Wearable Device Dome Forming to Replace Defect-Prone Epoxy Molding
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Solution Overview
Problem
Wearable devices face challenges in achieving durable and cost-effective manufacturing due to issues with epoxy molding, such as cracks, bubbles, and tight tolerances, leading to increased production costs and material waste.
Innovation Solution
Vacuum or pressure-forming dome-shaped protrusions using moldable materials like PMMA, PC, PET, or PA to cover internal components, which are cheaper and more versatile, allowing for faster charging and a lighter design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxy molding is used to manufacture wearable devices, then the device structure can be formed, but cracks and bubbles occur leading to reduced reliability and increased manufacturing cost
Solution Approach 1:
The patent replaces expensive epoxy molding material with cheaper, disposable vacuum-formed dome structures. These domes are made from thin plastic materials that can be easily formed and discarded after use, eliminating the need for expensive epoxy while reducing manufacturing costs and improving reliability by avoiding epoxy-related defects like cracks and bubbles.
Solution Approach 2:
The patent substitutes the chemical molding process (epoxy injection molding) with a mechanical vacuum-forming process. Instead of injecting liquid epoxy into molds, the invention uses vacuum pressure to form plastic material into dome shapes, replacing the chemical curing process with a physical vacuum-forming mechanism that eliminates epoxy defects.
2Manufacturing precision
If epoxy molding is used, then device structure is formed, but tight tolerances result in material waste and reduced productivity
Solution Approach 1:
The patent changes the manufacturing parameters from high-precision epoxy injection molding to vacuum-forming processes. This parameter change allows for more tolerant manufacturing tolerances while maintaining adequate device performance, significantly reducing material waste and improving production efficiency through faster, less demanding manufacturing cycles.
3Speed
If traditional manufacturing methods are used, then device can be produced, but charging time is slow and device weight is high
Solution Approach 1:
The patent employs thin-film vacuum-formed domes instead of bulky epoxy structures. These thin film structures reduce device weight while providing sufficient protective and functional coverage. The lightweight material also enables faster charging by reducing thermal mass and improving heat dissipation characteristics.
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 vacuum or pressure-forming process results in a less expensive and more efficient manufacturing method, reducing material costs and enabling faster charging while maintaining durability and improved physiological measurements.
Implementation Method 1
vacuum-formed domes
Implementation Method 2
pressure-formed domes
Data Source
AI summary
Methods, systems, and devices for manufacturing a wearable device are described. Techniques described herein may enable manufacture of wearable devices by vacuum and/or pressure-forming protrusions to cover and protect components (e.g., sensors, charging components) of a wearable device. For example, a moldable material may be heated then vacuum and/or pressure-formed in a mold to form the protrusions. The moldable material may be optically clear (e.g., transparent), a colored translucent, or opaque material. In some examples, the protrusions may be unfilled or may be filled with another optically clear material. For example, a manufacturing process may include fully filling the protrusions with the optically clear material through a hole in the protrusions or a hole in one or more other components of the wearable device. Additionally, or alternatively, the manufacturing process may include partially filling the protrusions with the optically clear material.