EP4297427A1

EP4297427A1 - Earpiece for a hearing device

Info

Publication number: EP4297427A1
Application number: EP22180375.2A
Authority: EP
Inventors: Markus LEUTHOLD; Erwin Kuipers; Hans-Ueli Roeck; Maryam MOSTAFEI; Patrizia RICHNER; Konstantin SILBERZAHN
Original assignee: Sonova AG
Current assignee: Sonova Holding AG
Priority date: 2022-06-22
Filing date: 2022-06-22
Publication date: 2023-12-27

Abstract

The invention relates to an earpiece (10) for a hearing device, the earpiece (10) being configured to be at least partially inserted into an ear canal of a user, the earpiece (10) comprising:
- a shell (11),
- a receiver (15) configured to reproduce sound into the ear canal through a sound outlet port (16),
- a flexible printed circuit board (12) facing an inner surface (32) of the shell (11), the flexible printed circuit board (12) comprising at least one sensor (13),
- a support element (14) having an outer surface (34) shaped complementary to the inner surface (32) of the shell (11) near the medial end thereof, wherein the outer surface (34) of the support element (14) and/or the inner surface (32) of the shell (11) has a recess (18) configured to accommodate the printed circuit board (12) or a part thereof carrying the at least one sensor (13),
wherein the shell (11) has one or more windows (31.1, 31.2) aligned with the one or more sensor (13) and/or components (13.1, 13.2) thereof on the flexible printed circuit board (12), wherein the support element (14) has a through-hole (19) with a seat (20) for the receiver (15).

Description

Technical Field

The invention relates to an earpiece for a hearing device.

Background of the Invention

Modern in-canal receivers (RIC - receiver in the canal) for hearing aids may be equipped with additional sensors that allow for measurements of physiological parameters of the user. For example, an optical photoplethysmographic sensor (PPG) is used to measures changes in microvascular blood volume, to further extract vital signs such as heart rate, respiration rate, blood oxygenation or blood pressure.
The quality of the PPG signal depends on the placement of the sensor with respect to the tissue to be measured. Consistent and close contact between the light source, the tissue and the photoreceptor ensure optimal penetration of the light through the tissue and efficient recording of the light reflections.
Currently, several solutions are known to integrate a PPG sensor including associated components into an earpiece sitting in the ear canal. The earpiece may be held in place in the middle of the ear canal by a replaceable dome. However, motion tolerance and sensor signal quality may be insufficient to support advanced use cases over and above simple heart rate measurements. This is due to on one hand the relative motion of the sensor components vs. the skin of the ear canal as the dome is flexible for comfort reasons. On the other hand, the sensor components may have a significant distance to the skin, thus causing reflections from the skin which does not contain physiologic information. Further, environmental light can also much easier reach the photodetector and thus disturb the received signal.

Summary of the Invention

It is an object of the present invention to provide an improved earpiece for a hearing device.
The object is achieved by an earpiece according to claim 1.
Preferred embodiments of the invention are given in the dependent claims.
According to the invention, an earpiece for a hearing device is configured to be at least partially inserted into an ear canal of a user, the earpiece comprising:

a shell,
a receiver configured to reproduce sound into the ear canal through a sound outlet port,
a flexible printed circuit board facing an inner surface of the shell, the flexible printed circuit board comprising at least one sensor,
a support element having an outer surface shaped complementary to the inner surface of the shell near the medial end thereof, wherein the outer surface of the support element and/or the inner surface of the shell has a recess configured to accommodate the printed circuit board or a part thereof carrying the at least one sensor,

In some embodiments, the one or more sensor and/or components thereof project into the one or more windows.
In some embodiments, the one or more windows are sized and shaped to match the size and shape the one or more sensor and/or components thereof.
The window may be open or the window may be filled with a material passable by radiation and/or matter detectable and/or emittable by the sensor. E.g., the window may be filled with a material transparent or translucent to light emitted and/or detectable by the sensor.
The recess may have a shape corresponding to a shape of the printed circuit board.
An inner surface of the support element may be defined as a surface extending around the through-hole, an outer surface of the shell may be defined as a surface at least partially in contact with the ear canal wall when the shell is at least partially inserted into the ear canal, the inner surface of the shell delimiting an inner volume enclosed by the shell, the window extending between the inner and outer surface of the shell.
In an exemplary embodiment, the sensor is an optical sensor, e.g., a PPG sensor, comprising at least one light source and at least one photo element.
Other examples of a sensor may include a temperature sensor or a bioelectric sensor comprising one or more electrodes sensitive to a bioelectric signal (i.e., an electrical current or potential generated by a living organism), e.g., an electrocardiogram (ECG) sensor, an electroencephalogram (EEG) sensor, an electrooculography (EOG) sensor.
In an exemplary embodiment, the shell and/or the support element comprises one or more locking elements for locking the support element in place within the shell. Note that such a locking element may not always be required. E.g., the support element may already be sufficiently fixed inside the shell by frictional forces, e.g., between the outer surface of the support element and the inner surface of the shell and/or at a hub comprised by the medial end of the support element.
In an exemplary embodiment, the support element is elastic such that the support element can be positioned relative to the one or more locking elements in the shell and/or the shell can be positioned relative to the one or more locking elements in the support element by elastic deformation of the support element.
E.g., the support element may thus be locked in place within the shell by the one or more locking elements when returning to an original shape after the elastic deformation of the support element.
In an exemplary embodiment, one or more of the locking elements are provided at the inner surface of the shell.
The one or more of the locking elements provided at the inner surface of the shell may be positioned at the inner surface of the shell to engage with the support element at a lateral end of the support element.
The lateral end may be defined as an end facing away from the ear and/or in a direction out of the ear canal when the shell is at least partially inserted into the ear canal.
In an exemplary embodiment, the one or more locking elements may comprise a flange at a medial end of the support element, the flange configured to be pulled through a medial hole in the shell and to subsequently engage the outer surface of the shell around the medial hole.
The medial end may be defined as an end facing a tympanic membrane inside the ear canal when the shell is at least partially inserted into the ear canal.
In an exemplary embodiment, the receiver and/or the support element comprises one or more receiver locking elements for locking the support element in place with the receiver.
Note that such a receiver locking element may not always be required. E.g., the receiver may already be sufficiently fixed inside the support element by frictional forces, e.g., between the inner surface defining the through hole of the support element and the surface of the receiver.
E.g., the support element may be elastic such that the support element can be positioned relative to the one or more receiver locking elements on the receiver and/or the receiver can be positioned relative to the one or more receiver locking elements in the support element by elastic deformation of the support element.
E.g., the support element may thus be locked in place within the shell by the one or more receiver locking elements when returning to an original shape after the elastic deformation of the support element.
In an exemplary embodiment, the one or more receiver locking elements comprise a flange provided on the receiver configured to click into a retention groove within the support element around the through-hole and/or seat.
In an exemplary embodiment, the shell may be made of a harder and/or less flexible material than the support element. In particular, the shell may have a greater radial stiffness than the support element.
In an exemplary embodiment, the sensor and/or its components may have a respective sealing ring around their respective circumference sealing against the shell.
In an exemplary embodiment, the inner shape of the shell near the medial end thereof is a dome shape.
In an exemplary embodiment, the recess comprises a first section essentially straight in view of an angular position relative to a longitudinal axis of the earpiece, and a second section branching of from the first section, wherein the part of the printed circuit board configured to be received in the recess has a complementary shape with a first section and a second section.
In an exemplary embodiment, the support element consists of or comprises an eleastomer, e.g., silicone. In other examples, the support element may also be formed from another material such as foam having elastic properties.
In an exemplary embodiment, e.g., when the shell is a custom shell customized to an individual ear canal, the support element may also be customized in accordance with the customization of the shell. E.g., the support element may have a shape customized to be positioned inside the custom shell and/or a recess provided in the support element may have a position and/or shape customized to the position of one or more windows provided in the shell.
In another exemplary embodiment, e.g., when the shell is a universal shell having a size and/or shape standardized with respect to an average ear canal, the support element, and a recess provided therein, may also have a standardized size and/or shape. E.g., the support element may be selected from a limited set of support elements each having a different standardized size and/or shape or the support element may have a fixed size and/or shape.
In an exemplary embodiment, an end of the flexible printed circuit board extending from the recess is fixedly connected to the receiver or is configured to be connected to the receiver by a connector on the receiver or a module on the printed circuit board.
In an exemplary embodiment, a medial end of the support element comprises a hub configured to extend through a medial hole in the shell to help positioning the support element in the shell.
In an exemplary embodiment, a medial end of the support element comprises a grip configured to be cut off after assembly of the support element into the shell.
A method of manufacturing an earpiece as described above may comprise:

determining a user-specific ear canal geometry;
providing constraints for positioning one or more of said windows on the shell and for positioning said recess on the outer surface of the support element and/or the inner surface of the shell;
determining a position of said one or more windows on the shell and a position of said recess on the outer surface of the support element and/or the inner surface of the shell by relating the constraints to said determined user-specific ear canal geometry; and
fabricating the shell and the support element based on said determined ear-canal geometry, wherein said one or more windows and said recess is provided at the determined position.

E.g., the shell may be fabricated from a resin in an additive manufacturing process, e.g. by a resin based 3D printing technology, such as digital light processing (DLP) or another stereolithography (SLA) process.
E.g., the support element may also be fabricated from a resin, e.g. an elastomeric resin, in an additive manufacturing process, e.g. by 3D printing.
The support element may also be fabricated from a body, which may have elastic properties, e.g., a foam material or an elastomeric body, by a subtractive manufacturing, e.g. by cutting the recess into the body and/or cutting the body into a suitable shape.
By determining the user-specific ear canal geometry, the shell may be at least partially customized to the ear canal of an individual user. For instance, the ear canal geometry may be determined from an ear impression taken from the user, e.g. by 3D scanning of the impression. A 3D model of the impression may then be created. This may comprise, e.g., with a 3D modeling software, specifying where the shape of the shell is fit into a dataset of the 3D scan of the impression. The shell may then be formed based on the dataset of the user-specific ear-canal geometry and/or the specifications. E.g., the dataset and/or the specifications may be input in a 3D printing device in order to print the shell in accordance with the user-specific ear canal geometry.
The one or more windows can be formed in the shell during an additive manufacturing of the shell. The recess can be formed on the outer surface of the support element and/or the inner surface of the shell during an additive manufacturing of the shell and/or support element and/or a subtractive manufacturing of the support element. To this end, the constraints for positioning the one or more windows and for positioning the recess may be related to the determined user-specific ear canal geometry. To illustrate, the creation of the 3D model, as described above, may further include determining an optimal position of the one or more windows and the recess in the shell and/or on the support element based on the constraints related to the ear canal geometry.
A shape of the outer surface of the support element may depend on constraints which are related to the determined user-specific ear canal geometry when forming the support element.
In some embodiments, the method of manufacturing the earpiece may further comprise:

providing constraints for positioning the one or more locking elements in the shell and/or on the support element;
determining a position of the one or more locking elements in the shell and/or on the support element by relating the constraints to said determined user-specific ear canal geometry, wherein the one or more locking elements are provided at the determined position during fabricating the shell and/or the support element.

In some embodiments, the method of manufacturing the earpiece may further comprise, e.g., during assembling the earpiece:

positioning the flexible printed circuit board in the shell, thereby aligning the one or more sensor and/or its components at the respective windows,
inserting the support element into the shell from the lateral end thereof towards the medial end by pulling on the grip,
pushing the receiver into the seat within the support element from a lateral end, (e.g., when a receiver locking element is provided, until the support element is locked in place with the receiver, (more particularly, until the flange on the receiver clicks into the retention groove within the support element)),
cutting the grip off,
electrically connecting the end of the flexible printed circuit board extending from the recess to the receiver.

In some embodiments, the method of manufacturing the earpiece may further comprise:

locking the support element in place within the shell using the one or more locking elements.

pulling the flange through a medial hole in the shell until it engages an outer surface of the shell around the medial hole.

pushing the receiver into the seat within the support element from the lateral end (E.g., when a receiver locking element is provided, until the support element is locked in place with the receiver, (more particularly, until the flange on the receiver clicks into the retention groove within the support element)),
laying the printed circuit board or the part thereof carrying the at least one sensor into the recess within the support element,
pushing the support element with the receiver and the printed circuit board into the shell from a lateral end thereof, thereby aligning the one or more sensor and/or its components in the respective windows and accommodating the printed circuit board between the shell and the support element.

A method for assembling the earpiece may comprise:

positioning the flexible printed circuit board in the shell, thereby positioning the one or more sensor and/or its components in the respective holes,
inserting the support element into the shell from the lateral end thereof towards the medial end by pulling on the grip,
pulling the flange through the medial hole in the shell until it engages the outer surface of the shell around the medial hole,
pushing the receiver into the seat within the support element from the lateral end, until the flange on the receiver clicks into the retention groove within the support element,
cutting the grip off,
electrically connecting the end of the flexible printed circuit board extending from the recess to the receiver.

Another method for assembling the earpiece may comprise:

pushing the receiver into the seat within the support element from the lateral end, until the flange on the receiver clicks into the retention groove within the support element,
laying the printed circuit board or the part thereof carrying the at least one sensor into the recess within the support element,
pushing the support element with the receiver and the printed circuit board into the shell from the lateral end thereof, thereby positioning the one or more sensor and/or its components in the respective holes and accommodating the printed circuit board between the shell and the support element,
locking the support element in place within the shell using the one or more locking elements.

Another method of assembling the ear piece (10) may comprise:

pushing the receiver into the seat within the support element from the lateral end,
laying the printed circuit board or the part thereof carrying the at least one sensor into the recess within the support element,
pushing the support element with the receiver and the printed circuit board into the shell from a lateral end thereof, thereby aligning the one or more sensor and/or its components in the respective windows and accommodating the printed circuit board between the shell and the support element.

Another method for assembling the ear piece may comprise:

positioning the flexible printed circuit board in the shell, thereby aligning the one or more sensor and/or its components at the respective windows,
inserting the support element into the shell from the lateral end thereof towards the medial end by pulling on the grip,
pushing the receiver into the seat within the support element from a lateral end,
cutting the grip off,
electrically connecting the end of the flexible printed circuit board extending from the recess to the receiver.

In some embodiments, the method further comprises:

In some embodiments, the method further comprises:

In the method, pushing the receiver into the seat within the support element from the lateral end may comprise, when a receiver locking element is provided, pushing the receiver until the support element is locked in place with the receiver. E.g., the receiver may be pushed until the flange on the receiver clicks into the retention groove within the support element.
The shell may be a custom shell customized to an individual ear canal of a user offering a secured seating resulting in a comfortable wearing and also an enhanced listening experience when at least partially inserted into the ear canal as compared to, e.g., a standardized earplug conforming to an averaged ear canal shape. The secured seating can also be exploited for precise PPG-measurements inside the ear canal, e.g., due to a decreased impact of motion artefacts in the sensor signal. Typically, a user-specific ear canal geometry is initially determined, e.g., by taking impressions of the user's ear canal, and the custom shell is formed from a resin by taking into account the predetermined individual ear canal geometry, e.g. by 3D printing technology.
The shell may also be a universal shell, which is not customized to an individual ear canal but rather fitted to an average ear canal size of a plurality of different users or customers, that is easy to manufacture, in particular without requiring determining of user-specific ear canal geometry, and also allows for rather precise PPG-measurements. In particular, the shell or tube may be as described in the application EP 21 187 003.5 , which is hereby incorporated by reference into the present application in its entirety.
The present invention provides a sensor earpiece combining the beneficial properties of motion tolerance, good signal quality, easy maintainability (i.e. replaceability of the shell and/or ear wax protection). Further, when the shell is provided as a custom shell, the earpiece can be manufactured in a precise manner, by taking advantage of the customization to an individual ear canal. Such a benefit may also be offered, to a certain extent, by a universal shell offering the additional advantage of immediate availability for the consumer when he enters the store (i.e. a generic or non-custom solution).
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

Brief Description of the Drawings

The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitative of the present invention, and wherein:

Figure 1: is a schematic view of an embodiment of an earpiece comprising a shell and a support element,
Figure 2: is a schematic view of another embodiment of an earpiece,
Figure 3: is a schematic view of the support element,
Figure 4: is a schematic view of an alternative embodiment of the support element,
Figure 5: is a schematic view of the shell;
Figure 6: is a schematic view of another embodiment of an earpiece,
Figure 7: is a schematic view of yet another embodiment of an earpiece, and
Figure 8: is a schematic view of yet another embodiment of an earpiece.

Corresponding parts are marked with the same reference symbols in all figures.

Detailed Description of Preferred Embodiments

Figure 1 is a schematic view of an earpiece 10. In some instances, the earpiece 10 may a be customized earpiece having a custom shell 11 customized to the shape of an ear canal of an individual user. In some instances, the earpiece 10 may a be universal earpiece or have a universal shell 11, or have one out of a set of shells 11 that have different sizes and shapes to fit a majority of the population. In particular, the earpiece 10 may be an earpiece as described in the application EP 21 187 003.5 .
The earpiece 10 may have an elongate shape and is configured to be inserted into an ear canal of a user and typically comprises a receiver 15 or speaker configured to reproduce sound into the ear canal through a sound outlet port 16 in a medial surface. The receiver 15 is electrically connected by a cable 17 which enters the earpiece 10 at a lateral end thereof. The cable 17 may also be connected to sound processing circuitry arranged in a behind the ear part of a hearing device.
Furthermore, the illustrated earpiece 10 comprises at least one sensor 13, e.g. a PPG sensor 13 (photoplethysmographic sensor) comprising at least one light source 13.2 such as an LED 13.2 and at least one photo element 13.1, e.g. a photo diode 13.1. The PPG sensor 13 is located on or in a lateral surface of the earpiece 10 and may also be electrically connected to processing circuitry through the cable 17.
The earpiece 10 comprises a relatively hard tube or shell 11 which may be manufactured using an injection molding process. Moreover, a flexible printed circuit board 12 is provided, on which the one or more sensors 13 or components 13.1, 13.2 of the one or more sensors 13 are arranged. The shell 11 has an inner surface 32 and an outer surface 33.
In order to assemble the earpiece 10, the flexible printed circuit board 12 is positioned in the shell 11. The shell 11 has windows 31.1, 31.2 at pre-defined positions and with pre-defined size and shape, matching the position, size and shape of the one or more sensor 13 and/or its components 13.1, 13.2 on the flexible printed circuit board 12.
In an embodiment, each of the one or more sensors 13 and/or its components 13.1, 13.2 have a sealing ring (not shown) around their respective circumference sealing against the shell 11 to prevent substances like cerumen and moisture to enter the shell 11.
After placing the flexible printed circuit board 12, a support element 14 is inserted into the shell 11 from the lateral end thereof towards the medial end. The support element 14 is shaped complementary to an inner shape, e.g. a dome shape, of the shell 11 near the medial end thereof but has a recess 18 to accommodate the printed circuit board 12 or a part thereof between the shell 11 and the support element 14, when the support element 14 and the printed circuit board 12 are in place within the shell 11.
In an embodiment, the support element 14 may consist of or comprise a relatively soft material such as silicone. Moreover, the support element 14 has a through-hole 19 with a seat 20 for the receiver 15. The support element 14 has an outer surface 34 and an inner surface 35.
A medial end of the support element 14 comprises a flange 21 configured to be pulled through a medial hole 22 in the shell 11 as the support element 14 is inserted and to subsequently engage the outer surface of the shell 11 around the medial hole 22 so that the support element 14 is secured in the shell 11 by the shell 11 around the medial hole 22 engaging in a groove formed between the flange 21 and the portion of the support element 14 within the shell 11. Moreover, the support element 14 may comprise a grip (not shown), e.g. a tubular grip, medially from the flange 21. The grip may be used to pull the support element 14 into position within the shell 11 until the support element 14 clips into the shell 11. At this point, the pulling may stop and the grip may be cut off.
The receiver 15 may then be pushed into the seat 20 within the support element 14 from the lateral end, until a flange 23 on the receiver 15 clicks into a retention groove 24 within the support element 14 around the through-hole 19 and/or seat 20.
The grip may likewise be cut off from the support element 14 at this point.
An end of the flexible printed circuit board 12 extending from the recess 18 may then be electrically connected to the receiver 15, e.g. sideways, at the top, bottom or rear thereof. The receiver 15 may have a connector (not shown) for this purpose.
As an alternative, instead of a connector for the flexible printed circuit board 12 on the receiver 15, the flexible printed circuit board 12 may be supplied with a module at its end extending from the recess 18. This module may be connected to the receiver 15. In another variant, the main cable 17 of the earpiece 10 or RIC device might be connected already to this module and the receiver 15 will be attached to that module.
The advantage of this design is that the earpiece 10 can be disassembled for maintenance, service or cleaning. The relative orientation and placement of the support element 14 does not require narrow geometrical tolerances.
The number of different support elements 14 may be equal to the number of different shells 11. For example, if there are four different shells 11 or tubes in a set as in the application EP 21 187 003.5 , four different support elements 14 respectively complementary to the shapes of the shells 11 may be required.
Figure 2 is a schematic view of another embodiment of an earpiece 10. The earpiece 10 may a be universal earpiece or have a universal shell 11, or have one out of a set of shells 11 that have different sizes and shapes to fit a majority of the population. In particular, the earpiece 10 may be an earpiece as described in the application EP 21 187 003.5 .
The earpiece 10 may have an elongate shape and is configured to be inserted into an ear canal of a user and typically comprises a receiver 15 or speaker configured to reproduce sound into the ear canal through a sound outlet port 16 in a medial surface. The receiver 15 is electrically connected by a cable 17 which enters the earpiece 10 at a lateral end thereof. The cable 17 may also be connected to sound processing circuitry arranged in a behind the ear part of a hearing device.
Furthermore, the illustrated earpiece 10 comprises at least one sensor 13, e.g. a PPG sensor 13 (photoplethysmographic sensor) comprising at least one light source 13.2 such as an LED 13.2 and at least one photo element 13.1, e.g. a photo diode 13.1. The PPG sensor 13 is located on or in a lateral surface of the earpiece 10 and may also be electrically connected to processing circuitry through the cable 17.
The earpiece 10 comprises a relatively hard tube or shell 11 which may be manufactured using an injection molding process. The shell 11 has an inner surface 32 and an outer surface 33. Moreover, a flexible printed circuit board 12 is provided, on which the one or more sensors 13 or components 13.1, 13.2 of the one or more sensors 13 are arranged. The flexible printed circuit board 12 is electrically connected, preferably fixedly connected, to the receiver 15.
Moreover, the earpiece 10 comprises a support element 14 configured to be inserted into the shell 11 from the lateral end thereof towards the medial end. The support element 14 has an outer surface 34 and an inner surface 35.
Figure 3 is a schematic view of the support element 14. The support element 14 is shaped complementary to an inner shape, e.g. a dome shape, of the shell 11 near the medial end thereof but has a recess 18 to accommodate the printed circuit board 12 or a part thereof between the shell 11 and the support element 14, when the support element 14 and the printed circuit board 12 are in place within the shell 11.
In an embodiment, the support element 14 may consist of or comprise a relatively soft material such as silicone. Moreover, the support element 14 has a through-hole 19 with a seat 20 for the receiver 15.
Figure 4 is a schematic view of an alternative embodiment of the support element 14 which is similar to the embodiment shown in figure 3. However, the recess 18 of the embodiment of figure 4 may comprise a first section 18.1 which may be essentially straight in view of an angular position relative to a longitudinal axis of the earpiece 10, and a second section 18.2 branching of from the first section 18.1, e.g. in a circumferential direction of the earpiece 10. The part of the printed circuit board 12 configured to be received in the recess 18 may have a complementary shape with a first section 12.1 and a second section 12.2, so that two or more components 13.1, 13.2, e.g. a photo diode 13.1 and a LED 13.2, may be arranged on the first section 12.1 at essentially the same angular position but different longitudinal positions, and a further component 13.1, e.g. a further photo diode 13.1 may be arranged on the second section 12.2 at a different angular position.
Figure 5 is a schematic view of the shell 11. The shell 11 has windows 31.1, 32.2 at pre-defined positions and with pre-defined size and shape, matching the position, size and shape of the one or more sensor 13 and/or its components 13.1, 13.2 on the flexible printed circuit board 12.
In order to assemble the earpiece 10, the receiver 15 may be pushed into the seat 20 within the support element 14 from the lateral end, until a flange 23 on the receiver 15 clicks into a retention groove 24 within the support element 14 around the through-hole 19 and/or seat 20. The printed circuit board 12 or the part thereof opposite the end connected to the receiver 15 is laid into the recess 18 within the support element 14. The subassembly formed including the support element 14, the receiver 15 and the printed circuit board 12 is then pushed into the shell 11 from the lateral end thereof. The one or more sensor 13 and/or its components 13.1, 13.2 on the flexible printed circuit board 12 enter the respective windows 31.1, 31.2 in the shell 11 and the printed circuit board 12 is accommodated between the shell 11 and the support element 14 so that the printed circuit board 12 and the sensor 13 do not fall out of the shell 11.
The shell 11 may be provided with one or more locking elements 26, e.g. one or more inward protrusions 26 with a lateral ramp to allow the support element 14 to pass and a medial stop surface to lock the support element 14 in place within the shell 11. Alternative embodiments of locking elements 26 may include one or more pins.
In an embodiment, each of the one or more sensors 13 and/or its components 13.1, 13.2 have a sealing ring (not shown) around their respective circumference sealing against the shell 11 to prevent substances like cerumen and moisture to enter the shell 11.
A medial end of the support element 14 may comprise a hub 27 configured to extend through a medial hole 22 in the shell 11 as the support element 14 is inserted. This way, the hub 27 may be centred in the medial hole 22 and help positioning the support element 14 in the shell 11.
The number of different support elements 14 may be equal to the number of different shells 11. For example, if there are four different shells 11 or tubes in a set as in the application EP 21 187 003.5 , four different support elements 14 respectively complementary to the shapes of the shells 11 may be required.
An advantage of the embodiment of figures 2 to 4 is that no connector between the flexible printed circuit board 12 and the receiver 15 is needed. In case of the need for exchanging either one of these components, both the receiver 15 and the flexible printed circuit board 12 have to be exchanged.
Moreover, the embodiment of figures 2 to 4 requires less processing steps with regard to the shell 11 than the embodiment of figure 1.
Figure 6 is a schematic view of an embodiment of an earpiece 10 comprising a shell 11 and a support element 14, similar to the one of figures 1 and 2. However, in the embodiment of figure 6, the one or more sensor 13 and/or its components 13.1, 13.2 do not extend into the windows 31.1, 31.2 but are merely aligned with them so as to be located below them. Moreover, figure 6 illustrates that the flange 23 on the receiver 15 shown in figures 1 and 2 is optional and may be omitted. Likewise, the flange 21 shown in figure 1 and/or the locking element 26 shown in figure 2 has been omitted in figure 6 to illustrate that it is not required, in particular if frictional forces are sufficient to hold the support element 14 in the shell 11.
Figure 7 is a schematic view of an embodiment of an earpiece 10 comprising a shell 11 and a support element 14, similar to the one of figures 1 and 2. However, in the embodiment of figure 7, the recess 18 is arranged in the shell 11 instead of in the support element 14. Moreover, figure 7 illustrates that the flange 23 on the receiver 15 shown in figures 1 and 2 is optional and may be omitted. Likewise, the flange 21 shown in figure 1 and/or the locking element 26 shown in figure 2 has been omitted in figure 6 to illustrate that it is not required, in particular if frictional forces are sufficient to hold the support element 14 in the shell 11.
Figure 8 is a schematic view of an embodiment of an earpiece 10 comprising a shell 11 and a support element 14, similar to the one of figures 1, 2 and 7. However, in the embodiment of figure 8, the recess 18 is arranged in the shell 11 as well as in the support element 14. Moreover, figure 8 illustrates that the flange 23 on the receiver 15 shown in figures 1 and 2 is optional and may be omitted. Likewise, the flange 21 shown in figure 1 and/or the locking element 26 shown in figure 2 has been omitted in figure 6 to illustrate that it is not required, in particular if frictional forces are sufficient to hold the support element 14 in the shell 11.
Moreover, any of the contacting options between the printed circuit board 12 and the receiver 15 shown in figures 1 or 2 is possible and may be applied in the embodiments of figures 6 to 8.
In an exemplary embodiment, the recess 18 may be created when printing the shell 11 and/or the support element 14.

List of References

10: earpiece
11: shell
12: printed circuit board
12.1: first section
12.2: second section
13: sensor, PPG sensor
13.1: component, photo element, photo diode
13.2: component, light source, LED
14: support element
15: receiver
16: sound outlet port
17: cable
18: recess
18.1: first section
18.2: second section
19: through-hole
20: seat
21: flange, locking element
22: medial hole
23: flange, receiver locking element
24: retention groove
26: locking element, protrusion
27: hub
31.1, 31.2: window
32: inner surface of the shell
33: outer surface of the shell
34: outer surface of the support element
35: inner surface of the support element

Claims

An earpiece (10) for a hearing device, the earpiece (10) being configured to be at least partially inserted into an ear canal of a user, the earpiece (10) comprising:
- a shell (11),

- a receiver (15) configured to reproduce sound into the ear canal through a sound outlet port (16),

- a flexible printed circuit board (12) facing an inner surface (32) of the shell (11), the flexible printed circuit board (12) comprising at least one sensor (13),

- a support element (14) having an outer surface (34) shaped complementary to the inner surface (32) of the shell (11) near the medial end thereof, wherein the outer surface (34) of the support element (14) and/or the inner surface (32) of the shell (11) has a recess (18) configured to accommodate the printed circuit board (12) or a part thereof carrying the at least one sensor (13), wherein the shell (11) has one or more windows (31.1, 31.2) aligned with the one or more sensor (13) and/or components (13.1, 13.2) thereof on the flexible printed circuit board (12), wherein the support element (14) has a through-hole (19) with a seat (20) for the receiver (15).
The earpiece (10) of claim 1, wherein the sensor (13) is an optical sensor, e.g., a PPG sensor (13), comprising at least one light source (13.2) and at least one photo element (13.1).
The earpiece (10) according to any one of the preceding claims, wherein the shell (11) and/or the support element (14) comprises one or more locking elements (21, 26) for locking the support element (14) in place within the shell (11).
The earpiece (10) according to claim 3, wherein the support element (14) is elastic such that the support element (14) can be positioned relative to the one or more locking elements (21, 26) in the shell (11) and/or the shell (11) can be positioned relative to the one or more locking elements (21, 26) in the support element (14) by elastic deformation of the support element (14).
The earpiece (10) according to claim 3 or 4, wherein one or more of the locking elements (21, 26) are provided at the inner surface (32) of the shell (11).
The earpiece (10) according to claim 5, wherein the one or more of the locking elements (21, 26) provided at the inner surface (32) of the shell (11) are positioned at the inner surface (32) of the shell (11) to engage with the support element (14) at a lateral end of the support element (14).
The earpiece (10) according to any of claims 3 to 6, wherein the one or more locking elements (21, 26) comprise a flange (21) at a medial end of the support element (14), the flange (21) configured to be pulled through a medial hole (22) in the shell (11) and to subsequently engage the outer surface (34) of the shell (11) around the medial hole (22).
The earpiece (10) according to any one of the preceding claims, wherein the receiver (15) and/or the support element (14) comprises one or more receiver locking elements (23) for locking the support element (14) in place with the receiver (15).
The earpiece (10) according to claim 8, wherein the one or more receiver locking elements (23) comprise a flange (23) provided on the receiver (15) configured to click into a retention groove (24) within the support element (14) around the through-hole (19) and/or seat (20).
The earpiece (10) according to any one of the preceding claims, wherein the inner shape of the shell (11) near the medial end thereof is a dome shape.
The earpiece (10) according to any one of the preceding claims, wherein the support element (14) consists of or comprises an elastomer.
The earpiece (10) according to any one of the preceding claims, wherein an end of the flexible printed circuit board (12) extending from the recess (18) is fixedly connected to the receiver or is configured to be connected to the receiver (15) by a connector on the receiver (15) or a module on the printed circuit board (12).
The earpiece (10) according to any one of the preceding claims, wherein a medial end of the support element (14) comprises a hub (27) configured to extend through a medial hole (22) in the shell (11) to help positioning the support element (14) in the shell (11).
The earpiece (10) according to any one of the preceding claims, wherein a medial end of the support element (14) comprises a grip configured to be cut off after assembly of the support element (14) into the shell (11).
A method of manufacturing an earpiece (10) according to any of claims 1 to 14, the method comprising:
- determining a user-specific ear canal geometry;

- providing constraints for positioning one or more of said windows (31.1, 31.2) on the shell (11) and for positioning said recess (18) on the outer surface (34) of the support element (14) and/or the inner surface (32) of the shell (11);

- determining a position of said one or more windows (31.1, 31.2) on the shell (11) and a position of said recess (18) on the outer surface (34) of the support element (14) and/or the inner surface (32) of the shell (11) by relating the constraints to said determined user-specific ear canal geometry; and

- fabricating the shell (11) and the support element (14) based on said determined ear-canal geometry, wherein said one or more windows (31.1, 31.2) and said recess (18) is provided at the determined position.
A method of assembling the ear piece (10) according to any one of claims 1 to 13, the method comprising:
- pushing the receiver (15) into the seat (20) within the support element (14) from the lateral end,

- laying the printed circuit board (12) or the part thereof carrying the at least one sensor (13) into the recess (18) within the support element (14),

- pushing the support element (14) with the receiver (15) and the printed circuit board (12) into the shell (11) from a lateral end thereof, thereby aligning the one or more sensor (13) and/or its components (13.1, 13.2) in the respective windows (31.1, 31.2) and accommodating the printed circuit board (12) between the shell (11) and the support element (14).
A method for assembling the ear piece (10) according to claim 14, the method comprising:
- positioning the flexible printed circuit board (12) in the shell (11), thereby aligning the one or more sensor (13) and/or its components (13.1, 13.2) at the respective windows (31.1, 31.2),

- inserting the support element (14) into the shell (11) from the lateral end thereof towards the medial end by pulling on the grip,

- pushing the receiver (15) into the seat (20) within the support element (14) from a lateral end,

- cutting the grip off,

- electrically connecting the end of the flexible printed circuit board (12) extending from the recess (18) to the receiver (15).