Method of forming a mold and molding a micro-device
AssigneeBecton, Dickinson and Company
InventorAlexander G. Lastovich
Life of this patent
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Abstract
A method of forming a device including a plurality of micron or sub-micron sized features is provided. A master having a surface contour defining a plurality of features is provided. The surface contour of the master is coated with at least one layer of material to form a shell. The master is removed from the shell to form a negative image of the surface contour in the shell. The negative image in the shell is filled with material, for example, polycarbonate, polyacrylic, or polystyrene, to form a device having features substantially the same as the master. The negative image may be filled using injection molding, compression molding, embossing or any other compatible technique.
Claims39
A method of forming a mold for a micro-device including an array of microfeatures, comprising:
- providing a master having a surface contour which includes skin penetration features;
- covering the surface contour with a layer of material having a thickness of about 0.01-0.2 inches;
- removing the master from the layer of material to form a negative image of the master in the layer of material wherein the negative image is fillable by a flowable process;
- filling the negative image fluidically with a flowable powdered metallic materiel to form a device having substantially the same features as the master;
- and
- sintering the powdered metallic material to form the micro-device.
A method of forming a device including a plurality of micron or sub-micron sized features, the method comprising:
- providing a master having a surface contour defining skin penetration features;
- coating the surface contour of the master with at least one layer of material having a thickness of about 0.01-0.2 inches;
- removing the master from the layer of material to form a negative image of the surface contour in the layer of material;
- forming a mold insert from the negative image;
- and
- performing injection molding to fill the negative image fluidicaily to form a device having substantially the same features as the master.
A method of forming a device including a plurality of micron or sub-micron sized features, the method comprising:
- providing a master having a surface contour defining features;
- coating the surface contour of the master with at least one layer of material at about 0.07 inches thick;
- removing the master from the layer of material to form a negative image of the surface contour in the layer of material;
- and
- filling the negative image to form a device having substantially the same features as the master.
A method of forming a medical device including a plurality of micron or sub-micron sized features which form skin penetration members, the method comprising:
- providing a master having a surface contour defining skin penetration features;
- coating the surface contour of the master with a single layer of material having a thickness of about 0.01-0.2 inches;
- removing the master from the layer of material to form a negative image of the surface contour in the layer of material
- forming a mold insert from the negative image;
- and
- performing injection molding to fill the negative image fluidically to form the medical device having substantially the same features as the master.
Dependencies are inferred from the claim text.