Eye-Mountable Sensor Placement via Asymmetric Molding
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Solution Overview
Problem
Existing eye-mountable devices face challenges in precisely placing sensors relative to channels in polymer layers to effectively detect analytes in tear films, which affects their accuracy and functionality.
Innovation Solution
The method involves forming a first polymer layer, positioning a ring-shaped sensor structure in a predetermined rotational orientation, and then encapsulating it with a second polymer layer, with a channel created through the second layer to allow analyte detection, using techniques like cast or compression molding and laser ablation to ensure precise sensor placement and channel formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is placed in an eye-mountable device without precise rotational orientation, then the device structure is simpler, but the sensor cannot accurately detect analytes through the channel
Solution Approach 1:
The patent employs asymmetric alignment features including an asymmetric keyway in the ring-shaped structure and a corresponding asymmetric pin in the polymer layer. This asymmetric design creates a unique rotational orientation that ensures the sensor's detection surface is precisely aligned with the channel opening, allowing accurate analyte detection while maintaining manufacturing simplicity.
Solution Approach 2:
The patent incorporates alignment features during the molding process itself, where the asymmetric keyway and pin are formed as integral parts of the mold structure. This preliminary integration of alignment mechanisms ensures precise sensor placement and rotational orientation are achieved automatically during manufacturing, eliminating the need for complex post-processing alignment steps.
2Reliability
If the ring-shaped structure is fully enclosed by polymer layers, then the device has better protection and sealing, but the sensor cannot receive analyte
Solution Approach 1:
The patent creates a localized opening or channel through the polymer layer at the precise location where the sensor needs to receive analyte. This localized modification allows the sensor to maintain its function while the rest of the polymer structure provides complete enclosure and sealing protection. The channel is positioned to align with the sensor's detection surface, enabling analyte access without compromising overall device integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables precise and repeatable placement of sensors within eye-mountable devices, enhancing their ability to detect analytes in tear films with improved accuracy and reliability.
Implementation Method 1
using techniques like cast or compression molding and laser ablation to ensure precise sensor placement and channel formation
Data Source
AI summary
Example eye-mountable devices and methods for placing a flexible ring containing electronics in an eye-mountable device are described. A method may involve forming a first polymer layer, which defines a posterior side of an eye-mountable device. Further, the method may involve positioning a ring-shaped structure on the first polymer layer in a predetermined rotational orientation, wherein the ring-shaped structure comprises a sensor configured to detect an analyte. Still further, the method may involve forming a second polymer layer over the first polymer layer and the ring-shaped structure, such that the ring-shaped structure is fully enclosed by the first polymer layer and the second polymer layer. The second polymer layer defines an anterior side of the eye-mountable device. The method may also involve forming a channel through the second polymer layer based on the predetermined rotational orientation, such that the sensor is configured to receive the analyte via the channel.