In November 2023 Patently Apple posted a granted patent report titled "Apple wins a patent covering possible design changes for Future AirPods using Flexible & Bendable Materials for a Comfortable Fit."

Today the U.S. Patent and Trademark Office officially granted Apple a patent that relates to AirPods, and more specifically, to possible future double flange ear tips.

Apple's granted patent covers a deformable ear tip comprising: an annular inner ear tip body having a sidewall extending between first and second opposing ends thereby defining a sound channel through the ear tip; an annular outer flange integrally formed with and surrounding the first end of the inner ear tip body and extending towards the inner ear tip second end forming an air gap between the annular inner ear tip body and the annular outer flange along a portion of a length of the ear tip, wherein the outer flange comprises a first material having a first durometer and is sized and shaped to be inserted into a human ear canal; and an inner flange integrally formed with the inner ear tip body and comprising a second material having a second durometer less than the first durometer, the inner flange body extending from a location along the inner ear tip body between the first and second ends towards an inner surface of the outer flange body.

Apple's patent FIG. 16 above is a simplified cross-sectional view of a double flange ear tip #1600 wherein the outer ear tip body #1620 can be made from a material that has a different durometer than inner flange #1630.

For example, ear tip #1600 can be formed with a double shot injection molding process in which a first injection molding step of the process forms both a portion #1610a of the inner ear tip body and all of inner flange  and a second injection molding step of the process forms both a portion #1610b of the inner ear tip body and all of outer ear tip body. The Inner ear tip body portion flange and inner flange can be made from a higher durometer material to provide more structure to the ear tip, while the inner ear tip body portion and outer ear tip body portion can be made from a lower durometer material that is more flexible to provide a better and more comfortable user fit.

For full details, review granted patent 12035094.