US 11,722,829 B2
Hybrid shell for hearing aid
Michael Karl Sacha, Chanhassen, MN (US); Jay Stewart, Eden Prairie, MN (US); Wes Gentry, Buffalo, MN (US); and Craig Feldsien, Prior Lake, MN (US)
Assigned to Starkey Laboratories, Inc., Eden Prairie, MN (US)
Filed by Starkey Laboratories, Inc., Eden Prairie, MN (US)
Filed on Mar. 14, 2022, as Appl. No. 17/693,565.
Application 17/693,565 is a continuation of application No. 16/551,343, filed on Aug. 26, 2019, granted, now 11,277,699.
Application 16/551,343 is a continuation of application No. 15/280,997, filed on Sep. 29, 2016, granted, now 10,397,714.
Claims priority of provisional application 62/235,888, filed on Oct. 1, 2015.
Prior Publication US 2022/0201413 A1, Jun. 23, 2022
Int. Cl. H04R 25/00 (2006.01)
CPC H04R 25/652 (2013.01) [H04R 25/658 (2013.01); H04R 2225/023 (2013.01); H04R 2225/025 (2013.01); H04R 2225/77 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A hearing aid shell for containing electronic components of a hearing aid, wherein the hearing aid shell is constructed by:
3D printing a part made of a hard material that comprises a shell region and a hollow cast region;
pouring a soft mold material into the hollow cast region and allowing the soft mold material to set;
applying primer and adhesive to the junction interface between the shell region and the soft mold material and allowing the adhesive to set;
removing the soft mold material from the hollow cast region to expose a hearing aid shell comprising a first shell portion made of the hard material and a second shell portion made of the soft mold material; and,
wherein the soft second shell portion forms an anterior surface of the hearing aid shell that contacts an anterior surface of a user's ear canal when the hearing aid is inserted therein while the hart first shell portion forms a posterior surface of the hearing aid shell that contacts a posterior surface of the user's ear canal when the hearing aid is inserted therein.