Hearing Aid Mold with Embedded Copper Plate
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Solution Overview
Problem
Existing earpiece mold coatings with copper ions fail to effectively prevent biofilm formation and infections due to difficulties in releasing Cu2+ ions and potential skin contact dermatitis, while metallic copper is more effective but not proven in ionic form and can cause adverse skin reactions.
Innovation Solution
A mold for earpiece devices with a metallic piece, preferably copper, placed inside to prevent infections by avoiding direct skin contact, using a copper plate adjusted to the ear canal shape to cover all skin-contact zones, allowing the metallic piece to exert antimicrobial properties without direct skin contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper ions are used in coating, then antimicrobial properties are provided, but the coating fails to effectively prevent biofilm formation due to difficulties in releasing Cu2+ ions
Solution Approach 1:
The patent extracts the copper from ionic form and uses it in metallic form instead. The metallic copper is incorporated into the mold material, eliminating the need for ion release mechanisms while maintaining antimicrobial effectiveness through direct metallic copper action.
Solution Approach 2:
The patent changes the physical state of copper from ionic (Cu2+) to metallic form. This parameter change resolves the issue of ion release difficulty while preserving and potentially enhancing the antimicrobial properties, as metallic copper provides sustained antimicrobial action without requiring dissolution or ionization.
2Reliability
If metallic copper is used, then antimicrobial properties are enhanced, but adverse skin reactions such as contact dermatitis may occur
Solution Approach 1:
The patent applies local quality by concentrating the metallic copper within the internal structure of the mold rather than on the external surface. The copper is dispersed throughout the mold material's interior, providing localized antimicrobial action at the ear canal interface while the outer surface remains free of direct copper exposure to skin.
Solution Approach 2:
The mold material itself acts as an intermediary between the metallic copper and the user's skin. The copper is embedded within the mold material matrix, which serves as a barrier preventing direct skin contact with metallic copper particles while still allowing the copper to exert its antimicrobial effect on microorganisms that contact the mold surface.
3Reliability
If the mold completely seals the ear canal to avoid feedback, then acoustic sealing is achieved, but air circulation is reduced and earwax evacuation is perturbed
Solution Approach 1:
The patent employs self-service by incorporating antimicrobial metallic copper into the mold to automatically prevent infections. The copper continuously exerts its antimicrobial effect on microorganisms that contact the mold, providing ongoing protection without requiring external intervention, thus maintaining acoustic sealing while preventing the infections that would result from reduced air circulation.
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
Significantly reduces microorganism adherence on the mold surface, effectively preventing otitis externa by utilizing the antimicrobial properties of copper without adverse skin reactions, as demonstrated by up to 100% reduction in microorganism adherence in various materials and thickness configurations.
Implementation Method 1
The efficacy of the antimicrobial activity of products based in copper has motivated the development of different studies aimed to know the mechanisms involved in this activity
Implementation Method 2
Some studies suggests that copper in high concentrations can have a toxic effect on bacteria due to its tendency to alter between its different oxidation states, the generation of hydroxyl radicals
Data Source
AI summary
A mold for earpiece devices either to connect an earphone to the ear canal or to act as a cover or plug thereof, allowing to prevent the development of ear diseases comprising: a mold placed in the ear canal and/or ear shell, adjusted to its shape, and whose external border is in direct contact with the user's skin; and a metallic piece with biocide properties, located inside the mold at a distance close to the border thereof; wherein the metallic piece is adjusted from inside the mold (10) to the shape of the external contour thereof, allowing that only the mold is in direct contact with the skin, and encompassing all the zones where contact is produced.