EP3425927B1 - Method for producing a housing section of a hearing device, housing section of a hearing aid and hearing aid - Google Patents

Description

The invention relates to a method for producing a housing part of a hearing device. The invention also relates to such a housing part and also to a hearing device with such a housing part.

A hearing device is usually used to output acoustic signals to the ear of a wearer of this hearing device. To this end, such a hearing device usually comprises an output converter, which is usually designed as a loudspeaker (also referred to as a “receiver” or “listener”). This output transducer is usually surrounded by a housing part of the hearing device, for example a housing shell or the like, in order to protect the output transducer from environmental influences and / or to enable the output transducer to be aligned as intended, for example in the ear canal of the wearer of the hearing device. Such a hearing device can be, for example, a headset, headphones, so-called (in ear) wearables, tinnitus masks or the like.

Frequently, however, hearing devices are also used to supply people with reduced hearing with (often wearer-specific) amplified and / or filtered acoustic signals in order to at least partially compensate for the hearing impairment present. In this case, such a hearing device is also referred to as a hearing aid device or hearing device for short. In the case of a hearing aid in particular, the hearing device usually also includes an input transducer, usually in the form of a microphone for capturing ambient noise and a downstream signal processor (also: “controller”) for processing (filtering) and / or amplification) of signals generated from the ambient noise and for outputting these processed signals to the output converter. In the case of hearing aids, the output transducer can also - depending on the type of hearing loss - be designed as a bone conduction receiver or cochlear implant for mechanical or electrical stimulation of the wearer's hearing.

Different designs are also used in hearing aids. In so-called behind-the-ear hearing aids (referred to as “BTE” for short), the at least one microphone, the signal processor and an energy source are arranged in a housing (part) to be worn behind the auricle. The output transducer can also be arranged in this housing (part) and in this case is connected to the ear canal of the wearer by means of a sound tube. Alternatively, the loudspeaker can also be arranged in its own housing part (often referred to as an “earpiece”) and be connected to the components arranged in the actual hearing aid housing via a signal line. In addition, so-called in-the-ear hearing aids (“ITE” for short) are also used, which have a housing that is to be worn entirely or partially in the auditory canal and contains the electronic components. Depending on the design of such an ITE, the outer contour of the hearing aid is individually adapted to the auditory canal or made adaptable to a multitude of different auditory canal shapes using flexible "plug-like" ear pieces (also referred to as "domes"). Out EP 1 385 355 A1 it is known, for example, to provide an ITE with a textile cover so that it can cling to the ear canal. Optionally, this coating can also be impregnated with an active ingredient (for example medicinal), which is then slowly released to the surrounding body tissue. For individual adaptation, an impression of the individual auditory canal is usually taken and this is reproduced, for example, using generative processes (3D printing, stereolithography and the like). The housing parts formed in this case, also referred to as "Earshell", are made of a comparatively rigid material. In the event that the loudspeaker has to have a high amplification effect, it must also be supported by flexible damping materials (in particular to reduce structure-borne noise-related feedback to the microphone), so that the required installation space increased. For a BTE, for example, this is off US 2008/0317269 A1 known. Here, the housing of the BTE should also be made of a fiber-reinforced plastic that is as rigid as possible.

The invention is based on the object of enabling an improved housing part for a hearing device.

This object is achieved according to the invention by a method for producing a housing part of a hearing device according to the features of claim 1. This object is also achieved according to the invention by a method for producing a hearing device according to the features according to claim 11. Furthermore, this object is achieved according to the invention by a Housing part for a hearing device with the features of claim 12. In addition, the object is achieved according to the invention by a hearing device with the features of claim 13. Further advantageous and in part inventive embodiments and developments of the invention are set out in more detail in the dependent claims and the following description.

The method according to the invention is used to produce a housing part of a hearing device to be worn in the auditory canal of a person (hereinafter referred to as “carrier” for short). This housing part serves to accommodate at least one electronic component of the hearing device in a housing interior. According to the method, a fiber framework for a wall of the housing part that at least partially delimits the housing interior is constructed from fibers (alternatively also referred to as “filaments”). By means of the fibers, a mechanical property of the wall (preferably to be finished in a later method step) is specified in a varying manner along a reference direction of the housing part. This means that the wall of the housing part in the intended final production state has a varying mechanical property over its extension along the reference direction. The fiber framework (in particular to form the wall) is then at least over part of its (preferably longitudinal extension running along the reference direction is infiltrated with a matrix material.

The term “reference direction” is understood here and below to mean a direction along which a (upper) surface of the housing part, which is predetermined by the wall or the fiber structure, extends. A longitudinal extension of the housing part preferably runs in this reference direction. In particular, it is not a question of the thickness direction of the wall or the fiber structure. Particularly preferably - in particular in the case of the housing part to be worn in the auditory canal - the reference direction is a direction of insertion of the housing part into the auditory canal. In this case, “direction of insertion” is to be understood in particular as the direction along which the housing part, specifically the finished hearing device, is intended to be inserted into the ear canal of the wearer.

The method according to the invention advantageously creates the possibility of reducing the number of individual parts required for a hearing device and of saving installation space and assembly costs. This is achieved in particular by integrating the functions of different structures of conventional hearing devices, in particular usually individual, separate components, which have different mechanical properties for their respective purpose, into a common component, namely the housing part described above.

The housing part according to the invention for the hearing device is produced by means of the method described here and below. The housing part according to the invention thus has the physical features resulting from the respective method steps.

The hearing device according to the invention comprises the housing part described above and thus produced according to the method according to the invention.

The housing part as well as the hearing apparatus comprising it thus also have the advantages of the method according to the invention.

According to the invention, a flexibility of the wall is specified in a varying manner as a mechanical property. In other words, the fiber framework is constructed in such a way that in the intended (final) production state of the housing part the wall has a specifically varying rigidity (i.e. different rigidity values). As a result, areas can be created on a single housing part, for example, which have increased rigidity (ie an increased rigidity value) for holding components (e.g. further housing parts and / or electronic components), and other areas which, due to particularly low rigidity (ie a low rigidity value), for example, enable a particularly comfortable adaptation to the ear canal of the wearer (i.e. being able to snuggle up to the ear canal). The wall therefore has a flexibility that varies along the reference direction, in particular the insertion direction, in the intended final production state.

In a further conceivable embodiment within the scope of the invention, a compressibility of the wall is also specified as a mechanical property (in addition or as an alternative to flexibility).

In an expedient development, the flexibility of the wall is increasingly specified, in particular in the direction of insertion. This means that the wall in the finished state has a higher flexibility (or lower rigidity) in the area of its end leading in the direction of insertion than at its end which is lagging in the direction of insertion. The course of flexibility (or also rigidity) can be continuous and / or at least one more or less pronounced jump in rigidity (ie a step-like change). The area with the lowest stiffness or the highest flexibility (hereinafter also referred to as the “flexible area”) is preferably designed in such a way that elastic deformation by hand is possible without the application of particular force. The area with the highest rigidity is preferred designed in such a way that such (manual) elastic deformation is not possible or, in comparison to the flexible area, is only possible with significantly increased use of force and / or only to a negligible degree.

In a further expedient embodiment, in order to specify the mechanical properties of the wall, the fiber framework is constructed in a varying manner in its geometric structure and / or in its density. Under the geometric structure, on the one hand, structural features reflected in external dimensions, such as B. the wall thickness, ribs, beads and the like, as well as "internal structural features", such as in particular an alignment of the fibers within the fiber structure. In the latter case, the fibers are aligned, for example, in such a way that they can absorb a large part of the forces acting on the wall during use, or, alternatively, that these forces act across the fibers, so that a reinforcing effect is comparatively small. In order to vary the density of the fiber framework, in particular the number of fibers running in a volume element of the fiber framework is specified differently.

In a preferred embodiment, a particularly crosslinkable elastomer is used as the matrix material. The matrix material is therefore a material with comparatively high elasticity and flexibility per se, which is reinforced to locally different stiffness values by means of the fiber structure. This elastomer is preferably a silicone (specifically a polyorganosiloxane), rubber, rubber or the like. The elastomer used preferably has a sufficiently low viscosity in the non-crosslinked state in order to enable the infiltration of the fiber structure as possible without the inclusion of air bubbles. To infiltrate the fiber structure, methods such as B. dipping or processes supported by a pressure difference, comparable to resin injection processes, in which the matrix material is sucked in using negative pressure or injected using overpressure. The matrix material, in particular the elastomer, is preferably also cured (ie crosslinked) after the infiltration.

In principle, it is also conceivable within the scope of the invention that a thermoplastic elastomer is used.

The fiber framework is preferably infiltrated in such a way that the resulting wall is closed, i.e. H. is not open-pored or penetrated like a channel. The wall is thus preferably tight against the passage of impurities or moisture.

In a further preferred embodiment, a thermoplastic plastic, in particular a polyamide or a polyether block amide, is used as the material for the fibers of the fiber structure. Alternatively, other thermoplastics such as polyester are also used.

In a particularly expedient embodiment, the fiber framework is built up by means of electrospinning. Under the action of an electric field, a number of fibers are drawn off from a polymer solution and deposited on a counter electrode, in particular in the form of a type of fleece. In one variant, the fibers formed are placed in a mold core (also referred to as a “target”), which defines the subsequent geometry of the fiber structure. In an alternative variant, the fibers are laid down in a manner comparable to a 3D printing process without such a mold core and "stacked" to form the fiber structure. The variation of the properties of the fiber structure (i.e. in particular the geometric structure and / or the density) takes place through targeted changes in the movement and / or movement speed of the mandrel and / or the spinning head (from which the fibers are drawn off), the size of the mandrel, a change in the electric field or the like. In this way, a variation of the framework properties and thus the mechanical properties of the later wall of the housing part can be set in a particularly simple manner - advantageously also individually, that is to say specific to the carrier. Electrospinning also makes it possible to set continuous transitions between areas of different flexibility (ie different stiffness values) in a particularly simple manner.

In an alternative embodiment, the fiber framework is made from a woven and / or non-woven (fiber) semi-finished product - i.e. H. in particular from a fabric, scrim, fleece or the like - built up. For example, there are additional forming processes for these semi-finished products, such as B. deep drawing, for use. The mechanical properties are preferably varied by using different semi-finished products that vary from one another, for example in terms of their density, their material thickness and / or their fiber orientation. In this case, the stiffness profile of the wall, compared to electrospinning, usually has clearly pronounced (i.e. in particular recognizable step-like) transitions between areas of different stiffness values.

In a further expedient embodiment, in particular during the infiltration of the fiber framework with the matrix material, an end of the fiber framework that is opposite to the reference direction (i.e. the one that lags in particular in the insertion direction) and that forms an annular edge around the housing interior is kept free of the matrix material. At this end, the fibers of the fiber framework are exposed and are not embedded in the matrix material.

In a further variant of the method for forming the "overall housing", the housing interior is preferably closed at the end or edge of the housing part kept free of matrix material with a cover plate - also referred to as a "faceplate" in the case of an ITE. This cover plate is expediently attached to the wall by means of an adhesive in such a way that the adhesive penetrates into the fiber framework, which is kept free from the matrix material, and thus, in addition to an adhesive (cohesive) connection, also claws with the fiber framework (and thus also a form-fitting connection) forms with the housing part. This enables a particularly stable fastening of the cover plate. The invention thus also relates to a method for producing the hearing device with the housing part described above. In the context of the hearing device, the cover plate is therefore preferably connected to the housing part in the manner described above.

The invention described above enables - as already described - the formation of a housing part, in particular a hearing aid housing, which has mechanical properties that vary at least in regions. The end of the housing part protruding into the auditory canal is preferably designed to be particularly flexible, so that, on the one hand, it clings to the auditory canal and, on the other hand, also offers a dampened fastening structure (or: mounting) for the loudspeaker, especially when the required sound levels are comparatively high.

In a particularly preferred embodiment, the housing part produced according to the method described above represents, viewed in the thickness direction, the sole casing delimiting the hearing aid components from the auditory canal Holder of hearing aid components is inserted. Such an inner housing is in particular a "frame part" made of a comparatively rigid plastic, for example a polyamide, an ABS (acrylonitrile-butadiene-styrene copolymer) or comparable plastics.

The conjunction “and / or” is to be understood here and below in such a way that the features linked by means of this conjunction can be designed both together (in combination) and as alternatives to one another.

Fig. 1

in einer perspektivischen Ansicht schematisch eine Hörvorrichtung, und

Fig. 2 und 3

in einer schematischen Teilschnittansicht II-II gemäß Fig. 1 jeweils ein alternatives Ausführungsbeispiel der Hörvorrichtung.

Exemplary embodiments of the invention are explained in more detail below with reference to a drawing. Show in it:

Fig. 1

in a perspective view schematically a hearing device, and

Figs. 2 and 3

in a schematic partial sectional view II-II according to Fig. 1 each an alternative embodiment of the hearing device.

Corresponding parts are always provided with the same reference symbols in all exemplary embodiments.

In Fig. 1 a hearing device 1, specifically an in-the-ear hearing device, is shown as the hearing device. To enclose electronic hearing aid components (not shown in detail), the hearing aid 1 comprises a housing 2 which is essentially formed from a first housing part 3 and a second housing part 4. How out Fig. 2 It can be seen that the first housing part 3 forms a component which is also referred to as "Earshell" and which circumferentially delimits a housing interior 5. The second housing part 4 is also referred to as a “faceplate” and forms a cover plate with which the housing interior 5 is closed on one side from the housing part 3. The second housing part 4 has, inter alia, a microphone opening 6 for recording ambient noise by means of a microphone arranged in the housing interior 5 and a battery compartment door 7 for reversibly holding and positioning a hearing aid battery (not shown in detail). The hearing aid 1 has an outer contour that tapers along a reference direction, specifically an insertion direction 8, along which the hearing aid 1 is intended to be inserted into an auditory canal of a wearer. At a tip end 9 leading in the direction of insertion 8, the first housing part 3 has a sound outlet opening 10 (shown schematically) through which airborne sound generated in the ear canal of the wearer by a loudspeaker arranged in the housing interior 5 is emitted in the direction of the eardrum when worn as intended. At the rear end 11 opposite the tip end 9 opposite to the insertion direction 8, the second housing part 4 or the faceplate is placed on the edge 12 of the first housing part 3 there and connected to it by an adhesive connection.

The first housing part 3 has increasing flexibility, that is to say decreasing rigidity values, in the insertion direction 8, ie from the rear end 11 or the edge 12 there, in the direction of the tip end 9. The first housing part 3 is designed so soft and flexible in the area of the tip end 9 that it clings to the contour of the auditory canal in this area can and at the same time can also serve as a damping element for the loudspeaker positioned in this area within the housing interior 5.

To implement this variation of the mechanical properties of the first housing part 3, ie the increasing flexibility of the housing part 3 in the insertion direction 8, specifically its wall 14, the housing part 3 is designed as a fiber composite component. To produce the housing part 3, a fiber framework (for the later wall 14) is first built up from fibers 20. A thermoplastic plastic, specifically a polyamide, is used as the material for these fibers 20. The fibers are electrospinned with - as in Fig. 2 schematically indicated - in the direction of insertion 8 decreasing density, ie specifically with a weight and / or volume-related fiber content decreasing in relation to the finished housing part 3, placed on top of the fiber structure. Subsequently, the fiber structure and thus the interstices between the fibers 20 are infiltrated with a matrix material, ie filled with wetting of the fibers 20. In this case, the wall 14 is tight, ie not penetrated by air inclusions or free spaces (or: "spongy"). A crosslinkable silicone, which cures, ie is crosslinked, after the infiltration of the fiber structure, is used as the matrix material 22. The matrix material 22 thus has a viscosity that is sufficiently low for the infiltration of the fiber structure and, in the crosslinked state, a sufficiently low flexibility.

In a not shown, based on Fig. 2 As explained in the further exemplary embodiment, during the infiltration of the fiber framework with the matrix material 22, the fiber framework is kept free in the region of the edge 12, so that the fibers 20 are exposed in this region and are not embedded in the matrix material 22. The second housing part 4 is then glued onto the edge 12 by means of an adhesive. The adhesive penetrates into the exposed fiber structure and forms both a material and form-fitting connection between the second housing part 4 and the first housing part 3.

In Fig. 3 a further embodiment is shown in more detail. The variation in the rigidity or flexibility of the first housing part 3 or its wall 14 along the direction of insertion 8 takes place here via a combination of the geometric structure of the fiber framework and also by the above-described variation of the fiber content of the fibers 20 along the direction of insertion 8 Housing part 3 has a gradually decreasing wall thickness as seen in the insertion direction 8. The fiber content of the fibers 20 increases analogously to that based on FIG Fig. 2 described embodiment also in the direction of the tip end 9 from.

In a further exemplary embodiment not shown in detail, the fibers 20 are not arranged by means of electrospinning, but are formed as part of at least two semi-finished fiber products of different types. In this case, the first housing part 3 has at least two areas separated from one another in a step-like manner with regard to flexibility. For example, the different semi-finished fiber products are draped on a mold core (for example wound or otherwise laid on) and / or reshaped by means of a mold core depicting the housing interior 5, for example by thermoforming (also referred to as deep drawing).

The subject matter of the invention is not limited to the exemplary embodiments described above. Rather, further embodiments of the invention can be derived from the above description by the person skilled in the art. In particular, the individual features of the invention described on the basis of the various exemplary embodiments and their design variants can also be combined with one another in other ways.

Reference list

1

Hearing aid

2

casing

3

first housing part

4th

second housing part

5

Housing interior

6

Microphone opening

7th

Battery compartment door

8th

Direction of insertion

9

Top end

10

Sound outlet opening

11

rear end

12th

edge

14th

Wall

20th

fiber

22nd

Matrix material

Claims (14)

1. Method for producing a housing part (3) of a hearing device (1) to be worn in the auditory canal of a person, wherein the housing part (3) serves for accommodating at least one electronic component of the hearing device (1) in a housing interior (5), wherein according to the method

   - a fiber skeleton is built up from fibers (20) for a wall (14) of the housing part (3), said wall at least partially surrounding the housing interior (5),

   - by means of the fibers (20) a mechanical property of the wall (14) along a reference direction (8) of the housing part (3) is variably predetermined, wherein as the mechanical property a flexibility of the wall (14) is variably predetermined, wherein the reference direction (8) extends along a surface of the housing part (3) that is predetermined by the wall (14), respectively by the fiber skeleton, and

   - the fiber skeleton is infiltrated with a matrix material (22) over at least a portion of its longitudinal extent.
2. Method according to claim 1,
   wherein the flexibility of the wall (14) is predetermined to increase in an insertion direction (8), along which the housing part (3) is inserted into the person's auditory canal as intended.
3. Method according to claim 1 or 2,
   wherein, for determining the mechanical property of the wall (14), the fiber skeleton is built up so as to vary in terms of its geometric structure and/or its density.
4. Method according to one of claims 1 to 3,
   wherein as matrix material (22) an in particular cross-linkable elastomer is used.
5. Method according to one of claims 1 to 4,
   wherein as material for the fibers (20) a thermoplastic material, in particular a polyamide or a polyether blockamide, is used.
6. Method according to one of claims 1 to 5,
   wherein the fiber skeleton is built up by means of electrospinning.
7. Method according to any one of claims 1 to 5,
   wherein the fiber skeleton is built up from a woven and/or unwoven semifinished product.
8. Method according to any one of claims 1 to 7,
   wherein an end (11) of the fiber skeleton lying opposite the reference direction (8) and forming an annular edge (12) around the housing interior (5) is kept free of matrix material (22).
9. Method according to claim 8,
   wherein the housing interior (5) of the housing part (3) is closed with a cover plate (4) at the end (11) of the housing part (3) which is kept free of matrix material (22), and wherein the cover plate (4) is secured to the wall (14) of the housing part (3) by means of an adhesive in such a way that the adhesive penetrates into the fiber skeleton that is kept free of the matrix material (22).
10. Method for manufacturing a hearing device (1),
    wherein a housing part (3) of the hearing device (1) to be worn in the auditory canal of a person is produced according to claim 8, wherein the housing interior (5) of the housing part (3) is closed with a cover plate (4) at the end (11) of the housing part (3) that is kept free of matrix material (22), and wherein the cover plate (4) is secured to the wall (14) of the housing part (3) by means of an adhesive in such a way that the adhesive penetrates into the fiber skeleton that is kept free of the matrix material (22).
11. Housing part (3) to be worn in the auditory canal of a person for a hearing device (1), manufactured according to one of claims 1 to 9.
12. Hearing device (1) with a housing part (3) according to claim 11.
13. Hearing device (1) according to claim 12,
    wherein the housing part (3) is to be worn in the auditory canal of a person and, viewed in the direction of its thickness, constitutes the sole sheathing which delimits hearing device components from the auditory canal.
14. Hearing device (1) according to claim 12,
    wherein in sections a kind of inner housing, which is formed by a frame part made of a comparatively stiff plastic, is inserted into the housing part (3) described above for holding hearing device components.

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