Hearing aid worn on the ear with electrical connector

Abstract

An ear-worn hearing aid connector comprising: an electrical connector receptacle connectable to a speaker unit or a base unit, the electrical connector receptacle comprising a plurality of electrical contacts disposed at least partially within a metal receptacle including a connector plug cavity, the electrical connector receptacle comprising a retention feature integrally formed on a portion of the metal receptacle; and an electrical connector plug connectable to the other part of the speaker unit or the base unit, the electrical connector plug comprising a plug body holding a plurality of electrical contacts, the plug body comprising a complementary retention feature, wherein electrical contacts of the electrical connector plug are electrically connected to corresponding electrical contacts of the electrical connector receptacle, and the retention feature engages the complementary retention feature when the plug body is inserted into the connector plug cavity.

Description

AREA OF REVELATION

[0001] The present disclosure relates generally to hearing devices, and more particularly to body-worn hearing devices including an electrical connector, electrical connectors for such hearing devices, and hearing device components including an electrical connector or a portion thereof. BACKGROUND

[0002] Some over-the-ear hearing aids include a speaker unit including a cable assembly connectable to a microphone device through an electrical connector. Such a hearing aid includes a receiver-in-the-canal (RIC) unit configured to be inserted at least partially into the user's ear canal and a behind-the-ear (BTE) unit configured to be worn at the back of the user's ear. The RIC unit includes a balanced armature receiver (also referred to herein as a "receiver") for converting electrical audio signals into sound. The BTE unit includes a housing containing a battery, a microphone, and electrical circuitry for converting sensed ambient sound into amplified electrical audio signals. The electrical connector includes an electrical connector plug coupled to the electrical cable assembly extending from the RIC unit.The connector plug connects to a connector receptacle on the BTE unit. In this configuration, electrical audio signals can be transmitted from the BTE unit to the RIC unit. The electrical connector must be relatively small and robust, accommodate an ever-increasing number of electrical contacts, prevent contaminants from entering, and reliably attach the RIC unit to the BTE unit. However, existing electrical connectors for hearing aids are relatively large and expensive, and include plastic parts with a short lifespan. Therefore, there is a continued need for improvements in electrical connectors for body-worn hearing aids and combinations thereof. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The objects, features, and advantages of the present disclosure will become more apparent from the following detailed description and the appended claims, taken in conjunction with the accompanying drawings. The description and drawings illustrate representative embodiments and suggest others and are not to be construed as limiting the scope of the disclosure. Fig. 1 is a representative hearing device including an electrical connector. Fig. Figure 2 is a disassembled perspective view of a representative hearing aid connector. Fig. 3 is a disassembled sectional view of the hearing aid connector of Fig. 2. Fig. 4 is an assembled sectional view of the hearing aid connector of Fig. 3.

[0004] Those skilled in the art will recognize that the drawings are illustrated for simplicity and clarity and therefore may not be to scale and may not include well-known features, that the order of operations or steps may vary from that described herein, that the order of operations or steps may be performed concurrently unless otherwise indicated, and that the terms and expressions used herein have a meaning understood by those skilled in the art unless a different meaning is expressly assigned herein. DETAILED DESCRIPTION

[0005] The present disclosure relates generally to hearing aids, and more particularly to body-worn hearing aids comprising an electrical connector, electrical connectors for such hearing aids, and hearing aid components comprising an electrical connector or a portion thereof. In one application, the electrical connector provides an interconnection between a speaker unit and a base unit of an ear-worn hearing aid. One such application is connecting a receiver-in-the-canal (RIC) component configured for insertion at least partially into the user's ear canal to a behind-the-ear (BTE) unit configured for wear at a rear of the user's ear. The electrical connectors described herein may also be connected to other hearing aids, including, but not limited to, earplugs and studio monitors.Representative examples are described here.

[0006] Generally, a body-worn hearing device includes a speaker unit and a base unit connected by an electrical connector. The connector includes a connector receptacle having a plurality of electrical contacts disposed at least partially within a metal receptacle defining a connector plug cavity. A connector plug includes a plug body that retains a plurality of electrical contacts. Electrical contacts of the electrical connector plug are electrically connected to corresponding electrical contacts of the electrical connector receptacle when the plug body is inserted into the connector plug cavity. A retention feature can securely attach the connector receptacle to the connector plug.A seal between the connector cavity and the connector body forms a dirt barrier and can securely attach the connector receptacle to the connector plug in addition to or instead of the retention feature. Other implementations will be apparent from the representative embodiments described herein.

[0007] Fig. 1 is a representative ear-worn hearing aid 100 generally comprising a speaker unit 110 connected to a base unit 120 via an electrical connector. An electrical cable assembly 130 extending from the speaker unit includes a first electrical connector portion connectable to a second electrical connector portion integrated into the base unit, as further described herein. The representative speaker unit is configured to be at least partially inserted into the user's ear canal. Thus, the speaker unit may be considered an ear-worn unit. Such a speaker unit, alone or in combination with the cable assembly, may be referred to as a receiver-in-canal (RIC) unit or component.The representative base unit is configured to be worn on the back of the user's ear and may be referred to as a behind-the-ear (BTE) unit or component. More generally, the speaker unit may be any component worn on, in, or over the ear, and the base unit may be any component worn on or around any portion of the user's body, such as the ear, neck, arm, waist, leg, or other body part.

[0008] In some hearing aids, the speaker unit is detachably connected to the base unit via the electrical connector. A detachable electrical connector allows for the interchangeable use of different combinations of speaker units and cable arrangements with a common base unit. Thus, the combination of speaker units with different power levels and differently dimensioned cable arrangements can accommodate variations in the user's anatomy and the amplification requirements when connected to the base unit. In other implementations, the speaker unit is permanently connected to the base unit via the electrical cable arrangement.

[0009] The speaker unit generally includes a speaker or receiver that generates an acoustic signal in response to an electrical audio signal provided by the base unit. The speaker unit may also include other electrical or mechanical parts of the hearing device. Fig. 1, the representative speaker unit 110 includes a receiver 112 having a sound port through a nozzle 113 coupled to an elastic ear cup 114 configured to be at least partially inserted into a user's ear canal. A receiver generally includes a diaphragm separating the interior of a receiver housing into a rear volume and a front volume acoustically connected to a sound port. The receiver also includes a motor located within the receiver housing and including an armature movably disposed between permanent magnets of a yoke and connected to the diaphragm. Applying an electrical audio signal to the motor actuates the diaphragm to produce sound. Other speaker units may include a plurality of receivers or a dynamic speaker, or a combination of one or more dynamic speakers and receivers.

[0010] In Fig. 1, the receiver housing forms an exterior of the speaker unit 110. The nozzle 113 is shown integrated directly into the receiver housing 112. For example, the nozzle may be mounted over the sound port at one end of the receiver housing. In this configuration, the speaker unit has no structure that would encapsulate the exterior of the receiver housing, thereby reducing the overall size of the speaker unit. The motor may be directly coupled to an interior of the receiver housing without any intervening structure, further reducing the overall size of the speaker unit. In other implementations, the receiver or speaker may be partially or fully encapsulated in an outer housing (not shown), and the nozzle may be formed integrally with the outer housing and acoustically coupled to the sound port of the receiver.The speaker unit may also include one or more microphones, vibration sensors, and physiological sensors, among other circuits and sensors attached to the receiver housing or otherwise integrated into the speaker unit housing, depending on the shape and application.

[0011] In Fig. 1, the representative BTE base unit 120 generally includes one or more microphones, an audio signal processor and other circuitry, and a battery. In this configuration, the base unit may process acoustic audio signals captured by the one or more microphones and deliver electrical audio signals to the speaker unit via the electrical cable assembly. More generally, the base unit may include other electrical or mechanical parts of a hearing aid instead of or in addition to one or more microphones, a processor and circuitry, and a battery. Such other parts may include, but are not limited to, a wireless transceiver, as well as other circuitry and sensors.

[0012] In the Fig. 2-4, an ear-worn hearing aid connector 200 comprises an electrical connector receptacle 210 which is connected to a speaker unit or a base unit, for example the RIC unit 110 or the base unit 120 of Fig. 1. The electrical connector receptacle generally comprises a plurality of electrical contacts disposed at least partially within a metal receptacle 240 having a connector plug cavity 242, which is best Fig. 3. The metal may be a conductive material to provide electromagnetic shielding and may be plated for corrosion resistance and wettability and for assembly by molten solder. Optionally, the metal may also be a hypoallergenic metal such as stainless steel or be coated with a hypoallergenic coating. Fig. 3, a first contact portion 222 of each electrical contact extends into the socket cavity 242, and a second contact portion 224 of each electrical contact is accessible from an exterior side of the metal receptacle. The first contact portion 222 of each electrical contact may include a projection 226 for engaging a complementary contact of a plug electrical connector, described further below.

[0013] The electrical contacts of the electrical connector receptacle may be electrically connected to electrical hearing aid parts of the base unit or the speaker unit. For example, if the electrical connector receptacle is integrated with a BTE unit, at least some of the electrical contacts may be connected to the audio processor, among other circuits or electrical parts. Alternatively, if the electrical connector receptacle is integrated with an electrical cable assembly connected to a RIC unit, at least some of the electrical contacts may be electrically connected to the receiver, the speaker, or other electrical parts of the RIC unit via conductors of the cable assembly. In either case, such electrical connections may be made directly via the second contact portions 224 or via a circuit board (not shown) to which the second contact portions 224 are soldered.

[0014] In the Fig. 2-4, the ear-worn hearing aid connector component 200 also includes an electrical connector plug 250 connectable to the other of the speaker unit and the base unit. The electrical connector plug may include a contact carrier 260 projecting from a connector body 262 comprising a plastic or other non-conductive material. The connector plug supports a plurality of electrical contacts 270. The representative contact carrier 260 has a rectangular cross-section, and the plurality of electrical contacts are spaced in parallel arrays on opposite sides of the contact carrier. In other implementations, the contact carrier may have a cylindrical or other cross-section upon which portions of the electrical contacts may be disposed.The electrical contacts can be held by the connector body and the contact carrier by press-fitting, overmolding or another assembly method.

[0015] When the electrical connector plug is integrated with an electrical cable assembly connected, for example, to a RIC unit, at least some of the electrical contacts are electrically connected to the receiver, speaker, or other electrical parts of the RIC unit via conductors of the cable assembly. Alternatively, when the electrical connector plug is integrated with a BTE unit, at least some of the electrical contacts are connected to the audio processor and other circuits or electrical parts of the BTE unit. Such electrical connections may be made directly to the electrical contacts of the electrical connector receptacle or to a circuit board (not shown) to which portions of the electrical contacts are soldered. Such a circuit board may be embedded in a base portion 268 of the electrical connector plug.

[0016] In Fig. 4, electrical contacts 270 of the electrical connector plug are electrically connected to electrical contacts 220 of the electrical connector receptacle when the connector body 262 of the connector plug is disposed within the connector cavity 242 of the connector plug receptacle. In the representative implementation, the contact projections 226 of the connector receptacle engage contacts 270 of the connector plug. In other implementations, the electrical contacts of the connector receptacle and the connector plug may have different shapes or configurations. In this configuration, the BTE unit may transmit electrical audio signals to the RIC unit. More generally, in some implementations, electrical signals (e.g., control, data, etc.) may be transmitted between the base unit and the speaker unit.

[0017] In some implementations, the electrical connector receptacle also includes a retention feature formed integrally with the metal connector receptacle, and the connector body includes a complementary retention feature, or vice versa. The resilient nature of the metal connector receptacle or the plastic connector plug allows for temporary deformation of one or both during assembly of the connector plug and connector receptacle. In this configuration, the engaged retention features securely fasten the connector plug and connector receptacle.

[0018] The retention feature may be implemented as a detent integral with the metal connector receptacle, and the complementary feature may be a recess into which the detent fits during assembly of the connector plug and the connector receptacle. In the representative implementation of the Fig. 2-4, the retention feature of the connector receptacle 210 includes one or more discrete protrusions 244 extending from a wall portion of the metal receptacle into the connector cavity. The complementary retention feature of the connector plug 250 includes a corresponding number of recesses 264 formed in the connector body 262. The metal receptacle and retention feature can form a single, deep-drawn article that is cost-effective and durable. Alternatively, the retention feature of the connector receptacle 210 can be a single circumferential protrusion disposed around the connector receptacle, and the complementary retention feature can be a circumferential recess disposed around the connector body.

[0019] In the Fig. 3 and Fig. 4, the electrical connector receptacle includes a non-conductive socket 230 disposed at least partially within the metal plug receptacle 240. The non-conductive socket flexibly retains the plurality of electrical contacts at least partially within the plug cavity of the connector receptacle. The representative non-conductive socket 230 includes a recess 232 forming a portion of the connector plug cavity. The representative recess 232 has a rectangular cross-sectional shape. Fig. 2, the plurality of electrical contacts 220 of the electrical connector receptacle comprise a first contact arrangement disposed on a first side of the recess and a second contact arrangement disposed on a second side of the recess. Each electrical contact of the first contact arrangement is disposed opposite a corresponding electrical contact of the second contact arrangement. In Fig. 4, the contact carrier 260 of the plug body and the contacts 270 are at least partially disposed within the recess 232 of the non-conductive receptacle when the plug body is inserted into the connector plug cavity. In this configuration, each electrical contact 270 of the connector plug is electrically connected to a corresponding electrical contact 220 of the connector receptacle when the plug body is inserted into the plug cavity. In other implementations, the recess of the non-conductive receptacle may have a cylindrical or other cross-sectional shape at which the electrical contacts may be disposed to contact electrical contacts of a plug body having a contact carrier with a complementary shape.

[0020] In one implementation, there is a gap between the socket 230 and the contact portion 222 to allow flexion of at least the portion of the contact from which the projection 226 extends upon engagement with electrical contacts 270 of the connector plug. In other implementations, the non-conductive socket is resilient to allow flexion of the electrical contacts. The non-conductive socket 230 may be press-fitted into the metal connector receptacle 240. Alternatively, the socket may be retained in the metal connector receptacle by crimping or gluing, or by other known or future fastening mechanisms.

[0021] In some implementations, the electrical connector receptacle optionally includes a gasket configured to form a seal between the electrical connector plug and the electrical connector receptacle when the connector body is inserted into the connector cavity. In the representative implementation of the Fig. 3-4, a seal in the form of an elastic ring 266 is arranged in a recess around the plug body 262. In Fig. 1, the plug body has a rectangular shape, but in other embodiments, the plug body may have a round or oval shape. The elastic ring may be an O-ring with a circular cross-section, a D-ring with a D-shaped cross-section, or a ring with another cross-sectional shape. Fig.4, the resilient ring is compressed between the connector body 262 and an inner surface of the connector cavity 242 to form a moisture and dirt barrier between the connector receptacle and the connector plug. The representative seal 266 is located closer to the opening of the connector cavity than the detent 224. In some implementations, the seal may provide sufficient friction to retain the connector plug in the connector receptacle without the retention features described herein. The metal connector receptacle may also include a recess (not shown) in the connector cavity to partially receive the seal. Such a recess on the metal connector receptacle may enhance both the sealing and retention functions of the seal. Thus, the seal may be used alone or in combination with the retention feature to securely attach the connector plug to the connector receptacle.

[0022] While the disclosure and what is presently believed to be the best mode thereof have been described in a manner conferring possession and enabling one skilled in the art to make and use the same, it is understood and appreciated that there are many equivalents to the representative embodiments described herein and that countless modifications and variations may be made therein without departing from the scope and spirit of the invention, which is not limited by the described embodiments but by the appended claims and their equivalents.

Claims

[1] An ear-worn hearing aid connector comprising: an electrical connector receptacle connectable to a speaker unit or a base unit, the electrical connector receptacle comprising a plurality of electrical contacts disposed at least partially within a metal receptacle including a connector plug cavity, the electrical connector receptacle comprising a retention feature integrally formed on a portion of the metal receptacle; and an electrical connector plug connectable to the other part of the speaker unit or the base unit, the electrical connector plug comprising a plug body holding a plurality of electrical contacts, the plug body comprising a complementary retention feature, wherein electrical contacts of the electrical connector plug are electrically connected to corresponding electrical contacts of the electrical connector receptacle, and the retention feature engages the complementary retention feature when the plug body is inserted into the connector plug cavity. [2] The hearing aid connector of claim 1, wherein the retention feature is a detent projecting into the cavity of the connector plug and the complementary retention feature is a recess in the plug body. [3] The hearing aid connector of claim 2, wherein the metal receptacle and the locking device form a unitary deep-drawn article. [4] The hearing aid connector of claim 1, wherein the electrical connector receptacle further comprises a non-conductive receptacle flexibly retaining the plurality of electrical contacts in the connector plug cavity. [5] The hearing aid connector of claim 4, wherein the complementary retention feature is a recess in the connector body and the retention feature is a detent projecting into the connector plug cavity, the detent and the metal plug receptacle forming a unitary deep-drawn article. [6] The hearing aid connector according to claim 5 further comprises a seal disposed around the plug body and located between the connector plug cavity and the plug body when the electrical connector plug is connected to the electrical connector receptacle. [7] Hearing aid connector according to claim 6, wherein the non-conductive socket includes a recess forming a portion of the connector plug cavity, wherein the plurality of electrical contacts are disposed on a portion of the non-conductive socket defining the connector plug cavity, wherein the electrical connector plug comprises a contact carrier which protrudes from the plug body and holds the plurality of electrical contacts of the electrical connector plug, wherein electrical contacts of the electrical connector plug are electrically connected to corresponding electrical contacts of the electrical connector socket when the contact carrier protruding from the plug body is inserted into the recess of the non-conductive socket. [8] Hearing aid connector according to claim 1 in combination with a base unit comprising a housing containing a microphone connected to an electronic circuit, wherein the electrical connector receptacle is integrated into the housing of the base unit and the electrical contacts of the electrical connector receptacle are electrically connected to the electronic circuit. [9] Hearing aid connector according to claim 8 in combination with a loudspeaker unit comprising a housing connected to an electrical cable assembly, wherein the housing of the loudspeaker unit contains a sound-generating transducer and the electrical connector plug is connected to the electrical cable assembly, wherein the sound-generating transducer is electrically connected to electrical contacts of the electrical connector plug via conductors of the electrical cable assembly. [10] A connector for an ear-worn hearing aid, comprising: an electrical connector receptacle connectable to a speaker unit or a base unit, the electrical connector receptacle comprising a plurality of electrical contacts flexibly retained by a non-conductive socket disposed at least partially within a metal plug receptacle comprising a connector plug cavity; an electrical connector plug connectable to the other of the speaker unit or the base unit, the electrical connector plug comprising a plug body holding a plurality of electrical contacts; and a seal arranged around the plug body, wherein electrical contacts of the electrical connector plug are electrically connected to corresponding electrical contacts of the electrical connector receptacle, and the seal forms a seal between the plug body and the connector plug cavity when the plug body is inserted into the connector plug cavity. [11] Hearing device connector according to claim 10, wherein the non-conductive socket includes a recess forming a portion of the connector plug cavity, wherein the plurality of electrical contacts are disposed on a portion of the non-conductive socket defining the connector plug cavity, wherein the electrical connector plug comprises a contact carrier projecting from a plug body and holding the plurality of electrical contacts, wherein electrical contacts of the electrical connector plug are electrically connected to corresponding electrical contacts of the electrical connector receptacle when the contact carrier is inserted into the recess of the non-conductive socket. [12] A hearing aid connector according to claim 11 in combination with a base unit comprising a housing containing a microphone connected to an electronic circuit, wherein the electrical connector receptacle is integrated with the housing of the base unit and electrical contacts of the electrical connector receptacle are electrically connected to the electronic circuit. [13] The hearing aid connector of claim 12, wherein the electrical connector receptacle further comprises a detent projecting from a wall portion of the metal connector socket and into the connector plug cavity, and the electrical connector plug further comprises a recess into which the detent extends when the plug body is inserted into the connector plug cavity, the detent and the recess cooperating to securely attach the electrical connector plug to the electrical connector receptacle. [14] The hearing aid connector of claim 13, wherein the metal receptacle and the locking means form a single, deep-drawn article. [15] Hearing aid connector according to claim 12 in combination with a loudspeaker unit comprising a housing connected to an electrical cable assembly, the housing of the loudspeaker unit containing a sound-generating transducer, the electrical connector plug being connected to an end portion of the electrical cable assembly, the sound-generating transducer being electrically connected to electrical contacts of the electrical connector plug via conductors of the electrical cable assembly. [16] Hearing aid component comprising: a body-worn unit comprising a housing containing electrical or mechanical hearing aid parts; and an electrical connector receptacle connected to the body-worn unit and comprising: a metal receptacle comprising a plug cavity near an opening of the metal receptacle and a detent projecting from a wall portion of the metal receptacle into the plug cavity; and a plurality of electrical contacts, wherein a first contact portion of each electrical contact extends into the plug cavity and a second contact portion of each electrical contact is accessible from an exterior of the metal plug receptacle. [17] Hearing device component according to claim 16, wherein the metal plug socket and the locking device form a one-piece deep-drawn article. [18] The hearing aid component of claim 17, further comprising a non-conductive socket disposed within the metal plug socket, the plurality of electrical contacts being flexibly retained by the non-conductive socket, the non-conductive socket including a recess forming a portion of the plug cavity, the plurality of electrical contacts being retained by the non-conductive socket adjacent the recess. [19] The hearing aid component of claim 18, wherein the body-worn unit is a behind-the-ear (BTE) unit, the hearing aid parts comprising a microphone connected to an electronic circuit, the electrical connector receptacle being integrated with the housing, and electrical contacts of the electrical connector receptacle being electrically connected to the electronic circuit. [20] The hearing aid component of claim 18, wherein the body-worn unit is a receiver-in-canal (RIC) unit further comprising an electrical cable assembly extending from the housing, the hearing aid parts comprising a sound-generating transducer, the electrical connector receptacle being connected to the electrical cable assembly, the sound-generating transducer and electrical contacts of the electrical connector receptacle being electrically connected to conductors of the electrical cable assembly.

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