Ultrasonic Welding Wearable Ring PCB Shielding
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Solution Overview
Problem
The manufacturing of wearable devices, particularly those with sensitive components like printed circuit boards (PCBs), is challenging due to the complexity of attaching or welding plastic components without damaging these components.
Innovation Solution
The use of ultrasonic welding to attach an outer lateral surface cover to an inner lateral surface cover in wearable devices, with the PCB positioned away from the welding features and protected by a material to shield it from ultrasonic waves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic welding is used to attach plastic components, then manufacturing cost is reduced and production is expedited, but sensitive components like PCB may be damaged by ultrasonic waves
Solution Approach 1:
A protective barrier or shielding material is introduced between the ultrasonic welding process and the PCB to block ultrasonic waves from reaching the sensitive components. This intermediary element allows the welding process to proceed while protecting the PCB from harmful ultrasonic vibrations.
Solution Approach 2:
The PCB is repositioned or removed from the immediate welding zone, extracting it from the harmful ultrasonic field. The component is placed in a location where it will not be exposed to ultrasonic waves during the welding process, thereby preventing damage while maintaining the overall device assembly.
2Ease of manufacture
If plastic materials are used instead of metal, then material cost is reduced and manufacturing is simplified, but attaching plastic components becomes challenging
Solution Approach 1:
Ultrasonic vibration is applied to the plastic components during assembly to facilitate bonding. The high-frequency mechanical vibrations generate friction heat that melts and fuses the plastic parts together, creating strong bonds without requiring complex welding equipment or processes.
Solution Approach 2:
The temperature and pressure parameters are controlled and optimized during the attachment process to achieve proper bonding of plastic components. By adjusting these parameters, the plastic parts can be securely attached through processes like ultrasonic welding or heat sealing, simplifying the manufacturing process despite the challenges of working with plastic materials.
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
This method reduces material costs and expedites production by using plastic materials instead of metal, while protecting sensitive components from damage during the welding process.
Implementation Method 1
activating an ultrasonic welding head configured for ultrasonic welding and simultaneously welding the first welding feature and the second welding feature with the inner lateral surface cover
Data Source
AI summary
Methods, systems, and devices for forming a wearable ring device are described. A welding process may use ultrasonic welding to attach an outer lateral surface cover to the inner lateral surface cover, which may form an arcuate frame for the wearable ring device. The welding process may involve ultrasonic welding, which may melt one or more welding features (e.g., welding ribs) to attach the outer lateral surface cover to the inner lateral surface cover. In some examples, the welding features may be located on the outer lateral surface cover, the inner lateral surface cover, or both. To reduce negative effects on fragile components, such as a PCB of the wearable ring device, the fragile components may be disposed in a location away from the welding features. Further, in some cases, a material may be used to cover and shield the fragile components from ultrasonic waves during the welding procedure.