Headworn sound processor case

A case for encasing a hearing device to allow the wearer to continue wearing the device while engaging in activities such as swimming. In certain embodiments, the case comprises a protective portion for providing mechanical protection to the device and a flexible portion for housing a coil associated with the hearing device. In specific embodiments, the case also includes one or more acoustic ports.

BACKGROUND

1. Field of Invention

The present disclosure relates to casings for hearing devices such as behind the ear (BTE) hearing devices.

2. Related Art

Hearing aid devices are commonly used to assist users who have difficulty in hearing. The hearing device typically includes a processor which receives surrounding sounds, processes the received sounds, and converts these sounds to an electrical signal, which is transmitted wirelessly via a coil acting as an antenna, to a corresponding coil implanted inside the user's skull. The external coil is often conveniently aligned with the implanted coil via one or more magnets associated with each coil. The implanted coil is typically just part of an implant system. Other parts of this system vary depending on the type of system.

In a cochlear implant system, for example, the internal coil is connected to an implanted stimulator which generates stimulating electrical signals corresponding to the received electrical signals, to stimulate nerves in the user's cochlea via an array of electrodes inserted into the cochlea. In Direct Acoustic Cochlear Stimulators (DACS) systems, the internal coil is attached to an actuator which is implanted in the middle ear to stimulate the cochlea via mechanical stimulation in accordance with the electrical signals received by the implant, from the external coil as described above. Other implant systems, such as auditory brain stem implant systems, exist and are within the scope of the invention. For the hearing device to function with any of these implant systems, the hearing device must be functionally connected to an internal system.

SUMMARY

In accordance with one embodiment of the present invention, a case for a BTE hearing device is provided. The case comprises a sealable opening through which the hearing device can be placed in the case, and a substantially flexible portion for receiving an antenna portion of the hearing device.

In accordance with another embodiment of the present invention, a case for a BTE hearing device is provided. The case comprises a protective portion, the protective portion being adapted to provide mechanical force protection for a first portion of a hearing device; and a flexible portion, the flexible portion being adapted to house a second portion of the hearing device such that the second portion maintains a fixed position relative to a reference point external to the case while the protective portion moves relative to the flexible portion

In accordance with a still other embodiment, a case for a BTE hearing device is provided. The case comprises: a first portion adapted to fix a first position of a first portion of a hearing device within the case relative to a port located on the first portion of the case; and a second portion adapted to fix a second position of a second portion of the hearing device relative to a location external to the case.

In some embodiments, the case also has an acoustic port to facilitate sounds transmission to the device in the case, and a support inside the case to hold the device in a certain orientation.

DETAILED DESCRIPTION

FIG. 1shows an exemplary Behind-The-Ear (BTE) hearing device20comprising, in this example, a processor portion, sometimes referred to as sound processor,21for receiving and processing sounds from around the wearer50, and converting the processed signals into signals for transmission as electrical radio frequency (RF) signals. The RF signals are transmitted via antenna portion or coil22that in use, is located on the wearer's head, over or near, a corresponding antenna or coil implanted under the wearer's scalp for subsequent conversion into electrical signals and stimulation of the user's functional hearing system. In one embodiment, antenna portion22is a coil. It will be understood that antenna portion22may be configured to function as part of a transceiver that transmits RF signals to the implanted coil as well as receive RF signals from the implanted coil. In some applications, it will be appreciated that the implant will generate signals and transmit these to the hearing device20via the antennae or coils. When not in use, the hearing device20, including the processor21and coil22can be removed.

Embodiments of the present invention are generally directed to a case that allows the wearer to continue conveniently using the hearing device when engaged in sporting or other activities that may otherwise affect or damage the hearing device. In certain embodiments, the case completely encase the hearing device and allows the coil22to be positioned in its usual position as shown inFIG. 1.

FIG. 2shows a plan view of the case100. The case100comprises a protective portion110and a flexible portion120. The protective portion provides some mechanical protection to an article within the protective portion110by reducing at least a portion of the force of an impact applied to the protective portion passing through to the article within. In one aspect, the protective portion will protect sensitive electronic components within the hearing device from being damaged.

In embodiments described herein, the protection or force reduction is accomplished through the selection of hard or hardened materials, such as injection mouldable plastic (e.g., Polycarbonate Acrylonitrile Butadiene Styrene), metal and/or hardened rubber. In other embodiments, the protection or force reduction is accomplished through other techniques such as softer or less protective material formed into protective shapes or structures including skeletal structures, ribbing, and the like. In yet further embodiments, the protection or force reduction is accomplished through other techniques such as providing a force-absorbing or damping material within the protective portion110. In one embodiment, a foam lining is provided on the inner surface which blankets and holds the portion of the hearing device within the protective portion110. In another embodiment, a gel-like substance such as silicone is used to line the, or a part of, the inner surface of protective portion110.

In this embodiment, the case100also comprises a flexible portion120. In embodiments described herein, the flexibility of the flexible portion120is accomplished through the selection of soft materials, including soft rubber, silicon and/or polyurethane. In some embodiments, a part of the flexible portion120distal from the protective portion110is made from a non-flexible material, but is connected to the protective portion by a flexible material such as silicone rubber, to allow movement of the flexible portion120with respect to the protective portion. The term “soft” as used herein will be understood to mean sufficiently deformable or malleable to allow the flexible portion to substantially conform to the shape of the surface of the wearer's head at the location of the received coil22. This can improve the co-location of coil22and the corresponding implanted coil and the communication of RF signals between the coil22and corresponding implanted coil.

In other embodiments, the flexible portion120is made of the same material as the protective portion but is thinned or otherwise structurally compromised to allow flexing within the flexible portion120. In one embodiment, strips of material are etched away or otherwise removed to allow flexing. In yet further embodiments, flexible portion120is made of a protective material however there is a region over which the coil22sits when in the case100, that is flexible or soft to allow the coil22to conform to the shape of the wearer's head at that point. In one embodiment, this region is about 40 mm to about 50 mm in diameter.

The protective portion110is made by any suitable techniques, including conventional injection moulding for plastic materials, metal injection moulding. In one embodiment, protective portion110is formed by machining. The flexible portion120is also made by any suitable method including conventional injection or transfer moulding. In one embodiment, flexible portion120is overmoulded onto the protective portion110. The overmoulding process provides bonding. In embodiments with separate moulding, a glue is used in conjunction with some mechanical fixation such as snaps and/or clips.

FIG. 3shows a perspective view of the case100. In this embodiment, an acoustic port111is located in the protective portion110. Acoustic port111can be any structure that allows sound energy to pass through more easily than through the case itself. In some embodiments, where waterproofing is not required, the acoustic port is an aperture in the case. In embodiments where waterproofing and/or sealing of the case is required, acoustic port111is provided by one or more regions where the casing material has been thinned, or in some embodiments, is provided by one or more protective membrane packaging vents such as those available under the brand name Gore™ Vents provided by W. L. Gore & Associates, Inc in Delaware, USA.

FIG. 4shows one embodiment of case100, in which the protective portion110is formed in two (2) pieces and is able to be separated to provide a sealable lid140. In the embodiment ofFIG. 4, case100has base150which comprises the flexible portion120and a part110aof protective portion110. In some embodiments, in which the case is split at the protective portion/flexible portion interface, the base150comprises the flexible portion120only and the lid140comprises the entire protective portion110.

In some embodiments, a seal is provided between the interface of the lid140and the base150. In the embodiment inFIG. 4, the seal is provided by two O-rings112. In some embodiments, other types of sealing are used, including tongue and groove, clips, screw threads, or using a grease or gel.

FIG. 5Bshows the case100with the encased hearing device20in dotted lines. As can be seen, at least the majority of the processor21is housed within protective portion110while the coil22is housed within the flexible portion120. In this way, the protective portion110provides some protection to the processor21therein. The protection is provided in the form of protection against mechanical impacts that may be received during the wearer's activity (e.g. by a contact sport), and/or protection against dust (e.g. if riding a bike in a dusty environment). The flexible portion120also provides protection against agents such as dust, but because it is soft, it is able to conform to the curve of the wearer's head under coil22and allows the coil22to adopt a curved state to allow better contact with the wearer's head as will be described in more detail below.

In one embodiment, flexible portion120is provided with a magnet121to attract the magnet of the coil22to help locate and retain coil22within flexible portion120. This arrangement is shown inFIG. 5A.FIG. 5Bshows the case100ofFIG. 5Awith a hearing device20encased within. In one embodiment, magnet121is about 10 mm in diameter and about 1 mm in thickness. In another embodiment, magnet121is about 5 mm in diameter and about 1 mm in thickness. In another embodiment, magnet121is about 3 mm in diameter and about 0.5 mm in thickness.

As can be seen, at least a part of the processor or processor portion21is housed within protective portion110while the antenna portion or coil22is housed within the flexible portion120.

In some embodiments, all or a portion of the case100is transparent or otherwise translucent, to allow visual access to the medical device20housed within case100. This will allow observing of any water ingress and will allow any indicators, such as LEDs or other indicator lights to be viewed from the outside. As will be understood, some hearing device models can indicate one or more modes of operation of the hearing device via one or more visual indicators.

In some embodiments, the division between the hard/flexible portions is graduated so that the protective portion110transitions into the flexible portion120. In other embodiments, the protective portion110and the flexible portion120is provided by the same material whose thickness is varied so that the material is thicker towards one end of the case100to provide the protective portion110and is thinner and more pliable towards the other end of the case100to provide the flexible portion120. In one embodiment, the thickness varies from about 5 mm to about 2 mm from one end to the other end. In one embodiment, the thickness of the material in the flexible portion120that will be disposed between the coil22and the head of the user in use, is equal to or less than about 2 mm. This includes between about 2 mm and about 1 mm; between about 1.5 mm and about 0.5 mm; between about 0.5 mm and about 0.1 mm; about 1.8 mm, about 1.6 mm, about 1.4 mm, about 1.2 mm, about 1.1 mm, about 1 mm, about 0.8 mm, about 0.6 mm, about 0.4 mm, about 0.3, about 0.2 mm, and about 0.1 mm.

In some embodiments, flexible portion120is shaped differently to allow for variations in the placement of the coil22to accommodate different locations of the implanted coil due to surgeons' individual styles or preferences in implant placement. In yet further embodiments, at least a portion of the flexible portion120is flexible to allow flexible placement of the coil22over the implanted coil with respect to the rest of the case100.

In one embodiment, and as shown inFIG. 6, the positioning and retaining of the processor21within the case100is facilitated by the use of a support130within case100. In one embodiment, support130comprises a tray which is removable from case100. In one embodiment, tray130is itself constructed so as to provide location guides such as moulding in the shape of the processor21, or guide pins, or guide walls.

FIG. 7shows a number of support130configurations in the form of foam padding131to support different hearing device models depending upon their shape and microphone locations. The foam padding131can be moulded or otherwise shaped to provide a stable location base in which to retain processor21in a particular position or orientation. The foam padding also provides increased sound absorption by absorbing reflected sound inside the case, further improving the function of the hearing device20. The foam padding131also mechanically decouples the processor20from the walls of the case100, reducing the audibility of mechanical vibrations on the case100. Furthermore, in a swimming or water-sports application, the presence of foam padding131provides further protection to processor21by absorbing any moisture that may have entered the case100, despite its sealing.

In one embodiment, this position maintains the processor20within about 10 mm of the acoustic port111. In one embodiment, this position or orientation is such that the microphone of the processor21is directed towards the acoustic port111, as shown inFIG. 5B. This orientation provides the most efficient access to the incoming sound energy into case100via acoustic port111.

FIG. 8shows a wearer50wearing case100housing a hearing device20(not visible in this view). The case100is located such that the coil22is located in substantially the same position on the wearer's head as it would when worn without the case100.

A particular advantage of this arrangement is that there is no additional equipment required to allow the hearing device20to continue to provide hearing assistance to the wearer50. In particular, in some prior art systems, where the hearing device is housed in a “body-worn” casing supported at the waist for example, there is also required a wire or cord connecting the processor to the coil on the user's head. In the arrangements disclosed herein, there is no need for any wires or cords connecting the hearing device20to the implanted device, or for providing “an extension cord” between the processor21worn on the body and the coil22worn on the head. The absence of such wires reduces inconvenience and eliminates any choking hazard to the wearer.

While in some embodiments, the case100is retained to the wearer's head by the magnetic attraction between the coil21and the corresponding implanted coil, in some embodiments, additional methods are also used to further secure the position of the case100on the wearer's head. These additional methods may depend upon the type of activity being undertaken.FIGS. 9A to 9Dshow a number of possible methods or apparatus for retaining the case100to the wearer's head.

FIG. 9Ashows one embodiment in which a pair of swimming goggles60, which are often used when swimming, is used to further secure case100on the wearer's50head. In this application, the strap61of the swimming goggles60is placed over the case. In one embodiment, the “Y”-point of the strap61is placed over at least a portion of the case100to provide even more security.

InFIG. 9B, even further security in retention is provided by a clip80in one embodiment, which in use is wrapped around the case100and the strap61. InFIG. 9C, illustrating another swimming application, case100, in one embodiment, is retained underneath a swimming cap65. In one embodiment as shown inFIG. 9D, a general-purpose application of a headband70is used to retain case100to the wearer's head50.

In one embodiment, case100is shaped (see for exampleFIG. 11B) so as to be able to be used on either or both sides of the wearer's head. This obviates the need to manufacture two different types of case shapes, one for each side.

FIG. 10shows a close up cross section view of the position of the coil22inside the flexible portion120of case100, when placed on the wearer50(not drawn to scale). Shown there is the corresponding implanted coil32located against the skull51of the wearer50, underneath the scalp52. As can be seen inFIG. 10, because the flexible portion120is soft it conforms to the shape of the wearer's50head at the location of the coil22. This provides a more direct co-location of the coil22and the corresponding implanted coil32. This provides a better communication between the two coils, and is also more comfortable for the wearer50. In this view, respective coil magnets23and33of coils22and32are also shown, in substantial co-location.

In another embodiment, at least a portion of the case100is hydrodynamically shaped so as to be biased towards the wearer's50head when water flows over the case100. This would occur in activities such as swimming laps in a pool or swimming underwater in a forward direction.FIGS. 11A to 11Dshow a case100that is hydrodynamically shaped.FIG. 11Ashows case100with protective portion110and flexible portion120. In this embodiment, flexible portion120is substantially transparent or translucent, showing a part of the support130in the form of a tray inside the case. Also visible in this view are two acoustic ports111.FIG. 11Bis a plan view. In this view, it can be seen that case100is symmetrical about a longitudinal centre line, thus allowing the case100to be worn on either side of the wearer's head.FIG. 11Cshows a front end view of the case100andFIG. 11Dshows a side view, showing the profile of the case100that provides a hydrodynamic effect.

FIG. 12shows the action of the hydrodynamic effect from the shape of the case100, so as to provide a bias force as indicated by arrows6towards the wearer's head as water flows over the case as indicated by arrow5.

In another aspect, there is provided a method of encasing a BTE hearing device for the wearer to use during an activity. In this method, as shown inFIG. 13, the method comprises in step500, placing the coil22in a flexible portion120of the case100. In step501, the processor is placed in a protective portion110of the case. In step502, the case is sealed, and in step503, the case is located on the wearer's head such that the coil is co-located with a corresponding implanted coil.

It will be appreciated that the step501of placing the processor in the protective portion could be performed before the step500of placing the coil in the flexible portion.

In one embodiment, the step of placing the coil in the flexible portion further comprises locating the coil in the flexible portion with a magnet in the flexible portion. In one embodiment, the step of placing the processor in the protective portion further comprises orienting the processor within the protective portion such that a microphone of the processor is directed towards an acoustic port of the case.

In yet another possible embodiment described herein and as illustrated inFIG. 14, the case100is formed entirely of the flexible portion120. In this embodiment, the case100will not provide the protection against mechanical impact, however, it will still provide the advantages of protection against moisture, or dust, and will provide the advantage of conforming to the wearer's head thus allowing the coil22to properly conform to the wearer's head as previously described.

In one embodiment as illustrated inFIG. 14, case100comprises a sealable element160allowing the case to be opened to insert a hearing device and resealed to seal the hearing device therein. In one embodiment, the case100is shaped so as to substantially conform to a general outline of the hearing device.

In one embodiment, as shown inFIG. 15, a magnet121is also provided at a convenient location within the case100so as to allow more effective placement of the coil22of the hearing device20within the case. In one embodiment as shown inFIG. 16, the case100is provided with an acoustic port111.

In one embodiment, the case100combines one or more of the features described with reference toFIGS. 14 to 16. In one embodiment for the example, the case will have both the magnet121and the acoustic port111as shown inFIG. 17.

In one embodiment, a separate support such as a tray130is provided to further assist the location and orientation of the hearing device20within the entirely soft case100. In one embodiment, a foam support131is provided to either provide the support entirely, or to sit within the tray130.FIG. 18shows an embodiment of this aspect, comprising support130in the form of a foam support131, retaining processor21in an orientation such that its microphone is directed toward acoustic port111as previously described. Coil22is also located towards the end of the case100and retained by a magnet121. Sealable opening160is provided to allow the hearing device and support130/131to be placed in and removed from case100.

In one embodiment, a portion of case100is provided by protective portion110as previously described and as illustrated inFIG. 2for example.

Another embodiment and aspect of the present invention is illustrated inFIGS. 19A and 19B. In one embodiment, a case100comprises a hardened portion110as previously described. In one embodiment, the hardened portion110has a portal, which in one example is an acoustic port111. The hardened portion110is adapted to house a first portion of a hearing device20, in such a way that the first portion21is maintained in a substantially fixed position adjacent to the portal. In one embodiment, the first portion is a microphone210of the hearing device. In another embodiment, the first portion is a processor21of the hearing device20.

As seen inFIG. 19A, the case100also comprises a flexible portion120, which is adapted to house a second portion of the hearing device such that the second portion maintains a fixed position relative to a reference point external to the case100when the hardened portion110moves.

This aspect is illustrated inFIG. 19Bwhich shows the original position of case100as was shown inFIG. 19A, illustrated inFIG. 19Bas dotted lines. The new position of case100after some movement, is illustrated in full lines as case100′. From this view, it can be seen that even though the hardened portion110has moved from its original position, together with the first portion of the hearing device, the second portion of the hearing device has maintained its original position, since the flexible portion120is able to flex to allow the hardened portion110to move with respect to the flexible portion. In this example, it is seen that the second portion of the hearing device has maintained its position relative to an external reference point. In one embodiment, the second portion is a coil22and the reference point is an implanted coil and in one particular example, is a magnet of the implanted coil as shown inFIG. 10.

It will also be seen that even though hardened portion110has moved, the first portion (e.g. microphone) has not moved relative to the port111and is still able to receive sounds from outside the case100.

Accordingly, in this embodiment, the case100allows the coil22to be stably retained in a position over the implanted coil to allow continued RF communication between the coil and the implanted coil to allow the user continued use of the hearing device even if the user's activities such as swimming or running, result in some movement of the case.

In another embodiment, case100comprises a first portion110that is adapted to receive a first portion of a hearing device and fix its position within the case relative to a port located on the first portion. In one embodiment, the port is an acoustic port. In this embodiment, case100also has a second portion which is adapted to receive and fix in position, a second portion of the hearing device, relative to a position external to the case100. In one embodiment, the second portion is flexile such that a movement of the first portion of the hearing device relative to the second portion of the hearing device does not move the second portion of the hearing device significantly from its position. In one embodiment, the second portion of the hearing device does not move more than about 5 mm from the position. In one embodiment, the second portion of the hearing device is a coil. In one embodiment, the position is a location on the wearer's head over an implanted coil. In this embodiment, because the case allows a part of the hearing device to move relative to another part (for example the coil), the coil still maintains effective or functional contact with the implanted coil to allow sufficient signals to be transmitted from the coil to the implanted coil to provide a hearing sensation in the wearer.

This action is also illustrated inFIGS. 19A and 19Bwhich shows relative movement between the first portion of the hearing device (for example processor21) and the second portion of the hearing device (for example coil22).

In one embodiment, the first portion is hardened such that a portion of mechanical force applied to the hardened portion is not applied to the hearing device within the case.

It will be understood that that the various aspects have been described with reference to specific embodiments and that many variations and modifications can be made within the present disclosure. It will also be understood that the various aspects of the case and its embodiments and methods are equally applicable to any hearing device or system that requires a coil to engage with the wearer's head, including a cochlear implant system and a Direct Acoustic Cochlear Stimulation (DACS) system. Other applicable systems include:

ABI (Auditory Brainstem Implant)—an electrode for hearing, placed in the brainstem such as Cochlear Corporation's Nucleus 24 [R] Multichannel Auditory Brainstem Implant (Multichannel ABI). The auditory brainstem implant consists of a small electrode that is applied to the brainstem where it stimulates acoustic nerves by means of electrical signals. The stimulating electrical signals are provided by a signal processor processing input sounds from a microphone located externally to the user. This allows the user to hear a certain degree of sound.

FES (Functional Electrical Stimulation)—FES is a technique that uses electrical currents to activate muscles and/or nerves, restoring function in people with paralysis-related disabilities.

SCS (Spinal Cord Stimulator)—This system delivers pulses of electrical energy via an electrode in the spinal area and may be used for pain management. An example of a commercially available system is the RESTOREPRIME system by Medtronic, Inc, USA.