Hearing Aid Charger Power Inlet Retention Against Cable Pull-Force
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Solution Overview
Problem
Charger devices for hearing aids face issues with interface breakage due to excessive pull-force when disconnecting cables, particularly when high voltage is mistakenly applied, leading to overheating and melting of solder joints.
Innovation Solution
A charger device with a power inlet having a substrate-mounted connector leg design, featuring bent tips to provide retention force and optional adhesive or solder for secure connection, along with a wireless communication interface for firmware updates and extended antenna functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a power inlet with detachable cable connection is used, then ease of operation is improved, but reliability deteriorates due to interface breakage from pull-force
Solution Approach 1:
The connector legs are pre-bent at an angle before assembly, creating a preliminary mechanical counter-force that opposes the pull-force during cable disconnection. This pre-positioned geometric feature actively resists the harmful extraction force before it can damage the solder joints, resolving the contradiction between easy operation and connection reliability.
2Power
If high voltage is applied to the power inlet, then power supply capability is improved, but harmful factors increase due to overheating and solder joint melting
Solution Approach 1:
Adhesive material is applied to the connector legs before assembly to create a protective bond with the substrate. This pre-established adhesive layer acts as a cushioning protective measure that prevents thermal damage to solder joints during high-voltage operation, allowing high power capability while preventing harmful overheating effects.
3Reliability
If connector legs are secured with adhesive or solder, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The connector legs are pre-bent to a specific angle before final assembly and adhesive application. This preliminary geometric preparation ensures proper alignment and positioning is achieved before the adhesive sets, reducing the stringency of precision requirements during the final assembly process while maintaining reliable mechanical and thermal bonding.
Data Source
AI summary
Disclosed herein are embodiments of a charger device for charging one or more hearing devices. The charging device includes a charger housing having a particular charging interface, a power inlet configured for receiving an external cable, and a substrate configured to hold the power inlet. A number of connector legs can be used for connection, where at least one connector leg includes a bent tip.