Dual-Layer Circuit Housing for Waterproof Intraoral Electronics
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Solution Overview
Problem
Existing electronic devices for intraoral use are inadequately protected by separate outer polymer housings, which often leak and fail to provide sufficient protection against moisture and mechanical damage.
Innovation Solution
A circuit housing with a dual-layer structure, comprising an inner layer made of protective lacquer materials like silicone, (meth)acrylate resin, or epoxy resin for waterproofing, and an outer layer made of 3D-printable materials such as (meth)acrylates or polycarbonate for spatial adaptation, providing mechanical protection and resistance to water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate outer polymer housing is used to protect electronic devices for intraoral use, then mechanical protection is provided, but the housing leaks and inadequately protects against moisture
Solution Approach 1:
The patent merges the protective housing structure with the circuit board itself by forming the housing directly from the circuit board material through additive manufacturing. This integration eliminates the need for separate polymer housing components and their associated sealing interfaces, which are the source of leakage problems. The unified structure provides reliable moisture protection while reducing overall device complexity.
Solution Approach 2:
The patent employs composite materials in the form of multi-material additive manufacturing, where different materials are deposited in layers to create distinct functional zones. The circuit board material provides structural integrity and electrical functionality, while the housing portion provides mechanical protection and moisture barrier. This composite approach resolves the contradiction by achieving both protection and simplicity through material integration.
2Reliability
If a separate outer polymer housing is used, then mechanical protection is provided, but the housing fails to provide sufficient protection against mechanical damage
Solution Approach 1:
The patent combines the circuit board and housing into a single integrated component manufactured through additive processes. This merger ensures that the housing is perfectly fitted to the circuit board without gaps or weak interfaces, providing superior mechanical protection. The integrated structure eliminates the complexity of assembling separate protective housings while enhancing reliability against mechanical damage.
3Reliability
If a dual-layer structure with protective lacquer is used, then waterproof protection is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent applies the protective lacquer coating during the additive manufacturing process itself, before the housing is fully formed or while the material is still in a receptive state. This preliminary application ensures complete coverage of all surfaces including internal cavities and interfaces, achieving superior waterproof protection. By integrating the coating step into the manufacturing process rather than adding it as a separate post-processing step, the patent actually simplifies overall manufacturing while enhancing waterproof reliability.
4Adaptability or versatility
If 3D-printable materials are used for the outer layer, then spatial adaptation to denture is achieved, but material selection and printing process complexity increases
Solution Approach 1:
The patent uses additive manufacturing to create a universal housing structure that can be digitally adapted to different denture geometries without requiring different physical tooling or molds. The same 3D printing process and material system can produce housings for various patient-specific applications by simply changing the digital model. This multi-functionality achieves spatial adaptability while avoiding the complexity of maintaining multiple specialized manufacturing systems.
Solution Approach 2:
The patent achieves spatial adaptation by changing the geometric parameters of the housing design through digital modeling and additive manufacturing. Instead of using different materials for different applications, the solution varies the shape, size, and surface features of the housing to match specific denture geometries. This parameter-based approach provides versatility while keeping the material and manufacturing process relatively simple and standardized.
Data Source
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AI summary
The present invention relates to a circuit housing (100) for a portable intraoral application, comprising an inner layer (105-1) made of a first material (101-1) for waterproof enclosure of an electronic circuit (103); and an outer layer (105-2) made of a second material (101-2) for spatial adaptation of the circuit housing to a denture (111), which at least partially covers the first material (101-1).