Component protective overmolding using protective external coatings

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.

What is claimed is: 
     
         1 . A method, comprising:
 selectively applying at least one layer of a securing coating over one or more of a plurality of elements coupled with a framework associated with a wearable device, 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 layer of the securing coating, the plurality of elements, and the framework;   performing an inspection of the first inner molding;   responsive to the inspection resulting in a defect, removing the first inner molding and selectively re-forming the first inner molding that covers all or substantially all of the at least one layer of the securing coating, 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 having an exterior configured to be positioned in contact with skin when the wearable device is worn.   
     
     
         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 another 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 at least one of the layers in the at least one layer of the securing coating comprises a curable material. 
     
     
         16 . A method, comprising:
 selectively applying at least one layer of a securing coating substantially over one or more of a plurality of elements coupled with a framework associated with a wearable device, 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 layer of the securing coating 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 having an exterior configured to be positioned in contact with skin when the wearable device is worn.   
     
     
         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 comprises a property selected from the group consisting of waterproofing, water-resistance, being hydrophobic, being oleophobic, being anti-bacterial, and ultraviolet radiation (UV) resistant. 
     
     
         19 . The method of  claim 16 , wherein the at least one layer of the securing coating 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. 
     
     
         20 . The method of  claim 16 , wherein at least one of the layers in the at least one layer of the securing coating comprises a curable material.