Methods and apparatuses for forming microprojection arrays

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• forcing an elastomeric material against the second face of the sheet and against the microprojections formed therein;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die;
• and
• reducing the force on at least a portion of the elastomeric material thereby causing the retraction of at least a portion of the elastomeric material from the cavities of the die.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• providing a block having a bore therethrough;
• positioning the block adjacent the second face of the sheet so that at least a portion of the plurality of microprojections and openings of the sheet are positioned within the bore of the block;
• providing a piston which is sized to fit within the bore of the block;
• disposing an elastomeric material in the bore of the block;
• and
• biasing the piston into the bore of the block to force the elastomeric material against the second face of the sheet and against the microprojections formed therein;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• wherein the elastomeric material is biased against the second face of the sheet with a force sufficient to bend at least a portion of the microprojections of the sheet into the cavities of the die to an angle of at least 45 degrees from a plane of the sheet.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• wherein the elastomeric material is biased against the second face of the sheet with a force sufficient to bend at least a portion of the microprojections of the sheet into the cavities of the die to an angle of at least 60 degrees from a plane of the sheet.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• wherein the elastomeric material is biased against the second face of the sheet with a force sufficient to bend at least a portion of the microprojections of the sheet into the cavities of the die to an angle of at least 90 degrees from a plane of the sheet.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• wherein the elastomeric material is biased against the second face of the sheet with a force sufficient to bend at least a portion of the microprojections of the sheet into the cavities of the die to an angle between about 1 degree to about 90 degrees relative to the a plane of the sheet and all of the microprojections are bent to substantially the same angle.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming, by an etching process, a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• forcing an elastomeric material against the second face of the sheet and against the microprojections formed therein;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• wherein the cavities of the die each have a depth greater than a length of the associated corresponding microprojection of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• forcing an elastomeric material against the second face of the sheet and against the microprojections formed therein;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• wherein the outer perimeter of each opening of the sheet is located inside of the outer perimeter of the adjacent cavity of the die;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• forcing an elastomeric material against the second face of the sheet and against the microprojections formed therein;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• forcing an elastomeric material against the second face of the sheet and against the microprojections formed therein;
• the elastomeric material being forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die;
• and
• wherein each of the microprojections of the sheet has a base positioned adjacent an inwardly extending lip of the corresponding adjacent cavity of the die so that during the bending of the microprojections, the base of each microprojection is bent against the inwardly extending lip of the corresponding adjacent cavity of the die.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• forcing an elastomeric material against the second face of the sheet and against the microprojections formed therein;
• the elastomeric material being forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die;
• and
• wherein each of the microprojections of the sheet has a base positioned adjacent an inwardly extending lip of the corresponding adjacent cavity of the die so that during the bending of the microprojections, the base of each microprojection is bent against the inwardly extending lip of the corresponding adjacent cavity of the die and each microprojection is bent into a shape corresponding to the contour of the inwardly extending lip of the corresponding cavity of the die.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• forcing an elastomeric material, said elastomeric material being selected from the group consisting of silicone rubber, butyl rubber and polyurethane, against the second face of the sheet and against the microprojections formed therein;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• each microprojection having a base;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• forcing an elastomeric material against the second face of the sheet and against the microprojections formed therein;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die, the base of each microprojection having an opening to facilitate bending of the microprojection along the base.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• each microprojection having a base;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• forcing an elastomeric material against the second face of the sheet and against the microprojections formed therein;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die, the base of each microprojection having a groove to facilitate bending of the microprojection along the base.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• each microprojection having a base;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• forcing an elastomeric material against the second face of the sheet and against the microprojections formed therein;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die, the base of each microprojection having an a notch along at least one side of the microprojection to facilitate bending of the microprojection along the base.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• providing a cover plate having a plurality of openings therethrough which correspond in size, shape and location to the plurality of cavities in the die;
• placing the cover plate on the second face of the sheet;
• and
• forcing an elastomeric material against the cover plate and against the microprojections formed in the sheet;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• providing a block having a bore therethrough;
• positioning the block adjacent the second face of the sheet so that at least a portion of the plurality of microprojections and openings of the sheet are positioned within the bore of the block;
• providing a piston which is sized to fit within the bore of the block;
• disposing an elastomeric material in the bore of the block;
• said elastomeric material shaped to fit within the bore;
• and
• biasing the piston into the bore of the block to force the elastomeric material against the second face of the sheet and against the microprojections formed therein;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• forcing an elastomeric material against the second face of the sheet and against the microprojections formed therein;
• said elastomeric material having a durometer hardness of 20A to about 100A as determined by the ASTM Test Method D2240-00, the elastomeric material being forced into the cavities of the die, causing the microprojections of the sheet to be bent into the cavities of the die.

A method for producing a device for piercing a body surface, the method comprising the steps of:

• providing a sheet having opposite first and second faces;
• forming a plurality of microprojections and openings through the first and the second faces of the sheet;
• providing a die having a plurality of cavities corresponding to the plurality of microprojections of the sheet;
• the die being comprised of a base plate and one or more forming plates;
• wherein each forming plate contains a plurality of openings therethrough and wherein the openings in each the forming plates are correspondingly located so that when the forming plates are aligned and disposed on the base plate, the openings also align and form said cavities;
• positioning the first face of the sheet against the die so that each of the microprojections of the sheet is positioned adjacent a corresponding cavity of the die;
• and
• forcing an elastomeric material against the second face of the sheet and against the microprojections formed therein;
• wherein the elastomeric material is forced into the cavities of the die causing the microprojections of the sheet to be bent into the cavities of the die.

A device for piercing a body surface, comprising:

• a stack of sheets including a top sheet, each of the sheets having an opening therethrough and one or more microprojections located along a periphery of the opening and outwardly extending from the respective sheet;
• the openings of the sheets in the stack being generally in alignment with the opening of the top sheet and the microprojections of the sheets beneath the top sheet outwardly extending through the openings of the top sheet;
• and
• wherein at least one of the microprojections of at least one of the sheets has a hole therethrough positioned at a base of the respective microprojection located adjacent the periphery of the opening of the respective sheet.

A device for piercing a body surface, comprising:

• a stack of sheets including a top sheet, each of the sheets having an opening therethrough and one or more microprojections located along a periphery of the opening and outwardly extending from the respective sheet;
• the openings of the sheets in the stack being generally in alignment with the opening of the top sheet and the microprojections of the sheets beneath the top sheet outwardly extending through the openings of the top sheet;
• and
• wherein the one or more microprojections of the top sheet each have a length less than each of the one or more microprojections of the other sheets of the stack.

A device for piercing a body surface, comprising:

• a stack of sheets including a top sheet, each of the sheets having an opening therethrough and one or more microprojections located along a periphery of the opening and outwardly extending from the respective sheet;
• the openings of the sheets in the stack being generally in alignment with the opening of the top sheet and the microprojections of the sheets beneath the top sheet outwardly extending through the openings of the top sheet;
• and
• wherein the microprojections of the sheets are spaced apart from each other.

A device for piercing a body surface, comprising:

• a pair of sheets each having an opening therethrough and a microprojection located along a periphery of the opening and outwardly extending from the respective sheet;
• the sheets being positioned adjacent one another such that peripheries of the openings of sheets are generally aligned with one another and the microprojection of one of the sheets extends through the opening of the other sheet;
• and
• wherein the microprojections of each of the sheets are positioned in different locations around the periphery of the openings.

A device for piercing a body surface, comprising:

• a pair of sheets each having an opening therethrough and a microprojection located along a periphery of the opening and outwardly extending from the respective sheet;
• the sheets being positioned adjacent one another such that peripheries of the openings of sheets are generally aligned with one another and the microprojection of one of the sheets extends through the opening of the other sheet;
• and
• wherein the microprojections of the one sheet are located at one end of the openings and the microprojections of the other sheet are located at the opposite end of the openings.