Patent Publication Number: US-9408004-B2

Title: Flex connector for a hearing assistance device

Description:
CLAIM OF PRIORITY 
     The present application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 61/643,861, filed on May 7, 2012, which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present subject matter relates generally to hearing assistance devices, and in particular to a flex connector for a hearing assistance device. 
     BACKGROUND 
     Modern hearing assistance devices, such as hearing aids, typically include digital electronics to enhance the wearer&#39;s listening experience. Hearing aids are electronic instruments worn in or around the ear that compensate for hearing losses by specially amplifying sound. Hearing aids use transducer and electro-mechanical components which are connected via wires to the hearing aid circuitry. In addition to transducers, modern hearing assistance devices incorporate A/D converters, DAC&#39;s, signal processors, memory for processing the audio signals, and wireless communication systems. The components frequently include multiple housings or shells that are connected to assemble the hearing aid. 
     Transducers, such as receivers (speakers) and microphones can have separate shells that are integrated with the device housing during assembly of the hearing aid. Receivers currently include a standard interface or spout that constrains the device design and implementation. Creating a connector scheme for receivers in custom products has been difficult if not impossible via traditional means because of the anatomical variations inherent in each impression. These variations do not permit the precise alignment and axial positioning required for repeatable performance. 
     What is needed in the art is an improved connector for hearing assistance devices. 
     SUMMARY 
     Disclosed herein, among other things, are methods and apparatus for hearing assistance devices, and in particular for improved connector for hearing assistance devices. 
     One aspect of the present subject matter relates to a hearing assistance system including a flex connector. A hearing assistance device housing includes hearing assistance electronics for a hearing assistance device. The system also includes a receiver configured to convert an electrical signal from the hearing assistance electronics to an acoustic signal. The receiver is configured to enable a quick connect and disconnect at various degrees on and off vertical axial alignment with repeatable reliability, according to various embodiments. 
     In one embodiment, a receiver module for a hearing aid includes a receiver, a receiver case, and a flex tab connector. The hearing aid includes a receptacle connector and circuitry connected to the receptacle connector. The receiver is configured to transmit sound to a user&#39;s ear canal and housed in the receiver case. The flex tab connector is electrically connected to the receiver and configured to mate with the receptacle connector to provide electrical connection between the receiver and the circuitry, and includes a flex substrate and conductive contacts constructed on the flex substrate. 
     In one embodiment, a hearing aid includes circuitry to process sounds, a shell housing the circuitry, and a receiver module. The receiver module includes a receiver configured to transmit the processed sounds and a bendable flex connector electrically connected to the receiver. The shell includes a cavity configured to accommodate at least a portion of the receiver module. A receptacle connector coupled to the shell and electrically connected to the circuitry. A receptacle connector is configured to mate with the flex connector of the receiver module to provide electrical connection between the receiver and the circuitry. 
     In one embodiment, a method for connecting a receiver module to hearing aid circuitry is provided. The receiver module includes a receiver. The hearing aid circuitry is housed in a hearing aid shell having a cavity shaped to accommodating at least a portion of the receiver module. The receiver module is provided with a first connector that is a bendable flex connector. A second connector is mounted to the shell to mate with the first connector to provide electrical connection between the receiver and the hearing aid circuitry. 
     This Summary is an overview of some of the teachings of the present application and not intended to be an exclusive or exhaustive treatment of the present subject matter. Further details about the present subject matter are found in the detailed description and appended claims. The scope of the present invention is defined by the appended claims and their legal equivalents. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an illustration of an embodiment of a hearing aid including a detachably connected receiver module. 
         FIG. 2  is another illustration showing another view of the hearing aid of  FIG. 1 . 
         FIG. 3  is an illustration of an embodiment of the receiver module. 
         FIG. 4  is an illustration of an embodiment of a receptacle connector assembly for mating with the receiver module. 
         FIG. 5  is an assembly diagram illustrating an embodiment of the receptacle connector assembly of  FIG. 4 . 
         FIG. 6  is an illustration of an embodiment of a receiver module assembly. 
         FIG. 7  is an illustration of another embodiment of the receiver module. 
         FIG. 8  is a diagram illustrating an embodiment of the receiver module showing flexibility of its flex connector. 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description of the present subject matter refers to subject matter in the accompanying drawings which show, by way of illustration, specific aspects and embodiments in which the present subject matter may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present subject matter. References to “an”, “one”, or “various” embodiments in this disclosure are not necessarily to the same embodiment, and such references contemplate more than one embodiment. The following detailed description is demonstrative and not to be taken in a limiting sense. The scope of the present subject matter is defined by the appended claims, along with the full scope of legal equivalents to which such claims are entitled. 
     Disclosed herein, among other things, are methods and apparatus for hearing assistance devices, and in particular improved connectors for hearing assistance devices. One aspect of the present subject matter relates to a hearing assistance system including a flex connector. A hearing assistance device housing includes hearing assistance electronics for a hearing assistance device. The system also includes a receiver configured to convert an electrical signal from the hearing assistance electronics to an acoustic signal. The receiver is constructed as a receiver module configured to enable a quick connection to and disconnection from the main body of the hearing assistance device at various degrees on and off vertical axial alignment with repeatable reliability, according to various embodiments. 
     The present subject matter provides a new flex based connector system that meets the needs for improved connectors without severely limiting the options of the modeler. This flex connector system will enable on the fly customization of the connector resulting in savings of not only time but cost as well. 
     In one example, a male flex tab is used of varying length in the place of solder pads, and a female connector is made from a sculpted flex format with a laminated epoxy glass stiffener board engineered to provide the necessary spring force to ensure a repeatable and reliable connection. Various embodiments of the present subject matter are discussed as follows. 
       FIG. 1  is an illustration of an embodiment of a hearing aid  100 . Hearing aid  100  includes a shell  102 , a faceplate  104 , a detachably connected receiver module  110 , and a cavity  106  on shell  102 . Cavity  102  is shaped to accommodate at least a portion of receiver module  110 . In the illustrated embodiment, cavity  102  is shaped to accommodate a major portion of receiver module  110 . In the illustrated embodiment, hearing aid  100  is a completely-in-canal (CIC) type hearing aid, with shell  102  having an irregular conical shape configured for the CIC type hearing aid. In various embodiments, hearing aid  100  is a custom fit hearing aid. In various other embodiments, receiver module  110  is used in a stand fit hearing aid. In various hearing aid designs, to improve performance of the hearing aid, it is beneficial to customize portions of the hearing aid to the hearing aid user. In some embodiments, shell  102  is customized to sealingly mate with the individual user&#39;s hearing canal. However, it should be understood that the present subject matter also includes standardized shells which are suitable for mating to an ear canal of the user. 
     In various embodiments, shell  102  includes a large opening configured for interfacing with faceplate  104 . In various embodiments, this opening is of an irregular shape, requiring that the mating faceplate  104  be customized to fit to it. In various embodiments, a standard faceplate that is larger than the opening is fitted to shell  102 , and then modified to a custom shape to form faceplate  104 . 
     In various embodiments, hearing aid components housed in shell  102  include a microphone to receive a sound signal and a processing circuit to process the sound signal to produce an output sound signal. Receiver module  110  houses a receiver (speaker) that converts the output sound signal to a sound audible to the user and transmits that sound to the user&#39;s ear canal. In various embodiments, cavity  106  is formed on shell  102  to accommodate at least a portion of receiver module  110 , allowing receiver module  110  to be detachably connected to the rest of hearing aid  100  through a connector mounted or otherwise coupled to shell  102  within cavity  106 . Thus, receiver module  110  is replaceable.  FIG. 2  is an illustration of portions of hearing aid  100  showing receiver module  110  accommodated in cavity  106  when connected to hearing aid  100 . In one embodiment, the connection between receiver module  110  and the rest of hearing aid  100  is a mechanically flexible connection, as further discussed with reference to  FIGS. 3-8 , to facilitate customization of shell  102  and/or improve durability of the connection. 
     In various embodiments, hearing aid  100  may include additional hearing aid components. In various embodiments, shell  102  houses a hearing aid circuitry including the microphone, processing circuitry, and optionally the additional hearing aid circuitry. In some embodiments, the hearing aid circuitry is constructed as a flex circuit including hearing aid components mounted on a flex substrate that is bendable. In various embodiments, common parts suitable for interface with faceplate  104  include a microphone housing, an insertion removal handle, a cover, and a battery. In further embodiments, faceplate  104  is configured to utilize various controls, such as adjusting dials and push-button switches. In various embodiments, hearing aid  100  provides the user with comfort due to its customized shape, and flexibility and/or durability due to the use of the detachably connected receiver module  110 . 
       FIG. 3  is an illustration of an embodiment of a receiver module  310 . Receiver module  310  represents an embodiment of receiver module  110  and includes a receiver assembly  312  coupled to a flex tab connector  320 . In various embodiments, receiver assembly  312  includes at least the receiver that transmits sounds to the user&#39;s ear canal, and may include a receiver case that houses at least a portion of the receiver. In the illustrated embodiment, receiver module  310  includes a sleeve  314  accommodating a major portion of receiver assembly  312 . In one example, sleeve  314  is an isolation sleeve made of a polymer such as silicone. 
     Flex tab connector  320  is a bendable flex connector (also known as, for example, flexible connector, flex circuit connector, or flexible circuit connector) including conductive contacts  322  constructed on a flex substrate  324  (also known as flexible substrate, flex circuit substrate, or flexible circuit substrate). With conductive contacts (flex pads)  322  made of mechanically flexible conductive traces such as copper traces, connector  320  is substantially bendable. Use of connector  320  with in-line flex conductive contacts  322  eliminates the need for solder pads for connecting the receiver assembly to the processing circuit of hearing aid  100 . In various embodiments, flex tab connector  320  has advantages over a rigid connector because, for example, it facilitates customization of the length of receiver module  310  and hence hearing aid  100 , allows for off-axis connector alignment, protects the receiver from heat during soldering (when solder pads are used), and provides for self-alignment for a blind insertion of hearing aid  100  into the user&#39;s ear canal. In one embodiment, conductive contacts  322  are constructed on both sides of substrate  324 . In one embodiment, duplication of the conductive contacts on both sides of the substrate provides fault free insurance of connection. In various embodiments, use of flex tab connector  320  eliminates wall stack-up, thereby permitting greater flexibility in vent type and placement in almost all circumstances for CIC type hearing aids. 
       FIG. 4  is an illustration of an embodiment of a receptacle connector assembly  430  for mating with receiver module  310 , and  FIG. 5  is an assembly diagram illustrating an embodiment of receptacle connector assembly  430  showing its unassembled components. Receptacle connector assembly  430  functions as a receptacle connector for connector  320 . In the illustrated embodiment, connector  320  is configured as a male connector, while connector assembly  430  is configured as a female connector. 
     Receptacle connector assembly  430  is configured to mate with connector  320 . In the illustrated embodiment, connector assembly  430  includes a connector  434  and a connector housing  432 . In one embodiment, connector  434  is a bendable flex connector. Connector housing  432  is made of an elastic material, such as a polymer, and configured to accommodate at least a portion of connector  434 . Thus, receptacle connector assembly  430  is bendable. Connector  434  includes conductive contacts  436  constructed on a bendable flex substrate  438 . In one embodiment, flex substrate  438  includes a contact layer  539  and a stiffener layer  540  to achiever a desired level of flexibility. Contact layer  539  may include s polyimide film, and stiffener layer  540  may include a glass-reinforced epoxy laminate sheet. For example, contact layer  539  may include a 0.07 millimeter Kapton film, and stiffener layer  540  may include a 0.13 millimeter FR4 type stiffener, thereby providing for a 0.2 millimeter-thick substrate  438 . Such a structure creates the necessary contact spring force in a substrate with a thin cross-section. In some embodiments, connector housing  432  is not needed as connector  434  could be built into a structure of hearing aid  100  such as a spine or faceplate  104 . When stand-alone use (without other physical support mechanism) is desired, connector housing  432  is configured to provide for a mounting structure and opposition force (when such structure and force are not available from the spine or faceplate, for example). In some embodiments, connector  434  can be leveraged into an ultra thin stand alone programming module or be built into the master flex board of hearing aid  100 . The master flex board is a flex circuit board on which at least a portion of the hearing aid circuitry is constructed. In one embodiment, at least a major portion of the hearing aid circuitry is constructed on the master flex board. 
       FIG. 6  is an illustration of an embodiment of a receiver module assembly that constitutes part of hearing aid  100  and includes receiver module  310  connected with connector  430 . In the illustrated embodiment, receiver module  310  is also connected to a receiver cover  650 , which is configured to mate with cavity  106  at its opening. In various embodiments, receiver cover  650  protects the receiver from unwanted materials such as earwax and moisture that may present in the ear canal of the user, while allowing sounds to pass, during operation of hearing aid  100 . 
     Receiver module  310  allows placement of the receiver of hearing aid  100  deep into the ear canal, minimizes casing time, and is easily replaceable in field or in house. In one embodiment, receiver module  310  is configured to fit into a CIC type hearing aid with a minimum cross-section of 3.8 mm 2  and a minimum acoustic gain of 60 dB. 
       FIG. 7  is an illustration of an embodiment of a receiver module  710 . Receiver module  710  includes receiver assembly  312 , sleeve  314 , and a flex tab connector  720 . Receiver module  710  represents an embodiment of receiver module  310  with connector  720  being an example of a variation of connector  310 . In the illustrated embodiment, receiver module  710  is substantially similar or identical to receiver module  310  except for that connector  720  is configured for use in a behind-the-ear (BTE) type hearing aid that includes a detachably connected receiver module that is to be placed in the ear canal of the user. Connector  720  is a bendable flex connector including conductive contacts  722  on a flex substrate  724 . Conductive contacts  724  are configured as pin locators to ensure a non-biased suspension when used with tube/spout suspension in the BTE type hearing aid. In various embodiments, finite element analysis (FEA) modeling can be used to match cutout suspension to stiffness of the tube. 
       FIG. 8  is a diagram illustrating an embodiment of a receiver module  810  (in a side view showing thickness of a flex tab connector) showing its connection flexibility. Receiver module  810  represents any receiver module designed according to the present subject matter as discussed in this document, including receiver modules  310  and  710  as examples. Receiver module  810  has a long axis  860  and includes receiver assembly  312 , optionally sleeve  314 , and flex tab connector  820 . Receiver assembly  312  includes a receiver  856  and a receiver case  858  housing receiver  856  or a portion thereof. Connector  820  represents any flex connector of the receiver module designed according to the present subject matter as discussed in this document, including connectors  320  and  720  as examples. In the illustrated embodiment, connector  820  is bendable from axis  860 . In one embodiment, connector  820 , or a major portion thereof, is on axis  860  when it is in an unconstrained state (e.g., not connected). In other embodiments, at least a portion of connector  820  is off axis  860  when it is in the unconstrained state, if desired based on various design considerations. In various embodiments, in addition to being bendable from axis  860 , connector  820  is also bendable about axis  860  to certain degree. In various embodiments, connector  820  has the mechanical characteristics of a flex circuit as known in the electronics art. In various embodiments, connect  820  provides receiver module  810  with ability of a quick connection and disconnection with the rest of the hearing aid at various degrees on and off vertical axial alignment (i.e., alignment with axis  860 ) with repeatable reliability. 
     In various embodiments, the present subject matter provides hearing aids with shortened build cycles, reduced touch points, quicker repair, fewer reprints of shells as the receiver module is replaceable, and “plug-and-play” receiver module selection (with less modeling), while not reducing number of options for or styles of vents. 
     It is understood that variations in communications protocols, antenna configurations, and combinations of components may be employed without departing from the scope of the present subject matter. Hearing assistance devices typically include an enclosure or housing, a microphone, hearing assistance device electronics including processing electronics, and a speaker or receiver. It is understood that in various embodiments the microphone is optional. It is understood that in various embodiments the receiver is optional. Antenna configurations may vary and may be included within an enclosure for the electronics or be external to an enclosure for the electronics. Thus, the examples set forth herein are intended to be demonstrative and not a limiting or exhaustive depiction of variations. 
     The present subject matter can be used for a variety of hearing assistance devices, including but not limited to, cochlear implant type hearing devices, hearing aids, such as behind-the-ear (BTE), in-the-ear (ITE), in-the-canal (ITC), or completely-in-the-canal (CIC) type hearing aids. It is understood that behind-the-ear type hearing aids may include devices that reside substantially behind the ear or over the ear. Such devices may include hearing aids with receivers associated with the electronics portion of the behind-the-ear device, or hearing aids of the type having receivers in the ear canal of the user. Such devices are also known as receiver-in-the-canal (RIC) or receiver-in-the-ear (RITE) hearing instruments. It is understood that other hearing assistance devices not expressly stated herein may fall within the scope of the present subject matter. 
     This application is intended to cover adaptations or variations of the present subject matter. It is to be understood that the above description is intended to be illustrative, and not restrictive. The scope of the present subject matter should be determined with reference to the appended claims, along with the full scope of legal equivalents to which such claims are entitled.