Patent ID: 6695943
Filing Date: 2004-02-24
Classification: C07D,C07H,H04R,Y10T

Abstract:
A method of manufacturing a hearing aid comprising the steps of:a) placing a moldable material in the ear canal of a patient to cast a form; b) using the form to vacuum form a hollow shell with an outer surface that approximates the shape of the patient's ear canal, the shell being of a soft polymeric material; c) providing a mounting member; d) mounting electronic hearing aid components to the mounting member; e) joining the mounting member to the hollow shell to define a mold cavity; f) filling the shell with a soft polymeric material that substantially encapsulates at least one of the electronic components; g) wherein in step â€œfâ€  the combination of shell, electronic components and fill material define a soft structure that is compliant to ear canal movement during use; and h) further comprising placing a bonding layer between the mounting member and soft polymeric material.