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Method of molding a microneedle

  • US 8,088,321 B2
  • Filed: 12/07/2005
  • Issued: 01/03/2012
  • Est. Priority Date: 12/07/2004
  • Status: Expired due to Fees
First Claim
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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.

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