Acoustic insert for earpiece

1 . An earpiece comprising:

a shell forming a cavity and a sound channel having a first end connected to and in communication with the cavity, and a second end opposite to the first end, the sound channel forming a single pass-through cavity extending from the first end to the second end;

an insert disposed within the cavity, wherein the insert comprises a through hole;

a speaker, wherein the speaker is received in the through hole, wherein the through hole has a longitudinal center axis that is non-orthogonal relative to a plane defined by an outer rim formed by a wall of the insert;

a circuit board assembly mounted onto the insert, the circuit board assembly comprising a printed circuit board defining a first side and a second side, and a first microphone disposed on the first side;

an acoustic chamber formed between the insert and the circuit board assembly, the first microphone being disposed within the acoustic chamber; and

an acoustic channel extending from the acoustic chamber, the acoustic channel being in communication with the sound channel.

2 . The earpiece of claim 1 , wherein the insert acoustically isolates the speaker from the first microphone.

3 . The earpiece of claim 1 , wherein the acoustic channel is formed by a groove in the shell, and a bottom outer surface of the insert.

4 . The earpiece of claim 1 , further comprising a second acoustic chamber and a second acoustic channel in series with the acoustic chamber and acoustic channel, wherein the acoustic channel extends from the acoustic chamber to the second acoustic chamber, and the second acoustic channel extends from the second acoustic chamber to the sound channel.

5 . A method for preventing microphone saturation or reducing acoustic coupling between a speaker and a microphone of an earpiece, the method comprising:

emitting sound into a sound channel of the earpiece using the speaker, the sound channel forming a single pass-through cavity extending from a first end to a second end;

attenuating sounds above a cut-off frequency using an acoustic channel and an acoustic chamber of the earpiece, wherein the acoustic channel extends from the sound channel to the acoustic chamber and the acoustic channel provides an acoustic path for sound around or through an acoustic barrier between the sound channel and the acoustic chamber;

receiving sound in the acoustic chamber and generating an acoustic signal based on the received sound using the microphone, wherein the microphone is located in the acoustic chamber, and wherein the received sound includes sound emitted into the sound channel using the speaker, and wherein the insert comprises a through hole, and wherein the speaker is received in the through hole, wherein the through hole has a longitudinal center axis that is non-orthogonal relative to a plane defined by an outer rim formed by a wall of the insert.

6 . The method of claim 5 , further comprising an insert disposed within a shell of the earpiece and a circuit board assembly comprising a printed circuit board and mounted onto the insert, wherein the acoustic chamber is formed between the insert and the circuit board assembly, and wherein the microphone is disposed on a first surface of the printed circuit board, wherein the insert acoustically isolates the speaker from the first microphone.

7 . The method of claim 5 , wherein the speaker comprises a first end operatively coupled with a printed circuit board of the earpiece and an opposing second end extending into the sound channel.

8 . The method of claim 6 , wherein the speaker is partially embedded in the insert.

9 . The method of claim 6 , wherein the insert comprises a single integral mass of elastomeric material, wherein the elastomeric material has a Shore A hardness of 65 or greater, wherein the elastomeric material comprises silicone.

10 . The method of claim 6 , further comprising attenuating sounds above a second cut-off frequency using a second acoustic chamber and a second acoustic channel in series with the acoustic chamber and acoustic channel, wherein the acoustic channel extends from the acoustic chamber to the second acoustic chamber, and the second acoustic channel extends from the second acoustic chamber to the sound channel.

11 . The earpiece of claim 1 , wherein the acoustic channel being configured to reduce sounds above a cut-off frequency from the speaker to the microphone by 12 dB or more per octave.

12 . The earpiece of claim 11 , wherein the cut-off frequency is from 500 Hz to 2000 Hz.

13 . The earpiece of claim 1 , wherein the insert comprises a single integral mass of elastomeric material, wherein the elastomeric material has a Shore A hardness of 65 or greater, wherein the elastomeric material comprises silicone.

14 . An earpiece comprising:

a shell forming a cavity and a sound channel having a first end connected to and in communication with the cavity, and a second end opposite to the first end, the sound channel forming a single pass-through cavity extending from the first end to the second end;

an insert disposed within the cavity;

a speaker;

a circuit board assembly mounted onto the insert, the circuit board assembly comprising a printed circuit board defining a first side and a second side, and a first microphone disposed on the first side;

an acoustic chamber formed between the insert and the circuit board assembly, the first microphone being disposed within the acoustic chamber;

an acoustic channel extending from the acoustic chamber, the acoustic channel being in communication with the sound channel; and

a second acoustic chamber and a second acoustic channel in series with the acoustic chamber and acoustic channel, wherein the acoustic channel extends from the acoustic chamber to the second acoustic chamber, and the second acoustic channel extends from the second acoustic chamber to the sound channel.

15 . The earpiece of claim 14 , wherein the insert acoustically isolates the speaker from the first microphone.

16 . The earpiece of claim 14 , wherein the speaker is partially embedded in the insert.

17 . The earpiece of claim 14 , wherein the insert comprises a single integral mass of elastomeric material, wherein the elastomeric material has a Shore A hardness of 65 or greater, wherein the elastomeric material comprises silicone.