Hearing-aid assembly using folded flex circuits

Abstract

Hearing aids improve not only the hearing, but the lives of millions. Unfortunately, far too many sufferers of hearing loss forego the benefits of hearing aids because of size and cost of the devices. To address this need, the present inventor devised hearing-aid circuit modules that use folded flexible circuits. The modules save space and reduce the cost of manufacturing hearing aids.

1 . A hearing aid comprising: 
 a flexible circuit module including at least first, second, and third unfolded regions and a first folded region between the first and second unfolded regions and a second folded region between the second and third unfolded regions;    one or more input-output connections mounted to one or more of the unfolded regions;    first and second signal processing chips mounted to the first and second unfolded regions and electrically coupled to the one or more of the input-output connections;    a microphone coupled to at least one of the input-output connections; and    a receiver coupled to at least another one of the input-output connections.    
     
     
         2 . The hearing aid of  claim 1 , wherein at least the first and second unfolded regions and the first folded region are formed from a continuous flexible circuit and wherein the first folded region includes a fold of about 90 degrees and the second folded region includes a fold of about 180 degrees.  
     
     
         3 . The hearing aid of  claim 1 , wherein at least the first and second unfolded regions and the first folded region are formed from two or more mechanically discontinuous sections of flexible circuit.  
     
     
         4 . The circuit module of  claim 1 , wherein the one or more electrical components include first and second integrated circuits, with the first integrated circuit mounted on a top surface of the second region and the second integrated circuit mounted on a top surface of the third region such that the first and second integrated circuits are back to back.  
     
     
         6 . A hearing-aid assembly comprising: 
 a deformable disk having a major surface;    a container attached or mounted to the deformable disk;    a flexible circuit module at least partially within the container and including: 
 at least first, second, and third unfolded regions and a first folded region between the first and second unfolded regions and a second folded region between the second and third unfolded regions;  
 one or more input-output connections mounted to one or more of the unfolded regions;  
 first and second signal processing chips mounted to the first and second unfolded regions and electrically coupled to the one or more of the input-output connections;  
   a microphone coupled to at least one of the input-output connections; and    a receiver coupled to at least another one of the input-output connections.    
     
     
         7 . The hearing-aid assembly of  claim 6 , wherein the microphone and the receiver are mounted to the disk.  
     
     
         8 . The hearing-aid assembly of  claim 6 , wherein the disk consist essentially of plastic.  
     
     
         9 . The hearing-aid assembly of  claim 6 , wherein the container is integral to the disk.  
     
     
         10 . The hearing-aid assembly of  claim 6 , wherein at least the first and second unfolded regions and the first folded region are formed from two or more mechanically discontinuous sections of flexible circuit.  
     
     
         11 . The hearing-aid assembly of  claim 6 , wherein the one or more electrical components include first and second integrated circuits, with the first integrated circuit mounted on a top surface of the second region and the second integrated circuit mounted on a top surface of the third region such that the first and second integrated circuits are back to back.