Eye-Tracking Glasses Assembly to Minimize Sensor Bonding Air Bubbles
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Solution Overview
Problem
The existing process for integrating photosensitive sensors in eye-tracking glasses is lengthy and prone to air bubble formation, leading to unstable yields due to difficulty in controlling layer uniformity and adhesion, particularly at gaps between electronic components and the substrate.
Innovation Solution
A method involving spraying a matching material to fill gaps between electronic components and the substrate surface, followed by a sealing layer to connect the lens, thereby reducing air bubble formation and improving yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the substrate with photosensitive sensor is encapsulated and solid optical adhesive is laminated to adhere the photosensitive sensor to the lens surface, then the photosensitive sensor can be fixed in position, but the process becomes very long requiring multiple coating, drying, shaping steps and is difficult to control layer uniformity, generating air bubbles and causing unstable yields
Solution Approach 1:
The patent combines the encapsulation and adhesive lamination steps into a single integrated process. The encapsulant material serves dual functions: it encapsulates the photosensitive sensor substrate and simultaneously acts as the adhesive layer to bond the sensor to the lens, eliminating the need for separate coating and drying steps for each layer.
Solution Approach 2:
The patent performs preliminary positioning of the photosensitive sensor within the encapsulant material before final curing. The sensor substrate is placed in the desired position on the lens surface, and then the encapsulant is applied to encapsulate and secure it, ensuring proper alignment before the adhesive sets.
2Manufacturing precision
If multiple coating, drying, shaping processes are used to laminate solid optical adhesive, then the photosensitive sensor can be adhered to the lens, but it is difficult to control the uniformity of each layer, which is more likely to generate air bubbles
Solution Approach 1:
The patent merges the adhesive layer and encapsulant layer into a single material layer. The encapsulant material is applied as one continuous layer that simultaneously provides adhesion and encapsulation functions, eliminating multiple coating steps and ensuring uniformity without complex process control.
Solution Approach 2:
The patent uses a homogeneous encapsulant material that serves multiple functions. This single material provides both the adhesive properties needed for bonding and the encapsulation properties for protecting the sensor, ensuring uniform composition and properties throughout the layer without interfaces between different materials.
3Strength
If the photosensitive sensor is adhered through multiple process steps, then the sensor can be fixed, but the process is very long requiring multiple coating, drying, shaping and other processes
Solution Approach 1:
The patent combines adhesion and encapsulation into a single step using the encapsulant material. The encapsulant is applied once to both adhere the sensor substrate to the lens and encapsulate the sensor, eliminating the need for separate adhesive application, drying, and encapsulation steps.
Solution Approach 2:
The patent ensures proper sensor positioning and adhesion preparation before applying the encapsulant material. The sensor substrate is pre-positioned on the lens surface with appropriate alignment, and the encapsulant is then applied to secure it, reducing the need for subsequent adjustment steps.
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
The method enhances the stability and efficiency of the eye-tracking glasses production by minimizing gaps and air bubbles, ensuring better optical performance and higher production yields.
Implementation Method 1
spraying a matching material by means of spraying towards the first surface, the matching material being piled up at least at a gap where the first surface is connected with the electronic components
Data Source
AI summary
A method for preparing eye-tracking glasses: providing a substrate assembly, the substrate assembly comprising a functional film, the functional film being located on an outermost surface of the substrate assembly as a first surface, the first surface is provided with electronic components. Spraying a matching material towards the first surface, the matching material accumulating at least at a gap difference between the first surface and the electronic component. Providing a sealing layer, the sealing layer covering the first surface and the electronic components and the matching material disposed on the first surface. Providing a lens, the lens being connected to the functional film and the electronic components by the sealing layer.