Additive Manufacturing Hearing Aid Antenna Integration
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Solution Overview
Problem
Existing methods for producing hearing aid devices face challenges in precisely positioning components, such as antennas, within limited earshell space, leading to suboptimal alignment and mounting difficulties, especially in in-the-ear hearing aids.
Innovation Solution
A method utilizing additive manufacturing to create a partially completed element with a pre-determined receptacle for the component, allowing for precise positioning and integration of the component during the manufacturing process, eliminating the need for additional positioning steps and ensuring secure fixation in three spatial directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fastening element (ring) is introduced by gluing into a finished ear shell to position the antenna, then the antenna position can be determined, but it is difficult to precisely position the ring in the ear cup and there is not enough space in the ear shell
Solution Approach 1:
The socket for the antenna is merged with the ear shell body to form an integral structure. The socket is produced as an integral part of the body using additive manufacturing, eliminating the need for separate fastening elements like rings that require gluing and precise positioning. This integration reduces assembly complexity while maintaining precise antenna positioning capability.
Solution Approach 2:
The socket is pre-formed as part of the ear shell body during the additive manufacturing process before the antenna is inserted. This preliminary creation of the mounting structure eliminates the need for subsequent gluing operations and positioning adjustments, directly achieving precise antenna placement without additional assembly steps.
2Manufacturing precision
If a prefabricated frame is positioned in a rapid prototyping device and a housing shell is manufactured around it, then the component position can be determined, but the process requires additional steps and time
Solution Approach 1:
The socket and ear shell body are merged into a single integral structure manufactured in one additive manufacturing process. This eliminates the need for separate frame positioning and shell manufacturing steps, reducing production time while maintaining precise component positioning through the integrated design.
Solution Approach 2:
The socket structure is preliminarily formed as part of the ear shell during the additive manufacturing process itself, rather than requiring a separate frame to be positioned and then having the shell manufactured around it. This preliminary integration of the mounting structure into the manufacturing process eliminates additional positioning and assembly steps.
3Ease of manufacture
If the antenna is inserted into the housing shell together with the earpiece during assembly, then the mounting process is simplified, but the small size makes mounting difficult and requires attention to mountability which leads to suboptimal positioning
Solution Approach 1:
The socket is merged with the ear shell body as an integral structure, providing a dedicated mounting location that guides the antenna into the correct position. This integration maintains ease of manufacture by incorporating the mounting feature into the shell production while ensuring optimal antenna positioning through the precisely formed socket geometry.
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 enables precise alignment and secure fixation of components, optimizes space usage, and reduces production complexity, ensuring accurate positioning of antennas in binaural hearing aids and minimizing material and space requirements.
Implementation Method 1
fabricating a portion of the element using an additive manufacturing process, the portion of the element including a portion of the body and a portion of the socket
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for manufacturing an element for a hearing aid, as well as to a corresponding element. The element comprises a body and a component (6). In one step of the method, a relative position of the component on the element is predetermined. Furthermore, a shape and position of a receptacle for the component in the predetermined relative position are predetermined as an integral part of the body. A portion of the body and the receptacle is manufactured using an additive manufacturing process, such that the component can be positioned in the predetermined relative position within the portion of the receptacle. The component is positioned within the portion of the receptacle. The body and/or the receptacle is completed using the additive manufacturing process.