Cable alignment features in a custom-fitted hearing device shell
An ear-wearable electronic device includes a shell with a cable retention slot. The cable entrance slot has an interior end and an exterior end. A bend surface extends from the exterior end of the cable retention slot to an exterior surface of the shell. The bend surface aligned with a crux of a user's ear when the ear-wearable device is installed in an ear of the user's ear. The shell may include a uniquely-shaped outer surface that corresponds uniquely to an ear geometry of the user of the ear-wearable device.
1. An ear-wearable electronic device, comprising:
a shell comprising:
a cable retention slot, the cable entrance slot comprising an interior end and an exterior end; and
a bend surface extending from the exterior end of the cable retention slot to an exterior surface of the shell, the bend surface aligned with a crux of a user's ear when the ear-wearable device is installed in an ear of the user's ear.
2. The ear-wearable device of claim 1 , further comprising a cable mounted in the cable retention slot, the cable comprising a blunt at a jacket-terminating end, the blunt fitting against a positioning surface at the interior end of the cable retention slot and axially locating the cable in the shell.
3. The ear-wearable device of claim 2 , where the cable comprises strengthening fibers co-extruded within a jacket together with conductors, the strengthening fibers extending from the jacket-terminating end and folded back over a fiber retention region at an outside surface of the jacket, the fiber retention region being between the cable retention slot and the cable.
4. The ear-wearable device of claim 3 , wherein a rigid adhesive adheres the cable to the cable retention slot near the jacket-terminating end of the cable, the rigid adhesive adhering the strengthening fibers to the outside surface of the jacket at the fiber retention region.
5. The ear-wearable device of claim 3 , further comprising a sensor coupled to the conductors of the cable, the sensor mounted in a void extending from an inner surface of the shell to the outer surface of the shell.
6. The ear-wearable device of claim 1 , wherein the bend surface is aligned to the crux of the user's ear within an angle of ±5 degrees.
7. The ear-wearable device of claim 1 , wherein the shell further comprises:
a faceplate void that has a curved and beveled perimeter edge, the faceplate void facilitating access to one or more devices installable into the shell, the cable retention slot intersecting the beveled perimeter edge; and
a faceplate with a beveled edge that mates with the perimeter edge, the faceplate comprising an unbroken covering surface that matches the outer surface of the shell surrounding the faceplate void and traps the cable into the cable retention slot.
8. The ear-wearable device of claim 1 , wherein the exterior surface of the shell intersects the bend surface at a region of the exterior surface, and wherein the region of exterior surface does not protrude toward the crux.
9. The ear-wearable device of claim 1 , wherein the shell has a uniquely-shaped outer surface that corresponds uniquely to an ear geometry of a user of the ear-wearable device.
10. The ear-wearable device of claim 9 , wherein the ear geometry is based on a mold of an ear of the user.
11. The ear-wearable device of claim 1 , wherein the shell, the cable retention slot, and the bend surface comprise an integrally 3D printed structure.
12. An ear-wearable electronic device, comprising: a shell having a uniquely-shaped outer surface that corresponds uniquely to an ear geometry of a user of the ear-wearable device, the shell comprising: a cable retention slot, the cable entrance slot comprising an interior end and an exterior end; a bend surface extending from the exterior end of the cable retention slot to an exterior surface of the shell, the bend surface aligned with a crux of a user's ear when the ear-wearable device is installed in an ear of the user; and a faceplate void that has a curved and beveled perimeter edge, the faceplate void facilitating access to one or more devices installable into the shell, the cable retention slot intersecting the perimeter edge.
13. The ear-wearable device of claim 12 , further comprising a cable mounted in the cable retention slot, the cable comprising a blunt at a jacket-terminating end, the blunt fitting against a positioning surface at the interior end of the cable retention slot and axially locating the cable in the shell.
14. The ear-wearable device of claim 13 , further comprising a faceplate with a beveled edge that mates with the perimeter edge and that traps the cable withing the cable retention slot.
15. The ear-wearable device of claim 14 , further comprising a biocompatible filler in the cable retention slot surrounding at least part of the cable and being flush with the covering surface of the faceplate and the outer surface of the shell.
16. The ear-wearable device of claim 13 , further comprising a sensor coupled to conductors of the cable, the sensor mounted in a void extending from an inner surface of the shell to the outer surface of the shell.
17. The ear-wearable device of claim 12 , wherein the bend surface is aligned to the crux of the user's ear within an angle of ±5 degrees.
18. The ear-wearable device of claim 12 , wherein the exterior surface of the shell intersects the bend surface at a region of the exterior surface, and wherein the region of exterior surface does not protrude toward the crux.
19. The ear-wearable device of claim 12 , wherein the ear geometry is based on a mold of an ear of the user.