Systems and methods for integrating electronics into a mouth guard

Mouth guard that includes a flexible printed circuit board encapsulated within a base member is provided. The flexible printed circuit board includes multiple separate stiff sections spaced apart from each other within the base member. One or more electronic devices are disposed within the base member. In particular, the one or more electronics are disposed on the base member.

BACKGROUND

The present disclosure relates generally to the integration of electronics into a mouth guard.

The scientific and medical research related to head trauma, in particular with regards to sports related concussions, has been increasing. To further this research, it is desirable to collect and analyze measurement data of the traumatic events. One such technique for providing this data may include sensing traumatic events utilizing a mouth guard to generate more accurate models of what the athlete experiences during a traumatic event. For example, biosensing systems may be utilized with the mouth guard to collect the data. However, these mouth guards incorporating the biosensing systems tend to be inflexible, uncomfortable, and cumbersome due to size of the electronics and/or the how the electronics are incorporated with the mouth guard, which discourages the user from wearing the mouth guard.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

As discussed in further detail below, embodiments of the present disclosure relate generally to providing a mouth guard that includes one or more electronic devices integrated within the mouth guard in a manner that makes the mouth guard less cumbersome and more comfortable for the user to wear. More specifically, the present disclosure relates to utilizing a flexible printed circuit board (PCB) that utilizes a plurality of separate stiff sections that are interconnected. The flexible PCB may be integrated in a front portion (e.g., labial-buccal portion) of the mouth guard. Each stiff section may include multiple layers such as a stiffener layer (e.g., closest to the user's teeth) and alternating layers of polyamide and adhesive layers.

The one or more electronic devices may be disposed on one or more of the stiff sections of the flexible PCB. In certain embodiments, the electronic devices may include one or more energy harvesting microbial fuel cells to generate and store power from the saliva within the user's mouth. The harvesting microbial fuel cells may solely or supplement power provided to other electronic devices within the mouth guard. In certain embodiments, the electronic devices disposed on the stiff sections of the flexible PCB of the mouth guard may be utilized to monitor a physiological parameter of the user. For example, the electronic devices may include a heart rate monitor disposed within a location of the mouth guard adjacent an artery in the face to measure the heart rate of the user. In certain embodiments, the electronic devices disposed on the stiff sections of the flexible PCB of the mouth guard may be utilized to facilitate communication between the user (e.g., athlete) and another person (e.g., coach). For example, the electronic devices may include a bone conducting device (e.g., bone conducting speaker) disposed within the mouth guard that can remotely receive communications from a transmitter (e.g., associated with another person such as the coach) and communicates them via the user's teeth and skull to the user's ear. These and other electronic devices may be integrated in the mouth guard on the flexible PCB to provide a less cumbersome and more comfortable mouth guard for the user.

With the foregoing in mind,FIG. 1illustrates a block diagram of a mouth guard10that may include the flexible PCB12. The mouth guard10may include the flexible PCB12encapsulated within a base member14. For example, the mouth guard10may be molded around the flexible PCB12with the separate but interconnected stiff sections spaced apart (e.g., laterally) from each other along base member14. The flexible PCB12may minimize the bulkiness of the mouth guard10while also increasing the comfort of it for the user. One or more electronic devices16may be integrated on one or more of the stiff sections of the flexible PCB12. Although the electronic devices16below are described as integrated on the flexible PCB12, in certain embodiments, the electronic devices16may be integrated within the mouth guard10without the flexible PCB12.

The electronic devices16may include one or more devices for harvesting energy. For example, one or more energy harvesting microbial fuel cells (MFCs) may be disposed on the flexible PCB12within the base member14. As described in greater detail below, the MFCs utilize the saliva of the user to generate power. One or more MFCs may be coupled to an energy harvesting circuit. Although the energy harvesting MFCs are described in detail below, other energy harvesting mechanisms may be utilized. For example, a piezoelectric device may be utilized to use the mechanical energy generated in the user's mouth (e.g., due to movement) to generate power. The energy harvesting devices may be utilized to solely or supplement power provided to one or more of the other electronic devices16within the base member14.

The electronic devices16may include devices for monitoring one or more physiological parameters of the user (e.g., athlete). For example, a photoplethysmograph (PPG) heart rate monitoring device may be utilized to measure the heart rate of the user. In some embodiments, the heart rate monitoring device may be disposed within the mouth guard10at a location adjacent an artery in the face and/or gums for measurements. If multiple wavelengths are utilized by the heart rate monitoring device other physiological parameters may be monitored via pulse oximetry such as peripheral capillary oxygen saturation (SpO2). Although the heart rate monitoring device is described in detail below, other devices may be utilized to determine physiological parameters of the user. For example, accelerometers may be utilized to measure the speed of the user and/or concussive forces experienced by the user.

The electronic devices16may include a device to enable discrete communication with the user of the mouth guard10from a person and location separate from the user (e.g., coach on sideline and/or in a booth). The device may include a bone conducting device (e.g., bone conducting speaker) that may receive communications from a transmitter associated with another person (e.g., coach) and transmit the communication to the user (e.g., athlete) via the user's teeth and skull. The bone conducting device is completely encapsulated within the base member14to make it waterproof and keeps the user from directly contacting the components of the bone conducing device. In certain embodiments, the bone conducting device may be able to communicate with other electronic devices in the mouth guard10. For example, the heart rate monitoring device may communicate with the bone conducting device to communicate an alarm related to an abnormal physiological parameter (e.g., irregular heart beat).

Each electronic device16may be associated with one or more different components such as controllers (having memory devices and processors), wireless communication devices (Bluetooth, ultra-wide band, etc.), wireless charging devices, energy storage devices (capacitors, etc.). Additionally or alternatively, the mouth guard10may have these different components integrated within the base member14separate from the electronic devices16. For example, additional energy storage devices may be integrated within the mouth guard10to provide power to the different electronic devices16. In some embodiments, the memory of the electronic devices16may include one or more tangible, non-transitory, computer-readable media that store instructions executable by a processor and/or data to be processed by the processor. For example, the memory may include random access memory (RAM), read only memory (ROM), rewritable non-volatile memory such as flash memory, hard drives, optical discs, and/or the like. Additionally, the processor of the electronic devices16may include one or more general purpose microprocessors, one or more application specific processors (ASICs), one or more field programmable logic arrays (FPGAs), or any combination thereof.

Turning now to a more detailed discussion of the flexible PCB12,FIG. 2illustrates a schematic diagram of a stiff section18of the flexible PCB12. As noted above, each stiff section18of the flexible PCB12includes a plurality of layers. The layer closest to the user's teeth (bottom-most layer) within the mouth guard10may be a stiffener layer20. The stiffener layer20may be composed of a glass-reinforced epoxy laminate material. In particular, the stiffener layer20may be composed of an FR4 grade material. The stiffener layer20may be configured to provide some stiffness or rigidity to the section18. The remaining layers of the section may include one or more adhesive layers (e.g., layers22,26,30) and one or more polyamide layers (e.g., layers24,28,32). The number of total layers of the section18may vary. In addition, the number of each of the layer types (e.g., stiffener, adhesive, and polyamide) may vary. AlthoughFIG. 2depicts the adhesive and polyamide layers as alternating, these layers may be arranged differently.

FIG. 3provides a schematic top view of the different locations of the flexible PCB12of the mouth guard10. As depicted, the base member14of the mouth guard10includes a U-shape. The mouth guard10may include a biting surface34configured, when disposed within the user's mouth, to be positioned between occlusal tooth surfaces of the upper and lower teeth. The base member14also may include an anterior portion36, a posterior portion38, a labial-buccal side40(e.g., front portion), and a lingual side42(e.g., rear portion). When the mouth guard10is disposed within the user's mouth, the anterior portion36faces the opening of the mouth, the posterior portion38faces the rear of the mouth (e.g., near the molars), the labial-buccal side40faces the user's inner cheeks, and the lingual side42faces the user's tongue. The flexible PCB12may be fully encapsulated within the base member14. In a preferred embodiment, the flexible PCB12may be disposed within the labial-buccal side40of the mouth guard10. For example,FIG. 4depicts the flexible PCB12solely in the labial-buccal side40of the mouth guard10. In particular, the separate stiff sections18of the flexible PCB12may be disposed adjacent each other (e.g., spaced apart or lateral spaced) along the base member14. The separate stiff sections18may be interconnected via electronic devices16disposed on the respective sections18and/or electrical connections disposed on the respective sections18. The number of sections18may also vary. Turning back toFIG. 3, in certain embodiments, the flexible PCB12may be disposed in the lingual side42of the base member14. In certain embodiments, a respective flexible PCB12may be disposed in both the labial-buccal side40and the lingual side42of the base member14. The flexible PCB12minimizes the bulkiness of the mouth guard10and makes the mouth guard10more comfortable for the user. Thus, the user may be encouraged to wear the mouth guard10. In certain embodiments, each separate stiff section may be associated with a respective tooth the user's mouth.

As mentioned above, an energy harvesting MFC is one of the electronic devices that may be disposed on the flexible PCB12within the mouth guard10.FIG. 5is a schematic diagram of an equivalent circuit44of the MFC46. The MFC46includes an anode48and a cathode50. The anode48of the MFC46may not be disposed within mouth guard10. Instead, the anode48may be disposed on the surface of the mouth guard10and exposed to the saliva within the user's mouth. The exposed surface area of the anode48may vary. In addition, the current densities and load generated by the MFC46may also vary. In certain embodiments, a plurality of MFCs46embedded on the mouth guard10may include a total anode surface area of at least 375 mm2. The number of MFCs46embedded on the mouth guard10may vary. The anode48may be made of graphene that contains bacteria that performs the decomposition of organic fluid (e.g., saliva within the user's mouth). The decomposition of the organic fluid by the bacteria may generate protons, CO2, and electrons. The electrons may be utilized to power a circuit52(e.g., energy harvesting circuit). Oxygen within the ambient air may serve as an acceptor (i.e., act as the cathode50) to generate water. As depicted inFIG. 6, the MFCs46may be disposed on the labial-buccal side40and/or the lingual side42of the base member14.

In some embodiments, the output current of the MFCs46may not be sufficient to use as a direct power source for circuits (e.g., of other electronic devices within the mouth guard10). Thus, the energy generated by the MFCs46may be harvested.FIG. 7illustrates a block diagram of an energy harvesting circuit54coupled to a plurality of MFCs46. AlthoughFIG. 7depicts multiple MFCs46coupled to the energy harvesting circuit54, in certain embodiments, each MFC46on the mouth guard10may be associated with a respective energy harvesting circuit54. The energy harvesting circuit54may include a rectifier56, a super capacitor58, and a buck converter60(e.g., step down converter). The output current of the MFCs46may be rectified into a direct current (DC) voltage suitable for energy storage in the super capacitor58. The buck converter60(e.g., DC/DC buck converter) may transform the storage voltage to a required output voltage or current for operation of the circuit (e.g., of the other electronic device(s) within the mouth guard10). The MFCs46may solely power and/or supplement power to one or more electronic devices within the mouth guard10via the energy harvesting circuit54.

While the anode48of the MFC46may be exposed to the user's saliva, the components of the energy harvesting circuit54may be embedded within the base member14of the mouth guard10.FIG. 8is a cross-sectional top view of the mouth guard10illustrating an interconnection between the MFC46and the energy harvesting circuit54and the flexible PCB12. As depicted inFIG. 8, the anode48of the MFC46may be disposed on an outer surface61(i.e., facing the user's cheek) of the labial-buccal side40of the base member14. The components (e.g., rectifier56, super capacitor58, and buck converter60) of the energy harvesting circuit54may be disposed on the flexible PCB12within the labial-buccal side40of the base member14. Conductive vias62within the labial-buccal side40may couple (e.g., electrically couple) the anode48to the energy harvesting circuit54. The anode48of the MFC46and/or the components of the energy harvesting circuit54may be disposed on multiple laterally adjacent stiff sections18of the flexible PCB12as depicted inFIG. 9. Also, as depicted inFIG. 9, the mouth guard10may include multiple MFCs46. In certain embodiments, the anode48of the MFC46and/or the components of the energy harvesting circuit54may be disposed on a single stiff section18of the flexible PCB12.

The utilization of the MFCs46may help avoid or minimize the utilization of other sources of power (e.g., batteries such as a lithium-ion polymer battery), which may enable the reduction in size of electronic devices disposed within the mouth guard10(as well as the size of the mouth guard10). The MFCs46may also provide a source of power with better usability. In particular, the MFCs46may provide a source of power without a life limit. In addition, the MFCs46may not need to be recharged. Further, the MFCs46(in particular, the anodes48) may not need to be disposed within the mouth guard10), which enables the MFCs46to be replaced when needed without having to replace the entire mouth guard10, thus, providing a more simple and cost effective option.

As mentioned above, a bone conducting device may be disposed on the flexible PCB12within the mouth guard10.FIG. 10is a block diagram of a bone conducting device64(e.g., bone conducting speaker). The bone conducting device64may be completely encapsulated within the mouth guard10, which makes the device64waterproof and protects the user from contacting the device64. In addition, the bone conducting device64may maintain a fixed position with respect to the user's teeth.

The bone conducting device64may include a wireless charging coil66to provide power to the device64(e.g., via inductive charging). Power provided by the wireless charging coil66may be stored in an energy storage device67(e.g., battery such as a lithium-ion polymer battery). In certain embodiments, the bone conducting device64may be powered (or partially powered) from energy collected by the MFCs46discussed above. The bone conducting device64may also include a wireless communications device or interface68to enable communications between the bone conducting device64and a transmitter or transceiver remote from the user of the mouth guard10(e.g., associated with a communication device of another person). The wireless communications device68may include a wireless transceiver or receiver. The wireless communications device68may utilize any suitable wireless communication protocol, such as an ultra-wideband (UWB) communication standard, a Bluetooth communication standard, or any 802.11 communication standard. The communication range between the bone conducting device64and the remote transmitter or transceiver may range from 30 meters to several meters.

The bone conducting device64may further include a bone conduction device70. The bone conduction device70may include a piezoelectric vibration device or a metal rod in a voice coil driven by an oscillating current. The wireless charging coil66, the energy storage device67, the wireless communications device68, and the bone conduction device70may be coupled to a controller72that controls the operation of the bond conducting device or speaker64. The controller72may include a memory74and a processor76as described above. The controller72may receive the wireless communication signal transmitted from the remote transmitter (via the wireless communications device68) and then drives the bone conduction device70to vibrate. The vibrations (e.g., sound waves) may be conducted through the teeth and skull to the inner ear of the user where the vibrations are translated into sound that only the user of the mouth guard10can hear. Thus, the mouth guard10with the bone conducting device64forms a discrete communications device that may be utilized in a number of situations (e.g., sporting events, military operations, etc.). Unlike current communications technology which involves multiple separate components, the mouth guard10with the bone conduction device70may provide a single platform that acts as a stand-alone discrete auditory communications device. In certain embodiments, the bone conducting device64may be utilized to communicate information from other electronic devices within the mouth guard10to the user (e.g., without the use of the wireless communications device68). For example, in certain embodiments, a warning or alarm of an abnormal condition related to a physiological parameter (e.g., abnormal heart beat) detected by a heart rate monitoring device within the mouth guard10may be communicated via the bone conducting device64. For example, a sound or verbal communication may be communicated via the bone conducting device64.

FIG. 11is a rear perspective view of the mouth guard10having a bone conducting device64. As depicted inFIG. 11, the bone conducting device64may be encapsulated within the base member14of the mouth guard10without the flexible PCB12. The wireless charging coil66and the bone conduction device70are disposed in the left and right sides of the labial-buccal side40of base member14, while other components78(e.g., controller72, wireless communications device68, etc.) are centrally disposed within the labial-buccal side40of the base member14. In certain embodiments, the bone conducting device or speaker64may be disposed in the lingual side42of the base member14. As depicted, the mouth guard10has been press fit for the maximum comfort and protection of the user. In particular, the mouth guard10may be fitted to make a tight connection with the molars. For example, as noted above, the right side of the base member14has the bone conduction device70that has a tight fit with the molars to conduct sound.

In certain embodiments, the bone conducting device64is disposed on the flexible PCB12within the mouth guard10as depicted inFIG. 12. As depicted inFIG. 12, components of the bone conducting device64may be disposed on the multiple stiff sections18of the flexible PCB along the mouth guard10. For example, as depicted inFIG. 12, the wireless charging coil66and the bone conducting device70are disposed on separate stiff sections18of the flexible PCB12.

As mentioned above, a heart rate monitoring device may be disposed on the flexible PCB12within the mouth guard10.FIG. 13is a block diagram of a heart rate monitoring device78disposed within the mouth guard10. The heart rate monitoring device78may be completely encapsulated within the mouth guard10. In particular, each component of the heart rate monitoring device78may be disposed on one or more stiff sections18of the flexible PCB12. In certain embodiments, the components of the heart rate monitoring device78may be disposed within the mouth guard10without the flexible PCB12. In certain embodiments, the mouth guard10may include a single heart rate monitoring device78. In other embodiments, the mouth guard10may include more than one heart rate monitoring device78(e.g., 2, 3, 4 or more devices78). The heart rate monitoring device78is configured to be located within the base member14of the mouth guard10adjacent an arterial location within the user's face and/or gums to enable the device78to acquire a plethysmographic signal at one or more wavelengths to determine one or more physiological parameters of the user.

The heart rate monitoring device78may include a wireless charging coil80to provide power to the device78(e.g., via inductive charging). Power provided by the wireless charging coil78may be stored in an energy storage device82(e.g., battery such as a lithium-ion polymer battery). In certain embodiments, the bone heart rate monitoring device78may be powered (or partially powered) from energy collected by the MFCs46discussed above. The heart rate monitoring device78may also include a wireless communications device or interface84to transmit physiological data to a remote location. The wireless communications device80may include a wireless transceiver. The wireless communications device80may utilize any suitable wireless communication protocol, such as an ultra-wideband (UWB) communication standard, a Bluetooth communication standard, or any 802.11 communication standard.

The heart rate monitoring device78may also include an emitter86and a detector88. Light from the emitter86(e.g., at one or more certain wavelengths) may pass into the user of the mouth guard10where the portions of the light may be differentially scattered, absorbed, and/or transmitted. Light that emerges from the user's tissue within the mouth may be detected by the detector88. In certain embodiments, the emitter86may emit light from one or more LEDs or other suitable light sources into a pulsatile tissue. The reflected or transmitted light may be detected with the detector88, such as photodiode or photo-detector, after the light has passed through or has been reflected by the pulsatile tissue. In certain embodiments, a plethysmographic signal at a single wavelength may be obtained that enables a determination of a heart rate of the user of the mouth guard10. In certain embodiments, a plethysmographic signal may be obtained at at least a couple of wavelengths (e.g., red and infrared) to determine the SpO2and/or heart rate of the user of the mouth guard10. The wireless charging coil80, the energy storage device82, the wireless communications device84, the emitter86, and the detector88may be coupled to a controller90that controls the operation of the heart rate monitoring device78. The controller90may include a memory92and a processor94as described above. The controller90may control the emission of light from the emitter and receive the detected signals from the detector88. In certain embodiments, the controller90may partially process the detected signals and transmit (via the wireless communications device84) the processed signals to a remote location where the one or more physiological parameters may be detected. In certain embodiments, the controller90may fully process the detected signals to determine the one or more physiological parameters and then transmit (via the wireless communications device84) the physiological parameters to a remote location. In certain embodiments, the data collected by the heart rate monitoring device78may be stored within the memory92for later transmission when requested or at a fixed interval. In certain embodiments, the data collected by the heart rate monitoring device78may be continuously transmitted (via the wireless communications device84) to a remote location. In certain embodiments, the memory92may store one or more ranges or thresholds. The heart rate monitoring device78may compare one or more physiological parameters to these ranges or thresholds and provide a warning or alarm signal if the one or more physiological parameters are abnormal or approaching abnormal (e.g., irregular heart beat). In certain embodiments, the warning or alarm signal may be provided to the bone conducting device described above disposed within the mouth guard10to provide an audio warning or alarm to the user of the mouth guard10. In certain embodiments, the one or more physiological parameters and/or associated alarms or warnings may be displayed on a screen of a device worn by the user of the mouth guard10. For example, a football player may wear a helmet that includes a visor configured to display the physiological parameters and/or associated alarms. In certain embodiments, a soldier may wear a wrist watch configured to display the physiological parameters and/or associated alarms.

The heart rate monitoring device78may be disposed at a variety of locations within the mouth guard10. In particular, the heart rate monitoring device78may be located within the mouth guard10at a location adjacent an artery in the user's mouth and/or gums to facilitate the acquisition of the physiological data. For example, the heart rate monitoring device78may be located adjacent the septal artery, the inferior labial artery, or the superior labial artery.FIGS. 14-16illustrate the various locations within the mouth guard10where the heart rate monitoring device78may be located. As depicted inFIG. 14, the heart rate monitoring device78may be located in the labial-buccal side40and/or the lingual side42of the base member14. In addition, the heart rate monitoring device78may be located in the anterior portion36and/or the posterior portion38of the base member14. Further, the heart rate monitoring device78may be located on the left side96or the right side98of the base member14. In certain embodiments, as depicted inFIG. 15, the mouth guard10may only include an upper portion100that extends across the user's upper teeth. Thus, the heart rate monitoring device78may be disposed in the upper portion100and only acquire physiological data from arterials locations of the user's mouth or gums adjacent the upper teeth. In certain embodiments, as depicted inFIG. 16, the base member14may include both the upper portion100that extend across the user's upper teeth and a lower portion102that extends across the user's lower teeth. The heart rate monitoring device in the mouth guard10inFIG. 16may be located in the upper portion100and/or the lower portion102of the base member14. Thus, the heart rate monitoring device78may acquire physiological data from arterials locations of the user's mouth or gums adjacent the upper teeth and/or lower teeth.

FIG. 17is a process flow diagram of a method104for manufacturing the mouth guard having the flexible PCB12. The method104may include providing the flexible PCB12that includes the separate stiff sections18(block106). The flexible PCB12as described above. The method104may also include disposing on or coupling to the flexible PCB12one or more electronic devices16(block108). The electronic devices16may include accelerometers, heart rate monitoring devices, bone conducting devices or speakers, energy harvesting MFCs, and/or other electronic devices. The method104may further include encapsulating the flexible PCB12and/or the one or more electronic devices16within the base member of the mouth guard10(block110). For example, the mouth guard10may be molded or fabricated about the flexible PCB12and/or the one or more electronic devices16utilizing the typical techniques for fabricating the mouth guard10. Depending on the type of mouth guard10, the flexible PCB12and/or the one or more electronic devices16may be disposed in an upper portion of the mouth guard that extends over the user's upper teeth or a lower portion of the mouth guard that extends over the user's lower teeth or both the upper and lower portions. In certain embodiments, the flexible PCB12and/or the one or more electronic devices16may be disposed in the labial-buccal side, the lingual side, and/or both the labial-buccal and lingual sides. Certain electronic devices16may not be encapsulated within the mouth guard10. For example, the anode of the MFC may be disposed on an outer surface of the mouth guard10.