CN114629194A - Hearing device charger apparatus and system and method of manufacturing a holder therefor - Google Patents

Abstract

The present application provides hearing device charger devices and systems and methods of manufacturing a holder therefor. A method of manufacturing a charger insert (40) comprising a holder (45) for holding a chargeable hearing device (1A, 1B) in a hearing device charger apparatus (20), the hearing device charger apparatus (20) comprising: a charger housing (21) and a first charger element (22, 23), the method comprising: providing a first virtual model comprising assigning a second position for the electronic hearing aid device (28) in the first virtual model; providing a second virtual model of a charger insert (40), the charger insert (40) being designed to support the chargeable hearing device (1A, 1B) such that the first charger element (22, 23) is positioned in a first relationship with the second charger element (4) when the charger insert (40) is placed in the receiving portion (29); a custom charger insert (40) is formed with the holder (45).

Description

Hearing device charger device and system and method of manufacturing a holder therefor

Technical Field

The present invention relates to a method of manufacturing a charger insert comprising a holder for holding a rechargeable hearing device individually customized for at least partial insertion into an ear canal of a user in a hearing device charger arrangement configured for charging the rechargeable hearing device. The invention also relates to a charger insert, a hearing device charger arrangement and a hearing device charger system comprising a hearing device and a hearing device charger arrangement.

Background

Rechargeable in-the-ear hearing aids are known in the art. In order to charge such hearing aids, the hearing aid user is equipped with a charging device. The charging means and the hearing aid may each comprise cooperating electrical contact means, or they may comprise cooperating charger coils, so that the hearing aid may be charged "wirelessly", thereby avoiding the need for the in-ear hearing aid to be provided with electrical contacts. In any case, such a charging device may have a holder for inserting and holding the hearing aid in a fixed position in the charging device during charging.

A problem with these devices is that the cooperating charger elements may not always be positioned correctly in a first relationship with each other, whereby the charging process may be interrupted or slowed down.

It is therefore an object to provide a more stable charging of a hearing device, such as a hearing aid.

It is another object of the invention to make a charger insert comprising a holder for custom hearing devices that can be inserted into a universal hearing device charger set for custom RHI (rechargeable hearing devices), which is low cost, fast and simple to manufacture, does not require post-processing, and meets biocompatibility and medical grade requirements.

US 2019/0089187 a1 discloses a standardized hearing aid with a hearing aid charger device.

Disclosure of Invention

In a first aspect, the object of the invention is achieved by a method of manufacturing a charger insert comprising a holder or holding a rechargeable hearing device in a hearing device charger arrangement, the rechargeable hearing device being individually customized to be at least partially inserted into an ear canal of a user, the hearing device charger arrangement being configured to charge the rechargeable hearing device, the hearing device charger arrangement comprising:

a charger housing having a receiving portion for a charger insert having a retaining socket, an

A first charger element having a first position in the charger housing,

the method comprises the following steps:

-providing a first virtual model of the chargeable hearing device shaped to at least partially conform to the shape of the ear canal part based on the data set representing the shape of the ear canal part of the user, including assigning a second position for an electronic hearing aid device comprising at least a second charger element in the first virtual model of the chargeable hearing device;

-providing, based on the first virtual model, a second virtual model of a charger insert for insertion into a receiving portion of the hearing device charger appliance, the charger insert in the second virtual model being designed to support the chargeable hearing device such that the first charger element is positioned in a first relationship with the second charger element when the charger insert is placed in the receiving portion of the hearing device charger appliance; and

-shaping a customized charger insert together with the holder by a 3D manufacturing process based on the second virtual model.

By 3D manufacturing process is meant any process that can be shaped to form a 3-dimensional object starting from a blank and removing material from the blank or creating the object by continuously adding material, based on a dataset of a virtual model of the object to be manufactured, such as the second virtual model described above. Such processes may be milling and stereolithography processes, such as 3D printing, respectively.

In one embodiment, the 3D manufacturing process may be a Rapid Prototyping (RPT) process.

In an embodiment, providing the second virtual model of the charger insert is further based on data about the shape of the charger housing. The shape may also include data regarding the size (size) of the charger housing.

In a further embodiment, providing the second virtual model of the charger insert may alternatively or additionally be further based on data regarding a first position of the first charger coil within the charger housing.

In a further embodiment, in addition to any of the preceding embodiments, providing the second virtual model of the charger insert may include configuring the holder in a predetermined orientation relative to the charger housing.

Here, spatial orientation with respect to other parts of the housing is meant, such as side walls, bottom and/or lid of the housing of the hearing device charger arrangement. In some embodiments, the housing and other components, such as the electronic components of the hearing device charger device, are a universal housing/hearing device charger device, except that the charger insert comprises a holder for holding a personalized/customized chargeable hearing device, universal in the sense that the housing and/or any electronic components of the hearing device charger device may have a standardized shape (e.g. including dimensions), such that the charger insert may be inserted into the charger housing and will fit into the space provided by the charger housing when customized for a customized chargeable hearing device, and such that the first and second charger elements form a mutual relationship such that the first charger element may charge the second charger element.

In a further embodiment, in addition to any of the preceding embodiments, positioning the first charger element in a first relationship with the second charger element comprises: aligning a first charger element in a charger housing with a second charger element in the chargeable hearing device when the charger insert is placed in the receiving portion of the hearing device charger appliance and when a charging hearing device is placed in the charger insert.

In a further embodiment, in addition to any of the preceding embodiments, providing the second virtual model comprises designing a holder, at least a subset of surface portions of which reflect corresponding surface portions of the customized chargeable hearing device.

Preferably, a subset of such surface portions is selected such that the customized chargeable hearing device is stably supported in the holder of the charger insert. Not all surface portions of a customized chargeable hearing device need be mirrored.

In a further embodiment, in addition to any of the preceding embodiments, providing the second virtual model includes removing an undercut surface of the holder in the second virtual model.

Thereby, it may be ensured that the customized chargeable hearing device may be inserted into and removed from the holder of the charger insert without damaging the charger insert and/or the customized chargeable hearing device, in particular if the charger insert is made of a rigid or semi-rigid material.

In a further embodiment, in addition to any of the preceding embodiments, providing the second virtual model of the charger insert includes digitally designing the second virtual model of the charger insert on a computer.

In a further embodiment, providing the first virtual model of the chargeable hearing device may comprise digitally designing the first virtual model of the chargeable hearing device on a computer in addition to any of the preceding embodiments.

In another embodiment, in addition to any of the preceding embodiments, the second charger element of the chargeable hearing device is formed in an outward facing faceplate of the chargeable hearing device having a flat outer surface, and wherein the method comprises designing the holder of the charger insert such that the flat surface of the outward facing faceplate of the chargeable hearing device is substantially parallel to the upward facing surface of the charger insert when the chargeable hearing device is held in the holder.

"substantially parallel" means parallel or within +/-5 degrees of parallel.

In a further embodiment, in addition to any of the preceding embodiments, the position of the first charger element is a fixed, standardized position in the charger housing. In some embodiments, the housing and other components, such as the electronics of the hearing device charger device, are a universal housing/hearing device charger device, except that the charger insert includes a holder for holding a personalized/customized rechargeable hearing device. The hearing device charger device/charger housing is universal in the sense that the housing of the hearing device charger device and/or any electronic components may have a standardized shape (e.g. including dimensions), such that when customized for a customized chargeable hearing device, the charger insert may be inserted into the charger housing and will fit into the space provided by the charger housing and bring the first and second charger elements into mutual relation such that the first charger element may charge the second charger element. Thus, in a further embodiment, the charger housing may have a fixed, standardized shape and size in addition to any of the preceding embodiments.

In a further embodiment, in addition to any of the preceding embodiments, the charger housing may include a box-shaped charger base and a charger cover configured to cover the charger base. In a further embodiment thereof, the first charger element is positioned in the charger lid. In the latter case, providing the second virtual model may comprise positioning a holder for the second charger element relative to the housing such that the second charger element is positioned in a first relationship with the first charger element when the rechargeable hearing device is placed in the holder of the charger insert, e.g. such that the second charger element is aligned with the first charger element in the lid (and the lid is closed to cover the box-shaped charger base).

In a further embodiment, in addition to any of the preceding embodiments, the first charger element is a first charger coil and the second charger element is a second charger coil. Alternatively, the first and second charger elements are electrical contact elements. In this case, the first relationship between the first charger element and the second charger element comprises bringing into electrical contact with each other.

In a further embodiment, in addition to any of the preceding embodiments, the charger insert comprising the holder is formed from a block of material by milling material out of the block of material. Alternatively, in addition to any of the preceding embodiments, instead of milling, the charger insert with the retaining socket is formed by an additive manufacturing process, e.g. a stereolithography process.

Thus, the charger insert with the retention socket may be formed by a 3D printing process.

In a further embodiment, the charger insert may include a plate portion and a holder portion in addition to any of the preceding embodiments.

The retainer seat portion forms a retainer seat, which may be considered a cavity in the retainer seat portion.

The holder portion may preferably be integrally formed with the plate portion. Alternatively, the plate portion and the holding seat portion are formed separately and then assembled.

The plate portion may comprise an edge shaped to mate with, i.e. be received in, a receiving portion of the charger housing. Preferably, the receiving portion of the charger housing is formed in a box-shaped charger base.

In any case, it is preferable that the holding seat portion extends from the plate portion, i.e., from one surface thereof.

In further embodiments, in addition to the aforementioned embodiment in which the holder is formed by a stereolithography process, the charger insert is formed such that the plate portion is formed before the holder portion.

Thus, in an embodiment of the method, the charger insert with the holder therein is formed by an additive manufacturing process, the charger insert comprises a plate portion and a holder portion, and the holder portion extends from the plate portion, and the charger insert is formed such that the plate portion is formed before the holder portion.

It is thus achieved that the charger insert can be formed without any support, as the plate portion will provide support throughout the stereolithography process.

In a further embodiment, in addition to any of the preceding embodiments, the charger insert including the holder is formed of a biocompatible material.

In a further embodiment, the method may comprise, in addition to any of the preceding embodiments, an initial step of determining a shape of a portion of the ear canal of the user, comprising:

-inserting a portion of a soft (pliable) material into the ear canal of a user, thereby forming an impression of the ear canal, and

-scanning the impression of the ear canal and providing a data set representing the shape of the part of the ear canal of the specific user based on the scanned shape of the impression of the ear canal to provide a first virtual model.

Providing a data set representing the shape of the ear canal part of the user may be obtained digitally by scanning on a computer.

An impression of the ear canal may be made by pouring a soft material (e.g. a casting material, typically a biocompatible silicone-based material) into the ear canal of a user who needs or wishes to purchase a custom/personalized hearing device. The casting material may be a two-part liquid material comprising a filler and a curing agent. After mixing of the two components, the casting material will cure within a few minutes.

Furthermore, photo-curing of casting materials is known in the art, using silicone-based materials suitable for photo-curing.

Two such types of silicone materials are known in the art. Products commonly used for this purpose are manufactured by Egger Otoplastik + Labortechnik GmbH or Dreve GmbH.

As an alternative to obtaining a data set representing the shape of a portion of the ear canal, in a further embodiment, the method may comprise, in addition to any of the preceding embodiments, an initial step of determining the shape of the ear canal portion of the user, comprising:

-scanning at least a portion of the user's ear canal; and

-providing a data set representing a scanned shape of the part of the user's ear canal from a scan of the part of the user's ear canal for providing a first virtual model.

The data set providing the shape of the part of the user's ear canal may be obtained digitally by scanning on a computer.

The scanning of at least a portion of the user's ear canal may be performed by optically scanning a portion of the user's ear canal.

In a second aspect of the invention, the object of the invention is achieved by a charger insert comprising a holder for holding a rechargeable hearing device in a hearing device charger arrangement, the rechargeable hearing device being individually customized to be at least partially inserted into an ear canal of a user, the hearing device charger arrangement being configured to charge the rechargeable hearing device, wherein the charger insert is formed by a method according to any of the above embodiments of the first aspect of the invention.

In a third aspect of the invention, the object of the invention is achieved by a hearing device charger arrangement for charging a rechargeable hearing device, the hearing device charger being individually customized to be at least partially inserted into an ear canal of a user, the hearing device charger arrangement comprising a charger insert comprising a holder for holding the rechargeable hearing device during charging, wherein the charger insert is formed by a method as described in connection with any one of the embodiments of the first aspect of the invention described above.

The hearing device charger arrangement for charging an individually shaped hearing device comprising a second charger element may comprise:

-a charger housing;

-a charger power supply disposed within the charger housing;

-a first charger coil connected to a charger power supply,

-charger electronics for controlling charging of the hearing device; and

a holder for receiving a chargeable hearing device arranged in a charger housing,

wherein the holder for the hearing device is shaped such that the holder supports the hearing device and the first charger element is adjacent to the second charger element when the hearing device is received in the holder.

In an embodiment, a holder for a rechargeable hearing device is provided in the charger insert.

The charger insert may thus model/plan/design a rechargeable hearing device for customization to insert a universal/standard hearing device charger device.

In an embodiment, the charger insert may be formed by a 3D manufacturing process.

In an embodiment, the charger insert is a flat structure having an upper surface, a lower surface, and a peripheral edge, wherein the holder extends away from the lower surface, and wherein the peripheral edge is configured to mate with an edge of the charger housing.

In an embodiment, the hearing device charger arrangement comprises a charger lid arranged to mate with the charger housing, the first charger element being arranged in the charger lid in such a way that the first charger element is in an operational position for providing charging power to the second charger element when the hearing device is placed in the holding receptacle and the charger lid is closed.

Hereby, it is achieved that charging can only be performed when the lid is closed, thereby reducing the risk that the hearing instrument accidentally falls out of the hearing instrument charger unit.

In a fourth aspect of the invention, the object is achieved by a hearing device system comprising:

-a chargeable hearing device; and

-a hearing device charger arrangement according to any of the embodiments of the third aspect of the invention.

In an embodiment, the hearing device charger arrangement comprises a charger lid arranged to mate with the charger housing, wherein the first charger element is arranged in the charger lid, and wherein the hearing device comprises a second charger element formed in an outward facing panel of the hearing device, wherein the first charger element and the second charger element are arranged such that the first charger element and the second charger element face each other when the hearing device is received in the holding receptacle and the lid is closed.

It should be emphasized that the term "comprises/comprising" when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

Drawings

Hereinafter, the present invention will be described in more detail with reference to the embodiments shown in the drawings. It should be emphasized that the illustrated embodiments are for purposes of example only and should not be taken as limiting the scope of the invention.

Figures 1A-1C illustrate the steps of providing a first virtual model of a chargeable hearing device, for an embodiment of the method according to the invention,

fig. 1A illustrates a virtual model or dataset, resembling the shape of a portion of the user's ear canal;

fig. 1B illustrates a virtual model or data set of a hearing device housing shape forming a negative (negative) corresponding to the shape of the user's ear canal part based on the virtual model or data set shown in fig. 1A;

fig. 1C illustrates a virtual model or dataset of the shape of the chargeable hearing device, the shape of which is customized to the shape of the ear canal of the user, the virtual model or dataset comprising the positions of the components of the chargeable hearing device;

figures 2A-2F illustrate the steps of providing a second virtual model or data set representing a chargeable hearing device, the second virtual model being used in an embodiment of the method according to the invention;

fig. 2A illustrates a first virtual model or data set representing the shape of a chargeable hearing device provided as shown in fig. 1A-1C or 4A-4C;

fig. 2B illustrates a modeling of a position of a representation of a chargeable hearing device relative to a position of a representation of a position of a first charging element of a charger device;

fig. 2C illustrates a representation of a chargeable hearing device in a charger insert, wherein the top description is a side view and the bottom description is a perspective view from above;

fig. 2D illustrates a representation of a rechargeable hearing device in a charger insert and modeling of a holder part of the charger insert;

figure 2E illustrates the modeling of the modified shape of the holder part of the charger insert;

fig. 2F shows in perspective a complete second virtual model of a charger insert for forming the charger insert;

3A-3D illustrate forming a set of customized chargeable hearing devices, FIGS. 3E-3G illustrate embodiments of a method according to the first aspect of the invention;

fig. 3A illustrates providing a first virtual model of a chargeable hearing device;

fig. 3B illustrates forming a housing part of a chargeable hearing device, for example in a 3D printer;

fig. 3C shows a finished housing part customized for the left and right ear canals of a user;

fig. 3D shows a customized set of chargeable hearing devices, where components (including a second charger element) have been mounted in each housing part shown in fig. 3C;

fig. 3E illustrates providing a second virtual model representing a customized charger insert suitable for use in the customized chargeable hearing device shown in fig. 3D based on the first virtual model provided in fig. 3A;

fig. 3F illustrates the formation of a charger insert, for example in a 3D printer, based on the second virtual model as shown in fig. 3E;

fig. 3G shows a complete custom charger insert, suitable for the custom rechargeable hearing device shown in fig. 3D, and ready to be mounted in the housing of the hearing device charger unit;

4A-4C illustrate one way of obtaining a data set regarding the shape of a portion of a user's ear canal for use in a method according to the present invention;

fig. 4A shows a partial cross-sectional view of a human ear and ear canal and an impression of the ear canal in a portion of the ear canal;

fig. 4B shows an impression of the ear canal in a 3D scanner and illustrates the step of scanning (e.g. optically scanning) the impression to obtain a data set resembling a part of the ear canal of a user;

fig. 4C shows a PC with a keyboard, a mouse and suitable 3D modeling software, and illustrates how the data set obtained by scanning is transferred to a computer with software to provide at least one virtual model/data set representing the shape of the user's ear canal part;

figure 5 shows a customized chargeable hearing device in cross-sectional side view; and

fig. 6 shows, in cross-sectional side view, a hearing device charger arrangement according to a third aspect of the invention with a charger insert according to the second aspect of the invention, the charger insert being formed in a method according to the first aspect of the invention.

List of reference numerals:

pinna of P users

Ear canal of EC user

Tympanic membrane for T-users

1 hearing device, HI

1A hearing device, left hearing device (left HI), HI housing with electronics

1A' left hearing device housing, (left HI housing)

1B hearing device, right hearing device (right HI), HI housing with electronics

1B' Right hearing instrument shell (Right HI shell)

4a second charging element, a charging element of a chargeable hearing device,

5 Panel

6 Hearing device electronics

7 rechargeable battery

8 ear canal impression

8 'data set representing the shape of the user's ear canal part, virtual representation of the ear canal part, virtual model of the ear canal part

9 receiver

103D scanner

11 PC with keyboard, mouse and appropriate 3D modeling software

123D printer

20 hearing device charger device/HI charger device

21 charger shell

22 first charger coil, charger coil of hearing instrument charger device of right hearing instrument

23 first charger coil, charger coil of a hearing instrument charger device of a left hearing instrument

24 cable connecting the charger electronics to the charger coil of the hearing device charger unit

25 charger power supply

26 charger shell base

27 charger cover

28 charger electronics

29 receiving portion, edge of charger housing

40 charger insert

41 plate portion of charger insert

45 holder for receiving a rechargeable hearing device

46 holder portion of charger insert

50 volume added to damascene to remove undercut

51 undercut surface

70 first virtual model, virtual model of a chargeable hearing device, data set representing a chargeable hearing device

80 second virtual model, virtual model of charger insert, data set representing charger insert

100 system

Detailed Description

Various embodiments are described below with reference to the drawings. Like reference numerals refer to like elements throughout. Therefore, similar elements will not be described in detail with respect to the description of each figure. It should also be noted that the figures are only intended to facilitate the description of the embodiments. They are not intended as an exhaustive description of the claimed invention or as a limitation on the scope of the claimed invention. Moreover, the illustrated embodiments need not have all of the aspects or advantages shown. Aspects or advantages described in connection with a particular embodiment are not necessarily limited to that embodiment and may be practiced in any other embodiment, even if not so illustrated or if not so expressly described.

The present invention relates to a customized chargeable hearing device 1A, 1B, and to the manufacture of a hearing device charger arrangement 20 for charging such a chargeable hearing device 1A, 1B, or at least for the manufacture of a charging insert 40 for such a hearing device charger arrangement 20.

The shape of the customized chargeable hearing devices 1A, 1B varies from user to user and from ear to ear of the user. Thus, the use of a standardized single-shaped holder in a hearing device charger arrangement does not necessarily ensure correct placement of the charger element of the rechargeable hearing device relative to the charger element of the hearing device charger arrangement. In order to improve the charging efficiency of the charging of the rechargeable hearing devices 1A, 1B, according to the present invention, the customized charger insert 40 is configured to hold such customized rechargeable hearing devices 1A, 1B in a correct position with respect to the charger element of the hearing device charger arrangement 20.

However, referring now to fig. 5, the hearing devices 1A, 1B will first be described. Fig. 5 shows a cross section of the hearing devices 1A, 1B. The hearing devices 1A, 1B comprise a hearing device housing 1, manufactured/formed as described above and described in further detail below.

The hearing devices 1A, 1B have a proximal end, which is closest to the eardrum T, i.e. the eardrum, of the user when the hearing devices 1A, 1B are inserted into the ear canal EC of the user, and an opposite distal end, which is located at the entrance of the ear canal EC of the user when the hearing devices 1A, 1B are inserted (not shown) into the ear canal of the user. The hearing instrument further comprises a set of internal components arranged within the hearing instrument housing 1, 1A ', 1B'.

These components include electronic components such as a speaker (which is often referred to as a receiver, hereinafter referred to as hearing device receiver 9), a rechargeable battery (or hearing device rechargeable battery 7), a second charger element 4 and control electronics; the hearing aid electronics 6 are used to control at least the hearing device receiver 9 and to charge the hearing device rechargeable battery 7 via the second charger element 4. The second charger element 4 is charged by means of the first charger elements 22, 23 provided in the hearing device charger arrangement 20 described below in connection with fig. 6.

The hearing device receiver 9 is typically arranged at a proximal end of the hearing device 1A, 1B so as to be close to the eardrum of the user when inserted into the ear canal EC of the user. Other components may be arranged in positions within the hearing device housings 1A ', 1B' that may vary depending on the individual shape of the hearing device housings 1A ', 1B'.

The hearing devices 1A, 1B may further comprise a passage from the hearing device receiver 9 to the proximal end of the hearing device, a filter for preventing cerumen and other impurities from entering the hearing devices 1A, 1B. Furthermore, the inner surface of the inner space of the hearing device housings 1A ', 1B' may be configured such that the inner components may be mounted/arranged in the designed/planned position.

The internal components may additionally include one or more microphones (not shown in fig. 5). For example, a microphone may be provided at the distal end of the hearing instrument.

The internal components may also include means for wireless communication with other devices. For example, such devices may communicate with behind-the-ear devices, mobile phones/handsets, or other external electronic devices.

The electronic components located in the inner space of the hearing devices 1A, 1B may be electrically connected to each other, e.g. by suitable wiring, for transmitting energy and/or data.

The hearing devices 1A, 1B shown in fig. 5 are provided with a faceplate 5 at the distal end for closing the inner space of the hearing devices 1A, 1B. The panel 5 serves to seal an inner space having inner components from foreign substances from the external environment.

The face plate 5 may be shaped to fit the contours of the ear canal of the user. However, when inserted into the ear canal, the distal end of the hearing device is typically not in contact with any surface of the user's ear canal, but is located at the opening/entrance from the outer ear into the user's ear canal. Thus, the panel 5 may be shaped to have a regular planar surface, as shown in fig. 5.

In the hearing devices 1A, 1B shown in fig. 5, the second charger element 4 is shown adjacent to the faceplate 5. For example, the second charger element 4 may be integrated in the faceplate 5 or located adjacent to the inner surface of the faceplate 5. In some embodiments, the second charger element 4 may be located in a recess formed in the inner surface of the faceplate 5. Alternatively, the charger element 4 may be structurally connected (not shown) to other components in the interior space or to the inner walls of the hearing device housings 1A ', 1B'.

As mentioned above, however, in other embodiments the second charger 4 may be located elsewhere within the cavity/interior of the hearing devices 1A, 1B.

Fig. 6 shows a hearing device charger arrangement 20 in which a charger insert 40 manufactured by the method of the invention described further below is inserted.

The hearing device charger arrangement 20 comprises a charger housing 21. The charger housing 21 in the present embodiment includes a charger base 26 and a charger cover 27. The charger base 26 in the present embodiment is formed in an open box-shaped structure having an internal volume. The interior volume may house a charger power supply 25. In the illustrated embodiment, the charger power supply 25 is a battery. The battery may be a replaceable battery, may be a disposable non-rechargeable battery or a rechargeable battery. Alternatively, the battery may be a stationary rechargeable battery. In embodiments where the charger power supply 25 is a rechargeable battery, the hearing device charger apparatus 20 may provide a portable mobile power supply (power bank) for one or more hearing devices 1A, 1B.

In other embodiments, the charger power supply 25 of the hearing device charger apparatus 20 may be a transformer for transforming mains power to a power supply for one or more hearing devices 1A, 1B. In other embodiments, the charger power supply 25 of the hearing device charger apparatus 20 may be a transformer connected to a rechargeable battery, such that the hearing device charger apparatus 20 may charge one or more hearing devices 1A, 1B when connected to and disconnected from mains (via a cable not shown).

The internal volume of the charger housing 21 of the hearing device charger arrangement 20 may also house charger electronics 28 for controlling the charger power supply 25 (when it is a stationary rechargeable battery) and/or the charging of one or more hearing devices 1A, 1B.

The hearing device charger arrangement 20 further comprises a first charger element 22, 23, one for each of the hearing devices 1A, 1B to be charged.

The charger electronics 28 are connected to the charger power supply 25 by suitable wiring (not shown). Furthermore, the charger electronics 28 are connected to the first charger coils 22, 23 by suitable wiring, such as a cable 24.

The charger electronics 28 is preferably configured such that it can detect the presence of the hearing device 1A, 1B in its vicinity and start charging if a hearing aid is present. This may be achieved if the presence of the first charger element 4 of the hearing devices 1A, 1B is detected.

As shown in fig. 6, the charger insertion portion 40 may cover an inner volume of the charger base 26 of the charger housing 21, the charger insertion portion 40 being provided in the receiving portion 29 of the charger housing 21. Referring to fig. 5, it should be understood that the receiving portion 29 may be an edge of the box-shaped charger base 26. The receiving portion 29 in the form of a rim of the box-like charger base 26 is preferably sized and shaped to receive the charger insert 40. For example, the size and shape of the peripheral edge of the plate portion 41 of the charger insert 40 may be received by the edge of the box-like charger base 26 of the housing 21.

In fig. 6, the charger insert 40 is illustrated with two holders 45, each holder 45 for holding a rechargeable hearing device 1A, 1B. Such a charger insert may be manufactured according to the method described below. However, it should be understood that the charger insert 40 may be formed with only a single holder 45 for holding a single chargeable hearing device 1A, 1B. In this case, the charger housing 21 may have a receiving portion 29 for each of a plurality of charger inserts 40, one for each of the customized chargeable hearing devices 1A, 1B to be charged. Typically, this means two charger inserts 40, one for each of the chargeable hearing devices 1A, 1B, since most users require one chargeable hearing device 1A, 1B per ear.

During face modeling, the position of the one or more holders 45 relative to the charger insert 20 is configured such that the second charger element 4 (in each hearing device 1A, 1B, not shown in fig. 6) is aligned with a respective one of the first charger elements 22, 23 when the charger insert 40 is inserted into the charger housing 21, and when the hearing devices 1A, 1B are inserted into the holders 45.

The shape of the holder 45 also ensures a precise alignment of the first charger element 4 with the second charger element 22, 24, allowing only insertion of the respective hearing device 1A, 1B in one particular orientation.

In one embodiment, as shown in fig. 6, the first charger elements 22, 23 may be arranged to be connected to a charger cover 27. This configuration of the hearing device charger arrangement 20 may ensure that charging is only started when the lid is closed and the first charger element 22, 24 has thus been aligned with the second charger element 4 in the respective hearing device 1A, 1B.

In the embodiment shown in fig. 6, the holder 45 and the charger insert 40 are configured such that the hearing devices 1A, 1B (when inserted into the holder 45) are positioned vertically with the proximal end/faceplate 5 facing upwards and the plane defined by the surface of the faceplate 5 being parallel to the plane defined by the upper surface of the charger insert 40. In this case, the first charger element 4 in the hearing devices 1A, 1B is arranged in a faceplate 5A, 5B, as shown in fig. 5.

It should be understood, however, that in alternative embodiments, the holder 45 and the charger insert 40 may be configured such that the hearing devices 1A, 1B are oriented differently with respect to the plane defined by the upper surface of the charger insert 40 than is the case in fig. 6. For example, the hearing devices 1A, 1B may "lie flat" instead of the vertical position shown in fig. 6. In this case, the second charger element 4 in the hearing devices 1A, 1B may be arranged parallel to the side wall portions of the hearing device housings 1A ', 1B' instead of being arranged in the faceplate 5 as shown in fig. 5 and 6.

It should also be understood that in other embodiments the first charger element 22, 23 may be arranged inside the charger base 26 of the charger housing 21 instead of in the charger cover 27, in which case the holder 45, the charger insert 40 and/or the hearing device 1A, 1B (positioning of the first charger element 4 in the hearing device 1A, 1B) are modelled and formed such that the first and second charger elements are aligned with each other when the hearing device 1A, 1B is placed in the holder 45.

A marking may be formed on the charger insert 40 close to the respective holder 45, which marking indicates which hearing instrument is inserted into which holder 45'. The markers may e.g. be "L" indicating "left" and "R" indicating "right", indicating the positions of inserting and charging the left and right hearing devices 1A, 1B, respectively. Other symbols or text may alternatively be considered. The marks may be formed as indentations in the charger insert 40. In other embodiments, the indicia may be provided on the charger insert 40 after the charger insert 40 has been formed with the holder/holders, for example, by stamping, printing, or other techniques known in the art.

The respective markings indicating the relation between the holder 45 and the respective hearing device 1A, 1B may be designed in a modeling phase such that the hearing device 1A, 1B is formed with markings on the outer surface.

Fig. 6 also illustrates a hearing device system 100 comprising a set of hearing devices 1A, 1B and a hearing device charger arrangement 20.

In a first aspect, the invention relates to a method of manufacturing a charger insert 40, the charger insert 40 comprising a holder 45 for holding a chargeable hearing device 1A, 1B, for example as described above. As also mentioned above, the chargeable hearing devices 1A, 1B are individually customized to be at least partially inserted into the ear canal of the user. The insert 40 comprising the retention socket 45 is configured to retain the chargeable hearing device 1A, 1B in the hearing device charger arrangement 20, and the hearing device charger arrangement 20 is configured to charge the chargeable hearing device 1A, 1B.

The hearing device charger arrangement 20 may be as described above in connection with fig. 6, however, more generally, the hearing device charger arrangement 20 may comprise a charger housing 21 and first charger elements 22, 23, the charger housing 21 having a receiving portion 29 for a charger insert 40 comprising a holding socket 45. The first charger elements 22, 23 have a first position in the charger housing 21.

The method according to the invention comprises the following steps:

providing a first virtual model 70 of the chargeable hearing device 1A, 1B shaped to at least partially conform to the shape of the ear canal part, based on the data set 8' representing the shape of the ear canal part of the user, including assigning a second position for the electronic hearing aid device 28 comprising at least the second charger element 4 in the first virtual model 70 of the chargeable hearing device 1A, 1B;

providing a second virtual model 70 of the charger insert 40 for insertion into the receiving portion 29 of the hearing device charger arrangement 20 based on the first virtual model, the charger insert 40 being designed to support the chargeable hearing device 1A, 1B in the second virtual model 80 such that the first charger element 22, 23 is positioned in the first relationship 20 with the second charger element 4 when the charger insert 40 is placed in the receiving portion 29 of the hearing device charger arrangement; and-shaping the customized charger insert 40 together with the holder 45 by a 3D manufacturing process based on the second virtual model 80.

Fig. 1A-1C illustrate the steps of providing a first virtual model 70 of a chargeable hearing device 1A, 1B, the first virtual model 70 being used in an embodiment of the method according to the invention.

Fig. 1A illustrates a virtual model 8 ', or data set, similar to the shape of a portion of the user's ear canal EC. Such a virtual model 8' may be obtained by scanning the ear canal EC of the user, or by making an impression 8 of a desired part of the ear canal and scanning the impression. This will be described in more detail below.

A data set 8 ' similar to/representing the shape of a portion of the ear canal EC of the user is used to provide a representation of the shape of the housing 1A ', 1B ' of the hearing device 1A, 1B. This is illustrated in fig. 1B. Fig. 1B illustrates a virtual model 75 or data set of the shape of the housing 1A ', 1B ' of the chargeable hearing device 1A, 1B forming a counterpart corresponding to the shape of the ear canal EC part of the user based on the virtual model 8 ' or data set shown in fig. 1A.

Any or all of these steps are preferably performed in a computer using suitable modeling software. It is therefore to be understood that in the method according to the invention, providing the first virtual model of the chargeable hearing device 1A, 1B may comprise digitally designing the first virtual model 70, 75 of the chargeable hearing device 1A, 1B on a computer.

The virtual model 75 or data set of the shape of the housing 1A ', 1B' of the chargeable hearing device 1A, 1B is then used to provide a representation of the shape of the chargeable hearing device 1A, 1B, e.g. as shown in fig. 1C. Fig. 1C illustrates a second virtual model 80 or data set representing the shape of the chargeable hearing devices 1A, 1B, having a shape customized to the shape of the user's ear canal EC. Providing the second first model 70 or data set comprises determining or assigning the positions of the components 4, 5, 6, 7, 9 of the chargeable hearing devices 1A, 1B, e.g. at least the second charger element 4, and the other hearing device electronics 6, the chargeable battery 7 and the receiver 9. In the illustrated embodiment, the first virtual model 70 is also shown to include a location or panel 5, for example as described above.

It is therefore to be understood that in the method according to the invention, the second charger element 4 of the chargeable hearing device 1A, 1B may be designed to be located in an outwardly facing faceplate 5 of the chargeable hearing device 1A, 1B, the faceplate having a flat outer surface, and wherein the method may further comprise designing the holder 45 of the charger insert 40 such that the flat surface of the outwardly facing faceplate 5 of the chargeable hearing device 1A, 1B is substantially parallel to the upwardly facing surface of the charger insert 40 when the chargeable hearing device 1A, 1B is held in the holder 45.

It is to be understood that in designing or modeling the second virtual model 80 for the chargeable hearing devices 1A, 1B, assigning space and position/location to its components, in particular the second charger element 4, may comprise using data regarding the expected position of the first charger element 22, 23 within the housing of the hearing device charger arrangement 20.

Preferably, at least the charger housing 21 may be a standardized shell. Thus, the components of the hearing device charger arrangement 20 and the layout of the chargeable hearing devices 1A, 1B may be customized with respect to the known configuration of the charger housing 21. In some embodiments, the position of at least the first charger element 22, 23 is in a fixed standardized position in the charger housing 21. In yet another embodiment, all components of the hearing device charger apparatus 20 are standardized. Thus, the only part to be personalized is the charger insert 40 comprising the holder 45.

In some embodiments, the method entails designing the charger insert 40 to conform to the charger housing 21, the charger housing 21 including a box-shaped charger base 26 and a charger cover 27 configured to cover the charger base 26, and wherein the first charger element 22, 23 is located in the charger cover 27.

In any embodiment, the charger elements 22, 23 are first charger coils and the second charger element 4 is a second charger coil. In this case, aligning the first and second charger elements means aligning the axes of the coils.

Turning now to fig. 2A-2F, these figures illustrate the steps of providing a second virtual model 80 or data set representing a chargeable hearing device 1A, 1B, the second virtual model 80 being used in an embodiment of the method according to the invention.

Fig. 2A illustrates a first virtual model 70 or data set representing the shape of a chargeable hearing device 1A, 1B provided as shown in fig. 1A-1C or 4A-4C. The first virtual model 70 comprises at least the above-mentioned virtual model 75 or data set representing the shape of the housings 1A ', 1B' of the chargeable hearing devices 1A, 1B, and the second charger element positions 4 'within the first virtual model 70 of the second charger element 4, and the planned positions of the first charger elements 22, 23, as shown in fig. 2B as the first charger element positions 22'.

Fig. 2B shows a modeling of the position of the representations 70, 75 of the chargeable hearing devices 1A, 1B with respect to the first charger element position 22 ", i.e. a representation of the position of the first charging element 22, 23 in the housing 21 of the hearing device charger arrangement 20.

Fig. 2C illustrates a representation of the chargeable hearing devices 1A, 1B in the charger insert 40, the first virtual model 70. In fig. 2C, the top description is a side view and the bottom description is a perspective view from above of a representation of the chargeable hearing device 1A, 1B in the charger insert 40.

Placing a shape representing the hearing device housings 1A ', 1B' in the charger insert may comprise: the rotation of the representation 75 of the hearing device housing 1A ', 1B' or the representation 70 of the chargeable hearing device 1A, 1B is oriented relative to the known position of the housing wall and the electronic components in the housing 21 of the hearing device charger arrangement 20. Such positioning may for example comprise a rotation of the representation 75 of the hearing device housing 1A ', 1B' or the representation 70 of the chargeable hearing device 1A, 1B relative to a known or desired position of all elements of the hearing device charger arrangement 20.

As shown in fig. 2B, the holder 45 may be modeled as shown in fig. 2D when the representation 75 of the hearing device housings 1A ', 1B' or the representation 70 of the rechargeable hearing devices 1A, 1B has been positioned in the charger insert 40. Fig. 2D illustrates a representation 70 of a chargeable hearing device in a charger insert and a modeling of the holder portion 46 of the charger insert 40. This part of the modeling requires making a cavity surface and offsetting the surface of the holder portion 46 to provide space for placing the rechargeable hearing devices 1A, 1B into the completed charger insert holder 45.

It will therefore be appreciated that in the method according to the invention, providing the second virtual model of the charger insert 40 may further be based on data regarding the shape of the charger housing. As described above, such data may include information regarding the size and shape of the charger housing, as well as the modeled location of components therein, such as described above in connection with fig. 6.

It is therefore to be understood that in the method according to the invention, the provision of the second virtual model of the charger insert 40 may be further based on data regarding the first position of the first charger coil 22, 23 within the charger housing 21.

It will also be appreciated that in the method according to the invention, providing the second virtual model of the charger insert 40 comprises configuring the holder 45 in a predetermined direction relative to the charger housing 21

It will be further understood that in the method according to the invention, positioning the first charger element 22, 23 in the first relationship with the second charger element 4 comprises: when the charger insert 40 is placed in the receiving section 29 of the hearing device charger arrangement 20, and when the charging hearing devices 1A, 1B are placed in the charger insert 40, the first charger element 22, 23 in the charger housing 21 is aligned with the second charger element 4 in the charging hearing devices 1A, 1B.

Fig. 2E illustrates modeling of a modified shape of the holder portion 46 of the charger insert. This may require removing the undercut volume/surface from the virtual model. Fig. 2F shows a completed second virtual model 80 of the charger insert 40 for forming the charger insert 40 in perspective view.

It is therefore to be understood that in the method according to the invention, providing the second virtual model may comprise designing the holder 45 with at least a subset of the surface portions being identical to the corresponding surface portions of the chargeable hearing devices 1A, 1B.

It will be further understood that in the method according to the invention, providing the second virtual model 80 may comprise removing the undercut surface of the holder 45 in the second virtual model 80.

Any or all of these steps are preferably performed in the computer 11 using suitable modeling software. It will therefore be appreciated that in a method according to the invention, providing a second virtual model of the charger insert 40 may comprise digitally designing the second virtual model of the charger insert on a computer.

Once the second virtual model 80 of the customized charger insert 40 with the retention socket 45 is provided as described above, the second virtual model 80 may be used to form or shape the charger insert 40, such as by a 3D manufacturing process, as briefly discussed above, as shown in fig. 3E-3F.

Fig. 3E illustrates providing a second virtual model 80 representing a customized charger insert 40 suitable for use in a customized chargeable hearing device 1A, 1B, e.g. as illustrated in fig. 3D, based on the first virtual model 70 provided as illustrated in fig. 3A or fig. 2A-2F above. Fig. 3D (as well as fig. 3A-3C) will be discussed in more detail below.

Turning now to fig. 3F, this illustrates forming a charger insert based on the second virtual model as shown in fig. 3E, for example, in the 3D printer 12.

Fig. 3G shows a complete custom charger insert 40, suitable for use with a custom rechargeable hearing device 1A, 1B such as shown in fig. 3D, and ready to be mounted in the housing 21 of the hearing device charger arrangement 20.

Turning now to fig. 3A-3D, these figures illustrate the formation of a customized set of chargeable hearing devices 1A, 1B.

Fig. 3A illustrates a first virtual model 70 providing a chargeable hearing device 1A, 1B, e.g. as described above in connection with fig. 1A-1C.

Fig. 3B illustrates housing parts 1A ', 1B' forming the chargeable hearing devices 1A, 1B, for example, in a 3D printer 12. It should be understood that other ways of forming the hearing device housings 1A ', 1B' may alternatively be used.

Fig. 3C shows finished hearing device housing parts 1A ', 1B' customized for the left and right ear canals, respectively, of a user.

Once the hearing device housing parts 1A ', 1B' are provided, various components, such as those described above in connection with fig. 5, may be mounted into the hearing device housing parts 1A ', 1B'. Fig. 3D shows a customized set of chargeable hearing devices, wherein components including the second charger element 4 have been mounted in each of the hearing device housing parts 1A ', 1B' shown in fig. 3C.

Fig. 4A shows in a partial cross-sectional view an ear and an ear canal EC of a (future) user of a hearing device, e.g. a hearing aid, and an impression 8 of the ear canal in a part of the ear canal. In the figure, reference numeral P is an auricle of the user's ear. EC is the ear canal, shown in cross-section, with T pointing towards the tympanic membrane of the user's ear. The ear canal impression 8 is shown as the position in which a hearing device, such as a hearing aid, is located in the ear canal EC during use.

The ear canal impression 8 may be used in a known process of manufacturing the personalized hearing devices 1A, 1B.

The hearing devices 1A, 1B may for example be prescription hearing aids for persons diagnosed with hearing loss, but the invention may also be used for charging of other types of hearing devices configured to be located in the ear canal of a user during use.

Today, hearing aid housings for custom hearing aids are made from digital 3D scans of the ear canal cast, i.e. an impression 8 of the ear canal as shown in fig. 4A.

Fig. 4A shows an ear and ear canal EC, in this case the right ear and ear canal EC, of a user. Obviously, the user may also have a left ear and a left ear canal. In fig. 4A, an ear canal impression 8 of the right ear canal EC shows the position in the right ear canal EC. One skilled in the art will appreciate that a similar impression may be made of the user's opposite ear canal.

The ear canal impression 8 is made by pouring a casting material, typically a biocompatible silicone-based material, into the ear canal of a user who needs or wishes to purchase a custom/personalized hearing device.

Although the biocompatible, silicone-based material is at least partially cured within the ear canal of the user, the ear canal impression 8 will thereby form a shape that conforms to the shape of the ear canal EC. Typically, the biocompatible silicone-based material may also cover the user's tragus so that the ear canal impression also reflects the shape of the user's tragus. Thus, the hearing devices 1A, 1B based on the impression 8 of the ear canal (see below) may be shaped to also match the tragus of the user, which facilitates correct insertion of the hearing devices 1A, 1B into the ear canal for their rotational direction.

When the material solidifies, the ear canal impression 8 is removed from the user's ear canal EC and the ear canal impression 8 is digitally 3D scanned, as shown in fig. 4B, for a modeling phase performed by an operator on a computer by means of suitable 3D modeling software, as shown in fig. 4C.

Fig. 4B illustrates a 3D scan of an ear canal impression 8 of the ear canal EC of the ear shown in fig. 4A. Obviously, an impression of the contralateral ear canal may be provided in the same manner instead of or in addition to the impression of the ear canal EC shown in fig. 4A.

In the modeling phase, the shape of the hearing device housings 1A ', 1B' is determined based on data from the scan. In case the ear canal impression 8 is a solid model of the ear canal (or at least a suitable part thereof), the hearing device housings 1A ', 1B' will be hollow structures having an outer surface shaped to conform to the ear canal of the user and an inner space for the various components of the rechargeable hearing devices 1A, 1B.

In the modeling phase, the locations of the required electronic components (e.g. speaker, rechargeable battery, microphone, etc., commonly referred to as receiver) in the finished device (hearing instrument) are defined (planned) in a 3D data file providing the design/layout of the finished hearing instrument 1A, 1B. Thus, in the modeling phase, the shape of the electronic components and the position/positioning of the electronic components and other parts within the hearing device housing are planned/designed.

The shape of the ear canal of a user may be very different from the shape of the ear canals of other users, and the shapes of the two ear canals of a user may also be different. Thus, the available space for the internal components may vary from one hearing instrument to another, and thus the position/location of the internal components within a single hearing instrument may also vary.

When the layout of each future hearing device 1A, 1B has been planned, each hearing device housing 1A ', 1B' is then typically manufactured in a 3D printer, as shown in fig. 3B. The hearing instrument housings 1A ', 1B' may be manufactured during the modeling phase directly from the design in the 3D data file created in the above-mentioned computer, as described above.

Each of the hearing device housings 1A ', 1B' may be made of a biocompatible material or be post-processed to make it suitable for insertion into the ear canal EC of a user under current biocompatibility and medical grade requirements and regulations. The material used may be soft/resilient to ease insertion of the finished hearing device 1A, 1B into the ear canal EC of the user and so that the hearing device may accommodate e.g. jaw movements during use.

The impression 8 of the ear canal is often recorded for later copying and documentation, etc.

Fig. 4A-4C illustrate the way personalized information about the shape of the user's ear canal is obtained by using a cast of the ear canal (impression of the ear canal) and 3D scanning the model. The data/information regarding the shape of the user's ear canal EC (and in some cases also the shape of the user's tragus) is transmitted to a computer for further processing.

Thus, fig. 4A illustrates a step a of obtaining an impression of the ear canal EC. Fig. 4B illustrates a step B of digitizing the ear canal shape. Fig. 4A-4B thus also show a combined step of determining the shape of at least a part of the ear canal of a user in a method of manufacturing a holder 40, the holder 40 being used for holding an individually shaped hearing device 1A, 1B in a hearing device charger arrangement 20 configured for charging the hearing device 1A, 1B.

In principle, this shape data/information may be obtained in other ways, e.g. by 3D scanning of the ear canal, e.g. by optical scanning of a part of the ear canal of the user.

As mentioned above, fig. 3A illustrates how the shape data obtained in step C are used to design/plan one or more hearing devices 1A, 1B using the computer 11.

Fig. 3B-3D illustrate three steps of a known process of forming the hearing devices 1A, 1B using the shape data 8' stored in the computer 11.

Fig. 3E-3G illustrate three steps of an embodiment of a process of forming at least one charger insert 40 comprising a holder 45 for receiving a hearing device 1A, 1B in a hearing device charger arrangement 30.

In all of the above cases, instead of being formed in the 3D printer 12 as shown, the 3D manufacturing process may involve forming the charger insert 40 including the holder 45 from a block of material by milling material out of the block of material.

It should be noted that the figures and the above description have shown the example embodiments in a simple and schematic manner. Many specific mechanical details are not shown as those skilled in the art should be familiar with these details.

While particular features have been shown and described, it will be understood that they are not intended to limit the claimed invention, and it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the scope of the claimed invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The claimed invention is intended to cover all alternatives, modifications, and equivalents.

Claims (17)

1. A method of manufacturing a charger insert (40), the charger insert (40) comprising a holder (45) for holding a chargeable hearing device (1A, 1B) in a hearing device charger apparatus (20), the chargeable hearing device (1A, 1B) being individually customized for at least partial insertion into an ear canal of a user, the hearing device charger apparatus (20) being configured to charge the chargeable hearing device (1A, 1B), the hearing device charger apparatus (20) comprising:

-a charger housing (21) having a receiving portion (29), the receiving portion (29) for a charger insert (40) having a holder (45), and

a first charger element (22, 23) having a first position in the charger housing (21),

the method comprises the following steps:

-providing a first virtual model of the chargeable hearing device (1A, 1B) shaped to at least partially conform to an ear canal part shape based on a data set representing the user ear canal part shape, including assigning a second position for an electronic hearing aid device (28) comprising at least a second charger element (4) in the first virtual model of the chargeable hearing device (1A, 1B);

-providing, based on the first virtual model, a second virtual model of a charger insert (40) for insertion into a receiving portion (29) of the hearing device charger apparatus (20), in which second virtual model the charger insert (40) is designed to support the chargeable hearing device (1A, 1B) such that the first charger element (22, 23) is positioned in a first relationship with the second charger element (4) when the charger insert (40) is placed in the receiving portion (29) of the hearing device charger apparatus (20); and

-shaping a customized charger insert (40) together with the holder (45) by a 3D manufacturing process based on the second virtual model.

2. The method according to claim 1, wherein providing a second virtual model of a charger insert (40) is further based on data about the shape of the charger housing (21).

3. The method according to claim 1 or 2, wherein providing the second virtual model of the charger insert (40) is further based on data about a first position of a first charger coil (22, 23) within the charger housing (21).

4. The method according to any one of claims 1-3, wherein providing a second virtual model of a charger insert (40) comprises configuring the holder (45) in a predetermined direction relative to the charger housing (21).

5. The method according to any one of claims 1-4, wherein positioning the first charger element (22, 23) in a first relationship with the second charger element (4) comprises: -aligning a first charger element (22, 23) in a charger housing with a second charger element (4) in the chargeable hearing device (1A, 1B) when the charger insert (40) is placed in the receiving portion (29) of the hearing device charger arrangement (20) and when a charging hearing device (1A, 1B) is placed in the charger insert (40).

6. The method of any of claims 1-5, wherein providing the second virtual model comprises:

-designing the holder (45) with at least a subset of surface portions identical to corresponding surface portions of the chargeable hearing device (1A, 1B).

7. The method according to claim 6, wherein providing the second virtual model comprises removing an undercut surface of the holder (45) in the second virtual model.

8. The method of any of claims 1-7, wherein providing the second virtual model of the charger insert (40) comprises digitally designing the second virtual model of the charger insert (40) on a computer.

9. The method according to any one of claims 1-8, wherein providing the first virtual model of the chargeable hearing device (1A, 1B) comprises digitally designing the first virtual model of the chargeable hearing device (1A, 1B) on a computer.

10. The method according to any one of claims 1-9, wherein the second charger element (4) of the chargeable hearing device (1A, 1B) is formed in an outward facing face plate (5) of the chargeable hearing device (1A, 1B) having a flat outer surface, and wherein the method comprises designing the holder (45) of the charger insert (40) such that the flat surface of the outward facing face plate (5) of the chargeable hearing device (1A, 1B) is substantially parallel to the upward facing surface of the charger insert (40) when the chargeable hearing device (1A, 1B) is held in the holder (45).

11. The method according to any one of claims 1-10, wherein the position of the first charger element (22, 23) is a fixed, standardized position in the charger housing (21).

12. The method according to any one of claims 1-11, wherein the charger housing comprises a box-like charger base (26) and a charger cover (27) configured to cover the charger base (26), and wherein the first charger element (22, 23) is located in the charger cover (27).

13. The method according to any of claims 1-12, wherein the first charger element (22, 23) is a first charger coil and the second charger element (4) is a second charger coil.

14. The method according to any one of claims 1-13, wherein the charger insert (40) comprising the holder (45) is formed from a block of material by milling the material out of the block of material.

15. The method of any of claims 1-13, wherein the charger insert (40) with the retaining socket (45) is formed by an additive manufacturing process.

16. The method according to any of claims 1-15, further comprising an initial step of determining the shape of the user's ear canal part, comprising:

-scanning at least a portion of the user's ear canal; and

-providing a data set representing a scanned shape of the portion of the user's ear canal from a scan of the portion of the user's ear canal for providing the first virtual model.

17. A hearing device charger arrangement (20) comprising a charger insert (40) with a holder (45) formed by the method according to any one of claims 1-16.

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