Flexible Printed Circuit Wearable Bands with Embedded LEDs

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Solution Overview

Problem

Incorporating input-output components such as sensors and light-emitting components into wearable devices poses challenges of fragility, bulkiness, and aesthetics if not designed carefully.

Innovation Solution

A wearable electronic device with a band featuring flexible printed circuits encapsulated in elastomeric polymer material, where light-emitting diodes are mounted within cavities with reflective sidewalls and light-diffusing clear polymer, allowing for flexible and durable integration of electrical components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If electrical components are incorporated into wearable devices, then functionality is improved, but fragility increases

Engineering Contradiction:

ImprovefunctionalityVSAvoidfragility

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent uses flexible printed circuits instead of rigid PCBs to mount electrical components. The flexible substrate allows the circuit board to bend and flex with the wearable device, preventing brittle fracture while maintaining electrical connectivity and component functionality.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent employs composite material structures combining flexible substrates with protective encapsulation layers. This composite approach provides both the flexibility needed for wearable applications and the protective barriers necessary to shield sensitive electrical components from environmental damage and mechanical stress.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If electrical components are incorporated into wearable devices, then functionality is improved, but device bulk increases

Engineering Contradiction:

ImprovefunctionalityVSAvoiddevice bulk

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The flexible printed circuits enable thin-film construction of the electrical component carrier, dramatically reducing the thickness and bulk of the wearable device compared to traditional rigid PCB assemblies while maintaining all necessary electrical functionality.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent replaces traditional mechanical mounting structures with flexible circuit board technology, eliminating the need for bulky mounting brackets, screws, and rigid support structures. The flexible circuit itself provides both structural support and electrical connectivity in a single integrated thin layer.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If electrical components are incorporated into wearable devices, then functionality is improved, but aesthetic quality deteriorates

Engineering Contradiction:

ImprovefunctionalityVSAvoidaesthetic quality

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The flexible printed circuits can be conformally shaped and bent to match aesthetic design curves, allowing electrical components to be integrated into organically shaped wearable devices without visible rigid edges or angular PCB structures that would compromise aesthetic quality.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent utilizes the flexibility of the circuit substrate to route traces and position components in three-dimensional space, allowing electrical connections to be made through layered and folded configurations that maintain smooth external surfaces and eliminate visible wiring from the device exterior.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enhances the flexibility and durability of wearable devices while providing effective integration of sensors and light-emitting components, ensuring the device is neither overly fragile nor bulky, and maintains an attractive design.

Implementation Method 1

Reflective sidewalls in the cavities may reflect light from the light-emitting diodes outwardly through a thinned portion of the band

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

Light-diffusing material in the cavities may be formed from clear polymer with light-scattering particles

Methodology Applied

Scientific EffectLight scattering: Scattering

Data Source

PatentUS11442503B2Wearable bands with embedded circuitry

Publication Date: 2022.09.13 APPLE INC

AI summary

An electronic device such as a wearable electronic device may have a band. The band may form a stand-alone device or a strap for a wristwatch unit or other device. Electrical components may be mounted on flexible printed circuit substrates. A substrate may be encapsulated by elastomeric polymer material or other material forming the band. The elastomeric polymer material may form cavities that receive the electrical components. Components such as light-emitting diodes may be mounted to the flexible printed circuit substrates so that the light-emitting diodes are located in the cavities. Reflective sidewalls in the cavities may reflect light from the light-emitting diodes outwardly through a thinned portion of the band. Light-diffusing material in the cavities may be formed from clear polymer with light-scattering particles.