U.S. patent application number 17/399833 was filed with the patent office on 2021-12-02 for systems and methods for custom object design.
The applicant listed for this patent is Lantos Technologies, Inc.. Invention is credited to Jonathan Aguilar, Xiaowei Chen, Robert J. Fei, Brian J. Fligor, Lydia Gregoret, Keith Guggenberger, Michael L. Rishton, David J. Wilfert, Brett Zubiate.
Application Number | 20210377508 17/399833 |
Document ID | / |
Family ID | 1000005769940 |
Filed Date | 2021-12-02 |
United States Patent
Application |
20210377508 |
Kind Code |
A1 |
Fei; Robert J. ; et
al. |
December 2, 2021 |
SYSTEMS AND METHODS FOR CUSTOM OBJECT DESIGN
Abstract
Systems and methods disclosed herein include a first scanner
comprising an inflatable membrane configured to be inflated with a
medium to conform an exterior surface of the inflatable membrane to
an interior shape of a cavity, the medium attenuating, at a first
rate per unit length, light having a first optical wavelength, and
attenuating, at a second rate per unit length, light having a
second optical wavelength; an emitter configured to illuminate an
interior surface of the inflatable membrane; a detector configured
to receive light from the interior surface; a processor configured
to generate a first electronic representation of the interior shape
based on the received light; and a design computer configured to
modify the first electronic representation into a three-dimensional
shape by correlating pixels of the first electronic representation
with corresponding distance information from the first scanner to
the inflatable membrane for each pixel.
Inventors: |
Fei; Robert J.; (Newton,
MA) ; Rishton; Michael L.; (Reading, MA) ;
Aguilar; Jonathan; (Haverhill, MA) ; Gregoret;
Lydia; (Concord, MA) ; Guggenberger; Keith;
(Minnetonka, MN) ; Zubiate; Brett; (Duxbury,
MA) ; Fligor; Brian J.; (Mansfield, MA) ;
Chen; Xiaowei; (Lexington, MA) ; Wilfert; David
J.; (Rockland, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lantos Technologies, Inc. |
Derry |
NH |
US |
|
|
Family ID: |
1000005769940 |
Appl. No.: |
17/399833 |
Filed: |
August 11, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16797631 |
Feb 21, 2020 |
11122255 |
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17399833 |
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16132055 |
Sep 14, 2018 |
10616560 |
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16797631 |
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15289061 |
Oct 7, 2016 |
10122989 |
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16132055 |
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62239811 |
Oct 9, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H04N 5/2252 20130101;
B33Y 30/00 20141201; H04R 1/1058 20130101; H04R 2460/15 20130101;
A61B 5/1077 20130101; A61B 5/0073 20130101; H04R 2460/17 20130101;
A61B 5/6817 20130101; A61B 5/1079 20130101; A61B 5/1076 20130101;
H04N 13/25 20180501; H04R 25/658 20130101; H04N 2005/2255 20130101;
A61B 1/00172 20130101; A61B 5/1127 20130101; B33Y 10/00 20141201;
A61B 5/0071 20130101; A61B 5/0064 20130101; A61B 1/227 20130101;
B33Y 50/00 20141201; A61B 5/7203 20130101; H04N 13/254 20180501;
H04R 25/652 20130101; H04R 1/1016 20130101 |
International
Class: |
H04N 13/25 20060101
H04N013/25; H04N 13/254 20060101 H04N013/254; A61B 1/227 20060101
A61B001/227; A61B 5/00 20060101 A61B005/00; A61B 1/00 20060101
A61B001/00; H04R 25/00 20060101 H04R025/00; H04R 1/10 20060101
H04R001/10; A61B 5/107 20060101 A61B005/107; B33Y 10/00 20060101
B33Y010/00; B33Y 30/00 20060101 B33Y030/00; B33Y 50/00 20060101
B33Y050/00 |
Claims
1. A system comprising: a first scanner comprising: an inflatable
membrane configured to be inflated with a medium to conform an
exterior surface of the inflatable membrane to an interior shape of
a cavity, the medium attenuating, at a first rate per unit length,
light having a first optical wavelength, and attenuating, at a
second rate per unit length, light having a second optical
wavelength; an emitter configured to generate light to illuminate
an interior surface of the inflatable membrane; a detector
configured to receive light from the interior surface of the
inflatable membrane, the received light comprising light at the
first optical wavelength and the second optical wavelength; a
processor configured to generate a first electronic representation
of the interior shape based on the received light; and a design
computer configured to modify the first electronic representation
into a three-dimensional shape corresponding to at least a portion
of the interior shape by correlating pixels of the first electronic
representation with corresponding distance information from the
first scanner to the inflatable membrane for each pixel.
2. The system of claim 1, wherein the corresponding distance
information from the first scanner to the inflatable membrane is
for groups of pixels.
3. The system of claim 1, wherein the design computer executes a
computer-aided design application.
4. The system of claim 1, wherein the modification includes at
least one of a digital deformation, a rotation, a translation, or
another adjustment of the first electronic representation.
5. The system of claim 1, further comprising: a second scanner
comprising a structured light source and a camera, the second
scanner configured to generate a second electronic representation
of a second shape, the second shape being of at least one of: a
second interior shape of a portion of the cavity; and a second
portion of a second surface proximate to the cavity.
6. The system of claim 5, wherein the design computer is further
configured to merge the first electronic representation and the
second electronic representation into a combined electronic
representation of the interior shape and the second shape.
7. The system of claim 5, wherein the design computer is further
configured to merge the first electronic representation and the
second electronic representation based on at least one or more
native references within the interior shape and the second
shape.
8. The system of claim 5, wherein the second scanner is coupled to
the first scanner.
9. The system of claim 6, wherein the combined electronic
representation corresponds to a concha region of an ear and at
least a portion of an ear canal.
10. The system of claim 1, wherein the object adapted to conform to
the cavity is at least one of an earbud, an earpiece, or an earbud
adapter.
11. A method comprising: performing a first scan, with at least a
first scanner, of an interior shape of a cavity, the first scan of
the interior shape comprising: inflating an inflatable membrane
with a medium, the inflating of the inflatable membrane conforms an
exterior surface of the inflatable membrane to the interior shape
of the cavity; generating light from an emitter to at least
illuminate an interior surface of the inflatable membrane;
detecting, at a detector, light from the interior surface of the
inflatable membrane, the light comprising a first optical
wavelength and a second optical wavelength; and generating, at a
processor, a first electronic representation of the interior shape,
the generating being based at least on the detected light;
modifying the first electronic representation into a
three-dimensional shape corresponding to at least a portion of the
interior shape by correlating, at a design computer, pixels of the
first electronic representation with corresponding distance
information from the first scanner to the inflatable membrane for
each pixel; and fabricating, at a fabricator, an object adapted to
conform to the cavity, the fabricating based at least on the
three-dimensional shape.
12. The method of claim 11, wherein the fabricating comprises at
least one of: forming, based at least on the interior shape, a mold
for the object; and fabricating the object with a three-dimensional
printer or a digital light processing system.
13. The method of claim 11, further comprising, adding, with a
second apparatus, one or more additional components to the object,
the one or more additional components comprising at least one
component for delivering sound to an area proximal to the
object.
14. The method of claim 11, performing a second scan of a second
shape proximate to the cavity, the second scan of the second shape
generating a second electronic representation of the second
shape.
15. The method of claim 14, further comprising: identifying, based
at least on the second electronic representation, one or more
native references within the interior shape and the second shape;
generating, at the design computer, based at least on the one or
more native references, a combined electronic representation
comprising the first electronic representation and the second
electronic representation; and modifying, at the design computer,
the combined electronic representation into a three-dimensional
shape corresponding to at least a portion of the interior
shape.
16. A system comprising: a first scanner comprising: an inflatable
membrane configured to be inflated with a medium to conform an
exterior surface of the inflatable membrane to an interior shape of
a cavity, the medium attenuating, at a first rate per unit length,
light having a first optical wavelength, and attenuating, at a
second rate per unit length, light having a second optical
wavelength; an emitter configured to generate light to illuminate
an interior surface of the inflatable membrane; a detector
configured to receive light from the interior surface of the
inflatable membrane, the received light comprising light at the
first optical wavelength and the second optical wavelength; and a
processor configured to generate a first electronic representation
of the interior shape based on the received light; a second scanner
comprising a structured light source and a camera, the second
scanner configured to generate a second electronic representation
of a second shape, the second shape being of at least one of: a
second interior shape of a portion of the cavity, and a second
portion of a second surface proximate to the cavity; and a design
computer configured to merge the first electronic representation
and the second electronic representation into a combined electronic
representation of the interior shape and the second shape.
17. The system of claim 16, wherein the second scanner further
comprises a laser rangefinder.
18. The system of claim 16, wherein the structured light source
emits light having spatial variations of intensity or
wavelength.
19. The system of claim 16, wherein the design computer executes a
computer-aided design application.
20. The system of claim 16, wherein the design computer is further
configured to merge the first electronic representation and the
second electronic representation based on at least one or more
native references within the interior shape and the second
shape.
21. The system of claim 20, wherein the one or more native
references comprises one or more specific portions of ear
anatomy.
22. The system of claim 16, wherein the combined electronic
representation corresponds to a concha region of an ear and at
least a portion of an ear canal.
23. The system of claim 16, wherein the object adapted to conform
to the cavity is at least one of an earbud, an earpiece, or an
earbud adapter.
24. The system of claim 16, wherein the first electronic
representation is generated based at least on measurements of
absorption of the light at the first optical wavelength and
measurements of absorption of the light at the second optical
wavelength.
25. The system of claim 16, wherein the inflatable membrane is
inflated to at least one of a predefined pressure or until a
predefined deformation of a concha is achieved.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/797,631 (Attorney Docket No.
LANT-0301-U01-001-001), filed Feb. 21, 2020, and entitled "SYSTEMS
AND METHODS FOR USING NATIVE REFERENCES IN CUSTOM OBJECT
DESIGN".
[0002] U.S. patent application Ser. No. 16/797,631 (Attorney Docket
No. LANT-0301-U01-001-001) is a continuation of U.S. patent
application Ser. No. 16/132,055 (LANT-0301-U01-001), filed Sep. 14,
2018 and entitled "CUSTOM EARBUD SCANNING AND FABRICATION", now
U.S. Ser. No. 10/616,560.
[0003] U.S. patent application Ser. No. 16/132,055
(LANT-0301-U01-001) is a continuation of U.S. patent application
Ser. No. 15/289,061 (Attorney Docket No. LANT-0301-U01), filed Oct.
7, 2016, and entitled "CUSTOM EARBUD SCANNING AND FABRICATION", now
U.S. Ser. No. 10/122,989.
[0004] U.S. patent application Ser. No. 15/289,061 (Attorney Docket
No. LANT-0301-U01), filed Oct. 7, 2016 claims the benefit of
priority to U.S. Provisional Patent Application Ser. No. 62/239,811
(Attorney Docket No. LANT-0301-P01), filed Oct. 9, 2015, and
entitled "CUSTOM EARBUD SCANNING AND FABRICATION".
[0005] Each of the foregoing applications is incorporated herein by
reference in its entirety.
FIELD
[0006] The subject matter described herein relates to producing
earbuds and earbud adapters customized to an individual ear.
BACKGROUND
[0007] Earbuds must be comfortable and provide a snug fit to
provide the best sound quality and reduce ambient noise. To provide
a comfortable and snug fit, customized earbuds may be produced that
are based the actual shape of an ear. Traditional methods of
determining the actual shape of an ear cavity include creating an
impression of the ear canal. Creating or taking an impression
includes injecting a material into the ear cavity or canal. The
material is allowed to harden and conform to the shape of the
cavity, and then the material is extracted from the cavity. An
impression created this way may cause complications or pain when
the impression material is injected into the cavity, when the
material is hardening, or when the impression is extracted.
SUMMARY
[0008] In one aspect, a first scanner includes an inflatable
membrane configured to be inflated with a medium to conform an
exterior surface of the inflatable membrane to an interior shape of
a cavity. The medium attenuates, at first rate per unit length,
light having a first optical wavelength, and attenuates, at a
second rate per unit length, light having a second optical
wavelength. The scanner also includes an emitter configured to
generate light to illuminate the interior surface of the inflatable
membrane and a detector configured to receive light from the
interior surface of the inflatable membrane. The received light
includes light at the first optical wavelength and the second
optical wavelength. The scanner further includes a processor
configured to generate a first electronic representation of the
interior shape based on the received light. The system includes a
design computer configured to modify the first electronic
representation into a three-dimensional shape corresponding to at
least a portion of the interior shape and a fabricator configured
to fabricate, based at least on the modified first electronic
representation, an earbud.
[0009] In some variations, one or more of the following features
can optionally be included in any feasible combination.
[0010] The first scanner may include a scanning tip. The scanning
tip may include the emitter and the detector. The scanning tip may
be configured to actuate between an extended position and a
retracted position.
[0011] The second scanner may include a structured light source and
a camera. The second scanner may be configured to generate a second
electronic representation of a second shape. The second shape may
be of at least one of: a second interior shape of a portion of the
cavity and a second portion of a second surface proximate to the
cavity. The second scanner may be coupled to the first scanner.
[0012] The design computer may be further configured to merge the
first electronic representation and the second electronic
representation into a combined electronic representation of the
interior shape and the second shape. The design computer may
execute a computer-aided design application.
[0013] The fabricator may include at least one of: a mold for the
earbud, the mold based at least on the interior shape, a
three-dimensional printer or digital light processing system, and a
second apparatus configured to add one or more additional
components to the earbud. The one or more additional components may
include at least one component for delivering sound to an area
proximal to the earbud.
[0014] The three-dimensional printer may be configured to fabricate
an object comprising a shell with a predetermined thickness, and
where the shell corresponds to the interior shape.
[0015] A silicone injector may be configured to inject silicone
inside of the shell. The silicone may have a hardness between 15
and 75 shore after curing.
[0016] In an interrelated aspect, a method includes performing a
first scan, with at least a first scanner, of an interior shape of
a cavity. The first scan of the interior shape includes inflating
an inflatable membrane with a medium. The inflating of the
inflatable membrane conforms an exterior surface of the inflatable
membrane to the interior shape of the cavity. The first scan also
includes generating light from an emitter to at least illuminate
the interior surface of the inflatable membrane. The first scan
further includes detecting, at a detector, light from the interior
surface of the inflatable membrane. The light has a first optical
wavelength and a second optical wavelength. The first scan also
includes generating, at a processor, a first electronic
representation of the interior shape. The generating is based at
least on the detected light.
[0017] A second scan of a second shape proximate to the cavity is
performed. The second scan of the second shape generates a second
electronic representation of the second shape.
[0018] A design computer modifies the first electronic
representation into a three-dimensional shape corresponding to at
least a portion of the interior shape. The design computer
generates a combined electronic representation including the first
electronic representation and the second electronic representation.
The fabricator fabricates an earbud. The fabricating is based at
least on the combined electronic representation.
[0019] In yet another interrelated aspect, a method includes
performing a first scan, with at least a first scanner, of an
interior shape of a cavity. The first scan of the interior shape
includes detecting, at a detector, light comprising a first optical
wavelength and a second optical wavelength. The detected light is
generated by at least one of: detecting structured light generated
from a pattern imprinted on an interior surface of an inflatable
membrane and emitting, by the emitter, structured light to form a
pattern on the interior surface of the inflatable membrane
conforming to an interior shape of an ear and the detected light
generated by reflection of the structured light from the interior
surface. A processor generates a first electronic representation of
the interior shape. The generating is based at least on the
detected structured light;
[0020] A second scan of a second shape proximate to the cavity is
performed. The second scan of the second shape generates a second
electronic representation of the second shape. A design computer
modifies the first electronic representation into a
three-dimensional shape corresponding to at least a portion of the
surface. The design computer generates a combined electronic
representation including the first electronic representation and
the second electronic representation. A fabricator fabricates an
earbud. The fabricating is based at least on the combined
electronic representation.
[0021] In some variations, one or more of the following features
can optionally be included in any feasible combination.
[0022] The second scan may be performed by a second scanner. The
second scanner may include at least one of the first scanner, a
structured light source and a camera, and a laser rangefinder.
[0023] The scanning tip may actuate between an extended position
and a retracted position. The actuation may include the emitter and
the detector and the scanning tip being actuated during the
generation and detection of the light.
[0024] A surface may be illuminated with a structured light source,
the structured light source emitting light having spatial
variations of intensity or wavelength. The illuminated surface may
be imaged with a camera, the imaging generating one or more images
resulting from the spatially varying light. The second electronic
representation of the surface may be generated based at least on
the one or more images.
[0025] The first electronic representation may be generated based
at least on measurements of absorption of the light at the first
optical wavelength and measurements of absorption of the light at
the second optical wavelength.
[0026] The combined electronic representation may correspond to a
concha region of an ear and at least a portion of an ear canal.
[0027] One or more native references within the first shape and the
second shape may be identified based on at least the second
electronic representation.
[0028] A number of electronic representations may be combined based
at least on the one or more native references.
[0029] The fabricating may include at least one of: forming, based
at least on the interior shape, a mold for the earbud, fabricating
the earbud with a three-dimensional printer or a digital light
processing system, and adding, with a second apparatus, one or more
additional components to the earbud. The one or more the additional
components may include at least one component for delivering sound
to an area proximal to the earbud.
[0030] The fabricating may further include fabricating, with the
three-dimensional printer, an object having a shell with a
predetermined thickness. The shell may correspond to the interior
shape. Silicone may be injected inside of the shell with a silicone
injector. The silicone injected inside of the shell may be cured.
The shell may be removed to form the earbud.
[0031] The above-noted aspects and features may be implemented in
systems, apparatus, methods, and/or articles depending on the
desired configuration. The details of one or more variations of the
subject matter described herein are set forth in the accompanying
drawings and the description below. Features and advantages of the
subject matter described herein will be apparent from the
description and drawings, and from the claims.
BRIEF DESCRIPTION OF DRAWINGS
[0032] In the drawings,
[0033] FIG. 1 is a diagram illustrating an example of a system
including a three-dimensional (3D) scanner having an inflatable
membrane, in accordance with some example embodiments;
[0034] FIG. 2 is a diagram illustrating an example 3D rendering of
a cavity formed based on scanner data collected and processed by
the 3D scanner, in accordance with some example embodiments;
[0035] FIG. 3 is a diagram illustrating the 3D scanner with a
scanning tip in an extended position, in accordance with some
example embodiments;
[0036] FIG. 4 is a diagram illustrating the 3D scanner with a
scanning tip in a retracted position, in accordance with some
example embodiments;
[0037] FIG. 5 is a diagram illustrating the attenuation of
reflected light by a medium in the inflatable membrane, in
accordance with some example embodiments;
[0038] FIG. 6 is a diagram illustrating membrane-less determination
of the distance to a proximal location of an inner surface of the
ear, in accordance with some example embodiments.
[0039] FIG. 7 is a diagram illustrating membrane-less determination
of the distance to a distant location of an inner surface of the
ear, in accordance with some example embodiments.
[0040] FIG. 8 is a diagram illustrating an exemplary reflectance
spectra of a portion of an ear, in accordance with some example
embodiments;
[0041] FIG. 9A, FIG. 9B, and FIG. 9C are diagrams illustrating a
serial linkage between a structured light source and camera, in
accordance with some example embodiments;
[0042] FIG. 10A, FIG. 10B, and FIG. 10C are diagrams illustrating
imaging a 3D object with a structured light source and camera, in
accordance with some example embodiments;
[0043] FIG. 11 is a process flow diagram illustrating combining a
scan from a 3D scanner and another scan from a structured light
source and camera, in accordance with some example embodiments;
[0044] FIG. 12 is a diagram illustrating an example transition
region between example scans from a 3D scanner and a structured
light source and camera, in accordance with some example
embodiments;
[0045] FIG. 13A and FIG. 13B are diagrams illustrating examples of
earbud adapters, in accordance with some example embodiments;
[0046] FIG. 14 is a process flow diagram illustrating a first
process, in accordance with some example embodiments;
[0047] FIG. 15 is a process flow diagram illustrating a second
process, in accordance with some example embodiments; and
[0048] FIG. 16 is a process flow diagram illustrating a third
process, in accordance with some example embodiments.
[0049] Like labels are used to refer to same or similar items in
the drawings.
DETAILED DESCRIPTION
[0050] An earbud is an object customized to fit the interior shape
and exterior shape of a particular person's ear. The earbud may be
made of a soft or flexible material in order to be comfortable for
the person to wear the earbud in their ear. The earbud may include
a speaker or other sound generating device. An earbud adapter may
be an object with customized shape to fit the interior or exterior
of a particular person's ear. In addition to being customized to
fit the ear, it may also customized to fit a commercial earbud or
other sound generating device. The commercial earbud may be held
into place in the earbud adapter by a clip, latch, or lip of earbud
material that holds the commercial earbud in place in the earbud
adapter so that the earbud adapter and commercial earbud operate as
one object. For example, an earbud adapter may be customized to
attach to an earbud and conform to a particular ear. A custom
earbud or earbud adapter may provide a more comfortable fit, stay
in the ear more securely, provide better sound quality to the
person, and/or reduce the ambient noise that passes through or past
the earbud.
[0051] Some example embodiments, may include a process for
generating a custom earbud and/or earbud adapter. The process may
include scanning or scoping and measuring the ear canal with an
optical scanner. Based on the scan, a mechanical device, such as an
earbud, earbud adapter, or earbud shell may be produced from the
scan information. An earbud shell (also referred to as a shell) may
include a shell made from a thin layer of rigid material formed
into the shape of the surface scanned, for example, the ear/ear
canal. The earbud shell may serve as a mold in which flexible
material is injected and allowed to cure in the shape of the mold
and corresponding ear. In some example embodiments, the shell may
comprise polyamide and/or urethane. Other materials may be used as
well. In some example embodiments, the shell may be produced using
a three-dimensional printer to lay down layers of polyamide,
urethane, or other material to produce the earbud shell. Although
the following disclosure applies to earbuds and earbud adapters,
the following may also apply to sleeping plugs and/or noise
plugs.
[0052] Before providing additional details with respect to
exemplary processes for making earbuds or earbud adapters (for
example, silicon or rubbery tips or covers that can be coupled to a
commercial earbud), the following describes an example of an
optical scanner that can be used for scanning the ear.
[0053] FIG. 1 is a diagram illustrating an example of a system 100
including a three-dimensional (3D) scanner having an inflatable
membrane 110, in accordance with some example embodiments of the
current subject matter. The system 100 and accompanying software
may generate three-dimensional (3D) scans of a cavity, such as an
ear cavity. System 100 may include a 3D scanner 120 including
inflatable membrane 110 and a processor, such as a computer. The
processor may process scanner data generated by 3D scanner 120
during a scan of the cavity. The processor may form an output, such
as a 3D impression of the scanned cavity.
[0054] FIG. 2 is a diagram illustrating an example 3D rendering of
a cavity formed based on scanner data collected and processed by
the 3D scanner 120, in accordance with some example embodiments.
The 3D surface, also referred to herein as an electronic
representation 200, may model the scanned cavity, such as an ear
cavity, and this 3D surface may be provided to a manufacturer, 3D
printer, and the like to form an object. In the case of the ear,
the object may be an earpiece or earbud/earbud adapter.
[0055] As used herein, the terms "earbud," "earpiece," and "earbud
adaptor" can include any sort of appliance that may be worn on the
ear, in the ear, or any combination thereof. For example, this may
include earbuds for speakers, wireless transmitter/receivers hooked
over the ear, earplugs, headphones, personal hearing protection,
hearing aids, or the like.
[0056] More generally, the terms "earbud," "earpiece," and "earbud
adaptor" may also refer to any appliance or object that may be
manufactured to conform to any cavity or internal space scanned by
any of the scanning techniques described herein. Many of the
implementations described herein refer to scanning an ear as part
of a process of manufacturing an earbud. However, these
implementations do not exclude using any of the apparatus or
techniques described herein for the manufacture of other objects,
apparatuses, tools, or the like.
[0057] FIG. 3 is a diagram illustrating the 3D scanner 120 with a
scanning tip 320 in an extended position, in accordance with some
example embodiments. FIG. 4 is a diagram illustrating the 3D
scanner 120 with a scanning tip 320 in a retracted position, in
accordance with some example embodiments. A medium 310 may be used
to inflate and expand the interior of the inflatable membrane 110
so that the inflatable membrane 110 conforms an external surface of
the inflatable membrane 110 to an interior shape of a cavity 330,
or portion of the cavity 330, or any other cavity 330 or surface
being scanned.
[0058] For example, the medium 310 may be inserted into the
inflatable membrane 110, so that inflatable membrane 110 conforms
to the cavity 330 being scanned. At this point, scanning tip 320
may scan the interior surface of the inflatable membrane 110 which,
when inflated with the medium 310, conforms an external surface of
the inflatable membrane 110 to an interior shape of the cavity 330.
The interior shape can be, for example, the interior shape of an
ear or other object. The scanning tip 320, which may include a
light emitter and detector, can actuate between an extended
position and a retracted position during the generation and
detection of the light used for scanning. In this way, scanning tip
320 may scan the interior surface of the inflatable membrane 110
and thus cavity 330. The scanning tip 320 may generate a 2D image
of the inflatable membrane approximating a snap shot of the cavity
330. Each pixel of the 2D image may then be associated with
distance information obtained during a scan, for example, the
distance from the scanning tip 320 to the scanned portion of the
membrane. The combination of the 2D image and distance information
for each pixel of the 2D image may correspond to 3D data (for
example, a 3D surface representative of the scanned cavity 330). In
some implementations, the distance information determined from
scanning data can correlate to groups of pixels, instead of a
single pixel, on the 2D image.
[0059] Medium 310 may, for example, be a liquid, a dissolved gas, a
gel, a hydrogel, and/or any combination of the four. The medium 310
may include additives dissolved into, or suspended in, the medium
310 to provide properties. These properties may include, for
example, such as selective absorption where one or more wavelengths
of light are absorbed more than one or more other wavelengths. To
illustrate, medium 310 may include a colored dye, suspension, a
luminescent substance, and/or a fluorescent substance (and/or any
other material having selective attenuation properties). The medium
310 may also contain a bio-neutralizing, anti-microbial, or
anti-oxidizing agent to improve the shelf life of the medium 310 as
well as a buffering agent to improve the stability of the medium
310. Moreover, the selective attenuation properties may, as
described further below, allow 3D scanner 120 and/or processor to
determine the shape of, distance to, and/or other properties of the
scanned interior surface of inflatable membrane 110.
[0060] The inflatable membrane 110 may be implemented as any
viscoelastic, elastic, plastic, and/or any other material that may
be inflated to conform to the ear cavity 330, when the inflatable
membrane 110 is inserted into the cavity 310 and inflated with
medium 310. When the cavity 330 corresponds to an ear canal,
inflatable membrane 110 may have an inflated 3D shape and size that
is substantially adapted to the ear cavity 330. The inflatable
membrane 110 may be used with other cavities and forms, for
example, a stomach, an esophagus, a bladder, and or the like. The
inflatable membrane 110 may also include, or be coated with, a
material to make the membrane fluoresce light of a particular
wavelength, or a range of wavelengths, as further described below.
In some implementations, the inflatable membrane may have a
balloon-like shape with an opening, an interior surface, and an
exterior surface. In some implementations, scanning the inflatable
membrane 110, rather than the ear cavity 330 directly, may reduce
(if not eliminate) the interference caused by artifacts, such as
ear hair, wax, and the like, and may thus improve the accuracy of
the cavity measurement scan.
[0061] FIG. 5 is a diagram illustrating the attenuation of
reflected light by a medium 310 in the inflatable membrane 110, in
accordance with some example embodiments. The 3D scanner 120 and/or
the scanning tip 320 may include at least one light source, such as
a light emitting diode, for emitting light into the inflatable
membrane 110, which may or may not include medium 310. In FIG. 5,
the emitted light 510 is represented by the arrows going out from
the scanning tip 320. The scanning tip 320 may also collect and/or
detect light 520 and 530 that is emitted from fluorescent material
in, or on, the inflatable membrane 110. The light 510 emanating
from scanning tip 320 may comprise light used to excite the
fluorescent material in, or on, the inflatable membrane 110.
Further, light from the fluorescent material in, or on, the
inflatable membrane 110 may be referred to as "fluoresced" light,
i.e., light resulting from the interaction of the fluorescent
material with the light 510 from scanning tip 320.
[0062] The inflatable membrane 110 may include a fluorescent
material, such as one or more fluorescent dyes, pigments, or other
coloring agents. The fluorescent material can be homogenously
dispersed within the inflatable membrane 110, although the
fluorescent material may be applied in other ways as well (for
example, the fluorescent material may be pad printed onto the
surface of the inflatable membrane). The fluorescent material may
be selected so that the fluorescent material is excited by one or
more wavelengths of light 510 emitted by the scanning tip 320. Once
the fluorescent material is excited by light 510, the fluorescent
material may emit light at two or more wavelengths .lamda..sub.1,
.lamda..sub.2, or a range of wavelengths. For example, wavelength
.lamda..sub.1 may represent a range of wavelengths associated
generally with red, although wavelength .lamda..sub.1 may be
associated with other parts of the spectrum as well.
[0063] In some implementations, the medium 310 may differentially
attenuate, for example based on wavelength or other property, light
passing through the medium 310. For example, as the two or more
wavelengths of light 520 propagate through the medium 310 along
paths l.sub.1 and l.sub.2, l.sub.1.noteq.l.sub.2, the medium 310
may absorb one or more of the wavelengths of light .lamda..sub.1,
.lamda..sub.2 to a greater degree than one or more other
wavelengths of the light. The medium 310 used in the system 100 may
also be selected to optimally and preferentially absorb one or more
of the wavelengths or a range of wavelengths of light from the
fluorescent material of the inflatable membrane. By selecting a
medium 310 that complements the fluorescent material, the scan data
collected by the 3D scanner 120 may be more accurate.
[0064] Similar to the process described with reference to FIG. 3,
when the scanning tip 320 of 3D scanner 120 is inserted into ear
cavity 330, 3D scanner 120 may pump (or insert in other ways)
medium 310 into inflatable membrane 110 until the inflatable
membrane 110 conforms to the interior surface of the cavity 330.
Once the inflatable membrane 110 is fully inflated, 3D scanner 120
and/or scanning tip 320 may emit light 510 with an emitter, for
example a light emitting diode. Light 510 may travel from the
scanning tip 320, through medium 310, and excite the fluorescent
material on, or in, a portion of the inflatable membrane 110. The
light 520, 530 emitted from the fluorescent material on, or in, the
inflatable membrane 110 may include at least two wavelengths of
light, .lamda..sub.1, and .lamda..sub.2. One of the wavelengths of
light or some ranges of wavelengths of light emitted by the
fluorescent material may be differentially attenuated by the medium
310. The differential attenuation may be due to the medium 310
attenuating light at a first optical wavelength .lamda..sub.1 at
first rate per unit length .mu..sub.1, and attenuating light at a
second optical wavelength .lamda..sub.2 at a second rate per unit
length .mu..sub.2. The attenuation can be described, for example,
as
I.sub.1(x)=I.sub.1(0)e.sup.-.mu..sup.1.sup.x (1)
for the attenuation of the intensity of light at wavelength
.lamda..sub.1 and
I.sub.2(x)=I.sub.2(0)e.sup.-.mu..sup.2.sup.x (2)
[0065] Here, the initial intensity, for example at the point of
emission from the fluorescent material, is I.sub.1(0) or
I.sub.2(0). As the light propagates through the medium 310 a
distance x along a path between the point of emission and the
scanning tip 320, the light may be reduced in intensity or
attenuated by the medium 310. The attenuation may be due to, for
example, absorption, reflection, scattering, diffraction, or the
like.
[0066] The light having wavelengths .lamda..sub.1, .lamda..sub.2 or
wavelength ranges of light, may then be received by a detector. The
detector may be integrated with the scanning tip 320 and may be
configured to receive light from the interior surface of the
inflatable membrane 110. The ratio of the intensities of light
.lamda..sub.1, .lamda..sub.2 or the ratio of the integral area of
light found under specific ranges may be measured and recorded by
3D scanner 120 and/or processor to determine a distance from the
scanning tip 320 to corresponding surface of the membrane 110. For
example, the distance x may be determined by inverting Eqns. (1)
and (2). The scanning tip 320 may move throughout the interior of
inflatable membrane 110 to scan various portions of the interior
surface of the inflatable membrane 110. The scanning tip 320 may
receive the fluoresced wavelength of light 520, 130 in order to
collect data that may be used by the 3D scanner 120 and/or
processor to generate an electronic representation 200 of an
interior shape of the ear to form a 3D surface representative of
the cavity 330. Alternatively, or additionally, the scanning tip
320 may include optical, electronic, or mechanical components for
focusing and directing the light used to excite the fluorescent
material. Although the scanning tip 320 may include one or more
components, such as one or more light emitting diodes, optics,
lenses, detectors/CCDs/CMOS sensors, and the like, one or more of
these components may be located in other portions of the 3D scanner
120 (for example, an optical fiber may carry light 510 to scanning
tip 320).
[0067] In some example embodiments, the 3D scanner 120 in
accordance with FIGS. 1-5 may scan the deep ear canal. The
inflatable membrane may also deform the concha by inflating the
inflatable membrane 110 to a predefined pressure or until a
predefined deformation of the concha is achieved.
[0068] FIG. 6 is a diagram illustrating membrane-less determination
of the distance to a proximal location 610 of an inner surface 620
of the ear, in accordance with some example embodiments. FIG. 7 is
a diagram illustrating membrane-less determination of the distance
to a distant location 710 of an inner surface 620 of the ear, in
accordance with some example embodiments. The light source may
comprise a red LED providing red wavelength light 630, and a green
LED providing green wavelength light 640. Any differing wavelength
of light may be used. The light source may emit light that reflects
from the actual tissue of the interior surface of the ear (i.e. no
inflatable membrane 110). Similar to that described above, because
the absorbing medium may absorb, for example, red and green light
differently, the reflected red and green light from portion C 610
may be received, detected, and represented as a ratio of
intensities, such as detected red wavelength intensity over the
detected green wavelength intensity. Meanwhile, as shown in FIG. 7
the reflected red and green light from portion D 710 may be
received, detected, and represented as a ratio of intensities as
well. Given that the distance from portion D 710 to the distal
portion of the scanning tip 320 (where the light receiver is
located) is greater than the corresponding distance between portion
C 610 and receiver, the medium 310 has a greater attenuating effect
on the reflected light from portion D 710 as shown by the inset
graphs. However, secondary reflections may be a source of noise for
the measurement. In some embodiments, the selection of wavelengths
used can reduce this noise.
[0069] FIG. 8 is a diagram illustrating an exemplary reflectance
spectra 810 of a portion of an ear, in accordance with some example
embodiments. In some embodiments, selection of the two different
wavelengths of light may be chosen such that their reflectance from
the interior surface of the ear is low. For example, when the
reflectance of the tissue is low, then each subsequent reflection
reduces the intensity by a factor of 1/R, where R is the
reflectance. Combined with the absorbing properties of the medium
310, this preferentially attenuate the light received at the
detector that was not due to the primary reflection from the point
whose distance from the detector is being determined. FIG. 8 shows,
for example, that the a first wavelength may be selected, for
example corresponding to green light within band 820 and a second
wavelength may be selected, for example corresponding to red within
band 830, so that these bands 810 and 820 are located where the
reflectance due to the tissue on the surface of the cavity 330 is
at a first minima 830 or at a reduced reflectance 840 relative to
another portion of the spectra. In the example of FIG. 8, the
reflectance from the tissue on the surface of the cavity 330 also
contains a maxima 850, so the reflectance from the tissue at this
wavelength may contribute to noise or interference at the detector.
In some example embodiments, the scanning tip 320 may include a
green light source in the range of 475-505 nanometers and a red
light source in the range of 655-700 nanometers.
[0070] Although some of the examples described herein refer to
using two wavelengths at red and green, other wavelengths may be
used as well. For example, the intensity of other wavelengths of
light can be detected at the scanning tip 320 and then measured and
compared may include an combination of the following: violet light
(approximately 380 to 450 nm), blue light (approximately 450 to 495
nm), green light (approximately 495 to 570 nm), yellow light
(approximately 570 to 590 nm), orange light (approximately 590 to
620 nm), and/or red light (620-750 nm).
[0071] FIGS. 9A, 9B, and 9C are diagrams illustrating a serial
linkage between a structured light source 910 and camera 920, in
accordance with some example embodiments. When making multiple
scans with the same scanner or different types of scanners, the
scanners can be rigidly coupled, made integral, or otherwise
mechanically joined so that the relative position of each scanner
is known when combining the resultant scan images.
[0072] The 3D scanner 120 such as the scanner disclosed in FIGS.
1-5 may be used to scan the deep ear canal. A structured light
source/camera assembly 940 integrating the structured light source
910 and camera 920 is also depicted in FIGS. 9A, 9B, and 9C. A
mechanical linkage between the structured light source/camera
assembly 940 and the 3D scanner 120 may provide more accurate
position information for the scan data. For example, a serial
linkage may be used between the structured light source/camera
assembly 940 and the 3D scanner 120. The serial linkage may include
mechanically coupling the 3D scanner 120 to the structured light
source/camera assembly 940 where both may also mechanically coupled
to a robotic arm 950 or other gantry. The robotic arm 950 may be
configured to monitor the position and orientation of the coupled
3D scanner 120 and structured light source/camera assembly 161. For
example, the 3D scanner 120 may be used to scan a portion of the
ear. Then, the structured light source/camera assembly 940 may be
translated by the arm into position to scan the same (or different)
portion of the ear. Combining the data on the positions of each
type of scanner when the scan was made may allow the spatial data
or generated 3D surfaces for the two scans to be synchronized for
combination to form a composite scan.
[0073] In some example embodiments, the concha region may be
scanned using a structured light source 920 and a camera 910
without deforming the concha. Methods described herein that do not
rely on physical contact between the scanning implement and the
surface being scanned can avoid the creation of artifact or other
distortions in the measurements of the scanned surface. In some
example embodiments, a scan of the ear canal including the deep ear
canal and the concha may include two scans; one with the 3D scanner
120 and another scan performed using structured light and/or direct
imaging by a camera. The two scans can be aligned and merged using
common locations at or near the aperture of the ear canal and
interpolate/smooth the transition between the two surfaces in the
scans. For example, the two scans may be merged by a design
computer to produce a combined scan or model of two or more scanned
surfaces or shapes. In some implementations, the camera 920,
detector, or other imaging receiver may include a stereoscopic
camera or optical system. A stereoscopic camera may enable 3D
images to be acquired without having to use structured light or an
inflatable membrane 110. However, some implementations can combine
the stereoscopic camera with any of the other imaging techniques
described herein.
[0074] FIGS. 10A, 10B, and 10C are diagrams illustrating imaging a
3D object 1010 with a structured light source 910 and camera 920,
in accordance with some example embodiments. A camera 920 may image
an object illuminated by structured light source 910. Geometric
details of the illuminated object can be determined from the image
as shown by the example of a hemisphere 1020. A structured light
source may include illumination that is patterned or includes some
form of spatial variations in intensity, wavelength, frequency,
phase, or other properties of the light. By generating a
predictable and predefined pattern of light on the surface to be
scanned, the images of the pattern can be analyzed to determine
distance or other surface features. For example, a structured light
source may include a series of alternating light and dark bars,
although other patterns may also be used. In some example
embodiments, features of a three-dimensional object may be
determined from the projection of the structured light onto the
object. In one example, the projection onto the hemisphere 1020 of
the alternating bars of light and dark causes the bars to appear
wider due to the hemispherical shape when viewed from the side.
FIG. 10C also illustrates an example of an image showing a
structured light pattern on the surface of a person. The structured
light pattern generated inside the ear may be similar to the
appearance of the structure light pattern on the person.
[0075] In some embodiments, the camera 920, or other detector, can
detect structured light generated from a pattern imprinted on an
interior surface of the inflatable membrane 110. For example, dots,
lines, grids, or other visual patterns can be present on the
inflatable membrane 110 prior to scanning. The pattern may be
illuminated to generate structured light from the interior surface.
In other embodiments, the emitter can emit structured light to form
a pattern on the interior surface of the inflatable membrane 110
conforming to an interior shape of an ear and detecting the
structured light generated by reflection from the interior surface.
These may be done without using the medium 320 by, for example,
inflating the inflatable membrane 110 with air or other uniformly
attenuating material. Once the light is detected, the light can be
analyzed as described herein to identify the shape of the scanned
surface.
[0076] FIG. 11 is a process flow diagram illustrating combining a
scan from a 3D scanner 120 and another scan from a structured light
source and camera, in accordance with some example embodiments. At
1110, a first scan of an ear may be taken using a 3D scanner 120
such as the scanner described in FIGS. 1-5. At 1120, the scan may
be adjusted and/or processed to determine a shape of the ear canal.
At 1130, another scan of the ear may be taken using a different
type of scanner. For example, the structured light/camera assembly
940 may be used to generate a second scan. At 1140, the second scan
may be adjusted and/or processed to determine a shape of the
concha. In some example embodiments, the first scan and the second
scan may be performed together at the same time. In some example
embodiments, one scanner may perform both scans. For example, a 3D
scanner 120 and a structured light source/camera assembly 940 may
be combined into a single scanner. At 1150, the scan from the 3D
scanner 120 and the scan from the structured light source/camera
assembly 940 may be aligned with one another. For example, the
position of first scan relative to the second scan may be adjusted
so that a region of the ear captured by both scans may be used to
align the two scans. After alignment, at 1160, the two scans may be
merged.
[0077] In some example embodiments, the scans may be merged where
the overlapping portions of the scans correspond to a transition
region from one scan to the other scan. In some example
embodiments, the scans in the transition region may be averaged
with the scans being assigned equal weighting, or different
weightings to preferentially bias the composite scan towards one
scanning technique. For example, some methods described herein
involve contact between the surface of the ear being scanned and
any foreign object, such as the inflatable membrane 110. Because
methods involving contact can cause mechanical deformation of the
surface, this can introduce an error in measurement. When combining
scans, methods that do not involve contact (such as membrane-less
scans using a structured light source) may be biased to have
greater weight than scans that did involve contact. The weighting
may be on a pixel-by-pixel basis, such as based on a measurement or
estimate of the amount of deformation of the ear surface, or can be
constant over all pixels for the given scan type. The weighting may
be applied to any interpolation/smoothing algorithms or be
indicated graphically to a user manually merging the scans with
modelling software.
[0078] In other embodiments, when the scans do not overlap,
interpolation between the scans may be used to combine the scans.
In another embodiment, one or more scans can be extrapolated to
extend the effective scan surface. In other embodiments, the scans
may be combined with input from an operator visually aligning the
individual scans rendered on a computing device.
[0079] In other example embodiments, based on the electronic
representation 200 or scans from either or both of the 3D scanner
120 and a structured light source/camera assembly 940, native
references in the ear can be identified. Native references can be
specific portions of the ear anatomy, for example, a concha,
eardrum, or the like. Native references can also be specific
contours of any portions of the ear anatomy. The native references
may be referenced by the processor to facilitate combining scans by
providing common points of reference. In some embodiments, this can
be used with the structured light source/camera assembly 940
generating electronic representations of the ear where, due to the
method not requiring the inflatable membrane 110, no deformation of
the interior surface of the ear is performed.
[0080] FIG. 12 is a diagram illustrating an example transition
region between example scans from a 3D scanner 120 and a structured
light source 930 and camera 920, in accordance with some example
embodiments. Depicted at 1210 are example scans for the right and
left ear canals from a conformal membrane scanner (also referred to
herein as a 3D scanner 120) such as a scanner consistent with FIGS.
1-5. Depicted at 1220 are example scans for the right and left ears
from another scanner such as a structured light source/camera
assembly 940 disclosed in FIGS. 9-10. Depicted at 1230 are
transition regions for the right and left ears. The transition
regions may correspond to areas where the scan from the 3D scanner
120 and the scan using the structured light source 930 and camera
920 overlap. In some example embodiments, the transition regions
1230 may be determined using interpolation, or averaging, or other
analytical method of merging the two scans. In some example
embodiments, the transition regions 1230 may be adjusted by an
operator. In regions where no scan was available, and interpolated,
extrapolated, or otherwise synthetic data was used to merge actual
scan surfaces, an indication of the transition region 1230 may be
indicated with different colors, patterns, or other visual
indicators.
[0081] In other implementations, a second scanner, or a second scan
from the 3D scanner 120, may generate a second electronic
representation of a second shape. The second shape may include a
second interior shape of a portion of the cavity, a second portion
of a second surface proximate to the cavity, or the like. The
second interior shape can be another part of an ear or any other
portion of the cavity 310. Similarly, the second portion of the
second surface can be part of an area outside the cavity, such as
the concha of an ear or other nearby external structural feature of
the object being scanned. The second scanner can be, for example,
the 3D scanner 120, a structured light source 910 and camera 920,
or a laser rangefinder.
[0082] FIGS. 13A and 13B are diagrams illustrating examples of
earbud adapters 1300, in accordance with some example embodiments.
The earbud adapter 1300 may have an adapting portion 1310 to fit a
commercial earbud or other earbud. Earbud adapter 1300 may have a
customized portion 1320 custom-produced to fit a particular
person's ear based on the scan. The customized portion 1320 may
comprise a soft and/or flexible material. The adapting portion 1310
may comprise the same material or a different material. A
right/left earbud adapter 1330 is shown coupled to a commercial
earbud. A left/right earbud adapter 1340 is shown coupled to a
commercial earbud is shown. The right and/or left earbuds may be
colored so to distinguish the right and left earbuds/earbud
adapters.
[0083] In accordance with some example embodiments, an earbud
adapter 1300 may be made from a flexible material such as silicone.
The earbud adapter 1300 may be produced from a scan performed on
the ear canal to measure the size and shape of the ear canal. In
some example embodiments, the scan may also determine the shape of
the concha and/or other external ear shape. The earbud adapter 1300
may be made to fit the measured shape. The measured shape may be
adjusted to reduce the length of the earbud in the ear canal,
adjust the shape of the earbud on the surface outside the ear,
and/or to change the shape to adapt the earbud to a standard
earbud, or any other commercial earbud.
[0084] The fabrication process for earbuds or in-ear headphones may
include adding speakers that may be wired devices or may be
wireless devices. The additional components, for example, the
speakers or wires, can be added by a second apparatus such as an
automated manufacturing device. A wireless earbud may receive a
signal transmitted from a cellular phone, music player or other
electronic device. The sound generating devices may generate sound
such as music or voice or may provide passive noise reduction
and/or active noise cancellation. Passive noise reduction may occur
due to the custom size and fit of the custom earbuds/earbud
adapters and/or by a choice of the earbud material. For example,
some earbud materials may provide more sound attenuation through
the earbud than other materials. Active noise cancellation may
include causing the sound generating devices in the earbuds to
cancel noise that passes through or around the earbud at the ear
canal side of the earbud. In this way, noise may be reduced at the
ear canal. In some example embodiments, active noise cancellation
may be performed in addition to sound generation of music or voice
that the user has selected. For example, active noise cancellation
and sound generation may be used to cancel aircraft noise and
provide the user with music or voice during a flight.
[0085] Other additional components that may be included as part of
the earbuds may include, for example, microphones, transmitters,
receivers, padding, additional conformal adaptors to increase
comfort or fit to the cavity 330, or the like. Also, the additional
components can include biometric scanners, sensors, computer
processors, electronic components for connected devices, or the
like.
[0086] FIG. 14 is a process flow diagram illustrating a first
process, in accordance with some example embodiments.
[0087] At 1410, the ear canal may be scanned by a scanner
consistent with FIGS. 1-5. In some example embodiments, a second
scanner consistent with FIGS. 9-10 may be used to scan the concha
or other outer region of the ear. After the first ear is scanned,
the second ear may be scanned. In some example embodiments, the
shape of the ear canal and/or concha may be provided electronically
as a 3D model or array of 2D models of the ear. In some example
embodiments, the shape of the ear canal and/or concha may be
determined from another source such as a magnetic resonance imaging
or other imaging. In some example embodiments, the shape and/or
model of the ear may be included in an electronic medical
record.
[0088] At 1420, an earbud design may be produced based on the scan.
In some example embodiments, the earbud design may include the scan
after one or more adjustments. For example, the length of the
earbud in the ear canal may be adjusted to be longer or shorter
than the scanned ear canal. In some example embodiments, the length
or external shape at the exterior of the ear may be adjusted. For
example, the earbud may be adjusted in length to protrude more or
less from the ear canal. In some example embodiments, the
adjustments may include adjustments to cause improved attachment to
the ear so that the earbud is less likely to fall out during use.
In some example embodiments, the adjustments may include an opening
at the exterior of the earbud to adapt and hold into place a
standard earbud and/or other earbud.
[0089] At 1430, the earbud design may be produced on a fabrication
machine. For example, the earbud design may be produced on a
three-dimensional (3D) printer. In some example embodiments, a 3D
printer may fabricate a 3D mechanical structure using one or more
selectable materials. For example, a 3D printer may produce layers
of material with selectable regions of the different materials. 3D
printers may deposit regions of material that include polyamide,
urethane, plastic, ceramic, metal, paper, wax, or other material.
In some example embodiments, the earbud design may be produced on a
3D printer with the exterior regions of the earbud made using a
shell of rigid material such as polyamide, urethane or other
material and with the interior volume made from another material
such as wax. The polyamide or urethane shell can be formed to a
predetermined thickness, for example, between 0.05 mm and 2 mm. In
some example embodiments, the removable material may have a lower
melting point than the rigid material, or may be soluble in a
solvent in which the rigid material is not soluble. The rigid
exterior region may be referred to as an earbud shell. In some
example embodiments, the wax from the interior of the earbud shell
may be removed by heating the earbud shell and allowing the wax to
drain out. For example, the wax may drain out when the shell is
heated due to gravity or draining may be assisted by applying air
pressure or placing the shell in a centrifuge. In some example
embodiments, after the interior material such as wax has been
removed, the earbud shell may be filled with a flexible material
such as curable silicone or other material. After the silicone has
cured in the shape of the interior of the earbud shell, the shell
may be removed leaving the flexible earbud. The silicone or other
flexible material may have a hardness of approximately 15-75 shore
or other hardness. In some example embodiments, the earbud shells
may be produced without a parting line for use one time. Earbud
shells produced with a parting line may be used multiple times to
make multiple earbuds. In some example embodiments, digital light
processing (DLP) may be used instead of or in addition to 3D
printing. In some example embodiments, DLP may include exposing
light to liquid resin to produce a desired shape. In some example
embodiments, DLP may result in solid objects without a shell and
without the interior wax to remove.
[0090] At 1440, finishing steps may be performed on the flexible
earbud. In some example embodiments, the earbud may be marked or
color-coded so that earbuds may be easily identified and which
earbud is for the right ear and which earbud is for the left ear.
In some example embodiments, the earbud may be smoothed, marked,
rinsed, cleaned, and/or prepared for use.
[0091] FIG. 15 is a process flow diagram illustrating a second
process, in accordance with some example embodiments.
[0092] At 1505, an ear may be scanned to determine the internal
and/or external shape of the scanned ear. In some example
embodiments, the scanning may be performed using an optical scanner
such as the scanner described with respect to FIGS. 1-5. In some
example embodiments, the scan may be performed using a different
type of scanner such as a photographic scanner, magnetic resonance
imaging, dye enhanced, or other scanner. In some example
embodiments, the shape of the ear may be provided electronically as
a 3D model or an array of 2D models or images. The shape/model may
be part of an electronic medical record.
[0093] At 1510, the scan may be adjusted to change the length
and/or accommodate an earbud. In some example embodiments, the
earbud design may include the scan after one or more adjustments.
In some example embodiments, the scan, or a mathematical or
electronic model of the scan, may be adjusted using a design
computer that may run 3D design/modelling software, Computer-Aided
Drafting/Drawing (CAD) software, or the like. The design computer
can be configured to modify one or more electronic representations
into a three-dimensional shape corresponding to at least a portion
of the interior shape of the ear. For example, the length of the
earbud in the ear canal may be adjusted to be shorter than the
scanned ear canal. In some example embodiments, the length or
external shape of the earbud at the exterior of the ear may be
adjusted. For example, the earbud may be adjusted in length to
protrude more or less from the ear canal. In some example
embodiments, the adjustments may include adjustments to cause
improved attachment to the ear so that the earbud is less likely to
fall out during use. In some example embodiments, the adjustments
may include an opening at the exterior of the earbud to adapt and
hold into place a standard earbud and/or other earbud.
[0094] At 1515, a shell or earbud may be produced on a fabrication
machine from the modified electronic representation or scan. In
some example embodiments, a 3D printer or digital light processing
system may be used to produce earbud shells. For example, a 3D
printer may "print" or deposit successive layers of material to
produce a 3D object. For example, a 3D printer may deposit two
materials in successive layers such as a hard or rigid material on
outside surfaces to produce a shell, and another material that is
removable in the interior such as wax that aids in supporting the
shell as the layers are deposited. In some example embodiments, the
removable material may have a lower melting point than the rigid
material, or may be soluble in a solvent in which the rigid
material is not soluble. The 3D printer may be controlled by a
computer to produce earbud shells in accordance with the scanned
ear or the adjusted scan of the ear. In some example embodiments,
extrusion and sintering-based processes may be used. The 3D printed
shells may be produced by the 3D printer on a plate. The shells may
then be cleaned or rinsed.
[0095] At 1520, the shell may be cured. For example, the shell may
be cured over a time period with or without being heated in an
oven.
[0096] At 1525, the shell may be released. For example, the earbuds
may be released from a plate associated with the 3D printer.
[0097] At 1530, the shell may be cleaned and the inner wax material
may be melted and drained out of the shells. For example, the wax
in the shells may be melted in the oven at a temperature such as 70
degrees Celsius or another temperature for 45 minutes or another
amount of time. The earbud shells with the internal wax removed may
be cleaned using a solution such as mineral oil, at a particular
temperature for a particular amount of time. For example, the
earbud shells may be cleaned with mineral oil at 70 degrees Celsius
for 15 minutes. The shells may be further cleaned and/or rinsed
with a second liquid such as water. The shells may be dried using
compressed air and/or placing the shells in an oven at, for
example, 70 degrees Celsius.
[0098] At 1535, the shell may be filled with a flexible material.
For example, the earbud shells may be filled by injecting silicone
or another flexible material into the shells. The injected compound
may be liquid before curing and solid after curing.
[0099] At 1540, the material in the shell may be cured to form the
earbud. In some example embodiments, the material in the shell may
include silicone. Pressure may be applied to the filled earbud
shells by, for example, a pressure pot. For example, the pressure
pot may be held at a pressure of 6 bars at a temperature of 85
degrees Celsius for 10 minutes. After the material such as silicone
in the shells has cured, the shells may be removed. In some example
embodiments, shells made without a parting line may be removed by
cracking them with an arbor press. In some example embodiments,
shells made with a parting line may not require cracking. In some
example embodiments, a shell post may be removed in a central
portion of the earbud. In some example embodiments, a grinder may
be used to finish the earbud to ensure smoothness and remove any
excess material remaining from the silicone injection process. In
some example embodiments, the left and right earbuds may be marked
in order to tell them apart. For example, the right and left
earbuds may be marked with dyed silicone. For example, a small hole
may be made in each earbud and colored silicone added. Additional
curing, cleaning, rinsing, and drying may be performed. In some
example embodiments, the earbuds may be lacquered. A centrifuge may
be used to ensure the lacquer coating is thin. For example, the
lacquered earbuds may be placed in a centrifuge at 500 RPM a few
seconds. In some example embodiments, the lacquered earbuds may be
dried under pressure at 85 degrees Celsius for 5 minutes.
[0100] At 1545, the earbud may be marked with an identifier. For
example, each earbud may be marked with an identifier to ensure
that the correct earbud is sent to a user. The right and left
earbuds may be marked using different colors so that the user can
visually distinguish the right earbud from the left earbud.
[0101] At 1550, the earbud may be shipped to a user.
[0102] Though the methods, apparatus, and systems are described
herein with respect to an earpiece and scanning an ear canal, these
methods, apparatus, and systems may be applied to any cavity 330 or
orifice assembly for scanning any suitable anatomical cavity 330.
For example, the methods, apparatus, and systems can be used for
scanning oral, nasal, renal, intestinal, or other anatomical
cavities, and can involve assemblies designed for those anatomical
cavities. Further, these methods, apparatus, and systems may be
used with sensitive or fragile cavities that are not anatomical in
nature, such as those made from brittle, pliable, or otherwise
delicate materials.
[0103] Without in any way limiting the scope, interpretation, or
application of the claims appearing below, a technical effect of
one or more of the example embodiments disclosed herein is
reusability of certain components. Moreover, without in any way
limiting the scope, interpretation, or application of the claims
appearing below, a technical effect of one or more of the example
embodiments disclosed herein is that the medium providing assembly
may be used for multiple scans, including for multiple patients. In
some implementations, the absorbing medium and medium providing
assembly may be used for 10-15 scans or more. Furthermore, without
in any way limiting the scope, interpretation, or application of
the claims appearing below, a technical effect of one or more of
the example embodiments disclosed herein is that the absorbing
medium, and the system as a whole, may be more likely to be
shelf-stable, as it can be shipped without contacting the
inflatable membrane until just before scanning.
[0104] FIG. 16 is a process flow diagram illustrating a third
process, in accordance with some example embodiments.
[0105] At 1610, the 3D scanner 120 may scan an interior shape of a
cavity 330. The scanning may include inflating an inflatable
membrane with a medium 310 to conform an exterior surface of the
inflatable membrane 110 to an interior shape of a cavity 330. For
example, the 3D scanner 120 can be coupled to the inflatable
membrane 110 as shown in FIG. 1.
[0106] At 1620, light can be generated from an emitter to
illuminate the interior surface of the inflatable membrane 110. For
example, the light may illuminate fluorescent portions of the
inflatable membrane 110, illuminate a pattern imprinted on the
inflatable membrane 110, create a structured light pattern on the
inside of the inflatable membrane 110, or the like.
[0107] At 1630, a detector may detect light emitted from the
interior surface of the inflatable membrane 110. For example, the
light may include a first optical wavelength and a second optical
wavelength. The first optical wavelength and the second optical
wavelength may be generated by differential attenuation of
fluorescing light from the inflatable membrane, reflection of light
from the inflatable membrane where the light was first generated by
a multiple-wavelength emitter, reflection of light from a pattern
on the inflatable membrane, or the like.
[0108] At 1640, a processor may generate a first electronic
representation 200 of the interior shape based at least on the
detected light. For example, the first electronic representation
200 may be a 3D rendering generated by computer software and
processor that combines one or more surfaces imaged by the 3D
scanner 120. The first electronic representation 200 may be
combined by interpolating or otherwise digitally expanding/merging
image portions, acquired by the 3D scanner 120 or other scanning
technique, into a composite image of the ear.
[0109] At 1650, a second shape proximate to the cavity 330 may be
scanned to generate a second electronic representation of the
second shape. For example, the second shape may correspond to an
outer part of the object scanned, or be another scan that overlaps
some or all of the interior shape scanned with the 3D scanner or
other scanning device.
[0110] At 1660, the design computer may modify the first electronic
representation into a three-dimensional shape corresponding to at
least a portion of the interior shape. For example, the
modification may include digital deformation of the first
electronic representation, rotation, translation, or other
adjustment performed in software automatically or by a user.
[0111] At 1670, the design computer may generate a combined
electronic representation from the first electronic representation
and the second electronic representation. For example, the combined
electronic representation may include interpolating, extrapolating,
or otherwise connecting features of the first electronic
representation and the second electronic representation.
[0112] At 1680, the fabricator may fabricate an earbud according to
the combined electronic representation. The fabrication process may
include translating the combined electronic representation to
instructions that for operation of a 3D printer or other
fabrication machine. The fabrication process can also include
forming a mold based on the combined electronic representation.
[0113] One or more aspects or features of the subject matter
described herein can be realized in digital electronic circuitry,
integrated circuitry, specially designed application specific
integrated circuits (ASICs), field programmable gate arrays (FPGAs)
computer hardware, firmware, software, and/or combinations thereof.
These various aspects or features can include implementation in one
or more computer programs that are executable and/or interpretable
on a programmable system including at least one programmable
processor, which can be special or general purpose, coupled to
receive data and instructions from, and to transmit data and
instructions to, a storage system, at least one input device, and
at least one output device. The programmable system or computing
system may include clients and servers. A client and server are
generally remote from each other and typically interact through a
communication network. The relationship of client and server arises
by virtue of computer programs running on the respective computers
and having a client-server relationship to each other.
[0114] These computer programs, which can also be referred to
programs, software, software applications, applications,
components, or code, include machine instructions for a
programmable processor, and can be implemented in a high-level
procedural language, an object-oriented programming language, a
functional programming language, a logical programming language,
and/or in assembly/machine language. As used herein, the term
"machine-readable medium" refers to any computer program product,
apparatus and/or device, such as for example magnetic discs,
optical disks, memory, and Programmable Logic Devices (PLDs), used
to provide machine instructions and/or data to a programmable
processor, including a machine-readable medium that receives
machine instructions as a machine-readable signal. The term
"machine-readable signal" refers to any signal used to provide
machine instructions and/or data to a programmable processor. The
machine-readable medium can store such machine instructions
non-transitorily, such as for example as would a non-transient
solid-state memory or a magnetic hard drive or any equivalent
storage medium. The machine-readable medium can alternatively or
additionally store such machine instructions in a transient manner,
such as for example as would a processor cache or other random
access memory associated with one or more physical processor
cores.
[0115] To provide for interaction with a user, one or more aspects
or features of the subject matter described herein can be
implemented on a computer having a display device, such as for
example a cathode ray tube (CRT) or a liquid crystal display (LCD)
or a light emitting diode (LED) monitor for displaying information
to the user and a keyboard and a pointing device, such as for
example a mouse or a trackball, by which the user may provide input
to the computer. Other kinds of devices can be used to provide for
interaction with a user as well. For example, feedback provided to
the user can be any form of sensory feedback, such as for example
visual feedback, auditory feedback, or tactile feedback; and input
from the user may be received in any form, including, but not
limited to, acoustic, speech, or tactile input. Other possible
input devices include, but are not limited to, touch screens or
other touch-sensitive devices such as single or multi-point
resistive or capacitive trackpads, voice recognition hardware and
software, optical scanners, optical pointers, digital image capture
devices and associated interpretation software, and the like.
[0116] In the descriptions above and in the claims, phrases such as
"at least one of" or "one or more of" may occur followed by a
conjunctive list of elements or features. The term "and/or" may
also occur in a list of two or more elements or features. Unless
otherwise implicitly or explicitly contradicted by the context in
which it used, such a phrase is intended to mean any of the listed
elements or features individually or any of the recited elements or
features in combination with any of the other recited elements or
features. For example, the phrases "at least one of A and B;" "one
or more of A and B;" and "A and/or B" are each intended to mean "A
alone, B alone, or A and B together." A similar interpretation is
also intended for lists including three or more items. For example,
the phrases "at least one of A, B, and C;" "one or more of A, B,
and C;" and "A, B, and/or C" are each intended to mean "A alone, B
alone, C alone, A and B together, A and C together, B and C
together, or A and B and C together." Use of the term "based on,"
above and in the claims is intended to mean, "based at least in
part on," such that an unrecited feature or element is also
permissible.
[0117] The subject matter described herein can be embodied in
systems, apparatus, methods, and/or articles depending on the
desired configuration. The implementations set forth in the
foregoing description do not represent all implementations
consistent with the subject matter described herein. Instead, they
are merely some examples consistent with aspects related to the
described subject matter. Although a few variations have been
described in detail above, other modifications or additions are
possible. In particular, further features and/or variations can be
provided in addition to those set forth herein. For example, the
implementations described above can be directed to various
combinations and subcombinations of the disclosed features and/or
combinations and subcombinations of several further features
disclosed above. In addition, the logic flows depicted in the
accompanying figures and/or described herein do not necessarily
require the particular order shown, or sequential order, to achieve
desirable results. Other implementations may be within the scope of
the following claims.
* * * * *