Folded Substrate Layout for Compact Hearing Aid Electronics
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Solution Overview
Problem
Existing portable electronic devices, particularly hearing aids designed for the ear canal, face challenges in maximizing space utilization due to limited volume constraints.
Innovation Solution
A portable electronic device comprising a folded substrate with components mounted on both sides and a housing, where the substrate is folded along a line to conform to the device's contours, allowing for efficient use of space and improved component placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a planar substrate is used to carry electronic components, then the device structure is simple and easy to manufacture, but the space utilization is poor and the device volume is larger
Solution Approach 1:
The substrate is folded from a two-dimensional planar form into a three-dimensional structure that conforms to the housing contours. This dimensional transformation allows the substrate to wrap around and utilize vertical and lateral spaces within the housing, effectively increasing the usable area for mounting components without increasing the overall device volume.
Solution Approach 2:
The substrate is folded along curved folding lines to create a contoured structure that follows the curved surfaces of the housing and battery. This curvature allows the substrate to adapt to the rounded geometry of the device components, maximizing space utilization in the limited volume while maintaining manufacturing feasibility through controlled bending zones.
2Area of stationary object
If the substrate area is increased to accommodate more components, then component placement is improved, but the device volume increases
Solution Approach 1:
By folding the substrate into three-dimensional space, the effective mounting area is increased without increasing the device's external dimensions. The substrate wraps around the battery and housing contours, utilizing vertical and lateral spaces that would be wasted with a flat substrate, thereby accommodating more components within the same volume.
Solution Approach 2:
The folded substrate is nested around the battery and housing contours, following the existing geometry of the device components. This nesting approach allows the substrate to conform to and utilize the available space within the housing, maximizing component placement area without requiring additional device volume.
3Volume of stationary object
If the substrate is folded to conform to housing contours, then space utilization is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The substrate incorporates curved folding lines that match the housing contours. By designing these folding lines with appropriate radii and curvature, the substrate can conform to the rounded geometry of the housing and battery while maintaining manufacturability through standardized bending processes.
Solution Approach 2:
The substrate design incorporates specific folding parameters such as folding line positions, bending radii, and fold angles that are optimized to balance space utilization with manufacturing precision requirements. These parameters are carefully selected to ensure that the folded substrate conforms to housing contours while remaining within achievable manufacturing tolerances.
Data Source
AI summary
Disclosed herein are embodiments of a portable electric device. The portable electronic device can include a substrate configured to retain one or more electrical components. The substrate can be configured include one or more arms and/or surfaces in particular configurations. The portable electronic device can be used to deliver audio to a user.