Methods and apparatus to form three-dimensional biocompatible energization elements

Patent metadata

Field	Value
Publication number	US-9406969-B2
Application number	US-201313839144-A
Country	US
Kind code	B2
Filing date	Mar 15, 2013
Priority date	Mar 15, 2013
Publication date	Aug 2, 2016
Grant date	Aug 2, 2016

Abstract

Methods and apparatus to form three-dimensional biocompatible energization elements are described. In some embodiments, the methods and apparatus to form the three-dimensional biocompatible energization elements involve forming conductive traces on the three-dimensional surfaces and depositing active elements of the energization elements on the conductive traces. The active elements are sealed with a biocompatible material. In some embodiments, a field of use for the methods and apparatus may include any biocompatible device or product that requires energization elements.

First claim

The invention claimed is:

1. A method of forming a three-dimensional biocompatible energization element, the method comprising:
receiving a substrate made from an insulating material, the substrate having a smooth three-dimensional curved surface;
forming two or more conductive traces on the three-dimensional curved surface;
depositing an anode chemical formulation on at least part of a first conductive trace to form an anode;
depositing a cathode chemical formulation on at least part of a second conductive trace to form a cathode;
depositing an electrolyte over at least part of the anode and the cathode; and
encapsulating the anode, the cathode and the electrolyte with a biocompatible material to form a three-dimensional biocompatible energization element having a shape corresponding to the three-dimensional curved surface of the substrate.

2. The method of claim 1 , further comprising roughening at least a portion of the three-dimensional curved surface.

3. The method of claim 1 , further comprising depositing a coating on at least a portion of the three-dimensional curved surface.

4. The method of claim 1 , further comprising depositing a bridge chemical formulation in contact with the anode and the cathode to form a bridge.

5. The method of claim 1 , further comprising removing the substrate to separate the three-dimensional biocompatible energization element.

6. The method of claim 1 , wherein the biocompatible material includes alginates, parylenes, polyacrylonitriles, polyethylene glycols, polypyrroles, derivatised celluloses, polysulfones, or polyamides.

7. The method of claim 1 , wherein forming the two or more conductive traces on the three-dimensional curved surface comprises depositing a conductive chemical formulation on the three dimensional curved surface.

8. The method of claim 1 , wherein the electrolyte is a gel.

9. The method of claim 1 , further comprising encapsulating the anode, the cathode, and the electrolyte with a first encapsulating material different from said biocompatible material prior to, encapsulating the first material encapsulated anode, cathode, and electrolyte with said biocompatible material to form the three-dimensional biocompatible energization element.

10. The method of claim 1 , wherein the anode chemical formulation includes zinc.

11. The method of claim 1 , wherein the conductive traces include metal particles.

12. The method of claim 1 , wherein the anode chemical formulation includes a first metal and the cathode chemical formulation includes a second metal, the second metal being different from the first metal.

13. The method of claim 4 , wherein the electrolyte is deposited over the anode, the cathode and the bridge.

14. The method of claim 4 , wherein the bridge completely covers the anode and the cathode.

15. The method of claim 9 , wherein the first encapsulating material includes epoxies, fluoropolymers, acrylics, silicones, polyurethanes, enamels, potting compounds, or conformal coatings.

16. A three-dimensional biocompatible energization element, comprising:
a substrate made from an insulating material, the substrate having a smooth three-dimensional curved surface;
two or more conductive traces on the three-dimensional curved surface;
an anode made of an anode chemical formulation disposed on at least part of a first conductive trace;
a cathode made of a cathode chemical formulation disposed on at least part of a second conductive trace;
an electrolyte covering at least part of the anode and the cathode; and
a biocompatible encapsulant covering the anode, the cathode and the electrolyte,
wherein the three-dimensional biocompatible energization element has a shape corresponding to the three-dimensional curved surface of the substrate.

17. The three-dimensional biocompatible energization element of claim 16 , further comprising a coating on a portion of the three-dimensional curved surface.

18. The three-dimensional biocompatible energization element of claim 16 , further comprising a bridge made of a bridge chemical formulation in contact with the anode and the cathode.

19. The three-dimensional biocompatible energization element of claim 16 , wherein the biocompatible encapsulant includes alginates, parylenes, polyacrylonitriles, polyethylene glycols, polypyrroles, derivatised celluloses, polysulfones, or polyamides.

20. The three-dimensional biocompatible energization element of claim 16 , wherein the anode chemical formulation includes zinc.

21. The three-dimensional biocompatible energization element of claim 16 , wherein the anode chemical formulation includes a first metal and the cathode chemical formulation includes a second metal, the second metal being different from the first metal.

22. The three-dimensional biocompatible energization element of claim 18 , wherein the electrolyte is deposited over the anode, the cathode and the bridge.

23. The three-dimensional biocompatible energization element of claim 18 , wherein the bridge completely covers the anode and the cathode.

Assignees

• Johnson & Johnson Vision Care

Inventors

• Pugh Randall B
• Otts Daniel B
• Flitsch Frederick A
• Hardy Katherine

Classifications

• Y10T29/49115

  including coating or impregnating · CPC title

• H01M4/26

  Processes of manufacture · CPC title

• H01M6/40

  Printed batteries {, e.g. thin film batteries} · CPC title

• H01M4/08

  Processes of manufacture · CPC title

• H01M4/42

  Alloys based on zinc · CPC title