Ear-Worn Hearing Cable Assembly With Discrete Retention Fixing

Solution Overview

Problem

The over-molding process for ear-worn hearing device cable assemblies is labor intensive and expensive, necessitating an improved cable design.

Innovation Solution

The use of discrete retention members, such as c-rings or closed-ring retention members, which are rotationally and axially fastened to the electrical conductor conduit, providing a secure and cost-effective method to prevent rotation and axial displacement of the cable relative to the hearing device housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an over-molding process is used to fix the cable assembly to the receiver housing, then the cable assembly is securely retained, but the manufacturing process becomes labor intensive and expensive

Engineering Contradiction:

Improvecable assembly retentionVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention divides the cable assembly system into separate functional components: a cable assembly with conductor conduit and a receiver housing with a separate retention mechanism. The retention member is attached to the conduit and engages with the housing through a dedicated retention feature, eliminating the need for over-molding while achieving secure retention through modular, discrete parts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces a retention member as an intermediary component between the cable assembly and the receiver housing. This retention member, attached to the conduit, works in conjunction with a retention feature in the housing to provide secure mechanical retention without requiring the cable assembly to be over-molded directly to the housing.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If an over-molding process is used to fix the cable assembly to the receiver housing, then the cable assembly is securely retained, but manufacturing costs increase

Engineering Contradiction:

Improvecable assembly retentionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention divides the cable assembly system into separate functional components: a cable assembly with conductor conduit and a receiver housing with a separate retention mechanism. The retention member is attached to the conduit and engages with the housing through a dedicated retention feature, eliminating the need for over-molding while achieving secure retention through modular, discrete parts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention replaces the expensive over-molding process with simpler, less costly discrete retention members that can be attached to the conduit using cost-effective methods such as adhesives, crimping, or ultrasonic welding. These retention members provide adequate retention functionality at lower manufacturing cost.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If discrete retention members are used instead of over-molding, then manufacturing cost and complexity are reduced, but the security of cable retention must be maintained

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidcable assembly retention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention introduces a retention member as an intermediary component between the cable assembly and the receiver housing. This retention member, attached to the conduit, works in conjunction with a retention feature in the housing to provide secure mechanical retention without requiring the cable assembly to be over-molded directly to the housing.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The retention member is pre-attached to the conductor conduit before final assembly with the housing. This preliminary attachment ensures proper positioning and secure engagement, allowing for simplified final assembly while maintaining reliable retention of the cable assembly.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12317040B2Electrical cable assembly for ear-worn hearing devices

Publication Date: 2025.05.27 KNOWLES ELECTRONICS LLC

AI summary

An ear-worn hearing device and an electrical cable assembly for such a hearing device are disclosed. The electrical cable assembly includes a discrete retention member rotationally and axially fixing the retention member at least partially about an end portion of an electrical conductor conduit. The retention member also axially and rotationally fixes the cable assembly to a housing. The housing can include an acoustic receiver and be configured for insertion at least partially in the user's ear. Alternatively, the housing can be part of a connector plug that mates with a base unit worn outside the user's ear.