Ear plugs and method of forming same

Abstract

A process for forming a foamed thermoplastic earplug, comprising the steps of extruding a foamed body of thermoplastic material; shaping the foamed thermoplastic material; and at least partially separating the resulting shaped material for forming individual earplugs.

1 ) A process for forming a foamed thermoplastic article, comprising the steps of: 
 a) extruding a foamed body of thermoplastic material;    b) shaping the foamed thermoplastic material; and    c) at least partially separating the resulting shaped material for forming individual articles.    
   
   
       2 ) A process for forming a foamed thermoplastic earplug, comprising the steps of: 
 a) waterfoam extruding a foamed body of thermoplastic material;    b) plastically deforming the foamed thermoplastic material; and    c) at least partially separating the resulting shaped material for forming individual earplugs.    
   
   
       3 ) A process for forming a foamed thermoplastic earplug, comprising the steps of: 
 a) waterfoam extruding a tube of a thermoplastic elastomer material;    b) plastically deforming the tube of foamed thermoplastic elastomer material to form a series of adjoining earplug precursors each having a hollow core; and    c) separating the resulting earplug precursors for forming individual earplugs.    
   
   
       4 ) The process of  claim 1 , wherein the extrusion step includes a waterfoaming step.  
   
   
       5 ) The process of  claim 1 , wherein the thermoplastic material is a thermoplastic elastomer.  
   
   
       6 ) The process of  claim 1 , wherein the step of separating includes forming only a partial cut in the resulting shaped material.  
   
   
       7 ) The process of  claim 1 , wherein the resulting article includes a corrugated outer surface.  
   
   
       8 ) The process of  claim 1 , wherein the foamed body is tubular.  
   
   
       9 ) The process of  claim 8 , wherein the resulting article includes a hollow core.  
   
   
       10 ) The process of  claim 1 , wherein the resulting article is an earplug that includes a stem portion and a bulbous portion that is collapsible upon itself.  
   
   
       11 ) The process of  claim 2 , wherein the thermoplastic material is a thermoplastic elastomer.  
   
   
       12 ) The process of  claim 2 , further comprising coating the resulting earplug over at least part of its exterior surface.  
   
   
       13 ) The process of  claim 2 , wherein the resulting earplug includes a corrugated outer surface configured for defining at least one sealing ring.  
   
   
       14 ) The process of  claim 2 , wherein the foamed body is tubular.  
   
   
       15 ) The process of  claim 14 , wherein the resulting earplug includes a hollow core.  
   
   
       16 ) The process of  claim 2 , wherein the resulting earplug includes a stem portion and a bulbous portion that is collapsible upon itself.  
   
   
       17 ) The process of  claim 3 , wherein the resulting earplug includes a corrugated outer surface adapted for defining a plurality of sealing rings.  
   
   
       18 ) The process of  claim 3 , wherein the resulting earplug includes a stem portion and a bulbous portion that is collapsible upon itself.  
   
   
       19 ) An earplug made according to the process of  claim 3 .  
   
   
       20 ) An earplug made according to the process of  claim 16.