U.S. patent application number 15/141725 was filed with the patent office on 2016-12-01 for component protective overmolding using protective external coatings.
This patent application is currently assigned to AliphCom. The applicant listed for this patent is Richard Lee Drysdale, Scott Fullam, Nora Elam Levinson, Skip Thomas Orvis. Invention is credited to Richard Lee Drysdale, Scott Fullam, Nora Elam Levinson, Skip Thomas Orvis.
Application Number | 20160346977 15/141725 |
Document ID | / |
Family ID | 47293414 |
Filed Date | 2016-12-01 |
United States Patent
Application |
20160346977 |
Kind Code |
A1 |
Drysdale; Richard Lee ; et
al. |
December 1, 2016 |
COMPONENT PROTECTIVE OVERMOLDING USING PROTECTIVE EXTERNAL
COATINGS
Abstract
Techniques for component protective overmolding using protective
external coatings include selectively applying a protective
material substantially over one or more elements coupled to a
framework configured to be worn, the elements including at least a
sensor, and forming one or more moldings substantially over a
subset or all of the framework, the protective material and the
elements, after the protective material has been selectively
applied, at least one of the one or more moldings having a
protective property.
Inventors: |
Drysdale; Richard Lee;
(Santa Cruz, CA) ; Fullam; Scott; (Palo Alto,
CA) ; Orvis; Skip Thomas; (San Jose, CA) ;
Levinson; Nora Elam; (Washington, DC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Drysdale; Richard Lee
Fullam; Scott
Orvis; Skip Thomas
Levinson; Nora Elam |
Santa Cruz
Palo Alto
San Jose
Washington |
CA
CA
CA
DC |
US
US
US
US |
|
|
Assignee: |
AliphCom
San Francisco
CA
|
Family ID: |
47293414 |
Appl. No.: |
15/141725 |
Filed: |
April 28, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13942503 |
Jul 15, 2013 |
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15141725 |
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13427839 |
Mar 22, 2012 |
8529811 |
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13942503 |
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13135728 |
Jul 12, 2011 |
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13427839 |
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13158416 |
Jun 11, 2011 |
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13135728 |
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13158372 |
Jun 10, 2011 |
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13158416 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C23C 28/00 20130101;
G06F 1/163 20130101; B29K 2021/003 20130101; B29K 2995/0093
20130101; B29K 2995/0069 20130101; B29C 45/1671 20130101; B29C
45/14639 20130101; B29C 45/1676 20130101; B29K 2023/12 20130101;
B29C 2045/1682 20130101; B29C 2045/14893 20130101; B29L 2031/3481
20130101; B29C 45/14819 20130101 |
International
Class: |
B29C 45/16 20060101
B29C045/16; G06F 1/16 20060101 G06F001/16; B29C 45/14 20060101
B29C045/14 |
Claims
1. A method, comprising: selectively applying at least one layer of
a securing coating over one or more of a plurality of elements
coupled with a framework associated with a wearable device, the
plurality of elements including at least a sensor; selectively
forming a first inner molding that covers all or substantially all
of the at least one layer of the securing coating, the plurality of
elements, and the framework; performing an inspection of the first
inner molding; responsive to the inspection resulting in a defect,
removing the first inner molding and selectively re-forming the
first inner molding that covers all or substantially all of the at
least one layer of the securing coating, the plurality of elements,
and the framework; selectively forming a second inner molding that
covers all or substantially all of the first inner molding; and
selectively forming an outer molding of the wearable device, the
outer molding covering all or substantially all of the second inner
molding, the outer molding having an exterior configured to be
positioned in contact with skin when the wearable device is
worn.
2. The method of claim 1, wherein the outer molding comprises an
anti-bacterial material.
3. The method of claim 1, wherein the outer molding comprises an
oleophobic material.
4. The method of claim 1, wherein the outer molding is configured
to protect against ultraviolet radiation.
5. The method of claim 1, wherein the outer molding comprises a
hydrophobic material.
6. The method of claim 1, wherein the outer molding is configured
to provide a waterproof seal over the plurality of elements.
7. The method of claim 1, wherein a pattern is formed on the outer
molding.
8. The method of claim 1, further comprising performing another
inspection of the outer molding to determine if the outer molding
is defective.
9. The method of claim 8, further comprising: removing the outer
molding after determining the outer molding is defective; and
re-forming the outer molding.
10. The method of claim 1, wherein the framework is comprised of a
synthetic fiber.
11. The method of claim 1, wherein the framework is formed using
carbon fiber.
12. The method of claim 1, wherein the framework is comprised of
one or more filaments.
13. The method of claim 1, wherein the framework is formed using a
thermoplastic elastomer.
14. The method of claim 13, wherein the thermoplastic elastomer
comprises polypropylene.
15. The method of claim 1, wherein at least one of the layers in
the at least one layer of the securing coating comprises a curable
material.
16. A method, comprising: selectively applying at least one layer
of a securing coating substantially over one or more of a plurality
of elements coupled with a framework associated with a wearable
device, the plurality of elements including at least a sensor;
forming one or more inner moldings substantially over a subset or
all of the framework, the at least one layer of the securing
coating and the plurality of elements, after the selectively
applying, at least one of the one or more inner moldings having a
protective property; and forming an outer molding of the wearable
device that covers all or substantially all of the one or more
inner moldings, the outer molding having an exterior configured to
be positioned in contact with skin when the wearable device is
worn.
17. The method of claim 16, wherein the plurality of elements are
configured to perform an operation using data from the sensor.
18. The method of claim 16, wherein the protective property
comprises a property selected from the group consisting of
waterproofing, water-resistance, being hydrophobic, being
oleophobic, being anti-bacterial, and ultraviolet radiation (UV)
resistant.
19. The method of claim 16, wherein the at least one layer of the
securing coating is configured to protect the one or more of the
plurality of elements from damage occurring during the forming of
the one or more inner moldings.
20. The method of claim 16, wherein at least one of the layers in
the at least one layer of the securing coating comprises a curable
material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of copending U.S. patent
application Ser. No. 13/942,503, filed Jul. 15, 2013 (Attorney
Docket No. ALI-001CIP1CIP1CON1CON1), entitled, "Component
Protective Overmolding Using Protective External Coatings," which
is a continuation of U.S. patent application Ser. No. 13/427,839,
filed Mar. 22, 2012 (Attorney Docket No. ALI-001CIP1CIP1CON1),
entitled "Component Protective Overmolding Using Protective
External Coatings," which is a continuation of U.S. patent
application Ser. No. 13/135,728, filed Jul. 12, 2011 (Attorney
Docket No. ALI-001CIP1CIP1), entitled "Component Protective
Overmolding Using Protective External Coatings," which is a
continuation-in-part of U.S. patent application Ser. No.
13/158,416, filed Jun. 11, 2011 (Attorney Docket No.: ALI-001CIP1),
entitled "Component Protective Overmolding," which is a
continuation-in-part of U.S. patent application Ser. No.
13/158,372, filed Jun. 10, 2011 (Attorney Docket No.: ALI-001),
entitled "Component Protective Overmolding," all of which are
hereby incorporated by reference in entirety for all purposes.
FIELD
[0002] The present invention relates generally to electrical and
electronic hardware, computer software, wired and wireless network
communications, and computing devices. More specifically,
techniques for component protective overmolding using protective
external coatings are described.
BACKGROUND
[0003] With the advent of greater computing capabilities in smaller
mobile form factors and an increasing number of applications (i.e.,
computer and Internet software or programs) for different uses,
consumers (i.e., users) have access to large amounts of data,
personal or otherwise. Information and data are often readily
available, but poorly captured using conventional data capture
devices. Conventional devices typically lack capabilities that can
record, store, analyze, communicate, or use data in a
contextually-meaningful, comprehensive, and efficient manner.
Further, conventional solutions are often limited to specific
individual purposes or uses, demanding that users invest in
multiple devices in order to perform different activities (e.g., a
sports watch for tracking time and distance, a GPS receiver for
monitoring a hike or run, a cyclometer for gathering cycling data,
and others). Although a wide range of data and information is
available, conventional devices and applications generally fail to
provide effective solutions that comprehensively capture data for a
given user across numerous disparate activities.
[0004] Some conventional solutions combine a small number of
discrete functions. Functionality for data capture, processing,
storage, or communication in conventional devices such as a watch
or timer with a heart rate monitor or global positioning system
("GPS") receiver are available, but are expensive to manufacture
and typically require purchasing multiple, expensive devices. Other
conventional solutions for combining data capture facilities often
present numerous design and manufacturing problems such as size
specifications, materials requirements, lowered tolerances for
defects such as pits or holes in coverings for water-resistant or
waterproof devices, unreliability, higher failure rates, increased
manufacturing time, and expense. Subsequently, conventional devices
such as fitness watches, heart rate monitors, GPS-enabled fitness
monitors, health monitors (e.g., diabetic blood sugar testing
units), digital voice recorders, pedometers, altimeters, and other
conventional data capture devices are generally manufactured for
conditions that occur in a single or small groupings of activities
and, subsequently, are limited in terms of commercial appeal to
consumers.
[0005] Generally, if the number of data inputs accessible by
conventional data capture devices increases, there is a
corresponding rise in design and manufacturing requirements and
device size that results in significant consumer expense and/or
decreased consumer appeal, which eventually becomes prohibitive to
both investment and commercialization. Still further, conventional
manufacturing techniques are often limited and ineffective at
meeting increased requirements to protect sensitive hardware,
circuitry, and other components that are susceptible to damage, but
which are required to perform various data capture activities. As a
conventional example, sensitive electronic components such as
printed circuit board assemblies ("PCBA"), sensors, and computer
memory (hereafter "memory") can be significantly damaged or
destroyed during manufacturing processes where protective
overmoldings or layers of material occurs using techniques such as
injection molding, cold molding, and others. Damaged or destroyed
items subsequently raises the cost of goods sold and can deter not
only investment and commercialization, but also innovation in data
capture and analysis technologies, which are highly compelling
fields of opportunity.
[0006] Thus, what is needed is a solution for efficiently
manufacturing devices without the limitations of conventional
techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Various embodiments or examples ("examples") are disclosed
in the following detailed description and the accompanying
drawings:
[0008] FIG. 1 illustrates a cross-sectional view of an exemplary
process for providing protective material in component protective
overmolding;
[0009] FIG. 2 illustrates another cross-sectional view of an
exemplary process for providing protective material in component
protective overmolding;
[0010] FIG. 3 illustrates a cross-sectional view of an exemplary
process for forming an inner molding in component protective
overmolding;
[0011] FIG. 4 illustrates another cross-sectional view of an
exemplary process for forming an outer molding in component
protective overmolding;
[0012] FIG. 5A illustrates an exemplary design applied during
component protective overmolding;
[0013] FIG. 5B illustrates another exemplary design applied during
component protective overmolding;
[0014] FIG. 5C illustrates a further exemplary design applied
during component protective overmolding;
[0015] FIG. 6A illustrates an exemplary process for component
protective overmolding;
[0016] FIG. 6B illustrates an alternative exemplary process for
component protective overmolding;
[0017] FIG. 6C illustrates another alternative exemplary process
for component protective overmolding;
[0018] FIG. 6D illustrates yet another alternative exemplary
process for component protective overmolding;
[0019] FIG. 7 illustrates a view of an exemplary data-capable
strapband configured to receive overmolding;
[0020] FIG. 8 illustrates a view of an exemplary data-capable
strapband having a first molding;
[0021] FIG. 9 illustrates a view of an exemplary data-capable
strapband having a second molding;
[0022] FIG. 10 illustrates an exemplary process for component
protective overmolding using protective external coatings;
[0023] FIG. 11 illustrates an alternative exemplary process for
component protective overmolding using protective external
coatings; and
[0024] FIG. 12 illustrates another alternative exemplary process
for component protective overmolding using protective external
coatings.
DETAILED DESCRIPTION
[0025] Various embodiments or examples may be implemented in
numerous ways, including as a system, a process, an apparatus, a
user interface, or a series of program instructions on a computer
readable medium such as a computer readable storage medium or a
computer network where the program instructions are sent over
optical, electronic, or wireless communication links. In general,
operations of disclosed processes may be performed in an arbitrary
order, unless otherwise provided in the claims.
[0026] A detailed description of one or more examples is provided
below along with accompanying figures. The detailed description is
provided in connection with such examples, but is not limited to
any particular example. The scope is limited only by the claims and
numerous alternatives, modifications, and equivalents are
encompassed. Numerous specific details are set forth in the
following description in order to provide a thorough understanding.
These details are provided for the purpose of example and the
described techniques may be practiced according to the claims
without some or all of these specific details. For clarity,
technical material that is known in the technical fields related to
the examples has not been described in detail to avoid
unnecessarily obscuring the description.
[0027] FIG. 1 illustrates a cross-sectional view of an exemplary
process for providing protective material in data-capable strapband
overmolding. Here, device 100 includes framework 102, elements
104-106, and covering 108. In some examples, framework 102 may be
referred to interchangeably as a substrate, wafer, board (printed,
unprinted, or otherwise), or other surface upon which elements
104-106 may be mounted, placed, or otherwise fixed. The type and
configuration of elements may be varied and are not limited to any
given type of electrical, electronic, or mechanical component. For
example, element 104 may be implemented as a microvibrator or motor
configured to provide a vibratory signal for an alarm or other
indicator. Element 104 may also be a printed circuit board assembly
("PCBA"), logic, processor, microprocessor, memory (e.g., solid
state, RAM, ROM, DRAM, SDRAM, or others), or other computing
element and is not limited to any specific type of component.
Further, element 104 may be coupled electrically or electronically
to element 106, which may also be an electrical, electronic, or
mechanical component that can be placed on framework 102. When
placed on framework 102, elements 104-106 may be fixed using
various techniques, including adhesives, mechanical fixing
structures (e.g., posts and holes), or others, without
limitation.
[0028] As shown, covering 108 may be placed over element 104 in
order to protect the latter from damage resulting from the
application of subsequent layers, coverings, moldings, or other
protective material, regardless of environmental conditions (e.g.,
temperature, pressure, thickness, and others). As shown, element
104 is covered by covering 108 and element 106 is uncovered.
However, other protective materials may be used to cover element
106. In still other examples, protective materials such as covering
108 may not be used if elements 104 or 106 are manufactured to
resist the formation, deposit, layering, or covering of other
protective materials at various temperatures, pressures, or other
atmospheric conditions. In other examples, device 100 and the
above-described elements may be varied and are not limited to those
shown and described.
[0029] FIG. 2 illustrates another cross-sectional view of an
exemplary process for providing protective material in data-capable
strapband overmolding. Here, device 200 includes framework 102,
elements 104-106, covering 108, syringe 202, arrows 204-206, and
protective coating 208. In some examples, covering 108 and
protective coating 208 may be referred to as "protective material"
interchangeably and without limitation. As shown, like numbered
elements shown in this drawing and others may refer to the same or
a substantially similar element previously described.
[0030] In some examples, an applicator (e.g., syringe 202) may be
used to selectively apply protective coating 208 to cover as a
protective layer over element 106. As used herein, "selectively
applying" may refer to the application, placement, positioning,
formation, deposition, growth, or the like, of protective material
to one, some, all, or none of any underlying elements (e.g.,
elements 104-106). In some examples, "protective material" may also
be used interchangeably with "protective layer," "covering,"
"housing," or "structure" regardless of the composition of material
or matter used, without limitation. In other words, covering 108
and protective coating 208 may each be referred to as "protective
material" and used to protect underlying elements (e.g., elements
104-106 (FIG. 1)) as described herein.
[0031] When the plunger of syringe 202 is depressed in the
direction of arrow 204, protective coating 208 is forced through
applicator tip 210 and applied as a protective layer over element
106. As an example, protective coating 208 may be applied at
substantially atmospheric pressure by applying 1-2 psi of pressure
to the plunger of syringe 202. When applied, protective coating 208
may be, for example, an ultraviolet ("UV") curable adhesive or
other material. In other words, when protective coating 208 is
applied (i.e., layered over element 106) and exposed to ultraviolet
radiation (or other curing conditions) at levels similar to those
found in natural sunlight or artificial light, it coalesces and
hardens into a covering that prevents the underlying element (e.g.,
element 106) from being damaged when other protective materials or
layers are applied such as those shown and described below.
Exemplary types of protective coating 208 may include coatings,
adhesives, gels, liquids, or any other type of material that
hardens to protect, prevent, minimize, or otherwise aid in avoiding
damage to a protected element. Examples of UV curable coatings
include Loctite.RTM. coatings produced by Henkel & Co AG of
Dusseldorf, Germany such as, for example, Loctite.RTM. 5083 curable
coating. Other types of curable coatings, in addition to those that
are UV curable, may be used to protect underlying elements without
limitation or restriction to any given type.
[0032] In some examples, protective material such as Loctite.RTM.
or others may be applied selectively to one, some, or all
electrical, electronic, mechanical, or other elements. Protective
coating 208 may also be applied in different environmental
conditions (e.g., atmospheric pressure, under vacuum, in a molding
cavity or chamber, within a deposition chamber, or the like) and is
not limited to the examples shown and described. As shown,
protective coating 208 has been selectively applied to element 106,
but not element 104, the latter of which is being protected by
covering 108. As an alternative, covering 108 may be used as
protective material in the form of an enclosure or physical
structure that is used to protect an underlying element. As
described herein, protective coating 208 may be selectively applied
by determining whether sensitive components, parts, or other
elements ("elements") are susceptible to damage or destruction from
subsequent processes, for example, to deposit additional protective
layers, such as those described in greater detail below. In other
examples, device 200 and the above-described elements may be varied
in function, structure, configuration, implementation, or other
aspects and are not limited to those provided.
[0033] FIG. 3 illustrates a cross-sectional view of an exemplary
process for forming an inner molding in data-capable strapband
overmolding. Here, device 300 includes framework 102, elements
104-106, covering 108, syringe 202, arrows 204-206, protective
coating 208, mold cavity 302, nozzle 304, arrows 306-310, and inner
molding 312. In some examples, framework 102 and elements 104-106
having selectively applied protective coating 208 may be placed in
mold cavity 302 where another protective layer or coating (e.g.,
inner molding 312) may be applied from nozzle 304 in the direction
of arrows 306-310. Types of materials that may be used for inner
molding 312 include plastics, thermoplastics, thermoplastic
elastomers, polymers, elastomers, or any other organic or inorganic
material that can molded in mold cavity 302. As shown, mold cavity
302 may be implemented using a variety of molding techniques. For
example, an injection molding machine may be used to inject a
thermoplastic polymer elastomer ("TPE") into mold cavity 302. When
injected under temperature (e.g., 400 to 460 degrees Fahrenheit)
and pressure (e.g., 200 to 600 psi, but which may be adjusted to
higher or lower pressure, without limitation), inner molding 208
forms a protective layer around framework 102, elements 104-106,
covering 108, protective coating 208, providing a layer of
additional protective material (e.g., inner molding 312), which may
completely or incompletely surround an object (e.g., framework
102). In some examples, inner molding 312 may be formed to provide
a watertight or hermetic seal around framework 102 and elements
104-106. Types of materials that may be used as inner molding 312
include TPEs such as Versaflex 9545-1 as manufactured by PolyOne
Corporation of McHenry, Ill. Other types of materials such as
epoxies, polymers, elastomers, thermoplastics, thermoplastic
polymers, thermoplastic polymer elastomers, and others may be used
to form inner molding 312, without limitation to a specific
material. In other examples, device 300 and the above-described
elements may be varied in function, structure, configuration,
implementation, or other aspects and are not limited to those
provided.
[0034] FIG. 4 illustrates another cross-sectional view of an
exemplary process for forming an outer molding in data-capable
strapband overmolding. Here, device 400 includes framework 102,
elements 104-106, covering 108, syringe 202, arrows 204-206,
protective coating 208, inner molding 312, mold cavity 402, nozzle
404, arrows 406-410, and outer molding 412. In some examples, mold
cavity 402 may be the same or different from that described above
in connection with FIG. 3. In other words, mold cavity 402 may be
the same mold cavity as mold cavity 302, but which is used to
injection mold outer molding 412. As shown, framework 102, elements
104-106, protective coating 208, and inner molding 312 are placed
in mold cavity 402. Material (e.g., TPE) may be injected through
nozzle 404 in the direction of arrows 406-410 into mold cavity 402
in order to form outer molding 412. Once formed, sprue or other
extraneous material may be present in inner molding 312 or outer
molding 412, which may be removed after device 400 is taken out of
molding cavity 402. A visual inspection, in some examples, may be
performed to determine if defects are present in either inner
molding 312 or outer molding 412. If defects are found in outer
molding 412, then removal may occur and a new outer molding may be
formed using mold cavity 402. The inspection and, if defects are
found, the removal of outer molding 412 allows for higher quality
moldings to be developed at a lower cost without requiring the
discarding of sensitive, expensive electronics. Outer molding 412,
in some examples, may also be used to provide surface ornamentation
to a given object. The use of thermoplastics or TPE material may be
used to form outer molding 412 and to provide material in which a
surface texture, design, or pattern may be imprinted, contoured, or
otherwise formed. In so doing, various types of patterns, designs,
or textures may be formed of various types. For example, miniature
"hills" and "valleys" may be formed in the protective material of
outer molding 412 in order to produce a "denim" feel or texture to
a given object. Examples of different patterns for outer molding
412 may be found in FIGS. 5A-5C, as shown by patterns 502, 512, and
522, respectively. Patterns 502, 512, and 522 are provided for
purposes of illustration and are neither limiting nor restrictive
with regard to the types, patterns, designs, or textures of surface
ornamentation that may be applied to outer molding 412, as
described herein. Protective material (e.g., TPE) injected into
mold cavity 402 may be used to form these patterns. Various types
of injection molding processes and equipment may be used and are
not limited to any specific type, make, manufacture, model, or
other specification.
[0035] Referring back to FIG. 4, the use of the described
techniques allows for more precise tolerances in forming moldings
that are form-fitting to various types of devices. Still further,
the use of the above-described techniques also allows for
relatively small devices having sensitive electronics to be
subjected to harsh environmental conditions during molding
processes in order to form protective layers (e.g., inner molding
312, outer molding 412) over various types of devices. As shown and
described, the disclosed techniques may be used on a variety of
devices, without limitation or restriction. In other examples,
device 400 and the above-described elements may be varied in
function, structure, configuration, implementation, or other
aspects and are not limited to those provided.
[0036] FIG. 6A illustrates an exemplary process for component
protective overmolding. Here, the start of process 600 includes
forming a protective layer on, for example, framework 102 (FIG. 1)
(602). In some examples, a protective layer may refer to protective
material, layers, or covers such as protective material 108 (FIG.
2) or structures that are formed to protect underlying elements
(e.g., covering 108 (FIG. 1). Examples of material that may be used
to form a protective layer include UV curable materials such as
those described above, including coatings, adhesives, liquids,
gels, and others that cure when exposed to ultraviolet radiation in
various concentrations and exposure levels without limitation.
After forming a protective layer (e.g., protective coating 208), an
inner molding (e.g., inner molding 312 (FIG. 3)) is formed (604).
After forming an inner molding, a function test is performed to
determine whether the inner molding and protective layer have
damaged the underlying item (606). In some examples, a function
test may be performed as part of an inspection and include applying
an electrical current to an underlying electronic element to
identify proper voltage or current flow or other parameters that
indicate whether damage has occurred during the formation of a
protective layer, an inner molding, or, in other examples, an outer
molding. Inspections may be performed at various stages of the
manufacturing process in order to identify defects early and reduce
costs incurred with re-applying protective layers or moldings. In
other examples, a function test may be performed to determine
whether the inner molding has sufficiently coated desired
underlying items (e.g., electrical, electronic, mechanical, or any
structure or elements thereof that are being protected from damage
using one or more moldings). In still further examples, the
function test may be performed to determine whether the formation
of an inner molding damaged underlying items that were previously
protected by the formation of protective layer, the latter of which
may be performed outside of a mold device or cavity (e.g., mold
cavity 302 (FIG. 3) or mold cavity 402 (FIG. 4)) at room
temperature and/or atmospheric conditions, including atmospheric or
ambient temperatures, pressures, and humidity levels, without
limitation.
[0037] In some examples, a determination is made as to whether a
function test is passed or failed (608). Here, if an item having a
protective layer and an inner molding fails to pass, the item is
rejected and the process ends (610). Alternatively, if an item
(e.g., framework 102 and elements 106-108 (FIG. 1)) fails to pass a
function test due to the presence of one or more defects, the inner
molding may be removed and re-applied. In other examples, the
underlying item may be rejected (i.e., destroyed, recycled, or
otherwise removed from a lot of items that have successfully passed
a function test). If a determination is made that a function test
has passed as part of an inspection, then an outer molding is
formed over the inner molding and protective layer (612).
[0038] In some examples, the protective layer, inner molding, and
outer molding may be selectively, partially, or completely applied
to a given item. As described here, an outer molding may also be
configured to completely enclose or encase an underlying item in
order to protect the inner molding, the protective layer, and any
elements from damage. Further, outer molding may be used to form
patterns, designs, or other surface features or contours for
usable, functional, or aesthetic purposes. As shown here, after an
outer molding is formed, a final test is performed to determine
whether defects are present or the formation of the outer molding
met desired parameters (e.g., did the outer molding fully coat an
item, were any underlying items damaged, and the like) (614). In
some examples, a final test may also be a function test, as
described above. In other examples, a final test may also evaluate
an item coated with an outer molding for other purposes. If the
final test is not passed, then the item may be rejected and, in
some examples, the outer molding may be removed and re-applied
(i.e., re-formed) (610). In other example, a failed final test may
also result in the item being rejected and destroyed, recycled, or
otherwise handled as unacceptable. Finally, after a final test is
performed a visual inspection may be performed to determine whether
an item has been covered by the formed outer molding as desired
(618). In other examples, process 600 may be implemented
differently in the order, function, configuration, or other aspects
described and is not limited to the examples shown and described
above.
[0039] FIG. 6B illustrates an alternative exemplary process for
component protective overmolding. Here, process 620 beings be
selectively applying protective material (e.g., protective coating
208 (FIG. 2)) to one or more elements (e.g., electrical,
electronic, mechanical, structural, or others) (622). In some
examples, selectively applying protective material may include
manually using an applicator (e.g., syringe 202 (FIG. 2) or any
other type of instrument, device, tool, or implement used to apply
protective material) to deposit a layer, covering, coating, or the
like over a desired element. In other examples, selectively
applying may also include the application of protective material to
one, some, all, or none of the elements present on a given item. In
other words, selectively applying protective material may be
performed uniformly or non-uniformly without limitation. Types of
protective materials may include curable or non-curable materials
such as those described above, including UV-curable coatings that,
when exposed to ultraviolet radiation, cure. In other examples,
other types of coatings may be used that, when exposed to
artificial or man-made conditions, cure. Still further, other types
of coatings may be used to form a protective layer (i.e.,
protective material) over sensitive elements that may require the
combination of two or more materials, chemicals, or compounds, such
as epoxies, polymers, elastomers, and the like, without
limitation.
[0040] Here, after selectively applying protective material an
inner molding is formed over a framework, associated elements
(i.e., elements coupled to the framework), and the previously,
selectively-applied protective material (624). As an example of a
framework, a "strapband" or, as used herein, "band" may refer to a
wearable device that is configured for various data capture,
analysis, communication, and other purposes. In some examples, a
band may refer to a wearable personal data capture device that,
when worn, may be used to record and store various types of data
associated with a given person's motion, behavior, and physical
characteristics (e.g., body temperature, salinity, blood sugar,
heart rate, respiration rate, movement, and many others, without
limitation). In other examples, a band may be implemented using
hardware, software, and firmware, where application-specific
programs may be downloaded onto a memory that is included as an
element and protected using the described overmolding processes. A
band may be implemented as described below in connection with FIGS.
7-9.
[0041] Referring back to FIG. 6B, an outer molding is formed over
the inner molding, the framework, its elements, and the protective
material (626). After the outer molding is formed, an inspection of
the outer molding is performed to determine whether a defect is
present (628). As used herein, an inspection may refer to any type
of process (e.g., automatic, semi-automatic, manual, robotic,
visual, structural, radiological, electrical, or others) that is
used to determine whether a defect is present. In some examples, an
inspection may include one or more function (i.e., functional)
tests to determine whether a coated (i.e., item receiving
protective material and protective layers or coatings) has been
damaged during the layering process. If a defect (e.g., a damaged
item or defective molding) is found, then the outer molding is
removed (632) and formed again over the inner molding, framework,
elements, and protective material (626). If no defect is found,
then the process ends. Examples of materials that may be used for
moldings (e.g., inner molding, outer molding) in process 620
include plastics, thermoplastics, thermoplastic elastomers,
polymers, thermoplastic polymer elastomers, epoxies, alloys,
metals, or any other type of organic or synthetic material, without
limitation. In other examples, process 620 may be implemented
differently in the order, function, configuration, or other aspects
provided and is not limited to the examples shown and described
above.
[0042] FIG. 6C illustrates another alternative exemplary process
for component protective overmolding. Here, an alternative 2-stage
process 640 for component protective overmolding may be performed.
First, selective application of a securing coating over components
placed on, for example, a framework, may be performed (642). As
used herein, a securing coating may refer to any type of protective
material, layer, cover, structure, liquid, gel, solid, or the like
that is placed substantially (i.e., partially or entirely) over an
item in order to prevent damage from later stages of a
manufacturing process (e.g., introduction into mold cavity 302
(FIG. 3) or mold cavity 402 (FIG. 4) in which rigorous
temperatures, pressures, or other environmental conditions are
created in order to apply other coated materials. Further, due to
the size and relatively sensitive operating, manufacturing, and
performance characteristics of various electrical, electronic,
mechanical, or structural features (e.g., microprocessors, solid
state computer memories, control logic and circuitry,
microvibrators, motors, motor controllers, batteries, battery
modules, battery controllers, and the like), the addition of
protective material can prevent inadvertent damage and increased
costs occurring during the manufacturing of finished products. As
an example, consumer electronics devices receiving both aesthetic
and functional protective overmoldings (i.e., moldings) can be
expensive to manufacture because, for each damage underlying
electronic component, an entire unit must be discarded. However, by
using the described techniques to protect sensitive and expensive
elements by replacing moldings as opposed to entire
partially-finished items, manufacturing costs can be significantly
reduced, thus increasing profit margins and incentives for
individuals and enterprises to commercially invest in manufacturing
devices that can advantageously capture, analyze, use, communicate
(via wired or wireless data communication facilities (e.g., network
interface cards (NICs), wireless radios using various types of
wireless data communication protocols for short, medium, and
long-range communication (e.g., Bluetooth.TM., ZigBee, ANT.TM.,
WiFi, WiMax, and others), and the like), or otherwise use valuable
and abundant personal data. As an example of these types of
devices, a strapband or band may be a wearable device that is
configured to capture data such as that described above. Sensitive
elements of various sizes and shapes may be protected from damage
occurring during later stages of protective overmolding (i.e.,
application of protective layers, covers, molds, or the like) using
the described techniques.
[0043] Here, after applying a securing coating, another molding may
be formed over the securing coating, band, and components (e.g.,
elements) (644). As described here and above, the application of
one or more moldings may be performed to both secure and protect
underlying items (e.g., components or elements) of a finished
product for various conditions such as use, weather, shock,
temperature, or other environmental conditions to which finished
products (e.g., band) may be subjected. In other examples, more,
fewer, or different steps may be implemented as part of process 620
including, for example, a single-stage process involving the
application of one or more protective layers (e.g., housings,
coverings, securing coatings, coatings, moldings, or the like). The
functions, operations, or processes performed during a single or
multi-stage or step process may be varied, without limitation, to
include more, fewer, or different types of sub-processes apart from
those shown and described. Alternatively, more steps in process 620
may be implemented are not limited to any of the examples shown and
described. In still other examples, process 620 may be implemented
differently in the order, function, configuration, or other aspects
provided and is not limited to the examples shown and described
above.
[0044] FIG. 6D illustrates yet another alternative exemplary
process for component protective overmolding. Here, process 650
begins by placing one or more elements on a framework (652). In
some examples, the one or more elements may be placed on a part of
a framework (not shown) or other support structure configured to
provide a substrate or base support. Once placed, the elements are
coated using a curable material (654). As an example of a curable
material, Loctite.RTM. 5083 UV curable coating may be layered
(i.e., deposited, poured, injected, layered, or otherwise covered)
over the elements and the framework. The curable material may be
comprehensively, universally, uniformly, semi-uniformly,
irregularly, or selectively placed so that some elements are
covered while others are left uncovered. Reasons for selectively
applying the curable coating may include other elements being
protected from damage during the molding process using physical
structures (e.g., covering 108) and yet others being manufactured
to withstand the environmental conditions (e.g., temperature ranges
between 400 and 460 degrees Fahrenheit and injection nozzle
pressures of 200 to 600 pounds per square inch (psi)) of molding
cavity 302 (FIG. 3) or 402 (FIG. 4) without using protective
material.
[0045] After securing elements to a framework using curable
material (e.g., UV curable coating, which may also be replaced with
other types of curable coating, without limitation or restriction
to any specific type), an inspection may be performed to determine
whether there are any defects, gaps, openings, or other
susceptibilities that can be anticipated before applying the first
or inner molding (656). After performing an inspection on the
curable coating, one or more moldings may be formed over the
curable material (i.e., coating), framework, and elements (658)
after which an inspection may be performed to determine whether
there are defects in the molding(s) (660). During the inspection, a
determination is made as to whether a defect has been found in one
or more moldings (662). If a defect is found, the defective molding
is removed (664) and another molding may be reformed over the
curable material, framework, and elements (666). By enabling a
defective molding to be replaced without requiring the discard of a
framework and its associated elements (e.g., electrical and
electronic components such as microprocessors, processors, data
storage and computer memory, sensors (e.g., accelerometers,
motion/audio/light sensors, velocimeters, pedometers, altimeters,
heart rate monitors, barometers, chemical/protein detectors, and
others, without limitation), mechanical and structural features or
functionality), substantial costs can be saved thus enabling
devices to be produced at lower costs to consumers and business
alike. In other examples, process 650 may be implemented
differently in the order, function, configuration, or other aspects
provided and is not limited to the examples shown and described
above.
[0046] FIG. 7 illustrates a side view of an exemplary data-capable
strapband configured to receive overmolding. Here, band 700
includes framework 702, covering 704, flexible circuit 706,
covering 708, motor 710, coverings 714-724, analog audio plug 726,
accessory 728, control housing 734, control 736, and flexible
circuit 738. In some examples, band 700 is shown with various
elements (i.e., covering 704, flexible circuit 706, covering 708,
motor 710, coverings 714-724, analog audio plug 726, accessory 728,
control housing 734, control 736, and flexible circuit 738) coupled
to framework 702. Coverings 708, 714-724 and control housing 734
may be configured to protect various types of elements, which may
be electrical, electronic, mechanical, structural, or of another
type, without limitation. For example, covering 708 may be used to
protect a battery and power management module from protective
material formed around band 700 during an injection molding
operation. As another example, housing 704 may be used to protect a
printed circuit board assembly ("PCBA") from similar damage.
Further, control housing 734 may be used to protect various types
of user interfaces (e.g., switches, buttons, lights, light-emitting
diodes, or other control features and functionality) from damage.
In other examples, the elements shown may be varied in quantity,
type, manufacturer, specification, function, structure, or other
aspects in order to provide data capture, communication, analysis,
usage, and other capabilities to band 700, which may be worn by a
user around a wrist, arm, leg, ankle, neck or other protrusion or
aperture, without restriction. Band 700, in some examples,
illustrates an initial unlayered device that may be protected using
the techniques for protective overmolding as described above.
[0047] FIG. 8 illustrates a view of an exemplary data-capable
strapband having a first molding. Here, band 800 includes molding
802, analog audio plug (hereafter "plug") 804, plug housing 806,
button 808, framework 810, control housing 812, and indicator light
814. In some examples, a first protective overmolding (i.e.,
molding 802) has been applied over band 700 (FIG. 7) and the
above-described elements (e.g., covering 704, flexible circuit 706,
covering 708, motor 710, coverings 714-724, analog audio plug 726,
accessory 728, control housing 734, control 736, and flexible
circuit 738) leaving some elements partially exposed (e.g., plug
804, plug housing 806, button 808, framework 810, control housing
812, and indicator light 814). However, internal PCBAs, flexible
connectors, circuitry, and other sensitive elements have been
protectively covered with a first or inner molding that can be
configured to further protect band 800 from subsequent moldings
formed over band 800 using the above-described techniques. In other
examples, the type, configuration, location, shape, design, layout,
or other aspects of band 800 may be varied and are not limited to
those shown and described. For example, plug 804 may be removed if
a wireless communication facility is instead attached to framework
810, thus having a transceiver, logic, and antenna instead being
protected by molding 802. As another example, button 808 may be
removed and replaced by another control mechanism (e.g., an
accelerometer that provides motion data to a processor that, using
firmware and/or an application, can identify and resolve different
types of motion that band 800 is undergoing), thus enabling molding
802 to be extended more fully, if not completely, over band 800. In
yet other examples, molding 802 may be shaped or formed differently
and is not intended to be limited to the specific examples shown
and described for purposes of illustration.
[0048] FIG. 9 illustrates a view of an exemplary data-capable
strapband having a second molding. Here, band 900 includes molding
902, plug 904, and button 906. As shown another overmolding or
protective material has been formed by injection molding, for
example, molding 902 over band 900. As another molding or covering
layer, molding 902 may also be configured to receive surface
designs, raised textures, or patterns, which may be used to add to
the commercial appeal of band 900. In some examples, band 900 may
be illustrative of a finished data capable strapband (i.e., band
700 (FIG. 7), 800 (FIG. 8) or 900) that may be configured to
provide a wide range of electrical, electronic, mechanical,
structural, photonic, or other capabilities.
[0049] Here, band 900 may be configured to perform data
communication with one or more other data-capable devices (e.g.,
other bands, computers, networked computers, clients, servers,
peers, and the like) using wired or wireless features. For example,
a TRRS-type analog audio plug may be used (e.g., plug 904), in
connection with firmware and software that allow for the
transmission of audio tones to send or receive encoded data, which
may be performed using a variety of encoded waveforms and
protocols, without limitation. In other examples, plug 904 may be
removed and instead replaced with a wireless communication facility
that is protected by molding 902. If using a wireless communication
facility and protocol, band 900 may communicate with other
data-capable devices such as cell phones, smart phones, computers
(e.g., desktop, laptop, notebook, tablet, and the like), computing
networks and clouds, and other types of data-capable devices,
without limitation. In still other examples, band 900 and the
elements described above in connection with FIGS. 1-9, may be
varied in type, configuration, function, structure, or other
aspects, without limitation to any of the examples shown and
described.
[0050] FIG. 10 illustrates an exemplary process for component
protective overmolding using protective external coatings. Here,
process 1000 includes selectively applying a material (such as
those described above) substantially over a framework that is
coupled to one or more elements (1002). Selective application of
the material, in some examples, may refer to point applications of
a material (e.g., an epoxy or other material used to protect an
underlying element from being damaged during subsequent deposition,
formation, or molding phases of other material). As used herein, a
framework may be an internal substrate, wafer, stiffener, or the
like, providing both an internal structure for bands 700-900 (FIGS.
7-9) and a structure to which the one or more elements may be
mounted or coupled, either directly or indirectly. In some
examples, the one or more elements may include any type of
electrical, electronic, mechanical, chemical, or other type of
device, component, sub-component, mechanism that is configured to
receive, transmit, process, or perform a data operation (i.e.,
"operation") using data gathered from a sensor coupled to bands
700-900. Also, as used herein, "sensory input" may refer to any
type, classification, powered or unpowered, of sensor configured to
sense data and information regarding the internal or external
environment of bands 700-900.
[0051] After selectively applying the material substantially over
the framework coupled to one or more elements, a protective layer
is molded over the framework, element(s), and selectively-applied
material (1004). After molding the protective layer, a coating may
be formed over the protective layer (1006). In some examples, the
coating is formed to provide a protective property, as described
above.
[0052] As used herein, "coating" is to be distinguished from
protective coating 208 (FIG. 2) in that the former is used to
provide a protective property to the structure to which it is
applied. In some examples, the protective property may include
protecting bands 700-900 (FIGS. 7-9) from external damage due to
shock, wear, immersion (in various types of liquids, including
water), temperature, pressure, or other environmental conditions
(or lack thereof, including vacuum). In other examples, a
protective property may be a characteristic of a coating that, when
applied, protects a wearer or users. For example, material used for
a coating may include anti-bacterial or medical-grade (i.e., any
type of material or combination of materials, synthetic or organic,
that have been tested and deemed suitable for biological uses,
including those internal and external to organisms or bodies)
materials such as TPE, polymers, elastomers, and others. Other
protective properties of a coating may include being water-proof,
water-resistant, oleophobic, hydrophobic, hardened (i.e., protected
from damage due to shock, which may require shock or
impact-absorbent materials that distribute kinetic energy when
applied via force or pressure), ultraviolet radiation (hereafter
"UV")-protective or resistive (i.e., resists color fading), and
others, without limitation. Protective properties may refer to any
property that protects the framework, elements, material, moldings,
coatings, or the like from either external or internal damage or
conditions that could result in damage. In other examples, process
1000 may be implemented differently in the order, function,
configuration, or other aspects provided and is not limited to the
examples shown and described above.
[0053] FIG. 11 illustrates an alternative exemplary process for
component protective overmolding using protective external
coatings. As an alternative process to those described above,
material may be provided (e.g., formed, molded, deposited, sprayed,
dipped, applied with a brush (i.e., brushed), or the like) over a
structure of a device (1102). In some examples, a device (e.g.,
bands 700-900 (FIGS. 7-9)) may be configured to perform one or more
operations, as described above, using data received from various
types and quantities of sensory inputs. As used herein, the
material may be applied to secure an element (e.g., a sensor,
battery, motor, detector, circuit, or any other type of element, as
described above) to a framework or stiffener of a device. Applying
material may also refer to the molding of a layer of material over
a framework and elements, providing a hermetic or substantially
hermetic or waterproof enclosure. In other examples, applying
material may refer to the formation of a single or multiple layers
of material over a device. After applying the material, a coating
is formed over it to provide a protective property, such as those
described above (1104). In other examples, process 1100 may be
implemented differently in the order, function, configuration, or
other aspects described and is not limited to the examples provided
above.
[0054] FIG. 12 illustrates another alternative exemplary process
for component protective overmolding using protective external
coatings. As a further alternative process to those described
above, material is selectively applied over a framework coupled to
one or more elements (1202). After applying the material over the
framework and coupled element(s), one or more layers (e.g.,
coatings, such as those described above) are molded to provide a
protective property (1204). In other examples, process 1200 may be
implemented differently in the order, function, configuration, or
other aspects described and is not limited to the examples provided
above.
[0055] Although the foregoing examples have been described in some
detail for purposes of clarity of understanding, the
above-described inventive techniques are not limited to the details
provided. There are many alternative ways of implementing the
above-described invention techniques. The disclosed examples are
illustrative and not restrictive.
* * * * *