Eye-mountable devices and methods for accurately placing a flexible ring containing electronics in eye-mountable devices

• US 9,636,016 B1
• Filed: 01/25/2013
• Issued: 05/02/2017
• Est. Priority Date: 01/25/2013
• Status: Active Grant

• Current Assignee: Google LLC (Alphabet Inc.)
• Original Assignee: Verily Life Sciences LLC (Alphabet Inc.)
• Inventors: Etzkorn, James, Ho, Harvey, Linhardt, Jeffrey George
• Primary Examiner(s): Tran, Binh X
• Application Number:
  US13/750,782
• Time in Patent Office: 1,558 Days
• 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 5/00 Measuring for diagnostic purposes radiation diagnosis A61B6/00; diagnosis by ultrasonic, sonic or infrasonic waves A61B8/00; Identification of persons
• CPC Class Codes: A61B 5/14507 specially adapted for measuring characteristics of body fluids other than blood devices for taking samples of body liquids A61B10/0045
• CPC Class Codes: A61B 5/14532 for measuring glucose, e.g. by tissue impedance measurement
• CPC Class Codes: A61B 5/1486 using enzyme electrodes, e.g. with immobilised oxidase
• CPC Class Codes: A61B 5/6821 Eye
• CPC Class Codes: B29D 11/00038 Production of contact lenses
• CPC Class Codes: B29D 11/00807 Producing lenses combined with electronics, e.g. chips
• CPC Class Codes: G02C 7/04 Contact lenses for the eyes disinfection or sterilisation of contact lenses A61L12/00

Abstract

Example eye-mountable devices and methods for placing a flexible ring containing electronics in an eye-mountable device are described. A method may involve forming a first polymer layer, which defines a posterior side of an eye-mountable device. Further, the method may involve positioning a ring-shaped structure on the first polymer layer in a predetermined rotational orientation, wherein the ring-shaped structure comprises a sensor configured to detect an analyte. Still further, the method may involve forming a second polymer layer over the first polymer layer and the ring-shaped structure, such that the ring-shaped structure is fully enclosed by the first polymer layer and the second polymer layer. The second polymer layer defines an anterior side of the eye-mountable device. The method may also involve forming a channel through the second polymer layer based on the predetermined rotational orientation, such that the sensor is configured to receive the analyte via the channel.

Claims

1. A method comprising:

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

positioning a ring-shaped structure on the first polymer layer in a predetermined rotational orientation, wherein the ring-shaped structure comprises a sensor configured to detect an analyte;

forming a second polymer layer over the first polymer layer and the ring-shaped structure, such that the ring-shaped structure is fully enclosed by the first polymer layer and the second polymer layer, wherein the second polymer layer defines an anterior side of the eye-mountable device; and

forming a channel through the second polymer layer based on the predetermined rotational orientation, such that the sensor is configured to receive the analyte via the channel.

2. The method of claim 1, wherein the first polymer layer has a thickness of less than 150 micrometers.

3. The method of claim 1, wherein the forming a first polymer layer comprises forming the first polymer layer in a molding piece.

4. The method of claim 1, wherein the ring-shaped structure is more rigid than the first and second polymer layers.

5. The method of claim 1, wherein the ring-shaped structure has a maximum height between 50 and 150 micrometers.

6. The method of claim 1, wherein the positioning a ring-shaped structure on the first polymer layer in a predetermined rotational orientation comprises placing an adhesive on the ring-shaped structure or the first polymer layer, such that the ring-shaped structure adheres to the first polymer layer.

7. The method of claim 1, wherein the second polymer layer has a thickness of greater than 50 micrometers.

8. The method of claim 1, wherein the forming a second polymer layer over the first polymer layer and the ring-shaped structure comprises forming the second polymer layer in a molding piece.

9. The method of claim 1, wherein the first polymer layer further comprises an alignment feature, and wherein the positioning a ring-shaped structure on the first polymer layer in a predetermined rotational orientation comprises aligning the ring-shaped structure with the alignment feature.

10. The method of claim 9, wherein the alignment feature comprises an asymmetric peg.

11. The method of claim 10, wherein the ring-shaped structure comprises a hole having an inner diameter configured to receive the asymmetric peg.

12. The method of claim 1, wherein the forming a channel through the second polymer layer comprises etching the second polymer layer.

13. The method of claim 12, wherein the ring-shaped structure further comprises a metal film over the sensor, such that the metal film acts as an etch stop.

14. The method of claim 12, wherein the etching the second polymer layer comprises etching the second polymer layer with an inductively coupled plasma.

15. The method of claim 14, wherein the inductively coupled plasma comprises oxygen plasma containing fluorine.

16. A method comprising:

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

positioning a ring-shaped structure on the first polymer layer in a predetermined rotational orientation, wherein the ring-shaped structure comprises a sensor configured to detect an analyte;

forming a mask layer over the sensor, such that the sensor is enclosed by the mask layer;

forming a second polymer layer over the first polymer layer and the ring-shaped structure, such that the ring-shaped structure is fully enclosed by the first polymer layer, the second polymer layer, and the mask layer, wherein the second polymer layer defines an anterior side of the eye-mountable device; and

removing the mask layer to form a channel through the second polymer layer, such that the sensor is configured to receive the analyte via the channel.

17. The method of claim 16, wherein the removing the mask layer to form a channel in the second polymer layer comprises dissolving the mask layer.

18. The method of claim 17, wherein the dissolving the mask layer comprises soaking each of the mask layer, the first polymer layer, and the second polymer layer in water.