Method for fabricating needles via conformal deposition in two-piece molds

• US 6,106,751 A
• Filed: 03/18/1998
• Issued: 08/22/2000
• Est. Priority Date: 03/18/1998
• Status: Expired due to Term

• Current Assignee: Regents of the University of California (University of California)
• Original Assignee: Regents of the University of California (University of California)
• Inventors: Pisano, Albert P., Talbot, Neil H., Keller, Christopher G.
• Primary Examiner(s): Fiorilla, Christopher A.
• Application Number:
  US09/044,398
• Time in Patent Office: 888 Days
• Field of Search: 264/81
• US Class Current: 264/81
• CPC Class Codes: A61M 5/32 Needles; Details of needles pertaining to their connection with syringe or hub infusion needles A61M5/158; Accessories for bringing the needle into, or holding the needle on, the body A61M5/42, A61M5/46 take precedence; guide needles for catheters A61M25/065; Devices for protection of needles apparatus specially adapted for cleaning or sterilising needles A61M5/001
• CPC Class Codes: A61M 5/3291 Shafts with additional lateral openings
• CPC Class Codes: A61M 5/46 having means for controlling depth of insertion
• CPC Class Codes: B29C 33/30 Mounting, exchanging or centering moulds, mould parts or cores; B29C33/485 takes precedence
• CPC Class Codes: B29K 2083/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29L 2031/759 Needles medical needles B29L2031/7544

Abstract

A method of fabricating a needle via conformal deposition in a two-piece mold includes the step of attaching a top mold member to a bottom mold member such that the top mold member and the bottom mold member define an enclosed, elongated needle trench with a deposition aperture. A conformal substance, such as polysilicon, is then passed through the deposition aperture such that the conformal substance is deposited within the enclosed, elongated needle trench to form a needle. The method is used to form needles with prongs, multiple channels, multiple ports, barbs, strength enhancement features, and circuitry.

Claims

1. A method of fabricating a needle via conformal deposition in a two-piece mold, said method comprising the steps of:

attaching a top mold member to a bottom mold member such that said top mold member and said bottom mold member define an enclosed, elongate needle trench with a deposition aperture;

passing a conformal substance through said deposition aperture such that said conformal substance is deposited via vapor deposition within said enclosed, elongated needle trench;

stopping said passing step before said elongated needle trench is filled with said conformal substance; and

removing said top mold member and said bottom mold member to expose a needle.

2. The method of claim 1 wherein said passing step includes the step of passing polysilicon through said deposition aperture.

3. The method of claim 2 wherein said passing step is repeated until said polysilicon is deposited to a desired depth.

4. The method of claim 1 wherein said passing step includes the step of passing said conformal substance through said deposition aperture such that said conformal substance is deposited within said enclosed, elongated needle trench, which defines a dual prong needle.

5. The method of claim 1 wherein said passing step includes the step of passing said conformal substance through said deposition aperture such that said conformal substance is deposited within said enclosed, elongated needle trench, which defines a barb.

6. The method of claim 1 wherein said passing step includes the step of passing said conformal substance through said deposition aperture such that said conformal substance is deposited within said enclosed, elongated needle trench, which defines a strength enhancement feature.