Custom Hearing Aid Charger Holder for Precise Coil Alignment
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Solution Overview
Problem
Existing hearing instrument chargers face alignment issues between charger coils, leading to interrupted or slowed charging processes, and there is a need for a cost-effective, fast, and simple method to manufacture custom holders that meet biocompatibility and medical grade requirements.
Innovation Solution
A method involving determining the shape of a user's ear canal, designing a virtual representation of a hearing instrument shell, and shaping a holder to ensure precise alignment of charger coils, using rapid prototyping and thermoforming techniques with biocompatible materials to create a custom holder for the hearing instrument charger device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a generic holder is used in the charging device, then the device complexity is reduced and manufacturing cost is lowered, but the alignment between charger coils deteriorates leading to interrupted or slowed charging
Solution Approach 1:
The holder is pre-shaped with integrated positioning features that guide the hearing instrument into the correct position before charging begins. The pre-formed recesses and alignment structures ensure proper coil alignment is achieved automatically upon insertion, eliminating the need for complex adjustment mechanisms while maintaining reliable charging.
2Manufacturing precision
If traditional manufacturing methods are used for custom holders, then manufacturing precision can be achieved, but the productivity is reduced and manufacturing cost increases
Solution Approach 1:
The manufacturing process utilizes adjustable molding parameters and material properties to achieve precise holder shapes through a single-step forming process. By optimizing parameters such as temperature, pressure, and material viscosity during injection molding or thermoforming, the method achieves high manufacturing precision while maintaining fast production speeds and low costs.
3Ease of manufacture
If standard materials are used for the holder, then the ease of manufacture is improved and cost is reduced, but the biocompatibility and medical grade requirements are not met
Solution Approach 1:
The holder is manufactured from biocompatible materials such as medical-grade silicone rubber or thermoplastic elastomers that combine the ease of molding with certified biocompatibility. These composite materials integrate multiple properties including flexibility, chemical inertness, and skin safety within a single material system, eliminating the need for separate components while meeting medical grade requirements.
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 ensures stable and efficient wireless charging by minimizing the distance between charger coils and allows for the production of cost-effective, biocompatible holders that align hearing instruments correctly within the charger device.
Implementation Method 1
The charging device and the hearing aid may each comprise a charger coil, such that the hearing aid may be charged 'wirelessly'
Implementation Method 2
forming a holder around the inlay
Data Source
AI summary
A hearing instrument charger device for charging an individually shaped hearing instrument, includes: a charger casing; a charger power supply within the charger casing; a first charger coil connected to the charger power supply; charger electronics for controlling charging of the hearing instrument; and a holder configured for receiving the hearing instrument, the holder located within the charger casing; wherein the holder for the hearing instrument has a shape that is specific for the individually shaped hearing instrument, such that when the individually shaped hearing instrument is received in the holder, a second charger coil of the individually shaped hearing instrument is in an operative position for receiving charging power from the first charger coil of the hearing instrument charger device.