Wearable Sensor Dome Formation Using a Temporary Release Layer
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Solution Overview
Problem
Wearable devices face limitations in forming dome-shaped protrusions for physiological data collection due to the high surface energy of materials like metal, resulting in shorter protrusions that affect measurement accuracy.
Innovation Solution
Using a temporary layer of material with lower surface energy, such as tape, adhesive, or plastic, to form dome-shaped protrusions before dispensing optically transparent material, allowing for higher protrusions and improved data collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal inner housing with high surface energy is used, then the structural strength and durability are improved, but the dome-shaped protrusion height is reduced due to higher surface energy preventing material from forming taller protrusions
Solution Approach 1:
A release layer is introduced as an intermediary between the metal inner housing and the optically transparent material. This release layer has lower surface energy than the metal housing, allowing the transparent material to form taller dome protrusions. The release layer mediates the interaction between the high-strength metal housing and the transparent material, enabling both structural integrity and increased protrusion height.
Solution Approach 2:
The surface energy parameter of the contact surface is changed by applying a release layer with lower surface energy than the metal housing. This parameter change allows the optically transparent material to achieve greater height in dome protrusions while maintaining adhesion and structural integrity.
2Stress or pressure
If the surface energy of the inner housing material is increased, then the adhesion strength is improved, but the dome protrusion height is reduced
Solution Approach 1:
The release layer serves as a mediator that provides optimal surface energy characteristics for dome formation. While the metal housing maintains high adhesion strength through its inherent properties, the release layer surface allows the transparent material to form taller protrusions by having lower surface energy that facilitates the desired dome shape.
Solution Approach 2:
Different regions of the housing have different surface energy characteristics. The metal housing bulk maintains high strength, while the inner surface contact area with the release layer has lower surface energy to enable taller dome protrusions. This local differentiation of surface properties resolves the contradiction between adhesion strength and protrusion height.
3Length of moving object
If a temporary release layer is added to enable taller domes, then the dome protrusion height is improved, but the manufacturing process complexity increases
Solution Approach 1:
The release layer is applied in advance to the metal inner housing before dispensing the optically transparent material. This preliminary action prepares the surface with the appropriate low surface energy characteristics needed to form tall dome protrusions, simplifying the subsequent dome formation process and making the added complexity a one-time preparation step.
Solution Approach 2:
The release layer is used temporarily during manufacturing to enable taller dome protrusions and is then removed after the domes are formed. This temporary use of the release layer justifies the added manufacturing step, as it enables the critical protrusion height improvement and can be discarded after serving its purpose.
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
Enables the formation of taller dome-shaped protrusions, enhancing the accuracy and quality of physiological measurements collected by wearable devices.
Implementation Method 1
a first material applied to an inner housing of the wearable device, the first material associated with a first surface energy, and the second material of the inner housing associated with a second surface energy higher than the first surface energy
Data Source
AI summary
Methods, systems, and devices for manufacturing a wearable device are described. Techniques described herein may enable a method for forming one or more dome-shaped protrusions over apertures of a wearable device usable to collect physiological data from a user. For example, a manufacturing process may include adhering a layer of a material with a relatively lower surface energy than metal onto an outer surface of the inner housing of the wearable device prior to dispensing an optically transparent material into the apertures. The optically transparent material may accordingly form the dome-shaped protrusions while in contact with the layer, which may enable the optically transparent material to form relatively higher dome-shaped protrusions as compared to a dome-shaped protrusion formed on a metal material. The layer may be removed following dispensing of the optically transparent material.