US5487012A
Expired / Lapsed
US
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Method of preparing an otoplasty or adaptive earpiece individually matched to the shape of an auditory canal
Assignee: Topholm and Westermann ApS
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Filing: 1994-10-12
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Granted: 1996-01-23
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Expires: 2014-10-12
Abstract
Abstract A process for making otoplasty or adaptive ear pieces individually matched to the shape of an auditory canal and consists of the following steps: a) direct or indirect tracing is provided of the shape of the auditory canal and conversion of the values obtained into digital form; b) conversion of the digital representation of this shape into a multi-dimensional computer model of the outer shape of otoplasty or adaptive ear piece; c) selection of the various components/functions for the inside of the computer model with simultaneous establishment of the wall thickness and optimization of the positions of the components/functions for best possible operation and minimum bulk; d) computer controlled production of an otoplasty or adaptive ear piece from the data thus obtained from the optimized, three-dimensional computer representation of the otoplasty or adaptive ear piece.
Inventors
- 👤 Jan Topholm
- 👤 Svend V. Andersen
- 👤 Soren E. Westermann
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 10:07
CPC Classifications
H; H04; H04R; H04R25/00; H04R25/65; H04R25/652; G; G05; G05B; G05B19/00; G05B19/02; G05B19/42; G05B19/4202; G05B19/4207; H04R25/658; G05B2219/00; G05B2219/30; G05B2219/37; G05B2219/37044; G05B2219/45; G05B2219/45172; G05B2219/49; G05B2219/49011; G05B2219/49013; G05B2219/49015; H04R2225/00; H04R2225/77; H04R2460/00; H04R2460/11
Claims Analysis
Total Claims: 39
Claim 1
Independent Claim
109 words
A method for computer-controlled production of otoplasties or adaptive earpieces comprising at least one part which is individually matched to contours of an auditory canal, said method comprising the steps of: tracing of the contours of the auditory canal to obtain contour data, digitization of the contour data and storage of the digitized values; converting the digitized values into a multi-dimensional computer model of the external contours of the otoplasty or adaptive earpiece; and automatically or interactively selecting the components/functions for the interior of the computer model while simultaneously defining the wall thickness and optimizing the positions of the components/functions with respect to optimum function, position and minimum bulk.
Claim 2
Independent Claim
109 words
A method for computer-controlled production of otoplasties or adaptive earpieces comprising at least one part which is individually matched to contours of an auditory canal, said method comprising the steps of: tracing of the contours of the auditory canal to obtain contour data, digitization of the contour data and storage of the digitized values; converting the digitized values into a multi-dimensional computer model of the external contours of the otoplasty or adaptive earpiece; and automatically or interactively selecting the components/functions for the interior of the computer model while simultaneously defining the wall thickness and optimizing the positions of the components/functions with respect to optimum function, position and minimum bulk.
Claim 3
Dependent Claim
27 words
A method in accordance with claim 1, characterized in that the tracing of the internal contours of the auditory canal is performed by contactless scanning using ultrasound.
Claim 4
Dependent Claim
63 words
A method in accordance with claim 1, characterized in that the tracing of the internal contours of the auditory canal is performed by an indirect tracing method comprising the steps of making an ear impression and then non-destructive scanning of this ear impression with radiation which penetrates the latter, whereby the values determined in this way are digitized and stored in digital form.
Claim 5
Dependent Claim
24 words
A method in accordance with claim 3, characterized in that scanning of the contours of the ear impression is performed by means of x-rays.
Claim 6
Dependent Claim
22 words
A method in accordance with claim 3, characterized in that scanning of the contours of the ear impression is performed with ultrasound.
Claim 7
Dependent Claim
56 words
A method in accordance with claim 1, characterized in that the step of tracing the contours of the auditory canal is performed by making an ear impression, cutting the ear impression into thin layers in successive steps, determining the dimensions of these thin cross-sectional layers, and converting the dimensions into digital form and digitally storing them.
Claim 8
Dependent Claim
55 words
A method in accordance with claim 6, characterized in that the material of the ear impression is removed by a small amount in each case in successive steps and that the resultant surface is then traced, i.e. by means of a video camera, and the acquired surface values then digitized and stored in digital form.
Claim 9
Dependent Claim
59 words
A method in accordance with claim 7, characterized in that the ear impression is embedded in a block of synthetic resin made of a contrasting color, that the block obtained in this way is cut into thin layers in successive steps, and that the dimensions of these thin cross-sectional layers are recorded, converted into digital form and digitally stored.
Claim 10
Dependent Claim
46 words
A method in accordance with claim 8 characterized in that the dimensions of successive cross-sections of the block containing the ear impression are determined without destruction by scanning in cross-sections with radiation, whereby the values obtained in this way are then digitized and then digitally stored.
Claim 11
Dependent Claim
48 words
A method in accordance with claim 1, characterized in that conversion of the digital representation of the contours of the auditory canal into a three-dimensional representation of the otoplasty or adaptive earpiece takes place by transforming the contours into a very large but finite number of finite elements.
Claim 12
Dependent Claim
36 words
A method in accordance with claim 1, characterized in that the contours of the three-dimensional model of the otoplasty or of the adaptive earpiece are transformed into a number of at least partially differentiable three-dimensional curves.
Claim 13
Dependent Claim
37 words
A method in accordance with claim 1, characterized in that the various components/functions are manually positioned or entered in the three-dimensional representation of the computer model of the otoplasty or adaptive earpiece using the computer monitor representation.
Claim 14
Dependent Claim
48 words
A method in accordance with claim 1, characterized in that this input is made with computer support with simultaneous optimization of the inner surface and its optimum distance from the outer surface of the otoplasty or adaptive earpiece along with simultaneous optimization of the positions/dimensions of the components/functions.
Claim 15
Dependent Claim
28 words
A method in accordance with claim 1, characterized in that the arrangement of components/functions and the whole of the optimization process are controlled fully automatically by the computer.
Claim 16
Dependent Claim
45 words
A method in accordance with claim 12, characterized in that the three-dimensional representation of the computer model of the otoplasty or of the adaptive earpiece is transformed into a two-dimensional display representation of the kind which conveys a three-dimensional representation when observed with polarizing glasses.
Claim 17
Dependent Claim
103 words
A method in accordance with claim 1 characterized by the following additional process steps: Generation of a computer representation of a sequence of cross sections of the computer model; build-up of the three-dimensional otoplasty or adaptive earpiece existing as a computer representation by repeated physical production of cross-sections and their progressive build-up on top of each other as a sequence of such cross-sectional layers and reworking of the finished otoplasty or adaptive earpiece after hardening by smoothing the surfaces, polishing, removal of support parts, assembly of the individual parts of the otoplasty or adaptive earpiece when necessary and securing of components when necessary.
Claim 18
Dependent Claim
107 words
A method in accordance with claim 16, characterized by the following process steps: Transformation of the sequence of cross-sections into a sequence of control signals; use of these control signals to control a focused laser beam and platform capable of controlled movement; use of a container filled with liquid activated synthetic resin located on the platform capable of controlled movement in order to produce at least parts of the otoplasty or adaptive earpiece by the focused laser beam moved in a controlled manner for build-up of the otoplasty or adaptive earpiece by way of local at least partial polymerization of two-dimensional surface areas of the synthetic resin.
Claim 19
Dependent Claim
152 words
A method in accordance with claim 16, characterized by the following process steps: Conversion of the thus optimized computer model into a sequence of control signals; use of these control signals for multi-dimensional control of the position of an injection nozzle and a platform capable of controlled movement for production of the complete form of at least parts of the otoplasty or of the adaptive earpiece; use of a container filled with a passivated liquid synthetic resin and located on the platform capable of controlled movement; injection of an activator from the nozzle, which is moved to produce at least parts of the otoplasty or adaptive earpiece in a and controlled manner, into the liquid synthetic resin, whereby radiation is continuously present to permit build-up of at least parts of the otoplasty or adaptive earpiece from the synthetic resin which polymerizes at least partially as a result of injection of the activator.
Claim 20
Dependent Claim
31 words
A method in accordance with claim 18, characterized in that heat is supplied at least at the place of injection in addition to the targeted supply of the activator by injection.
Claim 21
Dependent Claim
20 words
A method in accordance with claim 19, characterized in that the heat is supplied in the form of infrared radiation.
Claim 22
Dependent Claim
17 words
A method in accordance with claim 18, characterized in that essentially constant ultraviolet radiation is supplied additionally.
Claim 23
Dependent Claim
46 words
A method in accordance with claim 16, characterized in that the cross-sectional layers produced in this way made of plastic are placed on top of each other in layers and permanently bonded to each other by gluing, polymerization, use of heat and/or use of UV radiation.
Claim 24
Dependent Claim
110 words
A method in accordance with claim 22, characterized by the following additional process steps: Conversion of the optimized three-dimensional digital computer model into a sequence of control signals for repeated control of a discharge device for applying successive cross-sectional layers in the form of layers of a hardenable plastic mass corresponding to the patterns of the cross-sectional layers planes on a flat surface with partial hardening of the individual layers in each case; stacking of the layers on top of each other and hardening of the finished stack to form an otoplasty or an adaptive earpiece and reworking of the otoplasty or adaptive earpieces produced in this way after hardening.
Claim 25
Dependent Claim
98 words
A method in accordance with claim 23, characterized by the following additional process steps: Conversion of the optimized three-dimensional digitized computer model into a sequence of control signals for repeated control of a cutting device for cutting out successive cross-sections from one of a thin plastic film and a thin plastic sheet; stacking of the cross-sections produced in this way on top of each other to form the otoplasty or adaptive earpiece; joining of the cross-sections with each other by gluing by heat and/or ultraviolet radiation and reworking of the otoplasty or adaptive earpiece produced in this way.
Claim 26
Dependent Claim
22 words
A method in accordance with claim 24, characterized in that a laser beam with computer-controlled movement is used as the cutting device.
Claim 27
Dependent Claim
27 words
A method in accordance with claim 24, characterized in that a laser operating in the ultraviolet range and with computer-controlled movement is used as the cutting device.
Claim 28
Dependent Claim
145 words
A method in accordance with claim 1 characterized by the following process steps: Conversion of the thus optimized computer model into a sequence of control signals for following one or more paths in space in such a way that the sum of all paths forms a network, spiral or other polygon which describes the body of the otoplasty or adaptive earpiece on all sides; use of a container filled with a polymerizable synthetic resin; use of these control signals for multi-dimensional control of the position of an injection nozzle immersed in the container to inject an activator which hardens the synthetic resin at least partially relatively quickly after emerging from the nozzle under the given conditions and guidance of this nozzle along these paths in a multi-dimensional movement which covers and describes the complete contours of at least parts of the otoplasty or adaptive earpiece.
Claim 29
Dependent Claim
121 words
A method in accordance with claim 1 characterized by the following process steps: conversion of the thus optimized computer model of the otoplasty or adaptive earpiece into a sequence of control signals for following one or more paths in space in such a way that the sum of all paths form a polygon which describes the body of at least parts of the otoplasty or adaptive earpiece on all sides; use of these control signals for multi-dimensional control of the position of an extrusion nozzle along a three-dimensional path for extrusion onto a surface of a synthetic resin which hardens at least partially relatively quickly in a movement which covers and describes the complete contours of the otoplasty or adaptive earpiece.
Claim 30
Dependent Claim
59 words
A method in accordance with claim 28, characterized in that the nozzle is kept stationary, that a platform with controllable movements is used to build up the otoplasty or adaptive earpiece, and that the three-dimensional coordinates of the computer model are used for a computer-controlled movement of the controlled-movement platform along the specified paths in a multi-dimensional movement sequence.
Claim 31
Dependent Claim
25 words
A method in accordance with claim 28, characterized in that the relative movement of the nozzle and platform takes place with six degrees of freedom.
Claim 32
Dependent Claim
20 words
A method in accordance with claim 28, characterized in that an activated acrylic resin is used as the synthetic resin.
Claim 33
Dependent Claim
116 words
A method in accordance with claim 1 characterized by the following process steps: definition of at least one section which divides the computer model of the otoplasty or adaptive earpiece into at least two parts which can be produced individually by removal of material; generation of control signals for a material removing device to control the movement of such a device and separation of a block made of plastic which encloses the contour of the otoplasty or adaptive earpiece on all sides into the determined number of part-blocks; and removal of material from the part-blocks on all sides in order to produce corresponding parts of the otoplasty or adaptive earpiece and subsequent joining of these parts.
Claim 34
Dependent Claim
37 words
A method in accordance with claim 32, characterized in that the position and form of the cutting planes are optimized to achieve the smallest number of part-blocks and the most simple and practical way of material removal.
Claim 35
Dependent Claim
26 words
A method in accordance with claim 32, characterized in that a laser operating in the ultraviolet range is used to remove material from the individual part-blocks.
Claim 36
Dependent Claim
36 words
A method in accordance with claim 32, characterized in that the individual parts of the otoplasty or adaptive earpiece are provided with suitable structure for later permanent assembly by one of gluing, polymerization and heat treatment.
Claim 37
Dependent Claim
45 words
A method in accordance with claim 32, characterized in that engageable connecting parts such as pegs and bores and bores for screws, locating means are produced in computer-controlled production of the parts for detachable connection of the individual parts of the otoplasty or adaptive earpiece.
Claim 38
Dependent Claim
111 words
A method for computer-controlled removal of material from at least one selected block to produce the external contours of the otoplasty or adaptive earpiece in accordance with claim 1 characterized by the following process steps: storage of at least one set of definitions, dimensions and positions in a data base of all necessary functions/components of already prefabricated otoplasties or adaptive earpieces which are embedded in plastic blocks and where only the internal contours are predefined; manual, interactive or automatic optimization of the outer surface of the computer model or adaptive earpiece with respect to the position within a selected bock to achieve the minimum final dimensions and an optimum cosmetic appearance.
Claim 39
Dependent Claim
31 words
A method in accordance with claim 37, characterized in that a laser operating in the ultraviolet range is used for removal of the material from the selected block or selected blocks.
References Cited (Backward Citations)
US5056204A
Cited
US5121333A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1999-01-22 | 1999-07-24 | 2000-01-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2003-01-22 | 2003-07-24 | 2004-01-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2007-01-22 | 2007-07-24 | 2008-01-23 | $7700.00 | Window Closed / Lapsed |