fig1 to 5 show a right earcup assembly , indicated generally by the reference number 10 , incorporating an earseal constructed according to our invention . the corresponding left earcup assembly is a mirror image of the right earcup assembly 10 and therefore has not been shown . earcup assembly 10 includes a generally elliptical cup - shaped rigid shell 12 having an opening for receiving the ear of the wearer . shell 12 preferably comprises a low - impact grade of plastic , such as acrylonitrile - butadiene - styrene ( abs ) terpolymer , which crushes upon impact at an applied force less than that required to crush the skull of the wearer , as described in copending application ser . no . 07 / 182 , 851 , filed apr . 18 , 1988 , the specification of which is incorporated herein by reference . preferably , shell 12 is provided on its inner surface with a coating 60 of sound - deadening material , as described in said copending application . a flange indicated generally by the reference numeral 14 extends inwardly from the periphery of the shell 12 to define an opening for receiving the ear of the wearer . preferably , flange 14 is formed from the same material as shell 12 . referring particularly to fig2 flange 14 is formed with a peripheral portion 38 which is generally in register with the periphery of shell 12 and is formed with a stepped shoulder portion 40 for receiving said periphery of the shell . flange 14 also has a portion 42 extending inwardly away from peripheral portion 38 to define a smaller - circumference aperture for receiving the wearer &# 39 ; s ear as well as to provide a support for the earseal to be described . preferably the surface of portion 42 of flange 38 is contoured in a manner complementary to that of the adjacent portion of the wearer &# 39 ; s head as described in aileo u . s . pat . no . 3 , 875 , 592 , the specification of which is incorporated herein by reference . inwardly extending portion 42 of flange 38 in turn has a portion 44 extending in the direction of shell 12 and away from the wearer &# 39 ; s ear . flange 14 is secured to shell 12 by any suitably means such as a layer of cement ( not shown ) applied along the interface between shoulder 40 and the periphery of the shell . flange 14 supports an earseal , indicated generally by the reference character 62 , that is the subject matter of our invention and is described in detail below . earcup assembly 10 contains an earphone 46 of any suitable type known to the art . earphone 46 fits within a complementary cutout 54 formed in an earphone pad 48 preferably comprising polyurethane foam . a circular aperture 52 formed in the front of earphone pad 48 provides a direct acoustical coupling between earphone 46 and the wearer &# 39 ; s ear . a spacer pad 50 also preferably comprising polyurethane foam fills the interior of earcup shell 12 behind pad 48 . referring to fig4 and 5 , a cord 56 from earphone 46 passes through a grommet 58 carried by shell 12 for coupling to an external communication system ( not shown ). a plurality of tabs 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 extending outwardly from earcup shell 12 at circumferentially spaced locations about the periphery thereof define a circumferentially extending , outwardly opening channel . tabs 16 to 30 are preferably formed of the same material as shell 12 and flange 14 . any suitable means such as cement ( not shown ) is used to secure tabs 16 to 30 on earcup shell 12 . referring to fig5 the channel formed by tabs 16 to 30 receives a fabric loop 31 surrounding an opening 33 in the side panel of a helmet suspension 34 such as shown , for example , in aileo u . s . pat . no . 3 , 470 , 564 , the specification of which is incorporated herein by reference . a cord 32 disposed in the loop 31 is adapted to be tightened to hold the suspension 34 in engagement with the outer surface of earcup shell 12 , as shown in the above - identified patent . helmet suspension 34 supports a helmet , indicated generally by the reference number 89 , having a hard outer shell 80 extending over the earcup assembly 10 as shown in fig5 . shell 80 may comprise any suitable material , such as fiber - glass or a laminate of resin - impregnated layers of aramid cloth sold under the trademark kevlar . shell 80 may optionally carry a polyurethane foam pad 82 opposite earcup assembly 10 . referring to fig2 and 5 , earcup shell 12 also carries a strip 36 of pile fastener material , such as that sold under the trademark velcro , to permit assembly 10 alternatively to be releasably secured to the mounting shown in fig6 and 7 . strip 36 may be omitted if earcup assembly 10 is only intended for mounting in helmet suspensions , such as the suspension 34 shown in fig5 that engage tabs 16 to 30 . referring to fig1 to 3 , earseal 62 resiliently seals the region between the wearer &# 39 ; s head and earcup 12 and flange 14 . earseal 62 , which has the elongated annular shape of flange 14 , contains a first resilient foam layer 64 and a second resilient foam layer or ring 66 overlying the inner periphery of layer 64 . in the preferred embodiment , as shown in fig3 foam layer 64 is formed with a uniform rectangular cross - section having a width w 1 of 25 / 32 inch and a thickness t 1 of 1 / 2 inch , while layer 66 is formed with a uniform rectangular cross - section having a width w 2 of 3 / 16 inch and a thickness t 2 of 1 / 8 inch . layers 64 and 66 each have semicylindrical inner surface portions of radius r = 1 inch at the top and bottom of the seal 62 , as well as planar inner surface portions of length 2d = 15 / 16 inch between the two semicylindrical portions . preferably , layer 64 comprises an energy - absorbing , slow - recovery polyurethane foam such as temper foam type t - 38 , while layer 66 comprises a somewhat stiffer material , preferably a unicellular vinyl nitrile foam such as ensolite type alc from uniroyal . foam layers 64 and 66 are encased in an envelope formed from a base 70 and an outer cover 68 of polyurethane film . cover 68 is preformed in the shape shown in fig2 and 3 . preferably , cover 68 has a thickness of 0 . 020 inch while base 70 has a thickness of 0 . 015 inch . in assembling the parts of earseal 62 , the inner and outer surfaces of layer 66 are first tack cemented to the mating surfaces of cover 68 using adhesive ( not shown ). tacks of adhesive ( not shown ) are then applied to the surface portion of layer 64 adjoining layer 66 , following which layer 64 is placed on layer 66 and the two parts bonded together . cover 68 is then bonded to base 70 along the inner and outer peripheries thermally or ultrasonically . an annular lip 72 having a thickness of 0 . 015 inch is bonded in a similar manner to the outer periphery of base 70 on the other side from cover 68 . lip 72 is stretched over the periphery of flange 14 to retain earseal 62 on the earcup - flange subassembly . to facilitate assembly of the earseal 62 onto the flange 14 , lip 72 is formed with a bead 74 on its inner surface as shown in fig3 . perforations 76 formed at regular intervals about cover 68 vent the interior of earseal 62 to allow air to escape from the interior in response to external pressure . four 0 . 025 - inch holes 76 are provided in the embodiment shown . from the foregoing , it will be apparent that earseal 62 has an outer peripheral portion projecting a predetermined first distance d 1 = t 1 ( neglecting envelope thickness ) toward the wearer &# 39 ; s ear from flange 14 , as well as an inner peripheral portion 65 projecting a predetermined second distance d 2 = t 1 + t 2 toward the wearer &# 39 ; s ear from flange 14 that is appreciably greater than the first distance d 1 , the difference d 2 - d 1 being equal to t 2 , the thickness of the foam layer 66 . owing to this differential projection , inner peripheral portion 65 forms an effective seal with the portion of the wearer &# 39 ; s head that is closest to the ear and thus most uniform in contour from individual to individual . at the same time , the outer peripheral portion of earseal 62 bears against an annular portion of the wearer &# 39 ; s head that is more distant from the ear to enhance the effectiveness of the seal . owing to this formation of a more effective seal with the wearer &# 39 ; s head , an earcup equipped with earseal 62 provides significantly more attenuation of ambient sounds that similar assemblies lacking the inner ring 66 . thus , comparative tests indicate that the disclosed earcup assembly provides 8 . 6 db more attenuation at 500 hz and 5 . 7 db more attenuation at 2 khz . fig6 and 7 show an alternative earcup mounting using hook - and - loop fastener strips rather than the means shown in fig5 . more particularly , a modified helmet shell 84 carries on its inner surface a strip 98 of hook - type fastener material , such as that sold under the trademark velcro , that releasably adheres to the pile material of strip 98 directly or , as shown in fig6 through one or more spacer pads 86 and 92 which are preferably of different thicknesses to maximize the number of possible spacings . spacer pad 86 , also shown in fig7 carries complementary strips 88 and 90 of hook and pile material similar to that of strips 98 and 36 , respectively . spacer pad 92 , which is similar to pad 86 but twice as thick , carries strips 94 and 96 similar to strips 88 and 90 , respectively . if desired , there may also be interposed , between earcup 10 and helmet shell 84 , the side panel ( not shown ) of an inner helmet suspension that is similarly provided with hook and pile fastener strips on its opposite surfaces . such as arrangement is shown in aileo u . s . pat . nos . 4 , 231 , 117 and 3 , 9343 , 572 , the disclosures of which are incorporated herein by reference . if the earcup assembly is intended solely for use in helmets such as helmet 84 having hook and pile fasteners , tabs 16 to 30 may be omitted . it will be seen that we have accomplished the objects of our invention . our earseal effectively seals the region between the earcup shell and the wearer &# 39 ; s head , while at the same time being comfortable . our earseal accommodates a wide range of head shapes and sizes and is compatible with earcups of existing assemblies . it will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and combinations . this is contemplated by and within the scope of our claims . it is further obvious that various changes may be made in details within the cope of our claims without departing from the spirit of our invention . it is , therefore , to be understood that our invention is not to be limited to the specific details shown and described .
a resilient annular earseal for sealing the region between an earcup shell and a wearer &# 39 ; s head is formed with an aperture for receiving the wearer &# 39 ; s ear and has an outer peripheral portion projecting a predetermined first distance toward the wearer &# 39 ; s head and an inner peripheral portion projecting a predetermined second distance toward the wearer &# 39 ; s head that is appreciably greater than the first distance . since the inner peripheral portion contacts the wearer &# 39 ; s head along a strip that is closer to the ear , and hence more predictable in its three - dimensional contour , it forms an effective seal around the entire periphery of the ear .