Ring-Shaped Adhesive Pattern for Polymer Substrate Bonding
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Solution Overview
Problem
Existing body-mountable devices, such as contact lenses with embedded sensors, face challenges in adhering substrates to polymeric materials without obstructing the viewing area or inhibiting electronic components, due to excess adhesive causing optical defects and interference with device functionality.
Innovation Solution
A method involving the formation of polymer layers with precise adhesive application in a ring-shaped pattern, followed by curing, to securely adhere the substrate to the polymeric material while minimizing adhesive spread and ensuring optimal device functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to adhere substrate to polymeric material, then bonding strength is improved, but excess adhesive causes optical defects and interferes with electronic components
Solution Approach 1:
The adhesive is applied in a ring-shaped pattern with controlled geometry (outer radius Ro, inner radius Ri) rather than uniformly across the entire substrate. This localized application ensures adequate bonding strength at the periphery while preventing adhesive from reaching the central optical and electronic components, thus eliminating optical defects and electronic interference
Solution Approach 2:
The adhesive application area is segmented into a specific ring-shaped region, separating the bonding function from the optical/electronic component areas. This segmentation allows the substrate to be bonded to the polymeric material while maintaining clear zones for optical clarity and electronic component functionality
2Manufacturing precision
If ring-shaped substrate is positioned in predetermined rotational orientation, then alignment precision is improved, but positioning complexity increases
Solution Approach 1:
The ring-shaped substrate incorporates asymmetric alignment features (such as notches or markers at specific angular positions) that enable predetermined rotational orientation. These asymmetric features provide visual or mechanical cues for correct positioning, improving alignment precision without requiring complex positioning mechanisms
Solution Approach 2:
The alignment features are pre-formed on the ring-shaped substrate during manufacturing, allowing the substrate to be self-aligned when placed on the polymeric material. This preliminary preparation of alignment markers eliminates the need for complex real-time positioning systems during assembly
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 allows for precise adherence of substrates to polymeric materials, preventing optical defects and electronic interference, thereby enhancing the functionality and usability of body-mountable devices like contact lenses with embedded sensors.
Implementation Method 1
curing the ring-shaped substrate and the first polymer layer
Implementation Method 2
annealing the first layer of the bio-compatible material and the second layer of the bio-compatible material together to form an encapsulated structure
Data Source
AI summary
The present disclosure provides a method including forming a polymer layer defining a side of an eye-mountable device. The method may also include providing an adhesive in a ring-shaped pattern on a ring-shaped substrate or on the first polymer layer. The method may also include providing the ring-shaped substrate on the first polymer layer in a predetermined rotational orientation. The method may also include applying a force to one or more of the ring-shaped substrate and the polymer layer to adhere the first polymer layer to the ring-shaped substrate. The method may also include curing the ring-shaped substrate and the first polymer layer.