Molding Piece Protrusions for Polymer Encapsulation of Sensors
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Solution Overview
Problem
The existing methods for manufacturing body-mountable devices, such as contact lenses with sensors, are inefficient and labor-intensive, requiring significant resources and not suitable for high-volume production due to complex fabrication processes.
Innovation Solution
A method involving a molding piece with protrusions is used to position a sensor or electronic component, which is then encased in a polymer layer, allowing for efficient formation and removal of the device, reducing labor and resource requirements through a process that includes curing and retracting protrusions to form the polymer layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing manufacturing methods are used for body-mountable devices, then devices can be produced, but the process is labor-intensive and not suitable for high-volume production
Solution Approach 1:
The patent combines multiple manufacturing steps into a single injection molding process. The mold assembly integrates the ejection pin mechanism, polymer formation, and sensor encapsulation into one unified system, allowing all operations to occur simultaneously during a single molding cycle, thereby enabling high-volume production without increasing complexity
Solution Approach 2:
The ejection pin is designed to automatically eject the formed device from the mold cavity through a spring-loaded mechanism that activates during the molding cycle. This self-ejecting feature eliminates the need for manual intervention or complex ejection systems, simplifying the manufacturing process while maintaining high productivity
2Ease of manufacture
If complex fabrication processes are used, then devices can be manufactured, but resource consumption increases and efficiency decreases
Solution Approach 1:
The mold cavity and ejection pin mechanism are pre-configured before the molding process begins. The polymer material is pre-positioned in the cavity, and the ejection pin is pre-loaded with spring tension. This preliminary preparation allows the actual manufacturing to occur in a single continuous action, reducing the need for multiple processing steps and associated energy consumption
Solution Approach 2:
The injection molding process utilizes controlled changes in temperature, pressure, and material state (from liquid polymer to solidified polymer) to transform the material and form the device in one operation. These parameter changes are precisely controlled during the molding cycle, simplifying the fabrication process while minimizing energy waste through efficient thermal and pressure management
3Productivity
If manual assembly methods are used, then devices can be formed, but labor requirements increase and production efficiency decreases
Solution Approach 1:
The patent replaces manual assembly operations with an automated injection molding system that uses hydraulic or electric injection mechanisms to deposit polymer material and form the device. The spring-loaded ejection pin automatically completes the ejection operation, eliminating the need for manual handling and assembly while maintaining simple, reliable mechanics throughout the process
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 simplifies the manufacturing process, reduces resource consumption, and enables high-volume production of body-mountable devices by encapsulating sensors within a polymer layer, enhancing the efficiency and scalability of device fabrication.
Implementation Method 1
The polymer material is cured to form the polymer layer
Data Source
AI summary
A method may involve positioning a structure on a plurality of protrusions that extend from a surface of a molding piece, wherein the structure comprises a sensor or an electronic component; forming, using the molding piece, a body-mountable device by forming a polymer layer around the structure positioned on the plurality of protrusions, such that the structure is at least partially enclosed by the polymer layer, wherein the polymer layer defines a first side of the body-mountable device and a second side of the body-mountable device opposite the first side, and wherein the surface of the molding piece supports the polymer layer as the polymer layer is being formed; and removing the body-mountable device from the molding piece.