Component protective overmolding using protective external coatings

• US 8,529,811 B2
• Filed: 03/22/2012
• Issued: 09/10/2013
• Est. Priority Date: 06/10/2011
• Status: Expired due to Fees

• Current Assignee: JB IP Acquisitions LLC
• Original Assignee: AliphCom, Inc. (AliphCom Corp.)
• Inventors: Drysdale, Richard Lee, Fullam, Scott, Orvis, Skip Thomas, Levinson, Nora Elam
• Primary Examiner(s): Lee, Edmund H.
• Application Number:
  US13/427,839
• Publication Number:
  US 20120315379A1
• Time in Patent Office: 537 Days
• Field of Search: None
• US Class Current: 264/135
• CPC Class Codes: B29C 2045/14893 Preventing defects relating to shrinkage of inserts or coating material
• CPC Class Codes: B29C 2045/1682 preventing defects
• CPC Class Codes: B29C 45/14639 for obtaining an insulating effect, e.g. for electrical components
• CPC Class Codes: B29C 45/14819 the inserts being completely encapsulated
• CPC Class Codes: B29C 45/1671 with an insert
• CPC Class Codes: B29C 45/1676 using a soft material and a rigid material, e.g. making articles with a sealing part
• CPC Class Codes: B29K 2021/003 Thermoplastic elastomers
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2995/0069 non-permeable
• CPC Class Codes: B29K 2995/0093 hydrophobic
• CPC Class Codes: B29L 2031/3481 Housings or casings incorporating or embedding electric or electronic elements
• CPC Class Codes: C23C 28/00 Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
• CPC Class Codes: G06F 1/163 Wearable computers, e.g. on a belt

Abstract

Techniques for component protective overmolding using protective external coatings include selectively applying a protective material substantially over one or more elements coupled to a framework configured to be worn, the elements including at least a sensor, and forming one or more moldings substantially over a subset or all of the framework, the protective material and the elements, after the protective material has been selectively applied, at least one of the one or more moldings having a protective property.

Claims

1. A method, comprising:

selectively applying at least one covering substantially over one or more of a plurality of elements coupled with a framework for a wearable device configured to be worn by a user, the plurality of elements including at least a sensor;

selectively forming a first inner molding that covers all or substantially all of the at least one covering, the plurality of elements, and the framework;

selectively forming a second inner molding that covers all or substantially all of the first inner molding; and

selectively forming an outer molding of the wearable device, the outer molding covering all or substantially all of the second inner molding, the outer molding configured to be positioned in contact with the user.

2. The method of claim 1, wherein the outer molding comprises an anti-bacterial material.

3. The method of claim 1, wherein the outer molding comprises an oleophobic material.

4. The method of claim 1, wherein the outer molding is configured to protect against ultraviolet radiation.

5. The method of claim 1, wherein the outer molding comprises a hydrophobic material.

6. The method of claim 1, wherein the outer molding is configured to provide a waterproof seal over the plurality of elements.

7. The method of claim 1, wherein a pattern is formed on the outer molding.

8. The method of claim 1, further comprising performing an inspection of the outer molding to determine if the outer molding is defective.

9. The method of claim 8, further comprising:

removing the outer molding after determining the outer molding is defective; and

re-forming the outer molding.

10. The method of claim 1, wherein the framework is comprised of a synthetic fiber.

11. The method of claim 1, wherein the framework is formed using carbon fiber.

12. The method of claim 1, wherein the framework is comprised of one or more filaments.

13. The method of claim 1, wherein the framework is formed using a thermoplastic elastomer.

14. The method of claim 13, wherein the thermoplastic elastomer comprises polypropylene.

15. The method of claim 1, wherein the at least one covering comprises a curable coating.

16. A method, comprising:

selectively applying at least one protective material substantially over one or more of a plurality of elements coupled with a framework for a wearable device configured to be worn by a user, the plurality of elements including at least a sensor;

forming one or more inner moldings substantially over a subset or all of the framework, the at least one protective material and the plurality of elements, after the selectively applying, at least one of the one or more inner moldings having a protective property; and

forming an outer molding of the wearable device that covers all or substantially all of the one or more inner moldings, the outer molding configured to be positioned in contact with the user.

17. The method of claim 16, wherein the plurality of elements are configured to perform an operation using data from the sensor.

18. The method of claim 16, wherein the protective property is waterproofing.

19. The method of claim 16, wherein the protective property is water-resistance.

20. The method of claim 16, wherein the protective property is being hydrophobic.

21. The method of claim 16, wherein the protective property is being oleophobic.

22. The method of claim 16, wherein the protective property is being anti-bacterial.

23. The method of claim 16, wherein the at least one protective material is configured to protect the one or more of the plurality of elements from damage occurring during the forming of the one or more inner moldings.

24. The method of claim 16, wherein at least one of the one or more inner moldings comprises a medical-grade thermoplastic elastomer.

25. The method of claim 16, further comprising removing and re-applying at least one of the one or more inner moldings after an inspection of the one or more inner moldings.

26. The method of claim 16, at least one protective material comprises a curable coating.