Wearable device, and injection molding system, power-on method and manufacturing method therefor

Abstract

The present application relates to an Internet of things electronic device, and discloses a wearable device, and an injection molding system, a power-on method and a manufacturing method therefor. The injection molding system comprises: a mold, a support, a circuit board, and a battery. The circuit board and the battery are fixed onto the support, and the battery supplies power to the circuit board. The mold has a hollow cavity, and the support onto which the circuit board and the battery are fixed is placed in the cavity. A part of the support is in contact with the mold, allowing the support to be stably arranged in the cavity. Both the circuit board and the battery are arranged in the cavity without coming into contact with the inner surface of the cavity. The mold comprises at least one injection molding hole for communicating the cavity with the outside of the mold. The injection molding system can achieve integrated encapsulation of products, thereby reducing production costs and improving production efficiency, while improving waterproof performance and structural strength.

Description

Wearable devices and their injection molding systems, opening and manufacturing methods Technical Field

[0001] This application relates to Internet of Things (IoT) electronic devices, and more particularly to wearable devices and technologies for their manufacture and use. Background Technology

[0002] This section is intended to provide background or context for understanding the implementation of this application and is for reference only. It should not be construed as an admission by the applicant that this section pertains to prior art that was disclosed before the filing date of this application.

[0003] With the rapid development of IoT technology, wearable devices are being used more and more widely. Among the many application scenarios, animal wearable devices have attracted much attention due to their important role in livestock management, animal monitoring, and other fields. Animal wearable devices typically include core functional components such as printed circuit board assemblies (PCBAs), batteries, and sensors.

[0004] In existing technologies, the casing of wearable animal devices is typically packaged as follows: first, each functional component is fixed to a main board; then, the main board is installed inside the casing; and finally, the casing cover is sealed using screws or adhesive. Figure 1 shows an exploded view of a wearable animal device using this assembly method. This assembly method has the following technical problems:

[0005] 1. The assembly process is complex and production efficiency is low. Because multiple parts need to be installed and secured separately, the assembly process is cumbersome and prone to positioning deviations, affecting product quality.

[0006] 2. Waterproof performance is difficult to guarantee. Traditional casing encapsulation methods usually rely on sealing rings or adhesives to achieve waterproofing, but during long-term use, the sealing materials are prone to aging or falling off, leading to waterproofing failure.

[0007] 3. The product is large in size and weight. Due to the need to reserve space for assembly and fastening structure, the overall size of the product under traditional packaging method is large, which increases the burden on animals wearing it.

[0008] 4. Insufficient reliability. The shell, which is fixed by screws or glue, is prone to loosening or cracking during animal movement, reducing the product's lifespan.

[0009] 5. High production costs. Traditional packaging methods require the purchase and storage of a large number of components, and the cost of manual assembly is high, which is not conducive to the large-scale production of products.

[0010] Therefore, there is an urgent need to provide a new type of wearable device injection molding system to solve the technical problems existing in the current technology, such as poor waterproof performance, complex assembly, large size and weight, insufficient reliability and high production cost. Summary of the Invention

[0011] The purpose of this application is to provide a wearable device and its injection molding system, opening and manufacturing method, which can solve the technical problems of poor waterproof performance, complex assembly, large size and weight, insufficient reliability and high production cost in the prior art.

[0012] This application discloses an injection molding system for a wearable device, including: a mold, a bracket, a circuit board, and a battery;

[0013] The circuit board and the battery are fixed on the bracket, and the battery powers the circuit board.

[0014] The mold has a hollow cavity, and the bracket that holds the circuit board and the battery is placed in the cavity;

[0015] A portion of the bracket contacts the mold to stably position the bracket within the cavity;

[0016] Both the circuit board and the battery are located within the cavity and do not contact the inner surface of the cavity.

[0017] The mold includes at least one injection hole connecting the cavity and the outside of the mold.

[0018] In a preferred embodiment, the circuit board also includes a sensor and a wireless transceiver electrically connected to it.

[0019] The sensor and the wireless transceiver are mounted on the circuit board or the bracket;

[0020] The wireless transceiver and sensors that do not need to be exposed on the outer surface of the wearable device do not contact the inner surface of the cavity;

[0021] A portion of the outer surface of a sensor that needs to be exposed on the outer surface of the wearable device needs to contact the inner surface of the mold.

[0022] In a preferred embodiment, the mold is divided into an upper mold and a lower mold;

[0023] The upper mold and the lower mold sandwich the bracket in the middle.

[0024] This application also discloses a wearable device, including: a bracket, a circuit board, a battery, and a plastic casing;

[0025] The circuit board and the battery are fixed on the bracket, and the battery powers the circuit board.

[0026] The plastic casing encapsulates the bracket, the circuit board, and the battery through a one-piece injection molding process.

[0027] In a preferred embodiment, the circuit board also includes a sensor and a wireless transceiver electrically connected to it.

[0028] The sensor and the wireless transceiver are mounted on the circuit board or the bracket;

[0029] The wireless transceiver and sensors that do not need to be exposed on the outer surface of the wearable device are encased in the plastic housing by injection molding.

[0030] In a preferred embodiment, the circuit board further includes a magnetic switch, and the sensor includes an accelerometer, with the magnetic switch and the accelerometer encased in the plastic housing.

[0031] In a preferred embodiment, the bracket includes a cavity for receiving the battery, at least one latch is provided above the cavity, the cavity receives the battery, the circuit board is disposed above the battery, and the at least one latch secures the circuit board and the battery to the bracket.

[0032] In a preferred embodiment, the plastic housing is integrally injection molded at 180-240°C and 0.15-4MPa.

[0033] The material of the plastic shell includes polyamide or thermoplastic polyurethane.

[0034] This application also discloses a method for activating a wearable device, the wearable device including a controller, a magnetic switch, and an accelerometer; the method includes:

[0035] In response to an external magnet approaching the wearable device, the magnetic switch turns on the power to the controller and the accelerometer.

[0036] Within a predetermined time period, the controller detects whether the output of the accelerometer meets a predetermined pattern;

[0037] In response to the controller not detecting that the output of the accelerometer meets a predetermined pattern within the predetermined time period, the wearable device enters a sleep mode.

[0038] In a preferred embodiment, the wearable device enters a normal operating mode in response to the controller detecting that the output of the accelerometer meets a predetermined pattern.

[0039] In a preferred embodiment, the predetermined pattern includes the variation characteristics of the output value of the accelerometer when the wearable device is moved in a specific posture.

[0040] This application also discloses a method for turning on a wearable device, the wearable device including a magnetic switch and a wireless transceiver; the method includes:

[0041] In response to an external magnet approaching the wearable device, the magnetic switch turns on the power to the wireless transceiver;

[0042] Within a predetermined time period, the wireless transceiver detects whether it has received the agreed-upon wireless signal;

[0043] If the wireless transceiver does not receive the agreed wireless signal within the agreed time period, the wearable device enters a sleep mode.

[0044] In a preferred embodiment, the wearable device enters a normal operating mode in response to the wireless transceiver receiving the agreed wireless signal.

[0045] In a preferred embodiment, the agreed wireless signal is an agreed broadcast signal of the wireless gateway;

[0046] In response to the wireless transceiver receiving the agreed broadcast signal, the wireless transceiver further performs a handshake with the wireless gateway;

[0047] Upon successful handshake between the wireless transceiver and the wireless gateway, the wearable device enters normal operating mode.

[0048] This application also discloses a method for manufacturing a wearable device, including:

[0049] The sensors and wireless transceivers are mounted on the circuit board;

[0050] Secure the circuit board and battery to the bracket;

[0051] The bracket is placed in the cavity of the mold, the mold having a hollow cavity, a portion of the bracket contacts the mold to stably set the bracket in the cavity, the circuit board, the battery and the wireless transceiver are all in the cavity and do not contact the inner surface of the cavity;

[0052] Under conditions of 180-240℃ and 0.15-4MPa, the material is injected into the mold through the injection hole on the mold.

[0053] After the plastic parts inside the mold have cooled down, open the mold and remove the plastic parts.

[0054] In a preferred embodiment, the material of the plastic housing includes polyamide or thermoplastic polyurethane.

[0055] In the embodiments of this application, by fixing the circuit board and battery onto a bracket and placing the bracket in a mold cavity, while ensuring the bracket contacts the mold but the circuit board and battery do not contact the inner surface of the cavity, a one-piece injection molding process can be achieved. This avoids the complex assembly process of multiple components such as the outer shell and cover plate required in traditional packaging, thus reducing production costs. By completely encapsulating the electronic components with injection molding material, excellent waterproof performance is provided, overcoming the problem of easy failure of traditional packaging relying on sealing rings or glue. The elimination of fasteners and assembly space significantly reduces product volume and weight. The injection molding material and bracket form an integral structure, improving structural strength and solving the reliability issues of screw loosening and glue aging in traditional packaging. The positioning design of the bracket ensures the stable position of the electronic components during injection molding, improving production yield.

[0056] Furthermore, sensors that need to be exposed (such as temperature and humidity sensors) are partially exposed to the inner surface of the mold to ensure they can make necessary physical contact with the external environment. Sensors that do not need to be exposed (such as accelerometers and gyroscopes) and wireless transceivers are completely placed inside the cavity and do not contact the mold. This design achieves optimal protection while ensuring the normal operation of various sensors and avoiding damage to sensitive components during injection molding.

[0057] Furthermore, by dividing the mold into upper and lower halves and clamping the bracket in the middle, the assembly process can be simplified, production efficiency can be improved, and the positional accuracy of the bracket can be guaranteed.

[0058] Furthermore, the special design of the bracket (featuring a battery cavity and a snap-fit ​​structure) ensures reliable fixation of the battery and circuit board, preventing loosening.

[0059] Furthermore, by using specific injection molding process parameters with a temperature range of 180-240℃ and a pressure range of 0.15-4MPa, it can be ensured that the injection molding material flows fully without damaging the electronic components.

[0060] Furthermore, the selection of polyamide or thermoplastic polyurethane materials ensures both the mechanical strength of the product and good processing performance.

[0061] By combining a magnetic switch and an accelerometer for dual verification, the device can be effectively prevented from starting up accidentally, its standby time can be extended, and a convenient way to turn it on can be provided.

[0062] By combining a dual mechanism of magnetic switch and wireless signal confirmation, along with a wireless gateway handshake confirmation method, the reliability of device activation can be further improved, false triggering can be avoided, and the device can be ensured to establish a connection with the correct gateway.

[0063] The various technical features disclosed in the above-described invention, the various technical features disclosed in the following embodiments and examples, and the various technical features disclosed in the accompanying drawings can be freely combined to form various new technical solutions (all of which should be considered as having been recorded in this specification), unless such a combination of technical features is technically infeasible. For example, in one example, feature A+B+C is disclosed, and in another example, feature A+B+D+E is disclosed. Features C and D are equivalent technical means that serve the same function, and technically only one needs to be used; it is impossible to use both simultaneously. Feature E can be technically combined with feature C. Therefore, the solution A+B+C+D should not be considered as having been recorded because it is technically infeasible, while the solution A+B+C+E should be considered as having been recorded. Attached Figure Description

[0064] Figure 1 is an exploded view of a wearable animal device in the prior art;

[0065] Figure 2 is a schematic diagram of the structure of a wearable device according to an embodiment of this application;

[0066] Figure 3 is a schematic diagram of the internal structure and injection-molded housing of a wearable device according to an embodiment of this application;

[0067] Figure 4 is a three-dimensional schematic diagram of the bottom surface of a wearable device according to an embodiment of the present application;

[0068] Figure 5 is a frontal three-dimensional schematic diagram of a wearable device according to an embodiment of this application;

[0069] Figure 6 is a front view, a side view and a bottom view of a wearable device according to an embodiment of the present application;

[0070] Figure 7 is a cross-sectional view of the injection molding system of a wearable device according to an embodiment of the present application before casting;

[0071] Figure 8 is a cross-sectional view of the injection molding system of a wearable device according to an embodiment of the present application after casting;

[0072] Figure 9 is a schematic diagram of the assembly of the mold and main body module of the injection molding system of a wearable device according to an embodiment of the present application before casting.

[0073] Figure 10 is an assembly diagram of the injection molding system of the wearable device in Figure 9 from another direction;

[0074] Figure 11 is a schematic flowchart of a method for turning on a wearable device according to an embodiment of this application;

[0075] Figure 12 is a schematic flowchart of a method for turning on a wearable device according to an embodiment of this application;

[0076] Figure 13 is a schematic flowchart of a method for manufacturing a wearable device according to an embodiment of this application;

[0077] Figure 14 is a color cross-sectional view of the injection molding system of the wearable device in Figure 9 before casting;

[0078] Figure 15 is a color cross-sectional view of the injection molding system of the wearable device in Figure 9 after casting;

[0079] Figure 16 is a three-dimensional schematic diagram of the injection molding system of the wearable device in Figure 9 before casting;

[0080] Figure 17 is a three-dimensional schematic diagram of the injection molding system of the wearable device in Figure 9 after casting.

[0081] The reference numerals used in the attached drawings are as follows: 1: Circuit board; 2: Battery; 3: Bracket; 4: Plastic housing; 5: Sensor; 6: Functional position hole; 7: Upper mold half; 8: Lower mold half; 9: Upper mold support; 10: Lower mold support; 11: Mold cavity; 12: In-mold casting; 13: Mold side hole; 14: Buckle. Detailed Implementation

[0082] In the following description, many technical details are presented to help the reader better understand this application. However, those skilled in the art will understand that the technical solutions claimed in this application can be implemented even without these technical details and various variations and modifications based on the following embodiments.

[0083] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in further detail below with reference to the accompanying drawings.

[0084] The first embodiment of this application relates to an injection molding system for a wearable device, as shown in FIG7. The injection molding system for the wearable device typically includes: a mold, a bracket 3, a circuit board 1, a sensor 5, a wireless transceiver, and a battery 2. In some embodiments, the sensor 5 or the wireless transceiver may be omitted.

[0085] Circuit board 1 and battery 2 are fixed on bracket 3. Battery 2 supplies power to all electrical components, including circuit board 1, sensor 5 and wireless transceiver.

[0086] Sensor 5 and wireless transceiver are mounted on circuit board 1 or bracket 3 and are electrically connected to circuit board 1.

[0087] The mold has a hollow cavity 11, and a bracket 3, in which a circuit board 1 and a battery 2 are fixed, is placed. The bracket 3 serves two purposes: firstly, to fix or support other components; secondly, a portion of the bracket 3 contacts the mold to stably position the bracket 3 within the cavity 11. Both the circuit board 1 and the battery 2 are within the cavity 11 and do not contact the inner surface of the cavity 11. The mold includes at least one injection hole (e.g., a mold side hole 13) connecting the cavity 11 to the outside of the mold.

[0088] The wireless transceiver and sensors 5 that do not need to be exposed on the outer surface of the wearable device are housed within the cavity and do not contact the inner surface of the cavity. Sensors 5 that do not need to be exposed on the outer surface of the wearable device may include accelerometers, gyroscopes, magnetometers, etc.

[0089] A portion of sensor 5, which needs to be exposed on the outer surface of the wearable device, contacts the inner surface of the mold. Sensor 5, which needs to be exposed on the outer surface of the wearable device, may include a camera, an ambient light sensor, an infrared sensor, a temperature sensor, a humidity sensor, a UV sensor, a barometric pressure sensor, etc.

[0090] Optionally, in one embodiment, the mold is divided into an upper mold 7 and a lower mold 8. The upper mold 7 and the lower mold 8 sandwich the support 3 in the middle. The injection molding system of the first embodiment is used to produce the wearable device of the second embodiment, and the relevant technical details of the first embodiment can be used in the second embodiment, and vice versa. In other embodiments, the mold may also have more components, such as three or four parts.

[0091] Figure 8 is a schematic diagram of the injection molding example in Figure 7, where the diagonal lines indicate the injection location.

[0092] The main module consists of bracket 3, circuit board 1, sensor 5, wireless transceiver and battery 2. Figures 9 and 10 show the assembly relationship between the main module, upper mold 7 and lower mold 8 from different angles.

[0093] Figure 14 is a color cross-sectional view before casting, showing the main module placed inside the mold cavity and fixed together with the upper mold support column 9 and the lower mold support column 10. The casting material can enter the mold cavity 11 through the side holes 13 of the upper and lower molds to complete the casting process. Figure 15 is a color cross-sectional view after casting, where yellow represents the in-mold filler, that is, the material injected through the side holes of the mold.

[0094] Figure 16 shows the state of the main module placed in the mold before casting in a three-dimensional color model. Figure 17 shows the state after casting in a three-dimensional color model. The injection material can be polyamide (PA), which melts at 190–230°C, is injected under pressure, and then cooled to form the final shape.

[0095] The wearable device produced according to the first embodiment has the following beneficial effects:

[0096] 1. Excellent waterproof performance and impact resistance: The low-pressure injection molding technology can directly and completely wrap and fix the battery, circuit board and its surface components, effectively preventing moisture and dust from entering the equipment, while improving the equipment's impact resistance, enabling it to work normally in harsh environments.

[0097] 2. Lightweight design: Reduces the burden on animals when wearing the device, improving their comfort. This is very important for wearable products for animals, as excessively heavy equipment can affect the animal's normal activities.

[0098] 3. Reduced production costs: Simplified production processes eliminate the need for traditional assembly methods such as screws, glue application, and laser welding, as well as additional housings, encapsulation materials, and fillers. This not only reduces material costs but also increases production efficiency and reduces labor costs.

[0099] 4. Simple structure and easy manufacturing: Thanks to its integrated design and low-pressure injection molding technology, the product has a simpler structure, making it easier to manufacture and assemble. This helps improve product quality and reliability while reducing production costs.

[0100] The second embodiment of this application relates to a wearable device, as shown in Figures 2-6, which includes: a circuit board 1, a battery 2, a bracket 3, a sensor 5, a wireless transceiver, and a plastic housing 4. In some examples, the sensor 5 or the wireless transceiver may be omitted.

[0101] Circuit board 1 can be a printed circuit board, responsible for connecting all electronic components. Some electronic components can be fixed to circuit board 1 by means of soldering or other methods. Circuit board 1 can also be electrically connected to electronic components fixed on bracket 3 by means of connectors.

[0102] Circuit board 1 and battery 2 are fixed on bracket 3. Battery 2 supplies power to all electrical components, including circuit board 1, sensor 5 and wireless transceiver.

[0103] Sensor 5 and the wireless transceiver are mounted on circuit board 1 or bracket 3. A plastic housing 4 encapsulates bracket 3, circuit board 1, battery 2, wireless transceiver, and sensor 5 (which does not need to be exposed on the wearable device's outer surface) through a one-piece injection molding process. The injection-molded material serves as both the outer shell and filler, possessing natural waterproof and dustproof properties, impact resistance, and lightweight characteristics. The one-piece injection molding process enables the encapsulated IoT electronic device to operate in harsh environments, improving product reliability and lifespan. It is particularly suitable for IoT electronic devices, including wearable devices for animals. It meets the requirements of small size, light weight, waterproof and dustproof properties, and impact resistance for animal wearable devices, satisfying animal management needs. It can also be applied to medical devices, industrial sensors, and other fields, showing broad application prospects.

[0104] Figures 2-6 are merely non-limiting examples. Those skilled in the art can design the shape, internal structure, type and number of sensors, and type and number of wireless transceivers of wearable devices as needed.

[0105] The wireless transceiver is not shown in Figures 2-6. It can be soldered onto circuit board 1 or mounted on bracket 3 and electrically connected to circuit board 1 via wires. Various types of wireless transceivers can be used, such as Bluetooth, Zigbee, Wi-Fi, 5G, etc. Generally, any wireless transceiver capable of operating in low-power mode can be used. The antenna of the wireless transceiver can be mounted on bracket 3 and completely enclosed in the plastic housing 4 after injection molding.

[0106] Optionally, in one embodiment, the circuit board 1 further includes a magnetic switch, and the sensor 5 includes an accelerometer. The magnetic switch and the accelerometer are enclosed in a plastic housing 4.

[0107] Optionally, in one embodiment, the bracket 3 includes a cavity for accommodating the battery 2, with at least one latch 14 disposed above the cavity. The circuit board 1 is disposed above the battery 2, and at least one latch secures the circuit board 1 and the battery 2 to the bracket 3. In other embodiments, the battery and circuit board can also be secured by other means, such as using fasteners or welding.

[0108] Optionally, in one embodiment, battery 2 is a button cell battery 2.

[0109] Optionally, in another embodiment, battery 2 is a rechargeable battery, such as a lithium-ion battery or a sodium-ion battery. The wearable device also includes a wireless charging module, also encased in the plastic housing 4, for charging battery 2.

[0110] Optionally, in one embodiment, the wearable device does not have a wireless transceiver configured, but instead transmits the data collected by sensor 5 to an external computer via a wired connection through a data transmission interface (e.g., a USB port).

[0111] Optionally, in one embodiment, the plastic housing 4 is integrally injection molded at 180-240°C and 0.15-4 MPa. The material of the plastic housing 4 is preferably a low-temperature, low-pressure injection molding material, such as polyamide (PA) or thermoplastic polyurethane (TPU). These materials have the following characteristics: First, they have excellent low-temperature processing performance. Their melting point or softening point is generally between 80-160°C, allowing for injection molding at lower temperatures. This characteristic is particularly important for protecting temperature-sensitive electronic components, such as when encapsulating electronic devices containing lithium batteries, effectively preventing battery performance degradation or safety hazards due to high temperatures.

[0112] Secondly, these materials have excellent low-pressure filling properties. They can fully fill the mold at relatively low pressures of 2-10 MPa, which not only reduces the requirements for injection molding equipment, but more importantly, it reduces the pressure impact on internal electronic components, preventing damage to precision electronic devices due to high pressure.

[0113] Furthermore, this type of material exhibits excellent flexibility and sealing properties after molding. It can better adapt to electronic components of different shapes and form a complete sealing layer around them. This characteristic effectively prevents the intrusion of external factors such as moisture and dust, protecting the normal operation of internal components.

[0114] Finally, this type of material has excellent adhesion to a variety of materials, and can be firmly bonded to the surfaces of different materials such as plastic parts, metal pins and circuit boards, ensuring the stability of the overall structure.

[0115] To further improve material properties, various functional additives can be added:

[0116] 1) Plasticizers: Used to reduce the hardness and processing temperature of materials and improve the flexibility of products;

[0117] 2) Lubricant: Improves the flowability of materials within the mold, making the injection molding process smoother;

[0118] 3) Antioxidants: prevent oxidation and aging of materials during processing and use, and extend the service life of products.

[0119] The combined effect of the aforementioned material properties and additives gives injection-molded wearable devices excellent waterproof performance, structural strength, and service life, making them particularly suitable for use in harsh environments.

[0120] The third embodiment of this application relates to a method for opening a wearable device, which is applied to a wearable device manufactured using a one-piece injection molding process (such as the wearable device described in the second embodiment). All electronic components of the wearable device are tightly encapsulated by the injection molding material to significantly improve the device's reliability. Due to the one-piece injection molding process, traditional physical buttons or interfaces may no longer be suitable for better waterproofing; therefore, this embodiment employs a dual confirmation mechanism combining a magnetic switch and an accelerometer to reliably open the device.

[0121] Specifically, the wearable device includes a controller, a magnetic switch, and an accelerometer. As shown in Figure 11, the activation method includes the following steps:

[0122] In step 101, in response to an external magnet approaching the wearable device, the magnetic switch detects a change in the magnetic field strength or direction and then quickly responds in a non-contact manner to power on the controller and accelerometer. This non-contact switching control method not only avoids mechanical wear caused by physical contact but also enables the device to operate stably in special environments such as humid and dusty conditions, significantly improving the device's environmental adaptability and service life.

[0123] There are several ways to bring an external magnet close to a wearable device. These include having a staff member hold the magnet close to the device, moving the device near the magnet, energizing an electromagnet near the device, and so on.

[0124] Magnetic switches can be either reed switches or Hall effect switches. A reed switch consists of two magnetic reeds sealed in a glass tube filled with inert gas. It operates without a power supply; when an external magnet approaches, the reeds attract each other under the magnetic field, making contact and thus connecting the relevant circuit. A Hall effect switch integrates the Hall element and signal processing circuitry into a single chip, directly outputting digital signals. Although it requires a power supply, its power consumption is very low.

[0125] The system then proceeds to step 102. To prevent false triggering due to environmental electromagnetic interference, a secondary confirmation mechanism based on the accelerometer is activated. Within a predetermined duration (e.g., 5-60 seconds), the controller continuously checks whether the output of the accelerometer meets a predetermined motion pattern. If the controller detects that the output of the accelerometer meets the predetermined pattern within the predetermined duration, the system proceeds to step 103; otherwise, it proceeds to step 104.

[0126] A predetermined pattern refers to the characteristic change in the output value captured by the accelerometer when a wearable device is moved by a user in a specific posture. For example, this specific posture could be:

[0127] 1. Draw a complete circle in the air: At this time, the accelerometer will detect a periodic, approximately circular trajectory of acceleration change pattern;

[0128] 2. Draw a cross in the air: At this time, the accelerometer will detect linear motion acceleration change patterns in two vertical directions;

[0129] 3. Horizontal swinging: At this time, the accelerometer will detect that the absolute value of the horizontal acceleration exceeds the predetermined threshold twice within a predetermined time period, and the direction of the horizontal acceleration when the predetermined threshold is exceeded is opposite.

[0130] 4. Or other predefined, sufficiently specific movement postures (e.g., Z, X, L-shaped movements, etc.).

[0131] This dual confirmation mechanism (magnetic switch + specific motion posture) can effectively prevent the device from being accidentally woken up by electromagnetic interference in the environment, thereby avoiding unnecessary power consumption and extending the standby time of the device.

[0132] In step 103, once the system confirms the triggering of the magnetic switch and the completion of the specific motion posture, the wearable device will enter the normal working mode and begin to execute its preset functions.

[0133] In step 104, if the correct motion posture is not detected within a predetermined time period, the wearable device will automatically enter sleep mode to save power. In sleep mode, only the magnetic switch maintains a minimum power consumption operating state, while other modules are powered off until the magnetic switch is triggered again.

[0134] This implementation combines an integrated casting injection molding process with an intelligent switch mechanism, ensuring both the device's waterproof and dustproof rating and overall reliability, while also achieving convenient and reliable switch control, providing a new solution for the design of wearable devices.

[0135] The fourth embodiment of this application relates to a method for activating a wearable device, the wearable device including a magnetic switch and a wireless transceiver. This method is an alternative to the third embodiment and can also be used in the wearable device described in the second embodiment. As shown in FIG12, the activation method includes:

[0136] In step 201, in response to an external magnet approaching the wearable device, the magnetic switch turns on the power to the wireless transceiver. Specifically, when the magnetic field strength generated by the external magnet exceeds a preset threshold, the magnetic switch is triggered and closed, thereby turning on the power to the wireless transceiver. The magnetic switch can be implemented using a reed switch, a Hall sensor, or other magnetically sensitive elements. The external magnet can be a permanent magnet or an electromagnet, and its magnetic field strength needs to be sufficient to trigger the action of the magnetic switch.

[0137] Then proceed to step 202, where the wireless transceiver checks whether it has received the agreed-upon wireless signal within a predetermined time period. If the wireless transceiver receives the agreed-upon wireless signal within the predetermined time period, proceed to step 203; otherwise, proceed to step 204. The predetermined time period can be set as needed, for example, but not limited to 1-60 seconds.

[0138] In step 203, the wearable device enters normal operating mode.

[0139] In step 204, the wearable device enters sleep mode.

[0140] Optionally, in one embodiment, the agreed-upon wireless signal is a pre-defined broadcast signal from the wireless gateway. In response to the wireless transceiver receiving the pre-defined broadcast signal, the wireless transceiver further initiates a handshake with the wireless gateway. The handshake process may include steps such as authentication and communication parameter negotiation, and may employ industry-standard security authentication protocols. In response to the successful handshake between the wireless transceiver and the wireless gateway, the wearable device enters normal operating mode. This effectively reduces accidental activation, thereby extending battery life and increasing the standby time of the wearable device.

[0141] The fifth embodiment of this application relates to a method for manufacturing a wearable device, used to manufacture the wearable device described in the second embodiment. The technical details of the second embodiment can be used in this embodiment. As shown in FIG13, the manufacturing method includes:

[0142] In step 301, the sensor and wireless transceiver are mounted on the circuit board. For example, the sensor and wireless transceiver can be soldered onto pre-defined pad locations on the circuit board using a surface mount technology (SMT) process.

[0143] Next, proceed to step 302, where the circuit board and battery are secured to the bracket. This can be achieved using methods such as clips, fasteners, soldering, or gluing.

[0144] Then proceed to step 303, where the bracket is placed in the cavity of the mold, which has a hollow cavity. A portion of the bracket contacts the mold to stably position the bracket in the cavity. The circuit board, battery, and wireless transceiver are all in the cavity and do not contact the inner surface of the cavity.

[0145] Then proceed to step 304, where molding is performed through the injection hole in the mold at 180-240°C and 0.15-4 MPa. The injection material can be polyamide or thermoplastic polyurethane, etc. The characteristics of the injection molding material are described in detail in the second embodiment and will not be repeated here.

[0146] Then proceed to step 305, and after the plastic part inside the mold has cooled down, open the mold and remove the plastic part.

[0147] The aforementioned manufacturing method enables adaptive shell packaging for IoT devices, employing low-pressure injection molding technology to provide a novel packaging solution for IoT electronic devices, particularly wearable animal devices. This technology offers advantages such as waterproofing, dustproofing, impact resistance, lightweight design, and low cost, and has broad application prospects.

[0148] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one" does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element. In this application, if it refers to performing an action according to an element, it means performing the action at least according to that element, including two cases: performing the action only according to that element, and performing the action according to that element and other elements. Expressions such as "multiple," "repeatedly," and "various" include two, two times, two kinds, and more than two, more than two times, and more than two kinds.

[0149] This specification includes combinations of various embodiments described herein. Individual references to embodiments (e.g., “one embodiment”, “some embodiments”, or “preferred embodiments”) do not necessarily refer to the same embodiment; however, these embodiments are not mutually exclusive unless indicated to be mutually exclusive or are readily apparent to those skilled in the art. It should be noted that the word “or” is used in a non-exclusive sense throughout this specification unless the context explicitly indicates or requires it.

[0150] All references to this application are considered to be incorporated in their entirety into the disclosure of this application so that they can serve as a basis for modifications if necessary. Furthermore, it should be understood that after reading the contents of this application, those skilled in the art can make various alterations or modifications to this application, and these equivalent forms also fall within the scope of protection claimed in this application.

Claims

1. An injection molding system for wearable devices, comprising: include: Molds, brackets, circuit boards, and batteries; The circuit board and the battery are fixed on the bracket, and the battery powers the circuit board. The mold has a hollow cavity, and the bracket that holds the circuit board and the battery is placed in the cavity; A portion of the bracket contacts the mold to stably position the bracket within the cavity; Both the circuit board and the battery are located within the cavity and do not contact the inner surface of the cavity. The mold includes at least one injection hole connecting the cavity and the outside of the mold.

2. The injection molding system of a wearable device of claim 1, wherein, It also includes sensors and wireless transceivers electrically connected to the circuit board; The sensor and the wireless transceiver are mounted on the circuit board or the bracket; The wireless transceiver and sensors that do not need to be exposed on the outer surface of the wearable device do not contact the inner surface of the cavity; A portion of the outer surface of a sensor that needs to be exposed on the outer surface of the wearable device needs to contact the inner surface of the mold.

3. The injection molding system of a wearable device of claim 1, wherein, The mold is divided into an upper mold and a lower mold; The upper mold and the lower mold sandwich the bracket in the middle.

4. A wearable device, comprising: include: Bracket, circuit board, battery, and plastic casing; The circuit board and the battery are fixed on the bracket, and the battery powers the circuit board. The plastic casing encapsulates the bracket, the circuit board, and the battery through a one-piece injection molding process.

5. The wearable device of claim 4, wherein, It also includes sensors and wireless transceivers electrically connected to the circuit board; The sensor and the wireless transceiver are mounted on the circuit board or the bracket; The wireless transceiver and sensors that do not need to be exposed on the outer surface of the wearable device are encased in the plastic housing by injection molding.

6. The wearable device of claim 5, wherein, The circuit board also includes a magnetic switch, and the sensor includes an accelerometer. The magnetic switch and the accelerometer are encased in the plastic housing.

7. The wearable device according to claim 4, characterized in that, The bracket includes a cavity for accommodating the battery, and at least one latch is provided above the cavity. The cavity accommodates the battery, and the circuit board is disposed above the battery. The at least one latch secures the circuit board and the battery to the bracket.

8. The wearable device according to claim 7, characterized in that, The plastic shell is integrally injection molded under conditions of 180-240℃ and 0.15-4MPa. The material of the plastic shell includes polyamide or thermoplastic polyurethane.

9. A method for activating a wearable device, characterized in that, The wearable device includes a controller, a magnetic switch, and an accelerometer; the method includes: In response to an external magnet approaching the wearable device, the magnetic switch turns on the power to the controller and the accelerometer. Within a predetermined time period, the controller detects whether the output of the accelerometer meets a predetermined pattern; In response to the controller not detecting that the output of the accelerometer meets a predetermined pattern within the predetermined time period, the wearable device enters a sleep mode.

10. The method for activating a wearable device according to claim 9, characterized in that, In response to the controller detecting that the output of the accelerometer meets a predetermined pattern, the wearable device enters a normal operating mode.

11. The method for activating a wearable device according to claim 9, characterized in that, The predetermined pattern includes the variation characteristics of the output value of the accelerometer when the wearable device is moved in a specific posture.

12. A method for activating a wearable device, characterized in that, The wearable device includes a magnetic switch and a wireless transceiver; the method includes: In response to an external magnet approaching the wearable device, the magnetic switch turns on the power to the wireless transceiver; Within a predetermined time period, the wireless transceiver detects whether it has received the agreed-upon wireless signal; If the wireless transceiver does not receive the agreed wireless signal within the agreed time period, the wearable device enters a sleep mode. 13.The method of Claim 12, wherein, In response to the wireless transceiver receiving the agreed wireless signal, the wearable device enters a normal operating mode. 14.The method of Claim 12, wherein, The agreed-upon wireless signal is the agreed-upon broadcast signal of the wireless gateway; In response to the wireless transceiver receiving the agreed broadcast signal, the wireless transceiver further performs a handshake with the wireless gateway; Upon successful handshake between the wireless transceiver and the wireless gateway, the wearable device enters normal operating mode.

15. A method for manufacturing a wearable device, characterized in that, include: The sensors and wireless transceivers are mounted on the circuit board; Secure the circuit board and battery to the bracket; The bracket is placed in the cavity of the mold, the mold having a hollow cavity, a portion of the bracket contacts the mold to stably set the bracket in the cavity, the circuit board, the battery and the wireless transceiver are all in the cavity and do not contact the inner surface of the cavity; Under conditions of 180-240℃ and 0.15-4MPa, the material is injected into the mold through the injection hole on the mold. After the plastic parts inside the mold have cooled down, open the mold and remove the plastic parts.

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