MXPA00009294A - Tab and bus bar application method - Google Patents

Abstract

A method for applying bus bar tab system to the peripheral edge region of a substrate such as an ophthalmic lens is disclosed. The method involves:1) applying a curable conductive epoxy to the substrate so as to embed a tab into the curable conductive epoxy;and 2) curing the curable conductive epoxy.

Description

METHOD OF APPLYING TONGUE AND BUS BAR FIELD OF THE INVENTION This invention relates to a method for applying an electrical contact system based on conductive epoxy to a substrate, and to the resulting metallized substrate. A preferred embodiment involves applying a conductive epoxy bar / bus bar system to an optical substrate, such as an ophthalmic lens. The present method is particularly useful in the preparation of electro-optical devices, such as electrochromic lenses.

BACKGROUND OF THE ART The transmittance properties of electrochromic materials change in response to electrically driven changes in the oxidation state. Therefore, when applied to a voltage from an external power supply, causing the electrons to flow to (reduction) or from (oxidation) an electrochromic material, their transmittance properties change. In order to maintain charge neutrality, an ion charge equilibrium flux is necessary in the electrochromic device. By allowing the required electron and ion fluxes to occur, an electrochromic device uses reversible oxidation and reduction reactions to achieve optical commutation. Conventional electrochromic cells comprise at least one thin film of persistent electrochromic material, that is, a material which, in response to the application of an electric field of given polarity, changes from a high transmittance, a non-absorbing state to a low transmittance, state of absorption or reflection. Since the degree of optical modulation is directly proportional to the current flow induced by the applied voltage, the electrochromic devices demonstrate the ability to tune light transmission between states of high transmittance and low transmittance. Additionally, these devices show a long-term retention of a chosen optical state, not requiring the consumption of ££ ¡& & ± - energy to maintain that optical state. Optical commutation occurs when an inverted polarity electric field is applied. To facilitate the ipes and electron flows mentioned above, the electrochromic film that is both an ionic and an electronic conductor is in ion conductive contact, preferably direct physical contact, with a layer of ion-conducting material. The ion conducting material may be inorganic or organic, solid, liquid or gel, and is preferably an organic polymer. The electrochromic film (s) and the ion conductive material are disposed between two electrodes, forming a laminated cell. As voltage is applied through the electrodes, ions are conducted through the ion conductive material. When the electrode adjacent to the electrochromic film is the cathode, the application of an electric field causes the film to darken. Inverting the polarity causes the reversal of the electrochromic properties, and the film reverses its transmittance state. high. Typically, an electrochromic film, such as tungsten oxide, is deposited on a substrate coated with an electroconductive film such as tin oxide or indium tin oxide to form an electrode. The counter-electrode is typically a substrate coated with tin oxide or similar tin indium oxide. A complementary electrochromic film, for example an iridium oxide film, can also be used. An electrochromic device, such as an electrochromic lens, also requires a means for supplying electrical current from a power source to each of its electrodes. This can be achieved through the use of a bus bar, as described in U.S. Patent Nos. 5,520,851 and 5,618,390 to YU, et al. U.S. Patent No. 3,630,603 in the name of Letter describes a control circuit for electrochromic glasses. US Patent No. 4,991,591 in the name of Mizuno discloses metal eyeglass frames used in conjunction with electro-optical lenses. U.S. Patent No. 4,335,938 in the name of Giglia describes electrochromic devices having an oxide layer of - * - • - ~ - * ~ - ------ tungsten in contact with an organic electrolyte resin layer comprising a hydrophilic layer of 2-acrylamido-2-methylpropanesulfonic acid homopolymer and electrode means to change electrochromic properties of the device. United States Patent No. 5,327,281 in the name of Cogan describes the use of epoxy to seal a cavity formed when a spacer is used to separate electrodes and contains a liquid electrolyte injected between the spaced electrodes. U.S. Patent No. 5,656,150 to Kallman et al. Discloses electrochromic devices and the use of contacts that connect first and second electrodes to flexible circuits or other installation means.

This invention relates to a method for applying bus bar / tab systems to various substrates and to the resulting metallized substrates. More particularly, this method involves applying a conductive epoxy bus bar and a tongue to a substrate, said substrate having a peripheral edge region located between first and second extension surfaces, in a manner that provides reliable electrical contact between the tongue and the tongue. Bus bar, which allows the bus bar and the tongue to be used as electrical conduits between a power source and an electrode. For example, in electro-optical applications, a conductive epoxy bus bar is applied to the peripheral edge region of an optical substrate having or having an electroconductive film on an adjacent extension surface. The conductive epoxy and electroconductive film are arranged to coat at or near the interface of the peripheral edge region and the extension surface. The connecting portion of a tongue, preferably its connecting end, is embedded in the conductive epoxy. By hardening the epoxy the tab is firmly connected to the bus bar exposi, which, in combination with suitable circuitry, facilitates the supply of current from a power source to the tab and the conductive bus bar conductor to the electro-conductive film.

As used herein, the term "bus bar" refers to an electrically conductive strip, coating or strip of low strength that is applied to a substrate. A busbar is generally placed so that it is in contact with or will be in contact with an electroconductive material disposed on the substrate. In addition, the term "tongue" refers to a wire or conductive strip that connects or connects a bus bar to a power source through an electrical circuit, for example an electrochromic or electro-optical control circuit. A tongue can be either an integral part or a separate component of a circuit of this type. A tongue is generally fixed to a bus bar at one connection end, although this invention contemplates the connection of the tongue along any portion of its surface. A bus bar is preferably applied to the peripheral edge region of a substrate having or which will have an electroconductive, metal oxide or metal film (eg, fluoride-enhanced tin oxide, tin-indium oxide, oxide) of tin bonded with antimony, tin oxide bonded with aluminum, etc.) on an adjacent extension surface (referred to below as an electroconductive extension surface). The electrical contact between the bus bar and an electroconductive film is preferably made at the interface of the peripheral edge region and an electroconductive extension surface of a given substrate causing the electroconductive film on the extension surface to coat the busbar, or vice versa. It is desirable that a busbar have a lower electrical resistance than the electroconductive film contacting it. For example, bus bar sheet resistors of less than 20 ohms / sec are preferred. When using electroconductive films that have sheet resistances of 20-25 ohms / sec. In a preferred embodiment, a bus bar is applied to the peripheral edge region of a configured substrate. As used herein, the term "shaped substrate" refers to a substrate prepared by grinding or cutting the perimeter of an oversized raw substrate to a smaller size having a desired configuration. This rectification process is commonly referred to as bordered. For ophthalmic lenses, oversized, oversized lenses configured in the form of a disc are edged to be configured by conventional techniques well known to the artisan. The bus bar in a lens configured in this way is normally contained up to its peripheral edge region so that it is not obstructive. The dimensions of the bus bar are generally determined by resistance requirements and the configuration of the electroconductive film that contacts a given bus bar. Therefore, a bus bar may cover the entire peripheral edge region of a substrate or may be limited to some portion thereof. To avoid the application of conductive epoxy beyond the intended surface of a given substrate, the substrate can be mechanically masked so that only the intended surface of the bus bar is exposed during the application of the busbar. It is also desirable that a bus bar adheres strongly to the substrate to which it is applied. In a preferred embodiment involving applying a bus bar / conductive epoxy bar system to an ophthalmic lens, the edge region of a raw lens is first rectified to be configured through a conventional beading technique. A bus bar is then added by applying a hardenable conductive epoxy layer to the peripheral edge region of the lens configured by a suitable application means, with a masking as necessary. After or during the application of the hardenable conductive epoxy layer to the intended area of the bus bar of a given substrate, a tab is connected to the epoxy layer by embedding a portion of the tab, preferably a connecting end, in the epoxy layer. As used herein, the term "embedded" refers to placing, inserting or fixing a connecting portion of a tab in a conductive epoxy layer or between conductive epoxy layers to substantially enclose the connecting portion of the tab with conductive epoxy. The tongue can be incrusted by various means, including inserting the connecting portion of the tongue into an epoxy layer -_- ^ --- .----- ^ ----- i- ~ - - »- - * ---, .- ^ _ ^ _ ^ L _--------- --- hardenable conductive before or during curing (that is, while the epoxy is soft or flexible), place the connecting portion of the tongue on an outer surface of a non-hardened, partially or fully hardened conductive epoxy layer, then placing the additional hardenable conductive epoxy over the connection portion, or placing the tongue connection portion over the intended area of the bus bar of the substrate, with or without the use of a fixing means (e.g., an epoxy) structural, conductive epoxy or other adhesive) and then apply a hardenable conductive epoxy layer over the tongue connection portion. The hardening of the conductive epoxy then secures the tongue to the busbar. An embodiment of the electrical contact system of this invention is illustrated in the figures. As shown in FIGS. 3 and 4, the connecting ends of the tabs 9 and 10 are embedded in conductor epoxy bus bars 11 and 12, respectively, which in turn are placed on the upper peripheral edge regions of FIG. rear and front lenses configured 1 and 2. The configured lenses 1 and 2 are laminated to form electrochromic lenses 8, as shown in Figures 1 and 2.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a side view of a laminated electrochromic lens showing front and rear lens tabs. Figure 2 is a front view of the laminated lens of Figure 1 showing the orientation of the tongue and bus bar. Figure 3 is a cross-sectional enlargement of the front tab and the bus bar of the lens shown in Figure 1. Figure 4 is a cross-sectional enlargement of the rear tab and the bus bar of the lens shown in FIG. Figure 1 DETAILED DESCRIPTION OF THE INVENTION Except in the operative Examples, or where indicated otherwise, all the numbers that quantify ingredients, quantities, dimensions, relationships, intervals, reaction conditions, etc. used here * - * - __! - * - • "*" shall be understood as being modified in all cases by the term "approximately." In its broadest sense, the present invention relates to a method for applying or fixing a busbar / tongue system of conductive epoxy to a substrate, said system comprising a hardened conductive epoxy layer and a tongue having a connecting portion or end, wherein said connecting portion or end is embedded in said layer of hardened conductive epoxy, which method comprises: a) embedding the portion connecting said tongue in a hardenable conductive epoxy layer applied to an intended area of the bus bar on said substrate, preferably to an intended area on the peripheral edge region of said substrate, and b) hardening said hardenable conductive epoxy. connects a tab to a conductor epoxy bus bar placed on a given substrate, thereby establishing electrical contact re the tab and the bus bar. Preferably, a tongue is fixed by embedding one of its ends, i.e., its connecting end, in a conductive bus bar epoxy. In the preferred embodiments of this method, the connecting end or portion of a tongue is inserted into a layer of hardenable conductive epoxy (i.e., partially cured or uncured) while the layer is sufficiently flexible to allow insertion. Hardening of the hardenable epoxy layer then secures the tongue to the bus bar. Alternatively, the connecting end or portion of a tongue is placed on a first layer of conductive epoxy, said epoxy layer being in a hardenable state (ie, a partially hardened or uncured state) or hardened. The additional hardenable conductive epoxy (ie, a second conductive epoxy layer) is then applied over the connecting end or portion of the tongue, and all hardenable conductive epoxy layers are allowed to harden. These techniques embed the connecting end or portion of a tongue on an individual or multi-layer conductive epoxy bus bar. In another embodiment of the present method, the connecting end or portion of a tongue is placed on or fixed to the intended area of the bus bar of a substrate, and an epoxy layer_________________ hardenable conductor is applied over the end or portion of the tongue in contact with the substrate. Hardening of the hardenable conductive epoxy layer establishes electrical contact between the tab and the resulting conductive epoxy bus bar. A structural epoxy, conductive epoxy or other adhesive, with appropriate hardening, can be used to fix the tongue to the substrate if desired. In each of these embodiments, the conductive epoxy substantially embeds or surrounds the connecting portion or end of a tongue. Additional methods of embedding may be evident by the technicians. The present invention also relates to a substrate having a conductive epoxy bus bar and the tab attached thereto through any of the present methods. Such substrates, are preferably shaped substrates, can be used to prepare single-stacked electrochromic or electro-optical devices, where the electrodes, electrochromic material (s) and possibly an ion-conductive material are coated as a stack on a first substrate that can or can not be laminated to a second substrate, and to prepare electrochromic or electro-optical laminated devices, wherein the first and second electrodes are coated on first and second substrates, respectively, each of which contains a bus bar. Multiple bus bars can be applied to an individual substrate, if necessary. Preferred substrates are optical lenses; the most preferred substrates are ophthalmic substrates. Any hardenable conductive epoxy that adheres to and is compatible with the substrates being treated, which has feasible hardening characteristics (i.e. hardening time, hardening temperature, etc.) and which has suitable electrical conductivity properties can be used to form A conductive epoxy bus bar through the present method. For example, silver epoxies, nickel epoxies, chromium epoxies, gold epoxies, tungsten epoxies, commercially available alloy epoxies and combinations thereof can be used. as conductor epoxy bus bar materials. Preferred conductive epoxies are Tra-Duct® 2902 silver epoxy and Applied Technologies 5933 alloy epoxy, which are commercially available from Tra-Con, Inc., and Applied Technologies, respectively. An effective amount of hardenable conductive epoxy is applied. This means that the hardenable conductive epoxy applied to a given substrate is of sufficient thickness and coverage to fully coat the intended area of the bus bar of that substrate and to provide the desired resistivity. The conductive epoxy bus bars can be applied by any suitable means, for example, by brushing, extrusion, roller, etc. Such coating means are known to the technicians. Preferred conductive epoxy bus bars are generally 2 to 50 mils thick, and extend around a substantial portion or all of the peripheral edge region to which they are applied. The present hardenable conductive epoxies usually comprise resin and hardening components. These components are mixed before application in accordance with the instructions of the relevant manufacturers. The hardening is also preferably achieved according to the instructions of the manufacturers. Epoxy suitable conductors have hardening times ranging from a few minutes to a few hours. An effective hardening time is the time required for a given epoxy to harden to the extent that it is sufficiently rigid to secure the connecting end or portion of a tongue and develop sufficient electrical conductivity. In a preferred embodiment, a conductive epoxy bus bar is applied to the peripheral edge region of a configured substrate, i.e., a substrate that has been edged to be configured using edge / rectification techniques. The profile of the cross section of the peripheral edge region to which a conductive epoxy bus bar is applied is not considered critical; the profile of the edge region can be, for example, planar, configured in a V-shape, configured in a U-shape, configured in the form of a table, configured in square, round or irregularly shaped form. However, it is desirable to avoid sharp edges in some applications, since they tend to concentrate tension. A particularly preferred embodiment requires that a raw substrate be edged to form an inclined or rounded transition zone between its peripheral edge region and its electroconductive extension surface. Such an area facilitates contact between an electroconductive film and a conductive bus bar. After and / or during the application of a conductive epoxy layer to an intended area of the bus bar, a tongue is embedded within the hardenable conductive epoxy. The location of the tongue is not considered critical. Preferably the tabs are located to easily connect with corresponding circuitry. It is also preferred that the connecting end or portion of a tongue be configured with barbs, T-shaped, or otherwise irregularly shaped to help secure the tongue to the bus bar during the embedding step. Any suitable wire or metal strip can be used as a tongue. Preferably, a tongue is sufficiently rigid to allow insertion into a layer of foldable conductive epoxy, but strong enough and flexible to be bent, configured and / or connected to a circuit without breakage. Typical wire materials include, but are not limited to, nickel, silver, titanium, gold, platinum and copper. Such wires are commercially available from Aldrich, Inc., in 99.9% purity, by weight. Stainless steel tabs can also be used. The dimensions of the tongue are not critical, and should be based on the available space (for example the width of the peripheral edge region for a particular device) and strength specifications. Generally, for electrochromic applications, wire resistances of less than about 2 O through one inch (5 cm) in length are desired. The thickness of the tongue generally ranges between 0.5 and 5 thousandths. If strips are used instead of wires, the widths between 20 and 50 thousandths are typical. Although the present bar / tab bus application method is applicable to virtually any substrate, the preferred substrates of the present invention are glass or organic polymer substrates conventionally used to prepare optical lenses or articles. ^^ _ ^ J ^^ j¡ ^ | jfc¿jjjftf ^ í ^ _-- - r - - - ». .-. . .-. * n _-_ electrochromic or devices. Preferably, the polymeric organic substrates are used. For optical applications, the substrates of the present invention are preferably prepared from transparent materials suitable for producing spectacle lenses, lenses such as those prepared from synthetic organic resins are suitable. Alternatively, the substrates can be a non-transparent solid material. Suitable transparent lenses can have a conventional refractive index (1.48-1.5), a relatively high refractive index (1.60-1.75), or a mid-range refractive index (1.51-1). , 59), depending on extreme use. Generally speaking, a transparent lens can have a refractive index within the range of 1.48 to 1.75, for example, from about 1.50 to about 1.8. Synthetic polymer substrates that can be used as a lens material include, but are limited to: thermoplastic polycarbonate, such as the carbonate bound resin derived from bisphenol A and phosgene, sold under the trademark LEXAN; polyesters, such as the material sold under the trademark, MYLAR; poly (methyl methacrylates), such as the material sold under the trademark, PLEXIGLÁS; and polymerized from a polyol monomer (allyl carbonate) especially diethylene glycol bis (allyl carbonate), which is sold as CR-39® monomer by PPG Industries, Inc. The copolymers of the resins / monomers described above can also be used as a lens. These and other non-transparent and transparent polymeric substrates known in the art can be used for various non-optical and optical applications. After the tongue and bar bus application, an electroconductive film is typically applied to the electroconductive surface of the metallized substrate. This electrically conductive film preferably covers the bus bar, thereby providing electrical contact. Tin-bonded indium oxide films are preferred electroconductive films, particularly those having an indium to tin ratio by weight of about 90:10.

«^ J ^ BA ^^^ g * ^^^^^ _ ^ ____ ^ _____ ^ - ^ - ^^ - ^^ - ^ - ^ - ^. ^ ^ ^ ^ ^^^^^^^ The laminated electrochromic spectacle lens can be prepared by joining first and second lenses together, wherein each lens comprises a transparent bordered substrate containing an electroconductive film, a bus bar and a tongue. An electrochromic film is present in at least one of the lenses. Binding is preferably achieved by placing an effective amount of a curable ion-conducting polymer composition (ICP), i.e., a monomer solution comprising one or more monomers, an effective amount of an initiator and optionally up to one or more non-initiating components. reagents and / or additives, on the concave interface surface of a pair of matching lenses and joining together this concave surface and the convex surface of the corresponding lens, thereby extending the curable adhesive composition between the lenses. The hardenable ICP composition is then hardened through exposure to a suitable energy source. The hardening of the polymer places an ion-conducting polymer between the lenses thereby attaching the lenses within a laminate thus facilitating the necessary ion flow. The best mode known to the inventors is now described with reference to the figures. Figure 1, which is not shown to scale, shows a side view of laminated electrochromic lenses 8 containing a layer (ICP) of conductive polymer 7. In the lens 8, the configured substrate 1 is the front lens of the laminated electrochromic lens 8. The configured substrate 1 has a front extension surface 3 and an electroconductive extension surface 4. The coatings on the electroconductive extension surface 4 are not shown; these are conventional electrochromic and electroconductive coatings used in the preparation of electrochromic lenses and are not critical with respect to the present invention. The shaped substrate 2, which is the rear lens, is laminated to the configured substrate 1. The shaped substrate 2 has an electroconductive extension surface 5 and a rear extension surface 6. The coatings on the electroconductive extension surface 5 are not shown; these are conventional electrochromic and electroconductive coatings used in the preparation of electrochromic lenses and are not critical with respect to the present invention. The conductor polymer layer 7 is disposed between the configured substrates 1 and 2; this layer serves both as an ion-conducting elec- trolyte as well as a mechanical adhesive bonding the configured substrates 1 and 2. The tabs 9 and 10 are fixed to the peripheral edge regions of the configured substrates 1 and 2, as shown in greater detail in figures 2-4. Figures 2, 3 and 4 are not represented to scale. These figures show nodes 13 and 14 on the peripheral edge region of the configured substrates 1 and 2, respectively. The conductor epoxy bus bars 11 and 12 are positioned adjacent the nodes 13 or 14 on the configured substrates 1 and 2, respectively. The connecting end of the tongue 9 is embedded in the bus bar 11 and the connecting end of the tongue 10 is embedded in the bus bar 12. The tabs 9 and 10 can be located somewhere on the bus bars 11. and 12, but are generally located to allow convenient connection to related circuitry (not shown). Although the edge configuration is not critical with respect to the present invention, the nodes 13 and 14 represent preferred embodiments. These nodes are excellent bus bar foundations and can be interlocked with several edge joints.

EXAMPLES The present invention is described more particularly in the following Examples, which are intended to be illustrative only since numerous modifications and variations will be apparent here by those skilled in the art.

Example 1: Application of Bus Bars of Epoxy Conductor to Raw Substrates All conducting epoxies of this example were applied to cast 2"X 2" (5 cm by 5 cm) flat substrates prepared from CR-39® monomer. Each driver was formulated and hardened according to the manufacturer's instructions. Each bus bar was 2"(5 cm) long X 1/8" (3 mm) wide X 0.006"(0.15 mm) thick These bus bars were applied by brush. evaluated using a Fluke® 8060a multimeter that measured resistance O through each 2"(5 cm) bus bar using standard contact probes. Five (5) different conductive epoxies were evaluated, including: 1. Silver Epoxy Tra-Duct® 2902; 2. Tra-Duct® 2701 nickel epoxy; 3. Gold epoxy from Applied technologies; 4. Applied Technologies 5933 alloy epoxy; and 5. Applied Technologies tungsten epoxy. Resistances were measured under the following conditions: 1. Initial resistance of the busbar (Ri); 2. Cyclic moisture resistance (Rm-s); Protocol: a) Ambient temperature for 8 hours; b) 50 ° C, 100% relative humidity for 16 hours; c) Resistance measurement; and d) Repetition of stages a) to c) four times. 3. Resistance after soaking at 70 ° C for 24 hours. 4. Resistance after hydrothermal shock. Protocol: a) Immersion in water at 60 ° C for 6 min .; b) Immersion in water at 0 ° C for 6 min .; c) Repetition of steps a) and b) twice; and d) Measurement of resistance. 5. Resistance to sweat immersion. Protocol: a) Immersion of bus bars in synthetic sweat (1% NaCl, 0.1% Na2HPO4, 0.1% lactic acid, in water); b) Apply air in solution for 16 hours; and c) Measure the resistance.

"» ^ Te _.

The initial resistances and the relative humidity are shown in the Table! Table 1: Initial resistances v to moisture (O) 1) Tra-Duct ® 2902 and Tra-Duct® 2701 are commercially available from Tra-Con, Inc. 2) Gold, alloy and tungsten epoxies are commercially available from Applied Technologies, Inc. 3) The alloy epoxy is 70/25/5 weight percent in Ag / Au / Ni.

After completion of the moisture cycle test, only Tra-Duct 2902 silver alloys and Applied Technologies 5933 alloy were not peeled. All other bus bars were peeled from the substrates. These two epoxy bus bars were then compared in the remaining environmental tests. Results are shown in table 2.

Table 2: Thermal soaking, thermal shock and sweat immersion - Resistances of bus bars Table 2 shows that the alloy epoxy bus bar had the minimum resistance through the tests. This epoxy was not substantially affected by changes in temperature or exposure to moisture. In addition, it was found that the alloy epoxy bonded extremely well to CR-39® substrate. However, the alloying epoxy required a long time to mix and had a short shelf life of about 5 minutes.

Example 2: Tongue strength tests The resistance of wire tongues of silver, nickel, titanium, gold, copper and platinum was evaluated. Each tab tested was 2"(5 cm) long and 0.0127" (0.3 mm) in diameter. The purities were 99.9% by weight. These tabs were purchased from Aldrich, Inc. The initial strength was measured, as well as the resistance after 100 hours at 50 ° C and 100% relative humidity, using a Fluke® 8060A multimeter. The results are shown in Table 3.

Table 3: Resistance of the tongue Table 3 shows that the nickel wire had good conductivity and good environmental durability. The copper wire developed an oxide layer on its surface during the moisture test; this could be a serious flaw in some applications; since a layer of oxide could change the resistance of the wire.

Example 3: Mechanical durability The relative mechanical durability of each wire of Example 2 was tested by connecting one end of the wire to a V-groove bevel over the peripheral edge region of a 1 mm thick ophthalmic lens prepared from CR-39® monomer. . The wire was then stretched along the peripheral V groove, and its other end tacked. After securing each end of the wire with tape, the 1"center portion of the wire was covered with Applied Technologies 5933 alloy epoxy. After curing for 30 minutes at 50 ° C, the tape was removed and pulled from one end of the wire. wire This has led to either wire failure or epoxy failure, as shown in Table 4.

Table 4: Mechanical durability £ || ig ^ j

Claims (20)

1. CLAIMS 1. A method for applying a conductive epoxy bar / bus bar system to a substrate, said system comprising a hardened conductive epoxy layer and a tongue having a corresponding connecting portion embedded in said hardened conductive epoxy layer, which method comprises: a) embedding the connecting portion of said tongue in a hardenable conductive epoxy layer applied to an intended area of the bus bar on said substrate; and b) hardening said hardenable conductive epoxy. The method of claim 1, wherein the scale is produced by inserting the connecting portion of said tongue into a hardenable conductive epoxy layer applied to said substrate, and hardening said hardenable conductive epoxy layer. The method of claim 1, wherein the embedding occurs by placing the connecting portion of said tongue on a first hardenable or hardened conductive epoxy layer applied to said substrate, applying a second hardenable conductive epoxy layer on said connecting portion, and hardening all hardenable conductive epoxy layers. The method of claim 1, wherein the embedding occurs by placing or fixing the connecting portion of said tongue over the intended area of the bus bar of said substrate, applying a hardening conductive epoxy layer over said connecting portion, and hardening said hardenable conductive epoxy layer. The method of claim 1, wherein said substrate has a peripheral edge region between first and second extension surfaces, and said intended area of the bus bar is in said peripheral edge region. 6. The method of claim 5, wherein said substrate is a configured substrate. The method of claim 6, wherein said substrate is an ophthalmic lens. The method of claim 7, wherein said bus bar contacts an electroconductive film on said substrate. ^^^^^ j ^^^ g - ^^^^ g ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ Bus bar runs in contact with an electroconductive film on said substrate. The method of claim 6, wherein said bus bar contacts an electroconductive film on said substrate. The method of claim 1, wherein said connection portion is a connection end. The method of claim 5, wherein said connection portion is a connection end. 13. A substrate containing a conductor epoxy bus bar having a tongue embedded therein. The substrate of claim 13, wherein said bus bar comes into contact with an electroconductive film on said substrate. 15. The substrate of claim 14, wherein said bus bar is positioned on the peripheral edge region of said substrate and said electroconductive film is positioned on an adjacent extension surface. 16. A substrate having a conductive epoxy bus / tongue bar system applied by the method of claim 3. 17. The substrate of claim 13, wherein said substrate is an ophthalmic lens. 18. The substrate of claim 14, wherein said substrate is an ophthalmic lens. 19. The substrate of claim 15, wherein said substrate is an ophthalmic lens. The substrate of claim 16, wherein said substrate is an ophthalmic lens.