Canal Hearing Device Core and Zinc-Air Battery Design
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Solution Overview
Problem
Conventional extended wear hearing devices configured to be placed entirely within the bony region of the ear canal face challenges in fitting a significant portion of the adult population and providing acceptable sound quality due to dimensional and acoustic issues, as well as limitations in battery design and manufacturing processes.
Innovation Solution
A hearing device core with a battery and acoustic assembly is designed to fit within the bony region, featuring a microphone and receiver positioned closely together, a flexible seal apparatus, and a zinc-air battery with an inwardly contoured anode can and external retention ledge, allowing for improved fit and sound quality, and enhanced manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hearing device is designed to fit entirely within the bony region of the ear canal, then it avoids cartilaginous region motion and contamination, but it is difficult to fit a significant portion of the adult population due to dimensional constraints
Solution Approach 1:
The hearing device is divided into a core component and a separate seal apparatus. The core contains the acoustic assembly and battery, while the seal apparatus is configured to engage the ear canal wall. This segmentation allows the core to be compact for deep insertion while the seal provides adaptability to different ear canal dimensions, enabling the device to fit 75% of the adult population.
Solution Approach 2:
The seal apparatus is configured to engage the ear canal wall in a radial direction, providing support and stability without increasing the longitudinal length of the core. This dimensional approach allows the device to accommodate variations in ear canal diameter while maintaining a compact profile for deep insertion into the bony region.
2Duration of action of stationary object
If miniaturized receivers and microphones are used to fit within the ear canal, then the device can be worn continuously, but output efficiency decreases and power consumption increases
Solution Approach 1:
A zinc-air battery is used instead of conventional battery technologies, providing high energy density and extended operating life. The battery can be worn continuously for one month or more on a single insert, significantly reducing power consumption requirements and enabling the use of miniaturized acoustic components without compromising wear duration.
3Ease of manufacture
If the battery is designed with conventional manufacturing processes, then manufacturing is simpler, but the anode can may crack or deform during crimping, compromising battery integrity
Solution Approach 1:
An inwardly contoured region is formed in the anode can before the crimping process. This preliminary structural preparation creates an external retention ledge that will support the anode can during subsequent crimping operations, preventing cracking or deformation while maintaining manufacturing feasibility.
Solution Approach 2:
The external retention ledge acts as an intermediary structural element between the anode can and the crimping force. It distributes the crimping load and provides support during assembly, preventing direct transmission of damaging forces to the anode can walls while maintaining a relatively simple manufacturing process.
4Length of moving object
If the microphone and receiver are positioned close together to reduce device length, then the device fits better in the ear canal, but acoustic interference may increase
Solution Approach 1:
The acoustic assembly is configured with the microphone and receiver positioned close together along the longitudinal axis, with the microphone lateral to the receiver. This local arrangement minimizes the overall device length for better ear canal fit while the receiver is oriented to face the tympanic membrane, optimizing acoustic quality despite the compact positioning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enables the hearing device to fit within the bony region of 75% of the adult population, providing high fidelity sound and extended wear capability with improved battery performance and manufacturing feasibility.
Implementation Method 1
a zinc-air battery with an inwardly contoured anode can and external retention ledge
Data Source
AI summary
Hearing devices configured to fit within the bony portion of the ear canal and batteries that may be used with same.