Elongated oval battery assembly for canal hearing device

• US 6,567,527 B1
• Filed: 08/07/2000
• Issued: 05/20/2003
• Est. Priority Date: 08/07/2000
• Status: Expired due to Term

• Current Assignee: Insound Medical Incorporated (Sonova Holding AG)
• Original Assignee: Insound Medical Incorporated (Sonova Holding AG)
• Inventors: Baker, Ross, Buckley, James P., Shennib, Adnan, Urso, Richard C., Roy, Loren L., Williams, Patrick V.
• Primary Examiner(s): Kuntz, Curtis
• Assistant Examiner(s): Ni, Suhan
• Application Number:
  US09/632,888
• Time in Patent Office: 1,016 Days
• Field of Search: 381/312, 381/322, 381/323, 381/324, 381/328, 381/380, 181/130, 181/135, 600/25, 600/559, 607/55-57, 429/163, 429/164, 429/168
• 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 50/109 of button or coin shape
• CPC Class Codes: H01M 50/119 Metals
• CPC Class Codes: H01M 50/124 having a layered structure
• CPC Class Codes: H01M 50/1243 characterised by the internal coating on the casing
• CPC Class Codes: H01M 6/12 with flat electrodes
• CPC Class Codes: H04R 25/602 of batteries

Abstract

A miniature battery assembly for canal hearing devices is constructed of a cylindrically elongated metal shell having oval cross section. The elongated oval design offers superior volumetric utilization and energy capacity in the ear canal when compared with conventional button cell designs. In a preferred embodiment, the battery assembly is comprised of an elongated anode can with an inward bottom ledge holding a cathode cup. The anode can is tapered on the top and oval in cross section for fitting optimally in the bony part of the ear canal. The hearing device incorporating the battery assembly is disposable to be discarded upon depletion of the electrical energy of the battery assembly.

Claims

1. A battery assembly for a canal hearing device, comprising:

a cylindrically elongated metal shell medially tapered with a lateral base end having an opening therein forming a cavity within said shell, said shell being elongated with length (L) along the longitudinal axis of an ear canal when said canal hearing device is positioned within the ear canal, and oval in cross section having a long diameter (D_L) and a short diameter (D_S), said length (L) being greater than said short diameter D_S,

a metal base cap for covering said lateral opening of said shell when assembled thereto, and

a sealing grommet made of an electrically insulating material inserted in a sealing manner between said shell and said base cap.

2. The battery assembly of claim 1, wherein said shell is bullet shaped with oval cross section.

3. The battery assembly of claim 1, wherein the ratio of said long diameter (D_L) to said short diameter (D_S) is about 1.5.

4. The battery assembly of claim 1, wherein said battery assembly is of metal-air type.

5. The battery assembly of claim 1, wherein said shell contains zinc material as part of a battery therein.

6. The battery assembly of claim 1, wherein said shell is coated with thin non-structural biocompatible material when incorporated within said hearing device.

7. The battery assembly of claim 1, wherein said shell is structurally self-supporting and adapted to be substantially in direct contact with the environment of the ear canal when its associated hearing device is inserted therein, thereby eliminating the need for a secondary structural enclosure when incorporated within said hearing device.

8. The battery assembly of claim 1, wherein said base end of said shell comprises a bottom ledge for securing said base cap within said shell.

9. The battery assembly of claim 8, wherein said bottom ledge is formed by crimping said base end inwardly over said base cap.

10. The battery assembly of claim 8, wherein said bottom ledge is formed by a metal ring welded circumferentially at said base end.

11. The battery assembly of claim 1, wherein said base end of said metal shell comprises a circumferential groove for placement of said base cap thereover during the manufacture of said battery assembly.

12. The battery assembly of claim 11, wherein said base cap is crimped circumferentially over said groove within said base cap.

13. The battery assembly of claim 1 further comprising a cathode assembly positioned at the base end of said battery assembly.

14. The battery assembly of claim 13, wherein said base cap comprises one or more holes for air access into said cathode assembly.

15. The battery assembly of claim 13, wherein said cathode assembly comprises an air diffusion-limiting element.

16. The battery assembly of claim 13, wherein said cathode assembly comprises an air distribution element.

17. The battery assembly of claim 13, wherein said cathode assembly comprises an air-permeable hydrophobic element for allowing air access into the interior of said battery assembly while minimizing moisture penetration of said battery assembly.

18. The battery assembly of claim 1, wherein an electrical terminal of said battery assembly is formed by a conductive surface on the exterior of said battery assembly which is adapted to be contacted by an electrically conductive contact pad associated with said hearing device.

19. The battery assembly of claim 1, wherein an electrical terminal is formed by an external electrical wire soldered or welded onto an external conductive surface of said battery assembly.

20. The battery assembly of claim 1, wherein an electrical terminal is formed by a protruding pin soldered or welded onto an external conductive surface of said battery assembly.

21. The battery assembly of claim 1, wherein said shell comprises a retention ledge at the top of its base end for securing a cathode assembly and a grommet within said base end.

22. The battery assembly of claim 21, wherein said retention ledge is formed by a ring welded to the interior walls of said shell.

23. The battery assembly of claim 21, wherein said retention ledge is formed by a ring brazed to the interior walls of said shell.

24. The battery assembly of claim 21, wherein said retention ledge is formed by a collapsed bead along said shell.

25. A metal-air battery assembly associated with a canal hearing device, said battery assembly comprising:

an anode can cylindrically elongated and medially tapered with length (L) along the longitudinal axis of an ear canal when said hearing device is positioned within the ear canal, said anode can having an oval cross section with a long diameter (D_L) and short diameter (D_S) across its cross section, said length (L) being greater than said short diameter (D_S), said anode can laterally comprising a base end having an opening therein forming a cavity within said anode can;

a cathode cup covering said opening of said anode can, said cathode cup comprising one or more air holes for air access into said battery assembly; and

a sealing element comprising an insulator material inserted in a sealing manner between said base end of said anode can and said cathode cup;

said cathode cup being concentrically positioned within said base end of said anode can and secured therein partially by an inward ledge within said base end of said anode can.

26. The battery assembly of claim 25, wherein said anode can has thickness of less than 0.2 mm.

27. The battery assembly of claim 25, wherein the ratio of long diameter (D_L) to short diameter (D_S) is about 1.5.

28. The battery assembly of claim 25, wherein said anode can contains zinc.

29. The battery assembly of claim 25, wherein said battery assembly is coated with thin non-structural biocompatible material when incorporated within said hearing aid.

30. The battery assembly of claim 25, wherein said anode can is structurally self-supporting and being adapted to be substantially in direct contact with the environment of the ear canal when its associated hearing device is inserted therein, whereby eliminating the need for a secondary structural enclosure when incorporated within said hearing device.

31. The battery assembly of claim 25, wherein said inward ledge is formed by crimping inwardly and axially the base end of said anode can.

32. The battery assembly of claim 25, wherein said inward ledge is formed by a metal ring welded onto the anode can circumferentially at the base end.

33. The battery assembly of claim 25, wherein said cathode assembly comprises an air diffusion-limiting element.

34. The battery assembly of claim 25, wherein said cathode assembly comprises an air distribution element.

35. The battery assembly of claim 25, wherein said cathode assembly comprises an air-permeable hydrophobic element for allowing air access into the interior of said battery assembly while minimizing moisture penetration of said battery assembly.

36. The battery assembly of claim 25, wherein an electrical terminal is formed by an external electrical wire soldered or welded onto the external surface of said battery assembly being electrically conductive.

37. The battery assembly of claim 25, wherein shell comprises a retention ledge at the top of its base end for securing a cathode assembly and a grommet within said base end.

38. The battery assembly of claim 37, wherein retention ledge is formed by an oval ring brazed or welded along the interior walls of said shell.

39. A battery assembly associated with a canal hearing device, said battery assembly comprising:

a cylindrically elongated metal shell being medially tapered with length (L) along the longitudinal axis of an ear canal when said hearing device is positioned within the ear canal, said shell having an oval cross section with short diameter (D_S) across its cross section, said length (L) being greater than said short diameter (D_S), said shell laterally comprising a base end and an opening therein forming a cavity within said shell, and

a base cap covering said opening of said metal shell,

said metal shell being structurally self-supporting and being adapted to be substantially exposed and essentially in direct contact with the environment of the ear canal when its associated hearing device is inserted therein, whereby to eliminate the need for a secondary structural enclosure when incorporated within said hearing device.

40. The battery assembly of claim 39, wherein said battery assembly is coated with thin non-structural biocompatible material when incorporated within said hearing aid.

41. The battery assembly of claim 39, wherein said base end of said shell comprises an inward ledge formed for securing said base cap within said shell.

42. The battery assembly of claim 41, wherein said inward ledge is formed by crimping inwardly and axially said base end.

43. The battery assembly of claim 41, wherein said inward ledge is formed by a metal ring welded onto the base end of said shell.

44. The battery assembly of claim 39, wherein said base end of said shell comprises a circumferential groove for placement of said base cap thereover.

45. The battery assembly of claim 39, wherein shell comprises a retention ledge at the top of its base end for securing a cathode assembly and a grommet within said base end.

46. A hearing device incorporating a battery assembly, said battery assembly comprising:

a cylindrically elongated metal shell medially tapered with lateral base having an opening therein forming a cavity within said shell,

a metal base cap covering said opening of said shell, and

a sealing element made of an electrically insulating material inserted in a sealing manner between said base cap and said shell,

said battery assembly being elongated with length (L) along the longitudinal axis of an ear canal when said battery assembly is positioned therein, and oval in cross section having a short diameter (D_S), said length (L) being greater than said short diameter (D_S),

said battery assembly being cylindrically elongated and having oval cross section resembling the shape of said ear canal to maximize the energy capacity of said battery assembly and to optimize the fit and comfort of said battery assembly within said ear canal.

47. The hearing device of claim 46, wherein said battery assembly is zinc-air type.

48. The hearing device of claim 46, wherein said battery assembly is adapted to fit in the ear canal with minimal or no contact with the walls thereof, whereby to be non occluding therein.

49. The hearing device of claim 46, adapted for single-use disposability upon depletion of the electrical energy of said battery assembly.

50. The hearing device of claim 46, adapted for extended wear within the ear canal.

51. A hearing device incorporating a battery assembly, said battery assembly comprising:

a metal shell cylindrically elongated and medially tapered with length (L) along the longitudinal axis of an ear canal when said hearing device is positioned within the ear canal, said shell having an oval cross section having a short diameter (D_S) across its cross section, said length (L) being greater than said short diameter (D_S), said shell comprises a lateral base end having an opening therein forming a cavity within said shell, and

a base cap covering said opening of said metal shell,

said metal shell being structurally self-supporting and adapted to be substantially exposed and essentially in direct contact with the environment of the ear canal when its associated hearing device is inserted therein, whereby to eliminate the need for a secondary structural enclosure when incorporated within said hearing device.

52. The hearing device of claim 51, adapted for single-use disposability upon depletion of the electrical energy of said battery assembly incorporated therein.

53. The hearing device of claim 51, wherein said battery assembly is adapted to fit in the ear canal with minimal or no contact with the walls thereof, whereby to be non occluding therein.

54. The hearing device of claim 51 adapted for extended wear within the ear canal.