earplug since the surface of the earplug has smaller cells, a smoother configuration is generally formed on the outer cell surface than if the earplug were formed by cutting the earplug from a flat sheet. Although the earplug 10 may have smaller cells at the outer surface, the molded plugs are all porous on the outer surface although air may pass through the outer surface of the earplug a little more slowly than through the larger cells in the center of the plug.

[0033] A first embodiment of the present invention is illustrated in FIGS. 2 and 3. The present invention has a plug 100 which has an inner body 102 and an outer layer 104 infused with a transdermal material. The earplug 100 has generally the same shape as the prior art earplug in having a bullet shape main body portion with a flared backend. The inner body 102 may be constructed of the slow recovery foam or other types of resilient foams and the outer layer infused with the transdermal material such as the humectant material or as a sleep aid if the outer layer is infused with melatonin or a combination of both. In addition, the transdermal material can provide other beneficial effects so long as the active ingredient can be transferred to the body of the wearer by transdermal contact with the ear canal.

[0034] As indicated above, the humectant material could be made of a number of moisturizer/lubricating materials and a specific example would be glycerin. Glycerin is water soluble and the glycerin can be mixed with water with a ratio of one part glycerin to 2 parts water. Other examples of moisturizer/lubricating materials that may be used include a number of commercial products used in the hearing aid field that will aid in the insertion of hearing aids, molded to the exact size and shape of a wearer. In addition, some of these products aid in comfort due to the long use of the hearing aid in the ear canal. These products are described above and are sold under the trade names and descriptions listed above.

[0035] The layer of foam 104 infused with the transdermal material as part of the foam earplug itself may generally have a thickness between 0.1 to 40 mils. A preferred thickness would typically be 0.1 to 20 mils. The foam material provides an excellent host for the transdermal material because of its open cell structure and can support sufficient storage of this transdermal material to supply the transdermal material to the ear canal for extended periods of time. The operation of the earplugs of the present invention is similar to the many products in common use referred to as transdermal patches that are applied to the skin to transmit various active ingredients to the body of the wearer through the skin. In addition, the present invention can provide other beneficial effects of prior art patches so long as the active ingredient of the transdermal material infused into the earplug can be transferred to the body of the wearer by transdermal contact with the ear canal.

[0036] By producing earplugs with the outer layer infused with the transdermal material such as the humectant material or as a sleep aid if the outer layer is infused with melatonin or a combination of both or any transdermal material that provides a beneficial effect with an active ingredient transferred to the body of the wearer by transdermal contact with the ear canal. As shown in FIGS. 2 and 3, it is believed that there is a synergistic effect between the benefits of the earplugs made of foam material, such as slow recovery foam material, and the benefits of the transdermal material infused into the outer layer of the foam earplug. Not only are the earplugs in direct contact with the skin in the ear canal to operate as a transdermal patch but in addition, the resiliency of the foam earplug maintains the earplug in constant contact with the ear canal and the supply of the transdermal material infused into the earplug to form the outer layer of the earplug is maintained by the outer layer of foam infused with transdermal material to a sufficient depth to supply the transdermal material to the car canal for an extended period of time.

[0037] In addition to the form of the invention shown in FIGS. 2 and 3 it is also possible to have ear protectors, such as ear protectors 200, located at the ends of a headband 202 as shown in FIG. 4. This type of device provides for the ear protectors 200 to be partially inserted into the ear canal and to be held in the ear canal by the tension of the band 202. The band 202 may be constructed either of plastic or metal. As can be seen, the ear protectors 200 generally have a smaller insertable end 204 and a larger back portion 206 which typically would seal around the exterior of the opening to the ear canal.

[0038] FIG. 5 is a cross-sectional view of one of the ear protectors taken along lines 5-5 of FIG. 4 and, as can be seen, the ear protector is made of an interior foam material 206 with the outer layer 208 infused with the transdermal material such as the humectant material or as a sleep aid if the outer layer is infused with melatonin or a combination thereof. Again, the transdermal material may be any type of humectant material or sleep aid material or a combination of both. In addition, when the transdermal material provides a beneficial effect and has at least one active ingredient that is transferred systemically to the body of the wearer by transdermal contact with the ear canal by the outer layer of foam infused with the at least one active ingredient this will provide the beneficial effect to the wearer of the earplug as compared to the resilient foam plastic material without outer layer of foam infused with the at least one active ingredient.

[0039] The production of the earplug of the present invention may be produced by methods described with reference to FIGS. 6 to 8. In FIG. 6, a mold member 300 is shown to have multiple cavities 302, each having the form of an earplug or ear protector, shown in FIG. 2 or 4. Using the earplug shown in FIG. 2 as an example, the cavity would have a general bullet shape with a flared outer end. The cavity mold 300 is then moved as shown by the arrow 304 and with a first spray member 306 applying a pre-mold coating of the transdermal material 308 such as the humectant material or, if used as a sleep aid, the pre-mold coating is melatonin or a combination of both to the interior of each cavity 302. The spray head 306 may be actuated intermittently to ensure each cavity is coated with transdermal material 308 and without providing excess material to the exterior of the mold 300.

[0040] After each cavity 302 is coated with the transdermal material 308 an injector nozzle 312 fills each cavity with foamable plastic material 314 to form the main body of the earplug. After the foamable plastic material is completely foamed then the earplugs may be removed in the normal manner to produce the earplug as shown in FIG. 2. If it is desired to have the ends of earplugs also coated with the transdermal material, then the ends may be coated in a second step. This can be accomplished using the spray nozzle 306 before the earplugs are removed from the cavity or after the earplugs am removed from the cavities as shown in FIG. 8

[0041] In a second method of production shown in FIG. 7, the same cavity mold 300 having the plurality of cavities 302 is used and with the injection or nozzle 312 supplying foamable plastic material 314 to the interior of the cavities After the foamable plastic material has fully foamed, earplugs 318 are removed and may then be placed on a conveyer belt 316 shown in FIG. 8. The individual earplugs 318 are then sprayed using the sprayer head 306 with the transdermal material 308 to top coat the earplugs 318 with the coating.

[0042] The resultant earplug therefore has a body portion formed of resilient foam plastic material and an outer layer 104 or 209 foam infused with the transdermal material to form the layer integral with the body portion and with the combination having a synergistic effect between the benefits of the earplugs made of foam material, such as slow recovery foam material, and the benefits of the transdermal material infused into the foam to provide the outer layer.

[0043] Although the invention has been described with reference to particular embodiments, it is to be appreciated that various adaptations and modifications may be made. For example, the transdermal material can provide a variety of beneficial effects so long as the active ingredient can be transferred to the body of the wearer by transdermal contact with the ear canal. Therefore, the invention is only to be limited by the appended claims.