Ear-Wearable Tunnel Contacts for Reliable Cable Connection
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Solution Overview
Problem
In-ear wearable devices face challenges in attaching power and communication cables due to anatomical variability, leading to issues with debris ingress, water intrusion, and mechanical fatigue in existing attachment points.
Innovation Solution
An ear-wearable device with a shell featuring an open-ended tunnel containing immovable contact pins that make electrical contact with a cable plug, eliminating the need for separate cable attachment points and reducing exposure to debris, while an elastomeric spring pad ensures secure connection without moving parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate cable attachment points are provided in in-ear wearable devices, then cable connection functionality is enabled, but device size increases and anatomical variability causes reliability issues
Solution Approach 1:
The patent merges the cable attachment function with the existing vent tunnel structure. The tunnel, originally designed for acoustic venting, is repurposed to also serve as the cable insertion pathway. This eliminates the need for separate attachment points while maintaining cable connection functionality, thereby improving reliability without increasing device size.
Solution Approach 2:
The vent tunnel is designed to serve multiple functions: acoustic venting and cable insertion. By making the tunnel multi-functional, the patent eliminates the need for dedicated cable attachment structures, reducing device complexity and improving adaptability to anatomical variability while maintaining reliable cable connection.
2Adaptability or versatility
If separate cable attachment points are provided, then cable connection is enabled, but device size increases
Solution Approach 1:
The cable attachment function is merged with the vent tunnel structure. The tunnel serves dual purposes as both an acoustic vent and a cable insertion channel, eliminating the need for additional attachment points and thereby reducing device volume.
Solution Approach 2:
The vent tunnel is designed to perform multiple functions including acoustic venting and cable insertion. This multi-functionality eliminates the need for separate cable attachment structures, reducing overall device size while maintaining cable connection capability.
3Ease of operation
If cable attachment points are exposed on the device surface, then cable insertion is facilitated, but debris accumulation and water intrusion occur
Solution Approach 1:
The cable insertion pathway is nested within the existing vent tunnel structure rather than being exposed on the surface. The tunnel acts as a protective conduit that guides the cable into the device while shielding the internal components from debris and water, thus maintaining ease of insertion while reducing harmful factor exposure.
Solution Approach 2:
The vent tunnel serves as an intermediary structure between the external environment and internal components. It facilitates cable insertion while simultaneously protecting internal electronics from debris and water intrusion, acting as a mediator that enables functionality while reducing harmful effects.
4Reliability
If moving parts are used in cable attachment mechanisms, then secure connection is achieved, but mechanical fatigue develops
Solution Approach 1:
The patent removes moving parts from the cable attachment mechanism. Instead of using springs, clips, or other mechanical fastening elements, the design relies on the fixed tunnel structure to guide and secure the cable plug through friction and geometric constraints, eliminating mechanical fatigue while maintaining connection security.
Solution Approach 2:
The mechanical fastening system is replaced with a passive geometric constraint system. The tunnel's shape and size are designed to securely hold the cable plug through friction and interference fit, replacing active mechanical fastening mechanisms with a static structural solution that eliminates mechanical fatigue.
Data Source
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AI summary
An ear-wearable device (100) includes a shell (102) shaped for wearing in a user's ear. The shell (102) comprises a tunnel wall (116) shaped to define a tunnel (108) that passes through the ear- wearable device (100). The tunnel wall (116) defines one or more contact pin apertures (208, 212) through which distal ends (210, 214) of two or more contact pins (202, 204) pass. One or more electrical components (216) are encased within the shell (102). The contact pins (202, 204) are conductors from the one or more electrical components (216). The distal ends (210, 214) of the contact pins (202, 204) are positioned to make electrical contact with terminals (218, 220) of a cable plug (200) that is removably inserted into the tunnel (108).