Wristband for wearable devices and method of manufacturing same

Abstract

In one aspect, a wristband for wearable devices is presented. A wristband may have a first band having a first proximal end couplable to a wearable device and a first distal end extending away from the wearable device. A wristband may have a second band having a second proximal end formed as part of a portion of the first distal end of the first band and a second distal end couplable to a locking element configured to secure the wearable device to a portion of a user.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of, U.S. Prov. App. No. 63 / 687,950, filed August 28, 2024, the entirety of which is incorporated by reference.TECHNICAL FIELD

[0002] The present disclosure relates to the field of wearable devices. In particular, the present disclosure relates to wearable bands for wearable devices and manufacturing thereof.SUMMARY

[0003] In one aspect, a wristband for wearable devices is presented. A wristband may have a first band having a first proximal end couplable to a wearable device and a first distal end extending away from the wearable device. A wristband may have a second band having a second proximal end formed as part of a portion of the first distal end of the first band and a second distal end couplable to a locking element configured to secure the wearable device to a portion of a user.

[0004] In another aspect, a method of manufacturing a wristband for wearable devices is presented. A method may include positioning a second proximal end of a second band at least partially onto a top surface of a first distal end of a first band in a mold cavity of a band mold. A method may include injecting a molding material into a mold cavity. A method may include allowing a molding material to cure, thereby materially integrating a second band at least partially into a first band.BRIEF DESCRIPTION OF THE FIGURES

[0005] FIG. 1 is an illustration of a wearable band coupled to a wearable device;

[0006] FIG. 2 is a side-view of the wearable band and wearable device of FIG. 1;

[0007] FIGS. 3A-C are side-views of a wearable band coupled to a wearable device;

[0008] FIG. 3D is a side-view of a wearable band with sacrificial geometry;

[0009] FIG. 4 is a side-view of an embodiment of a mold;

[0010] FIG. 5 is a side-view of another embodiment of a mold;

[0011] FIG. 6 is a side-view of another embodiment of a mold;

[0012] FIG. 7 is a top-view of a flow guide and flow director;

[0013] FIG. 8 is a side-view of an embodiment of a mold;

[0014] FIGS. 9A-B are illustrations of an embodiment of a mold cavity and a mold core of the mold of FIG. 8;

[0015] FIGS. 10A-B are illustrations of another embodiment of a mold cavity and a mold core; and

[0016] FIG. 11 is a flowchart of a method of manufacturing a wearable device.DETAILED DESCRIPTION

[0017] Aspects of the present disclosure may provide for wristbands for wearable devices. In some embodiments, a multi-part wristband is presented. A multi-part wristband may have a first band and a second band formed as part of the first band. A multi-part wristband may allow for a visual seamless wristband while incorporating a locking element into a band having one or more stimulators. In some embodiments, a second band may be overmolded onto a portion of a first band, which may cause the second band to become formed as part of the first band. Embodiments of manufacturing a wearable device are presented. For instance, a mold cavity may contain a portion of a wearable device and / or band, and a mold core may be shaped as a second band and / or contain a second band. A first band and a second band may be aligned through, but not limited to, alignment pins, magnets, vacuums, or other alignment methods. In some embodiments, flow guides and / or flow directors may be implemented in methods and devices described herein. Flow guides may aid in directing molding material throughout a surface of a band. A flow director may be designed to ensure molding material evenly coats two or more portions of a band.

[0018] In some embodiments, aspects of the present disclosure may allow for integration of molding material throughout hook and loop elements of a second band without compromising functionality of the hook and loop elements. For instance, molding material may be interwoven into hook and / or loop elements of a second band through a manufacturing process resulting in a unified band with hook and / or loop functionality.

[0019] Referring now to FIG. 1, an illustration of a wearable band 100 coupled to a wearable device is presented. Wearable band 100 (also referred to as “band 100”) may be rectangular, ovular, or other shapes. In some embodiments, band 100 may be relatively flat, such as with a thickness of less than about 1 inch. In other embodiments, band 100 may have a thickness of greater than about 1 inch. Band 100 may have a length of about, but not limited to, 8 inches to about 16 inches or greater. In some embodiments, band 100 may have edges that are rounded out or squared. For instance, ends of band 100 may be square, while a length of band 100 may have rounded edges which may help alleviate discomfort in a user in wearing band 100. Band 100 may be made out of materials such as, but not limited to, rubbers, plastics, thermoplastics, elastomers, or other materials. For instance and without limitation, band 100 may be made out of silicone. Band 100 may be flexible. A flexibility of band 100 may allow band 100 to bend, twist, or otherwise distort from a resting position. A resting position may be a position in which band 100 is laid out flat or slightly curved. From a laid out flat or slightly curved position, band 100 may bend and / or twist into a secondary position. For instance and without limitation, band 100 may have a flexibility that may allow it to wrap around a portion of a user, such as wrists, arms, legs, or other portions of a user, without limitation.

[0020] Band 100 may be a multi-part band, but may appear as a uniform, singular band. For instance, band 100 may include first band 104 and second band 116. First band 104 and second band 116 may form together to create band 100. First band 104 may have first proximal end 108 and first distal end 112. First proximal end 108 may be an end of first band 104 closest to wearable device 128 with respect to other portions of first band 104. In some embodiments, first proximal end 108 may be couplable to a side of wearable device 128. For instance, first proximal end 108 may be adhered to or coupled to a side of a housing of wearable device 128. In some embodiments, first proximal end 108 may have a curvature. For instance and without limitation, first proximal end 108 may be curved with respect to a longitudinal axis of band 100 at degrees of about, but not limited to, 0 degrees to about 45 degrees or greater. First distal end 112 may be a portion of first band 104 most distal to wearable device 128 with respect to other portions of first band 104. First distal end 112 may extend away from wearable device 128. First distal end 112 may extend away from wearable device 128 at lengths of about, but not limited to, 1 inch to about 8 inches or greater.

[0021] Second band 116 may have second proximal end 120 and second distal end 124. Second proximal end 120 may be a portion of second band 116 that may overlay a portion of first distal end 112. In some embodiments, a portion of second proximal end 120 may be formed as part of first distal end 112. For instance, second proximal end 120 may be an extension of first distal end 112 such that second band 116 and first band 104 form a continuous material without any separation. For instance, band 100 may be absent multiple layers, instead having a single layer of material forming both first band 104 and second band 116. In some embodiments, first band 104 and second band 116 may be chemically bonded such that there is no chemical difference between first band 104 and second band 116. In some embodiments, second band 116 may be formed as part of first band 104 to form a uniform band 100. For instance, band 100 may structurally be a single material extending distally from wearable device 128. In some embodiments, first band 104 and second band 116 may be structurally indistinguishable from each other when formed together. For instance, band 100 may have uniform material properties throughout its entire length, with no variation in tensile strength, flexibility, and / or chemical composition between portions that were originally first band 104 and portions that were originally second band 116. Uniform integration may result in band 100 having consistent mechanical properties along its longitudinal axis, such that no point along the band exhibits different stress-strain characteristics than any other point. In some embodiments, integration of second band 116 into first band 104 may create a monolithic structure where the boundary between the original components is eliminated at the molecular level, resulting in a single, continuous wristband structure. In some embodiments, a portion of second proximal end 120 may be positioned on top of a portion of first distal end 112 and / or first proximal end 108 and may be molded or wielded to the portion of first distal end 112 and / or first proximal end 108. In some embodiments, second proximal end 120 and first distal end 112 may be made out of a single manufacturing mold.

[0022] In some embodiments, second proximal end 120 may be formed as part of first distal end 112 through a manufacturing process. For instance, second proximal end 120 may be overmolded on top of first distal end 112 and / or a portion of first proximal end 108. “Overmolding” as used in this disclosure refers to a process of adding molding material over an existing substrate. First band 104 may act as an existing substrate, and one or more portions of second band 116 may be overmolded onto first band 104, which may create one uniform band. For instance, first band 104 may have no clear demarcation from first proximal end 108 to first distal end 112. An absence of any demarcation of first band 104 from second band 116 may allow for band 100 to appear seamless to someone viewing band 100. In some embodiments, first band 104 may be made of a first material such as, but not limited to, an elastomer, plastic, or other material. Second band 116 may be made out of a second material different than a first material that first band 104 may be made out of. A second material may include, but is not limited to, elastomers, plastics, or other materials. In some embodiments, a material of first band 104 and a material of second band 116 may be the same. In other embodiments, a material of first band 104 may differ from a material of second band 116. In embodiments where a material of first band 104 differs from a material of second band 116, band 100 may be a composite structure made out of two or more differing materials. In other embodiments, a single material may be utilized to manufacture band 100 such that band 100 may be made out of a single uniform material. A single uniform material may be, but is not limited to, plastic, rubber, elastomers, or other materials.

[0023] In some embodiments, overmolding of second band 116 onto first band 104 may create molded portion 150. Molded portion 150 may be made out of a same material used in overmolding second band 116 onto first band 104. Molded portion 150 may be a continuation of a molding material of second band 116. For instance, second band 116 may be formed as part of first band 104 via molded portion 150. Molded portion 150 may be an amount of molding material that may be combined into a top surface of first band 104. For instance, molded portion 150 may be a layer of molded material molded on top of a top surface of first band 104. In some embodiments, molded portion 150 may have a same thickness as second band 116, which may allow for a clean aesthetic appearance and enhanced structural integrity throughout band 100. For instance, second band 116, molded portion 150, and first band 104 may all be chemically bonded to each other.

[0024] Band 100 may be couplable to wearable device 128. A “wearable device” as used in this disclosure refers to any device capable of securing itself to a portion of a user. Wearable device 128 may be designed to secure around a portion of a user, such as but not limited to, a wrist, arm, leg, shoulder, or other part of a user. In some embodiments, wearable device 128 may include a power source, processing component, and / or memory in communication with the processing component. A processing component of wearable device 128 may be, but is not limited to, a microcontroller, microprocessor, System on Chip (SoC), or other processing component. A bottom of band 100, such as a bottom of first distal end 112 and / or first proximal end 108 may house one or more stimulators 136A-D. A “stimulator” as used in this disclosure refers to a device capable of producing a stimulation output. A “stimulation output” as used in this disclosure is any form of energy output that interacts with a biology of a user. In some embodiments, stimulators 136A-D may be vibratory transducers, electrodes, resistive heating elements, radiative heating elements, ultrasonic transducers, or other forms of energy outputting elements. In some embodiments, band 100 may have a single stimulator. In other embodiments, band 100 may have two or more stimulators. Wearable device 128 may be electrically connected to each of stimulators 136A-D. In some embodiments, wearable device 128 may be configured to command one or more of stimulators 136A-D to produce a stimulation output. Frequencies, pulse widths, power, and other parameters of a stimulation output may be adjusted by wearable device 128.

[0025] Second distal end 124 may include hooks 140. Hooks 140 may be a rounded end of second band 116 that may be designed to loop around a structure. In some embodiments, hooks 140 may be designed to loop around an object. For instance, hooks 140 may loop around connector 132 of wearable device 128. Connector 132 may be an extension of a housing of wearable device 128 that may have a slot or hole for hooks 140 to enter. Hooks 140 may enter connector 132 and may wrap around connector 132. In some embodiments, hooks 140 may be pulled through connector 132, which may shorten a length of band 100 that may wrap around a portion of a user. Hooks 140 may secure to locking element 144. Locking element 144 may be made out of loop fastening materials. For instance, hooks 140 may be made of a polyester, nylon, or other material and may be shaped as angled structures extending outwards from second band 116. Locking element 144 may be loops made out of, but not limited to, polyester, nylon, or other materials that may be shaped as ovular structures extending out of a surface of second band 116. Hooks 140 may be designed to engage one or more loops of locking element 144, which may couple second band 116 to itself. In some embodiments, hooks 140 may be magnetic and may magnetically attach to locking element 144, which may also be magnetic. A user may adjust a secureness of wearable device 128 to themselves through adjustment of band 100 via hooks 140 and / or locking element 144.

[0026] In some embodiments, molding material may be interwoven through one or more loops of locking element 144. Interweaving of molding material through locking element 144 may occur when a molding material in its liquid or semi-liquid state during a manufacturing process flows into and around the individual loop structures of locking element 144. Interweaving of molding material into loop structures of locking element 144 may include penetrating spaces between fibers, strands, or other structures of locking element 144 and becoming mechanically entangled within the structures of locking element 144. Molding material may cure and solidify throughout loops or other structures of locking element 144 while allowing for locking functionality of the loops or other structures of locking element 144. Interweaving of molding material through locking element 144 may allow for a seamless appearance of band 100 while retaining functionality of locking element 144.

[0027] Molding material may penetrate into one or more loop structures at a depth of about 10% to about 90% of a loop height of the one or more loop structures, which may create mechanical interlocking between a cured molding material and the loop structures. Mechanical interlocking of molding material and locking element 144 may result in a bond strength that is substantially higher than adhesive or stitching attachment methods, as the cured molding material may form a three-dimensional matrix within and around the loop structures. In some embodiments, locking element 144 may be pre-manufactured before second band 116 and first band 104 form a unified band 100. For instance, locking element 144 may have one or more loops that may retain their functionality after molding material becomes interweaved through the one or more loops using manufacturing processes described herein. Molding material interwoven through locking element 144 may allow for a substantially consistent tensile strength throughout band 100.

[0028] Second band 116 may retain an original visual element before a manufacturing process forming band 100. An original visual element may be, but is not limited to, a surface texture, a color, surface finish, dimensional characteristics, tactile properties, or any other attributes of an appearance of second band 116. For instance, surface texture may include smooth, textured, ribbed, or patterned finishes that remain visually and tactilely distinguishable after the manufacturing process. Color retention may include maintaining original hues, saturation levels, and color uniformity across the surface of second band 116. Dimensional characteristics may include maintaining original thickness, width, and contour profiles that preserve the intended ergonomic and aesthetic design. Surface finish properties may include maintaining original gloss levels, matte finishes, or specialized coatings that contribute to the visual and tactile experience. In some embodiments, at least second distal end 124 may appear substantially unmodified from an original state before second band 116 and first band 104 formed together, such that visually second band 116 may have no features indicating that second band 116 has undergone an overmolding process.

[0029] In some embodiments, band 100 may have sacrificial geometry 148. “Sacrificial geometry” as used in this disclosure refers to a structure designed to be incorporated into an object through a manufacturing process. Sacrificial geometry 148 may be made of, but is not limited to being made of, plastic, rubber, ceramics, or other materials. In some embodiments, sacrificial geometry 148 may be positioned on a portion of band 100 to align second band 116 with first band 104. For instance, sacrificial geometry 148 may be positioned at a point of first band 104 in which second band 116 is formed. Sacrificial geometry 148 may be designed to aid in aligning second band 116 with first band 104 during a manufacturing process and may be molded over with molding material. For instance, sacrificial geometry 148 may be alignment pins or other structures that may aid in aligning second band 116 with first band 104 during a manufacturing process and may be molded over to create a continuous band from second band 116 and first band 104.

[0030] Referring now to FIG. 2, a side view of first band 104 and second band 116 before an overmolding process is presented. A portion of second proximal end 120 of second band 116 may be overlaid onto a portion of first distal end 112 of first band 104. In some embodiments, second proximal end 120 may be overlaid on about 50% of a length of first band 104. In some embodiments, a portion of second proximal end 120 may be overlaid on about 50% to about 80% or greater of a length of first band 104. Second band 116 may be formed as part of first band 104 through any method described herein, without limitation. Second proximal end 120 may be positioned on first distal end 112 such that second band 116 and first band 104 are parallel to each other. In some embodiments, second band 116 may have a width smaller than that of first band 104. A difference in widths of second band 116 and first band 104 may be about, but is not limited to, 1 mm to about 10 mm or greater. A smaller width of second band 116 compared to first band 104 before an overmolding process may allow for more precise alignment of second band 116 overlaid on first band 104 compared to if both first band 104 and second band 116 had the same width. In some embodiments, first band 104 and second band 116 may have substantially the same width. In some embodiments, first band 104 may be placed within a mold cavity of a mold. A “mold cavity” as used in this disclosure refers to an opening within a mold. Second band 116 may be partially positioned on top of a top surface of first band 104 within a mold cavity. For instance and without limitation, a bottom surface of second proximal end 120 may be placed on a top surface of first distal end 112.

[0031] In some embodiments, molding material may be injected or otherwise directed into a mold cavity containing first band 104 and / or second band 116. “Molding material” as used in this disclosure refers to a substance that is capable of cooling into a solid structure from a liquid form. Molding material may include, but is not limited to, rubbers, elastomeric materials, silicone, metals, thermoplastics, or other materials. Molding material may be directed into a mold cavity containing first band 104 and second band 116. Molding material may substantially coat a portion of second band 116 and / or a portion of first band 104. “Substantially coat” as used in this disclosure refers to a process of surrounding a surface area of an object with a material by at least 90% of the surface area of the object. For instance and without limitation, molding material may substantially coat at least second proximal end 120 and first distal end 112. Coating of at least second proximal end 120 and first distal end 112 may allow for a chemical and / or mechanical bonding of second proximal end 120 to first distal end 112 via a hardening of a molding material. For instance and without limitation, a molding material may harden in time periods of about, but not limited to, 1 minute to about 1 hour or greater. In some embodiments, a molding material may harden in less than about 1 minute. In some embodiments, only a top surface of first distal end 112 and a bottom surface of second proximal end 120 are coated with a molding material, which may ensure that additional mechanical combinations to first band 104 and / or second band 116 may be carried out. For instance a bottom half of second proximal end 120 may be coated in a molding material along with a bottom half of first distal end 112, while a top half of second proximal end 120 and / or a bottom half of first distal end 112 remain uncoated.

[0032] First band 104 may be pre-manufactured. For instance, first band 104 may have already gone through a manufacturing process, such as a molding or other manufacturing process. First band 104 may be coupled to wearable device 128 at first proximate end 108 before addition of second band 116. In some embodiments, first band 104 may house one or more of stimulators 136A-D before addition of second band 116. In some embodiments, second band 116 may be pre-manufactured. For instance, second band 116 may have gone through a manufacturing process, such as a molding or other manufacturing process. Second band 116 may have hooks 140 and / or locking element 144 before being formed as part of first band 104. Second band 116, which may be a pre-existing structure, may be formed as part of first band 104, which may also be a pre-existing structure.

[0033] Still referring to FIG. 2, in some embodiments, overmolding of second band 116 onto first band 104 may include adding molding material to parts of first band 104 overlaid by second band 116 and parts of first band 104 uncovered by second band 116. A combination of coating of molding material on parts of first band 104 covered and uncovered by second band 116 may allow for a uniform thickness of a combined band formed by combining second band 116 and first band 104 together. For instance, molding material may coat an entire top surface of first band 104. In some embodiments, more molding material may be added to portions of first band 104 uncovered by second band 116 compared to portions of first band 104 covered by second band 116, which may ensure a uniform thickness of a combined band formed by first band 104 and second band 116. In some embodiments, a molding material that may be used to overmold second band 116 onto first band 104 may be a same material that either or both of second band 116 and first band 104 are composed of. For instance and without limitation, a molding material may be a thermoplastic, and both first band 104 and second band 116 may be made out of a thermoplastic. In some embodiments, a molding material may be made out of a different material than either or both of first band 104 and second band 116. For instance, a molding material may be a material having a higher durability than a material of either or both of first band 104 and second band 116, which may allow for increased durability of a wristband formed from first band 104 and second band 116. As a non-limiting example, molding material may include polyetheretherketon (PEEK), while a material of first band 104 and / or second band 116 may be silicone. A band formed from a partial combination of first band 104 and second band 116 may have a consistent tensile strength along a longitudinal axis of itself such that no one point along a longitudinal axis of the band has a higher or lower tensile strength than another point along the longitudinal axis of the band. In some embodiments, a tensile strength at a location of a material integration of second band 116 into first band 104 may be higher than any other part of a band formed from first band 104 and second band 116. Tensile strengths of a band formed from a partial combination of first band 104 and second band 116 may range anywhere from about, but not limited to, 50 MPa to about 250 MPa or greater. For instance, tensile strengths of a band formed from a partial combination of first band 104 and second band 116 may have a greater strength and / or durability compared to stitching or adhesive attachment methods due to a molding material interweaving through second band 116 and first band 104.

[0034] Referring now to FIGS. 3A-D, an embodiment of manufacturing a wristband is presented. Referring to FIG. 3A, second band 116 may be aligned with first band 104. Second band 116 may include alignment holes 304. In some embodiments, a single alignment hole 304 is used. In other embodiments, two or more alignment holes 304 may be used. Alignment holes 304 may be positioned at a most proximal end of second proximal end 120. In some embodiments, alignment holes 304 may each be positioned a same distance away from an edge of second band 116. In some embodiments, alignment holes 304 may be positioned over sacrificial geometry 308 of first band 104. Sacrificial geometry 308 may be buttons, pins, or other structures that may protrude upwards from a top surface of first band 104. In some embodiments, sacrificial geometry 308 may be positioned at about a half length of first band 104, which may ensure second band 116 bonds to first band 104 at the about half length. In some embodiments, sacrificial geometry 308 may be positioned closer to first distal end 112 than to first proximal end 108. Sacrificial geometry 308 may be placed at about, but not limited to, 0% a length of first band 104 with respect to a distalmost end of first distal end 112 to about 80% or greater of a length of first band 104 with respect to a distalmost end of first distal end 112.

[0035] Referring now to FIG. 3B, alignment holes 304 may be placed on top of sacrificial geometry 308. Sacrificial geometry 308 may be as depicted above with reference to FIG. 3A. Sacrificial geometry 308 may be inserted into alignment holes 304. An insertion of sacrificial geometry 308 into alignment holes 304 may cause second band 116 to be temporarily coupled to first band 104. For instance, second band 116 may be removable from first band 104 via lifting of second band 116 off of sacrificial geometry 308. In some embodiments, insertion of sacrificial geometry 308 into alignment holes 304 may cause second band 116 to become aligned along a longitudinal axis of first band 104. For instance, insertion of sacrificial geometry 308 into alignment holes 304 may cause second band 116 to be oriented parallel to first band 104. In some embodiments, sacrificial geometry 308 may be sized to not extend past a top surface of second band 116 when inserted into alignment holes 304. For instance and without limitation, insertion of sacrificial geometry 308 into alignment holes 304 may cause second band 116 to become temporarily coupled to first band 104 while second band 116 has a flush top surface.

[0036] Referring now to FIG. 3C, a depiction of second band 116 overmolded to first band 104 is presented. Molding material may substantially coat a top surface of second proximal end 120 and a top surface of first distal end 112, which may cause second proximal end 120 to become formed as part of first distal end 112 of first band 104. In some embodiments, mold material may be added to parts of first band 104 uncovered by second band 116, which may allow for a uniform thickness of a final manufactured band formed by first band 104 and second band 116. In some embodiments, additional molding material may be added to portions of first band 104 uncovered by second band 116 which may account for a difference in thickness of first distal end 112 caused by incorporation of a thickness of second proximal end 120. A difference in thickness may be applied to portions of first band 104 uncovered by second band 116 to ensure a uniform thickness of a final manufactured band. For instance, molding material may cover a portion of first band 104 to form molded portion 150. Molded portion 150 may be made out of a same material as that of first band 104 and / or second band 116. In some embodiments, molded portion 150 may have a same thickness as that of second band 116, which may allow for a uniform aesthetic appearance.

[0037] Referring now to FIG. 3D, another embodiment of manufacturing a wristband is presented. A mold used to overmold second band 116 to first band 104 may include sacrificial geometry 308D. Sacrificial geometry 308D may be positioned at or coupled with first distal end 112. In some embodiments, sacrificial geometry 308D may have one or more prongs. For instance, sacrificial geometry 308D may have prongs that may extend upwards from a top surface of first band 104. Prongs of sacrificial geometry 308D may be inserted into one or more alignment holes of second band 116. For instance, second band 116 may have one or more alignment holes near second proximate end 120. Second band 116 may be placed on top of sacrificial geometry 308D, which may allow second band 116 to become aligned with first band 104. For instance, a center width of second band 116 may be aligned with a center width of first band 104. Second band 116 may be aligned parallel to first band 104. Molding material may be applied to areas of first band 104 coupled to second band 116 and areas of first band 104 uncoupled to second band 116. Molding material matching a thickness of sacrificial geometry 308D and / or a thickness of second band 116 may be applied to uncovered portions of first band 104, which may allow for a uniform thickness of a manufactured band formed through overmolding of second band 116 to first band 104. Sacrificial geometry 308D may become embedded into a new band formed through application of molding material to first band 104 and second band 116.

[0038] Referring now to FIG. 4, a side view illustration of mold 400 with alignment pins is presented. Mold 400 may have a mold cavity. A mold cavity of mold 400 may be shaped as a positive mold of a first band and / or a second band. A “positive mold” as used in this disclosure refers to a mold having a concavity in which mold material may be placed. For instance, mold 400 may be a positive mold that has a mold cavity such that when molding material is placed inside the mold cavity, a positive mold of the first band and / or second band is manufactured. In some embodiments, mold 400 may be a negative mold. A “negative mold” as used in this disclosure refers to an inverse of a positive mold. For instance, a negative mold may be a mold cavity that may be a negative of a first band and / or a second band such that when molding material is placed inside the mold cavity an outline of the first band and / or second band is produced.

[0039] In some embodiments, mold 400 may include top portion 404 and bottom portion 408. Top portion 404 may have a mold cavity shaped as a first band and / or second band. In some embodiments, top portion 404 may have a mold cavity shaped as a top half of a first band and / or a second band. Bottom portion 408 may have a mold core shaped as a first band and / or a second band. In some embodiments, bottom portion 408 may have a mold core shaped as a bottom half of a first band and / or a second band. In some embodiments, top portion 404 has a mold cavity while bottom portion 408 has no mold cavity or vice versa. In some embodiments, top portion 404 may have one or more alignment pins 412A-E. Alignment pins 412A-E may be evenly spaced apart across top portion 404. In other embodiments, a spacing between two or more alignment pins 412A-E may differ. Alignment pins 412A-E may be inserted into top portion 404. In some embodiments, top portion 404 has one or more premade holes within its structure that may allow alignment pins 412A-E to insert into top portion 404. In other embodiments, alignment pins 412A-E may pierce through top portion 404. Each alignment pin of alignment pins 412A-E may be positioned across top portion 404 to secure placement of a first band and / or a second band during an overmolding process. For instance, each alignment pin of alignment pins 412A-E may be placed around a perimeter of a first band and / or a second band. Alignment pins 412A-E may be inserted into bottom portion 408, which may couple top portion 404 to bottom portion 408. Alignment pins 412A-E may be removable. For instance and without limitation, after a molding process incorporating top portion 404 and / or bottom portion 408, each alignment pin of alignment pins 412A-E may be removed from top portion 404 and / or bottom portion 408, leaving a manufactured band.

[0040] Top portion 404 and / or bottom portion 408 may have one or more degrees of freedom. A “degree of freedom” as used in this disclosure refers to an independent way in which an object can move in space. For instance, top portion 404 and / or bottom portion 408 may have 3 translational degrees of freedom, such as along X, Y, and / or Z axes, and / or 3 rotational degrees of freedom, such as about X, Y, and / or Z axes. Placement of one or more alignment pins 412A-E into top portion 404 and bottom portion 408 may remove a degree of freedom of either or both of top portion 404 and bottom portion 408. For instance, insertion of one or more alignment pins 412A-E may restrict movement of top portion 404 and / or bottom portion 408 along and / or about X, Y, and / or Z axes. As a non-limiting example, a single alignment pin of alignment pins 412A-E may remove lateral movement in two directions, such as X and / or Y axes. A subsequent alignment pin inserted into both of top portion 404 and bottom portion 408 may prevent rotation of top portion 404 and / or bottom portion 408. In some embodiments, alignment pins 412A-E may be inserted along a perimeter of top portion 404, such as along lengths and / or widths of top portion 404. In some embodiments, alignment pins 412A-E may be inserted along a point of a longitudinal axis of top portion 404.

[0041] Referring now to FIG. 5, another embodiment of a mold 500 is presented. Mold 500 may have one or more vacuum ports 504A-E. Vacuum ports 504A-E may pull fluid into vacuum cavity 512. In some embodiments, vacuum ports 504A-E may cause a pressure differential between an inside of top portion 516 of mold 500 and vacuum cavity 512. A pressure differential of vacuum cavity 512 may be about 0 PSI to about -20 PSI. A pressure differential may aid in securing a second band to a first band. For instance, a pressure differential of vacuum cavity 512 may cause a second band to secure to a first band, which may ensure alignment of the second band overlaid on the first band. In some embodiments, a vacuum created in mold 500 may pull a second band onto a first band in a direction towards bottom portion 520. In other embodiments, a vacuum created in mold 500 may pull a second band onto a first band in a direction towards top portion 516. Vacuum port 508 may be fluidically coupled to a vacuum source, such a vacuum, air pump, or other vacuum source. A vacuum source coupled to vacuum port 508 may cause fluid to enter one or more of vacuum ports 504A-E. Fluid may be air, in some embodiments. Fluid entering vacuum ports 504A-E may cause a pressure differential within vacuum cavity 512, which may cause securement of a second band to a first band. Molding material may be injected between top portion 516 and bottom portion 520, and may experience a pressure differential via one or more of vacuum ports 504A-E. Molding material may be uniformly distributed across a first band and / or a second band due to a pressure differential in vacuum cavity 512, which may ensure a uniform bonding of the second band to the first band. Vacuum portions 504A-E may be used in conjunction with alignment pins 412A-E described above with reference to FIG. 4, without limitation.

[0042] Referring now to FIG. 6, an embodiment of a mold 600 that may be used to manufacture devices described herein is presented. Mold 600 may have top portion 604 and bottom portion 608. In some embodiments, top portion 604 may have a mold cavity and bottom portion 608 may be a mold core, or vice versa.

[0043] Top portion 604 may have one or more magnets 612A-D. Magnets 612A-D may be permanent magnets. For instance and without limitation, magnets 612A-D may be neodymium magnets, samarium cobalt magnets, or other types of magnets. In some embodiments, each of magnets 612A-D may be of a same magnet type. In other embodiments, one or more magnets of magnets 612A-D may differ in magnet type than one or more other magnets of magnets 612A-D. In some embodiments, each magnet of magnets 612A-D may be spaced equidistant from each other. For instance, a space between adjacent magnets of magnets 612A-D may be about, but is not limited to, 0.1 inch to about 5 inches or greater. In some embodiments, a spacing between two magnets 612A-D may differ from a spacing between one of the two magnets 612A-D and one other magnet of magnets. In some embodiments, each magnet of magnets 612A-D may be embedded into top portion 604. For instance, each magnet of magnets 612A-D may be embedded into a material of top portion 604. In some embodiments, magnets 612A-D may be removably placed into slots or other openings within top portion 604 that may accommodate housing of magnets 612A-D. In some embodiments, magnets 612A-D may be positioned proximate a bottom surface of top portion 604. For instance, magnets 612A-D may be positioned at a bottommost part of top portion 604. In some embodiments, magnets 612A-D may be positioned within top portion 604 such that magnets 612A-D outline a geometry of a wristband. For instance, each magnet of magnets 612A-D may be positioned at a key geometric shape of a wristband. Key geometric shapes may include, but are not limited to, edges of a first band, edges of a second band, locations of overlap between a first band and a second band, outlines of wearable devices, or other key geometric shapes. Positioning of one or more of magnets 612A-D at one or more key geometric shapes of an outline of a wristband may provide stronger securement at the one or more key geometric shapes compared to non-key geometric shapes. In other embodiments, magnets 612A-D may be evenly spaced across a bottom portion of top portion 604 such that a magnetic pull to bottom portion 608 may be substantially equal across top portion 604.

[0044] Referring still to FIG. 6, bottom portion 608 may include one or more magnets 612 E-H. In some embodiments, magnets 612E-H may be made of a same magnet type as that of magnets 612A-D. In other embodiments, magnets 612E-H may differ in magnet type than that of magnets 612A-D. In some embodiments, magnets 612E-H may be configured to magnetically attract one or more stimulators positioned within a first band during a manufacturing process. For instance, stimulators may include magnetic components that may be attracted to magnets 612E-H, which may aid in securing a first band in a desired position within bottom portion 608. Magnetic attraction between magnets 612E-H and stimulators may provide additional alignment stability during overmolding processes. This magnetic attraction may ensure that stimulators remain properly positioned relative to bottom portion 608 throughout a molding process. Magnets 612E-H may be positioned equidistant across a top surface of bottom portion 608. For instance, spacing between adjacent magnets of magnets 612E-H may be about, but is not limited to, 0.1 inches to about 5 inches or greater. In other embodiments, spacing between magnets of magnets 612E-H may differ. For instance, a spacing between a first magnet and a second magnet of magnets 612E-H may differ from a spacing between the second magnet and a third magnet of magnets 612E-H. In some embodiments, magnets 612E-H may be embedded into bottom portion 608. For instance, magnets 612E-H may be positioned within a material of bottom portion 608. In other embodiments, magnets 612E-H may be positioned in slots or other openings within bottom portion 608 that may facilitate housing of magnets 612E-H. Magnets 612E-H may be positioned proximate a top surface of bottom portion 608. For instance, magnets 612E-H may be positioned at a topmost portion of bottom portion 608.

[0045] Referring now to FIG. 7, an embodiment of a wristband 700 is presented. Wristband 700 may have proximal end 704 and distal end 708. Proximal end 704 may be an end of wristband 700 closest to casing 712. Distal end 708 of wristband 700 may be an end of wristband 700 farthest away from casing 712. Wristband 700 may be first band 104 and second band 116 described above with reference to FIGS. 1-2, without limitation.

[0046] Wristband 700 may include flow guides 716A and 716B. A “flow guide” as used in this disclosure refers to a structure capable of defining a fluidic pathway. In some embodiments, flow guides 716A and 716B may be sacrificial geometry. Flow guide 716A and / or 716B may be rectangular or ovular structures that may extend from distal end 708 towards proximal end 704. Flow guide 716A and / or 716B may provide support for placement of a second band. For instance, flow guide 716A and / or 716B may act as sacrificial geometry, such as shown above with reference to FIG. 3D. Flow guide 716A may be positioned opposite flow guide 716B. An area between flow guide 716A and flow guide 716B may encompass one or more portions of wristband 700. For instance, an area between flow guide 716A and flow guide 716B may encompass portions of distal end 708. A spacing between flow guide 716A and flow guide 716B may be about, but is not limited to, 0.1 inches to about 5 inches or greater. In some embodiments, flow guide 716A may be positioned substantially parallel relative to flow guide 716B. For instance both flow guide 716A and flow guide 716B may be aligned with a longitudinal axis of wristband 700. In other embodiments, either or both of flow guide 716A and flow guide 716B may be non-parallel with a longitudinal axis of wristband 700. For instance and without limitation, ends of flow guide 716A and flow guide 716B may be oriented towards each other in a “V” shape. In some embodiments, flow guides 716A, 716B may be linear. In other embodiments, flow guides 716A, 716B may be non-linear. For instance, flow guides 716A, 716B may be curved or twisted. In some embodiments, flow guide 716A and / or flow guide 716B may be serpentine shaped. A serpentine shape of flow guide 716A and flow guide 716B may form a serpentine fluidic pathway between flow guide 716A and flow guide 716B. In some embodiments, flow guides 716A, 716B may be curved and may form an hourglass shaped fluidic channel between them. One of ordinary skill in the art, upon reading this disclosure, will understand the various shapes and forms flow guides 716A and 716B may take.

[0047] Wristband 700 may have flow director 720. A “flow director” as used in this disclosure refers to an object designed to guide a flow of fluid around and / or through itself. Flow director 720 may guide molding material across wristband 700. Flow director 720 may be made of plastic, rubber, or other materials. In some embodiments, flow director 720 may be positioned between distal end 708 and proximal end 704. In some embodiments, flow director 720 may be positioned at a half-length of wristband 700. Flow director 720 may be designed to contact molding material. For instance, flow director 720 may contact molding material and may direct the molding material to one or more portions of wristband 700. Flow director 720 may have first side 732A and second side 732B. First side 732A may mirror second side 732B across a longitudinal axis of wristband 700. First side 732A may be square, circular, or other shapes. Second side 732B may be square, circular, or other shapes. In some embodiments, first side 732A and second side 732B are shaped similarly. In other embodiments, first side 732A may have a shape that differs from a shape of second side 732B. In some embodiments, flow director 720 is symmetrical across a longitudinal axis of wristband 700. A symmetry of flow director 720 across a longitudinal axis of wristband 700 may aid in directing molding material throughout wristband 700.

[0048] In some embodiments, first side 732A may be connected to flow guide 716A and second side 732B may be connected to flow guide 716B. A connection of sides 732A,B, and flow guides 716A,B, may form an overmolding area inside a perimeter of sides 732A,B, and flow guides 716A,B. An overmolding area may be a portion of wristband 700 in which overmolding may occur. For instance, an area of wristband 700 inside a perimeter of flow guides 716A,B, and flow director 720 may be designed for overmolding of a second band onto wristband 700. Molding material may flow onto a top surface of distal end 708 and may be guided by flow guides 716A,B, towards flow director 720. For instance, molding material may contact flow guide 716A and / or 716B and may be directed along a portion of wristband 700 within an area formed by a spacing between flow guide 716A and 716B towards flow director 720. In some embodiments, flow director 720 may be a solid or hollow structure with no openings. Molding material may flow towards flow director 720 and may contact flow director 720. A contacting of molding material with flow director 720 may direct molding material into an area formed by flow director 720 and flow guides 716A,B. In some embodiments, flow director 720 may prevent flow of molding material past itself. For instance, molding material may contact flow director 720 and may be stopped by a contacting of flow director 720 from traveling along a point of wristband 700 more proximate to proximal end 704 than a position of flow director 720 on wristband 700.

[0049] In some embodiments, flow director 720 has an opening. An opening of flow director 720 may be positioned at a center point between first side 732A and second side 732B. An opening of flow director 720 may be circular, ovular, or other shapes. An opening of flow director 720 may have a radius of about, but not limited to, 0.1 inches to about 0.5 inches or greater. An opening of flow director 720 may allow for a channeling of mold material from distal end 708 towards proximal end 704.

[0050] Still referring to FIG. 7, in some embodiments, flow director 720 may be a separate structure from flow guide 716A and / or 716B. For instance, flow guides 716A,B, may terminate before reaching sides 732A,B, of flow director 720. A spacing between ends of flow guides 716A,B, and sides 732A,B, may allow for a fluidic channel to form. For instance, molding material may pass between flow guides 716A,B, and may exit through a spacing between each of flow guide 716A and side 732A and flow guide 716B and side 732B. In some embodiments, a molding material may enter through a spacing between flow guide 716A and side 732A. Exiting or entering through a spacing between flow guides 716A,B and sides 732A,B, may cause molding material to flow around flow director 720. A flowing of molding material around flow director 720 may allow the molding material to flow towards proximal end 704 of wristband 700. Sides 732A,B, may be curved, which may cause a curvature in a flow of molding material around flow director 720. A curvature of a flow of molding material around flow director 720 may allow for even distribution of the molding material from distal end 708 towards proximal end 704. In some embodiments, flowing of molding material around flow director 720 may help regulate a volume of the molding material throughout wristband 700. A spacing between flow guide 716A and side 732A may be about, but is not limited to, 0.1 inches to about 3 inches or greater. A spacing between flow guide 716B and side 732B may be about, but is not limited to, 0.1 inches to about 3 inches or greater. In some embodiments, spacing between flow guide 716A and side 732A may be the same value as a spacing between flow guide 716B and side 732B. In other embodiments, a difference in spacing between flow guide 716A and side 732A and flow guide 716B and side 732B may differ. Pressure of molding material flowing through gaps of flow guide 716A,B, and sides 732A,B, may be about, but are not limited to, 1PSI to about 10PSI or greater. In some embodiments, molding material may be substantially evenly distributed across a top surface of wristband 700. Controlling of volumes and directions of a flow of molding material via flow guides 716A,B, and / or flow director 720 may allow for a uniform, aesthetic appearance of an over molded wristband. For instance, a wristband over molded using flow guides 716A,B, and / or flow director 720 may have no clear demarcation across it’s surface with respect to a second band molded onto wristband 700.

[0051] In some embodiments, molding material may be channeled onto wristband 700 between stimulator 724C and stimulator 724D. Molding material may flow towards casing 712 and towards distal end 708, covering band 700. Molding material may contact flow director 720 in a direction from stimulator 724C towards stimulator 724B. Molding material may flow around first side 732A and second side 732B of flow director 720. In some embodiments, an equal amount of molding material may be separated into guides created by first side 732A and second side 732B. For instance, an equal mass of molding material and / or an equal rate of flow of molding material may be present on flow channels created by first side 732A and second side 732B, which may allow for a uniform distribution of molding material across distal end 708. A flow of molding material may flow around first side 732A and may contact guide 716A. A contacting of guide 716A may cause molding material to enter towards a center of distal end 708. A flow of molding material may in parallel flow around second side 732B and may contact guide 716B. A contacting of guide 716B may cause molding material to flow towards a center of distal end 708. Molding material may flow into a center of distal end 708 from guide 716A and 716B at a same time, which may allow for even distribution across distal end 708 of molding material.

[0052] Referring now to FIG. 8, an embodiment of a mold core 804 and a mold cavity 808 is presented. A “mold core” as used in this disclosure refers to a positive of a mold. Mold core 804 may have one or more features that may be convex. Features of mold core 804 may include, but are not limited to, outlines of a second band, outlines of a first band, outlines of a wearable device, or other features. Mold cavity 808 may have one or more concave features, such as, but not limited to, an outline of a wearable device and / or one or more bands. For instance, mold core 804 may be shaped as a wearable device and a first band, and mold cavity 808 may be shaped as a second band positioned to overmold the second band onto a portion of the first band. Mold core 804 may be couplable to mold cavity 808. For instance, one or more surfaces or other features of mold core 804 may be inserted into mold cavity 808. In some embodiments, a casing 816 of a wearable device and / or a first band may be positioned between mold core 804 and mold cavity 808. For instance, a casing of a wearable device may be coupled to a first band and may be positioned between mold core 804 and mold cavity 808. A second band may be positioned on top of a first band between mold core 804 and mold cavity 808. In some embodiments, mold cavity 808 and / or mold core 804 may utilize size insert 812. A “size insert” as used in this disclosure refers to an object insertable into a section of a mold that sets forth dimensions of part of the mold. For instance, an amount of molding material may be contained within size insert 812, which may dictate dimensions of a mold. Size insert 812 may be, but is not limited to, rectangular, square, circular, or any other shape. In some embodiments, various size inserts 812 may be used depending on a targeted band size. For instance, a large size insert 812 may be used for a large band size. A large size insert 812 may be about 5 inches or greater in length and about 1 inch or greater in width. A medium size insert 812 may be used for a medium band size. A medium size insert may be less than about 5 inches in length and less than about 1 inch in width. A small size insert 812 may be used for a small band size. A small size insert 812 may be less than about 3 inches in length and less than about 0.5 inches in width. Any dimensions of a size insert 812 may be used, without limitation. In some embodiments, size insert 812 may dictate dimensions of a second band. For instance, a length, width, and / or thickness of a second band may correlate with a length, width, and / or thickness of size insert 812. Size insert 812 may be positioned within mold core 804. In some embodiments, size insert 812 may be positioned between mold core 804 and mold cavity 808.

[0053] Referring now to FIGS. 9A-B, embodiments of a mold cavity and a mold core are presented. Referring now to FIG. 9A, a cavity-side view of a mold is presented. A mold may include cavity 908 which may be as described above with reference to FIG. 8. Cavity 908 may hold casing 916 of a wearable device. For instance in some embodiments, casing 916 and / or a flexible printed circuit board (PCB) of a first band may be inserted into cavity 908. A first band may come in contact with molding material to create molded portion 920. Casing 916 may be coupled to molded portion 920. Molded portion 920 may be a first band that has been overmolded with a molding material. For instance, a first band may be coupled to casing 916 and molding material may contact a surface of the first band. In some embodiments, molding material may be elastomeric. Contacting of molding material with a surface of a first band may create an overmold of the first band. For instance, molded portion 920 may be an overmold of a first band. Molded portion 920 may lay linearly within cavity 908. For instance, molded portion 920 may extend along a longitudinal axis of cavity 908. In some embodiments, mold cavity 908 may have angled structure 932. Angled structure 932 may be a part of cavity 908 that may be vertically rotated relative to a longitudinal axis of cavity 908. For instance, angled structure 932 may curve upwards relative to a bottom of cavity 908 at angles of about, but not limited to, 0 degrees to about 45 degrees or greater. Angled structure 932 may allow for curving of parts of proximal end 936 with respect to casing 916.

[0054] In some embodiments, molded portion 920 may have one or more stimulators 924A-D. Stimulators 924A-D may be coupled to a flexible printed circuit board (PCB). For instance, a flexible PCB may be inserted in cavity 908 and may be coupled to one or more stimulators 924A-D. In other embodiments, stimulators 924A-D may be added to molded portion 920 after manufacturing of a second band onto molded portion 920. Cavity 908 may have size insert 912. Size insert 912 may surround a perimeter of molded portion 920. For instance, size insert 912 may overlap with a width and / or length of molded portion 920. Differences in overlap of size insert 912 with a perimeter of molded portion 920 may correspond to band sizes. For instance, a greater difference in overlap between size insert 912 and molded portion 920 may correspond to a larger band size than a smaller difference in overlap between size insert 912 and molded portion 920. In some embodiments, size insert 912 extends along molded portion 920 until angled surface 932. For instance, size insert 912 may not extend past angled surface 932 to proximal end 936 of molded portion 920. Proximal end 936 of molded portion 920 may be curved in some embodiments. For instance, proximal end 936 may follow a curvature of angled surface 932. In some embodiments, proximal end 936 may couple molded portion 920 to casing 916. Size insert 912 may overlap molded portion 920 except for proximal end 936. Omission of size insert 912 on proximal end 936 may prevent overmolding to occur on proximal end 936. In other embodiments, overmolding occurs on molded portion 920 including proximal end 936. In some embodiments, a second band may be overmolded onto a length of molded portion 920 except for a portion of molded portion 920 coupling molded portion 920 to casing 916.

[0055] Cavity 908 may include mold material dispenser 950. Mold material dispenser 950 may be a cylindrical object that may provide molding material to mold cavity 908. For instance, molding material may flow through mold material dispenser 950 and out of arm 940. In some embodiments, arm 940 may be positioned between stimulators 924D and 924C, which may cause molding material to flow initially onto a space of molded portion 920 between stimulators 924D and 924C. Flow rates of molding material may include, but are not limited to, about 1 ml / min to about 100 ml / min or greater. Pressures of any mold described herein may be between, but is not limited to, about 4,000 PSI to about 5,000 PSI or greater. Temperatures of any mold described herein may reach between about, but not limited to, 350 degrees Fahrenheit to about 500 degrees Fahrenheit.

[0056] Referring now to FIG. 9B, a core-side view of a mold is presented. Mold core 904 may include molded portion 920, casing 916, stimulators 924A-D, size insert 912, mold material dispenser 950, and / or arm 940, each of which may be as described above with reference to FIG. 9A. Mold core 904 may include one or more components that may fit into a cavity, such as cavity 908 described above with reference to FIG. 9A.

[0057] In some embodiments, molded portion 920 may include flow guides 920A and 920B. Flow guides 920A and 920B may be the same as flow guides 716A and 716B described above with reference to FIG. 7. In some embodiments, molded portion 920 may include flow director 955. Flow director 955 may be the same as flow director 720 described above with reference to FIG. 7.

[0058] Mold core 904 may include one or more hole pins 932A-I. A “hole pin” as used in this disclosure refers to a cylindrical object designed to make an aperture in another object. For instance, hole pins 932A-I may be inserted through molded portion 920 such that removal of hole pins 932A-I leaves a hole in molded portion 920. In some embodiments, each hole pin 932A-I may have a same radius. In other embodiments, at least two hole pins 932A-I may have differing radii. Radii of hole pins 932 may include ranges of about, but not limited to, 0.1 inches to about 0.2 inches or greater. Mold core 904 may include hole pin 932A. Hole pin 932A may be positioned at halfway point between first stimulator 924A and second stimulator 924B. Hole pin 932A may be inserted through molded portion 920. Hole pin 932B may be positioned at a halfway point between stimulator 924B and stimulator 924C. Hole pin 932C may be positioned at a halfway point between stimulator 924C and stimulator 924D. Mold core 904 may include arrangements of hole pins. For instance, mold core 904 may include arrangements of two or more hole pins. In some embodiments, arrangements of two or more hole pin may include a linear arrangement in which two or more hole pins are aligned on a same axis. In other embodiments, arrangements of two or more hole pins may include non-linear arrangements, in which a first hole pin may be non-linearly aligned with a second hole pin with respect to an axis such as a horizontal axis of mold core 904. For instance, mold core 904 may include hole pins 932D-F, which may be an arrangement of three hole pins in a non-linear manner. Hole pin 932D may be positioned at a first side of molded portion 920 while hole pin 932F may be positioned at a second side of molded portion 920 opposite the first side where hole pin 932D may be positioned. Hole pin932E may be positioned between hole pins 932D and 932F in a non-linear manner. For instance, hole pin 932E may be offset from a horizontal axis aligning hole pins 932D and 932F. Hole pin 932E may be positioned through a flexible PCB portion of molded portion 920. In some embodiments, mold core 904 may include hole pins 932G-I. Hole pins 932G-I may be arranged linearly. For instance, each of hole pins 932G-I may be aligned with a horizontal axis of mold core 904. In some embodiments, each of hole pins 932G-I may be evenly spaced apart from each other. In other embodiments, hole pins 932G-I may be unevenly spaced apart. Hole pins 932G-I may be inserted into a flexible PCB portion of molded portion 920. Hole pins 932D-F may be positioned between stimulator 924D and casing 916. In some embodiments, mold core 904 may be used to create a wearable device with a first band. For instance, mold core 904 may be used in an injection molding or other molding process that may create a wearable device with a first band. In some embodiments, casing 916 and / or a flexible PCB may be inserted into cavity 908 and may be molded, such as through injection molding, overmolding, or other molding processes. An output of using mold core 904 and / or mold cavity 908 described with reference to FIGS. 9A-B may be a casing of a wearable device coupled to a first band and a second band formed as part of the first band, such as described above with reference to FIGS. 1-2.

[0059] Referring now to FIGS. 10A-B, an embodiment of a mold core and mold cavity is presented. Referring now to FIG. 10A, mold cavity 1008 coupled with mold core 1004 is presented. Mold cavity1008 and mold core 1004 may be used in creating a finished mold having both a wearable device, first band, and second band overmolded onto the first band, such as described above with reference to FIGS. 1-2, without limitation. For instance, a casing of a wearable device and / or first band that may have been manufactured through molds described above with reference to FIGS. 9A-B may be inserted into one or more portions of mold cavity 1008 and / or mold core 1004. Mold cavity 1008 may house a wearable device and / or first band coupled to the wearable device. For instance, mold cavity 1008 may house a wearable device and / or first band manufactured through a manufacturing process using mold core 904 and mold cavity 908 described above with reference to FIGS. 9A-B. Mold cavity 1008 may include size insert 1012. Size insert 1012 may be used to determine a length, width, and / or thickness of a second band overmolded onto a first band. Mold cavity 1008 may include one or more alignment pins 1016, which may aid in aligning a second band with a first band.

[0060] Referring now to FIG. 10B, a cavity-side view of a mold cavity 1008 is presented. Mold cavity 1008 may house casing 1020 and / or first band 1025. Casing 1020 and / or first band 1025 may have been manufactured through mold core 904 and mold cavity 908 described above with reference to FIGS. 9A-B. First band 1025 may have stimulators 1040A-D. In some embodiments, first band 1025 may be positioned near mold material dispenser 1032, which may have arm 1036. Molding material may flow out of arm 1036 and into mold cavity 1008. In some embodiments, first band 1025 may include stimulators 1040A-D. Second band 1028 may be positioned on top of a top surface of first band 1025. Second band 1028 may be held in place with alignment pin 1016.

[0061] Referring now to FIG. 11, a method 1100 of manufacturing a wristband for wearable devices is presented. At step 1105, method 1100 includes positioning a second proximal end of a second band onto a top surface of a first distal end of a first band. Positioning of a second band onto a first band may be carried out manually or by robotic systems. In some embodiments, positioning of a second band onto a first band may include aligning the second band onto the first band. Alignment may include utilization of one or more alignment pins of a mold. In some embodiments, alignment may include utilization of a vacuum source which may pull fluid out of a mold cavity. A vacuum source may create a pressure differential within a mold cavity, which may cause a second band to press against a first band. In some embodiments, alignment may occur through two or more magnets. For instance, magnets of a first polarity may be distributed across a top portion of a mold, while magnets of a second polarity may be distributed across a bottom portion of a mold.. In some embodiments, sacrificial geometry may be positioned on a first band. Sacrificial geometry may couple to one or more portions of a second band, which may help align the second band to a first band.

[0062] At step 1110, method 1100 includes injecting a molding material into a mold cavity. A molding material may include, but is not limited to, elastomers, thermoplastics, silicone, or other molding materials described herein. In some embodiments, a first band may have one or more flow guides and / or flow directors. Flow guides and / or flow directors of a first band may direct molding material across a top surface of a second band and / or first band, which may allow for a uniform distribution of molding material.

[0063] At step 1115, method 1100 includes allowing a molding material to cure. A molding material may cure after a period of time of anywhere between 1 minute to about 1 hour or greater. In some embodiments, molding material may cure in less than about 1 minutes.

[0064] Any step of method 1100 may be performed as described above with references to FIG. 1-10B.

[0065] While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular embodiments. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

[0066] Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.

[0067] Particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. For example, the actions recited in the claims can be performed in a different order and still achieve desirable results. As one example, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous. Other steps or stages may be provided, or steps or stages may be eliminated, from the described processes. Accordingly, other implementations are within the scope of the following claims.

Examples

Embodiment Construction

[0017] Aspects of the present disclosure may provide for wristbands for wearable devices. In some embodiments, a multi-part wristband is presented. A multi-part wristband may have a first band and a second band formed as part of the first band. A multi-part wristband may allow for a visual seamless wristband while incorporating a locking element into a band having one or more stimulators. In some embodiments, a second band may be overmolded onto a portion of a first band, which may cause the second band to become formed as part of the first band. Embodiments of manufacturing a wearable device are presented. For instance, a mold cavity may contain a portion of a wearable device and / or band, and a mold core may be shaped as a second band and / or contain a second band. A first band and a second band may be aligned through, but not limited to, alignment pins, magnets, vacuums, or other alignment methods. In some embodiments, flow guides and / or flow directors may be implemented in methods...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of, U.S. Prov. App. No. 63 / 687,950, filed August 28, 2024, the entirety of which is incorporated by reference.TECHNICAL FIELD

[0002] The present disclosure relates to the field of wearable devices. In particular, the present disclosure relates to wearable bands for wearable devices and manufacturing thereof.SUMMARY

[0003] In one aspect, a wristband for wearable devices is presented. A wristband may have a first band having a first proximal end couplable to a wearable device and a first distal end extending away from the wearable device. A wristband may have a second band having a second proximal end formed as part of a portion of the first distal end of the first band and a second distal end couplable to a locking element configured to secure the wearable device to a portion of a user.

[0004] In another aspect, a method of manufacturing a wristband for wearable devices is presented. A method may include positioning a second proximal end of a second band at least partially onto a top surface of a first distal end of a first band in a mold cavity of a band mold. A method may include injecting a molding material into a mold cavity. A method may include allowing a molding material to cure, thereby materially integrating a second band at least partially into a first band.BRIEF DESCRIPTION OF THE FIGURES

[0005] FIG. 1 is an illustration of a wearable band coupled to a wearable device;

[0006] FIG. 2 is a side-view of the wearable band and wearable device of FIG. 1;

[0007] FIGS. 3A-C are side-views of a wearable band coupled to a wearable device;

[0008] FIG. 3D is a side-view of a wearable band with sacrificial geometry;

[0009] FIG. 4 is a side-view of an embodiment of a mold;

[0010] FIG. 5 is a side-view of another embodiment of a mold;

[0011] FIG. 6 is a side-view of another embodiment of a mold;

[0012] FIG. 7 is a top-view of a flow guide and flow director;

[0013] FIG. 8 is a side-view of an embodiment of a mold;

[0014] FIGS. 9A-B are illustrations of an embodiment of a mold cavity and a mold core of the mold of FIG. 8;

[0015] FIGS. 10A-B are illustrations of another embodiment of a mold cavity and a mold core; and

[0016] FIG. 11 is a flowchart of a method of manufacturing a wearable device.DETAILED DESCRIPTION

[0017] Aspects of the present disclosure may provide for wristbands for wearable devices. In some embodiments, a multi-part wristband is presented. A multi-part wristband may have a first band and a second band formed as part of the first band. A multi-part wristband may allow for a visual seamless wristband while incorporating a locking element into a band having one or more stimulators. In some embodiments, a second band may be overmolded onto a portion of a first band, which may cause the second band to become formed as part of the first band. Embodiments of manufacturing a wearable device are presented. For instance, a mold cavity may contain a portion of a wearable device and / or band, and a mold core may be shaped as a second band and / or contain a second band. A first band and a second band may be aligned through, but not limited to, alignment pins, magnets, vacuums, or other alignment methods. In some embodiments, flow guides and / or flow directors may be implemented in methods and devices described herein. Flow guides may aid in directing molding material throughout a surface of a band. A flow director may be designed to ensure molding material evenly coats two or more portions of a band.

[0018] In some embodiments, aspects of the present disclosure may allow for integration of molding material throughout hook and loop elements of a second band without compromising functionality of the hook and loop elements. For instance, molding material may be interwoven into hook and / or loop elements of a second band through a manufacturing process resulting in a unified band with hook and / or loop functionality.

[0019] Referring now to FIG. 1, an illustration of a wearable band 100 coupled to a wearable device is presented. Wearable band 100 (also referred to as “band 100”) may be rectangular, ovular, or other shapes. In some embodiments, band 100 may be relatively flat, such as with a thickness of less than about 1 inch. In other embodiments, band 100 may have a thickness of greater than about 1 inch. Band 100 may have a length of about, but not limited to, 8 inches to about 16 inches or greater. In some embodiments, band 100 may have edges that are rounded out or squared. For instance, ends of band 100 may be square, while a length of band 100 may have rounded edges which may help alleviate discomfort in a user in wearing band 100. Band 100 may be made out of materials such as, but not limited to, rubbers, plastics, thermoplastics, elastomers, or other materials. For instance and without limitation, band 100 may be made out of silicone. Band 100 may be flexible. A flexibility of band 100 may allow band 100 to bend, twist, or otherwise distort from a resting position. A resting position may be a position in which band 100 is laid out flat or slightly curved. From a laid out flat or slightly curved position, band 100 may bend and / or twist into a secondary position. For instance and without limitation, band 100 may have a flexibility that may allow it to wrap around a portion of a user, such as wrists, arms, legs, or other portions of a user, without limitation.

[0020] Band 100 may be a multi-part band, but may appear as a uniform, singular band. For instance, band 100 may include first band 104 and second band 116. First band 104 and second band 116 may form together to create band 100. First band 104 may have first proximal end 108 and first distal end 112. First proximal end 108 may be an end of first band 104 closest to wearable device 128 with respect to other portions of first band 104. In some embodiments, first proximal end 108 may be couplable to a side of wearable device 128. For instance, first proximal end 108 may be adhered to or coupled to a side of a housing of wearable device 128. In some embodiments, first proximal end 108 may have a curvature. For instance and without limitation, first proximal end 108 may be curved with respect to a longitudinal axis of band 100 at degrees of about, but not limited to, 0 degrees to about 45 degrees or greater. First distal end 112 may be a portion of first band 104 most distal to wearable device 128 with respect to other portions of first band 104. First distal end 112 may extend away from wearable device 128. First distal end 112 may extend away from wearable device 128 at lengths of about, but not limited to, 1 inch to about 8 inches or greater.

[0021] Second band 116 may have second proximal end 120 and second distal end 124. Second proximal end 120 may be a portion of second band 116 that may overlay a portion of first distal end 112. In some embodiments, a portion of second proximal end 120 may be formed as part of first distal end 112. For instance, second proximal end 120 may be an extension of first distal end 112 such that second band 116 and first band 104 form a continuous material without any separation. For instance, band 100 may be absent multiple layers, instead having a single layer of material forming both first band 104 and second band 116. In some embodiments, first band 104 and second band 116 may be chemically bonded such that there is no chemical difference between first band 104 and second band 116. In some embodiments, second band 116 may be formed as part of first band 104 to form a uniform band 100. For instance, band 100 may structurally be a single material extending distally from wearable device 128. In some embodiments, first band 104 and second band 116 may be structurally indistinguishable from each other when formed together. For instance, band 100 may have uniform material properties throughout its entire length, with no variation in tensile strength, flexibility, and / or chemical composition between portions that were originally first band 104 and portions that were originally second band 116. Uniform integration may result in band 100 having consistent mechanical properties along its longitudinal axis, such that no point along the band exhibits different stress-strain characteristics than any other point. In some embodiments, integration of second band 116 into first band 104 may create a monolithic structure where the boundary between the original components is eliminated at the molecular level, resulting in a single, continuous wristband structure. In some embodiments, a portion of second proximal end 120 may be positioned on top of a portion of first distal end 112 and / or first proximal end 108 and may be molded or wielded to the portion of first distal end 112 and / or first proximal end 108. In some embodiments, second proximal end 120 and first distal end 112 may be made out of a single manufacturing mold.

[0022] In some embodiments, second proximal end 120 may be formed as part of first distal end 112 through a manufacturing process. For instance, second proximal end 120 may be overmolded on top of first distal end 112 and / or a portion of first proximal end 108. “Overmolding” as used in this disclosure refers to a process of adding molding material over an existing substrate. First band 104 may act as an existing substrate, and one or more portions of second band 116 may be overmolded onto first band 104, which may create one uniform band. For instance, first band 104 may have no clear demarcation from first proximal end 108 to first distal end 112. An absence of any demarcation of first band 104 from second band 116 may allow for band 100 to appear seamless to someone viewing band 100. In some embodiments, first band 104 may be made of a first material such as, but not limited to, an elastomer, plastic, or other material. Second band 116 may be made out of a second material different than a first material that first band 104 may be made out of. A second material may include, but is not limited to, elastomers, plastics, or other materials. In some embodiments, a material of first band 104 and a material of second band 116 may be the same. In other embodiments, a material of first band 104 may differ from a material of second band 116. In embodiments where a material of first band 104 differs from a material of second band 116, band 100 may be a composite structure made out of two or more differing materials. In other embodiments, a single material may be utilized to manufacture band 100 such that band 100 may be made out of a single uniform material. A single uniform material may be, but is not limited to, plastic, rubber, elastomers, or other materials.

[0023] In some embodiments, overmolding of second band 116 onto first band 104 may create molded portion 150. Molded portion 150 may be made out of a same material used in overmolding second band 116 onto first band 104. Molded portion 150 may be a continuation of a molding material of second band 116. For instance, second band 116 may be formed as part of first band 104 via molded portion 150. Molded portion 150 may be an amount of molding material that may be combined into a top surface of first band 104. For instance, molded portion 150 may be a layer of molded material molded on top of a top surface of first band 104. In some embodiments, molded portion 150 may have a same thickness as second band 116, which may allow for a clean aesthetic appearance and enhanced structural integrity throughout band 100. For instance, second band 116, molded portion 150, and first band 104 may all be chemically bonded to each other.

[0024] Band 100 may be couplable to wearable device 128. A “wearable device” as used in this disclosure refers to any device capable of securing itself to a portion of a user. Wearable device 128 may be designed to secure around a portion of a user, such as but not limited to, a wrist, arm, leg, shoulder, or other part of a user. In some embodiments, wearable device 128 may include a power source, processing component, and / or memory in communication with the processing component. A processing component of wearable device 128 may be, but is not limited to, a microcontroller, microprocessor, System on Chip (SoC), or other processing component. A bottom of band 100, such as a bottom of first distal end 112 and / or first proximal end 108 may house one or more stimulators 136A-D. A “stimulator” as used in this disclosure refers to a device capable of producing a stimulation output. A “stimulation output” as used in this disclosure is any form of energy output that interacts with a biology of a user. In some embodiments, stimulators 136A-D may be vibratory transducers, electrodes, resistive heating elements, radiative heating elements, ultrasonic transducers, or other forms of energy outputting elements. In some embodiments, band 100 may have a single stimulator. In other embodiments, band 100 may have two or more stimulators. Wearable device 128 may be electrically connected to each of stimulators 136A-D. In some embodiments, wearable device 128 may be configured to command one or more of stimulators 136A-D to produce a stimulation output. Frequencies, pulse widths, power, and other parameters of a stimulation output may be adjusted by wearable device 128.

[0025] Second distal end 124 may include hooks 140. Hooks 140 may be a rounded end of second band 116 that may be designed to loop around a structure. In some embodiments, hooks 140 may be designed to loop around an object. For instance, hooks 140 may loop around connector 132 of wearable device 128. Connector 132 may be an extension of a housing of wearable device 128 that may have a slot or hole for hooks 140 to enter. Hooks 140 may enter connector 132 and may wrap around connector 132. In some embodiments, hooks 140 may be pulled through connector 132, which may shorten a length of band 100 that may wrap around a portion of a user. Hooks 140 may secure to locking element 144. Locking element 144 may be made out of loop fastening materials. For instance, hooks 140 may be made of a polyester, nylon, or other material and may be shaped as angled structures extending outwards from second band 116. Locking element 144 may be loops made out of, but not limited to, polyester, nylon, or other materials that may be shaped as ovular structures extending out of a surface of second band 116. Hooks 140 may be designed to engage one or more loops of locking element 144, which may couple second band 116 to itself. In some embodiments, hooks 140 may be magnetic and may magnetically attach to locking element 144, which may also be magnetic. A user may adjust a secureness of wearable device 128 to themselves through adjustment of band 100 via hooks 140 and / or locking element 144.

[0026] In some embodiments, molding material may be interwoven through one or more loops of locking element 144. Interweaving of molding material through locking element 144 may occur when a molding material in its liquid or semi-liquid state during a manufacturing process flows into and around the individual loop structures of locking element 144. Interweaving of molding material into loop structures of locking element 144 may include penetrating spaces between fibers, strands, or other structures of locking element 144 and becoming mechanically entangled within the structures of locking element 144. Molding material may cure and solidify throughout loops or other structures of locking element 144 while allowing for locking functionality of the loops or other structures of locking element 144. Interweaving of molding material through locking element 144 may allow for a seamless appearance of band 100 while retaining functionality of locking element 144.

[0027] Molding material may penetrate into one or more loop structures at a depth of about 10% to about 90% of a loop height of the one or more loop structures, which may create mechanical interlocking between a cured molding material and the loop structures. Mechanical interlocking of molding material and locking element 144 may result in a bond strength that is substantially higher than adhesive or stitching attachment methods, as the cured molding material may form a three-dimensional matrix within and around the loop structures. In some embodiments, locking element 144 may be pre-manufactured before second band 116 and first band 104 form a unified band 100. For instance, locking element 144 may have one or more loops that may retain their functionality after molding material becomes interweaved through the one or more loops using manufacturing processes described herein. Molding material interwoven through locking element 144 may allow for a substantially consistent tensile strength throughout band 100.

[0028] Second band 116 may retain an original visual element before a manufacturing process forming band 100. An original visual element may be, but is not limited to, a surface texture, a color, surface finish, dimensional characteristics, tactile properties, or any other attributes of an appearance of second band 116. For instance, surface texture may include smooth, textured, ribbed, or patterned finishes that remain visually and tactilely distinguishable after the manufacturing process. Color retention may include maintaining original hues, saturation levels, and color uniformity across the surface of second band 116. Dimensional characteristics may include maintaining original thickness, width, and contour profiles that preserve the intended ergonomic and aesthetic design. Surface finish properties may include maintaining original gloss levels, matte finishes, or specialized coatings that contribute to the visual and tactile experience. In some embodiments, at least second distal end 124 may appear substantially unmodified from an original state before second band 116 and first band 104 formed together, such that visually second band 116 may have no features indicating that second band 116 has undergone an overmolding process.

[0029] In some embodiments, band 100 may have sacrificial geometry 148. “Sacrificial geometry” as used in this disclosure refers to a structure designed to be incorporated into an object through a manufacturing process. Sacrificial geometry 148 may be made of, but is not limited to being made of, plastic, rubber, ceramics, or other materials. In some embodiments, sacrificial geometry 148 may be positioned on a portion of band 100 to align second band 116 with first band 104. For instance, sacrificial geometry 148 may be positioned at a point of first band 104 in which second band 116 is formed. Sacrificial geometry 148 may be designed to aid in aligning second band 116 with first band 104 during a manufacturing process and may be molded over with molding material. For instance, sacrificial geometry 148 may be alignment pins or other structures that may aid in aligning second band 116 with first band 104 during a manufacturing process and may be molded over to create a continuous band from second band 116 and first band 104.

[0030] Referring now to FIG. 2, a side view of first band 104 and second band 116 before an overmolding process is presented. A portion of second proximal end 120 of second band 116 may be overlaid onto a portion of first distal end 112 of first band 104. In some embodiments, second proximal end 120 may be overlaid on about 50% of a length of first band 104. In some embodiments, a portion of second proximal end 120 may be overlaid on about 50% to about 80% or greater of a length of first band 104. Second band 116 may be formed as part of first band 104 through any method described herein, without limitation. Second proximal end 120 may be positioned on first distal end 112 such that second band 116 and first band 104 are parallel to each other. In some embodiments, second band 116 may have a width smaller than that of first band 104. A difference in widths of second band 116 and first band 104 may be about, but is not limited to, 1 mm to about 10 mm or greater. A smaller width of second band 116 compared to first band 104 before an overmolding process may allow for more precise alignment of second band 116 overlaid on first band 104 compared to if both first band 104 and second band 116 had the same width. In some embodiments, first band 104 and second band 116 may have substantially the same width. In some embodiments, first band 104 may be placed within a mold cavity of a mold. A “mold cavity” as used in this disclosure refers to an opening within a mold. Second band 116 may be partially positioned on top of a top surface of first band 104 within a mold cavity. For instance and without limitation, a bottom surface of second proximal end 120 may be placed on a top surface of first distal end 112.

[0031] In some embodiments, molding material may be injected or otherwise directed into a mold cavity containing first band 104 and / or second band 116. “Molding material” as used in this disclosure refers to a substance that is capable of cooling into a solid structure from a liquid form. Molding material may include, but is not limited to, rubbers, elastomeric materials, silicone, metals, thermoplastics, or other materials. Molding material may be directed into a mold cavity containing first band 104 and second band 116. Molding material may substantially coat a portion of second band 116 and / or a portion of first band 104. “Substantially coat” as used in this disclosure refers to a process of surrounding a surface area of an object with a material by at least 90% of the surface area of the object. For instance and without limitation, molding material may substantially coat at least second proximal end 120 and first distal end 112. Coating of at least second proximal end 120 and first distal end 112 may allow for a chemical and / or mechanical bonding of second proximal end 120 to first distal end 112 via a hardening of a molding material. For instance and without limitation, a molding material may harden in time periods of about, but not limited to, 1 minute to about 1 hour or greater. In some embodiments, a molding material may harden in less than about 1 minute. In some embodiments, only a top surface of first distal end 112 and a bottom surface of second proximal end 120 are coated with a molding material, which may ensure that additional mechanical combinations to first band 104 and / or second band 116 may be carried out. For instance a bottom half of second proximal end 120 may be coated in a molding material along with a bottom half of first distal end 112, while a top half of second proximal end 120 and / or a bottom half of first distal end 112 remain uncoated.

[0032] First band 104 may be pre-manufactured. For instance, first band 104 may have already gone through a manufacturing process, such as a molding or other manufacturing process. First band 104 may be coupled to wearable device 128 at first proximate end 108 before addition of second band 116. In some embodiments, first band 104 may house one or more of stimulators 136A-D before addition of second band 116. In some embodiments, second band 116 may be pre-manufactured. For instance, second band 116 may have gone through a manufacturing process, such as a molding or other manufacturing process. Second band 116 may have hooks 140 and / or locking element 144 before being formed as part of first band 104. Second band 116, which may be a pre-existing structure, may be formed as part of first band 104, which may also be a pre-existing structure.

[0033] Still referring to FIG. 2, in some embodiments, overmolding of second band 116 onto first band 104 may include adding molding material to parts of first band 104 overlaid by second band 116 and parts of first band 104 uncovered by second band 116. A combination of coating of molding material on parts of first band 104 covered and uncovered by second band 116 may allow for a uniform thickness of a combined band formed by combining second band 116 and first band 104 together. For instance, molding material may coat an entire top surface of first band 104. In some embodiments, more molding material may be added to portions of first band 104 uncovered by second band 116 compared to portions of first band 104 covered by second band 116, which may ensure a uniform thickness of a combined band formed by first band 104 and second band 116. In some embodiments, a molding material that may be used to overmold second band 116 onto first band 104 may be a same material that either or both of second band 116 and first band 104 are composed of. For instance and without limitation, a molding material may be a thermoplastic, and both first band 104 and second band 116 may be made out of a thermoplastic. In some embodiments, a molding material may be made out of a different material than either or both of first band 104 and second band 116. For instance, a molding material may be a material having a higher durability than a material of either or both of first band 104 and second band 116, which may allow for increased durability of a wristband formed from first band 104 and second band 116. As a non-limiting example, molding material may include polyetheretherketon (PEEK), while a material of first band 104 and / or second band 116 may be silicone. A band formed from a partial combination of first band 104 and second band 116 may have a consistent tensile strength along a longitudinal axis of itself such that no one point along a longitudinal axis of the band has a higher or lower tensile strength than another point along the longitudinal axis of the band. In some embodiments, a tensile strength at a location of a material integration of second band 116 into first band 104 may be higher than any other part of a band formed from first band 104 and second band 116. Tensile strengths of a band formed from a partial combination of first band 104 and second band 116 may range anywhere from about, but not limited to, 50 MPa to about 250 MPa or greater. For instance, tensile strengths of a band formed from a partial combination of first band 104 and second band 116 may have a greater strength and / or durability compared to stitching or adhesive attachment methods due to a molding material interweaving through second band 116 and first band 104.

[0034] Referring now to FIGS. 3A-D, an embodiment of manufacturing a wristband is presented. Referring to FIG. 3A, second band 116 may be aligned with first band 104. Second band 116 may include alignment holes 304. In some embodiments, a single alignment hole 304 is used. In other embodiments, two or more alignment holes 304 may be used. Alignment holes 304 may be positioned at a most proximal end of second proximal end 120. In some embodiments, alignment holes 304 may each be positioned a same distance away from an edge of second band 116. In some embodiments, alignment holes 304 may be positioned over sacrificial geometry 308 of first band 104. Sacrificial geometry 308 may be buttons, pins, or other structures that may protrude upwards from a top surface of first band 104. In some embodiments, sacrificial geometry 308 may be positioned at about a half length of first band 104, which may ensure second band 116 bonds to first band 104 at the about half length. In some embodiments, sacrificial geometry 308 may be positioned closer to first distal end 112 than to first proximal end 108. Sacrificial geometry 308 may be placed at about, but not limited to, 0% a length of first band 104 with respect to a distalmost end of first distal end 112 to about 80% or greater of a length of first band 104 with respect to a distalmost end of first distal end 112.

[0035] Referring now to FIG. 3B, alignment holes 304 may be placed on top of sacrificial geometry 308. Sacrificial geometry 308 may be as depicted above with reference to FIG. 3A. Sacrificial geometry 308 may be inserted into alignment holes 304. An insertion of sacrificial geometry 308 into alignment holes 304 may cause second band 116 to be temporarily coupled to first band 104. For instance, second band 116 may be removable from first band 104 via lifting of second band 116 off of sacrificial geometry 308. In some embodiments, insertion of sacrificial geometry 308 into alignment holes 304 may cause second band 116 to become aligned along a longitudinal axis of first band 104. For instance, insertion of sacrificial geometry 308 into alignment holes 304 may cause second band 116 to be oriented parallel to first band 104. In some embodiments, sacrificial geometry 308 may be sized to not extend past a top surface of second band 116 when inserted into alignment holes 304. For instance and without limitation, insertion of sacrificial geometry 308 into alignment holes 304 may cause second band 116 to become temporarily coupled to first band 104 while second band 116 has a flush top surface.

[0036] Referring now to FIG. 3C, a depiction of second band 116 overmolded to first band 104 is presented. Molding material may substantially coat a top surface of second proximal end 120 and a top surface of first distal end 112, which may cause second proximal end 120 to become formed as part of first distal end 112 of first band 104. In some embodiments, mold material may be added to parts of first band 104 uncovered by second band 116, which may allow for a uniform thickness of a final manufactured band formed by first band 104 and second band 116. In some embodiments, additional molding material may be added to portions of first band 104 uncovered by second band 116 which may account for a difference in thickness of first distal end 112 caused by incorporation of a thickness of second proximal end 120. A difference in thickness may be applied to portions of first band 104 uncovered by second band 116 to ensure a uniform thickness of a final manufactured band. For instance, molding material may cover a portion of first band 104 to form molded portion 150. Molded portion 150 may be made out of a same material as that of first band 104 and / or second band 116. In some embodiments, molded portion 150 may have a same thickness as that of second band 116, which may allow for a uniform aesthetic appearance.

[0037] Referring now to FIG. 3D, another embodiment of manufacturing a wristband is presented. A mold used to overmold second band 116 to first band 104 may include sacrificial geometry 308D. Sacrificial geometry 308D may be positioned at or coupled with first distal end 112. In some embodiments, sacrificial geometry 308D may have one or more prongs. For instance, sacrificial geometry 308D may have prongs that may extend upwards from a top surface of first band 104. Prongs of sacrificial geometry 308D may be inserted into one or more alignment holes of second band 116. For instance, second band 116 may have one or more alignment holes near second proximate end 120. Second band 116 may be placed on top of sacrificial geometry 308D, which may allow second band 116 to become aligned with first band 104. For instance, a center width of second band 116 may be aligned with a center width of first band 104. Second band 116 may be aligned parallel to first band 104. Molding material may be applied to areas of first band 104 coupled to second band 116 and areas of first band 104 uncoupled to second band 116. Molding material matching a thickness of sacrificial geometry 308D and / or a thickness of second band 116 may be applied to uncovered portions of first band 104, which may allow for a uniform thickness of a manufactured band formed through overmolding of second band 116 to first band 104. Sacrificial geometry 308D may become embedded into a new band formed through application of molding material to first band 104 and second band 116.

[0038] Referring now to FIG. 4, a side view illustration of mold 400 with alignment pins is presented. Mold 400 may have a mold cavity. A mold cavity of mold 400 may be shaped as a positive mold of a first band and / or a second band. A “positive mold” as used in this disclosure refers to a mold having a concavity in which mold material may be placed. For instance, mold 400 may be a positive mold that has a mold cavity such that when molding material is placed inside the mold cavity, a positive mold of the first band and / or second band is manufactured. In some embodiments, mold 400 may be a negative mold. A “negative mold” as used in this disclosure refers to an inverse of a positive mold. For instance, a negative mold may be a mold cavity that may be a negative of a first band and / or a second band such that when molding material is placed inside the mold cavity an outline of the first band and / or second band is produced.

[0039] In some embodiments, mold 400 may include top portion 404 and bottom portion 408. Top portion 404 may have a mold cavity shaped as a first band and / or second band. In some embodiments, top portion 404 may have a mold cavity shaped as a top half of a first band and / or a second band. Bottom portion 408 may have a mold core shaped as a first band and / or a second band. In some embodiments, bottom portion 408 may have a mold core shaped as a bottom half of a first band and / or a second band. In some embodiments, top portion 404 has a mold cavity while bottom portion 408 has no mold cavity or vice versa. In some embodiments, top portion 404 may have one or more alignment pins 412A-E. Alignment pins 412A-E may be evenly spaced apart across top portion 404. In other embodiments, a spacing between two or more alignment pins 412A-E may differ. Alignment pins 412A-E may be inserted into top portion 404. In some embodiments, top portion 404 has one or more premade holes within its structure that may allow alignment pins 412A-E to insert into top portion 404. In other embodiments, alignment pins 412A-E may pierce through top portion 404. Each alignment pin of alignment pins 412A-E may be positioned across top portion 404 to secure placement of a first band and / or a second band during an overmolding process. For instance, each alignment pin of alignment pins 412A-E may be placed around a perimeter of a first band and / or a second band. Alignment pins 412A-E may be inserted into bottom portion 408, which may couple top portion 404 to bottom portion 408. Alignment pins 412A-E may be removable. For instance and without limitation, after a molding process incorporating top portion 404 and / or bottom portion 408, each alignment pin of alignment pins 412A-E may be removed from top portion 404 and / or bottom portion 408, leaving a manufactured band.

[0040] Top portion 404 and / or bottom portion 408 may have one or more degrees of freedom. A “degree of freedom” as used in this disclosure refers to an independent way in which an object can move in space. For instance, top portion 404 and / or bottom portion 408 may have 3 translational degrees of freedom, such as along X, Y, and / or Z axes, and / or 3 rotational degrees of freedom, such as about X, Y, and / or Z axes. Placement of one or more alignment pins 412A-E into top portion 404 and bottom portion 408 may remove a degree of freedom of either or both of top portion 404 and bottom portion 408. For instance, insertion of one or more alignment pins 412A-E may restrict movement of top portion 404 and / or bottom portion 408 along and / or about X, Y, and / or Z axes. As a non-limiting example, a single alignment pin of alignment pins 412A-E may remove lateral movement in two directions, such as X and / or Y axes. A subsequent alignment pin inserted into both of top portion 404 and bottom portion 408 may prevent rotation of top portion 404 and / or bottom portion 408. In some embodiments, alignment pins 412A-E may be inserted along a perimeter of top portion 404, such as along lengths and / or widths of top portion 404. In some embodiments, alignment pins 412A-E may be inserted along a point of a longitudinal axis of top portion 404.

[0041] Referring now to FIG. 5, another embodiment of a mold 500 is presented. Mold 500 may have one or more vacuum ports 504A-E. Vacuum ports 504A-E may pull fluid into vacuum cavity 512. In some embodiments, vacuum ports 504A-E may cause a pressure differential between an inside of top portion 516 of mold 500 and vacuum cavity 512. A pressure differential of vacuum cavity 512 may be about 0 PSI to about -20 PSI. A pressure differential may aid in securing a second band to a first band. For instance, a pressure differential of vacuum cavity 512 may cause a second band to secure to a first band, which may ensure alignment of the second band overlaid on the first band. In some embodiments, a vacuum created in mold 500 may pull a second band onto a first band in a direction towards bottom portion 520. In other embodiments, a vacuum created in mold 500 may pull a second band onto a first band in a direction towards top portion 516. Vacuum port 508 may be fluidically coupled to a vacuum source, such a vacuum, air pump, or other vacuum source. A vacuum source coupled to vacuum port 508 may cause fluid to enter one or more of vacuum ports 504A-E. Fluid may be air, in some embodiments. Fluid entering vacuum ports 504A-E may cause a pressure differential within vacuum cavity 512, which may cause securement of a second band to a first band. Molding material may be injected between top portion 516 and bottom portion 520, and may experience a pressure differential via one or more of vacuum ports 504A-E. Molding material may be uniformly distributed across a first band and / or a second band due to a pressure differential in vacuum cavity 512, which may ensure a uniform bonding of the second band to the first band. Vacuum portions 504A-E may be used in conjunction with alignment pins 412A-E described above with reference to FIG. 4, without limitation.

[0042] Referring now to FIG. 6, an embodiment of a mold 600 that may be used to manufacture devices described herein is presented. Mold 600 may have top portion 604 and bottom portion 608. In some embodiments, top portion 604 may have a mold cavity and bottom portion 608 may be a mold core, or vice versa.

[0043] Top portion 604 may have one or more magnets 612A-D. Magnets 612A-D may be permanent magnets. For instance and without limitation, magnets 612A-D may be neodymium magnets, samarium cobalt magnets, or other types of magnets. In some embodiments, each of magnets 612A-D may be of a same magnet type. In other embodiments, one or more magnets of magnets 612A-D may differ in magnet type than one or more other magnets of magnets 612A-D. In some embodiments, each magnet of magnets 612A-D may be spaced equidistant from each other. For instance, a space between adjacent magnets of magnets 612A-D may be about, but is not limited to, 0.1 inch to about 5 inches or greater. In some embodiments, a spacing between two magnets 612A-D may differ from a spacing between one of the two magnets 612A-D and one other magnet of magnets. In some embodiments, each magnet of magnets 612A-D may be embedded into top portion 604. For instance, each magnet of magnets 612A-D may be embedded into a material of top portion 604. In some embodiments, magnets 612A-D may be removably placed into slots or other openings within top portion 604 that may accommodate housing of magnets 612A-D. In some embodiments, magnets 612A-D may be positioned proximate a bottom surface of top portion 604. For instance, magnets 612A-D may be positioned at a bottommost part of top portion 604. In some embodiments, magnets 612A-D may be positioned within top portion 604 such that magnets 612A-D outline a geometry of a wristband. For instance, each magnet of magnets 612A-D may be positioned at a key geometric shape of a wristband. Key geometric shapes may include, but are not limited to, edges of a first band, edges of a second band, locations of overlap between a first band and a second band, outlines of wearable devices, or other key geometric shapes. Positioning of one or more of magnets 612A-D at one or more key geometric shapes of an outline of a wristband may provide stronger securement at the one or more key geometric shapes compared to non-key geometric shapes. In other embodiments, magnets 612A-D may be evenly spaced across a bottom portion of top portion 604 such that a magnetic pull to bottom portion 608 may be substantially equal across top portion 604.

[0044] Referring still to FIG. 6, bottom portion 608 may include one or more magnets 612 E-H. In some embodiments, magnets 612E-H may be made of a same magnet type as that of magnets 612A-D. In other embodiments, magnets 612E-H may differ in magnet type than that of magnets 612A-D. In some embodiments, magnets 612E-H may be configured to magnetically attract one or more stimulators positioned within a first band during a manufacturing process. For instance, stimulators may include magnetic components that may be attracted to magnets 612E-H, which may aid in securing a first band in a desired position within bottom portion 608. Magnetic attraction between magnets 612E-H and stimulators may provide additional alignment stability during overmolding processes. This magnetic attraction may ensure that stimulators remain properly positioned relative to bottom portion 608 throughout a molding process. Magnets 612E-H may be positioned equidistant across a top surface of bottom portion 608. For instance, spacing between adjacent magnets of magnets 612E-H may be about, but is not limited to, 0.1 inches to about 5 inches or greater. In other embodiments, spacing between magnets of magnets 612E-H may differ. For instance, a spacing between a first magnet and a second magnet of magnets 612E-H may differ from a spacing between the second magnet and a third magnet of magnets 612E-H. In some embodiments, magnets 612E-H may be embedded into bottom portion 608. For instance, magnets 612E-H may be positioned within a material of bottom portion 608. In other embodiments, magnets 612E-H may be positioned in slots or other openings within bottom portion 608 that may facilitate housing of magnets 612E-H. Magnets 612E-H may be positioned proximate a top surface of bottom portion 608. For instance, magnets 612E-H may be positioned at a topmost portion of bottom portion 608.

[0045] Referring now to FIG. 7, an embodiment of a wristband 700 is presented. Wristband 700 may have proximal end 704 and distal end 708. Proximal end 704 may be an end of wristband 700 closest to casing 712. Distal end 708 of wristband 700 may be an end of wristband 700 farthest away from casing 712. Wristband 700 may be first band 104 and second band 116 described above with reference to FIGS. 1-2, without limitation.

[0046] Wristband 700 may include flow guides 716A and 716B. A “flow guide” as used in this disclosure refers to a structure capable of defining a fluidic pathway. In some embodiments, flow guides 716A and 716B may be sacrificial geometry. Flow guide 716A and / or 716B may be rectangular or ovular structures that may extend from distal end 708 towards proximal end 704. Flow guide 716A and / or 716B may provide support for placement of a second band. For instance, flow guide 716A and / or 716B may act as sacrificial geometry, such as shown above with reference to FIG. 3D. Flow guide 716A may be positioned opposite flow guide 716B. An area between flow guide 716A and flow guide 716B may encompass one or more portions of wristband 700. For instance, an area between flow guide 716A and flow guide 716B may encompass portions of distal end 708. A spacing between flow guide 716A and flow guide 716B may be about, but is not limited to, 0.1 inches to about 5 inches or greater. In some embodiments, flow guide 716A may be positioned substantially parallel relative to flow guide 716B. For instance both flow guide 716A and flow guide 716B may be aligned with a longitudinal axis of wristband 700. In other embodiments, either or both of flow guide 716A and flow guide 716B may be non-parallel with a longitudinal axis of wristband 700. For instance and without limitation, ends of flow guide 716A and flow guide 716B may be oriented towards each other in a “V” shape. In some embodiments, flow guides 716A, 716B may be linear. In other embodiments, flow guides 716A, 716B may be non-linear. For instance, flow guides 716A, 716B may be curved or twisted. In some embodiments, flow guide 716A and / or flow guide 716B may be serpentine shaped. A serpentine shape of flow guide 716A and flow guide 716B may form a serpentine fluidic pathway between flow guide 716A and flow guide 716B. In some embodiments, flow guides 716A, 716B may be curved and may form an hourglass shaped fluidic channel between them. One of ordinary skill in the art, upon reading this disclosure, will understand the various shapes and forms flow guides 716A and 716B may take.

[0047] Wristband 700 may have flow director 720. A “flow director” as used in this disclosure refers to an object designed to guide a flow of fluid around and / or through itself. Flow director 720 may guide molding material across wristband 700. Flow director 720 may be made of plastic, rubber, or other materials. In some embodiments, flow director 720 may be positioned between distal end 708 and proximal end 704. In some embodiments, flow director 720 may be positioned at a half-length of wristband 700. Flow director 720 may be designed to contact molding material. For instance, flow director 720 may contact molding material and may direct the molding material to one or more portions of wristband 700. Flow director 720 may have first side 732A and second side 732B. First side 732A may mirror second side 732B across a longitudinal axis of wristband 700. First side 732A may be square, circular, or other shapes. Second side 732B may be square, circular, or other shapes. In some embodiments, first side 732A and second side 732B are shaped similarly. In other embodiments, first side 732A may have a shape that differs from a shape of second side 732B. In some embodiments, flow director 720 is symmetrical across a longitudinal axis of wristband 700. A symmetry of flow director 720 across a longitudinal axis of wristband 700 may aid in directing molding material throughout wristband 700.

[0048] In some embodiments, first side 732A may be connected to flow guide 716A and second side 732B may be connected to flow guide 716B. A connection of sides 732A,B, and flow guides 716A,B, may form an overmolding area inside a perimeter of sides 732A,B, and flow guides 716A,B. An overmolding area may be a portion of wristband 700 in which overmolding may occur. For instance, an area of wristband 700 inside a perimeter of flow guides 716A,B, and flow director 720 may be designed for overmolding of a second band onto wristband 700. Molding material may flow onto a top surface of distal end 708 and may be guided by flow guides 716A,B, towards flow director 720. For instance, molding material may contact flow guide 716A and / or 716B and may be directed along a portion of wristband 700 within an area formed by a spacing between flow guide 716A and 716B towards flow director 720. In some embodiments, flow director 720 may be a solid or hollow structure with no openings. Molding material may flow towards flow director 720 and may contact flow director 720. A contacting of molding material with flow director 720 may direct molding material into an area formed by flow director 720 and flow guides 716A,B. In some embodiments, flow director 720 may prevent flow of molding material past itself. For instance, molding material may contact flow director 720 and may be stopped by a contacting of flow director 720 from traveling along a point of wristband 700 more proximate to proximal end 704 than a position of flow director 720 on wristband 700.

[0049] In some embodiments, flow director 720 has an opening. An opening of flow director 720 may be positioned at a center point between first side 732A and second side 732B. An opening of flow director 720 may be circular, ovular, or other shapes. An opening of flow director 720 may have a radius of about, but not limited to, 0.1 inches to about 0.5 inches or greater. An opening of flow director 720 may allow for a channeling of mold material from distal end 708 towards proximal end 704.

[0050] Still referring to FIG. 7, in some embodiments, flow director 720 may be a separate structure from flow guide 716A and / or 716B. For instance, flow guides 716A,B, may terminate before reaching sides 732A,B, of flow director 720. A spacing between ends of flow guides 716A,B, and sides 732A,B, may allow for a fluidic channel to form. For instance, molding material may pass between flow guides 716A,B, and may exit through a spacing between each of flow guide 716A and side 732A and flow guide 716B and side 732B. In some embodiments, a molding material may enter through a spacing between flow guide 716A and side 732A. Exiting or entering through a spacing between flow guides 716A,B and sides 732A,B, may cause molding material to flow around flow director 720. A flowing of molding material around flow director 720 may allow the molding material to flow towards proximal end 704 of wristband 700. Sides 732A,B, may be curved, which may cause a curvature in a flow of molding material around flow director 720. A curvature of a flow of molding material around flow director 720 may allow for even distribution of the molding material from distal end 708 towards proximal end 704. In some embodiments, flowing of molding material around flow director 720 may help regulate a volume of the molding material throughout wristband 700. A spacing between flow guide 716A and side 732A may be about, but is not limited to, 0.1 inches to about 3 inches or greater. A spacing between flow guide 716B and side 732B may be about, but is not limited to, 0.1 inches to about 3 inches or greater. In some embodiments, spacing between flow guide 716A and side 732A may be the same value as a spacing between flow guide 716B and side 732B. In other embodiments, a difference in spacing between flow guide 716A and side 732A and flow guide 716B and side 732B may differ. Pressure of molding material flowing through gaps of flow guide 716A,B, and sides 732A,B, may be about, but are not limited to, 1PSI to about 10PSI or greater. In some embodiments, molding material may be substantially evenly distributed across a top surface of wristband 700. Controlling of volumes and directions of a flow of molding material via flow guides 716A,B, and / or flow director 720 may allow for a uniform, aesthetic appearance of an over molded wristband. For instance, a wristband over molded using flow guides 716A,B, and / or flow director 720 may have no clear demarcation across it’s surface with respect to a second band molded onto wristband 700.

[0051] In some embodiments, molding material may be channeled onto wristband 700 between stimulator 724C and stimulator 724D. Molding material may flow towards casing 712 and towards distal end 708, covering band 700. Molding material may contact flow director 720 in a direction from stimulator 724C towards stimulator 724B. Molding material may flow around first side 732A and second side 732B of flow director 720. In some embodiments, an equal amount of molding material may be separated into guides created by first side 732A and second side 732B. For instance, an equal mass of molding material and / or an equal rate of flow of molding material may be present on flow channels created by first side 732A and second side 732B, which may allow for a uniform distribution of molding material across distal end 708. A flow of molding material may flow around first side 732A and may contact guide 716A. A contacting of guide 716A may cause molding material to enter towards a center of distal end 708. A flow of molding material may in parallel flow around second side 732B and may contact guide 716B. A contacting of guide 716B may cause molding material to flow towards a center of distal end 708. Molding material may flow into a center of distal end 708 from guide 716A and 716B at a same time, which may allow for even distribution across distal end 708 of molding material.

[0052] Referring now to FIG. 8, an embodiment of a mold core 804 and a mold cavity 808 is presented. A “mold core” as used in this disclosure refers to a positive of a mold. Mold core 804 may have one or more features that may be convex. Features of mold core 804 may include, but are not limited to, outlines of a second band, outlines of a first band, outlines of a wearable device, or other features. Mold cavity 808 may have one or more concave features, such as, but not limited to, an outline of a wearable device and / or one or more bands. For instance, mold core 804 may be shaped as a wearable device and a first band, and mold cavity 808 may be shaped as a second band positioned to overmold the second band onto a portion of the first band. Mold core 804 may be couplable to mold cavity 808. For instance, one or more surfaces or other features of mold core 804 may be inserted into mold cavity 808. In some embodiments, a casing 816 of a wearable device and / or a first band may be positioned between mold core 804 and mold cavity 808. For instance, a casing of a wearable device may be coupled to a first band and may be positioned between mold core 804 and mold cavity 808. A second band may be positioned on top of a first band between mold core 804 and mold cavity 808. In some embodiments, mold cavity 808 and / or mold core 804 may utilize size insert 812. A “size insert” as used in this disclosure refers to an object insertable into a section of a mold that sets forth dimensions of part of the mold. For instance, an amount of molding material may be contained within size insert 812, which may dictate dimensions of a mold. Size insert 812 may be, but is not limited to, rectangular, square, circular, or any other shape. In some embodiments, various size inserts 812 may be used depending on a targeted band size. For instance, a large size insert 812 may be used for a large band size. A large size insert 812 may be about 5 inches or greater in length and about 1 inch or greater in width. A medium size insert 812 may be used for a medium band size. A medium size insert may be less than about 5 inches in length and less than about 1 inch in width. A small size insert 812 may be used for a small band size. A small size insert 812 may be less than about 3 inches in length and less than about 0.5 inches in width. Any dimensions of a size insert 812 may be used, without limitation. In some embodiments, size insert 812 may dictate dimensions of a second band. For instance, a length, width, and / or thickness of a second band may correlate with a length, width, and / or thickness of size insert 812. Size insert 812 may be positioned within mold core 804. In some embodiments, size insert 812 may be positioned between mold core 804 and mold cavity 808.

[0053] Referring now to FIGS. 9A-B, embodiments of a mold cavity and a mold core are presented. Referring now to FIG. 9A, a cavity-side view of a mold is presented. A mold may include cavity 908 which may be as described above with reference to FIG. 8. Cavity 908 may hold casing 916 of a wearable device. For instance in some embodiments, casing 916 and / or a flexible printed circuit board (PCB) of a first band may be inserted into cavity 908. A first band may come in contact with molding material to create molded portion 920. Casing 916 may be coupled to molded portion 920. Molded portion 920 may be a first band that has been overmolded with a molding material. For instance, a first band may be coupled to casing 916 and molding material may contact a surface of the first band. In some embodiments, molding material may be elastomeric. Contacting of molding material with a surface of a first band may create an overmold of the first band. For instance, molded portion 920 may be an overmold of a first band. Molded portion 920 may lay linearly within cavity 908. For instance, molded portion 920 may extend along a longitudinal axis of cavity 908. In some embodiments, mold cavity 908 may have angled structure 932. Angled structure 932 may be a part of cavity 908 that may be vertically rotated relative to a longitudinal axis of cavity 908. For instance, angled structure 932 may curve upwards relative to a bottom of cavity 908 at angles of about, but not limited to, 0 degrees to about 45 degrees or greater. Angled structure 932 may allow for curving of parts of proximal end 936 with respect to casing 916.

[0054] In some embodiments, molded portion 920 may have one or more stimulators 924A-D. Stimulators 924A-D may be coupled to a flexible printed circuit board (PCB). For instance, a flexible PCB may be inserted in cavity 908 and may be coupled to one or more stimulators 924A-D. In other embodiments, stimulators 924A-D may be added to molded portion 920 after manufacturing of a second band onto molded portion 920. Cavity 908 may have size insert 912. Size insert 912 may surround a perimeter of molded portion 920. For instance, size insert 912 may overlap with a width and / or length of molded portion 920. Differences in overlap of size insert 912 with a perimeter of molded portion 920 may correspond to band sizes. For instance, a greater difference in overlap between size insert 912 and molded portion 920 may correspond to a larger band size than a smaller difference in overlap between size insert 912 and molded portion 920. In some embodiments, size insert 912 extends along molded portion 920 until angled surface 932. For instance, size insert 912 may not extend past angled surface 932 to proximal end 936 of molded portion 920. Proximal end 936 of molded portion 920 may be curved in some embodiments. For instance, proximal end 936 may follow a curvature of angled surface 932. In some embodiments, proximal end 936 may couple molded portion 920 to casing 916. Size insert 912 may overlap molded portion 920 except for proximal end 936. Omission of size insert 912 on proximal end 936 may prevent overmolding to occur on proximal end 936. In other embodiments, overmolding occurs on molded portion 920 including proximal end 936. In some embodiments, a second band may be overmolded onto a length of molded portion 920 except for a portion of molded portion 920 coupling molded portion 920 to casing 916.

[0055] Cavity 908 may include mold material dispenser 950. Mold material dispenser 950 may be a cylindrical object that may provide molding material to mold cavity 908. For instance, molding material may flow through mold material dispenser 950 and out of arm 940. In some embodiments, arm 940 may be positioned between stimulators 924D and 924C, which may cause molding material to flow initially onto a space of molded portion 920 between stimulators 924D and 924C. Flow rates of molding material may include, but are not limited to, about 1 ml / min to about 100 ml / min or greater. Pressures of any mold described herein may be between, but is not limited to, about 4,000 PSI to about 5,000 PSI or greater. Temperatures of any mold described herein may reach between about, but not limited to, 350 degrees Fahrenheit to about 500 degrees Fahrenheit.

[0056] Referring now to FIG. 9B, a core-side view of a mold is presented. Mold core 904 may include molded portion 920, casing 916, stimulators 924A-D, size insert 912, mold material dispenser 950, and / or arm 940, each of which may be as described above with reference to FIG. 9A. Mold core 904 may include one or more components that may fit into a cavity, such as cavity 908 described above with reference to FIG. 9A.

[0057] In some embodiments, molded portion 920 may include flow guides 920A and 920B. Flow guides 920A and 920B may be the same as flow guides 716A and 716B described above with reference to FIG. 7. In some embodiments, molded portion 920 may include flow director 955. Flow director 955 may be the same as flow director 720 described above with reference to FIG. 7.

[0058] Mold core 904 may include one or more hole pins 932A-I. A “hole pin” as used in this disclosure refers to a cylindrical object designed to make an aperture in another object. For instance, hole pins 932A-I may be inserted through molded portion 920 such that removal of hole pins 932A-I leaves a hole in molded portion 920. In some embodiments, each hole pin 932A-I may have a same radius. In other embodiments, at least two hole pins 932A-I may have differing radii. Radii of hole pins 932 may include ranges of about, but not limited to, 0.1 inches to about 0.2 inches or greater. Mold core 904 may include hole pin 932A. Hole pin 932A may be positioned at halfway point between first stimulator 924A and second stimulator 924B. Hole pin 932A may be inserted through molded portion 920. Hole pin 932B may be positioned at a halfway point between stimulator 924B and stimulator 924C. Hole pin 932C may be positioned at a halfway point between stimulator 924C and stimulator 924D. Mold core 904 may include arrangements of hole pins. For instance, mold core 904 may include arrangements of two or more hole pins. In some embodiments, arrangements of two or more hole pin may include a linear arrangement in which two or more hole pins are aligned on a same axis. In other embodiments, arrangements of two or more hole pins may include non-linear arrangements, in which a first hole pin may be non-linearly aligned with a second hole pin with respect to an axis such as a horizontal axis of mold core 904. For instance, mold core 904 may include hole pins 932D-F, which may be an arrangement of three hole pins in a non-linear manner. Hole pin 932D may be positioned at a first side of molded portion 920 while hole pin 932F may be positioned at a second side of molded portion 920 opposite the first side where hole pin 932D may be positioned. Hole pin932E may be positioned between hole pins 932D and 932F in a non-linear manner. For instance, hole pin 932E may be offset from a horizontal axis aligning hole pins 932D and 932F. Hole pin 932E may be positioned through a flexible PCB portion of molded portion 920. In some embodiments, mold core 904 may include hole pins 932G-I. Hole pins 932G-I may be arranged linearly. For instance, each of hole pins 932G-I may be aligned with a horizontal axis of mold core 904. In some embodiments, each of hole pins 932G-I may be evenly spaced apart from each other. In other embodiments, hole pins 932G-I may be unevenly spaced apart. Hole pins 932G-I may be inserted into a flexible PCB portion of molded portion 920. Hole pins 932D-F may be positioned between stimulator 924D and casing 916. In some embodiments, mold core 904 may be used to create a wearable device with a first band. For instance, mold core 904 may be used in an injection molding or other molding process that may create a wearable device with a first band. In some embodiments, casing 916 and / or a flexible PCB may be inserted into cavity 908 and may be molded, such as through injection molding, overmolding, or other molding processes. An output of using mold core 904 and / or mold cavity 908 described with reference to FIGS. 9A-B may be a casing of a wearable device coupled to a first band and a second band formed as part of the first band, such as described above with reference to FIGS. 1-2.

[0059] Referring now to FIGS. 10A-B, an embodiment of a mold core and mold cavity is presented. Referring now to FIG. 10A, mold cavity 1008 coupled with mold core 1004 is presented. Mold cavity1008 and mold core 1004 may be used in creating a finished mold having both a wearable device, first band, and second band overmolded onto the first band, such as described above with reference to FIGS. 1-2, without limitation. For instance, a casing of a wearable device and / or first band that may have been manufactured through molds described above with reference to FIGS. 9A-B may be inserted into one or more portions of mold cavity 1008 and / or mold core 1004. Mold cavity 1008 may house a wearable device and / or first band coupled to the wearable device. For instance, mold cavity 1008 may house a wearable device and / or first band manufactured through a manufacturing process using mold core 904 and mold cavity 908 described above with reference to FIGS. 9A-B. Mold cavity 1008 may include size insert 1012. Size insert 1012 may be used to determine a length, width, and / or thickness of a second band overmolded onto a first band. Mold cavity 1008 may include one or more alignment pins 1016, which may aid in aligning a second band with a first band.

[0060] Referring now to FIG. 10B, a cavity-side view of a mold cavity 1008 is presented. Mold cavity 1008 may house casing 1020 and / or first band 1025. Casing 1020 and / or first band 1025 may have been manufactured through mold core 904 and mold cavity 908 described above with reference to FIGS. 9A-B. First band 1025 may have stimulators 1040A-D. In some embodiments, first band 1025 may be positioned near mold material dispenser 1032, which may have arm 1036. Molding material may flow out of arm 1036 and into mold cavity 1008. In some embodiments, first band 1025 may include stimulators 1040A-D. Second band 1028 may be positioned on top of a top surface of first band 1025. Second band 1028 may be held in place with alignment pin 1016.

[0061] Referring now to FIG. 11, a method 1100 of manufacturing a wristband for wearable devices is presented. At step 1105, method 1100 includes positioning a second proximal end of a second band onto a top surface of a first distal end of a first band. Positioning of a second band onto a first band may be carried out manually or by robotic systems. In some embodiments, positioning of a second band onto a first band may include aligning the second band onto the first band. Alignment may include utilization of one or more alignment pins of a mold. In some embodiments, alignment may include utilization of a vacuum source which may pull fluid out of a mold cavity. A vacuum source may create a pressure differential within a mold cavity, which may cause a second band to press against a first band. In some embodiments, alignment may occur through two or more magnets. For instance, magnets of a first polarity may be distributed across a top portion of a mold, while magnets of a second polarity may be distributed across a bottom portion of a mold.. In some embodiments, sacrificial geometry may be positioned on a first band. Sacrificial geometry may couple to one or more portions of a second band, which may help align the second band to a first band.

[0062] At step 1110, method 1100 includes injecting a molding material into a mold cavity. A molding material may include, but is not limited to, elastomers, thermoplastics, silicone, or other molding materials described herein. In some embodiments, a first band may have one or more flow guides and / or flow directors. Flow guides and / or flow directors of a first band may direct molding material across a top surface of a second band and / or first band, which may allow for a uniform distribution of molding material.

[0063] At step 1115, method 1100 includes allowing a molding material to cure. A molding material may cure after a period of time of anywhere between 1 minute to about 1 hour or greater. In some embodiments, molding material may cure in less than about 1 minutes.

[0064] Any step of method 1100 may be performed as described above with references to FIG. 1-10B.

[0065] While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular embodiments. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

[0066] Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.

[0067] Particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. For example, the actions recited in the claims can be performed in a different order and still achieve desirable results. As one example, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous. Other steps or stages may be provided, or steps or stages may be eliminated, from the described processes. Accordingly, other implementations are within the scope of the following claims.

Examples

Embodiment Construction

[0017] Aspects of the present disclosure may provide for wristbands for wearable devices. In some embodiments, a multi-part wristband is presented. A multi-part wristband may have a first band and a second band formed as part of the first band. A multi-part wristband may allow for a visual seamless wristband while incorporating a locking element into a band having one or more stimulators. In some embodiments, a second band may be overmolded onto a portion of a first band, which may cause the second band to become formed as part of the first band. Embodiments of manufacturing a wearable device are presented. For instance, a mold cavity may contain a portion of a wearable device and / or band, and a mold core may be shaped as a second band and / or contain a second band. A first band and a second band may be aligned through, but not limited to, alignment pins, magnets, vacuums, or other alignment methods. In some embodiments, flow guides and / or flow directors may be implemented in methods...

Claims

1. A wristband for wearable devices, comprising: a first band having a first proximal end couplable to a wearable device and a first distal end extending away from the wearable device; anda second band having a second proximal end formed as a portion of the first distal end of the first band and a second distal end couplable to a locking element configured to secure the wearable device to a portion of a user.

2. The wristband of claim 1, wherein the second proximal end is formed as part of the first distal end through a process of overmolding.

3. The wristband of claim 1, wherein a bottom surface of the first band comprises a stimulating element configured to emit a stimulation waveform.

4. The wristband of claim 3, wherein the stimulating element comprises one or more of a vibratory element, heating element, electrical element, and ultrasonic element.

5. The wristband of claim 1, wherein the locking element is a hook and loop structure.

6. The wristband of claim 1, wherein the second proximal end is overlaid onto sacrificial geometry of the first distal end.

7. The wristband of claim 1, wherein a tensile strength of the first and second band is at least 50 MPa.

8. The wristband of claim 1, wherein the second distal end retains an original visual element prior to a manufacturing process combining the first and second band.

9. The wristband of claim 1, wherein the locking element is interwoven with a molding material.

10. The wristband of claim 1, wherein a top surface of the first proximal end is absent demarcation from a top surface of the first distal end.

11. A method of manufacturing a wristband for wearable devices, comprising: positioning a second proximal end of a second band at least partially onto a top surface of a first distal end of a first band in a mold cavity of a band mold;injecting a molding material into the mold cavity;allowing the molding material to cure, thereby materially integrating the second band at least partially into the first band.

12. The method of claim 11, further comprising aligning a mold core with the mold cavity through alignment pins.

13. The method of claim 11, further comprising directing a flow of the molding material around a portion of the second band via a flow director.

14. The method of claim 11, further comprising directing a flow of the molding material around a portion of the second band via a flow guide.

15. The method of claim 11, further comprising applying a vacuum within the mold to hold the second band at least partially on top the top surface of the first distal end of the first band.

16. The method of claim 11, further comprising securing the second band to the first band through sacrificial geometry incorporated into the first band.

17. The method of claim 16, wherein the sacrificial geometry is positioned at the first distal end of the first band.

18. The method of claim 11, wherein the first band is absent any demarcation from the second band.

19. The method of claim 11, wherein the first band is couplable to a wearable device at a first proximal end.

20. The method of claim 11, further comprising aligning a mold core with the mold cavity through a set of magnets.

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