Hearing Aid Packaging with Inert Atmosphere and ESD Protection
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Solution Overview
Problem
Zinc-air battery-powered hearing devices require a controlled environment for shipping and storage to prevent degradation from humidity, oxygen, and mechanical shock, while maintaining functionality and preserving sensitive components.
Innovation Solution
A packaging system with an air-impermeable container, conductive materials for electrostatic discharge protection, and a controlled atmosphere with specific oxygen and humidity levels to maintain battery functionality and protect components during shipping and storage, including an irreversible thermal indicator for temperature exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an air-impermeable packaging is used to protect the hearing device from humidity and carbon dioxide, then the protection from environmental degradation is improved, but the battery functionality deteriorates due to lack of oxygen
Solution Approach 1:
The patent applies the inert atmosphere principle by creating a controlled packaging environment that excludes harmful gases (carbon dioxide, excess oxygen, humidity) while maintaining sufficient oxygen for battery function. The air-impermeable packaging with controlled atmosphere prevents degradation from environmental contaminants while preserving battery functionality through carefully managed internal conditions.
2Ease of operation
If a live battery is integrated into the hearing aid for immediate usability, then the convenience is improved, but the battery degradation accelerates during shipping and storage
Solution Approach 1:
The patent applies preliminary action by pre-configuring the packaging with controlled atmosphere conditions (specific oxygen and humidity levels) before the hearing aid is placed inside. This preliminary preparation ensures that when the hearing aid with integrated battery is stored or shipped, the battery remains functional and ready for immediate use upon opening, while the pre-established protective environment prevents degradation over time.
3Strength
If the hearing aid is packaged tightly to protect from mechanical shock, then the mechanical protection is improved, but the access and removal becomes more difficult
Solution Approach 1:
The patent applies segmentation by dividing the packaging into distinct components: a removable cap assembly and a base container. The cap can be easily removed to access the hearing aid, while the base provides mechanical protection through its structure and interaction with the hearing aid body. This segmented design allows the packaging to provide robust mechanical protection while maintaining ease of access and removal.
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
The packaging system ensures the hearing device remains functional for extended periods, protects against environmental degradations, and provides immediate usability upon opening, while safeguarding against mechanical shock and electrostatic discharge.
Implementation Method 1
These batteries use air (oxygen) as the cathode of the battery cell. The cathode typically comprises an electrolytic gel. An air hole in the cell allows oxygen from the environment to enter the cell into a cavity comprising the cathode and subsequently into the anodic electrolyte.
Data Source
AI summary
Embodiments of the invention provide systems, assemblies and methods for packaging hearing devices to protect them during shipping and storage. Many embodiments provide packaging systems that allow metal-air battery powered hearing aids to be stored for several months or longer with a live battery and then ready for use upon opening of the packaging. One embodiment provides a packaging system for a hearing aid comprising a packaging container and a hearing aid disposed in the container. The container comprises an air-impermeable material and has a removal cap that forms an air-impermeable seal with the container. The hearing aid can be positioned on a compliant support coupled to the interior surface of the cap. The support and container protect the hearing aid from shock and vibration as well as reducing the application of force to sensitive components. The container can also include one or more structures for ESD protection.