Method of molding a microneedle
First Claim
1. A method of molding a microneedle comprising:
- (i) providing a mold apparatus comprising;
a mold insert having the negative image of at least one microneedle;
a compression core;
a mold housing configured to allow a reciprocal motion between the mold insert and the compression core; and
sidewalls having an injection gate and the polymeric material is injected through the injection gate into the closed mold apparatus;
wherein the mold apparatus has an open position and a closed position;
(ii) placing the mold apparatus in the closed position;
(iii) heating the mold insert to a temperature of greater than or equal to 200°
F. (93.3°
C.) before the polymeric material is injected through the injection gate into the closed mold apparatus;
(iii) injecting polymeric material into the closed mold apparatus;
(iv) compressing the injected polymeric material between the mold insert and the compression core by a reciprocal motion between the compression core and the mold insert;
(v) opening the mold; and
(vi) removing a molded microneedle from the mold;
wherein the mold insert has a mold insert height and the molded microneedle has a height that is from about 90% of the mold insert height to about 115% of the mold insert height; and
wherein the mold insert has the negative image of a plurality of microneedles in the form of an array comprising a plurality of microneedles integrally formed with a substrate, and wherein the microneedle array comprises a plurality of microneedles having a substantially flat tip comprising a surface area measured in a plane aligned with the base of about 20 square micrometers or more and 100 square micrometers or less.
1 Assignment
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Accused Products
Abstract
A method of molding a microneedle using a mold apparatus that comprises a mold insert (210)having the negative image of at least one microneedle (12), a compression core (240), and a mold housing configured to allow a reciprocal motion between the mold insert and the compression core. The mold apparatus has an open position and a closed position. The mold apparatus is placed in the closed position and polymeric material is injected into the closed mold apparatus. The injected polymeric material is compressed between the mold insert and the compression core by a reciprocal motion between the compression core and the mold insert. Also, molding methods wherein the mold apparatus has sidewalls having an injection gate (270). Also, molding methods comprising a heated mold insert. Also, molding methods comprising the application of high frequency acoustic energy, such as ultrasonic energy, to the mold apparatus.
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Citations
16 Claims
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1. A method of molding a microneedle comprising:
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(i) providing a mold apparatus comprising; a mold insert having the negative image of at least one microneedle; a compression core; a mold housing configured to allow a reciprocal motion between the mold insert and the compression core; and sidewalls having an injection gate and the polymeric material is injected through the injection gate into the closed mold apparatus; wherein the mold apparatus has an open position and a closed position; (ii) placing the mold apparatus in the closed position; (iii) heating the mold insert to a temperature of greater than or equal to 200°
F. (93.3°
C.) before the polymeric material is injected through the injection gate into the closed mold apparatus;(iii) injecting polymeric material into the closed mold apparatus; (iv) compressing the injected polymeric material between the mold insert and the compression core by a reciprocal motion between the compression core and the mold insert; (v) opening the mold; and (vi) removing a molded microneedle from the mold; wherein the mold insert has a mold insert height and the molded microneedle has a height that is from about 90% of the mold insert height to about 115% of the mold insert height; and wherein the mold insert has the negative image of a plurality of microneedles in the form of an array comprising a plurality of microneedles integrally formed with a substrate, and wherein the microneedle array comprises a plurality of microneedles having a substantially flat tip comprising a surface area measured in a plane aligned with the base of about 20 square micrometers or more and 100 square micrometers or less. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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Specification