Granted Patent B2

US 12,532,136 · App. 17/889,064 · Granted Jan 20, 2026

Inventors: Justin Barlow (Minneapolis, MN); Janet Glenn (Minneapolis, MN); Toto Saykeo (Eden Prairie, MN)

Assignee: Starkey Laboratories, Inc.

H04R25/652H04R25/658B33Y80/00H04R2225/77

Abstract

Claims (43)

1 . An ear-wearable electronic device comprising:

a faceplate having a beveled edge; and

a shell having an organically-shaped outer surface that corresponds uniquely to an ear geometry of a user of the ear-wearable device, the shell comprising 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,

wherein the faceplate is installed in the faceplate void and the beveled edge mates with the perimeter edge, the faceplate comprising an unbroken covering surface that matches the outer surface of the shell surrounding the faceplate void, wherein the beveled edge of the faceplate and the beveled perimeter edge of the faceplate void have a stadium shape, and wherein the stadium shape is configured to allow mated edges and an unbroken covering surface when the faceplate void is manufactured at a tolerance limit.

2 . The ear-wearable device of claim 1 , wherein the beveled edge is at an angle between 40 and 50 degrees relative to a major plane of the faceplate.

3 . The ear-wearable device of claim 1 , wherein the shell further comprises a cable retention slot intersecting the perimeter edge of the faceplate void, the faceplate trapping a cable into the cable retention slot when installed into the faceplate void.

4 . The ear-wearable device of claim 3 , further comprising a filler surrounding the cable and filling the cable retention slot, the filler being smoothed to match the outer surface of the shell and the faceplate.

5 . The ear-wearable device of claim 1 , wherein the faceplate and faceplate void are sized to leave a gap between the beveled edge of the faceplate and the perimeter edge of the faceplate void when the faceplate is positioned flush with the outer surface of the shell, the gap being filled with an adhesive that adheres the faceplate to the faceplate void.

6 . The ear-wearable device of claim 5 , wherein the adhesive comprises an ultraviolet-curable adhesive.

7 . The ear-wearable device of claim 1 , wherein the shell comprises a 3D printed resin and the faceplate comprises an injection molded plastic.

8 . A method of assembling an ear-wearable electronic device, comprising:

digitally capturing an ear geometry of a user of the ear-wearable electronic device into a data file;

using the data file to generate a geometry file of a shell having an outer surface that corresponds uniquely to the ear geometry of the user, the shell comprising a faceplate void that has a curved and beveled perimeter edge;

3D printing the shell using the geometry file;

injection molding a faceplate having 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, wherein the beveled edge of the faceplate and the beveled perimeter edge of the faceplate void have a stadium shape, and wherein the stadium shape is configured to allow mated edges and an unbroken covering surface when the faceplate void is manufactured at a tolerance limit;

installing one or more devices into the shell through the faceplate void; and

installing the faceplate within the faceplate void to seal the shell.

9 . The method of claim 8 , wherein the beveled edge is at an angle between 40 and 50 degrees relative to a major plane of the faceplate.

10 . The method of claim 8 , wherein the shell further comprises a cable retention slot intersecting the perimeter edge of the faceplate void, the method further comprises trapping a cable into the cable retention slot when installing the faceplate into the faceplate void.

11 . The method of claim 10 , further comprising:

installing a filler surrounding the cable and filling the cable retention slot; and

smoothing the filler to match the outer surface of the shell and the faceplate.

12 . The method of claim 8 , wherein the faceplate and faceplate void are sized to leave a gap between the beveled edge of the faceplate and the perimeter edge of the faceplate void when the faceplate is positioned flush with the outer surface of the shell, the gap being filled with an adhesive that adheres the faceplate to the faceplate void.

13 . The method of claim 8 , further comprising adhering the faceplate within the faceplate void using an ultraviolet-curable adhesive.

14 . An ear-wearable electronic device comprising:

a faceplate having a beveled edge; and

a shell having an organically-shaped outer surface that corresponds uniquely to an ear geometry of a user of the ear-wearable device, the shell comprising:

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; and

one or more protrusions from an inner surface of the shell and blocking a part of the void, the one or more protrusions preventing the faceplate from passing through the void and into an interior volume of the shell, and wherein the faceplate is mated to the shell such that the beveled edge of the faceplate is in contact with the beveled perimeter edge of the faceplate void, and wherein an inner surface of the faceplate is separated from the one or more protrusions via a clearance gap;

wherein the faceplate is installed in the faceplate void and the beveled edge mates with the perimeter edge, the faceplate comprising an unbroken covering surface that matches the outer surface of the shell surrounding the faceplate void.

15 . The ear-wearable device of claim 14 , wherein the clearance gap is configured to ensure no interference between the one or more protrusions and the faceplate when the faceplate is securely installed in the shell and the beveled edge is mated with the perimeter edge.

16 . The ear-wearable device of claim 14 , wherein the beveled edge of the faceplate and the beveled perimeter edge of the faceplate void have a stadium shape, and wherein the stadium shape is configured to allow mated edges and the unbroken covering surface when the faceplate void is manufactured at a tolerance limit.

17 . The ear-wearable device of claim 14 , wherein the faceplate further comprises an inward-facing ridge that runs along an internal perimeter of the faceplate configured to stiffen the faceplate and define a maximum inward protrusion of the faceplate into the shell.

18 . A method of assembling an ear-wearable electronic device, comprising:

digitally capturing an ear geometry of a user of the ear-wearable electronic device into a data file;

using the data file to generate a geometry file of a shell having an outer surface that corresponds uniquely to the ear geometry of the user, the shell comprising a faceplate void that has a curved and beveled perimeter edge;

3D printing the shell using the geometry file;

injection molding a faceplate having 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;

installing one or more devices into the shell through the faceplate void; and

installing the faceplate within the faceplate void to seal the shell;

wherein the shell further comprises one or more protrusions from an inner surface of the shell and blocking a part of the void, the one or more protrusions preventing the faceplate from passing through the void and into an interior volume of the shell when installing the faceplate within the faceplate void to seal the shell, and wherein the faceplate is mated to the shell such that the beveled edge of the faceplate is in contact with the beveled perimeter edge of the faceplate void, and wherein an inner surface of the faceplate is separated from the one or more protrusions via a clearance gap.

19 . The method of claim 18 , wherein the clearance gap is configured to ensure no interference between the one or more protrusions and the faceplate when the faceplate is securely installed in the shell and the beveled edge is mated with the perimeter edge.

20 . The method of claim 18 , wherein the beveled edge of the faceplate and the beveled perimeter edge of the faceplate void have a stadium shape, and wherein the stadium shape is configured to allow mated edges and the unbroken covering surface when the faceplate void is manufactured at a tolerance limit.

Continuity (2)

References Cited (10)