Hearing device charger device and system and method of manufacturing a holding seat thereof

Abstract

The present application provides a hearing device charger arrangement and system and a method of manufacturing a holding seat thereof. A method of manufacturing a charger insert (40) comprising a holding seat (45) for holding a chargeable hearing device (1A, 1B) in a hearing device charger arrangement (20) comprising a charger housing (21) and a first charger element (22, 23), the method comprising: providing a first virtual model, comprising assigning a second position for an electronic hearing aid device (28) in the first virtual model; providing a second virtual model of the charger insert (40) designed to support the chargeable hearing device (1A, 1B) such that the first charger element (22, 23) is positioned in a first relationship with a second charger element (4) when the charger insert (40) is placed in the receiving portion (29); shaping the customized charger insert (40) together with the holding seat (45).

Description

Technical Field

[0001] This invention relates to a method of manufacturing a charger insert, the charger insert including a holder for holding a rechargeable hearing device in a hearing device charger assembly, the rechargeable hearing device being individually customized to be at least partially inserted into a user's ear canal, the hearing device charger assembly being configured to charge the rechargeable hearing device. The invention also relates to the charger insert, the hearing device charger assembly, and a hearing device charger system including the hearing device and the hearing device charger assembly. Background Technology

[0002] Rechargeable in-ear hearing aids are known in the art. To charge such hearing aids, the user is equipped with a charging device. The charging device and the hearing aid may each include cooperating electrical contact means, or they may include a cooperating charger coil, allowing the hearing aid to be charged "wirelessly," thus eliminating the need for electrical contacts in the in-ear hearing aid. In either case, such a charging device may have a retainer for inserting and holding the hearing aid in a fixed position within the charging device during charging.

[0003] The problem with these devices is that the cooperating charger components may not always be correctly positioned in their primary relationship with each other, which may cause the charging process to be interrupted or slowed down.

[0004] Therefore, the goal is to provide a more stable charge for hearing devices such as hearing aids.

[0005] Another object of the present invention is to manufacture a charger insert comprising a holder for a custom hearing device, the charger insert being insertable into a universal hearing device charger device for a custom RHI (rechargeable hearing device), which is low in cost, quick and simple to manufacture, requires no post-processing, and meets biocompatibility and medical-grade requirements.

[0006] US 2019 / 0089187 A1 discloses a standardized hearing aid with a hearing aid charger device. Summary of the Invention

[0007] In a first aspect, the object of the present invention is achieved by a method of manufacturing a charger insert comprising a retainer or for holding a rechargeable hearing device in a hearing device charger assembly, the rechargeable hearing device being individually customized to be at least partially inserted into a user's ear canal, the hearing device charger assembly being configured to charge the rechargeable hearing device, the hearing device charger assembly comprising:

[0008] - Charger housing, having a receiving portion for a charger insert with a retaining seat, and

[0009] - A first charger element having a first position within the charger housing.

[0010] The method includes:

[0011] - Based on a dataset representing the shape of a user's ear canal portion, a first virtual model of the rechargeable hearing device is provided, shaped to at least partially conform to the shape of the ear canal portion, including assigning a second position in the first virtual model of the rechargeable hearing device for an electronic hearing aid device including at least a second charger element;

[0012] - Based on the first virtual model, a second virtual model of a charger insert is provided for insertion into the receiving portion of the hearing device charger assembly. In the second virtual model, the charger insert is designed to support the rechargeable hearing device, such that when the charger insert is placed in the receiving portion of the hearing device charger assembly, the first charger element is positioned in a first relationship with the second charger element; and

[0013] - Based on the second virtual model, the customized charger insert is formed together with the retainer using a 3D manufacturing process.

[0014] 3D manufacturing processes refer to any process that, based on a dataset of virtual models of the object to be manufactured (such as the second virtual model mentioned above), can be shaped into a 3D object by starting with a blank and removing material from the blank or by continuously adding material. Such processes can be milling and stereolithography, such as 3D printing.

[0015] In one embodiment, the 3D manufacturing process can be a rapid prototyping (RPT) process.

[0016] In one embodiment, the second virtual model providing the charger insert is also based on data regarding the shape of the charger housing. The shape may also include data regarding the dimensions (size) of the charger housing.

[0017] In a further embodiment, the second virtual model of the charger insert may alternatively or additionally be based on data regarding the first position of the first charger coil within the charger housing.

[0018] In a further embodiment, in addition to any of the foregoing embodiments, a second virtual model providing a charger insert may include a retainer configured in a predetermined direction relative to the charger housing.

[0019] Here, "will" refers to the spatial orientation relative to other parts of the housing, such as the sidewalls, bottom, and / or cover of the housing of the hearing device charger assembly. In some embodiments, the housing and other components, such as the electronic components of the hearing device charger assembly, are generic housing / hearing device charger assemblies, except that the charger insert includes a holder for holding a personalized / customized rechargeable hearing device. The housing and / or any electronic components of the hearing device charger assembly are generic in the sense that they may have standardized shapes (e.g., including dimensions), such that when customized for a customized rechargeable hearing device, the charger insert can be inserted into the charger housing and fitted into the space provided by the charger housing, and such that the first and second charger elements are mutually related, allowing the first charger element to charge the second charger element.

[0020] In a further embodiment, in addition to any of the foregoing embodiments, positioning the first charger element in a first relationship with the second charger element includes aligning the first charger element in the charger housing with the second charger element in the rechargeable hearing device when the charger insert is placed in the receiving portion of the hearing device charger assembly and when the rechargeable hearing device is placed in the charger insert.

[0021] In a further embodiment, in addition to any of the foregoing embodiments, providing a second virtual model includes designing a retainer whose surface portions at least a subset reflect corresponding surface portions of a custom-designed rechargeable hearing device.

[0022] Preferably, a subset of such surface portions is selected to ensure that the custom-designed rechargeable hearing device is stably supported in the holder of the charger insert. Not all surface portions of the custom-designed rechargeable hearing device need to be reflected.

[0023] In a further embodiment, in addition to any of the foregoing embodiments, providing a second virtual model includes removing the undercut surface of the holder in the second virtual model.

[0024] This ensures that the custom rechargeable hearing device can be inserted into and removed from the charger insert without damaging the charger insert and / or the custom rechargeable hearing device, especially when the charger insert is made of rigid or semi-rigid material.

[0025] In a further embodiment, in addition to any of the foregoing embodiments, providing a second virtual model of the charger insert includes digitally designing a second virtual model of the charger insert on a computer.

[0026] In a further embodiment, in addition to any of the foregoing embodiments, providing a first virtual model of a rechargeable hearing device may include digitally designing a first virtual model of the rechargeable hearing device on a computer.

[0027] In another embodiment, in addition to any of the foregoing embodiments, a second charger element of the rechargeable hearing device is formed in an outward-facing panel of the rechargeable hearing device having a flat outer surface, and wherein the method includes designing a holder for the charger insert such that when the rechargeable hearing device is held in the holder, the flat surface of the outward-facing panel of the rechargeable hearing device is substantially parallel to the upward-facing surface of the charger insert.

[0028] "Basically parallel" means parallel or within + / - 5 degrees of parallel.

[0029] In a further embodiment, in addition to any of the foregoing embodiments, the position of the first charger element is a fixed, standardized position within the charger housing. In some embodiments, the housing and other components, such as the electronic components of the hearing device charger assembly, are generic housing / hearing device charger assemblies, except that the charger insert includes a holder for holding a personalized / customized rechargeable hearing device. The hearing device charger assembly / charger housing is generic in the sense that the housing and / or any electronic components of the hearing device charger assembly may have standardized shapes (e.g., including dimensions), such that when customized for a customized rechargeable hearing device, the charger insert can be inserted into the charger housing and fitted into the space provided by the charger housing, and such that the first and second charger elements are mutually related, allowing the first charger element to charge the second charger element. Therefore, in a further embodiment, in addition to any of the foregoing embodiments, the charger housing may also have a fixed, standardized shape and size.

[0030] In a further embodiment, in addition to any of the foregoing embodiments, the charger housing may include a box-shaped charger base and a charger cover configured to cover the charger base. In a further embodiment, a first charger element is positioned within the charger cover. In the latter case, providing a second virtual model may include a holder positioned relative to the housing for a second charger element such that when the rechargeable hearing device is placed in the holder of the charger insert, the second charger element is positioned in a first relationship with the first charger element, for example, such that the second charger element is aligned with the first charger element in the cover (and the cover is closed to cover the box-shaped charger base).

[0031] In a further embodiment, in addition to any of the foregoing embodiments, the first charger element is a first charger coil and the second charger element is a second charger coil. Alternatively, the first and second charger elements are electrical contact elements. In this case, the first relationship between the first charger element and the second charger element includes making them electrically contact each other.

[0032] In a further embodiment, in addition to any of the foregoing embodiments, the charger insert including the retainer is formed from a block of material by milling away material from the block. Alternatively, in addition to any of the foregoing embodiments, instead of milling, the charger insert having the retainer is formed by an additive manufacturing process, such as stereolithography.

[0033] Therefore, charger inserts with retainers can be formed using 3D printing technology.

[0034] In a further embodiment, in addition to any of the foregoing embodiments, the charger insert may include a plate portion and a retainer portion.

[0035] The retainer portion forms the retainer, which can be considered as a cavity within the retainer portion.

[0036] The retainer portion can preferably be integrally formed with the plate portion. Alternatively, the plate portion and the retainer portion are formed separately and then assembled.

[0037] The plate portion may include an edge shaped to mate with a receiving portion of the charger housing, i.e., to be received within the receiving portion of the charger housing. Preferably, the receiving portion of the charger housing is formed within a box-shaped charger base.

[0038] In any case, preferably, the retaining portion extends from the plate portion, i.e., from one of its surfaces.

[0039] In another embodiment, in addition to the aforementioned embodiment in which the holder is formed by stereolithography, the charger insert is formed such that the plate portion is formed before the holder portion.

[0040] Therefore, in an embodiment of the method, the charger insert with a retainer is formed by an additive manufacturing process, the charger insert including a plate portion and a retainer portion, the retainer portion extending from the plate portion, and the charger insert being formed such that the plate portion is formed before the retainer portion.

[0041] Therefore, it is possible to form the charger insert without any support, as the plate portion will provide support throughout the stereolithography process.

[0042] In a further embodiment, in addition to any of the foregoing embodiments, the charger insert including the holder is formed of a biocompatible material.

[0043] In a further embodiment, in addition to any of the foregoing embodiments, the method may include an initial step of determining the shape of a portion of the user's ear canal, including:

[0044] - A portion of soft, pliable material is inserted into the user's ear canal to create an ear canal impression, and

[0045] - Scan the ear canal impression and provide a dataset representing the shape of a specific user's ear canal portion based on the scanned shape of the ear canal impression to provide a first virtual model.

[0046] A dataset representing the shape of a user's ear canal portion can be obtained digitally via scanning on a computer.

[0047] Ear canal impressions are made by pouring a soft material (such as a casting material, typically a biocompatible silicone-based material) into the ear canal of a user who needs or wishes to purchase a custom / personalized / individualized hearing device. The casting material can be a two-component liquid material containing a filler and a curing agent. After the two components are mixed, the casting material will cure within minutes.

[0048] Furthermore, photocuring of casting materials is known in the art, using silicone-based materials suitable for photocuring.

[0049] These two types of silicone materials are known in the art. Products typically used for this purpose are manufactured by Egger (egger Otoplastik+Labortechnik GmbH) or Dreve GmbH.

[0050] As an alternative to obtaining a dataset representing the shape of a portion of the ear canal, in a further embodiment, in addition to any of the foregoing embodiments, the method may further include an initial step of determining the shape of a portion of the user's ear canal, including:

[0051] - Scan at least a portion of the user's ear canal; and

[0052] - Provide a dataset representing the scanned shape of a portion of the user's ear canal from a scan of that portion, for providing a first virtual model.

[0053] A dataset that provides the shape of a portion of a user's ear canal can be obtained digitally via scanning on a computer.

[0054] A scan of at least a portion of the user's ear canal can be performed by optically scanning a portion of the user's ear canal.

[0055] In a second aspect of the invention, the object of the invention is achieved by a charger insert comprising a holder for holding a rechargeable hearing device in a hearing device charger assembly, the rechargeable hearing device being individually customized to be at least partially inserted into a user's ear canal, the hearing device charger assembly being configured to charge the rechargeable hearing device, wherein the charger insert is formed by a method according to any of the above embodiments of the first aspect of the invention.

[0056] In a third aspect of the invention, the object of the invention is achieved by a hearing device charger device for charging a rechargeable hearing device, the hearing device charger being individually customized to be inserted at least partially into a user's ear canal, the hearing device charger device including a charger insert including a holder for holding the rechargeable hearing device during charging, wherein the charger insert is formed by means of a method described in conjunction with any embodiment of the first aspect of the invention described above.

[0057] A hearing device charger assembly for charging a separately formed hearing device, including a second charger element, may include:

[0058] - Charger housing;

[0059] - The charger power supply is located inside the charger housing;

[0060] - The first charger coil connected to the charger's power source.

[0061] - Charger electronics used to control the charging of hearing devices; and

[0062] - A holder for receiving a rechargeable hearing device housed within the charger casing.

[0063] The holder for the hearing device is shaped to support the hearing device, and when the hearing device is housed in the holder, the first charger element is adjacent to the second charger element.

[0064] In one embodiment, a holder for a rechargeable hearing device is disposed in a charger insert.

[0065] The charger insert can thus be modeled / planned / designed for custom rechargeable hearing devices to insert into universal / standard hearing device charger devices.

[0066] In one embodiment, the charger insert can be formed using a 3D manufacturing process.

[0067] In one embodiment, the charger insert is a flat structure having an upper surface, a lower surface, and a periphery, wherein the retainer extends away from the lower surface, and wherein the periphery is configured to engage with the edge of the charger housing.

[0068] In one embodiment, the hearing device charger device includes a charger cover arranged to mate with a charger housing. When the hearing device is placed in a holder and the charger cover is closed, a first charger element is arranged in the charger cover in an operating position for providing charging power to a second charger element.

[0069] This allows charging to occur only when the cover is closed, thus reducing the risk of the hearing device accidentally falling out of the charging unit.

[0070] In a fourth aspect of the invention, the object of the invention is achieved by a hearing device system comprising:

[0071] - Rechargeable hearing devices; and

[0072] -A hearing device charger device according to any embodiment of the third aspect of the present invention.

[0073] In one embodiment, the hearing device charger assembly includes a charger cover arranged to mate with a charger housing, wherein a first charger element is disposed in the charger cover, and wherein the hearing device includes a second charger element formed in an outward-facing panel of the hearing device, wherein the first charger element and the second charger element are arranged such that when the hearing device is housed in a holder and the cover is closed, the first charger element and the second charger element face each other.

[0074] It should be emphasized that the term "comprising / including" is used in this specification to describe the presence of the stated feature, integer, step, or component, but does not exclude the presence or addition of one or more other features, integers, steps, components, or combinations thereof. Attached Figure Description

[0075] The invention will be described in more detail below with reference to the embodiments shown in the accompanying drawings. It should be emphasized that the illustrated embodiments are for illustrative purposes only and should not be used to limit the scope of the invention.

[0076] - Figure 1A-1C The illustration depicts the steps of providing a first virtual model of a rechargeable hearing device, the first virtual model being used in an embodiment of the method according to the invention.

[0077] - Figure 1A The illustration depicts a virtual model or dataset that resembles the shape of a portion of a user's ear canal.

[0078] - Figure 1B The diagram illustrates the basis Figure 1AThe virtual model or dataset shown forms a virtual model or dataset of the shape of the hearing device housing that corresponds to the shape of the user's ear canal.

[0079] - Figure 1C A virtual model or dataset illustrating the shape of a rechargeable hearing device, customized to the shape of a user's ear canal, including the location of the components of the rechargeable hearing device.

[0080] - Figures 2A-2F The illustration depicts the steps of providing a second virtual model or dataset representing a rechargeable hearing device, the second virtual model being used in an embodiment of the method according to the invention;

[0081] - Figure 2A The diagram illustrates how... Figure 1A-1C Or a first virtual model or dataset of the shape of the rechargeable hearing device provided as shown in 4A-4C;

[0082] - Figure 2B The illustration shows the modeling of the position of the rechargeable hearing device relative to the position of the first charging element of the charger device;

[0083] - Figure 2C The illustration shows a rechargeable hearing device in a charger insert, with the top description being a side view and the bottom description being a perspective view from above.

[0084] - Figure 2D The illustration shows a representation of a rechargeable hearing device in a charger insert and a model of the retainer portion of the charger insert;

[0085] - Figure 2E The illustration shows a model of the modified shape of the retainer portion of the charger insert;

[0086] - Figure 2F A complete second virtual model of the charger insert used to form the charger insert is shown in a 3D view;

[0087] - Figures 3A-3D The illustration shows how to create a customized set of rechargeable hearing devices. Figure 3E-3G An embodiment of the method according to the first aspect of the present invention is illustrated;

[0088] - Figure 3A The illustration shows a first virtual model of a rechargeable hearing device;

[0089] - Figure 3B The illustration shows, for example, the formation of the outer casing of a rechargeable hearing device in a 3D printer;

[0090] - Figure 3CThe finished shell portion, customized for the user's left and right ear canals, is shown;

[0091] - Figure 3D A custom-designed rechargeable hearing device was shown, in which components (including a second charger element) were installed. Figure 3C In each of the outer casing sections shown;

[0092] - Figure 3E The diagram illustrates the basis Figure 3A The first virtual model provided in the middle provides a representation suitable for Figure 3D A second virtual model of a custom charger insert for a custom rechargeable hearing device shown in the image;

[0093] - Figure 3F The illustration shows, for example, a 3D printer based on... Figure 3E The second virtual model shown forms the charger insert;

[0094] - Figure 3G A complete custom charger insert is shown, suitable for... Figure 3D The custom-designed rechargeable hearing device shown is ready to be installed in the housing of the hearing device charger.

[0095] Figures 4A-4C The illustration shows a way of obtaining a dataset about the shape of a portion of a user's ear canal used in the method according to the invention;

[0096] - Figure 4A A partial sectional view showing a human ear and ear canal, as well as an ear canal impression in a portion of the ear canal;

[0097] - Figure 4B The image shows an ear canal impression in a 3D scanner and illustrates the steps involved in scanning (e.g., optical scanning) the impression to obtain a dataset that resembles a portion of a user's ear canal.

[0098] - Figure 4C A PC with a keyboard, mouse and suitable 3D modeling software is shown, and it is illustrated how a dataset obtained by scanning is transferred to a computer with software to provide at least one virtual model / dataset representing the shape of a user's ear canal.

[0099] - Figure 5 A custom-designed rechargeable hearing device is shown in a cross-sectional side view; and

[0100] - Figure 6 A hearing device charger assembly according to a third aspect of the invention is shown in a cross-sectional side view, having a charger insert according to a second aspect of the invention, the charger insert being formed according to a method according to a first aspect of the invention.

[0101] List of reference numerals in the attached diagram:

[0102] P user's auricle

[0103] EC user's ear canal

[0104] T user's tympanic membrane

[0105] 1. Hearing equipment, HI

[0106] 1A Hearing device, left hearing device (left HI), HI housing with electronic components

[0107] 1A' Left hearing aid casing (left HI casing)

[0108] 1B Hearing device, right hearing device (right HI), HI housing with electronic components

[0109] 1B' Right hearing device housing (Right HI housing)

[0110] 4. Second charging element, charging element for rechargeable hearing devices.

[0111] 5 panels

[0112] 6. Electronic components of hearing aids

[0113] 7 Rechargeable batteries

[0114] 8 Ear canal impression

[0115] 8' represents a dataset of the shape of the user's ear canal, a virtual representation of the ear canal, and a virtual model of the ear canal.

[0116] 9 Receivers

[0117] 10 3D scanners

[0118] 11. A PC equipped with a keyboard, mouse, and suitable 3D modeling software.

[0119] 12 3D printers

[0120] 20 Hearing Equipment Charger Unit / HI Charger Unit

[0121] 21 Charger casing

[0122] 22 First charger coil, charger coil of the right hearing device's hearing device charger unit.

[0123] 23 First charger coil, charger coil of the left hearing device's hearing device charger unit.

[0124] 24. Cable connecting the charger electronics to the charger coil of the hearing device charger unit.

[0125] 25 Charger power supply

[0126] 26 Charger housing base

[0127] 27. Charger Cover

[0128] 28 Charger Electronic Components

[0129] 29. The receiving part of the charger casing, edge

[0130] 40. Charger insert

[0131] 41. The plate portion of the charger insert.

[0132] 45. Holder for receiving rechargeable hearing devices

[0133] 46. ​​Retaining portion of the charger insert

[0134] 50 added to the inlay to remove undercut volume.

[0135] 51 Bottom section

[0136] 70. The first virtual model, a virtual model of a rechargeable hearing device, represents the dataset of the rechargeable hearing device.

[0137] 80. The second virtual model, a virtual model of the charger insert, represents the dataset of the charger insert.

[0138] 100 System Detailed Implementation

[0139] Various embodiments are described below with reference to the accompanying drawings. The same reference numerals consistently refer to the same elements. Therefore, similar elements will not be described in detail with respect to each figure. It should also be noted that the drawings are intended only to facilitate the description of the embodiments. They are not intended as an exhaustive description of the claimed invention or a limitation on the scope of the claimed invention. Furthermore, the illustrated embodiments are not required to have all the aspects or advantages shown. Aspects or advantages described in connection with a particular embodiment are not necessarily limited to that embodiment and may be practiced in any other embodiment, even if not so stated or explicitly described.

[0140] The present invention relates to custom-made rechargeable hearing devices 1A and 1B, and the manufacture of a hearing device charger device 20 for charging such rechargeable hearing devices 1A and 1B, or at least the manufacture of a charging insert 40 for such hearing device charger device 20.

[0141] The shapes of the customized rechargeable hearing devices 1A and 1B vary depending on the user and their ear. Therefore, using a standardized, single-shaped holder in the hearing device charger assembly does not necessarily ensure the correct placement of the charger element of the rechargeable hearing device relative to the charger element of the hearing device charger assembly. To improve the charging efficiency of the rechargeable hearing devices 1A and 1B, according to the present invention, a customized charger insert 40 is configured to hold such customized rechargeable hearing devices 1A and 1B in the correct position relative to the charger element of the hearing device charger assembly 20.

[0142] However, now referencing Figure 5 The hearing devices 1A and 1B will be described first. Figure 5 Cross-sections of hearing devices 1A and 1B are shown. Hearing devices 1A and 1B include a hearing device housing 1, which is manufactured / formed as described above and is further described in detail below.

[0143] Hearing devices 1A and 1B have a proximal end and an opposite distal end. When hearing devices 1A and 1B are inserted into a user's ear canal EC, the proximal end is closest to the user's eardrum, i.e., the tympanic membrane T. When hearing devices 1A and 1B are inserted (not shown) into a user's ear canal, the distal end is located at the entrance of the user's ear canal EC. The hearing devices also include a set of internal components arranged within the hearing device housings 1, 1A', and 1B'.

[0144] These components include electronic components such as a speaker (which is generally referred to as a receiver, hereinafter referred to as hearing device receiver 9), a rechargeable battery (or hearing device rechargeable battery 7), a second charger element 4, and control electronics; the hearing aid electronics 6 are used to at least control the hearing device receiver 9 and charge the hearing device rechargeable battery 7 via the second charger element 4. The second charger element 4 is configured as follows: Figure 6 The first charger elements 22 and 23 in the described hearing device charger device 20 are charged.

[0145] The receiver 9 of the hearing device is typically positioned near the proximal end of the hearing device 1A, 1B so as to be close to the user's eardrum when inserted into the user's ear canal EC. Other components may be arranged within the hearing device housing 1A', 1B' in positions that vary depending on the individual shape of the hearing device housing 1A', 1B'.

[0146] Hearing devices 1A and 1B may also include a channel from the hearing device receiver 9 to the proximal end of the hearing device, and filters for preventing earwax and other impurities from entering the hearing devices 1A and 1B. Furthermore, the inner surfaces of the internal spaces of the hearing device housings 1A' and 1B' may be configured to allow internal components to be installed / placed in designed / planned locations.

[0147] The internal components may additionally include one or more microphones. Figure 5 (Not shown in the image). For example, a microphone can be provided at the far end of the hearing device.

[0148] The internal components may also include means for wireless communication with other devices. For example, such a means can communicate with a behind-the-ear device, a mobile phone / cell phone, or other external electronic devices.

[0149] Electronic components located within the internal spaces of hearing devices 1A and 1B can be electrically connected to each other, for example, through appropriate wiring, to transmit energy and / or data.

[0150] Figure 5 The hearing devices 1A and 1B shown have a panel 5 at their distal ends for sealing the internal space of the hearing devices 1A and 1B. The panel 5 is used to seal the internal space containing internal components, protecting it from impurities from the external environment.

[0151] Panel 5 can be shaped to fit the contour of the user's ear canal. However, when inserted into the ear canal, the distal end of the hearing device typically does not contact any surface of the user's ear canal, but is located at the opening / entry point from the outer ear into the user's ear canal. Therefore, panel 5 can be shaped with a regular planar surface, such as... Figure 5 As shown.

[0152] exist Figure 5 In the hearing devices 1A and 1B shown, the second charger element 4 is shown adjacent to the panel 5. For example, the second charger element 4 may be integrated into the panel 5 or located adjacent to the inner surface of the panel 5. In some embodiments, the second charger element 4 may be located in a recess formed in the inner surface of the panel 5. Alternatively, the charger element 4 may be structurally connected (not shown) to other components in the internal space or connected to the inner wall of the hearing device housing 1A', 1B'.

[0153] As described above, however, in other embodiments, the second charger 4 may be located at other locations within the cavity / internal space of the hearing devices 1A, 1B.

[0154] Figure 6 A hearing device charger assembly 20 is shown, in which a charger insert 40 manufactured by the method of the present invention described further below is inserted.

[0155] The hearing device charger 20 includes a charger housing 21. In this embodiment, the charger housing 21 includes a charger base 26 and a charger cover 27. The charger base 26 in this embodiment is formed as an open box-shaped structure with an internal volume. The internal volume can accommodate a charger power supply 25. In the illustrated embodiment, the charger power supply 25 is a battery. The battery can be a replaceable battery, a disposable non-rechargeable battery, or a rechargeable battery. Alternatively, the battery can be a fixed rechargeable battery. In embodiments where the charger power supply 25 is a rechargeable battery, the hearing device charger 20 can provide a portable power bank for one or more hearing devices 1A, 1B.

[0156] In other embodiments, the charger power supply 25 of the hearing device charger device 20 may be a transformer for converting mains power into power for one or more hearing devices 1A, 1B. In other embodiments, the charger power supply 25 of the hearing device charger device 20 may be a transformer connected to a rechargeable battery, such that the hearing device charger device 20 can charge one or more hearing devices 1A, 1B when connected to mains power (via a cable not shown) and when disconnected from mains power.

[0157] The internal volume of the charger housing 21 of the hearing device charger assembly 20 can also accommodate charger electronics 28 for controlling the charger power supply 25 (when it is a stationary rechargeable battery) and / or the charging of one or more hearing devices 1A, 1B.

[0158] The hearing device charger device 20 also includes first charger elements 22 and 23, respectively for each of the hearing devices 1A and 1B to be charged.

[0159] Charger electronics 28 are connected to charger power supply 25 via suitable wiring (not shown). Additionally, charger electronics 28 are connected to first charger coils 22, 23 via suitable wiring, such as cable 24.

[0160] The charger electronics 28 are preferably configured such that they can detect the presence of hearing devices 1A, 1B in their vicinity and, if the hearing aids are present, begin charging. This can be achieved if the presence of the first charger element 4 of the hearing devices 1A, 1B is detected.

[0161] like Figure 6 As shown, the charger insertion part 40 can cover the internal volume of the charger base 26 of the charger housing 21, and the charger insertion part 40 is disposed in the receiving part 29 of the charger housing 21. (Refer to...) Figure 5It should be understood that the receiving portion 29 may be the edge of the box-shaped charger base 26. The receiving portion 29, in the form of the edge of the box-shaped charger base 26, is preferably sized and shaped to receive the charger insert 40. For example, the size and shape of the outer edge of the plate portion 41 of the charger insert 40 may be received by the edge of the box-shaped charger base 26 of the housing 21.

[0162] exist Figure 6 The charger insert 40 is illustrated as having two retainers 45, each retainer 45 for holding rechargeable hearing devices 1A, 1B. This charger insert can be manufactured according to the method described below. However, it should be understood that the charger insert 40 can be formed with only a single retainer 45 for holding a single rechargeable hearing device 1A, 1B. In this case, the charger housing 21 may have a receiving portion 29 for each of the plurality of charger inserts 40, each for each of the custom rechargeable hearing devices 1A, 1B to be charged. Typically, this means two charger inserts 40, each for one of the rechargeable hearing devices 1A, 1B, as most users require one rechargeable hearing device 1A, 1B per ear.

[0163] During the modeling process on the opposite side, one or more retainers 45 are positioned relative to the charger insert 20 such that when the charger insert 40 is inserted into the charger housing 21, and when the hearing devices 1A, 1B are inserted into the retainer 45, the second charger element 4 (in each hearing device 1A, 1B, Figure 6 (not shown) Aligned with a corresponding one of the first charger elements 22, 23.

[0164] The shape of the retainer 45 also ensures precise alignment of the first charger element 4 with the second charger elements 22, 24, allowing only the corresponding hearing devices 1A, 1B to be inserted in a specific orientation.

[0165] In one embodiment, such as Figure 6 As shown, the first charging elements 22, 23 can be configured to connect to the charger cover 27. This configuration of the hearing device charger assembly 20 ensures that charging only begins when the cover is closed and the first charging elements 22, 24 are thus aligned with the second charging element 4 in the respective hearing devices 1A, 1B.

[0166] exist Figure 6In the illustrated embodiment, the retainer 45 and charger insert 40 are configured such that the hearing devices 1A, 1B (when inserted into the retainer 45) are vertically positioned with the proximal end / panel 5 facing upwards, and the plane defined by the surface of the panel 5 is parallel to the plane defined by the upper surface of the charger insert 40. In this case, the first charger element 4 in the hearing devices 1A, 1B is arranged in the panels 5A, 5B, as shown. Figure 5 As shown.

[0167] However, it should be understood that in alternative embodiments, the retainer 45 and the charger insert 40 may be configured such that the hearing devices 1A, 1B are aligned with the plane defined by the upper surface of the charger insert 40. Figure 6 The different orientation methods shown illustrate the different situations. For example, hearing devices 1A and 1B can be "laid flat" instead of... Figure 6 The vertical position shown. In this case, the second charger element 4 in the hearing devices 1A and 1B can be arranged parallel to the side wall portion of the hearing device housings 1A' and 1B', instead of as shown. Figure 5 and Figure 6 The layout is shown in panel 5.

[0168] It should also be understood that in other embodiments, the first charger elements 22, 23 may be arranged inside the charger base 26 of the charger housing 21 instead of in the charger cover 27. In this case, the retainer 45, the charger insert 40 and / or the hearing devices 1A, 1B (positioning of the first charger element 4 in the hearing devices 1A, 1B) are modeled and formed such that when the hearing devices 1A, 1B are placed in the retainer 45, the first and second charger elements are aligned with each other.

[0169] A marking may be formed on the charger insert 40 near the corresponding retainer 45, indicating which hearing device is inserted into which retainer 45'. The marking may be, for example, an "L" for "left" and an "R" for "right," indicating the position for inserting and charging the left and right hearing devices 1A and 1B, respectively. Other symbols or text may be considered alternatively. The marking may be formed as an indentation in the charger insert 40. In other embodiments, the marking may be provided on the charger insert 40 after it has been formed together with one or more retainers, for example, by stamping, printing, or other techniques known in the art.

[0170] During the modeling stage, corresponding markings indicating the relationship between the retainer 45 and the corresponding hearing devices 1A and 1B can be designed, so that the hearing devices 1A and 1B have markings on their outer surfaces.

[0171] Figure 6 The illustration also shows a hearing device system 100 including a set of hearing devices 1A, 1B and a hearing device charger device 20.

[0172] In a first aspect, the present invention relates to a method of manufacturing a charger insert 40, the charger insert 40 including a retaining base 45 for holding rechargeable hearing devices 1A, 1B, such as as described above. Also as described above, the rechargeable hearing devices 1A, 1B are individually customized to be at least partially inserted into a user's ear canal. The insert 40, including the retaining base 45, is configured to hold the rechargeable hearing devices 1A, 1B in a hearing device charger device 20, and the hearing device charger device 20 is configured to charge the rechargeable hearing devices 1A, 1B.

[0173] The hearing device charger 20 can be combined as described above. Figure 6 As described, however, more generally, the hearing device charger assembly 20 may include a charger housing 21 and first charger elements 22, 23, the charger housing 21 having a receiving portion 29 for a charger insert 40 including a retainer 45. The first charger elements 22, 23 have a first position within the charger housing 21.

[0174] The method according to the present invention includes:

[0175] -Based on a dataset 8' representing the shape of a user's ear canal portion, a first virtual model 70 of a rechargeable hearing device 1A, 1B shaped to at least partially conform to the shape of the ear canal portion is provided, including assigning a second position in the first virtual model 70 of the rechargeable hearing device 1A, 1B to an electronic hearing aid device 28 including at least a second charger element 4.

[0176] - Based on the first virtual model, a second virtual model 70 is provided for inserting a charger insert 40 into the receiving portion 29 of the hearing device charger assembly 20. In the second virtual model 80, the charger insert 40 is designed to support rechargeable hearing devices 1A and 1B, such that when the charger insert 40 is placed in the receiving portion 29 of the hearing device charger assembly, the first charger elements 22 and 23 are positioned in a first relationship 20 with the second charger element 4; and - Based on the second virtual model 80, the customized charger insert 40 is formed together with the retainer 45 through a 3D manufacturing process.

[0177] Figure 1A-1C The illustration shows the steps of providing a first virtual model 70 for rechargeable hearing devices 1A and 1B, the first virtual model 70 being used in an embodiment of the method according to the invention.

[0178] Figure 1AThe illustration shows a virtual model 8' or dataset that resembles the shape of a portion of a user's ear canal EC. Such a virtual model 8' can be obtained by scanning the user's ear canal EC, or by creating an impression 8 of the desired portion of the ear canal and scanning the impression. This will be described in more detail below.

[0179] A dataset 8', resembling / representing the shape of a portion of a user's ear canal EC, is used to provide a representation of the shape of the housings 1A' and 1B' of hearing devices 1A and 1B. This is in Figure 1B This was explained in the text. Figure 1B The diagram illustrates the basis Figure 1A The virtual model 8' or dataset shown is a virtual model 75 or dataset that forms the shape of the housing 1A', 1B' of the rechargeable hearing devices 1A, 1B, corresponding to the shape of the EC portion of the user's ear canal.

[0180] Any or all of these steps are preferably performed in a computer using suitable modeling software. Therefore, it should be understood that, in the method according to the invention, providing a first virtual model of the rechargeable hearing devices 1A, 1B may include digitally designing first virtual models 70, 75 of the rechargeable hearing devices 1A, 1B on a computer.

[0181] A virtual model 75 or dataset of the shape of the housing 1A', 1B' of the rechargeable hearing devices 1A, 1B is then used to provide a representation of the shape of the rechargeable hearing devices 1A, 1B, for example, as Figure 1C As shown in the image. Figure 1C The illustration shows a second virtual model 80 or dataset representing the shape of rechargeable hearing devices 1A, 1B, having a shape customized according to the shape of the user's ear canal EC. Providing the second virtual model 70 or dataset includes determining or assigning the positions of components 4, 5, 6, 7, 9 of the rechargeable hearing devices 1A, 1B, such as at least the second charger element 4, and other hearing device electronics 6, rechargeable battery 7, and receiver 9. In the illustrated embodiment, the first virtual model 70 is also shown to include positions or panels 5, such as those described above.

[0182] Therefore, it should be understood that in the method according to the invention, the second charger element 4 of the rechargeable hearing devices 1A, 1B may be designed to be located in the outward-facing panel 5 of the rechargeable hearing devices 1A, 1B, the panel having a flat outer surface, and the method may further include designing the holder 45 of the charger insert 40 such that when the rechargeable hearing devices 1A, 1B are held in the holder 45, the flat surface of the outward-facing panel 5 of the rechargeable hearing devices 1A, 1B is substantially parallel to the upward-facing surface of the charger insert 40.

[0183] It should be understood that in the process of designing or modeling a second virtual model 80 for rechargeable hearing devices 1A, 1B, allocating space and position / location for their components (particularly the second charger element 4) may include using data regarding the intended positions of the first charger elements 22, 23 within the housing of the hearing device charger assembly 20.

[0184] Preferably, at least the charger housing 21 can be a standardized housing. Therefore, the layout of the components of the hearing device charger assembly 20 and the rechargeable hearing devices 1A, 1B can be customized relative to known configurations of the charger housing 21. In some embodiments, at least the positions of the first charger elements 22, 23 are in fixed, standardized locations within the charger housing 21. In yet another embodiment, all components of the hearing device charger assembly 20 are standardized. Therefore, the only part that needs to be customized is the charger insert 40, which includes the retainer 45.

[0185] In some embodiments, the method requires designing a charger insert 40 to conform to a charger housing 21, the charger housing 21 including a box-shaped charger base 26 and a charger cover 27 configured to cover the charger base 26, wherein the first charger elements 22, 23 are located in the charger cover 27.

[0186] In any embodiment, charger elements 22 and 23 are first charger coils and second charger element 4 is a second charger coil. In this case, aligning the first and second charger elements means aligning the axes of the coils.

[0187] Turn now Figures 2A-2F These figures illustrate the steps of providing a second virtual model 80 or dataset representing rechargeable hearing devices 1A, 1B, the second virtual model 80 being used in embodiments of the method according to the invention.

[0188] Figure 2A The diagram illustrates how... Figure 1A-1C Or, as shown in 4A-4C, a first virtual model 70 or dataset representing the shape of the rechargeable hearing devices 1A and 1B. The first virtual model 70 includes at least the aforementioned virtual model 75 or dataset representing the shape of the housings 1A' and 1B' of the rechargeable hearing devices 1A and 1B, the location 4' of the second charger element 4 within the first virtual model 70, and the planned locations of the first charger elements 22 and 23, such as... Figure 2B The first charger component is shown at position 22'.

[0189] Figure 2BThe modeling of the positions of the rechargeable hearing devices 1A and 1B, represented by 70 and 75, relative to the position 22” of the first charging element is shown, that is, the representation of the position of the first charging element 22 and 23 in the housing 21 of the hearing device charger assembly 20.

[0190] Figure 2C The illustration shows rechargeable hearing devices 1A and 1B within a charger insert 40, and a first virtual model 70. Figure 2C The top description is a side view, while the bottom description is a perspective view viewed from above of the rechargeable hearing devices 1A and 1B in the charger insert 40.

[0191] Placing the shape representing the hearing device housings 1A', 1B' in the charger insert may include orienting the representation 75 of the hearing device housings 1A', 1B' or the representation 70 of the rechargeable hearing devices 1A, 1B relative to the known positions of the housing walls and electronic components in the housing 21 of the hearing device charger assembly 20. This orientation may, for example, include rotation of the representation 75 of the hearing device housings 1A', 1B' or the representation 70 of the rechargeable hearing devices 1A, 1B relative to the known or desired positions of all components of the hearing device charger assembly 20.

[0192] like Figure 2B As shown, when the representation 75 of the hearing device housing 1A', 1B' or the representation 70 of the rechargeable hearing devices 1A, 1B are positioned in the charger insert 40, the retainer 45 can be modeled as follows: Figure 2D As shown. Figure 2D The illustration shows a representation 70 of a rechargeable hearing device in a charger insert and a model of the retainer portion 46 of the charger insert 40. This part of the modeling requires creating the cavity surface and offsetting the surface of the retainer portion 46 to provide space for placing the rechargeable hearing devices 1A, 1B into the completed charger insert retainer 45.

[0193] Therefore, it should be understood that, in the method according to the invention, the second virtual model of the charger insert 40 can be further based on data regarding the shape of the charger housing. As mentioned above, such data may include information about the size and shape of the charger housing, as well as the modeling locations of the components therein, for example, in conjunction with the above. Figure 6 As described.

[0194] Therefore, it should be understood that, in the method according to the invention, the second virtual model of the charger insert 40 may be further based on data regarding the first positions of the first charger coils 22, 23 within the charger housing 21.

[0195] It should also be understood that, in the method according to the invention, providing a second virtual model of the charger insert 40 includes configuring a retainer 45 in a predetermined direction relative to the charger housing 21.

[0196] It will be further understood that, in the method according to the invention, positioning the first charger elements 22, 23 in a first relationship with the second charger element 4 includes: aligning the first charger elements 22, 23 in the charger housing 21 with the second charger element 4 in the rechargeable hearing devices 1A, 1B when the charger insert 40 is placed in the receiving portion 29 of the hearing device charger assembly 20 and when the rechargeable hearing devices 1A, 1B are placed in the charger insert 40.

[0197] Figure 2E The illustration shows the modeling of the modified shape of the retainer portion 46 of the charger insert. This may require removing the undercut volume / surface from the virtual model. Figure 2F A second virtual model 80 of the completed charger insert 40, which is used to form the charger insert 40, is shown in a three-dimensional view.

[0198] Therefore, it should be understood that, in the method according to the invention, providing a second virtual model may include designing a retainer 45, at least a subset of the surface portions of which are equivalent to the corresponding surface portions of the rechargeable hearing devices 1A, 1B.

[0199] It will be further understood that, in the method according to the invention, providing the second virtual model 80 may include removing the undercut surface of the retainer 45 in the second virtual model 80.

[0200] Any or all of these steps are preferably performed on computer 11 using suitable modeling software. Therefore, it should be understood that, in the method according to the invention, providing a second virtual model of the charger insert 40 may include digitally designing a second virtual model of the charger insert on a computer.

[0201] Once a second virtual model 80 of the custom charger insert 40 with a retainer 45 is provided as described above, the second virtual model 80 can be used to form or shape the charger insert 40, for example, through 3D manufacturing processes, as briefly discussed above. Figure 3E-3F As shown.

[0202] Figure 3E The diagram illustrates the concept based on the above. Figure 3A or Figures 2A-2F The first virtual model 70 provided in the diagram provides a representation suitable for, for example... Figure 3D The second virtual model 80 of the custom charger insert 40 of the custom rechargeable hearing devices 1A and 1B shown. Figure 3D (as well as Figures 3A-3CThis will be discussed in more detail below.

[0203] Now return to Figure 3F The figure illustrates, for example, a 3D printer 12 based on, such as Figure 3E The second virtual model shown forms the charger insert.

[0204] Figure 3G The complete custom charger insert 40 is shown, suitable for, for example Figure 3D Custom rechargeable hearing devices 1A and 1B are shown and are prepared to be installed in the housing 21 of the hearing device charger device 20.

[0205] Now back Figures 3A-3D These diagrams illustrate the formation of a set of customized rechargeable hearing devices 1A and 1B.

[0206] Figure 3A The illustration shows a first virtual model 70 providing rechargeable hearing devices 1A and 1B, for example, as described above. Figure 1A-1C As stated above.

[0207] Figure 3B The illustration shows, for example, the formation of housing portions 1A' and 1B' of rechargeable hearing devices 1A and 1B in a 3D printer 12. It should be understood that other methods of forming the hearing device housings 1A' and 1B' can be used alternatively.

[0208] Figure 3C The images show the finished hearing device housings 1A' and 1B', customized for the user's left and right ear canals, respectively.

[0209] Once the hearing device housing parts 1A' and 1B' are provided, various components, such as those mentioned above, will be combined. Figure 5 The components described can be installed into the outer casing of the hearing device, parts 1A' and 1B'. Figure 3D A custom-designed rechargeable hearing device was shown, including components such as a second charger element 4 that had been installed. Figure 3C In each of the hearing device housing portions 1A' and 1B' shown.

[0210] Figure 4A A partial sectional view shows the ear and ear canal EC of a (future) user of a hearing device (such as a hearing aid), as well as an ear canal impression 8 within a portion of the ear canal. In the figure, reference numeral P represents the auricle of the user's ear. The EC is the ear canal, shown in section, and T points towards the tympanic membrane of the user's ear. The ear canal impression 8 shows the position of a hearing device, such as a hearing aid, within the ear canal EC during use.

[0211] Ear canal impression 8 can be used in known processes for manufacturing personalized hearing devices 1A and 1B.

[0212] Hearing devices 1A and 1B may be, for example, prescription hearing aids for people diagnosed with hearing loss, but the present invention may also be used to configure other types of hearing devices that are located in the user's ear canal during use for charging.

[0213] Today, hearing aid shells used in custom hearing aids are made from digital 3D scans of ear canal castings, such as... Figure 4A Ear canal impression 8 shown.

[0214] Figure 4A This shows one of the user's ears and the ear canal EC, in this case, the right ear and ear canal EC. Obviously, the user could also have a left ear and left ear canal. Figure 4A In the image, the ear canal impression 8 of the right ear canal EC is shown in its position within the right ear canal EC. Those skilled in the art will recognize that a similar impression can be formed on the user's opposite ear canal.

[0215] Ear canal impressions are made by pouring a casting material (usually a biocompatible silicone-based material) into the ear canal of a user who needs or wants to purchase a custom / personalized / personalized hearing device.

[0216] Although the biocompatible, silicone-based material is at least partially cured within the user's ear canal, the ear canal impression 8 will thus be shaped to conform to the shape of the ear canal EC. Typically, the biocompatible silicone-based material may also cover the user's tragus so that the ear canal impression also reflects the shape of the user's tragus. Therefore, hearing devices 1A, 1B based on the ear canal impression 8 (see below) can be shaped to also match the user's tragus, which facilitates proper insertion of hearing devices 1A, 1B into the ear canal according to their rotational direction.

[0217] When the material has cured, the ear canal impression 8 is removed from the user's ear canal EC, and the ear canal impression 8 is digitally 3D scanned, such as... Figure 4B As shown, this is the modeling phase performed by an operator on a computer using suitable 3D modeling software, such as... Figure 4C As shown.

[0218] Figure 4B The diagram shows Figure 4A The image shown is a 3D scan of the ear canal EC of the ear, 8. Clearly, this is in contrast to or other than... Figure 4A An impression of the ear canal EC shown can be used to provide an impression of the contralateral ear canal in the same manner.

[0219] During the modeling phase, the shapes of the hearing device housings 1A' and 1B' are determined based on data from the scans. In the case where the ear canal impression 8 is a solid model of the ear canal (or at least a suitable portion thereof), the hearing device housings 1A' and 1B' will be hollow structures with an outer surface shaped to fit the user's ear canal, and internal spaces for the various components of the rechargeable hearing devices 1A and 1B.

[0220] During the modeling phase, the locations of the required electronic components (such as speakers, rechargeable batteries, microphones, etc., commonly referred to as receivers) in the finished hearing devices 1A and 1B are defined (planned) in the 3D data files that provide the design / layout of the finished hearing devices 1A and 1B. Therefore, during the modeling phase, the shapes of the electronic components and their positions / locations within the hearing device housing are planned / designed.

[0221] A user's ear canal shape may differ significantly from that of another person, and the shapes of a user's two ear canals may also differ. Therefore, the available space for internal components may vary from one hearing device to another, and consequently, the position / location of internal components within a single hearing device may also differ.

[0222] Once the layout of each future hearing device 1A, 1B has been planned, the outer shells 1A', 1B' of each hearing device are typically manufactured in a 3D printer, such as... Figure 3B As shown. The hearing device housings 1A' and 1B' can be manufactured directly during the modeling stage based on the design in the 3D data file created in the aforementioned computer, as described above.

[0223] Each of the hearing device housings 1A' and 1B' can be made of a biocompatible material, or post-treated to make it suitable for insertion into a user's ear canal EC under current biocompatibility and medical-grade requirements and regulations. The material used can be soft / elastic to facilitate insertion of the finished hearing devices 1A' and 1B into the user's ear canal EC, and to allow the hearing devices to adapt to, for example, jaw movements during use.

[0224] Ear canal impressions are often recorded for future copying and documentation.

[0225] Figures 4A-4C The illustration shows a method for obtaining personalized information related to the shape of one or more ear canals of a user by using a casting of the ear canal (ear canal impression) and 3D scanning of the model. Data / information about the shape of the user's ear canal EC (and in some cases, the shape of the user's tragus) is transmitted to a computer for further processing.

[0226] therefore, Figure 4A The illustration shows step A of obtaining an impression of the ear canal EC. Figure 4BThe illustration shows step B of digitizing the shape of the ear canal. Figures 4A-4B Therefore, a combination step of determining the shape of at least a portion of the user's ear canal is also shown in the method of manufacturing the retainer 40 for holding separately formed hearing devices 1A, 1B in a hearing device charger device 20 configured to charge the hearing devices 1A, 1B.

[0227] In principle, this shape data / information can be obtained in other ways, such as by 3D scanning of the ear canal, or by optical scanning of a portion of the user's ear canal.

[0228] As mentioned above, Figure 3A The illustration shows how to use the shape data obtained in step C to design / plan one or more hearing devices 1A, 1B using computer 11.

[0229] Figure 3B-3D The diagram illustrates three steps of a known process for forming hearing devices 1A and 1B using shape data 8' stored in computer 11.

[0230] Figure 3E-3G The illustration shows three steps of an embodiment of the process of forming at least one charger insert 40, including a holder 45 for receiving hearing devices 1A, 1B in a hearing device charger assembly 30.

[0231] In all of the above cases, instead of forming in a 3D printer 12 as shown, the 3D manufacturing process may involve forming the charger insert 40, including the retainer 45, from a material block by milling away material from the material block.

[0232] It should be noted that the accompanying drawings and the above description have illustrated exemplary embodiments in a simple and illustrative manner. Many specific mechanical details are not shown, as those skilled in the art should be familiar with such details.

[0233] Although specific features have been shown and described, it should be understood that they are not intended to limit the claimed invention, and it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the scope of the claimed invention. Therefore, the specification and drawings are to be considered illustrative rather than restrictive. The claimed invention is intended to cover all alternatives, modifications, and equivalents.

Claims

1. A method of manufacturing a charger insert (40), the charger insert (40) comprising a holder (45) for holding rechargeable hearing devices (1A, 1B) in a hearing device charger assembly (20), the rechargeable hearing devices (1A, 1B) being individually customized to at least partially insert into a user's ear canal, the hearing device charger assembly (20) being configured to charge the rechargeable hearing devices (1A, 1B), the hearing device charger assembly (20) comprising: - A charger housing (21) having a receiving portion (29) for a charger insert (40) having a retaining seat (45), and - The first charger element (22, 23) has a first position in the charger housing (21). The method includes: - Based on a dataset representing the shape of a user’s ear canal portion, a first virtual model of the rechargeable hearing device (1A, 1B) shaped to at least partially conform to the shape of the ear canal portion is provided, including assigning a second position in the first virtual model of the rechargeable hearing device (1A, 1B) for an electronic hearing aid device (28) including at least a second charger element (4). - Based on the first virtual model, a second virtual model of a charger insert (40) is provided for insertion into the receiving portion (29) of the hearing device charger assembly (20). In the second virtual model, the charger insert (40) is designed to support the rechargeable hearing devices (1A, 1B) such that when the charger insert (40) is placed in the receiving portion (29) of the hearing device charger assembly (20), the first charger element (22, 23) is positioned in a first relationship with the second charger element (4); and - Based on the second virtual model, the customized charger insert (40) is formed together with the retainer (45) through a 3D manufacturing process.

2. The method of claim 1, wherein the second virtual model of the charger insert (40) is also based on data regarding the shape of the charger housing (21).

3. The method according to claim 1 or 2, wherein the second virtual model of the charger insert (40) is further based on data regarding the first position of the first charger element (22, 23) within the charger housing (21).

4. The method of claim 1, wherein providing a second virtual model of the charger insert (40) includes configuring the retainer (45) in a predetermined direction relative to the charger housing (21).

5. The method according to claim 1, wherein positioning the first charger element (22, 23) in a first relationship with the second charger element (4) comprises: When the charger insert (40) is placed in the receiving portion (29) of the hearing device charger assembly (20), and when the rechargeable hearing devices (1A, 1B) are placed in the charger insert (40), the first charger element (22, 23) in the charger housing is aligned with the second charger element (4) in the rechargeable hearing devices (1A, 1B).

6. The method of claim 1, wherein providing the second virtual model comprises: - The retainer (45) is designed such that at least a subset of its surface portion is equivalent to the corresponding surface portion of the rechargeable hearing device (1A, 1B).

7. The method of claim 6, wherein providing the second virtual model includes removing the undercut surface of the retainer (45) in the second virtual model.

8. The method of claim 1, wherein providing a second virtual model of the charger insert (40) includes digitally designing a second virtual model of the charger insert (40) on a computer.

9. The method of claim 1, wherein providing a first virtual model of the rechargeable hearing devices (1A, 1B) comprises digitally designing a first virtual model of the rechargeable hearing devices (1A, 1B) on a computer.

10. The method of claim 1, wherein a second charger element (4) of the rechargeable hearing device (1A, 1B) is formed in an outward-facing panel (5) of the rechargeable hearing device (1A, 1B) having a flat outer surface, and wherein the method includes designing a holder (45) of the charger insert (40) such that when the rechargeable hearing device (1A, 1B) is held in the holder (45), the flat surface of the outward-facing panel (5) of the rechargeable hearing device (1A, 1B) is substantially parallel to the upward-facing surface of the charger insert (40).

11. The method according to claim 1, wherein, The first charger element (22, 23) is located in a fixed, standardized position within the charger housing (21).

12. The method according to claim 1, characterized in that, The charger housing includes a box-shaped charger base (26) and a charger cover (27) configured to cover the charger base (26), wherein the first charger elements (22, 23) are located in the charger cover (27).

13. The method according to claim 1, wherein the first charger element (22, 23) is a first charger coil, and the second charger element (4) is a second charger coil.

14. The method according to claim 1, wherein, The charger insert (40), including the retainer (45), is formed from the material block by milling material away from the material block.

15. The method according to claim 1, wherein, The charger insert (40) having the retainer (45) is formed by an additive manufacturing process.

16. The method of claim 1, further comprising an initial step of determining the shape of a portion of the user's ear canal, including: - Scan at least a portion of the user's ear canal; as well as - Provide a dataset representing the scan shape of said portion of the user's ear canal from a scan of said portion of the user's ear canal, for providing the first virtual model.

17. A hearing device charger assembly (20) comprising a charger insert (40) having a retainer (45) formed by the method according to any one of claims 1-16.

Images