US20040141627A1 - Hearing-aid assembly using folded flex circuits - Google Patents
Hearing-aid assembly using folded flex circuits Download PDFInfo
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- US20040141627A1 US20040141627A1 US10/752,414 US75241404A US2004141627A1 US 20040141627 A1 US20040141627 A1 US 20040141627A1 US 75241404 A US75241404 A US 75241404A US 2004141627 A1 US2004141627 A1 US 2004141627A1
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- Prior art keywords
- hearing
- aid
- input
- unfolded regions
- regions
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/18—Printed circuits structurally associated with non-printed electric components
- H05K1/189—Printed circuits structurally associated with non-printed electric components characterised by the use of a flexible or folded printed circuit
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; DEAF-AID SETS; PUBLIC ADDRESS SYSTEMS
- H04R25/00—Deaf-aid sets, i.e. electro-acoustic or electro-mechanical hearing aids; Electric tinnitus maskers providing an auditory perception
- H04R25/60—Mounting or interconnection of hearing aid parts, e.g. inside tips, housings or to ossicles
- H04R25/609—Mounting or interconnection of hearing aid parts, e.g. inside tips, housings or to ossicles of circuitry
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; DEAF-AID SETS; PUBLIC ADDRESS SYSTEMS
- H04R2225/00—Details of deaf aids covered by H04R25/00, not provided for in any of its subgroups
- H04R2225/57—Aspects of electrical interconnection between hearing aid parts
Definitions
- the present invention concerns hearing aids, particularly hearing-aid assemblies and components.
- a key factor in both the visibility and cost of hearing aids is still their size. Smaller hearing aids are generally less visible than larger devices, but more difficult and costly to manufacture. Moreover, even where cost is of less concern, manufacturers often have to increase hearing-aid size to provide all the circuitry needed to address some severe forms of hearing loss, ultimately forcing some sufferers to choose between better hearing or less visible hearing aids.
- One exemplary hearing-aid embodiment includes at least a portion of a hearing-aid housing or earshell containing a unique flex circuit coupled to a microphone and a receiver.
- the flexible circuit includes 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 of the unfolded regions include input-output connections to electrical conductors within and/or on the flex circuit, and to a signal processor and supporting resistive and/or reactive components, such as capacitors.
- One exemplary intermediate assembly includes a formable plastic disk comprising an integral plastic container containing the exemplary flex circuit (described above.) Mounted to the surface of the disk are a microphone and a receiver which are electrically coupled to the flex circuit.
- the plastic disk portion of the assembly can be heated and shaped using conventional methods to form housing, or earshell, portion of a hearing aid.
- FIG. 1 is a top perspective view of an exemplary flex circuit module 100 incorporating teachings of the present invention
- FIG. 2 is a bottom perspective view of flex circuit module 100 in FIG. 1;
- FIG. 3 is a perspective view of flex circuit module 100 in a partially disassembled state
- FIG. 4 is a diagrammatic view of an exemplary hearing-aid assembly 400 incorporating flex circuit module 100 ;
- FIG. 5 is a simplified cross-sectional view of an exemplary hearing aid 500 incorporating flex circuit module 100 .
- FIGS. 1 - 5 describe and illustrates one or more exemplary embodiments of the invention. These embodiments, offered not to limit but only to exemplify and teach the invention, are shown and described in sufficient detail to enable those skilled in the art to practice the invention. Thus, where appropriate to avoid obscuring the invention, the description may omit certain information known to those of skill in the art.
- FIGS. 1 and 2 show respective top and bottom perspective views of an exemplary circuit module 100
- FIG. 3 shows a partially disassembled perspective view of module 100
- Module 100 includes a flex circuit 110 , components 120 , input-output pads 130 , and component groups 140 and 150 .
- flex circuit 110 includes folded (or more generally foldable or flexible) regions 111 , 112 , and 113 , and three non-folded or generally straight regions 114 , 115 , and 116 .
- Flex circuit 110 has respective top and bottom sides 110 a and 110 b , and each region of circuit 100 also has a top and bottom side.
- folded region 111 includes a top side 111 a and a bottom side 111 b.
- one or more portions of the flex circuit includes a flexible base material and a conductive coating or cladding.
- Exemplary materials for the flexible base material include thermoplastic, thermoset, polyimide (PI), polyester (PIT), polyethylene naphthalate (PEN), flourinated ethylene-proplene coplymet (FEP), polyetherimide (PEI), aramiad, and epoxy.
- Exemplary material forms used in some embodiments of the invention. include copper-clad flexible laminates, coverlayers, photoimageable coverlayers, covercoats, and bondplies.
- Exemplary conductive coating or cladding materials includes copper foil, electrodeposited copper (standard and heat treated), rolled and anneal copper, specialty copper alloys, electroplated copper, sputtered or vapor deposited copper, beryllium copper, aluminum foil, iron alloy, or polymer thick film (PTF).
- Some embodiments use built-in resistor-material flexible circuits, platable toner flexible circuits, and/or indium-tin oxide (ITO) flexible circuits. The invention, however, is not limited to any type or composition of flexible circuit.
- folded regions 111 , 112 , and 113 have respective fold axes or lines 111 c , 112 c , and 113 c which are generally parallel to each other and perpendicular to the length dimension of the flex circuit.
- two or more of the fold lines are substantially perpendicular to each other.
- two or more of the fold lines are more generally not parallel.
- one or more of the fold lines are parallel to or skewed relative the length dimension of the flex circuit.
- Some embodiments with two or more non-parallel folds have I-, L-, T-, or V-shaped pre-folded configuration.
- the L-shaped configuration an upper portion of the top leg of the L is folded over a lower portion of the top leg, and the bottom leg of the L is folded over or under or up or down relative the folded portions of the top leg of the L.
- multiple fold-overs, fold-unders, and/or 90-degree folds are used.
- the legs of the L can be physically discontinuous flex circuits.
- Components 120 include one or more resistors, capacitors, inductors, transistors, jumpers, switches, circuit boards, or integrated circuits. Components 120 are electrically coupled in conventional ways to one or more conductors in flex circuit 110 , specifically regions 114 and 115 . Although the exemplary embodiment places components 120 on the bottom of flex circuit 110 , other embodiments place all or a portion of the components on the top of the flex circuit. Still other embodiments distribute the components along a greater length of the flex circuit than does the exemplary embodiment. For example, some embodiments even place components on folded regions 111 , 112 , or 113 .
- Input-output pads 130 are mounted on the bottom side of region 115 .
- pads 130 form a C-shaped arrangement around the components mounted to region 115 .
- the invention is not limited to any particular arrangement of pads.
- other embodiments fully encircle the components with pads, mount pads along the full length of the flex circuit, including on one or more of regions 111 , 112 , or 113 , and/or mount pads on one or both sides of any region of the flex circuit.
- the exemplary embodiment uses solder pads or solder balls, or ball-grid-array technology.
- the invention is amenable to virtually any form of input-output connection.
- Components 140 and 150 are mounted using conventional techniques to respective regions 115 and 116 .
- Components 140 and 150 which include one or more resistors, capacitors, inductors, transistors, jumpers, switches, circuit boards, or integrated circuits, are electrically coupled in conventional ways to one or more conductors in regions 115 and 116 .
- the exemplary embodiments mounts components 140 and 150 such that the top sides of the components 140 confront the top sides of components 150 as shown in FIGS. 2 and 3.
- all of components 140 and all of components 150 are integrated into respective integrated circuits packages, for example, flip-chip packages, or circuit boards or other circuit-bearing substrates designed to form specific functions.
- the flip-chip includes hearing-aid circuitry, such as a digital and/or analog signal processor. which facilitate a hearing aid function.
- one of components 140 and 150 is a heat sink, and in others a heat sink or more generally some form of heat-distribution member or agent sandwiched between components 150 and 160 upon final assembly.
- FIG. 4 shows an exemplary hearing-aid assembly 400 incorporating circuit module 100 .
- Assembly 400 additionally includes a deformable disk 410 , a deformable container 420 , a microphone 430 , and wires 440 and 452 .
- Deformable disk 410 which for example comprises plastic or foam, constitutes the material for forming a housing or earshell of a hearing aid.
- Container 420 which is integral to disk 410 in the exemplary embodiment, has a similar composition to disk 410 and provides a protective enclosure for flex circuit module 100 , which is coupled respectively via wires 422 and 424 to microphone 430 and receiver 440 .
- container 420 includes an opening on its bottom side for receiving a battery which is coupled to battery terminals that are in turn coupled to flex module 100 .
- Microphone 430 and receiver 440 are fastened to disk 410 using glue, tape, or other readily available means, to hold them in place during shipment and/or during subsequent deformation that transforms the disk into an earshell or hearing-aid housing.
- FIG. 5 shows an exemplary hearing aid 500 incorporating flex circuit module 100 .
- hearing aid 500 includes an earshell or housing 510 , a battery 520 , a microphone 530 , and a receiver 530 .
- the battery, microphone, and receiver are coupled to flex circuit module 100 (although for convenience the internal wiring is not shown.)
- module 100 includes two integrated circuit chips directly mounted to a flexible circuit.
- One exemplary assembly includes a flex circuit having at least two folds. The folds not only facilitate ease of manufacture, but also save space.
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.
Description
- This application is a continuation of U.S. patent application Ser. No. 09/792,700, filed Feb. 23, 2001 which is a continuation of U.S. Provisional application No. 60/184,237 which was filed Feb. 23, 2000 and which is incorporated herein by reference.
- The present invention concerns hearing aids, particularly hearing-aid assemblies and components.
- For many, it is surprising to learn that one out of every ten Americans suffers from some form of hearing loss, ranking it the third most common disability in the United States, behind arthritis and high-blood pressure. Perhaps even more surprising is that half of those suffering hearing loss are under age 65.
- Many hearing-loss sufferers enjoy considerable relief through use of electronic hearing aids. A multitude of advancements ranging from basic miniaturization and microphone and amplifier improvements to digital sound filtering and custom programmability have made it possible for hearing aids to improve the hearing of over 90% of hearing-loss sufferers. Unfortunately, even with these advances, many miss out on the benefits of these miraculous devices because of concerns regarding visibility or cost of the device.
- A key factor in both the visibility and cost of hearing aids is still their size. Smaller hearing aids are generally less visible than larger devices, but more difficult and costly to manufacture. Moreover, even where cost is of less concern, manufacturers often have to increase hearing-aid size to provide all the circuitry needed to address some severe forms of hearing loss, ultimately forcing some sufferers to choose between better hearing or less visible hearing aids.
- Accordingly, there continues to be a need for smaller hearing aids, particularly hearing-aid circuit assemblies that allow for more cost- and space-effective manufacture.
- To address this and other needs, the present inventor devised a unique hearing-aid assembly concept that saves space and facilitates manufacture of hearing aids. One exemplary hearing-aid embodiment includes at least a portion of a hearing-aid housing or earshell containing a unique flex circuit coupled to a microphone and a receiver. The flexible circuit includes 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 of the unfolded regions include input-output connections to electrical conductors within and/or on the flex circuit, and to a signal processor and supporting resistive and/or reactive components, such as capacitors.
- Other aspects of the invention include methods of manufacturing hearing aids and intermediate hearing-aid assemblies. One exemplary intermediate assembly includes a formable plastic disk comprising an integral plastic container containing the exemplary flex circuit (described above.) Mounted to the surface of the disk are a microphone and a receiver which are electrically coupled to the flex circuit. The plastic disk portion of the assembly can be heated and shaped using conventional methods to form housing, or earshell, portion of a hearing aid.
- FIG. 1 is a top perspective view of an exemplary
flex circuit module 100 incorporating teachings of the present invention; - FIG. 2 is a bottom perspective view of
flex circuit module 100 in FIG. 1; - FIG. 3 is a perspective view of
flex circuit module 100 in a partially disassembled state; - FIG. 4 is a diagrammatic view of an exemplary hearing-
aid assembly 400 incorporatingflex circuit module 100; and - FIG. 5 is a simplified cross-sectional view of an
exemplary hearing aid 500 incorporatingflex circuit module 100. - The following detailed description, which incorporates FIGS.1-5, describes and illustrates one or more exemplary embodiments of the invention. These embodiments, offered not to limit but only to exemplify and teach the invention, are shown and described in sufficient detail to enable those skilled in the art to practice the invention. Thus, where appropriate to avoid obscuring the invention, the description may omit certain information known to those of skill in the art.
- U.S. Pat. No. 6,014,320, entitled High Density Stacked Circuit Module, is incorporated herein by reference.
- FIGS. 1 and 2 show respective top and bottom perspective views of an
exemplary circuit module 100, and FIG. 3 shows a partially disassembled perspective view ofmodule 100.Module 100 includes aflex circuit 110,components 120, input-output pads 130, andcomponent groups - More particularly,
flex circuit 110 includes folded (or more generally foldable or flexible)regions straight regions flex circuit 110 is flexible, meaning thatregions Flex circuit 110 has respective top andbottom sides 110 a and 110 b, and each region ofcircuit 100 also has a top and bottom side. Thus, for example, foldedregion 111 includes a top side 111 a and a bottom side 111 b. - In some embodiments, one or more portions of the flex circuit includes a flexible base material and a conductive coating or cladding. Exemplary materials for the flexible base material include thermoplastic, thermoset, polyimide (PI), polyester (PIT), polyethylene naphthalate (PEN), flourinated ethylene-proplene coplymet (FEP), polyetherimide (PEI), aramiad, and epoxy. Exemplary material forms used in some embodiments of the invention. include copper-clad flexible laminates, coverlayers, photoimageable coverlayers, covercoats, and bondplies. Exemplary conductive coating or cladding materials includes copper foil, electrodeposited copper (standard and heat treated), rolled and anneal copper, specialty copper alloys, electroplated copper, sputtered or vapor deposited copper, beryllium copper, aluminum foil, iron alloy, or polymer thick film (PTF). Some embodiments use built-in resistor-material flexible circuits, platable toner flexible circuits, and/or indium-tin oxide (ITO) flexible circuits. The invention, however, is not limited to any type or composition of flexible circuit.
- In the exemplary embodiment, folded
regions lines - Some embodiments with two or more non-parallel folds have I-, L-, T-, or V-shaped pre-folded configuration. For example, with the L-shaped configuration, an upper portion of the top leg of the L is folded over a lower portion of the top leg, and the bottom leg of the L is folded over or under or up or down relative the folded portions of the top leg of the L. Depending on the length of the L and desired uses of the resulting module, multiple fold-overs, fold-unders, and/or 90-degree folds are used. The legs of the L can be physically discontinuous flex circuits.
-
Components 120 include one or more resistors, capacitors, inductors, transistors, jumpers, switches, circuit boards, or integrated circuits.Components 120 are electrically coupled in conventional ways to one or more conductors inflex circuit 110, specificallyregions components 120 on the bottom offlex circuit 110, other embodiments place all or a portion of the components on the top of the flex circuit. Still other embodiments distribute the components along a greater length of the flex circuit than does the exemplary embodiment. For example, some embodiments even place components on foldedregions - Input-
output pads 130 are mounted on the bottom side ofregion 115. In the exemplary embodiment,pads 130 form a C-shaped arrangement around the components mounted toregion 115. However, the invention is not limited to any particular arrangement of pads. For example, other embodiments fully encircle the components with pads, mount pads along the full length of the flex circuit, including on one or more ofregions -
Components respective regions Components regions components components 140 confront the top sides ofcomponents 150 as shown in FIGS. 2 and 3. - In the exemplary embodiment, all of
components 140 and all ofcomponents 150 are integrated into respective integrated circuits packages, for example, flip-chip packages, or circuit boards or other circuit-bearing substrates designed to form specific functions. In one embodiment, the flip-chip includes hearing-aid circuitry, such as a digital and/or analog signal processor. which facilitate a hearing aid function. In some embodiments, one ofcomponents components 150 and 160 upon final assembly. - FIG. 4 shows an exemplary hearing-
aid assembly 400 incorporatingcircuit module 100.Assembly 400 additionally includes adeformable disk 410, adeformable container 420, amicrophone 430, andwires 440 and 452.Deformable disk 410, which for example comprises plastic or foam, constitutes the material for forming a housing or earshell of a hearing aid.Container 420, which is integral todisk 410 in the exemplary embodiment, has a similar composition todisk 410 and provides a protective enclosure forflex circuit module 100, which is coupled respectively viawires microphone 430 andreceiver 440. Though not visible in this view,container 420 includes an opening on its bottom side for receiving a battery which is coupled to battery terminals that are in turn coupled to flexmodule 100.Microphone 430 andreceiver 440 are fastened todisk 410 using glue, tape, or other readily available means, to hold them in place during shipment and/or during subsequent deformation that transforms the disk into an earshell or hearing-aid housing. - FIG. 5 shows an
exemplary hearing aid 500 incorporatingflex circuit module 100. In addition,hearing aid 500 includes an earshell orhousing 510, abattery 520, amicrophone 530, and areceiver 530. The battery, microphone, and receiver are coupled to flex circuit module 100 (although for convenience the internal wiring is not shown.) Notably,module 100 includes two integrated circuit chips directly mounted to a flexible circuit. - In furtherance of the art, the inventor has presented a unique hearing-aid assemblies comprising folded flex circuits. One exemplary assembly includes a flex circuit having at least two folds. The folds not only facilitate ease of manufacture, but also save space.
- The embodiments described above are intended only to illustrate and teach one or more ways of making and using the present invention, not to restrict its breadth or scope. The actual scope of the invention, which embraces all ways of practicing or implementing the teachings of the invention, is defined only by the following claims and their equivalents.
Claims (10)
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.
Priority Applications (1)
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US10/752,414 US20040141627A1 (en) | 2000-02-23 | 2004-01-06 | Hearing-aid assembly using folded flex circuits |
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US18423700P | 2000-02-23 | 2000-02-23 | |
US09/792,700 US6674869B2 (en) | 2000-02-23 | 2001-02-23 | Hearing-aid assembly using folded flex circuits |
US10/752,414 US20040141627A1 (en) | 2000-02-23 | 2004-01-06 | Hearing-aid assembly using folded flex circuits |
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US09/792,700 Continuation US6674869B2 (en) | 2000-02-23 | 2001-02-23 | Hearing-aid assembly using folded flex circuits |
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US20040141627A1 true US20040141627A1 (en) | 2004-07-22 |
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US09/792,700 Expired - Lifetime US6674869B2 (en) | 2000-02-23 | 2001-02-23 | Hearing-aid assembly using folded flex circuits |
US10/752,414 Abandoned US20040141627A1 (en) | 2000-02-23 | 2004-01-06 | Hearing-aid assembly using folded flex circuits |
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US09/792,700 Expired - Lifetime US6674869B2 (en) | 2000-02-23 | 2001-02-23 | Hearing-aid assembly using folded flex circuits |
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Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090016553A1 (en) * | 2007-07-09 | 2009-01-15 | Wai Kit David Ho | Hearing aid with component mounted in the housing by a damping clip |
US8111852B2 (en) * | 2007-07-09 | 2012-02-07 | Siemens Audiologische Technik Gmbh | Hearing aid with component mounted in the housing by a damping clip |
US20100158296A1 (en) * | 2008-12-19 | 2010-06-24 | Starkey Laboratories, Inc. | Hearing assistance device with stacked die |
US8369553B2 (en) * | 2008-12-19 | 2013-02-05 | Starkey Laboratories, Inc. | Hearing assistance device with stacked die |
US20180098162A1 (en) * | 2016-10-04 | 2018-04-05 | Starkey Laboratories, Inc. | Hearing assistance device incorporating system in package module |
US10085097B2 (en) * | 2016-10-04 | 2018-09-25 | Starkey Laboratories, Inc. | Hearing assistance device incorporating system in package module |
US20180367923A1 (en) * | 2016-10-04 | 2018-12-20 | Starkey Laboratories, Inc. | Hearing assistance device incorporating system in package module |
US10582319B2 (en) * | 2016-10-04 | 2020-03-03 | Starkey Laboratories, Inc. | Hearing assistance device incorporating system in package module |
Also Published As
Publication number | Publication date |
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US6674869B2 (en) | 2004-01-06 |
US20010038703A1 (en) | 2001-11-08 |
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Legal Events
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