Electrically-isolated and moisture-resistant designs for wearable devices

1. A wearable device comprising:

a low-profile sensor assembly configured to be disposed within a low-profile wearable housing configured to be worn on a wearer's skin, the low-profile sensor assembly comprising:

a printed circuit board (“PCB”) having a first layer and a second layer;

a semiconductor package having a plurality of electrical conductors, the semiconductor package coupled to the first layer of the PCB;

a trace having a first portion disposed on the first layer, a second portion disposed on the second layer, the first portion of the trace having a first end coupled to a first electrical conductor of the plurality of electrical conductors and a second end electrically coupled to an interior trace disposed on an interior layer of the PCB, and the second portion of the trace having a first end electrically coupled to the interior trace;

a sensor wire electrically coupled to the second portion of the trace and extending from the PCB, the sensor wire configured to be inserted into the wearer's skin; and

an encapsulant disposed on the first layer, the encapsulant positioned to provide contaminant protection and enable placement of the low-profile sensor assembly within the low-profile wearable housing and covering at least one of: (i) the plurality of electrical conductors, (ii) the first portion of the trace, or (iii) the second portion of the trace, wherein an upper surface of the semiconductor package remains exposed.

2. The wearable device of claim 1 , further comprising the low-profile wearable housing, the low-profile wearable housing defining a cavity and comprising a first housing portion and a second housing portion, the first housing portion coupled to the second housing portion to define the cavity, the low-profile sensor assembly disposed within the low-profile wearable housing and the sensor wire extending out of the low-profile wearable housing.

3. The wearable device of claim 2 , wherein the second housing portion includes a first hole to allow the sensor wire to extend outside of the low-profile wearable housing.

4. The wearable device of claim 3 , wherein the PCB includes a second hole, wherein the second hole is aligned with the first hole and to allow the sensor wire to extend through the PCB.

5. The wearable device of claim 4 , wherein the encapsulant is further disposed within the first hole and/or the second hole.

6. The wearable device of claim 2 , wherein the first housing portion is heat welded to the second housing portion.

7. The wearable device of claim 2 , wherein the sensor wire comprises first and second electrodes, the first electrode comprising a platinum or platinum-coated wire, and the second electrode comprising a silver/silver-chloride (Ag/AgC) material.

8. The wearable device of claim 1 , wherein the encapsulant has a glass transition temperature greater than 45 degrees Celsius and a cure temperature of less than 175 degrees Celsius.

9. The wearable device of claim 1 , wherein the encapsulant has a glass transition temperature greater than an operating temperature range of the wearable device and a cure temperature substantially lower than a melting temperature of a housing material of the wearable device.

10. The wearable device of claim 1 , wherein the encapsulant has a resistivity of at least 10 13 ohms per centimeter.

11. The wearable device of claim 1 , wherein a total height of the PCB and the semiconductor package is less than 9 millimeters.

12. The wearable device of claim 1 , wherein the via is a first via and the PCB further comprises a third layer, further comprising a second via formed within the PCB and between the second and third layers of the PCB and a third portion of the trace electrically connected between the first and second vias, wherein the second portion of the trace is electrically connected to the first via by the second via and the third portion of the trace.