Channel Formation
First Claim
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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Accused Products
Abstract
A body-mountable device may be formed of a polymeric material. A molding form can define a cavity and polymeric material can be formed using the mold to create a device shaped in accordance with the cavity. Electronics disposed on a substrate can be encapsulated within the polymeric material by forming a first layer of polymeric material, positioning the substrate on the first layer, and then forming a second layer of polymeric material over the substrate. A channel can expose a sensor disposed on the substrate. The channel may be formed while molding the second layer of polymeric material over the substrate. The molding form can include a protrusion that extends toward the sensor. A sacrificial sealant material can be applied to the sensor or the protrusion to create a seal between the protrusion and the sensor. The polymeric material forms around the sealed protrusion to create the channel.
60 Citations
20 Claims
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1. A method comprising:
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A system comprising:
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a molding form comprising a 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, wherein the first part comprises a surface that defines a portion of the cavity, wherein the second part comprises a surface that defines a portion of the cavity and a protrusion that extends from the surface, wherein the protrusion is configured to contact a sacrificial sealant material while the sacrificial sealant material contacts a sensor of a body-mountable device that is being formed within the molding form, and wherein the body-mountable device comprises a channel through which the sensor is exposed, and wherein the channel is at least partially formed by the protrusion. - View Dependent Claims (15, 16, 17)
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18. A body-mountable device comprising:
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a polymeric material shaped in accordance with a molding form, wherein the molding form comprises a first and 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; a substrate having a sensor disposed thereon, wherein the substrate is substantially encapsulated within the polymeric material; and wherein the sensor is exposed through a channel in the polymeric material, and wherein the channel is at least partially formed by the protrusion and by a sacrificial sealant material that contacts both the sensor and the protrusion during formation of the body-mountable device. - View Dependent Claims (19, 20)
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Specification