Shell for a hearing device
A shell ( 10 ) for a hearing device, and a method of producing the same. The shell ( 10 ) comprises a sub-shell ( 11 ) produced by a generative method, and a thermoformed hull ( 12 ) covering the subshell ( 11 ). The sub-shell ( 11 ) comprises lateral openings ( 13 ) covered by the thermoformed hull ( 12 ) so as to render the shell ( 10 ) more flexible in the region of the openings ( 13 ), and thereby to relieve pressure exerted by the shell ( 10 ) due to dynamic changes in the shape of the wearer's ear canal during jaw movement.
1. An auditory device for use in an ear canal having a region that changes shape in response to jaw movement, the device comprising:
a shell including
a sub-shell formed from a rigid biocompatible material and having at least two lateral openings on substantially opposite sides of the sub-shell, and
a thermoformed hull covering the at least two lateral openings of the sub-shell,
wherein the shell is configured such that, when the shell is within the ear canal, the ear canal region that changes shape in response to jaw movement will exert pressure on the at least two lateral openings; and
a hearing device component located within the shell.
2. An auditory device as claimed in claim 1 , wherein the hearing device component includes one or more of a hearing device electronics module, a receiver and a sound tube.
3. An auditory device as claimed in claim 1 , wherein the sub-shell is more rigid than the thermoformed hull.
4. An auditory device as claimed in claim 1 , further comprising:
a vent channel formed between the thermoformed hull and a groove in the sub-shell.
5. An auditory device as claimed in claim 1 , wherein
the thermoformed hull defines an interior surface and the sub-shell is situated on the interior surface of the thermoformed hull.
6. An auditory device as claimed in claim 1 , wherein
the thermoformed hull is formed from a material selected from the group consisting of PE, BAREX, PET, COP, EVA, PCTFE, and PEEK; and
the rigid biocompatible material is selected from the group consisting of a polymer and a ceramic-filled polymer.
7. An auditory device as claimed in claim 1 , wherein
the shell defines a thickness that ranges from 0.1 millimeters to 20 micrometers in regions adjacent to the at least two lateral openings and a total thickness of at least 0.4 millimeters in the remainder of the shell.
8. An auditory device for use in an ear canal having a region that changes shape in response to jaw movement, the device comprising:
a shell defining a shell stiffness and including
a sub-shell defining an interior cavity and longitudinal ends, and
a thermoformed hull covering the sub-shell;
means for reducing the stiffness, as compared to the remainder of the shell, of two lateral portions of the shell that are located between the longitudinal ends of the sub-shell and on substantially opposite sides of the shell, without reducing the stiffness of the shell at other locations between the longitudinal ends of the sub-shell, such that the two lateral portions will flex relative to the remainder of the shell, in response to pressure exerted onto the two lateral portions as a result of jaw movement; and
a hearing device component located within the shell.
9. An auditory device as claimed in claim 8 , wherein
the hearing device component includes one or more of a hearing device electronics module, a receiver and a sound tube.
10. An auditory device as claimed in claim 8 , wherein
the sub-shell is more rigid than the thermoformed hull.
11. An auditory device as claimed in claim 8 , further comprising:
a vent channel formed between the thermoformed hull and a groove in the sub-shell.
12. An auditory device as claimed in claim 8 , wherein
the thermoformed hull defines an interior surface and the sub-shell is situated on the interior surface of the thermoformed hull.
13. An auditory device as claimed in claim 8 , wherein
the thermoformed hull is formed from a material selected from the group consisting of PE, BAREX, PET, COP, EVA, PCTFE, and PEEK; and
the sub-shell is formed from a material selected from the group consisting of a polymer and a ceramic-filled polymer.
14. An auditory device as claimed in claim 8 , wherein
the shell defines a thickness that ranges from 0.1 millimeters to 20 micrometers in regions adjacent to the at least two lateral openings and a total thickness of at least 0.4 millimeters in the remainder of the shell.
15. A method, comprising the step of:
placing an auditory device, which includes a shell with a sub-shell formed from a rigid biocompatible material and having at least two lateral openings on substantially opposite sides of the sub-shell and a thermoformed hull covering the at least two lateral openings of the sub-shell, and a hearing device component located within the shell, within a patient's ear canal such that the at least two lateral openings are within an ear canal region that changes shape in response to jaw movement and will exert pressure on the shell at the at least two lateral openings.
16. A method as claimed in claim 15 , further comprising the step of:
prior to the step of placing the auditory device into the patient's ear canal, ascertaining the shape of the patient's ear canal during jaw movements by taking at least two measurements of the ear canal at different jaw open positions.
17. A method as claimed in claim 16 , further comprising the step of:
after ascertaining the shape of the patient's ear canal during jaw movements, modelling a shape, a size, and a stiffness of the shell and locations of the at least two lateral openings based on the ascertained the shape of the patient's ear canal during jaw movements.
18. A method as claimed in claim 15 , wherein
the hearing device component includes one or more of a hearing device electronics module, a receiver and a sound tube.
19. A method as claimed in claim 15 , wherein
the sub-shell is more rigid than the thermoformed hull.
20. A method as claimed in claim 15 , wherein
the auditory device includes a vent channel formed between the thermoformed hull and a groove in the sub-shell.
21. A method as claimed in claim 15 , wherein
the thermoformed hull defines an interior surface and the sub-shell is situated on the interior surface of the thermoformed hull.