Hearing aid with a flexible shell

• US 20010043707A1
• Filed: 03/13/2001
• Published: 11/22/2001
• Est. Priority Date: 03/13/2000
• Status: Active Grant

• Current Assignee: K/S HIMPP
• Original Assignee: Sarnoff Corporation (SRI International, Inc.)
• Inventors: Leedom, Marvin A.
• Granted Patent: US 6,865,279 B2
• Time in Patent Office: Days
• US Class Current: 381/312
• CPC Class Codes: H04R 2225/023 Completely in the canal [CIC] hearing aids
• CPC Class Codes: H04R 2225/61 Aspects relating to mechanical or electronic switches or control elements, e.g. functioning
• CPC Class Codes: H04R 25/456 mechanically
• CPC Class Codes: H04R 25/602 of batteries
• CPC Class Codes: H04R 25/603 of mechanical or electronic switches or control elements
• CPC Class Codes: H04R 25/604 of acoustic or vibrational transducers
• CPC Class Codes: H04R 25/609 of circuitry of electronic switches or control elements H04R25/603
• CPC Class Codes: H04R 25/65 Housing parts, e.g. shells, tips or moulds, or their manufacture
• CPC Class Codes: H04R 25/652 Ear tips; Ear moulds hybrid ear moulds or post-processing thereof for their customisation H04R25/659
• CPC Class Codes: H04R 25/654 Ear wax retarders
• CPC Class Codes: H04R 25/656 Non-customized, universal ear tips, i.e. ear tips which are not specifically adapted to the size or shape of the ear or ear canal
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence

Abstract

A hearing aid assembled from three sections includes a first section having a first housing containing a microphone and electronics, a second section having a second housing containing a battery a flex circuit mounted around the battery and a third section having a compliant tip and a receiver contained within a receptacle in the tip. The flex circuit provides solderless electrical connections among the electrical components of the hearing aid. The hearing aid also includes an actuator switch that allows the user to engage the hearing aid in an ON or an OFF mode of operation. Preferably, the actuator is electrically connected to the hearing aid without the use of solder. Connection between the first and second sections includes a mechanical securing mechanism, such as an interlocking joint.

Claims

1. A hearing aid comprising:

a first section, the first section containing a microphone and electronics;

a second section attached to the first section, the second section containing a battery and a flex circuit mounted around the battery; and

a third section attached to the second section, the third section having a compliant tip and a receiver contained within a receptacle in the tip, the flex circuit electrically connecting the microphone, electronics, receiver and battery.

2. The hearing aid of

claim 1

wherein the flex circuit comprises a receiver mating portion and a microphone mating portion, the receiver mating portion abutting the receiver and the microphone mating portion abutting the microphone.

3. The hearing aid of

claim 1

wherein the flex circuit comprises compliant electrical connectors for connecting the microphone, electronics, receiver and battery, the compliant electric connectors providing strain relief for the flex circuit.

4. The hearing aid of

claim 1

wherein the flex circuit includes a microphone mating portion that abuts the microphone and forms an electric connection between the flex circuit and the microphone.

5. The hearing aid of

claim 1

wherein the flex circuit includes a receiver mating portion that abuts the receiver and forms an electric connection between the flex circuit and the receiver.

6. The hearing aid of

claim 1

wherein the flex circuit includes a plurality of conductive paths.

7. The hearing aid of

claim 6

wherein the conductive paths include of at least one receiver lead.

8. The hearing aid of

claim 6

wherein the conductive paths include at least one anode lead.

9. The hearing aid of

claim 8

wherein the anode lead includes a discontinuity which prevents the hearing aid from drawing power from the battery, unless bridged.

10. The hearing aid of

claim 9

further comprising an actuator mounted to the hearing aid, the actuator having a conductive surface contacting the anode such that the conductive surface bridges the discontinuity in the anode to engage the hearing aid in an ON mode of operation.

11. The hearing aid of

claim 1

wherein the flex circuit comprises at least one aperture to allow air to travel to the battery.

12. The hearing aid of

claim 1

further comprising a mechanical securing mechanism between the first section and the second section.

13. The hearing aid of

claim 1

wherein the second section comprises a potting material surrounding the receiver such that the potting material and the receptacle of the tip encapsulate the receiver to attenuate acoustic feedback.

14. The hearing aid of

claim 1

wherein the tip includes a channel for removal of wax from a bore in the tip.

15. The hearing aid of

claim 1

wherein the tip comprises a mushroom shaped portion and a sound port attached to the mushroom shaped portion.

16. The hearing aid of

claim 15

wherein the tip comprises a first durometer material and a second durometer material, the first durometer material being more compliant than the second durometer material.

17. The hearing aid of

claim 16

wherein the first durometer material forms the mushroom shaped portion of the tip.

18. The hearing aid of

claim 16

wherein the second durometer material forms the sound port of the tip.

19. A method of assembling a hearing aid comprising:

casting a tip for a hearing aid, the tip having a receptacle for a receiver;

providing a receiver;

inserting the receiver into the receptacle within the tip;

providing a second section housing;

attaching the second section housing to the tip;

applying potting material the receiver within the second section housing;

providing a battery and flex circuit assembly;

inserting a battery and flex circuit assembly within the second section housing;

providing a microphone and housing assembly;

mechanically securing a microphone and housing assembly to the second section housing;

providing an actuator having a conductive surface; and

inserting the actuator within the hearing aid, the actuator being electrically connected to the hearing aid without solder, the actuator allowing for powering of the hearing aid.

20. The method of

claim 19

further comprising electrically connecting the receiver to the flex circuit using a non-soldered connection.

21. The method of

claim 19

further comprising electrically connecting the microphone to the flex circuit using a non-soldered connection.

22. The method of

claim 19

further comprising sealing the receiver in the hearing aid with the potting material.

23. The method of

claim 19

further comprising bonding the second section housing to the tip with the potting material.

24. The method of

claim 19

further comprising electrically connecting the actuator with the flex circuit using a non-soldered connection.

25. The method of

claim 19

further comprising engaging a latching aperture located on the actuator with a latching projection located on the hearing aid, the latching projection preventing removal of the actuator from the hearing aid.

26. A hearing aid comprising:

a first section, the first section having a first housing containing a microphone and electronics;

a second section attached to the first section, the second section having a second housing containing a battery a flex circuit mounted around the battery; and

a third section attached to the second section, the third section having a compliant tip and a receiver contained within a receptacle in the tip, the flex circuit electrically connecting the microphone, electronics, receiver and battery.

27. The hearing aid of

claim 26

wherein the flex circuit comprises a receiver mating portion and a microphone mating portion, the receiver mating portion abutting the receiver and the microphone mating portion abutting the microphone.

28. The hearing aid of

claim 26

wherein the flex circuit comprises compliant electrical connectors for connecting the microphone, electronics, receiver and battery, the compliant electric connectors providing strain relief for the flex circuit.

29. The hearing aid of

claim 26

wherein the flex circuit includes a microphone mating portion that abuts the microphone and forms an electric connection between the flex circuit and the microphone.

30. The hearing aid of

claim 26

wherein the flex circuit includes a receiver mating portion that abuts the receiver and forms an electric connection between the flex circuit and the receiver.

31. The hearing aid of

claim 26

wherein the flex circuit includes a plurality of conductive paths.

32. The hearing aid of

claim 31

wherein the conductive paths include of at least one receiver lead.

33. The hearing aid of

claim 31

wherein the conductive paths include at least one anode lead.

34. The hearing aid of

claim 33

wherein the anode lead includes a discontinuity which prevents the hearing aid from drawing power from the battery, unless bridged.

35. The hearing aid of

claim 34

further comprising an actuator mounted to the hearing aid, the actuator having a conductive surface contacting the anode such that the conductive surface bridges the discontinuity in the anode to engage the hearing aid in an ON mode of operation.

36. The hearing aid of

claim 26

wherein the flex circuit comprises at least one aperture to allow air to travel to the battery.

37. The hearing aid of

claim 26

further comprising a mechanical securing mechanism between the first section and the second section.

38. The hearing aid of

claim 26

wherein the second section comprises a potting material surrounding the receiver such that the potting material and the receptacle of the tip encapsulate the receiver to attenuate acoustic feedback.

39. The hearing aid of

claim 26

wherein the tip includes a channel for removal of wax from a bore in the tip.

40. The hearing aid of

claim 26

wherein the tip comprises a mushroom shaped portion and a sound port attached to the mushroom shaped portion.

41. The hearing aid of

claim 40

wherein the tip comprises a first durometer material and a second durometer material, the first durometer material being more compliant than the second durometer material.

42. The hearing aid of

claim 41

wherein the first durometer material forms the mushroom shaped portion of the tip.

43. The hearing aid of

claim 41

wherein the second durometer material forms the sound port of the tip.