Method for manufacturing microstructures having hollow microelements using fluidic jets during a molding operation
First Claim
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1. A method for constructing a microstructure comprising an array of microneedles designed to penetrate the stratum corneum of human skin, said method comprising:
- (a) providing a moldable material to be formed into a predetermined shape;
(b) during a molding procedure, forcing a predetermined fluid under pressure toward a surface of said moldable material, said predetermined fluid forming at least one opening at said surface; and
(c) substantially solidifying said moldable material while said pressurized predetermined fluid continues to flow toward said surface, thereby forming a solid microstructure which includes said at least one opening at said surface, wherein the solid microstructure has the predetermined shape comprising an array of microneedles protruding from a substrate wherein said microneedles are able to penetrate the stratum corneum of human skin.
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Abstract
A method is provided for constructing microstructures that can penetrate skin layers, in which the microelements are formed during a molding process while fluidic jets produce openings in the microelements. The structures used in the molding process are formed by tooling that creates the shapes of the microelements in a material deposition step, and also creates the sizes and shapes of the openings that will be formed by the fluidic jets.
85 Citations
19 Claims
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1. A method for constructing a microstructure comprising an array of microneedles designed to penetrate the stratum corneum of human skin, said method comprising:
- (a) providing a moldable material to be formed into a predetermined shape;
(b) during a molding procedure, forcing a predetermined fluid under pressure toward a surface of said moldable material, said predetermined fluid forming at least one opening at said surface; and
(c) substantially solidifying said moldable material while said pressurized predetermined fluid continues to flow toward said surface, thereby forming a solid microstructure which includes said at least one opening at said surface, wherein the solid microstructure has the predetermined shape comprising an array of microneedles protruding from a substrate wherein said microneedles are able to penetrate the stratum corneum of human skin. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
- (a) providing a moldable material to be formed into a predetermined shape;
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9. A method for constructing a micromold, said method comprising:
- (a) providing a tooling structure having a first surface and a second surface opposite said first surface, and having a substrate having a plurality of protrusions formed upon said first surface, said plurality of protrusions exhibiting at least one height;
(b) depositing a material upon the first surface of said tooling structure, said material having a thickness that is generally less than said at least one height of said plurality of protrusions; and
(c) separating said material from said tooling structure to form a micromold, said micromold exhibiting a first plurality of openings that correspond to a portion of a three-dimensional negative form of said plurality of protrusions of the tooling structure along said thickness of said material, wherein said depositing step comprises one of;
(a) electroplating;
(b) spin coating;
(c) vapor deposition;
(d) injection molding; and
(e) casting. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17)
- (a) providing a tooling structure having a first surface and a second surface opposite said first surface, and having a substrate having a plurality of protrusions formed upon said first surface, said plurality of protrusions exhibiting at least one height;
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18. A method for constructing a microstructure, said method comprising:
- (a) providing a tooling structure having a first surface and a second surface opposite said first surface, and having a first substrate having a plurality of protrusions formed upon said first surface, said plurality of protrusions exhibiting at least one height;
(b) depositing a first material upon the first surface of said tooling structure, said first material having a thickness that is generally less than said at least one height of said plurality of protrusions;
(c) releasing said first material from said tooling structure, said first material exhibiting a plurality of openings that correspond to a portion of a three-dimensional negative form of said plurality of protrusions of the tooling structure along said thickness of said first material, said plurality of openings exhibiting at least one predetermined inner area proximal to a first surface of said first material;
(d) providing a backing member at a predetermined and spaced-apart distance from a second surface of said first material, said fourth surface being opposite said first surface of the first material, said backing member exhibiting comparatively little porosity with respect to a moldable second material, but exhibiting substantial porosity with respect to a predetermined fluid;
(e) introducing said moldable second material between said backing member and the second surface of said first material, and forcing said predetermined fluid under pressure through said plurality of openings of the first material to form at least one channel in said second material between said first material and said backing member, and substantially solidifying said second material while said pressurized predetermined fluid continues to flow through said plurality of openings; and
(f) separating said solidified second material from said backing member and said first material, said solidified second material exhibiting a second substrate and exhibiting a plurality of microelements that substantially correspond in size and shape to a three-dimensional negative form of said plurality of openings in the first material, and further exhibiting said at least one channel running completely through said second substrate and at least one of said plurality of micro elements. - View Dependent Claims (19)
- (a) providing a tooling structure having a first surface and a second surface opposite said first surface, and having a first substrate having a plurality of protrusions formed upon said first surface, said plurality of protrusions exhibiting at least one height;
Specification