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Methods and apparatus for forming a polymer layer around a structure using a plurality of protrusions

  • US 10,232,531 B1
  • Filed: 07/08/2014
  • Issued: 03/19/2019
  • Est. Priority Date: 07/08/2014
  • Status: Active Grant
First Claim
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1. A method comprising:

  • positioning a structure on a plurality of protrusions that extend from a surface of a molding piece, wherein the structure comprises a sensor or an electronic component;

    forming, using the molding piece, a body-mountable device by forming a polymer layer around the structure positioned on the plurality of protrusions, such that the structure is at least partially enclosed by the polymer layer, wherein the polymer layer defines a first side of the body-mountable device and a second side of the body-mountable device opposite the first side, wherein the surface of the molding piece supports the polymer layer as the polymer layer is being formed, and wherein forming the polymer layer comprises;

    providing a polymer material on the surface of the molding piece,bringing the molding piece and a press together into a forming position, wherein the press comprises a second plurality of protrusions that extend from a surface of the press, and wherein in the forming position the molding piece and press apply pressure to the polymer material, andin the forming position, (i) conforming, using the second plurality of protrusions, the structure to a curvature of the polymer layer and (ii) curing the polymer material to form the polymer layer, wherein curing the polymer material comprises;

    after providing the polymer material, curing the polymer material to a uniform partially-cured state, such that the partially-cured polymer material supports the structure as the polymer layer is being formed, wherein curing the polymer material to the uniform partially-cured state comprises curing the polymer material to the uniform partially-cured state using light,after curing the polymer material to the uniform partially-cured state, retracting the plurality of protrusions through the surface of the molding piece, andafter retracting the plurality of protrusions, curing the polymer material to a fully-cured state to form the polymer layer, wherein curing the polymer material to the fully-cured state comprises curing the polymer material to the fully-cured state using light; and

    removing the body-mountable device from the molding piece.

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