Process for making microneedles, microneedle arrays, masters, and replication tools
First Claim
1. A process for preparing microneedles comprising(a) providing a photoreactive composition, said photoreactive composition comprising(1) at least one reactive species that is capable of undergoing an acid- or radical-initiated chemical reaction, and(2) at least one multiphoton photoinitiator system;
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Accused Products
Abstract
A process for making a microneedle array master comprises: (a) providing a photoreactive composition, the photoreactive composition comprising: (1) at least one reactive species that is capable of undergoing an acid- or radical-initiated chemical reaction, and (2) at least one multiphoton photoinitiator system; and (b) imagewise exposing at least a portion of the composition to light sufficient to cause simultaneous absorption of at least two photons, thereby inducing at least one acid- or radical-initiated chemical reaction where the composition is exposed to the light, the imagewise exposing being carried out in a pattern that is effective to define at least the surface of a plurality of microneedles. The microneedles may be solid and the outer surface of the microneedles may be characterized by at least one concave area. The master may be used to fabricate a tool for replication.
45 Citations
20 Claims
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1. A process for preparing microneedles comprising
(a) providing a photoreactive composition, said photoreactive composition comprising (1) at least one reactive species that is capable of undergoing an acid- or radical-initiated chemical reaction, and (2) at least one multiphoton photoinitiator system; - and
(b) imagewise exposing at least a portion of said composition to light sufficient to cause simultaneous absorption of at least two photons, thereby inducing at least one acid- or radical-initiated chemical reaction where said composition is exposed to the light, said imagewise exposing being carried out in a pattern that is effective to define at least the surface of a plurality of solid microneedles, wherein the outer surface of the microneedles is characterized by at least one concave area. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A microneedle array comprising a plurality of polymeric microneedles, the microneedle array being prepared according to a process comprising:
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(a) providing a photoreactive composition, said photoreactive composition comprising; (1) at least one reactive species that is capable of undergoing an acid- or radical-initiated chemical reaction, and (2) at least one multiphoton photoinitiator system, wherein the multiphoton photoinitiator system comprises photochemically effective amounts of;
(a) at least one multiphoton photosensitizer that is capable of simultaneously absorbing at least two photons and that has a two-photon absorption cross-section greater than that of fluorescein;
(b) at least one electron donor compound different from the multiphoton photosensitizer and capable of donating an electron to an electronic excited state of the photosensitizer; and
(c) at least one photoinitiator that is capable of being photosensitized by accepting an electron from an electronic excited state of the photosensitizer, resulting in the formation of at least one free radical and/or acid; and(b) imagewise exposing at least a portion of said composition to light sufficient to cause simultaneous absorption of at least two photons, thereby inducing at least one acid- or radical-initiated chemical reaction where said composition is exposed to the light, said imagewise exposing being carried out in a pattern that is effective to define at least the surface of the plurality of polymeric microneedles, wherein the outer surface of the polymeric microneedles is characterized by at least one concave area. - View Dependent Claims (14, 15, 16, 17, 18, 19)
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20. A microneedle array comprising a plurality of polymeric microneedles comprising photochemically cured compositions, the microneedle array being prepared according to a process comprising:
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(a) providing a photoreactive composition, said photoreactive composition comprising; (1) at least one reactive species that is capable of undergoing an acid- or radical-initiated chemical reaction, and (2) at least one multiphoton photoinitiator system, wherein the multiphoton photoinitiator system comprises photochemically effective amounts of;
(a) at least one multiphoton photosensitizer that is capable of simultaneously absorbing at least two photons and that has a two-photon absorption cross-section greater than that of fluorescein;
(b) at least one electron donor compound different from the multiphoton photosensitizer and capable of donating an electron to an electronic excited state of the photosensitizer; and
(c) at least one photoinitiator that is capable of being photosensitized by accepting an electron from an electronic excited state of the photosensitizer, resulting in the formation of at least one free radical and/or acid; and(b) imagewise exposing at least a portion of said composition to light sufficient to cause simultaneous absorption of at least two photons, thereby inducing at least one acid- or radical-initiated chemical reaction where said composition is exposed to the light, said imagewise exposing being carried out in a pattern that is effective to define at least the surface of the plurality of polymeric microneedles, wherein the outer surface of the polymeric microneedles is characterized by at least one concave area.
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Specification