Hearing Device Shell With Segmented Sub-Shell and Thermoformed Hull
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Solution Overview
Problem
Current hearing device shells are uncomfortable due to pressure exerted by hard shells during jaw movement, leading to sound leakage and potential migration out of the ear, and are bulky for 'Invisible In the Canal' applications, which require miniaturization.
Innovation Solution
A shell design featuring a sub-shell with lateral openings and a thermoformed hull, reducing local rigidity in pressure areas for flexibility and comfort, while maintaining overall mechanical stability through a combination of sub-shell and thermoformed hull rigidity, and incorporating a vent channel for space efficiency and reduced cerumen buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard shell is used for the hearing device, then structural integrity and mechanical stability are improved, but wearer comfort deteriorates due to pressure during jaw movement
Solution Approach 1:
The shell is divided into two distinct parts: a rigid sub-shell providing structural integrity and a flexible thermoformed hull providing comfort. This segmentation allows each part to fulfill its specific function - the sub-shell maintains mechanical stability while the thermoformed hull adapts to ear canal movements, eliminating pressure discomfort.
Solution Approach 2:
The invention uses a composite structure combining a rigid sub-shell material with a flexible thermoformed hull material. This composite approach enables the shell to exhibit both structural strength from the sub-shell and flexibility from the thermoformed hull, simultaneously achieving structural integrity and wearer comfort.
2Adaptability or versatility
If the shell thickness is reduced for miniaturization, then adaptability to ear canal movements is improved, but overall mechanical stability deteriorates
Solution Approach 1:
The shell is segmented into a thin flexible thermoformed hull and a rigid sub-shell. The thermoformed hull can be made very thin (0.1 mm or less) to provide flexibility and adaptability, while the sub-shell maintains overall mechanical stability. This segmentation allows the thin region to be flexible without compromising the overall structural stability.
Solution Approach 2:
Different regions of the shell have different thicknesses and material properties. The region with lateral openings has reduced thickness (0.1 mm or less) for flexibility, while other regions maintain greater thickness (0.4 mm or greater) for mechanical stability. This local variation in quality allows the shell to be both flexible where needed and stable overall.
3Adaptability or versatility
If lateral openings are added to the sub-shell, then local flexibility is improved in pressure regions, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into two steps: first forming the sub-shell with lateral openings, then forming the thermoformed hull to cover these openings. This segmentation of the manufacturing process allows the complex feature of lateral openings to be integrated into the sub-shell fabrication, while the thermoformed hull is subsequently formed to complete the flexible outer layer.
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 design enhances wearer comfort by allowing the shell to flex with ear canal movements, reduces thickness for miniaturization, and maintains structural integrity, making it suitable for 'Invisible In the Canal' applications with improved sound transmission and reduced noise leakage.
Implementation Method 1
a thermoformed hull attached to the subshell and covering the two or more lateral openings
Data Source
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AI summary
A shell (10) for a hearing device, and a method of producing the same. The shell (10) comprises a sub-shell (11) produced by a generative method, and a thermoformed hull (12) covering the subshell (11). The sub-shell (11) comprises lateral openings (13) covered by the thermoformed hull (12) so as to render the shell (10) more flexible in the region of the openings (13), and thereby to relieve pressure exerted by the shell (10) due to dynamic changes in the shape of the wearer's ear canal during jaw movement.