Integrated Sensor Mounting Bridges for Custom-Fitted Hearing Shells
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Solution Overview
Problem
Integrating sensors into custom-fitted ear-wearable devices is challenging due to the unique, organically shaped outer shells, which are difficult to produce at scale and align other components like cables optimally with the ear geometry for comfort and fit.
Innovation Solution
A custom-fitted hearing device shell with a uniquely shaped outer surface and integrated mounting features allows for precise placement of sensors and cables using 3D printing, ensuring accurate biometric measurements and comfortable fit by aligning components with the ear geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If custom-fitted shells with unique outer surfaces are produced to match individual ear geometries, then measurement precision and comfort are improved, but manufacturing complexity and difficulty increase
Solution Approach 1:
The shell is segmented into multiple functional regions: the outer shell structure, the mounting bridge, the mounting surface, and the access void. This segmentation allows the complex unique outer surface to be produced while the sensor mounting function is handled by the integrated mounting bridge structure, resolving the contradiction between custom fit requirements and manufacturing complexity
Solution Approach 2:
The mounting bridge is formed integrally with the shell, combining the shell structure and sensor mounting function into a single component. This integration allows custom-fitted shells to be produced with built-in sensor placement features, improving measurement precision without significantly increasing manufacturing complexity
2Manufacturing precision
If traditional mounting methods are used for sensors in custom shells, then ease of manufacture is maintained, but sensor placement precision deteriorates
Solution Approach 1:
The mounting bridge and mounting surface are pre-formed as integral parts of the shell during the 3D printing process. This preliminary action ensures that the sensor placement geometry is precisely defined before assembly, achieving high manufacturing precision while maintaining ease of manufacture through simple sensor attachment to the pre-formed surface
3Measurement precision
If elongated sensor assemblies are mounted in custom shells, then measurement accuracy is improved, but ease of operation during assembly deteriorates
Solution Approach 1:
The access void acts as an intermediary feature that facilitates the assembly of elongated sensor assemblies. By providing a dedicated pathway from the outer surface to the mounting surface, the access void makes it easy to insert and position sensors while maintaining the precision required for accurate biometric measurements
Data Source
Figure 1A~1B
Figure 2~4
Figure 5~7
AI summary
An ear-wearable electronic device includes a shell having a uniquely-shaped outer surface that corresponds uniquely to an ear geometry of a user of the ear-wearable device. The device includes a sensor assembly. A mounting bridge is formed integrally with the shell and has a mounting surface that supports the sensor assembly. An elongated void is in the shell that exposes the mounting surface of the mounting bridge. The shell includes an access void that extends from the inner surface to the outer surface of the shell near a first end of the mounting bridge. The access void is larger than a minor cross section of the sensor assembly such that the sensor assembly is able to pass through the access void and be held against the mounting surface.