Method of manufacturing a hearing device housing, a preform of a hearing device housing, a hearing device housing and a hearing device

Abstract

A method of manufacturing a hearing device housing including at least one opening. The method includes the steps of: designing a pre-model of the hearing device housing by 3D-modelling software, the pre-model including a protective structure covering the opening, the protective structure being prepared for removal; producing a preform of the hearing device housing based on the pre-model; and removing the protective structure thus providing the hearing device housing with the opening.

Claims

1. A method of manufacturing a hearing device housing comprising at least one opening, said method comprises the steps of: designing a pre-model of the hearing device housing by means of a 3D-modelling software, said pre-model comprising a protective structure covering said opening against entrance of abrasive media, said protective structure being prepared for removal by designing the protective structure connected to the housing by spaced-apart connection points, producing a preform of the hearing device housing based on the pre-model such that the connection points extend from the protective structure to the hearing device housing and are formed integrally with the protective structure and the hearing device housing, said hearing device housing is made of a metal comprising titanium, thereafter, surface treating of the preform by means of vibratory grinding using the abrasive media, wherein during said surface treating of the preform, the connection points remain integrally formed with the protective structure and the hearing device housing, and subsequently removing the protective structure from the hearing device housing by separating the connection points from the hearing device housing or from the protective structure, thus providing the hearing device housing with the opening.

2. The method according to claim 1, wherein the protective structure at least in a periphery thereof is formed with recesses.

3. The method according to claim 1, wherein the protective structure comprises apertures.

4. The method according to claim 1, wherein the removing step comprises breaking out the protective structure from the preform.

5. The method according to claim 1, further comprising the step of: subsequently to the removing step, trimming remaining connection points from an inner rim and/or a periphery of the opening.

6. The method according to claim 5, wherein the remaining connection points are trimmed by means of milling and/or grinding.

7. The method according to claim 1, wherein the protective structure extends parallel to a plane defined by the opening.

8. The method according to claim 1, wherein, in a region surrounding the opening, a top surface of the protective structure is formed inwardly displaced from a top surface of the preform.

9. The method according to claim 1, wherein, in a region surrounding the opening, a portion of a periphery of the protective structure is directly positioned onto a top surface of the preform.

10. The method according to claim 1, wherein, in a region surrounding the opening, a portion of a periphery of the protective structure is located onto a top surface of the preform via interposed platforms.

11. The method according to claim 1, wherein the protective structure on a top surface thereof is provided with a labelling.

12. The method according to claim 1, wherein a wall thickness of the hearing device housing is 0.2 mm or less.

13. A hearing device housing manufactured by a method according to claim 1.

14. A hearing device comprising a hearing device housing according to claim 13.

15. A preform of a hearing device housing made of a metal comprising titanium, wherein said preform is produced based on a pre-model of the hearing device housing designed by means of a 3D-modelling software, wherein: said pre-model comprises a protective structure covering an opening against entrance of abrasive media, said protective structure being prepared for removal by designing the protective structure connected to the housing by spaced-apart connection points, wherein the protective structure is configured to be removed from the housing after a surface treating operation by separating the connection points from the housing or from the protective structure, and wherein during said surface treating operation, the connection points extend from the protective structure to the hearing device housing and are formed integrally with the protective structure and the hearing device housing.

16. The preform of claim 15, wherein a periphery of the protective structure comprises recesses.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention is further described with reference to the accompanying drawings jointly illustrating various exemplary embodiments which are to be considered in connection with the following detailed description. What is shown in the figures is:

(2) FIG. 1 is a perspective view of a hearing device comprising a module received into a housing,

(3) FIG. 2 is a perspective view of a preform of a hearing device housing according to the invention,

(4) FIGS. 3A and 3B schematically depict protective structures in different aspects, and

(5) FIG. 4 schematically depicts a hearing device housing which is clogged with abrasive media according to the prior art.

DETAILED DESCRIPTION OF THE INVENTION

(6) FIG. 1 depicts a hearing device 10 in a perspective view. The hearing device 10 is an In-The-Ear (ITE) hearing device. Of course, other hearing device types can be used, as well. In the shown example, the housing 12 of the hearing device 10 is made of titanium. One of a plurality of advantages in using titanium is the ability of creating housings which are very thin while still showing increased strength. The hearing device 10 further comprises a module 14 which is inserted into an opening formed into the hearing device housing 12. The module 14 can be mounted to the hearing device housing 12 by means of sealing. The module 14 can be pre-assembled, comprising a battery compartment which openable end thereof is for receiving a battery (not shown). The openable end can be opened and closed via a battery door 16. The FIG. 1 shows the battery door 16 being closed. The battery door 16 can be opened to exchange a used battery as well as for service, maintenance, etc. Next to the battery, the module 14 can further comprise at least one microphone, a GMR switch, processing means, etc. The module 14 can be easily pre-assembled to the hearing device housing 12. The hearing device 10 further comprises a sound outlet 18 for outputting sound from a receiver (not shown) of the hearing device 10 to the ear canal of the user. The module 14 comprises an outer rim 20 which abuts against the periphery of an opening of the hearing device housing 12 once inserted.

(7) FIG. 2 depicts a preform 100 of a hearing device housing according to the invention. The hearing device housing can be embodied as the hearing device housing as shown in FIG. 1. The preform 100 comprises a protective structure 102 covering the opening of the preform 100. Designing the protective structure 102 is part of the step of designing a pre-model of the hearing device housing by means of a 3D-modelling software. In a next step, the preform 100 of the hearing device housing is produced based on the pre-model. The protective structure 102 is formed to be prepared for removal in a later stage.

(8) In an aspect, which is also illustrated in FIG. 2, the protective structure 102 is at least in a periphery thereof formed with recesses 104. The recesses 104 allow that the protective structure 102 is connected to the preform 100 solely by (remaining) connecting points 106. Therefore, in a later stage, the protective structure 102 can be removed by simply breaking out the protective structure 102 (by its connection points 106) from the preform 100. In other words, the protective structure 102 can be removed by simply breaking the connection points 106 thus disconnecting the protective structure 102 from the preform 100.

(9) The preform 100 can be surface-treated by means of a process using abrasive media, e.g. vibratory grinding (not shown). After termination of the surface treatment process, the protective structure 102 is removed (not shown) as a sacrificial structure thus providing the hearing device housing (with the opening). The protective structure 102 can comprise apertures 108. The apertures 108 can allow to compensate for tolerances which possibly arise during manufacturing of the preform 100 and/or protective structure 102.

(10) The protective structure 102 can be formed such to substantially extend parallel to a plane defined by the opening. As depicted in the FIG. 2, in a region surrounding the opening, the top surface of the protective structure 102 can be formed inwardly displaced from the top surface of the preform 100 in a direction as indicated by an arrow A. In this case, the edges of the protective structure 102 are not flush with the surface of the preform 100 at the border of the opening but are slightly inwardly displaced and therefore will be less exposed during a following mechanical surface treating step. While not shown, in the region surrounding the opening, a portion of the periphery of the protective structure can be directly positioned onto the top surface of the preform 100. In another example, while not shown, in a region surrounding the opening, a portion of the periphery of the protective structure can be located onto the top surface of the preform 100 via interposed platforms.

(11) Subsequently to the step of removing the protective structure 102 from the preform 100, residuals of the (former) connection points 106 remaining on the hearing device housing can be eliminated from the inner rim and/or periphery of the opening by trimming, e.g. by means of milling, grinding, etc.

(12) FIGS. 3A,B schematically depict the protective structure 102 in different aspects of the invention. The thickness of the protective structure 102 can be selected such to withstand the surface treatment process. In an example, the thickness can vary between 0.1 to 0.15 mm. The protective structure 102 can be removed after the surface treatment process manually by using a tool or just by hand. As shown in FIG. 3B, the protective structure 102 can be provided with a code 110 which can bear information, e.g. an ID of the hearing device, an information about how to process the housing, etc. The protective structure 102 can be provided with apertures 108.

(13) FIG. 4 schematically depicts a hearing device housing 200 according to the prior art, wherein the housing 200 is clogged inside with grinding stones 202 of abrasive media. In this prior art example, during surface treatment of the housing 200, the grinding stones 202 are entered the housing 200 via the opening thereof. The surface treatment can comprise e.g. vibratory grinding. Generally, removal of the clogged grinding stones 202 out of the hollow body of the housing 200 is impossible at least without damaging of the housing 200. Any efforts to do so would be inefficient. A further problem is an overly strong abrasion of the exposed area surrounding the opening (periphery of the opening), which might result in a wavy, imprecise opening.