Deformable, multi-material hearing aid housing

• US 6,393,130 B1
• Filed: 07/16/1999
• Issued: 05/21/2002
• Est. Priority Date: 10/26/1998
• Status: Expired due to Term

• Current Assignee: Belton Electronics Company Limited (Belton Macao Commercial Offshore Limited)
• Original Assignee: Belton Electronics Company Limited (Belton Macao Commercial Offshore Limited)
• Inventors: Yoest, Robert S., Stonikas, Paul R.
• Primary Examiner(s): Tran, Sinh
• Assistant Examiner(s): DABNEY, PHYLESHA LARVINIA
• Application Number:
  US09/356,223
• Time in Patent Office: 1,040 Days
• Field of Search: 381/328, 381/322, 381/324, 381/380, 381/326, 381/FOR.133, 381/FOR.135, 181/129, 181/130, 181/135
• US Class Current: 381/322
• CPC Class Codes: H04R 2225/023 Completely in the canal [CIC] hearing aids
• CPC Class Codes: H04R 2225/57 Aspects of electrical interconnection between hearing aid parts
• CPC Class Codes: H04R 25/456 mechanically
• 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 25/656 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: H04R 25/658 Manufacture of housing parts

Abstract

A compliant hearing aid has a housing formed with an exterior peripheral layer of a deformable material. Electronic components located within the deformable layer can be encapsulated, at least in part, with a second deformable material. The second material also fills voids in the interior of the deformable peripheral layer. The second material can be cured within the deformable layer. Alternately, the second material can be cured apart from the deformable layer. The layer can then be attached to the second material.

Claims

1. A multi-material elastomeric housing for a hearing aid comprising:

a housing with an exterior periphery defined by a layer of a first deformable, elastomeric material wherein the layer of the first material deformably bounds, at least in part, an interior region with an interior surface;

a second elastomeric material which, at least in part, fills the interior region and abuts the interior surface at least in part in abutting regions wherein the second material, in the abutting regions, exhibits a corresponding male shape to that of the interior surface wherein substantial identity of the corresponding male shape of the second material and the interior surface of the layer preclude distortion of the layer by the second material, and a foam member in the interior region.

2. A housing as in claim 1 wherein the first and the second materials are the same.

3. A housing as in claim 1 wherein a third material is located adjacent to a portion of the surface.

4. A housing as in claim 3 wherein the third material comprises a fluid.

5. A housing as in claim 3 wherein the third material comprises a selected, deformable solid.

6. A housing as in claim 1 which includes a rotatable element with a shield between the element and at least the second material.

7. A housing as in claim 6 wherein the element comprises a rotatable battery door.

8. A housing as in claim 1 wherein the first and second materials are selected from a class which includes silicone, latex, polyurethane, polyvinyl.

9. A housing as in claim 8 wherein the first and second materials exhibit a hardness parameter in a range of less than 90 ShoreA.

10. A housing as in claim 1 which includes a preformed component receiving cavity therein wherein a component inserted into the cavity has a size or shape which would preclude insertion into the cavity in the absence of at least the layer temporarily deforming in response to an applied deformation force.

11. A housing as in claim 10 wherein the component is an output transducer.

12. A multi-material housing for a hearing aid comprising:

a housing with an exterior periphery defined by a layer of a first deformable material wherein the layer of the first material deformably bounds, at least in part, an interior region with an interior surface;

a second material which, at least in part, fills the interior region and abuts the interior surface at least in part in abutting regions wherein the second material, in the abutting regions, exhibits a corresponding male shape to that of the interior surface wherein substantial identity of the corresponding male shape of the second material and the interior surface of the layer preclude distortion of the layer by the abutting material; and

wherein the layer is bonded to the second material only at selected locations whereby at least selected regions of the layer are movable relative to the second material.

13. A multi-material deformable housing for a hearing aid comprising:

a housing with an exterior periphery defined by a layer of a first elastomeric material wherein the layer of the first material deformably bounds, at least in part, an interior region with an interior surface;

a second elastomeric material which, at least in part, fills the interior region and abuts the interior surface at least in part in abutting regions wherein the second material, in the abutting regions, exhibits a corresponding male shape to that of the interior surface wherein substantial identity of the corresponding male shape of the second material and the interior surface of the layer preclude distortion of the layer by the abutting material; and

which includes a rotatable element with a shield wherein the shield is located between the element and at least the second material.

14. A method of minimizing feedback in a user'"'"'s ear wherein incident acoustic waves are processed by a hearing instrument located in the ear canal, the method comprising:

providing a hearing instrument having a deformable housing compliant enough to dynamically adjust to changes in the shape and size of the ear canal wherein the housing has a shape which corresponds, at least in part, to a portion of the ear canal;

inserting the instrument into the ear canal wherein the housing deforms on insertion, and, when inserted, blocks external feedback by sealing against adjacent regions of the ear canal when the canal is in a quiescent, non-changing state; and

altering the shape of the compliant housing dynamically in response to altering the size and shape of the ear canal so as to maintain the feedback minimizing seal with the dynamically changing ear canal which includes providing a compliant layer of a first material which comprises the outer periphery of the housing, except for a selected face plate region, wherein the outer periphery has a section that abuts the adjacent regions of the ear canal with an interior formed at least in part by a compliant second material and which includes temporarily deforming at least the compliant layer while inserting a selected component therein or while removing a component.

15. A process for molding a thin walled, deformable shell for a hearing aid for a user comprising:

forming an ear impression which includes a portion having an exterior peripheral surface that replicates the user'"'"'s ear canal;

forming a substantially rigid shell with a hollow interior region and with an exterior peripheral surface that duplicates at least a portion of the impression;

casting a female mold about the exterior peripheral surface of the shell;

casting a male mold of the hollow interior region;

removing the rigid shell;

positioning the male mold in the female mold so as to form a space therebetween indicative of the rigid shell;

filling the space with a curable elastomer thereby forming a hollow elastomeric shell; and

curing the elastomeric shell.

16. A process as in claim 15 which includes removing the elastomeric shell from the molds;

and

inserting at least one of a selected component and a mandrel into the shell including temporarily deforming the shell, if needed, to position the at least one.

17. A process as in claim 16 which includes forming a rigid exterior coating about the exterior of the elastomeric shell to prevent distortion thereof;

and

filling the interior of the shell with a selected, curable interior elastomer.

18. A process as in claim 17 which includes, prior to the filling step, locating a selected deformable material-in the interior region adjacent to the elastomeric shell.

19. A process as in claim 18 wherein the deformable material is the same type of material as the elastomer of the shell.

20. A process as in claim 17 which includes curing the internal elastomer, and, then removing the rigid exterior coating from the exterior of the shell.

21. A process as in claim 15 which includes removing the 10 elastomeric shell from the molds;

and

forming a separate elastomeric male representation of the interior of the rigid shell.

22. A process as in claim 21 which includes forming component receiving pockets in the male representation.

23. A process as in claim 22 which includes using pocket defining mandrels.

24. A process as in claim 21 which includes, prior to forming the male representation, locating selected electronic components to be cast therein.

25. A process as in claim 21 which includes coupling the male representation to the elastomeric shell.

26. A process as in claim 25 which includes attaching the shell to the male representation at at least one selected location.

27. A process as in claim 26 which includes using adhesive in the attaching step.

28. An elastomeric hearing aid comprising:

a deformable housing having an external, deformable shell formed of an elastomer which has an exterior shape that corresponds to a part of a user'"'"'s ear canal when the ear canal is in a first state, wherein the shell includes a second elastomer and at least one foam member and carrying at least one component in the shell whereby when the ear canal moves to a second, different state at least the first elastomer deforms but not the component thereby providing a comfortable fit for the user.

29. A hearing aid as in claims 28 wherein the first elastomer is selected from a class which includes polyurethane, silicone, polyvinyl and latex.

30. A hearing aid as in claim 28 wherein the second elastomer is selected from a class which includes polyurethane, silicone, polyvinyl and latex.

31. A hearing aid as in claim 28 wherein the foam member is carried adjacent part of the shell.

32. A hearing aid as in claim 28 wherein a plurality of foam members is carried in the shell.

33. A hearing aid as in claim 28 wherein the component comprises an audio output transducer.

34. A hearing aid as in claim 33 wherein the output transducer deforms at least the shell as it is being inserted thereinto.

35. A hearing aid as in claim 34 wherein at least the shell has been cured before inserting the transducer and wherein the shell exhibits an open proximal end into which the transducer is inserted with the shell returning substantially to its respective undistorted shape once the transducer has been positioned therein.

36. A hearing aid as in claim 35 which includes at least one internal channel which extends between the open proximal end and a component region whereupon the transducer is insertable through the channel into the region, temporarily enlarging the channel as needed to slide the transducer therethrough.

37. A hearing aid as in claim 36 wherein the transducer will not pass through the channel unless at least the first elastomer is temporarily deformed thereby.

38. A hearing aid as in claim 28 wherein at least part of the shell, adjacent to the user'"'"'s ear canal, forms a feedback reducing seal with that portion of the ear canal when the ear canal is in the first state and wherein the seal is maintained by deformation of at least the shell when the ear canal moves to the second state.

39. A composite in-the-ear hearing aid comprising:

an outer bounding elastomeric periphery sized for insertion into a user'"'"'s ear canal and having an audio output port; and

at least one foam element carried within the periphery wherein the periphery bounds an internal region, wherein the foam element is carried in the region and wherein elastomeric material fills the remainder of the internal region at least in part and is in part in contact with the foam element.

40. A composite hearing aid comprising:

an outer bounding elastomeric periphery;

at least one foam element carried within the periphery wherein the periphery bounds an internal region, wherein the foam element is carried in the region and wherein elastomeric material fills the remainder of the internal region, at least in part, and is in part in contact with the foam element wherein the periphery includes a proximal end and a distal end, an output transducer carried within the periphery near the distal end and supported by elastomeric material also within the periphery.

41. A hearing aid as in claim 40 wherein the output transducer is supported by the elastomeric material only at discrete, spaced apart locations with one of foam, and air spaces therebetween.

42. A hearing aid as in claim 41 wherein the transducer is selectively oriented to reduce feedback.

43. A hearing aid as in claim 42 wherein the transducer is insertable throung the proximal end and positonable near the distal end only by temporarily deforming the periphery.

44. A composite in-the-ear hearing aid comprising:

an outer bounding elastomeric periphery sized for insertion into a user'"'"'s ear canal; and

at least one deformable foam element carried completely within the periphery wherein the periphery bounds an internal region, wherein the foam element is carried in the region and wherein deformable elastomeric material fills the remainder of the internal region, at least in part, and is in part in contact with both the deformable foam element and the outer bounding elastomeric periphery.