Sensor Positioning on Polymer Layers for Contact Lenses
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Solution Overview
Problem
Existing body-mountable devices, such as eye-mountable contact lenses, face challenges in accurately positioning sensors to detect analytes like glucose in tears without distorting the polymer layers or components, which can affect the wearer's line of sight and the accuracy of analyte detection.
Innovation Solution
A method involving a rod with a plunger to precisely position a structure, such as a sensor, on a first polymer layer, followed by forming a second polymer layer to enclose it, ensuring accurate placement and minimizing distortion, allowing for effective analyte detection while maintaining the wearer's line of sight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are positioned on polymer layers in body-mountable devices, then analyte detection capability is improved, but distortion of polymer layers or components occurs which affects line of sight and detection accuracy
Solution Approach 1:
The device is divided into multiple polymer layers (first polymer layer, second polymer layer) with the sensor positioned between them. This segmentation allows the sensor to be integrated without distorting the overall structure, as each layer can be independently formed and positioned.
Solution Approach 2:
The sensor is positioned on the first polymer layer before the second polymer layer is formed. This preliminary positioning ensures accurate placement while allowing subsequent layers to be formed around the sensor without causing distortion.
2Adaptability or versatility
If sensors are positioned on polymer layers, then analyte detection is enabled, but distortion occurs affecting the wearer's line of sight
Solution Approach 1:
The sensor is nested between two polymer layers, with the first polymer layer forming a base and the second polymer layer encapsulating the sensor. This nested structure allows the sensor to be integrated without distorting the external shape or affecting the wearer's line of sight.
Solution Approach 2:
The polymer layers are formed as thin, flexible films that can accommodate the sensor without significant distortion. These flexible layers maintain the overall shape and optical properties required for clear vision while enabling sensor functionality.
3Ease of manufacture
If a structure is positioned on a polymer layer, then sensor integration is achieved, but positioning accuracy may be compromised without proper apparatus
Solution Approach 1:
A positioning apparatus with a rod and plunger is used as an intermediary tool to position the sensor on the first polymer layer. The rod supports the sensor while the plunger applies controlled pressure to secure it in the correct position, ensuring manufacturing precision during integration.
Solution Approach 2:
The manual or less precise mechanical positioning methods are replaced with a controlled apparatus system involving a rod and plunger. This system provides more accurate and repeatable positioning through controlled mechanical action, improving manufacturing precision.
Data Source
AI summary
Methods and apparatus for positioning a structure on a polymer layer are described. A method may involve forming a first polymer layer. The method may further involve positioning, by an apparatus, a structure on the first polymer layer, where the apparatus comprises a rod having a first end that supports the structure as the structure is being positioned and a plunger located around the first end of the rod that presses the structure onto the first polymer layer as the structure is being positioned. And the method may involve forming a second polymer layer over the first polymer layer and the structure, where the first polymer layer defines a first side of a body-mountable device and the second polymer layer defines a second side of the body-mountable device opposite the first side.