Mandrel-Based Shadow Mask for 3D Lens Patterning
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Solution Overview
Problem
The challenge lies in manufacturing three-dimensional substrates, such as ophthalmic lenses, with integrated microelectronic devices and power sources while ensuring precise electrical connections, safety for ocular use, and comfort, due to size constraints and the difficulty of mounting planar devices on non-planar surfaces.
Innovation Solution
A method involving the use of a mandrel with machined forms to create precision masks for depositing layers on three-dimensional substrates, utilizing a plating layer and metal layer with a ring-shaped aperture to form interconnections, and achieving thin, precise shadow masks for patterning and deposition on complex surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If planar electronic devices are mounted on non-planar lens surfaces, then enhanced functionality is achieved, but manufacturing precision and device integration difficulty increase
Solution Approach 1:
The patent transitions from planar mounting to three-dimensional conformal mounting of electronic devices on the lens surface. By using a mandrel that replicates the lens curvature and employing deposition techniques that follow the surface topology, the invention enables precise device integration on non-planar surfaces while maintaining manufacturing feasibility.
2Area of moving object
If electronic components are integrated on a small lens area, then miniaturization is achieved, but manufacturing complexity and connection precision requirements increase
Solution Approach 1:
The manufacturing process is divided into discrete steps: mandrel preparation, selective deposition zones, layer-by-layer material deposition, and controlled release. This segmentation of the complex integration process into manageable stages reduces overall manufacturing complexity while enabling precise placement of electronic components on the miniaturized lens surface.
3Reliability
If precise electrical connections are ensured between deposited layers, then reliability is improved, but manufacturing process complexity increases
Solution Approach 1:
The mandrel is pre-configured with machined forms and designated deposition zones before the actual material deposition begins. This preliminary preparation ensures that subsequent deposition steps automatically achieve precise electrical connections without requiring complex real-time adjustments, thereby improving reliability while managing process complexity.
4Manufacturing precision
If thin shadow masks are used for patterning, then manufacturing precision is improved, but mask fabrication difficulty increases
Solution Approach 1:
The mandrel serves as an intermediary tool that simplifies shadow mask fabrication. By using the mandrel's pre-machined forms as templates, thin shadow masks can be created with high precision through simpler deposition and release processes, rather than attempting to fabricate precise masks directly without the mandrel's guidance.
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 the precise adhesion and patterning of microelectronic devices on three-dimensional substrates, ensuring safe and comfortable integration for vision correction and biomarker monitoring, with reduced capacitance and improved dimensional control.
Implementation Method 1
A plating layer is deposited in a first region of the form. A metal layer is deposited in a second region of the form
Implementation Method 2
A portion of the mandrel below the plating layer in the first region and below the metal layer in the second region is then removed
Data Source
AI summary
The present invention provides a method of making a mask for patterning a three-dimensional substrate. A mandrel includes a form machined in a surface corresponding to a shape of the substrate. A layer of material is deposited in a first region of the form and a metal layer is deposited in a second region of the form. A portion of the mandrel is subsequently removed. The present invention also provides a method of patterning a three-dimensional substrate with a mask.