After a lot of experimentation and testing, the issue of the ear-loop detached problem has now been resolved. The early batch of the ear-loop design have a non-woven felt piece welded onto both end of the ear-loop. The welding quality turns out to be less predictable than anticipated. A few of these felt pieces detached from the elastic ear-loop when put under high tension. Attempt has been made to improve the welding process and quality check procedure. However, problem still occur from time to time.
A parallel action has been triggered to come up with an alternative design – targeted to eliminate the need of the felt piece welding. This has been proved to be the better option. Without the felt-piece the ear-loop is now much stronger and is able to withstand similar tension force as the original elastic strap. We are very pleased that the new solution has been working very well so far.
Totobobo ear-loop version is now improved and much stronger