Support Pillars for Flexible PCB Encapsulation in Hydrogel Contact Lenses
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Solution Overview
Problem
Existing electronic contact lenses face challenges in manufacturing, resulting in safety, comfort, and durability issues due to the separation of soft contact lens material from electronics, leading to low durability and discomfort for wearers.
Innovation Solution
The development of electronic contact lenses with encapsulated components supported by pillars formed from contact lens material, which aids in accurate positioning and encapsulation within the lens body, enhancing safety, comfort, and durability by using a method where supports are formed on a mold before placing components, allowing uncured material to flow and cure around them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electronic components are placed directly in contact lens material, then manufacturing is simplified, but the contact lens material separates from electronics resulting in low durability
Solution Approach 1:
The patent applies preliminary action by forming support pillars from contact lens material on the mold surface before placing electronic components. This preliminary structuring creates predetermined support locations that guide component placement and ensure proper encapsulation, resolving the contradiction by maintaining manufacturing simplicity while preventing material separation through pre-established structural support.
2Object-affected harmful factors
If electronic components are encapsulated within contact lens material, then safety and comfort improve, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the contact lens material into two functional portions: support pillars formed on the mold surface and bulk material that encapsulates components. This segmentation creates distinct manufacturing zones where pillars provide structural support for safe encapsulation while the bulk material ensures comfort, thereby improving safety and comfort without proportionally increasing manufacturing complexity.
3Manufacturing precision
If support pillars are formed on mold before placing components, then component positioning accuracy improves, but manufacturing steps increase
Solution Approach 1:
The patent applies self-service by designing support pillars that automatically perform multiple functions: they serve as positioning fixtures for components, provide structural support during encapsulation, and become integral parts of the final contact lens. This self-multiplying functionality improves positioning accuracy while minimizing the net increase in manufacturing steps, as the same structural elements serve multiple purposes 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 results in a safer, more comfortable, and durable electronic contact lens with fully encapsulated components, preventing material separation and improving the manufacturing process for better integration of electronics within the lens material.
Implementation Method 1
The mold may be filled with contact lens material. The contact lens material may be cured.
Data Source
AI summary
A contact lens may include a body of contact lens material extending between a first surface and a second surface. An electromechanical component may be supported in the contact lens material between the first surface and the second surface. A support comprising a plurality of pillars may be formed of the contact lens material and may extend from at least one of the first surface and the second surface to the electromechanical component.