Method of molding for microneedle arrays
First Claim
1. A method of manufacturing a molded microneedle array comprising:
- providing a negative mold insert characterized by a negative image of microneedle topography wherein at least one negative image of a microneedle is characterized by an aspect ratio of between about 2 to 1 and about 5 to 1;
transferring the negative mold insert into an injection molding apparatus, wherein the negative mold insert is exposed and defines a structured surface of a negative mold cavity;
heating the negative mold cavity to a temperature above the softening temperature of a moldable plastic material;
heating the moldable plastic material to at least the molten temperature of the moldable plastic material in a chamber separate from the negative mold cavity;
injecting the molten plastic material into the heated negative mold cavity, allowing the molten plastic material to fill at least about 90 percent of the volume of the negative indentations defined by the negative mold insert;
cooling the molten plastic material to a temperature below the softening temperature of the moldable plastic material; and
detaching the molded microneedle array from the negative mold insert.
1 Assignment
0 Petitions
Accused Products
Abstract
A method of manufacturing a moldable microneedle array (54) is described comprising providing a negative mold insert (44) characterized by a negative image of microneedle topography wherein at least one negative image of a microneedle is characterized by an aspect ratio of between about 2 to 1 and about 5 to 1. The negative mold insert (44) is used to define a structured surface of a negative mold cavity (42). Molten plastic material is injected into the heated negative mold cavity. The molten plastic material is subsequently cooled and detached from the mold insert to provide a molded microneedle array (54). One manner of using microneedle arrays of the present invention is in methods involving the penetration of skin to deliver medicaments or other substances and/or extract blood or tissue through the skin.
167 Citations
30 Claims
-
1. A method of manufacturing a molded microneedle array comprising:
-
providing a negative mold insert characterized by a negative image of microneedle topography wherein at least one negative image of a microneedle is characterized by an aspect ratio of between about 2 to 1 and about 5 to 1;
transferring the negative mold insert into an injection molding apparatus, wherein the negative mold insert is exposed and defines a structured surface of a negative mold cavity;
heating the negative mold cavity to a temperature above the softening temperature of a moldable plastic material;
heating the moldable plastic material to at least the molten temperature of the moldable plastic material in a chamber separate from the negative mold cavity;
injecting the molten plastic material into the heated negative mold cavity, allowing the molten plastic material to fill at least about 90 percent of the volume of the negative indentations defined by the negative mold insert;
cooling the molten plastic material to a temperature below the softening temperature of the moldable plastic material; and
detaching the molded microneedle array from the negative mold insert. - View Dependent Claims (3, 4, 5, 6, 7, 8, 9, 10, 12, 16, 17, 18, 29, 30)
-
-
2. A method of manufacturing a molded microneedle array comprising:
-
providing a negative mold insert characterized by a negative image of microneedle topography wherein at least one negative image of a microneedle is characterized by an aspect ratio of between about 2 to 1 and about 5 to 1;
transferring the negative mold insert into an injection molding apparatus, wherein the negative mold insert is exposed and defines a structured surface of a negative mold cavity;
heating the negative mold cavity to a temperature of more than about 10 degrees centigrade above the softening temperature of a moldable plastic material;
heating the moldable plastic material to at least the molten temperature of the moldable plastic material in a chamber separate from the negative mold cavity;
injecting the molten plastic material into the heated negative mold cavity, allowing the molten plastic material to fill at least about 90 percent of the volume of the negative indentations defined by the negative mold insert;
cooling the molten plastic material to a temperature at least below the softening temperature of the moldable plastic material; and
detaching the molded microneedle array from the negative mold insert. - View Dependent Claims (15)
-
-
11. (canceled)
-
13-14. -14. (canceled)
-
19. A method of manufacturing a negative mold insert used for preparing molded microneedle arrays comprising:
-
providing a positive mold master member characterized by microneedle topography wherein at least one microneedle is characterized by an aspect ratio of between about 2 to 1 and about 5 to 1;
electroforming a negative mold insert around the positive mold master; and
detaching the negative mold insert from the positive mold master member. - View Dependent Claims (20, 21, 23, 26, 27, 28)
-
-
22. (canceled)
-
24-25. -25. (canceled)
Specification