US 12,109,045 B2
Mouth guard having user-notification feature of impact force
Anthony M. Gonzales, Canoga Park, CA (US); Robert M. Merriman, Gilbert, AZ (US); Susan M. Merriman, Gilbert, AZ (US); and Christopher T. Cooper, Stittsville (CA)
Assigned to Force Impact Technologies, Inc., Gilbert, AZ (US)
Filed by Force Impact Technologies, Inc., Gilbert, AZ (US)
Filed on Jul. 15, 2022, as Appl. No. 17/812,885.
Application 17/812,885 is a continuation of application No. 16/723,246, filed on Dec. 20, 2019, granted, now 11,389,113.
Claims priority of provisional application 62/782,965, filed on Dec. 20, 2018.
Prior Publication US 2022/0346711 A1, Nov. 3, 2022
Int. Cl. A61B 5/00 (2006.01); A61B 5/11 (2006.01); A63B 71/08 (2006.01); B29C 51/12 (2006.01); B29C 51/26 (2006.01); B29C 51/30 (2006.01); B29K 23/00 (2006.01); B29L 31/00 (2006.01); B29L 31/52 (2006.01); G01C 17/02 (2006.01); G01C 19/00 (2013.01); G01P 15/00 (2006.01); G06F 3/01 (2006.01); G06F 3/16 (2006.01); H05K 1/02 (2006.01); H05K 1/18 (2006.01); H05K 3/28 (2006.01)
CPC A61B 5/682 (2013.01) [A61B 5/1126 (2013.01); A61B 5/4064 (2013.01); A61B 5/742 (2013.01); A61B 5/7455 (2013.01); A63B 71/085 (2013.01); B29C 51/12 (2013.01); B29C 51/266 (2013.01); B29C 51/30 (2013.01); G01C 17/02 (2013.01); G01C 19/00 (2013.01); G01P 15/00 (2013.01); G06F 3/016 (2013.01); G06F 3/16 (2013.01); H05K 1/028 (2013.01); H05K 1/189 (2013.01); H05K 3/284 (2013.01); A61B 2503/10 (2013.01); A61B 2560/0214 (2013.01); A61B 2562/0219 (2013.01); A63B 2220/40 (2013.01); A63B 2220/53 (2013.01); A63B 2225/50 (2013.01); B29K 2023/083 (2013.01); B29K 2909/14 (2013.01); B29L 2031/52 (2013.01); B29L 2031/768 (2013.01); H05K 2201/09027 (2013.01); H05K 2201/10037 (2013.01); H05K 2201/10106 (2013.01); H05K 2201/10151 (2013.01); H05K 2201/10159 (2013.01); H05K 2201/10545 (2013.01); H05K 2203/1322 (2013.01); H05K 2203/1327 (2013.01)] 21 Claims
OG exemplary drawing
 
1. A method for manufacturing a custom mouth guard that detects impact forces of a user, comprising:
conforming a first layer of material to a model of the user's maxillary region, the model includes the user's replicated teeth;
placing a flexible printed circuit board onto the first layer, the flexible printed circuit having a first end portion located adjacent to one molar region on the replicated teeth, a second end portion located adjacent to the other molar region on the replicated teeth, a middle portion adjacent to an incisor region on the replicated teeth, and at least one bridge portion adjacent to one of the first and second end portions, the first and second end portions having widths that are greater than the at least one bridge portion, the flexible printed circuit having a plurality of components including at least a processor, a memory device, a first sensor for determining linear acceleration, a second sensor for determining rotational acceleration, a battery, a wireless battery charging component, and a communication transmitter for transmitting an indication signal in response to an impact experienced by the user, the battery being mounted in the first or second end portions of the printed circuit board, the wireless battery charging component being mounted in the first or second end portions of the printed circuit board, the communication transmitter being mounted in the middle portion of the printed circuit board, wherein the placing includes (i) initially forcing one of the components into the first layer at a location aligned with a central part of the incisor region to set the location for the printed circuit board and (ii) subsequently forcing other components into the first layer at locations closer to the molar regions;
overlaying a second layer of material over the flexible printed circuit board and the first layer;
heating at least one of the first and second layers to help conform the plurality of components on the flexible circuit board to the first and second layers of material to create the custom mouth guard, the custom mouth guard having a front portion with a generally arched-shaped peripheral side surface for facing the buccal region of a mouth of a user, the printed circuit board being within the front portion of the custom mouth guard, the wireless battery charging component and the communication transmitter facing outwardly toward the buccal region.