TECHNICAL FIELD
[0001] This document relates generally to hearing assistance systems and more particularly
to methods and apparatus for solderless module connectors for hearing assistance devices.
BACKGROUND
[0002] Hearing assistance devices, such as hearing aids, include, but are not limited to,
devices for use in the ear, in the ear canal, completely in the canal, and behind
the ear. Such devices have been developed to ameliorate the effects of hearing losses
in individuals. Hearing deficiencies can range from deafness to hearing losses where
the individual has impairment responding to different frequencies of sound or to being
able to differentiate sounds occurring simultaneously.
[0003] The hearing aid in its most elementary form usually provides for auditory correction
through the amplification and filtering of sound. Hearing aids typically include an
enclosure or housing, a microphone, hearing assistance device electronics including
processing electronics, and a speaker or receiver. Existing hearing aid circuits and
bodies are hand assembled, use individual wires for interconnects, and use a messy
and time-consuming soldering process.
[0004] Accordingly, there is a need in the art for methods and apparatus for improved assembly
for hearing assistance devices.
SUMMARY
[0005] Disclosed herein, among other things, are systems and methods for solderless module
connectors for hearing assistance devices. One aspect of the present subject matter
includes a method of assembling a hearing assistance device. According to various
embodiments, the method includes providing a structure including a laser-direct structuring
(LDS) portion, and inserting a flexible universal circuit module (UCM) having conductive
surface traces and elastomeric backing into the structure. The UCM is electrically
connected to the LDS portion using direct compression without the use of wires or
solder, according to various embodiments.
[0006] One aspect of the present subject matter includes a hearing assistance device. According
to various embodiments, the hearing assistance device includes a structure including
a laser-direct structuring (LDS) portion, and a flexible universal circuit module
(UCM) having conductive surface traces and elastomeric backing, the flexible circuit
module configured to be inserted into the structure. In various embodiments, the UCM
is configured to electrically connect to the LDS portion using direct compression
without the use of wires or solder.
[0007] 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
[0008]
FIG. 1 shows a block diagram of a hearing assistance device, according to various
embodiments of the present subject matter.
FIGS. 2A-2B illustrate views of a flexible circuit module for a hearing assistance
device, according to various embodiments of the present subject matter.
FIGS. 3A-3C illustrate views of a MID housing including conductive surface traces
for a hearing assistance device, according to various embodiments of the present subject
matter.
FIGS. 4-5 illustrate views of a MID housing including a microphone connection for
a hearing assistance device, according to various embodiments of the present subject
matter.
FIGS. 6-7 illustrate views of a MID housing including programming connections for
a hearing assistance device, according to various embodiments of the present subject
matter.
FIGS. 8-10 illustrate views of a MID housing including receiver connections for a
hearing assistance device, according to various embodiments of the present subject
matter.
FIGS. 11-12 illustrate views of a standard product application of a UCM connection,
according to various embodiments of the present subject matter.
FIGS. 13-14 illustrate views of a custom product application of a UCM connection,
according to various embodiments of the present subject matter.
DETAILED DESCRIPTION
[0009] 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.
[0010] The present detailed description will discuss hearing assistance devices using the
example of hearing aids. Hearing aids are only one type of hearing assistance device.
Other hearing assistance devices include, but are not limited to, those in this document.
It is understood that their use in the description is intended to demonstrate the
present subject matter, but not in a limited or exclusive or exhaustive sense. Hearing
aids typically include an enclosure or housing, a microphone, hearing assistance device
electronics including processing electronics, and a speaker or receiver. Hearing assistance
devices may include a power source, such as a battery. In various embodiments, the
battery may be rechargeable. In various embodiments multiple energy sources may be
employed. It is understood that in various embodiments the microphone is optional.
It is understood that in various embodiments the receiver is optional. 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. 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. Existing hearing aid circuits and bodies are hand assembled,
use individual wires for interconnects, and use a messy and time-consuming soldering
process.
[0011] Disclosed herein, among other things, are systems and methods for solderless module
connectors for hearing assistance devices. One aspect of the present subject matter
includes a method of assembling a hearing assistance device. According to various
embodiments, the method includes providing a structure including a laser-direct structuring
(LDS) portion, and inserting a flexible universal circuit module (UCM) having conductive
surface traces and elastomeric backing into the structure. The UCM is electrically
connected to the LDS portion using direct compression without the use of wires or
solder, according to various embodiments. One aspect of the present subject matter
includes a hearing assistance device. According to various embodiments, the hearing
assistance device includes a structure including a laser-direct structuring (LDS)
portion, and a flexible universal circuit module (UCM) having conductive surface traces
and elastomeric backing, the flexible circuit module configured to be inserted into
the structure. In various embodiments, the UCM is configured to electrically connect
to the LDS portion using direct compression without the use of wires or solder.
[0012] Disclosed herein, among other things, are systems and methods for solderless assembly
for hearing assistance devices. One aspect of the present subject matter includes
a hearing assistance device. According to various embodiments, the hearing assistance
device includes a MID housing, such as a LDS housing and a flexible circuit module
having conductive surface traces and also may have elastomeric backing, the flexible
circuit module configured to be inserted into the MID housing. One or more hearing
assistance electronic modules are configured to connect to the flexible circuit module
using direct compression without the use of wires or solder, in various embodiments.
The present subject matter uses molded interconnect device (MID) technology that combines
injection-molded thermoplastic parts with integrated electronic circuit traces using
selective metallization. One type of MID technology is LDS. In LDS, thermoplastic
parts are doped with a metal-plastic additive that can be activated using a laser.
The present subject matter contemplates any and all types of MID technology for implementation
of the solderless hearing assistance device system.
[0013] FIG. 1 shows a block diagram of a hearing assistance device 100 according to one
embodiment of the present subject matter. In this exemplary embodiment the hearing
assistance device 100 includes hearing assistance electronics such as a processor
110 and at least one power supply 112. In one embodiment, the processor 110 is a digital
signal processor (DSP). In one embodiment, the processor 110 is a microprocessor.
In one embodiment, the processor 110 is a microcontroller. In one embodiment, the
processor 110 is a combination of components. It is understood that in various embodiments,
the processor 110 can be realized in a configuration of hardware or firmware, or a
combination of both. In various embodiments, the processor 110 is programmed to provide
different processing functions depending on the signals sensed from the microphone
130. In hearing aid embodiments, microphone 130 is configured to provide signals to
the processor 110 which are processed and played to the wearer with speaker 140 (also
known as a "receiver" in the hearing aid art).
[0014] Other inputs may be used in combination with the microphone. For example, signals
from a number of different signal sources can be detected using the teachings provided
herein, such as audio information from a FM radio receiver, signals from a BLUETOOTH
or other wireless receiver, signals from a magnetic induction source, signals from
a wired audio connection, signals from a cellular phone, or signals from any other
signal source.
[0015] The present subject matter overcomes several problems encountered in assembling hearing
assistance devices and their subcomponents. One of these problems is the time consuming,
messy process of hand assembly and soldering. Another problem overcome by the present
subject matter is the lengthy design time of each hearing aid circuit. Finally, the
overall cost of materials, such as high density flex, is reduced by the present subject
matter.
[0016] Currently, the assembly of flexible circuits into hearing aids can be complicated.
Once the flexible circuit is inserted into the spine, each limb of the circuit must
be bent down and connected to another component. The connection is currently made
by direct soldering, such as to a battery contact, or a wire must be soldered to the
flexible circuit pad and then run to a second component, such as a push button or
microphone. Currently the primary method of soldering wire connections is hand soldering,
and this process alone contributes significantly to the time required to make a custom
hearing assistance product. In addition, the use of heat in the soldering process
can cause component and circuit damage both during assembly and repair. Thus, the
current method of using wires and soldering for hearing assistance device component
interconnects consumes labor, time, additional parts (wires and additional subassemblies),
additional parts cost, additional connection points and increased system volume. It
also provides a difficult and messy repair process. Furthermore, the wires must be
placed over the spine, taking up valuable space, and can be pulled or broken during
the process.
[0017] Previous solutions to the hand soldering and assembly steps include attempts to reduce
the number of wires necessary in standard hearing aid designs, specifically by replacing
them with additional flexible circuit limbs. The addition of more limbs leads to even
more complex and abstractly shaped circuits. This leads to fewer circuits per panel
and consequently a larger numbers of costly circuit panels. The past solutions to
reduce the time and effort related to designing flexible circuits have focused on
designing a common flexible circuit board between products. A common flexible circuit
board is difficult to accomplish due to the diverse hearing aid design shapes, electrical
requirements and location of connection points. Previously, when a common design has
been successfully developed it has required the removal of a circuit limb for each
hearing aid design. This results in wasted flexible circuit material as well as wasted
space per panel. There are also efforts made to redesign current product flexible
circuit designs in order to fit more circuits per panel. These attempts result in
only a few more circuits fitting onto the panel and the cost savings is minimal. This
also results in even more circuit design time spent per hearing aid design.
[0018] The present subject matter provides a hearing aid circuit and body that can be assembled
without the need for solder or conductive epoxy. The present subject matter is unique
in that it provides a method of assembling a hearing aid circuit to the spine and
other components without the need of solder or conductive epoxy by utilizing a high
density flexible circuit without wires in combination with a low density MID spine
or housing, in various embodiments. Various embodiments of the present subject matter
include a solderless microphone connection, solderless DSP module connection, solderless
integration of a receiver jack, and solderless integrated programming interface. The
present subject matter improves upon previous solutions because it does not require
the addition of more wires or flexible circuit limbs. In various embodiments, the
method of the present subject matter leads to higher yields of hearing aid components
since they are not subjected to soldering temperatures. Additionally, the design time
and effort associated with developing new hearing aids is reduced, making assembly
and repair substantially easier and quicker, and eliminating the need for circuit
limbs leading to more circuits per panel.
[0019] According to various embodiments, the present subject matter includes four types
of solderless assembly connection. The connections are made via direct compression
where the MID conductors form a connection with the flex without intermediary materials
such as solder or conductive epoxy. The drawings illustrate a custom hearing aid application,
but one of skill in the art would understand that the present subject matter is equally
applicable to other types of hearing aids, such as those with a standard spine.
[0020] FIGS. 2A-2B illustrate views of a flexible circuit module for a hearing assistance
device, according to various embodiments of the present subject matter. A DSP module
200 includes an integrated flex connection area 202 having exposed traces. The exposed
traces include Nickel Gold plating, in an embodiment. Other types of traces can be
used without departing from the scope of the present subject matter. The traces are
locate on the edges of the module, in various embodiments. An elastomeric material
204 is located between the flex and the module sides in various embodiments, providing
pressure to ensure proper connections.
[0021] FIGS. 3A-3C illustrate views of a MID housing 300 including conductive surface traces
for a hearing assistance device, according to various embodiments of the present subject
matter. The electrical connection with the flex connection area 302 is made with plastic
fingers with traces 306 that have been processed using LDS or other three-dimensional
(3D) molded interconnect device (MID) technologies to provide both the connection
point as well as interconnection to other components, according to various embodiments.
The elastomeric material 204 located between the flex and the module sides provides
pressure to ensure proper connections, in various embodiments.
[0022] FIGS. 4-5 illustrate views of a MID housing 300 including a microphone connection
for a hearing assistance device, according to various embodiments of the present subject
matter. In various embodiments, a connection to a microphone 410 is made directly
to the microphone pads. An LDS or other 3D MID technology is used to create metallized
contacts 406 that can also function as interconnects to other components, in various
embodiments. According to various embodiments, the contacts 406 are integral to the
polymer contact fingers which provide one side of the connection. A retention band
412 of irradiated polymer (heat shrink) is applied over the microphone and fingers
and heat applied to provide compression, in an embodiment. In another embodiment,
the retention is provided using a metal clip 514. Other retention mechanisms are possible
without departing from the scope of the present subject matter.
[0023] FIGS. 6-7 illustrate views of a MID housing including programming connections for
a hearing assistance device, according to various embodiments of the present subject
matter. In various embodiments, program connections are made using LDS or other 3D
MID technologies to create metallized connection contacts 620 that can also function
as interconnects to other components. The MID housing accepts a programming strip
622, in an embodiment. The connection contacts 620 are integral to the MID housing
300, in various embodiments. A battery drawer 730 has cam action that provides compression
to ensure a proper connection, according to various embodiments. In conjunction with
a stereolithography (SLA) shell with module retention features, any component can
be replaced and sent to a central reprocessing point for recovery and possible reuse,
all without component or shell damage.
[0024] FIGS. 8-10 illustrate views of a MID housing 300 including receiver connections for
a hearing assistance device, according to various embodiments of the present subject
matter. To acoustically isolate a microphone and a receiver, no rigid connections
are made to the receiver, in various embodiments. Flexible wires can be used and twisted
to afford electromagnetic interference (EMI) protection as well, in various embodiments.
According to various embodiments, LDS is used to provide a receptacle (via) 802. In
various embodiments, the receptacle 802 is lasered at the same time as a traces pattern.
In one embodiment, the receptacle 802 and custom plug 904 are smaller than currently
available receiver connections. In order to provide compression in the connection,
twisted wire interconnect (TWI) pins 1006 are used with a custom mold to create a
jack/connector, in various embodiments. The TWI plug includes wires 1002 to the receiver
and a molded grip 1004, in various embodiments. Other direct insertion mechanisms
are possible without departing from the scope of the present subject matter.
[0025] The present subject matter provides for specific connection schemes for the UCM,
components and devices to solderlessly connect to a unifying LDS structure. In various
embodiments, a system that incorporates this connector as well as solderless microphone,
programming and accessory connections is provided. The present subject matter has
application for both Standard and Custom hearing aids, and is superior to previous
solutions in that it decreases the number of heat cycles, touch points and increases
the ability to reuse more components. The present subject matter provides an injection
molded plastic structure made with an LDS capable plastic. In various embodiments,
it is included in an area of a larger part and the entire part is LDS capable. The
UCM includes a ball grid array (BGA) format, in an embodiment. The UCM is reflowed
to a simple 2 layer flex that is long enough to wrap up both sides of the UCM and
partially across the back, in an embodiment. The flex along the sides and back has
a specified thickness of pressure sensitive adhesive (0.005 thick in an embodiment)
applied so that it holds the flex to the sides and back. The flex along the sides
is designed to provide exposed connective traces that are finished with a corrosion
resistant finish similar to standard PCB pad finishes, in various embodiments. The
UCM with flex is inserted into the LDS structure, and the LDS structure is designed
to have conductive pressure points that align with conductive traces on the UCM flex
circuit, in various embodiments. The LDS conductive traces also have a corrosion resistant
finish, in an embodiment. The design of the LDS structure also provides a compressive
force on the UCM with flex, in various embodiments. Additional retention features
can be incorporated as needed.
[0026] FIGS. 11 and 12 show an example in a standard product application of the present
subject matter, showing an LDS structure 1100 and a UCM 1200. FIGS. 13 and 14 show
an embodiment of a custom application. This subject matter can be used as a means
of connection without solder of the UCM. In various embodiments the connections made
by the LDS structure to other solderless connection structures for microphone, six
pin jack, programming, TC, switches, etc., can be used. The present subject matter
provides for the ability to replace or salvage the UCM. In the case of a defective
UCM, the time to replace would only be a fraction of the time that would be need to
rewire as in the case of a custom repair. The UCM can be removed without damage, in
various embodiments. Additionally, using the solderless connection to the UCM in standard
products provides for the replacement of the UCM rather than having to replace the
entire electronics system (the radio section and the entire high density flex, SMT
switches, program jack etc.). When in conjunction with other solderless connectors
made using LDS, the assembly time and component damage can be greatly reduced. The
present subject matter provides for recovering and replacing of most the higher cost
components possible without unnecessary damage or time required.
[0027] The present subject matter can be used for standard fit as well as custom hearing
aids, in various embodiments. Modules can be used in place of or in combination with
flexible circuits, according to various embodiments. Benefits of the present subject
matter include substantial assembly time and cost savings. Furthermore, the use of
a common flexible circuit board for a variety of spine designs leads to less design
time required for each hearing aid circuit style. The elimination of soldered wires
as well as flexible circuit limbs leads to smaller hearing aids, in various embodiments.
[0028] Various embodiments of the present subject matter support wireless communications
with a hearing assistance device. In various embodiments the wireless communications
can include standard or nonstandard communications. Some examples of standard wireless
communications include link protocols including, but not limited to, Bluetoothâ„¢, IEEE
802.11(wireless LANs), 802.15 (WPANs), 802.16 (WiMAX), cellular protocols including,
but not limited to CDMA and GSM, ZigBee, and ultra-wideband (UWB) technologies. Such
protocols support radio frequency communications and some support infrared communications.
Although the present system is demonstrated as a radio system, it is possible that
other forms of wireless communications can be used such as ultrasonic, optical, infrared,
and others. It is understood that the standards which can be used include past and
present standards. It is also contemplated that future versions of these standards
and new future standards may be employed without departing from the scope of the present
subject matter.
[0029] The wireless communications support a connection from other devices. Such connections
include, but are not limited to, one or more mono or stereo connections or digital
connections having link protocols including, but not limited to 802.3 (Ethernet),
802.4, 802.5, USB, SPI, PCM, ATM, Fibre-channel, Firewire or 1394, InfiniBand, or
a native streaming interface. In various embodiments, such connections include all
past and present link protocols. It is also contemplated that future versions of these
protocols and new future standards may be employed without departing from the scope
of the present subject matter.
[0030] 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 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.
[0031] It is further understood that any hearing assistance device may be used without departing
from the scope and the devices depicted in the figures are intended to demonstrate
the subject matter, but not in a limited, exhaustive, or exclusive sense. It is also
understood that the present subject matter can be used with a device designed for
use in the right ear or the left ear or both ears of the user.
[0032] It is understood that the hearing aids referenced in this patent application include
a processor. The processor may be a digital signal processor (DSP), microprocessor,
microcontroller, other digital logic, a separate analog and separate digital chip,
or combinations thereof. The processing of signals referenced in this application
can be performed using the processor. Processing may be done in the digital domain,
the analog domain, or combinations thereof. Processing may be done using subband processing
techniques. Processing may be done with frequency domain or time domain approaches.
Some processing may involve both frequency and time domain aspects. For brevity, in
some examples drawings may omit certain blocks that perform frequency synthesis, frequency
analysis, analog-to-digital conversion, digital-to-analog conversion, amplification,
audio decoding, and certain types of filtering and processing. In various embodiments
the processor is adapted to perform instructions stored in memory which may or may
not be explicitly shown. Various types of memory may be used, including volatile and
nonvolatile forms of memory. In various embodiments, instructions are performed by
the processor to perform a number of signal processing tasks. In such embodiments,
analog components are in communication with the processor to perform signal tasks,
such as microphone reception, or receiver sound embodiments (i.e., in applications
where such transducers are used). In various embodiments, different realizations of
the block diagrams, circuits, and processes set forth herein may occur without departing
from the scope of the present subject matter.
[0033] The present subject matter is demonstrated for hearing assistance devices, including
hearing aids, including but not limited to, behind-the-ear (BTE), in-the-ear (ITE),
in-the-canal (ITC), receiver-in-canal (RIC), completely-in-the-canal (CIC) or invisible-in-canal
(IIC) 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, including but not limited to receiver-in-canal (RIC) or receiver-in-the-ear
(RITE) designs. The present subject matter can also be used in hearing assistance
devices generally, such as cochlear implant type hearing devices and such as deep
insertion devices having a transducer, such as a receiver or microphone, whether custom
fitted, standard, open fitted or occlusive fitted. It is understood that other hearing
assistance devices not expressly stated herein may be used in conjunction with the
present subject matter.
[0034] In addition, the present subject matter can be used in other settings in addition
to hearing assistance. Examples include, but are not limited to, telephone applications
where noise-corrupted speech is introduced, and streaming audio for ear pieces or
headphones.
[0035] 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.
1. A method of assembling a hearing assistance device, the method comprising:
providing a structure including a laser-direct structuring (LDS) portion;
inserting a flexible universal circuit module (UCM) having conductive surface traces
and elastomeric backing into the structure; and
electrically connecting the UCM to the LDS portion using direct compression without
the use of wires or solder.
2. The method of claim 1, wherein the structure includes multiple LDS portions configured
to electrically connect to additional components without wires or solder.
3. The method of claim 1 or claim 2, wherein the UCM includes an integrated flex connection
on an edge of the UCM, the integrated flex connection including exposed traces.
4. The method of claim 1 or claim 2, wherein the UCM includes a ball grid array (BGA)
portion.
5. The method of claim 1 or claim 2, wherein the UCM includes a layered flex circuit
wrapped on at least one side.
6. The method of claim 5, wherein the flex circuit includes a pressure sensitive adhesive
to adhere the flex circuit to the UCM.
7. The method of claim 5, wherein at least a portion of the flex circuit includes exposed
conductive traces finished with a corrosion resistant material.
8. The method of claim 7, wherein the LDS portion includes conductive pressure points
that are configured to align with the exposed conductive traces, and wherein the structure
is configured to provide a compressive force on the UCM with flex.
9. The method of claim 8, wherein the conductive pressure points include a corrosion
resistant finish.
10. A hearing assistance device, comprising
a structure including a laser-direct structuring (LDS) portion; and
a flexible universal circuit module (UCM) having conductive surface traces, the flexible
circuit module configured to be inserted into the structure;
wherein the UCM is configured to electrically connect to the LDS portion using direct
compression without the use of wires or solder.
11. The device of claim 10, wherein the hearing assistance device includes a standard
product assembly.
12. The device of claim 10, wherein the hearing assistance device includes a custom shell.
13. The device of any of clam 10 through claim 12, wherein the hearing assistance device
includes a hearing aid.
14. The device of claim 13, wherein the hearing aid includes an in-the-ear (ITE) hearing
aid.
15. The device of claim 13, wherein the hearing aid includes a behind-the-ear (BTE) hearing
aid.