Hearing instrument charger device and system and method of manufacturing a stand therefor

Abstract

A method of manufacturing a support for supporting a rechargeable hearing device in a hearing device charger device (30) that charges the hearing device (1A, 1B) and includes a first charger coil (22, 24), the method comprising: determining the shape of at least a portion of a user's ear canal based on an ear canal impression (8); digitally designing a virtual representation of the hearing device housing (1A', 1B') of the hearing device (1A, 1B) based on the determined shape, and planning a position for a second charger coil (4) in the hearing device (1A, 1B); and forming a support (40) based on the virtual representation of the hearing device housing (1A', 1B') such that the support (40) supports the shape of the hearing device (1A, 1B) in a predetermined position in the hearing device charger device (30), and such that the first charger coil (22, 24) is adjacent to the second charger coil (4). Preferably, the support is manufactured by vacuum forming a biocompatible thermoplastic sheet into the desired shape.

Description

Technical Field

[0001] This invention relates to a method of manufacturing a support for supporting a separately formed rechargeable hearing device in a hearing device charger assembly configured to charge the hearing device. The invention also relates to a hearing device charger assembly and a hearing device charger system, the system comprising a hearing device and a hearing device charger assembly. Background Technology

[0002] Rechargeable in-ear hearing aids are known in the art. To recharge such a hearing aid, the user is provided with a charging device. Both the charging device and the hearing aid may include a charger coil, allowing the hearing aid to be charged "wirelessly," thus avoiding the need for current contacts in in-ear hearing aids. This charging device may have a support for insertion into and supporting the hearing aid at a fixed position within the charging device during charging.

[0003] The problem with these devices is that the charger coils may not always be aligned with each other, which can cause the charging process to be interrupted or slowed down.

[0004] Therefore, one object of the present invention is to provide more stable charging for hearing devices (e.g., hearing aids).

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

[0006] US 8,137,607 discloses a reusable tool for manufacturing parts by applying a mixture of sand and an activator as a layer, wherein printing resin is deposited on the layer to form a substrate and a pattern. The stamping die can be formed by vacuuming the sand layer when the resin coating is applied to penetrate a stamping die. Using sand is unsuitable for manufacturing parts of hearing device size (a few centimeters) and sufficient detail (below 1 / 10 mm).

[0007] WO 2018 / 119176 discloses a system for applying a topical formulation to an isolated body part. The system includes an applicator mask having an applicator surface with a three-dimensional shape corresponding to the isolated body part, and at least one membrane releasably disposed on the applicator surface and having an outer surface facing the applicator surface and an opposing inner adhesive surface. 3D printing and thermoforming methods can be used to form the applicator mask, but these methods are considered mutually exclusive. Summary of the Invention

[0008] In a first aspect, the object of the present invention is achieved by a method of manufacturing a support for supporting a separately formed rechargeable hearing device in a hearing device charger assembly configured to charge the hearing device and including a first charger coil, wherein the method includes the following steps:

[0009] - Determine the shape of at least a portion of the user's ear canal based on the ear canal impression;

[0010] - Based on the defined shape of the ear canal portion, design a virtual representation of the hearing device housing in digital form on a computer, and plan the location of the second charger coil in the hearing device.

[0011] - The support is shaped based on a virtual representation of the hearing device housing, such that when the support is located in the hearing device charger device, it supports the shape of the hearing device in a predetermined position, and the first charger coil is adjacent to the second charger coil.

[0012] Therefore, ensuring perfect alignment between the charging coil of the hearing device (second charging coil) and the charging coil of the hearing device charging unit (first charging coil) ensures a stable charging process. Since charging / recharging is wireless, the distance between the charging coil in the hearing device charging unit and one or more charging coils in the RHI is minimized to maintain efficiency through a bracket manufactured in this way.

[0013] Virtual representations in computers can be provided as vectors, point clouds, or other types of 3D data files.

[0014] When the operator models / designs the location of the receiver, rechargeable battery, and electronics in the finished hearing device using 3D data files provided for the design, the formwork can be formed automatically during the modeling stage or by the operator on a computer screen.

[0015] In one implementation, the step of determining the shape of at least a portion of the ear canal also includes determining the shape of the user's tragus. Therefore, the hearing device can also be shaped to match the user's tragus, which helps to correctly insert the hearing device into the ear canal corresponding to its direction of rotation.

[0016] In this embodiment, the step of shaping the support includes the following steps:

[0017] - The inlay is shaped such that at least a subset of its surfaces are identical to the corresponding surfaces of the virtual hearing device housing; and

[0018] - A support structure is formed around the inlay.

[0019] Therefore, an efficient and cost-effective method for forming scaffolds has been achieved, and the materials can be readily available, biocompatible, and medical-grade.

[0020] In one implementation, the step of shaping the inlay includes rapid prototyping (RPT) of the inlay based on a virtual representation of the hearing device housing.

[0021] Rapid prototyping can include laser-printed inlays or milled inlays.

[0022] In any of the above-described cases, the step of forming the support may include thermoforming a plastic sheet on a portion of the insert. In one embodiment, the step of thermoforming a plastic sheet on a portion of the insert includes vacuum forming a plastic sheet on a portion of the insert.

[0023] Plastic sheets can be formed from polyethylene (PE), polypropylene (PP), or polyethylene terephthalate (PETG).

[0024] Preferably, the scaffold is formed of a biocompatible material.

[0025] In any of the above embodiments, the step of determining the shape of at least a portion of the user's ear canal includes:

[0026] - Inserting a portion of flexible material into the user's ear canal and tragus to create an ear canal impression; and

[0027] - Scan the ear canal impression and input the scanned shape into the computer.

[0028] In an alternative implementation, the shape can be determined by scanning the user's ear canal, for example, using MRI or ultrasound scans or other suitable 3D scanning techniques.

[0029] The flexible material can be a silicone resin, for example, supplied by manufacturers such as Egger (Egger Otoplastik+Labortechnik GmbH) or Dreve Otoplastik GmbH. This material is typically a silicone-based liquid, usually including fillers and hardeners. An example of this two-component molding material is a series from manufacturer Dreve. The material cures within minutes due to the hardener and is fully biocompatible. Also known in the art are silicone-based liquid materials formulated for photocuring.

[0030] In this embodiment, the material used for the support is the same as the material used for the ear canal impression.

[0031] In a second aspect of the invention, the object of the invention is achieved by a hearing device charger device for charging a separately formed hearing device including a second charger coil, the hearing device charger device comprising:

[0032] -Charger case;

[0033] - The charger power supply is located inside the charger box;

[0034] - The first charger coil is connected to the charger power supply;

[0035] - Charger electronics for controlling the charging of hearing devices; and

[0036] - A stand, configured to store hearing aids and housed within the charging case.

[0037] The support for the hearing device is shaped such that when the hearing device is housed in the support, the support supports the shape of the hearing device, and the first charger coil is adjacent to the second charger coil.

[0038] The stent can be manufactured using the process described in any of the embodiments of the first aspect of the present invention.

[0039] In one implementation, the support includes a surface equivalent to the corresponding surface (or at least a subset thereof) of the virtual hearing device.

[0040] In one embodiment, the support for the hearing device is disposed in the charger insertion part.

[0041] Therefore, it is possible to model / plan / design a charger insertion part for inserting a customized rechargeable hearing device into a universal / standard hearing device charger device.

[0042] In one embodiment, the charger insertion portion may be formed from a vacuum-formed sheet.

[0043] In one embodiment, the charger insertion part is a flat structure having an upper surface, a lower surface and a peripheral edge, wherein the bracket extends away from the lower surface and wherein the peripheral edge is configured to engage with the edge of the charger box.

[0044] In one embodiment, the hearing device charger includes a charger cover configured to engage with a charger case, and a first charger coil disposed within the charger cover, such that when the hearing device is placed in the holder and the charger cover is closed, the first charger coil is in an operating position providing charging power.

[0045] Therefore, charging can be achieved only when the cover is closed, thereby reducing the risk of hearing devices accidentally falling out of the hearing device charger.

[0046] In a third aspect of the invention, the object of the invention is achieved by a hearing device system comprising:

[0047] - Rechargeable hearing devices; and

[0048] -A hearing device charger according to any embodiment of the second aspect of the present invention.

[0049] The bracket for the hearing device charger can be manufactured using the process described in any of the embodiments of the first aspect of the invention.

[0050] In one embodiment, the hearing device charger includes a charger cover configured to mate with a charger case, wherein a first charger coil is disposed in the charger cover, and wherein the hearing device includes a second charger coil formed in an outer panel of the hearing device, and wherein the first charger coil and the second charger coil are configured such that they face each other when the hearing device is housed in a holder and the cover is closed.

[0051] It should be emphasized that the term "comprising / including / consisting of" when used in the specification is used to specify 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

[0052] In the following description, the invention will be described in more detail with reference to the embodiments shown in the accompanying drawings. It should be emphasized that the embodiments shown are for illustrative purposes only and should not be used to limit the scope of the invention.

[0053] - Figure 1A A partial cross-section of an ear canal impression is shown through the human ear and ear canal, and in a portion of the ear canal.

[0054] - Figure 1B This shows an ear canal impression taken in a 3D scanner.

[0055] - Figure 1C A PC with a keyboard, mouse, and suitable 3D modeling software is shown.

[0056] - Figure 1D1-1D3 The process of forming a hearing device is shown in three steps;

[0057] - Figure 1E1-1E3 The process of forming a charger insert with two supports is shown in three steps, each of which is used to house a hearing device.

[0058] - Figure 2 The cross-section through the hearing device is shown;

[0059] - Figure 3Showing the corresponding Figure 2 The inlay of the hearing device shown;

[0060] - Figure 4 Show Figure 2 The hearing devices shown and Figure 3 The differences in shape between the corresponding inlays are shown;

[0061] - Figure 5 The molding of the charger insert on a pair of inserts is shown in a cross-sectional side view;

[0062] - Figure 6 The finished charger insertion section is shown in a cross-sectional side view;

[0063] - Figure 7 The hearing device charger assembly is shown in a cross-sectional side view. Detailed Implementation

[0064] Various embodiments are described below with reference to the accompanying drawings. The same reference numerals always refer to the same elements. Therefore, in the description of each figure, the same elements will not be described in detail. It should also be noted that the drawings are for illustrative purposes only. They are not intended as an exhaustive description of the claimed invention or as a limitation on the scope of the claimed invention. Furthermore, the illustrated embodiments do not need 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 can be practiced in any other embodiment, even if not so stated or explicitly described.

[0065] Figure 1A The partial cross-sectional view shows the ear and ear canal (EC) of a (future) user of a hearing device (e.g., a hearing aid), and an ear canal impression 8 in a portion of the ear canal. In the figure, reference P is the auricle of the user's ear. The EC is the ear canal, as shown in the cross-section, and T points towards the tympanic membrane of the user's ear. The ear canal impression 8 is shown located within the ear canal EC, for example, in the position where the hearing device (e.g., a hearing aid) is positioned during use of such a device.

[0066] Ear canal impression 8 can be used in known processes for manufacturing personalized hearing devices 1A, 1B (e.g., hearing aids).

[0067] According to one aspect of the invention, the ear canal impression 8 can be used in the process of manufacturing a support for a hearing device in a hearing device charging device 30, see [link to invention]. Figure 7 It is used to charge hearing devices.

[0068] Hearing devices 1A and 1B can be, for example, prescription hearing aids for people diagnosed with hearing loss, but the present invention can also be used for charging other types of hearing devices configured to be located in the user's ear canal during use.

[0069] Today, hearing aid housings used in custom hearing aids are made from ear canal castings (i.e., such as...). Figure 1A The ear canal impression shown (8) was made by digital 3D scanning.

[0070] Figure 1A The image shows one of the user's ears and ear canal ECs, in this case the right ear and ear canal EC. It is clear that the user could also have a left ear and left ear canal. Figure 1A In the image, an ear canal impression 8 of the right ear canal EC is shown at the location of the right ear canal EC. Those skilled in the art will recognize that a similar impression can be made from the opposite ear canal of the user.

[0071] An ear canal impression is made by pouring a casting material (usually a biocompatible silicone-based material) into the ear canal of a user who needs or wishes to purchase a customized / personalized hearing device. The casting material is a two-component liquid material comprising a filler and a curing agent. After the two components are mixed, the casting material will cure within minutes.

[0072] Furthermore, the use of suitable photocurable silicone-based materials for photocuring casting materials is a known technique in the art.

[0073] Both types of this silicone material are known in the art. Products typically used for this purpose are manufactured by Egger (egger Otoplastik+Labortechnik GmbH) or Dreve GmbH.

[0074] When the biocompatible silicone-based material is at least partially cured within the user's ear canal, the ear canal impression 8 will thus form a shape conforming to the ear canal's EC. Typically, the biocompatible silicone material will also be formed to cover the user's tragus, so that the ear canal impression also reflects the shape of the user's tragus. Therefore, hearing devices 1A and 1B based on the ear canal impression 8 (see below) can also be formed to match the user's tragus, which helps to correctly insert the hearing devices 1A and 1B into the ear canal relative to their rotational direction.

[0075] Once the material has cured, the ear canal impression 8 is removed from the user's ear canal EC, and a digital 3D scan of the ear canal impression 8 is performed, such as... Figure 1B As shown, this is used by the operator in the modeling stage using suitable 3D modeling software on a computer, such as... Figure 1C As shown.

[0076] Figure 1BAs shown Figure 1A The image shown is a 3D scan of the ear canal EC of the ear, 8. It is clear that, instead of, or except as... Figure 1A The ear canal EC impression shown can be used to provide an impression of the opposite ear canal in the same manner.

[0077] During the modeling phase, the shapes of the hearing device housings 1A' and 1B' can be determined based on the scanning data. If the ear canal impression 8 is a solid model of the ear canal (or at least a suitable cross-section thereof), the hearing device housings 1A' and 1B' can be hollow structures with an outer surface conforming to the shape of the user's ear canal, and internal spaces for various components of the hearing device.

[0078] During the modeling phase, the locations of the electronic components (e.g., speakers, often referred to as receivers, rechargeable batteries, microphones, etc.) required in the finished hearing devices 1A and 1B are defined (planned) in the 3D data files that provide the design / layout for the finished hearing devices 1A and 1B. Therefore, during the modeling phase, the shapes of the electronic components and their locations within the hearing device housing are planned / designed.

[0079] The shape of a user's ear canal can differ greatly from that of another person, and even the two ear canals of a single user can differ in shape. Therefore, the available space for the internal components of a hearing device may differ from that of another, and consequently, the positions of the internal components within an individual's hearing device may also vary.

[0080] Once the layout of each future hearing device 1A, 1B has been planned, then each hearing device housing 1A', 1B' is typically manufactured in a 3D printer, such as... Figure 1D1 As shown. During the modeling stage, the hearing device housings 1A' and 1B' can be designed and manufactured directly from the 3D data files created on the aforementioned computer, as described above.

[0081] Each of the hearing device housings 1A' and 1B' may be manufactured or post-processed from a biocompatible material, making it suitable for insertion into a user's ear canal EC under current biocompatibility and medical grade requirements and regulations. The material used may be flexible / 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.

[0082] Figure 1D1 The steps for 3D printing hearing device housings 1A' and 1B' are shown. It should be understood that other methods can be used to form hearing device housings 1A' and 1B'.

[0083] Figure 1D2A set of finished hearing device housings 1A' and 1B' is shown, with the left hearing device housing 1A' molded for the left ear canal and the right hearing device housing 1B' molded for the user's right ear canal.

[0084] When the hearing device housings 1A' and 1B' are completed, for example, the aforementioned internal components are installed in the hearing device housings 1A' and 1B', for example, manually installed in their planned / defined positions. Figure 1D3 A set of finished hearing devices 1A and 1B is shown, one for the left ear and one for the right ear, i.e., hearing device housings 1A' and 1B' with internal components installed in their internal spaces.

[0085] Ear canal impressions are often kept in records for subsequent reproduction and recording.

[0086] therefore, Figure 1A -B illustrates a method for obtaining personalized information about the shape of one or more ear canals of a user by using an ear canal casting (ear canal impression) and a 3D scanning casting. 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.

[0087] therefore, Figure 1A Step A for obtaining an EC impression of the ear canal is shown. Figure 1B Step B shows the digital shape of the ear canal. Figure 1A -B also shows the combination steps of determining the shape of at least a portion of the user's ear canal by means of manufacturing a bracket 40 for supporting separately formed hearing devices 1A and 1B in a hearing device charger device 30 configured to charge hearing devices 1A and 1B.

[0088] In principle, this shape data / information can be obtained in other ways (e.g., by 3D scanning of the ear canal).

[0089] Figure 1C This demonstrates how to design / plan one or more hearing devices 1A, 1B using the shape data obtained in step C via computer 11.

[0090] Figure 1D1-1D3 The diagram illustrates three steps of a known process for forming hearing devices 1A and 1B using shape data 8' stored in computer 11.

[0091] Figure 1E1-1E3 The diagram illustrates three steps of an embodiment of the process for forming at least one support 40 in the hearing device charger 30 for receiving hearing devices 1A and 1B. Further, Figure 1E1-1E3The diagram illustrates three steps in the process of forming a charger insertion portion 20 with two supports 40, each of which is used to house hearing devices 1A and 1B. This process relies on obtaining personalized information / data regarding the shape of one or more ear canals (ECs) of the user used to form the aforementioned hearing devices 1A and 1B.

[0092] According to the present invention, data regarding the shape of the user's ear canal EC, input into a computer, can be used to design molded inlays, or simply inlays 2, 2A, and 2B. Inlays 2, 2A, and 2B are formed to achieve the shapes of the corresponding hearing devices 1A and 1B (finished products). In conjunction with the following... Figure 3 and Figure 4 The design of inlays 2, 2A, and 2B will be discussed in more detail.

[0093] However, now refer to Figure 2 First, we will describe hearing devices 1A and 1B. Figure 2 The diagram shows cross-sections through hearing devices 1A and 1B. Hearing devices 1A and 1B include hearing device housings 1 manufactured / formed as described above.

[0094] Hearing devices 1A and 1B have a proximal end and a relatively 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 tympanic membrane (T), and when hearing devices 1A and 1B are inserted into a user's ear canal (EC), 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 disposed within the hearing device housings 1, 1A', and 1B'.

[0095] These components include electronic components, such as a speaker (hearing device receiver 9 hereinafter, also commonly referred to as a receiver), a rechargeable battery (or hearing device rechargeable battery 7), a second charger coil 4, and control electronics; the hearing aid electronics 6 are at least used to control the charging of the hearing device receiver 9 and the hearing device rechargeable battery 7 via the second charger coil 4. The second charger coil 4 is configured to... Figure 7 The first charger coils 22 and 24 in the hearing device charger device 30 described below are charged.

[0096] The receiver 9 of the hearing device is typically located at the proximal end of the hearing device 1A, 1B, so as to be close to the user's eardrum when it is inserted into the user's ear canal EC. Other components may be located within the hearing device housing 1A', 1B', and the location may vary depending on the individual shape of the hearing device housing 1A', 1B'.

[0097] 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 structured, allowing internal components to be installed in designed / planned locations.

[0098] The internal components may additionally include one or more microphones. Figure 2 (Not shown in the image). A microphone may, for example, be positioned at the distal end of the hearing device.

[0099] The internal components may additionally include means for wireless communication with other devices. For example, such means may communicate with behind-the-ear devices, mobile phones, or other external electronic devices.

[0100] Electronic components located within the internal spaces of hearing devices 1A and 1B can be electrically connected to each other, for example, by transmitting energy and / or data through suitable wiring.

[0101] Figure 2 The hearing devices 1A and 1B shown have a panel 5 at their distal ends for closing the internal space of the hearing devices 1A and 1B. The panel 5 is used to seal the internal space containing internal components to prevent impurities from the external environment.

[0102] Panel 5 can be shaped to fit the contour of the user's ear canal. However, when the hearing device is inserted into the ear canal, the distal end of the 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 ear canal. Therefore, panel 5 can be shaped with a regular planar surface, such as... Figure 2 As shown.

[0103] exist Figure 2 In the illustrated hearing devices 1A and 1B, the second charger coil 4 is shown adjacent to the panel 5. For example, the second charger coil 4 may be integrated into the panel 5. Alternatively, the charger coil 4 may be structurally connected to other components in the internal space or to the inner wall of the hearing device housing 1A' or 1B', and adjacent to the inner surface of the panel 5. In some embodiments, the second charger coil 4 may be located in a recess formed in the inner surface of the panel 5.

[0104] However, as mentioned above, the second charger coil 4 may be located at other positions within the cavity / internal space of the hearing devices 1A and 1B in other embodiments.

[0105] Now refer to Figure 1E1-1E3 The method of manufacturing a support 40 in a hearing device charger 30 for housing hearing devices 1A and 1B is described.

[0106] Figure 1E1 Step 1E is shown to form the insert 2 for molding the support 40. The step of forming the insert 40 can be completed using 3D printing. The insert 2 can be formed from the same material as the hearing device housing 1A', 1B'. However, other suitable materials can be used alternatively.

[0107] As mentioned above, Figure 1E1 The 3D printed inlay 2 is shown. However, other RPT (rapid prototyping) or milling techniques can be used to form the inlay 2.

[0108] The inlay 2 is typically formed to correspond to the shape of the ear canal and the hearing devices 1A and 1B, so that it can be charged when housed in the holder 40. It should be understood that the shape of the inlay does not need to be 100% identical to the corresponding hearing devices 1A and 1B. For example, some or all of the concave surfaces may not be reproduced in the inlay 2. This will combine... Figure 3 and Figure 4 A more detailed description follows.

[0109] Now, Figure 1E2 A set of inlays 2A and 2B are shown, each of which is formed as described above. Inlay 2A corresponds in shape to the hearing device housing 1A' and the hearing device 1A, respectively, for example... Figure 1D2 and Figure 1D3 As shown. Similarly, the inlay 2B corresponds in shape to the hearing device housing 1B' and the hearing device 1B, respectively, for example... Figure 1D2 and Figure 1D3 As shown.

[0110] Figure 1E3 The present invention illustrates a method for forming supports for two hearing devices 1A, 1B (formed in steps E1, E2) in step E3 by vacuum forming a vacuum forming sheet 14 on two inserts 2A, 2B to obtain a charger insert 20 having two supports 40 for a set of hearing devices 1A, 1B.

[0111] Examples of suitable biocompatible vacuum forming materials are polyethylene (PE), polypropylene (PP), or polyethylene terephthalate (PETG).

[0112] Figure 5The cross-sectional view shows two inserts 2A, 2B, on which a vacuum-formed sheet 14 is placed and a vacuum is applied to shape the vacuum-formed sheet 14 into a charger insert 20 having two supports 40. One 40' has the shape of an impression 2A' (i.e., a substrate) forming the left insert 2A, and the other 40" has the shape of an impression 2B' (i.e., a substrate) forming the right insert 2B. The material of the vacuum-formed sheet 14 is preferably heated to a thermoplastic temperature before being formed on the inserts 2A, 2B. The vacuum forming process can be performed alternatively using an overpressure above atmospheric pressure, such that a pressure gradient forces the vacuum-formed sheet 14 to take shape. Thus, one support 40' is configured to receive the corresponding left hearing device 1A, and the other support 40" is configured to receive the corresponding right hearing device 1B.

[0113] Therefore, by forming supports 40' and 40" on inlays 2A and 2B based on customized data of the corresponding ear canal shape, it can be ensured that the corresponding hearing devices 1A and 1B can only be correctly inserted into one of the supports 40' and 40" and remain in only one position / direction relative to the supports 40' and 40" respectively. Therefore, it can be determined that the second charger coil 4 of the hearing devices 1A and 1B is precisely aligned with the first charger coils 22 and 24 disposed in the hearing device charger device 30 (see...). Figure 7 ), which will be described further below.

[0114] Figure 6 The charger insertion portion 20 is shown to be formed from the vacuum-formed sheet 14 as described above, and has two customized / personalized hearing device supports 40', 40" for supporting customized / personalized hearing devices 1A, 1B respectively. It should be understood that the supports 40', 40" are formed by the impressions 2A', 2B', and thus the formed structure extends from the plane defined by the vacuum-formed sheet 14. Figure 6 Corresponding to Figure 5 In this case, inserts 2A and 2B have been removed from the formed brackets 40' and 40" and the charger insertion part 20 has been flipped over.

[0115] It should be understood that this method of forming the support 40 can also be applied to forming a single support 40 for supporting only a single hearing device 1A, 1B, or to forming two individual supports for a set of hearing devices 1A, 1B.

[0116] It should also be understood that one or more supports can be formed using other thermoforming techniques in combination with inserts 2, 2A, and 2B.

[0117] In other embodiments, one or more supports 40 may be formed by molding using inserts 2, 2A, 2B as inserts in a mold.

[0118] In other embodiments, one or more scaffolds 40 can be formed by 3D printing using the data described above regarding the shape of the user's ear canal. In this case, it is not necessary to form any inlays. However, this method is not currently considered cost-effective because scaffolds manufactured using this method require necessary post-processing to ensure biocompatibility.

[0119] Figure 7 A hearing device charger 30 is shown, in which the aforementioned charger insertion part 20 is inserted. The hearing device charger 30 includes a charger housing 28 and a charger cover 26. The charger housing 28 forms 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 single non-rechargeable battery, or a rechargeable battery. Alternatively, the battery can be a fixed rechargeable battery. In the embodiment where the charger power supply 25 is a rechargeable battery, the hearing device charger 30 can provide a portable power source for one or more hearing devices 1A, 1B.

[0120] In other embodiments, the charger power supply 25 of the hearing device charger device 30 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 30 may be a transformer connected to a rechargeable battery, such that the hearing device charger device 30 can charge one or more hearing devices when connected to and disconnected from mains power (via a cable not shown).

[0121] The internal volume of the charger box 28 of the hearing device charger device 30 can also accommodate charger electronics 27, which is used to control the charging of the charger power supply 25 (when the charger power supply 25 is a fixed rechargeable battery) and / or one or more hearing devices 1A, 1B.

[0122] The hearing device charger 30 also includes first charger coils 22 and 24, each charger coil for each hearing device 1A and 1B to be charged.

[0123] Charger electronics 27 are connected to charger power supply 25 via suitable wiring (not shown). Additionally, charger electronics are connected to first charger coils 22 and 24.

[0124] The charger electronics 27 are preferably configured such that they can detect the presence of nearby hearing aids 1A and 1B, and if the hearing aids are present, begin charging. This can be achieved if the presence of the first charger coil 4 of the hearing aids 1A and 1B is detected.

[0125] like Figure 7 As shown, the charger insertion part 20 can cover the internal volume of the charger box 28, which is disposed on the edge of the box-shaped charger box 28. The molds 2A' and 2B' forming the brackets 40' and 40" extend into the internal volume.

[0126] The positions of the brackets 40', 40" relative to the charger insertion part 20 are configured such that during modeling, when the charger insertion part 20 is inserted into the charger box 28 and the hearing devices 1A, 1B are inserted into the brackets 40', 40" the second charger coil 4 (in each of the hearing devices 1A, 1B, not in) Figure 7 (As shown) Aligned with the first charger coils 22 and 24 respectively.

[0127] The precise alignment of the first charger coil 4 with the second charger coils 22 and 24 is also ensured by the shape of the brackets 40' and 40" that allow each hearing device 1A and 1B to be inserted in a specific direction.

[0128] In one implementation, such as Figure 7 As shown, the first charger coils 22 and 24 can be configured to connect to the charger cover 26. This configuration of the hearing device charger assembly 30 ensures that charging only begins when the cover is closed and the first charger coils 22 and 24 are aligned with the second charger coil 4 in the corresponding hearing devices 1A and 1B.

[0129] In such Figure 7 In the illustrated embodiment, the supports 40', 40" and the charger insertion portion 20 are configured such that the hearing devices 1A, 1B (when the supports 40', 40" are inserted) are positioned upright with the proximal ends / panels 5, 5A, 5B facing upwards, and the plane defined by the surfaces of the panels 5A, 5B is parallel to the plane defined by the upper surface of the charger insertion portion 20. In this case, the first coil 4 in the hearing devices 1A, 1B is disposed in the panels 5A, 5B, as shown. Figure 2 As shown.

[0130] However, it should be understood that, in alternative embodiments, the supports 40', 40" and the charger insertion portion 20 may be configured such that the hearing devices 1A, 1B are positioned relative to the plane defined by the upper surface of the charger insertion portion 20 in a different manner. Figure 7 The orientation is as shown. For example, hearing devices 1A and 1B can be "laid flat" instead of being positioned as shown. Figure 7 The upright position is shown. In this case, the second charger coil 4 in the hearing devices 1A and 1B can be set parallel to the side wall portion of the hearing device housings 1A' and 1B' instead of being in the position shown. Figure 2 and Figure 7 In panels 5A and 5B shown.

[0131] It should also be understood that, in other embodiments, the first charger coils 22, 24 may be disposed within the charger housing 28 instead of within the charger cover 26. In this case, the supports 40', 40'', the charger insertion portion 20 and / or the hearing devices 1A, 1B (positioning or first charger coil 4 in the hearing devices 1A, 1B) are modeled and formed such that the first and second charger coils are aligned when the hearing devices 1A, 1B are placed in the supports.

[0132] Markings can be formed on the charger insert 20 adjacent to their respective holders, indicating which hearing device is inserted into which holder 40', 40'. The markings can be, for example, "L" for "left" and "R" for "right," to indicate the positions of the left and right hearing devices 1A, 1B, respectively, for insertion and repeated charging. Other alternative symbols or text may be considered. The markings can be formed by an impression in the charger insert 20, for example, by a film formed on the inserts 2A, 2B. For this purpose, the distal ends of the inserts 2A, 2B can be shaped into panels having the film for marking. In other embodiments, after the insert 20 is shaped to have one or more holders, the markings can be applied to the insert 20 by stamping, printing, or other techniques known in the art.

[0133] The corresponding markings between the brackets 40', 40" and the corresponding hearing devices 1A, 1B can be designed during the modeling stage, so that the hearing devices 1A, 1B are formed with markings on their outer surfaces.

[0134] Figure 7 The diagram also shows a hearing device system 100, including a set of hearing devices 1A and 1B and a hearing device charger device 30.

[0135] As mentioned above, Figure 3 Showing the corresponding Figure 2 The figure shows the inlay 2 of the hearing device element. More precisely, the figure shows the corresponding... Figure 2 The outline of the inlay 2 is shown as the outline of the hearing device element. As mentioned above, it should be understood that the outline / shape of inlay 2 does not necessarily have to be 100% identical to the corresponding hearing devices 1A and 1B. For example, some or all of the concave surfaces may not need to be reproduced in inlay 2. Figure 4 As shown. In Figure 4 middle, Figure 2 The outline of the hearing device shown (represented by the hearing device housing 1) is placed in Figure 3 The outline of the corresponding inlay 2 is shown to illustrate... Figure 2 The hearing devices shown and Figure 3 The shape differences between the corresponding inlays are shown.

[0136] Because the inlay 2 forms an imprint 2A, 2B' that defines the shape of the brackets 40', 40" it is obvious that if the shape of the brackets 40', 40" has, for example, a concave surface, it would be difficult to insert the hearing devices 1A, 1B that need to pass through the concave surface during the insertion of the hearing devices 1A, 1B into the brackets 40', 40"

[0137] Therefore, as Figure 4 As shown, volume 50 can be added to the insert 2 to compensate for the "hook" shape provided by the concave surface. Adding this volume 50 to the insert will produce corresponding impressions 2A', 2B' in the vacuum-formed material sheet 14, and will give the resulting supports 40', 40" corresponding additional volumes.

[0138] Furthermore, to avoid situations where hearing devices 1A and 1B need to pass through narrow channels at the entrances of brackets 40' and 40" of the insert, a volume 51 can be added to a portion of the inlay 2. This portion corresponds to the end of the hearing device 1A and 1B furthest from the end into which the bracket 40' and 40" are first inserted. Adding this volume 51 to the inlay during the manufacture of the insertion portion 20 will cause the corresponding molds 2A' and 2B' to be formed from vacuum-formed material sheets 14, and thus give the resulting brackets 40' and 40" a corresponding additional volume.

[0139] Therefore, when molding the inlays 2, 2A, 2B (and / or molding the brackets 40', 40”), it should be ensured that the brackets 40, 40', 40” are shaped such that when the finished hearing devices 1A, 1B are inserted into the brackets 40, 40', 40”, the brackets 40, 40', 40” support the shape of the hearing devices (1A, 1B) in the predetermined position.

[0140] This is accomplished by ensuring that at least a subset of the surfaces of the supports 40, 40', 40" are shaped to be equivalent to the corresponding surfaces of the virtual hearing device housings 1A', 1B'.

[0141] In an implementation, where the support is formed by molding (e.g., vacuum forming) around the inlays 2, 2A, 2B, the inlays 2, 2A, 2B should be designed (modeled) and shaped such that at least a subset of the surfaces are equivalent to the corresponding surfaces of the virtual hearing device housing (1A', 1B').

[0142] This invention can also be defined by the following items:

[0143] 1. A hearing device charger 30 for charging separately molded hearing devices 1A and 1B, the hearing device charger 30 comprising:

[0144] Charger case 28;

[0145] The charger power supply 25 is located inside the charger box 28;

[0146] The first charger coils 22 and 24 are connected to the charger power supply 25;

[0147] Charger electronics 27, used to control the charging of hearing devices 1A and 1B; and

[0148] The stand 40 is configured to store hearing devices 1A and 1B, and the stand 40 is located inside the charger box 28.

[0149] The bracket 40 for hearing devices 1A and 1B has a shape specific to the individually formed hearing devices 1A and 1B, such that when the individually formed hearing devices 1A and 1B are housed in the bracket 40, the second charger coil 4 of the individually formed hearing devices 1A and 1B is in an operating position receiving charging power from the first charger coils 22 and 24 of the hearing device charger device 30.

[0150] 2. The hearing device charger device 30 according to Item 1, wherein the support 40 includes a cavity and one or more surface portions corresponding to one or more surface portions of a separately formed hearing device.

[0151] The cavity can be formed by the impression 2A' (i.e., film) of the left inlay 2A or by the impression 2B' (i.e., film) of the right inlay 2B, as described above.

[0152] 3. According to the hearing device charger device 30 of Project 1, wherein the bracket 40 includes shape features corresponding to the shape features of the separately formed hearing devices 1A and 1B.

[0153] 4. A hearing device charger device 30 according to any one of items 1-3, wherein a bracket 40 for hearing devices 1A and 1B is provided in the charger insertion portion 20. In its embodiment, the bracket 40 for hearing devices 1A and 1B forms part of the charger insertion portion 20.

[0154] 5. The hearing device charger device 30 according to Project 4, wherein the charger insertion part 20 is formed by a vacuum forming sheet 14.

[0155] 6. A hearing device charger device according to item 4 or 5, wherein the charger insertion part 20 includes a flat structure having an upper surface, a lower surface and a peripheral edge, wherein the brackets 40, 40', 40" extend away from the lower surface of the charger insertion part 20, and wherein the peripheral edge of the charger insertion part 20 is configured to engage with the edge of the charger box.

[0156] 7. The hearing device charger device 30 according to item 6 includes a charger cover 26 configured to mate with a charger box 28, wherein first charger coils 22, 24 are positioned in the charger cover 26 in such a way that when the hearing device is placed in the holder 40 and the charger cover 26 is closed, the first charger coils face the second charger coil 4.

[0157] 8. A hearing device charger 30 according to any one of items 1-7, wherein the shape of the brackets 40, 40', and 40" is a custom shape.

[0158] 9. A hearing device system 100, comprising:

[0159] Hearing device charger device 30 according to any one of items 1-8; and

[0160] Individually molded hearing devices 1A and 1B.

[0161] 10. The hearing device system 100 according to item 9, wherein the hearing device charger device 30 includes a charger cover 26 configured to mate with a charger case 28, wherein first charger coils 22, 24 are in the charger cover 26, and wherein the first charger coils 22, 24 and the second charger coil 4 are configured such that when separately formed hearing devices 1A, 1B are housed in supports 40, 40', 40" and the charger cover 26 is closed, they face each other.

[0162] 11. The hearing device system 100 according to item 9 or 10, wherein the second charger coil 4 of the separately formed hearing devices 1A, 1B is in the outer panel 5 of the separately formed hearing devices 1A, 1B.

[0163] 12. A method of manufacturing a support 40 for supporting separately formed hearing devices 1A and 1B in a hearing device charger 30 configured to charge hearing devices 1A and 1B, the hearing device charger 30 including first charger coils 22 and 24, the method comprising:

[0164] Acquire data on the representation of the hearing device housings 1A' and 1B' of the hearing devices 1A and 1B and / or the representation of items used to form the supports 40, 40' and 40" of the hearing devices 1A and 1B, wherein the representation of the hearing device housings 1A' and 1B' and / or the representation of the items are specific to the user of the hearing devices 1A and 1B;

[0165] Obtain the position of the second charger coil 4 in hearing devices 1A and 1B; and

[0166] Based on the data and position of the second charger coil 4, brackets 40, 40', and 40' are formed such that when the separately formed hearing devices 1A and 1B are housed in brackets 40, 40', and 40', the second charger coil 4 of the separately formed hearing devices 1A and 1B is in the working position of receiving charging power from the first charger coils 22 and 24 of the hearing device charger device 30.

[0167] 13. According to the method of Project 12, the actions of forming stents 40, 40', and 40" include:

[0168] Inlays 2A and 2B are formed, wherein at least a subset of their surface portions correspond to the respective surface portions represented by the hearing device housing; and

[0169] Supports 40, 40', and 40' are formed around inlays 2A and 2B.

[0170] 14. The method according to item 13 further includes removing inlays 2A and 2B from supports 40, 40', 40”, leaving imprints 2A' and 2B' of inlays 2A and 2B on supports 40, 40', 40”.

[0171] 15. The method according to any one of items 12-14, wherein the representation of the item includes the representation of inlays 2A and 2B, and wherein the behavior of forming inlays 2A and 2B includes rapid prototyping of the inlays based on the representation of the inlays.

[0172] 16. According to the method of item 12, wherein the representation of the item is derived from the representation of hearing device housings 1A' and 1B'.

[0173] 17. According to the method of item 16, wherein the representation of the item includes the representation of inlays 2A and 2B, wherein the supports 40, 40', and 40" are formed using inlays 2A and 2B.

[0174] 18. According to the method of item 16, wherein the representation of the item is obtained by enlarging the representation of the hearing device housings 1A' and 1B'.

[0175] 19. According to the method of Project 12, wherein the act of forming the supports 40, 40', 40" includes thermoforming a plastic sheet on a portion of the inserts 2A, 2B.

[0176] 20. The method of Item 19, wherein the act of thermoforming a plastic sheet on a portion of the inserts 2A, 2B includes vacuum forming a plastic sheet on a portion of the inserts 2A, 2B.

[0177] 21. The method according to item 12, wherein the hearing device housings 1A', 1B' represent the shape of at least a portion of the ear canal and tragus of the user of the hearing devices 1A, 1B.

[0178] 22. According to the method of Project 12, wherein the representation of the hearing device housing 1A', 1B' includes scanning data acquired based on the ear canal.

[0179] 23. According to the method of Project 12, wherein the scaffolds 40, 40', and 40" are formed using biocompatible materials.

[0180] 24. According to the method of Project 12, wherein the representation of the hearing device housings 1A' and 1B' is based on ear canal impressions 2A' and 2B'.

[0181] 25. According to the method of Item 24, wherein the supports 40, 40', 40" are formed using the same material as the material of the ear canal impression.

[0182] 26. The method according to item 12 also includes creating representations of hearing device housings 1A' and 1B' by:

[0183] A portion of the flexible material is inserted into the user's ear canal and tragus to form ear canal impressions 2A' and 2B'.

[0184] Scan ear canal impressions 2A' and 2B' to obtain scan data; and

[0185] Representations of hearing device housings 1A' and 1B' are created based on scanned data.

[0186] 27. The method of Item 12, wherein supports 40, 40', 40" are formed around inlays 2A, 2B, and wherein inlays 2A, 2B are configured to allow insertion and removal of hearing device housings 1A', 1B' without obstruction by any part of inlays 2A, 2B.

[0187] 28. The method according to item 27, wherein the representation of the item includes the representation of inlays 2A, 2B, and wherein the representation of inlays 2A, 2B includes design features for inlays 2A, 2B such that when the inlays are formed, the inlays allow insertion and removal of hearing device housings 1A', 1B' without obstruction by any part of the inlays 2A, 2B.

[0188] It should be noted that the accompanying drawings and the above description have illustrated exemplary embodiments in a simple and schematic manner. Many specific mechanical details are not shown, as those skilled in the art will be familiar with them.

[0189] 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 considered illustrative rather than restrictive. The claimed invention is intended to cover all alternatives, modifications, and equivalents.

[0190] Parts list:

[0191] P user's auricle

[0192] EC user's ear canal

[0193] T user's tympanic membrane

[0194] Step A: Imprint of the ear canal (and tragus)

[0195] Step B: 3D scanning of the impression

[0196] Step C: Digital design of the virtual HI housing and the insert for the charger insertion

[0197] Step D1: 3D printing of the HI shell with a cavity

[0198] Step D2: Preparing the 3D-printed HI housing for mounting electronic components within the cavity.

[0199] Step D3: Finished hearing devices with electronic components

[0200] E1 Step: 3D Printing of Inlays

[0201] E2 Step: Finished 3D Printed Inlay

[0202] E3 Step: Vacuum forming of the charger insert with an imprint from the insert

[0203] 1. Hearing device housing, HI housing

[0204] 1A Hearing device, with a left HI housing containing electronic components.

[0205] 1A' Left HI shell

[0206] 1B Hearing device, right HI housing with electronic components

[0207] 1B' Right HI shell

[0208] 1' HI volume

[0209] 2 Inlay

[0210] 2A Left Inlay

[0211] 2A' Imprint of the left insert in the vacuum-formed charger insertion part (bottom view)

[0212] 2B right inlay

[0213] 2B' Imprint of the right insert in the vacuum-formed charger insert (bottom view)

[0214] 3. Volume of the inlay

[0215] 4HI charger coil

[0216] 5 panels

[0217] 6HI ​​electronic devices

[0218] 7HI rechargeable battery

[0219] 8 Ear canal impression

[0220] Virtual representation of an 8' scanned ear canal impression

[0221] 9HI receiver

[0222] 10 3D scanners

[0223] 11. A PC with a keyboard, mouse, and suitable 3D modeling software.

[0224] 12 3D printers for printing HI housings

[0225] 12' 3D printer for printing inlays

[0226] 14 Vacuum-formed sheets of biocompatible materials

[0227] 20. Charger insertion section

[0228] 22. Right charger coil of the charger

[0229] 23. Cable connecting the charger electronics to the charger coil.

[0230] 24. Left charging coil of the charger.

[0231] 25 Charger power supply

[0232] 26. Charger cover

[0233] 27 Charger Electronic Components

[0234] 28 Charger Case

[0235] 30 Hearing Device Charger Unit / HI Charger Unit

[0236] 40. Stand for storing hearing devices

[0237] 50 added to the volume of the inlay

[0238] 51. Volume added to the inlay

Claims

1. A method of manufacturing a holder (40) for supporting an individually shaped chargeable hearing instrument (1A, 1B) in a hearing instrument charger arrangement (30) configured to charge the hearing instrument (1A, 1B) and comprising a first charger coil (22, 24), the method comprising the steps of: - determining a shape of at least a portion of an ear canal of a user from an ear canal impression (8); - designing a virtual representation of a hearing instrument housing (1A', 1B') of the hearing instrument (1A, 1B) in digital form on a computer based on the determined shape of the portion of the ear canal and planning a position for a second charger coil (4) in the hearing instrument (1A, 1B); - shaping a holder (40) based on the virtual representation of the hearing instrument housing (1A', 1B') such that the holder (40) supports the shape of the hearing instrument (1A, 1B) at a predetermined position when located in the hearing instrument charger arrangement (30) and such that the first charger coil (22, 24) is adjacent to the second charger coil (4).

2. The method of claim 1, wherein, The step of shaping the holder (40) comprises the steps of: - shaping an inlay (2A, 2B) such that at least a subset of a surface of the inlay (2A, 2B) is identical to a corresponding surface of the virtual hearing instrument housing; and - forming the holder (40) around the inlay (2A, 2B).

3. The method of claim 2, wherein, The step of shaping the inlay (2A, 2B) comprises rapid prototyping (RPT) of the inlay (2A, 2B) based on the virtual representation of the hearing instrument housing (1A', 1B').

4. The method of claim 2 or 3, wherein, The step of shaping the holder (40) comprises thermoforming a plastic sheet on a portion of the inlay (2A, 2B).

5. The method of claim 4, wherein, The step of thermoforming a plastic sheet on a portion of the inlay (2A, 2B) comprises vacuum forming the plastic sheet on a portion of the inlay (2A, 2B).

6. The method of claim 1, wherein, The step of determining a shape of at least a portion of an ear canal of a user comprises: - inserting a portion of a pliable material into an ear canal of a user thereby forming an ear canal impression (8), and - scanning the ear canal impression (8) and inputting the scanned shape into the computer (11).

7. The method of claim 1, wherein, The holder (40) is formed of a biocompatible material.

8. The method of claim 5, wherein, The material used for the holder (40) is the same material used for the ear canal impression (8).

9. A hearing instrument system (100) comprising: - a hearing instrument (1A, 1B) individually shaped for an ear canal of a user and comprising a second charger coil (4); and - a hearing instrument charger arrangement (30), the hearing instrument charger arrangement (30) comprising: - a charger box (28); - a charger cover (26) arranged to cooperate with the charger box (28); - a charger power supply (25) arranged within the charger box (28); - a first charger coil (22, 24) connected to the charger power supply (25). ​ - charger electronics (27) for controlling charging of the hearing instrument (1A, 1B); and - a cradle (40) configured to receive the hearing instrument (1A, 1B) and located within the charger case (28); wherein the cradle (40) for the hearing instrument (1A, 1B) is shaped such that, when the hearing instrument (1A, 1B) is received in the cradle (40), the cradle (40) supports the shape of the hearing instrument (1A, 1B) and the first charger coil (22, 24) is adjacent to the second charger coil (4); and wherein, when the hearing instrument (1A, 1B) is received in the cradle (40) and the charger cover (26) is closed, the first charger coil (22, 24) is arranged in the charger cover (26) in a way that the first charger coil (22, 24) is in an operating position for providing charging power to the second charger coil (4).

10. The hearing instrument system (100) according to claim 9, wherein The cradle (40) comprises a surface identical to a corresponding surface of the hearing instrument (1A, 1B).

11. The hearing instrument system (100) according to claim 9 or 10, wherein The cradle (40) for the hearing instrument (1A, 1B) is arranged in a charger insert (20).

12. The hearing instrument system (100) according to claim 11, wherein The charger insert (20) is formed by a vacuum formed sheet (14).

13. The hearing instrument system (100) according to claim 11, wherein The charger insert (20) is a flat structure having an upper surface, a lower surface and a peripheral edge, wherein the cradle (40) extends away from the lower surface, and wherein the peripheral edge is configured to cooperate with an edge of the charger case (28).

14. The hearing instrument system (100) according to claim 13, wherein The second charger coil (4) in the hearing instrument (1A, 1B) is formed in an outward facing panel (5) of the hearing instrument (1A, 1B). The charger electronics (27) are arranged in the charger cover (26).

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