Precision micro-hole for extended life batteries

• US 20050259840A1
• Filed: 01/26/2005
• Published: 11/24/2005
• Est. Priority Date: 06/08/1999
• Status: Active Grant

• Current Assignee: Insound Medical Incorporated (Sonova Holding AG)
• Original Assignee: Insound Medical Incorporated (Sonova Holding AG)
• Inventors: Gable, Richard, Baker, Ross, O'Hara, Tom
• Granted Patent: US 7,379,555 B2
• Time in Patent Office: Days
• US Class Current: 381/323
• CPC Class Codes: H01M 12/06 with one metallic and one gaseous electrode
• CPC Class Codes: H01M 50/107 having curved cross-section, e.g. round or elliptic H01M50/103, H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/119 Metals
• CPC Class Codes: H01M 50/121 Organic material
• CPC Class Codes: H01M 50/124 having a layered structure
• CPC Class Codes: H01M 50/128 with two or more layers of only inorganic material
• CPC Class Codes: H01M 50/129 with two or more layers of only organic material
• CPC Class Codes: H01M 50/14 for protecting against damage caused by external factors
• CPC Class Codes: H04R 2225/61 Aspects relating to mechanical or electronic switches or control elements, e.g. functioning
• 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: Y02E 60/10 Energy storage using batteries

Abstract

Various embodiments of the invention provide an enclosure for a metal-air battery assembly for an extended wear hearing aid. The enclosure includes a diffusion control element having a dimensional property configured for controlling oxygen and moisture diffusion into the metal-air battery assembly to maintain a minimum battery voltage when the hearing aid is operating and worn in an ear canal of a user over an extended period. In an embodiment, the enclosure can comprise a shell with a base end having an opening therein forming a cavity within the shell and a base cap for covering the opening of the base end. A diffusion element is disposed on the base cap. In an embodiment, the diffusion element comprises a laser drilled precision micro hole having an aspect ratio of least about four and a diameter in the range of about 10 to 15 microns.

Claims

1. An enclosure for a metal-air battery assembly for an extended wear hearing aid, the enclosure including a diffusion control element having a dimensional property configured for controlling oxygen and moisture diffusion into the metal-air battery assembly to maintain a minimum battery voltage when the hearing aid is operating and worn in an ear canal of a user over an extended period.

2. The enclosure of claim 1, wherein the enclosure comprises a shell with a base end having an opening therein forming a cavity within the shell and a base cap for covering the opening of the base end.

3. The enclosure of claim 2, wherein the diffusion control element is disposed on the base cap.

4. The enclosure of claim 1, wherein the diffusion control element is configured to improve an operational life of the battery assembly in the ear canal.

5. The enclosure of claim 1, wherein the voltage is in a range from about 1 to 1.3 volts.

6. The enclosure of claim 1, wherein a current drain at which the minimum voltage is maintained is in range from about 40 to 175 μ

A.

7. The enclosure of claim 1, wherein a current drain at which the minimum voltage is maintained is in range from about 40 to 90 μ

A.

8. The enclosure of claim 1, wherein the diffusion control element is configured to control moisture diffusion into the battery assembly to maintain a battery electrolyte concentration within a range sufficient to allow the battery to power the hearing aid.

9. The enclosure of claim 1, wherein the diffusion control element comprises a precision micro through-hole.

10. The enclosure of claim 9, wherein at least a portion of the through-hole is curved, or non-linear.

11. The enclosure of claim 9, wherein the hole is laser drilled.

12. The enclosure of claim 9, wherein the through-hole has a length to diameter ratio such that the gas ingress into the battery assembly is substantially diffusion controlled.

13. The enclosure of claim 9, wherein the through-hole has a length to diameter ratio of at least about 4.

14. The enclosure of claim 9, wherein the precision micro hole has a diameter not greater than about 15 microns.

15. The enclosure of claim 9, wherein the precision hole comprises a plurality of holes.

16. The enclosure of claim 9, wherein, a portion of the enclosure including the micro-hole comprises at least one of a polymer, a metallized polymer, a metallized PEEK, or a multilayer polymer.

17. The enclosure of claim 1, wherein the diffusion control element includes a regulator configured regulate oxygen and moisture diffusion into the metal-air battery assembly responsive to a hearing aid parameter.

18. The enclosure of claim 17, wherein the regulator is a shutter, a MEM device, or a MEM shutter device.

19. The enclosure of claim 17, wherein the parameter is a user selected hearing aid volume.

20. The enclosure of claim 1, where the diffusion control element comprises a non-compressed portion of a compressed porous membrane coupled to a portion of the enclosure.

21. The enclosure of claim 20, where the non-compressed portion has a substantially circular shape.

22. An extended wear canal hearing device comprising the enclosure of claim 1.

23. An enclosure for a metal-air battery assembly for an extended wear hearing aid, the enclosure including a precision micro through-hole, the through-hole having a length to diameter ratio configured for controlling oxygen and moisture diffusion into the metal-air battery assembly to maintain a minimum battery voltage when the hearing aid is operating and worn in an ear canal of a user over an extended period.

24. The enclosure of claim 23, wherein the through-hole has a length to diameter ratio of at least about 4.

25. An enclosure for a metal-air battery assembly for an extended wear hearing aid, the enclosure including a diffusion regulator configured to regulate oxygen and moisture diffusion into the metal-air battery assembly responsive to a hearing aid parameter.

26. The enclosure of claim 25, wherein the parameter is a user selected hearing aid volume.

27. A method for improving the performance of a metal-air hearing aid battery, the method comprising:

providing a hearing aid with a metal-air battery assembly including a diffusion control element;

positioning the hearing aid into an ear of a user; and

controlling air ingress into the battery assembly to maintain a minimum battery voltage when the hearing aid draws a current from the battery.

28. The method of claim 27, wherein the voltage is in a range from about 1 to 1.3 volts.

29. The method of claim 27, where the current is in a range from about 40 to 175 μ

A.

30. The method of claim 27, wherein the current is in a range from about 40 to 90 μ

A.

31. A method for improving the performance of a metal-air hearing aid battery, the method comprising:

providing a hearing aid with a metal air-battery assembly including a regulator;

positioning the hearing aid into an ear of a user; and

regulating air ingress into the battery assembly responsive to a hearing aid parameter.

32. The method of claim 31, wherein the hearing aid parameter is a hearing aid gain, a microphone output, a preamp output, a hearing aid volume, or a user selected hearing aid volume.