Patent ID: 6432247
Filing Date: 2002-08-13
Classification: 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 shape 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 , the soft, solid polymeric body defining a soft and solid interface that conforms to the ear canal and encapsulates at least one of the hearing aid components; g) allowing the soft polymeric material to cure; h) removing the soft polymeric material from the shell; i) wherein in step â€œfâ€  the combination of electronic components and fill material define a soft structure that is compliant to ear canal movement during use.