Process for producing an aural communications receiving device

Claim 1

A process for producing a formed-in-place communications receiver for the human ear, said process comprising the steps of: (a) wrapping longitudinally around a small diameter coring form a disc of a composition which comprises a non-irritating curable synthetic elastomer having a stiff putty-like consistency, molding said composition on said coring form and into the shape of a blunt tapered cone, the coring form extending inwardly from the base of the cone to a point adjacent the apex of the cone, leaving at least the outer end of the coring form exposed, the coring form having an outside diameter sized to correspond to the diameter of a small sound transmitting passageway in said receiver and comprising a material which is easily releasable from the cured elastomer; (b) inserting the apex of the tapered cone into the outer opening of the ear canal to a depth slightly beyond the cartilage regions of the tragus and the eminentia conchae, firmly packing the composition around the ear canal opening to produce a receiver body having a protuberance which extends into and conforms to the outer opening of the ear canal, and leaving a part of the receiver body outside of the ear canal opening and the coring form centrally located within the receiver body and the ear canal; (c) molding the external portion of the receiver body into an ear shell conforming surface and adding an additional amount of said composition to provide a mass at least sufficient to moldably engage with the outer ear and provide means for assisting in the retention of the receiver in the ear; (d) engaging the outer, exposed end of said coring form with an aperture in a combination comprising (1) a finishing plate and (2) an apertured communications component or an apertured means for connecting a communications component to said receiver body, pushing said combination down the coring form and into engagement with the receiver body using sufficient force to embed the communications component or connecting means into the composition and to cause the inner surface of the finishing plate to press the composition into a substantially flat surface at the area of contact with the plate, said communications component or connecting means comprising a material which is bondable to the elastomer, and said finishing plate comprising a material which is easily releasable from the elastomer; (e) allowing the elastomer to cure to a permanent shape; and (f) removing the finishing plate and the coring form from the communications receiver so produced.