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Channel Formation

  • US 20160066825A1
  • Filed: 09/04/2014
  • Published: 03/10/2016
  • Est. Priority Date: 09/04/2014
  • Status: Active Grant
First Claim
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1. A method comprising:

  • forming a first layer of polymeric material in a first part of a molding form, wherein the molding form comprises the first part and a second part configured to engage one another at an interface that defines a boundary of a cavity between the first and second parts, and wherein the second part comprises a surface that defines a portion of the cavity and a protrusion that extends from the surface;

    positioning a substrate over the first layer of polymeric material, wherein the substrate has a sensor disposed thereon;

    applying a sacrificial sealant material to at least one of the protrusion or the sensor;

    engaging the second part of the molding form with the first part such that the protrusion contacts the sacrificial sealant material while the sacrificial sealant material contacts the sensor, wherein the sacrificial sealant material substantially covers the sensor;

    while the sacrificial sealant material contacts both the protrusion and the sensor, forming a second layer of polymeric material over the substrate and the first layer and around the protrusion, wherein the second layer of polymeric material and the first layer of polymeric material combine within the molding form so as to substantially encapsulate the substrate within polymeric material shaped in accordance with the cavity;

    removing the shaped polymeric material from the molding form; and

    removing the sacrificial sealant material covering the sensor to thereby expose the sensor, wherein the sensor is exposed through a channel in the polymeric material, and wherein the channel is at least partially formed by the protrusion.

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