Methods for Adhering a Substrate to a Polymer Layer

• US 20150005602A1
• Filed: 06/28/2013
• Published: 01/01/2015
• Est. Priority Date: 06/28/2013
• Status: Active Grant

• Current Assignee: Twenty Twenty Therapeutics, LLC
• Original Assignee: Google Inc. (Alphabet Inc.)
• Inventors: Linhardt, Jeffrey George, Liu, Zenghe
• Granted Patent: US 9,901,247 B2
• Time in Patent Office: Days
• US Class Current: 600/347
• CPC Class Codes: A61B 3/101 for examining the tear film
• CPC Class Codes: B29C 65/522 by spraying, e.g. by flame spraying
• CPC Class Codes: B29D 11/00048 composed of parts with dissimilar composition B29D11/00057 takes precedence
• CPC Class Codes: B29D 11/00817 Producing electro-active lenses or lenses with energy receptors, e.g. batteries or antennas
• CPC Class Codes: B32B 2551/00 Optical elements
• CPC Class Codes: B32B 37/185 Laminating sheets, panels or inserts between two discrete plastic layers
• CPC Class Codes: G02C 2202/16 Laminated or compound lenses
• CPC Class Codes: G02C 7/04 Contact lenses for the eyes disinfection or sterilisation of contact lenses A61L12/00
• CPC Class Codes: G02C 7/049 Contact lenses having special fitting or structural features achieved by special materials or material structures

Abstract

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.

Claims

1. A method comprising:

forming a polymer layer, wherein the polymer layer defines a side of an eye-mountable device;

providing an adhesive in a ring-shaped pattern on a ring-shaped substrate or on the polymer layer;

providing the ring-shaped substrate on the polymer layer in a predetermined rotational orientation;

applying a force to one or more of the ring-shaped substrate and the polymer layer to adhere the polymer layer to the ring-shaped substrate; and

curing the ring-shaped substrate and the polymer layer.

2. The method of claim 1, wherein providing an adhesive in a ring-shaped pattern comprises spraying the adhesive on the ring-shaped substrate or the polymer layer.

3. The method of claim 2, wherein the adhesive is sprayed using a nebulizer.

4. The method of claim 1, wherein providing an adhesive in a ring-shaped pattern comprises stamping the adhesive on the ring-shaped substrate or the polymer layer.

5. The method of claim 4, wherein the adhesive is stamped using a polydimethylsiloxane (PDMS) stamp.

6. The method of claim 1, wherein the adhesive has a thickness of less than about 5 micrometers.

7. The method of claim 1, wherein forming a polymer layer comprises forming a first polymer layer and wherein the first polymer layer defines a first side of the eye-mountable device, and the method further comprises:

forming a second polymer layer over the first polymer layer and the ring-shaped substrate, such that the ring-shaped substrate is substantially enclosed within the first polymer layer and the second polymer layer, wherein the second polymer layer defines a second side of the eye-mountable device.

8. The method of claim 7, wherein the first polymer layer and the second polymer layer comprise a hydrogel material or a silicone elastomer.

9. The method of claim 7, wherein the ring-shaped substrate is more rigid than the first polymer layer and the second polymer layer.

10. The method of claim 7, wherein the second polymer layer is configured to be removably mounted over a corneal surface, and wherein the first polymer layer is configured to be compatible with eyelid motion when the eye-mountable device is so mounted.

11. The method of claim 1, wherein the eye-mountable device has a thickness that is between about 100 micrometers and about 500 micrometers.

12. The method of claim 1, wherein curing the ring-shaped substrate and the polymer layer comprises curing by use of one or more of:

chemical additives, ultraviolet radiation, electron beam, and heat.

13. The method of claim 1, wherein forming the polymer layer comprises forming the polymer layer via spin-casting.

14. The method of claim 1, wherein forming the polymer layer comprises forming the polymer layer in a molding cavity.

15. A method comprising:

forming a first layer of a bio-compatible material;

providing an adhesive in a ring-shaped pattern on a ring-shaped substrate or on the first layer of the bio-compatible material;

providing the ring-shaped substrate on the first layer of the bio-compatible material in a predetermined rotational orientation;

applying a force to one or more of the ring-shaped substrate and the first layer to adhere the first layer of the bio-compatible material to the ring-shaped substrate;

forming a second layer of the bio-compatible material to cover the ring-shaped substrate; and

annealing the first layer of the bio-compatible material and the second layer of the bio-compatible material together to form an encapsulated structure, wherein the encapsulated structure comprises the ring-shaped substrate fully enclosed between the first layer of the bio-compatible material and the second layer of the bio-compatible material.

16. The method according to claim 15, further comprising:

embedding the encapsulated structure in an eye-mountable device including a transparent polymeric material having a concave surface and a convex surface, wherein the concave surface is configured to be removably mounted over a corneal surface, and wherein the convex surface is configured to be compatible with eyelid motion when the concave surface is so mounted.

17. The method according to claim 15, wherein the bio-compatible material includes a dichlorodi-p-xylylene polymer.

18. An eye-mountable device comprising:

a first polymer layer that defines a posterior side of the eye-mountable device, wherein the first polymer layer is configured to be removably mounted over a corneal surface;

a second polymer layer that defines an anterior side of the eye-mountable device, wherein the second polymer layer is configured to be compatible with eyelid motion;

a ring-shaped substrate at least partially embedded between the first polymer layer and the second polymer layer, wherein the ring-shaped substrate is coupled to the first polymer layer via an adhesive provided in a ring-shaped pattern on the ring-shaped substrate or on the first polymer layer, and wherein the ring-shaped substrate is coupled to the first polymer layer in a predetermined rotational orientation; and

an electronics module on the ring-shaped substrate, wherein the electronics module includes;

an electrochemical sensor having a working electrode and a reference electrode;

an antenna; and

a controller electronically connected to the electrochemical sensor and the antenna, wherein the controller is configured to control the electrochemical sensor to obtain a sensor measurement related to a concentration of an analyte in a fluid to which the eye-mountable device is exposed and use the antenna to indicate the sensor measurement.

19. The eye-mountable device of claim 18, wherein the first polymer layer and the second polymer layer comprise a hydrogel material or a silicone elastomer.

20. The eye-mountable device of claim 18, wherein the adhesive has a thickness of less than about 5 micrometers.