Method of forming a mold and molding a micro-device

Abstract

A method of forming a device including a plurality of micron or sub-micron sized features is provided. A master having a surface contour defining a plurality of features is provided. The surface contour of the master is coated with at least one layer of material to form a shell. The master is removed from the shell to form a negative image of the surface contour in the shell. The negative image in the shell is filled with material, for example, polycarbonate, polyacrylic, or polystyrene, to form a device having features substantially the same as the master. The negative image may be filled using injection molding, compression molding, embossing or any other compatible technique.

Description

CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation of Ser. No. 10 / 193,317 filed Jul. 12, 2002, which is herein incorporated by reference in its entirety.FIELD OF THE INVENTION [0002] The present invention relates to a method of manufacturing a device, and particularly, a micro-device. More particularly, the invention is directed to a method of forming a mold for a micro-device and molding a micro-device for medical use. BACKGROUND OF THE INVENTION [0003] There has been an increase in interest in processes for the manufacture of small devices in the field of biological and biochemical analysis. The manufacture of devices used for analytical testing uses techniques similar to those used in the electronics industry. Examples of these manufacturing techniques include photolithography and wet chemical etching. The devices are often made from solid substrates such as silicon and glass. [0004] Microanalytical devices have been used for performing various anal...

AI Technical Summary

Benefits of technology

The present invention is about a method and apparatus for manufacturing micro-devices, such as analytical microchannel devices, microneedles, and pipettes, with micrometer and submicrometer features. The invention is suitable for molding plastic devices having channels, needles, or other structural features with dimensions ranging from less than 1 micron to several hundred microns in length or width. The micro-devices can be used for penetrating or abrading the stratum corneum of the skin and for the transdermal delivery of substances through the abraded area. The invention provides a method for forming a mold for a micro-device by coating a master with a layer of material and removing the master to form a negative image of the master in the layer of material. The negative image can then be used in a molding process to form a positive image with features that are substantially the same as the master. The invention also provides a method for forming a device with features by filling a shell with a suitable material, where the shell can have recesses or peaks on its surface contour ranging from about 0.5 micron to several hundred microns in length. The advantages of the invention include improved precision and accuracy in the manufacturing of micro-devices and the ability to produce complex micro-device structures with micrometer and submicrometer features.

Problems solved by technology

Although effective, the resulting microneedle devices are expensive to manufacture and are difficult to produce in large numbers.

The microelectrode-discharge machining or photolithographic processing used to form the mold are time consuming and expensive processes.

The prior methods and apparatus for the manufacture of micro-devices for medical use have exhibited some success but are generally time consuming and expensive.

For example, the process of Lee et al. can only form a mold for a singular device.

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