Ear Insert Design Using Sub-Dermal Anatomical Scanning
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Solution Overview
Problem
Traditional methods for manufacturing custom earplugs lack precision in accounting for sub-dermal anatomical features and the precise location of the bony region of the ear, leading to discomfort and suboptimal performance due to the reliance on physical ear impressions that do not provide information beyond the ear canal's surface.
Innovation Solution
The use of advanced scanning technologies such as CT, CBCT, OCT, and MR scanners to acquire user-specific anatomical information, which is then used to design and manufacture ear insert devices that accommodate sub-dermal features and precisely locate the bony region, enabling the creation of custom-fit earplugs with improved comfort and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical ear impressions are used to manufacture custom earplugs, then the manufacturing process is simple and direct, but the precision of anatomical information is insufficient because sub-dermal features cannot be captured
Solution Approach 1:
The patent creates a digital copy (3D digital model) of the ear canal anatomy through scanning technologies instead of using physical impressions. This digital replica preserves all anatomical details including sub-dermal features, allowing precise manufacturing without the limitations of physical molds.
Solution Approach 2:
The patent replaces the mechanical physical impression-taking process with optical/electromagnetic scanning technologies (OCT, CT, MR scanners). This substitution enables non-contact acquisition of high-resolution anatomical data including sub-dermal structures that physical impressions cannot capture.
2Ease of operation
If conservative design is used to stay clear of the second bend, then comfort is improved, but performance is reduced because the ear insert device may not be long enough for acceptable performance
Solution Approach 1:
The patent performs preliminary identification of the second bend location and sub-dermal anatomical features through 3D scanning and digital modeling before manufacturing the ear insert device. This advance knowledge allows optimal positioning that balances comfort and performance by precisely placing the device tip relative to the second bend based on individual anatomy.
Solution Approach 2:
The patent applies different design considerations to different regions of the ear insert device based on local anatomical characteristics. By identifying sub-dermal features like the second bend location, the device can be designed with specific clearances or interferences in localized areas to optimize both comfort and performance simultaneously.
3Reliability
If the ear insert device is made longer to reach the bony part, then performance is improved, but comfort deteriorates because the device becomes too large near the bone
Solution Approach 1:
The patent performs preliminary identification of the second bend location and sub-dermal anatomical features through 3D scanning and digital modeling before manufacturing the ear insert device. This advance knowledge allows optimal positioning that balances comfort and performance by precisely placing the device tip relative to the second bend based on individual anatomy.
Solution Approach 2:
The patent uses individual anatomical measurements from scanning to customize parameters of the ear insert device such as length, diameter, and curvature. By adjusting these parameters based on the user's specific anatomy (ear canal length, second bend location, tissue thickness), the device achieves both high performance and comfort without being too long or too large.
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
This approach allows for the precise design and manufacturing of ear insert devices that account for sub-dermal features and the bony region, enhancing comfort and performance by providing clearances and interferences tailored to individual anatomical characteristics, resulting in more effective hearing protection and enhancement.
Implementation Method 1
The anatomical information may be derived from imaging data acquired using computed tomography (CT), volume computed tomography (VCT), cone beam computed tomography (CBCT)
Implementation Method 2
The anatomical information may be derived from imaging data acquired using computed tomography (CT), volume computed tomography (VCT), cone beam computed tomography (CBCT), positron emission tomography (PET), magnetic resonance (MR), ultrasound, optical scanning, or a laser scanner
Implementation Method 3
The anatomical information may be derived from imaging data acquired using computed tomography (CT), volume computed tomography (VCT), cone beam computed tomography (CBCT), positron emission tomography (PET), magnetic resonance (MR)
Data Source
AI summary
A method for designing an ear insert device using anatomical information relating to the ear. A user record is that includes anatomical information relating to an ear of a user is received. The anatomical information comprises at least one sub-dermal feature of an ear canal. The user record is processed to obtain an ear insert device design record. The ear insert device design record comprises a three dimensional representation of a bounding surface shape having surface boundaries that substantially conform to surface boundaries of the ear canal and the at least one sub-dermal feature of the ear canal. An ear insert device may be produced using the ear insert design record.