Methods for adhering a substrate to a polymer layer
First Claim
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1. A method comprising:
- forming a first polymer layer in a molding cavity defined by a first molding piece and a second molding piece, wherein the first polymer layer defines a first side of an eye-mountable device, and wherein the first polymer layer includes an alignment feature, wherein the alignment feature includes an asymmetric peg;
providing an adhesive in a pattern on a substrate or on the first polymer layer, wherein the substrate has a first surface and a second surface opposite the first surface, and wherein the substrate has a hole with an asymmetric inner diameter such that the hole receives the alignment feature in only a predetermined rotational orientation;
and wherein the substrate has an electronic component mounted on the second surface;
adhering the substrate to the first polymer layer while the first polymer layer is on the first molding piece, wherein the adhering comprises (i) positioning the first surface of the substrate on the first polymer layer in the predetermined rotational orientation such that the substrate is aligned with the alignment feature, (ii) applying a force to one or more of the substrate and the first polymer layer, and (iii) curing the adhesive while applying the force; and
forming a second polymer layer over the first polymer layer and the second surface of the substrate while the first polymer layer is on the first molding piece, such that the substrate is at least partially enclosed by the first polymer layer and the second polymer layer.
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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.
27 Citations
13 Claims
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1. A method comprising:
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forming a first polymer layer in a molding cavity defined by a first molding piece and a second molding piece, wherein the first polymer layer defines a first side of an eye-mountable device, and wherein the first polymer layer includes an alignment feature, wherein the alignment feature includes an asymmetric peg; providing an adhesive in a pattern on a substrate or on the first polymer layer, wherein the substrate has a first surface and a second surface opposite the first surface, and wherein the substrate has a hole with an asymmetric inner diameter such that the hole receives the alignment feature in only a predetermined rotational orientation; and wherein the substrate has an electronic component mounted on the second surface; adhering the substrate to the first polymer layer while the first polymer layer is on the first molding piece, wherein the adhering comprises (i) positioning the first surface of the substrate on the first polymer layer in the predetermined rotational orientation such that the substrate is aligned with the alignment feature, (ii) applying a force to one or more of the substrate and the first polymer layer, and (iii) curing the adhesive while applying the force; and forming a second polymer layer over the first polymer layer and the second surface of the substrate while the first polymer layer is on the first molding piece, such that the substrate is at least partially enclosed by the first polymer layer and the second polymer layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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Specification