Systems and methods for encapsulating electronics in a mountable device

• US 9,113,829 B2
• Filed: 03/27/2013
• Issued: 08/25/2015
• Est. Priority Date: 03/27/2013
• Status: Active Grant

• Current Assignee: Google LLC (Alphabet Inc.)
• Original Assignee: Google Inc. (Alphabet Inc.)
• Inventors: Etzkorn, James
• Primary Examiner(s): Mallari, Patricia
• Assistant Examiner(s): WESTON, TIFFANY C
• Application Number:
  US13/851,290
• Publication Number:
  US 20140290054A1
• Time in Patent Office: 881 Days
• Field of Search: 600/319, 600/345, 600/347, 600/365, 298/32, 298/41, 298/46, 298/48, 298/51
• US Class Current: 1/1
• CPC Class Codes: A61B 2560/0214 of power generation or supply
• CPC Class Codes: A61B 2562/12 Manufacturing methods specially adapted for producing sensors for in-vivo measurements
• CPC Class Codes: A61B 3/101 for examining the tear film
• CPC Class Codes: A61B 5/0002 Remote monitoring of patients using telemetry, e.g. transmission of vital signals via a communication network A61B5/07 takes precedence; transmission systems for measured values G08C; transmission H04B; transmission of digital information H04L; wireless communication networks H04W
• CPC Class Codes: A61B 5/14532 for measuring glucose, e.g. by tissue impedance measurement
• CPC Class Codes: A61B 5/14546 for measuring analytes not otherwise provided for, e.g. ions, cytochromes
• CPC Class Codes: A61B 5/1473 invasive, e.g. introduced into the body by a catheter A61B5/1482 takes precedence
• CPC Class Codes: A61B 5/1477 non-invasive
• CPC Class Codes: A61B 5/6813 Specially adapted to be attached to a specific body part A61B5/6802 takes precedence
• CPC Class Codes: A61B 5/6821 Eye
• CPC Class Codes: B29D 11/00817 Producing electro-active lenses or lenses with energy receptors, e.g. batteries or antennas
• CPC Class Codes: C12Q 1/006 for glucose
• CPC Class Codes: G01N 27/3272 Test elements therefor, i.e. disposable laminated substrates with electrodes, reagent and channels optical biosensors G01N33/52
• CPC Class Codes: G02B 1/043 Contact 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
• CPC Class Codes: G02C 7/083 Electrooptic lenses
• CPC Class Codes: H01L 2224/04105 Bonding areas formed on an encapsulation of the semiconductor or solid-state body, e.g. bonding areas on chip-scale packages
• CPC Class Codes: H01L 2924/18162 of a chip with build-up interconnect
• CPC Class Codes: H05K 1/185 Components encapsulated in the insulating substrate of the printed circuit or incorporated in internal layers of a multilayer circuit semiconductor chips encapsulated by interconnect and support structures H01L23/5389, H01L24/00
• CPC Class Codes: H05K 2201/10098 : Components for radio transmission, e.g. radio frequency identification [RFID] tag, printed or non-printed antennas
• CPC Class Codes: H05K 2201/10151 : Sensor
• CPC Class Codes: H05K 2203/1469 : Circuit made after mounting or encapsulation of the components
• CPC Class Codes: H05K 3/32 : electrically connecting electric components or wires to printed circuits
• CPC Class Codes: Y10T 29/49018 : with other electrical component
• CPC Class Codes: Y10T 29/4913 : Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49146 : with encapsulating, e.g., potting, etc.
• CPC Class Codes: Y10T 29/49155 : Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/49158 : with molding of insulated base
• CPC Class Codes: Y10T 29/49163 : with sintering of base

Abstract

A mountable device includes a bio-compatible structure embedded in a polymer that defines at least one mounting surface. The bio-compatible structure includes an electronic component having electrical contacts, sensor electrodes, and electrical interconnects between the sensor electrodes and the electrical contacts. The bio-compatible structure is fabricated such that it is fully encapsulated by a bio-compatible material, except for the sensor electrodes. In the fabrication, the electronic component is positioned on a first layer of bio-compatible material and a second layer of bio-compatible material is formed over the first layer of bio-compatible material and the electronic component. The electrical contacts are exposed by removing a portion of the second layer, a conductive pattern is formed to define the sensor electrodes and electrical interconnects, and a third layer of bio-compatible material is formed over the conductive pattern. The sensor electrodes are exposed by removing a portion of the third layer.

Claims

1. A mountable device, comprising:

a polymer, wherein the polymer defines at least one mounting surface of the mountable device; and

a bio-compatible structure embedded in the polymer, wherein the bio-compatible structure comprises;

a first layer of bio-compatible material;

an integrated circuit disposed on the first layer of bio-compatible material, wherein the integrated circuit has a first surface adhered to the first layer of bio-compatible material and a second surface opposite the first surface, wherein the second surface of the integrated circuit includes electrical contacts;

a second layer of bio-compatible material disposed on the first layer of bio-compatible material, wherein the second layer of bio-compatible material has a surface that is substantially flush with the second surface of the integrated circuit;

sensor electrodes and electrical interconnects between the sensor electrodes and the electrical contacts, wherein the sensor electrodes and electrical interconnects are disposed on the surface of the second layer of bio-compatible material; and

a third layer of bio-compatible material disposed on the second layer of bio-compatible material, wherein the integrated circuit is fully encapsulated by the first, second, and third layers of bio-compatible material.

2. The mountable device of claim 1, wherein the bio-compatible structure further comprises an antenna and electrical interconnects between the antenna and additional electrical contacts on the second surface of the integrated circuit.

3. The mountable device of claim 1, wherein the bio-compatible structure has a thickest portion that is less than 100 micrometers thick.

4. The mountable device of claim 1, wherein the first, second, and third layers of bio-compatible material are annealed together.

5. The mountable device of claim 1, wherein the third layer of bio-compatible material covers the integrated circuit and has an opening that exposes at least a portion of the sensor electrodes.

6. The mountable device of claim 1, further comprising a reagent layer proximal to the sensor electrodes.

7. The mountable device of claim 1, wherein the bio-compatible structure is ring shaped.

8. The mountable device of claim 1, wherein the bio-compatible material comprises parylene.

9. The mountable device of claim 1, wherein the mountable device comprises an eye-mountable device and the at least one mounting surface comprises a concave surface configured to mount the eye-mountable device to a corneal surface.