JP2010017275A - Method for manufacturing die core, and die core - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To precisely and easily manufacture a die core used for shaping a plastic made needle having a blood collecting flow path for puncturing. <P>SOLUTION: Photoresist is applied onto a substrate 1. The first exposing step of exposing to light using the first reticle for forming a site corresponding to a device body to the photoresist and the second exposing step of exposing to light using the second reticle for forming a site corresponding to the liquid collecting flow path to the photoresist are individually carried out. A resist convex mold 4 in which the site corresponding to the device body and the liquid collecting flow path are formed is formed by developing the photoresist. A concave mold is formed by reversing the convex shape of the resist convex mold 4 and a transferring mold is formed by reversing the concave shape of the concave mold. Thereby, the application and the development of the photoresist can be carried out in one step respectively. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a mold core for use in molding a plastic medical device (for example, a puncture needle) having a liquid collection channel, and a method for manufacturing the same.

  As this type of puncture needle, conventionally, a metal needle is frequently used (see, for example, Patent Document 1). However, a metal puncture needle restricts the shape of the needle, so that not only pain during puncture cannot be sufficiently reduced, but also a large amount is consumed, and its disposal method has become a social problem.

Therefore, a plastic puncture needle has been proposed to deal with such problems (see, for example, Patent Document 2).
JP 2007-38021 A JP 2002-172169 A

  However, in order to reduce pain at the time of puncture, it is necessary not only to reduce the diameter of the puncture part but also to finish it into a fine and complex shape (a shape resembling a mosquito's snout). A mold core for plastic molding such a fine and complicated shape has the disadvantage that it cannot be produced by conventional machining.

  In order to eliminate such inconvenience, it is conceivable to manufacture a mold core by photolithography. However, there are the following three problems.

  First, if the needle body of the puncture needle and the fluid collection channel are to be formed with high accuracy, the manufacturing process of the mold core becomes complicated. That is, first, a photoresist is applied, exposed, and developed in order to create an alignment mark on the glass substrate indicating the positions of the needle body and the collection channel. Next, a photoresist is applied, exposed, and developed in order to form a portion corresponding to the liquid collection channel on the glass substrate. Further, in order to form a portion corresponding to the needle body on the glass substrate, a photoresist is applied, exposed and developed. In this way, the same process (photoresist application / exposure / development) is repeated three times, which complicates the mold core manufacturing process.

  Secondly, as described above, the manufacturing process of the mold core becomes complicated, so that shape defects are likely to occur in the mold core.

  Thirdly, when the shape of the liquid collection channel becomes complicated, a developing residue is generated in the vicinity of the portion corresponding to the liquid collection channel when developing the photoresist, so that the liquid collection channel is accurately formed. It becomes difficult.

  In view of such circumstances, the present invention provides a mold core manufacturing method and a mold core capable of easily and accurately manufacturing a mold core having a fine and complicated shape by photolithography. With the goal.

  A first mold core manufacturing method according to the present invention includes a mold for use in molding a plastic medical device (20) in which a liquid collection channel (25) is formed in a device body (21). A method of manufacturing a child (7), which corresponds to the device body with respect to a resist coating step of applying a photoresist (2) on a substrate (1) and the photoresist applied in the resist coating step. A first exposure step of performing exposure using a first reticle for forming a portion to be formed and a second exposure step of performing exposure using a second reticle for forming a portion corresponding to the liquid collection channel A resist exposure step (4) in which a portion corresponding to the device main body and the liquid collecting flow path is formed by developing the photoresist exposed in the resist exposure step and developing the photoresist exposed in the resist exposure step. Forming a concave mold (8) by reversing the convex shape of the resist convex mold formed in the convex mold forming process, and forming the concave mold formed in the concave mold forming process. A transfer mold forming step for forming the transfer mold (5) by reversing the concave shape, and a core manufacturing for manufacturing the mold core by reversing the convex shape of the transfer mold formed in the transfer mold forming step. And a method of manufacturing a mold core including a process.

  The mold core (7) according to the present invention is a mold core manufactured by the above-described mold core manufacturing method.

  Here, in order to explain the present invention in an easy-to-understand manner, the description has been made in association with the reference numerals of the drawings representing the embodiments. However, it goes without saying that the present invention is not limited to the embodiments.

  According to the present invention, when a mold core having a fine and complicated shape is manufactured by photolithography, the application and development of the photoresist can be performed in one step. It becomes simple.

Embodiments of the present invention will be described below.
Embodiment 1 of the Invention

  1 to 7 are diagrams according to Embodiment 1 of the present invention.

  A plastic puncture needle (medical device) 20 according to the first embodiment has a fan-shaped flat needle body (device body) 21 as shown in FIG. A puncture section 22 having a trapezoidal cross-section bar shape is formed in the section. As shown in FIGS. 6 and 7, the needle body 21 has a cusp-shaped portion 24 formed at the tip of the puncture portion 22, and an uneven surface portion 23 on each of the left and right inclined side surfaces of the puncture portion 22. , 23 are formed. Furthermore, a blood storage portion 26 is recessed on the surface of the needle body 21. In addition, two liquid collection channels 25 and 25 are formed in parallel with each other on the surface of the puncture portion 22 of the needle body 21, and one ends of the liquid collection channels 25 and 25 reach the peak-shaped portion 24. In addition, the other ends of the liquid collection channels 25 and 25 communicate with the blood storage unit 26.

  Prior to the injection molding of the puncture needle 20 having the above-described configuration, a mold core is manufactured by photolithography according to the following procedure.

  First, in a resist coating process, as shown in FIG. 1, a positive photoresist 2 is applied on a glass substrate (substrate) 1 by a predetermined thickness T1 (for example, T1 = 120 μm). At this time, the thickness T1 of the photoresist 2 is made to coincide with the height of the needle body 21 of the puncture needle 20. The number of times the photoresist 2 is applied is not particularly limited, and may be applied three times, for example.

  When the photoresist 2 is coated on the glass substrate 1 in this way, the process proceeds to a resist exposure process, and the exposure apparatus (for example, a g-line stepper NSR-G8 type manufactured by Nikon Corporation) is used to apply the photoresist 2 to the photoresist 2. After performing one exposure process for a predetermined exposure time (for example, 20 seconds), the second exposure process is performed for a predetermined exposure time (for example, 4 seconds). Here, the first exposure step is a step of exposing using a gray scale mask (not shown) as the first reticle in order to form a portion corresponding to the needle body 21 of the puncture needle 20. The second exposure step is a step of performing exposure using a binary mask (not shown) as the second reticle in order to form portions corresponding to the two liquid collection channels 25 and 25 of the puncture needle 20. is there.

  When the first exposure process and the second exposure process are performed on the photoresist 2 in this way, the process proceeds to a convex forming process, and the photoresist is used for a predetermined development time (for example, 20 minutes) using an organic developer. 2 is developed. Then, on the glass substrate 1, as shown in FIG. 2, a resist convex mold 4 is formed in which portions corresponding to the needle main body 21 and the collection channels 25, 25 of the puncture needle 20 are formed.

  When the resist convex mold 4 is formed on the glass substrate 1 in this way, the process proceeds to the concave mold forming step, and the convex shape of the resist convex mold 4 is reversed, and as shown in FIG. A concave mold 8 is formed.

  For this purpose, as shown in FIG. 3A, a liquid first ultraviolet curable resin 11 is dropped on a glass substrate 1 on which a resist convex mold 4 is formed, and a first white plate glass 13 is placed thereon. Then, by applying an equally distributed load, the first ultraviolet curable resin 11 is uniformly stretched. In this state, the first ultraviolet curable resin 11 is irradiated with ultraviolet rays using a mercury lamp (not shown) to cure the first ultraviolet curable resin 11. Then, the 1st white plate glass 13 is peeled from the glass substrate 1 as shown in FIG.3 (b) using resist stripping solution. Then, the concave mold 8 made of the first ultraviolet curable resin 11 is formed on the first white plate glass 13.

  When the concave mold 8 is thus formed on the first white plate glass 13, the process proceeds to the transfer mold forming step, and the concave mold 8 is inverted to form the transfer mold 5 as shown in FIG.

  For this purpose, as shown in FIG. 4 (a), after the concave mold 8 is turned upside down, a liquid second ultraviolet curable resin 12 is dropped on the concave mold 8, and the second white glass 14 is placed thereon. The second ultraviolet curable resin 12 is uniformly stretched by placing and applying an equally distributed load. In this state, the second ultraviolet curable resin 12 is cured by irradiating the second ultraviolet curable resin 12 with ultraviolet rays using a mercury lamp (not shown). Thereafter, as shown in FIG. 4B, the second white plate glass 14 is peeled from the first white plate glass 13. Then, the transfer mold 5 made of the second ultraviolet curable resin 12 is formed on the second white plate glass 14.

  When the transfer mold 5 is thus formed on the second white plate glass 14, the process proceeds to the core manufacturing process, and the convex shape of the transfer mold 5 is reversed, and as shown in FIG. The core 7 is manufactured. For this purpose, a nickel film to be an electroformed electrode is formed on the transfer mold 5 on the second white glass 14 by sputtering, and then the transfer mold 5 is nickel electroformed as shown in FIG. A nickel electroformed ingot 9 having a predetermined thickness T2 (for example, about T2 = 2 mm) is manufactured by dipping in a bath. Thereafter, as shown in FIG. 5 (b), the nickel electroformed ingot 9 is separated from the transfer mold 5, and the nickel electroformed ingot 9 is incorporated in a mold (mold base). Predetermined processing is performed on the outer periphery and the back surface of. Then, the mold core 7 is completed.

  Here, the manufacturing operation of the mold core 7 is completed. A cavity having a predetermined three-dimensional shape is formed by incorporating the mold core 7 thus manufactured into the mold.

  As described above, in the first embodiment, when the mold core 7 is manufactured by photolithography, the photoresist 2 can be applied and developed in one step. Therefore, the manufacturing process of the mold core 7 is simplified.

  In addition, since the manufacturing process of the mold core 7 is simplified, shape defects are less likely to occur in the mold core 7.

  Further, even if the shape of the liquid collection channels 25 and 25 becomes complicated, when the photoresist 2 is developed, no development residue is generated in the vicinity of the portion corresponding to the liquid collection channels 25 and 25. It becomes easy to form the flow paths 25, 25 with high accuracy.

Moreover, in general, the positive photoresist 2 has a property that the non-exposed portion (the unexposed portion) is somewhat dissolved by the development. In the first embodiment, the development can be performed only once. It is possible to form the resist convex mold 4 and, consequently, the mold core 7 with high accuracy while minimizing the dissolution of the non-exposed portion 2.
[Embodiment 2 of the Invention]

  FIG. 8 is a diagram according to Embodiment 2 of the present invention.

  In the second embodiment, the mold core 7 is manufactured in substantially the same procedure as in the first embodiment. However, in the resist exposure process, after performing the first exposure process and the second exposure process on the photoresist 2, a third exposure process is performed in which exposure is performed using a binary mask (not shown) as the third reticle. As shown in FIG. 8, in the convex forming step, the tip corresponding to the tip of the resist convex die 4 (the portion corresponding to the tip of the pointed portion 24 of the puncture needle 20) is performed. ) Is formed vertically to form the rising surface 4a. At this time, the area of the rising surface 4a of the resist convex mold 4 is set to a size that does not increase pain during puncturing with the puncture needle 20.

By doing so, the tip of the mold core 7 is formed vertically as in the case of the resist convex mold 4. Therefore, when the puncture needle 20 is injection molded using the mold core 7, a molded product is formed. Thus, it is possible to prevent the occurrence of burrs at the tip of the cusp-shaped portion 24 of the puncture needle 20.
[Other Embodiments of the Invention]

  In Embodiment 1 described above, the case where the second exposure process is performed after the first exposure process is performed on the photoresist 2 in the resist exposure process has been described. You may make it perform a 1st exposure process after performing a 2nd exposure process.

  In the second embodiment, the case where the third exposure process is performed after the first exposure process and the second exposure process are performed on the photoresist 2 in the resist exposure process has been described. The order of 1 exposure process, 2nd exposure process, and 3rd exposure process is not ask | required. For example, you may perform in order of a 1st exposure process, a 3rd exposure process, and a 2nd exposure process. Moreover, it can also carry out in order of a 3rd exposure process, a 2nd exposure process, and a 1st exposure process.

  Furthermore, in Embodiment 2 mentioned above, after performing a 1st exposure process, a 2nd exposure process, and a 3rd exposure process with respect to the photoresist 2 in a resist exposure process, the photoresist 2 is formed in a convex-shaped formation process. The case of developing only once has been described. However, after the first exposure process and the second exposure process are performed on the photoresist 2 and development is performed, after the actual finish of the resist convex mold 4 is visually confirmed, a third exposure is performed as necessary. You may make it perform a process and to develop again.

  In the above-described second embodiment, the case where the peripheral portion of the corresponding portion of the resist convex mold 4 is formed vertically so as not to generate burrs at the tip of the cusp-shaped portion 24 of the puncture needle 20 has been described. Further, the peripheral portion of the corresponding portion of the resist convex mold 4 may be formed vertically so that burrs do not occur in other portions of the puncture needle 20 (for example, left and right inclined side surfaces of the puncture portion 22). .

  In the first and second embodiments described above, the mold core 7 for injection molding has been described. However, it is used for plastic molding other than injection molding (for example, extrusion molding, blow molding, compression molding, vacuum molding, etc.). The present invention can be similarly applied to the mold core 7 to be used.

  In the first and second embodiments described above, the puncture needle 20 having the two liquid collection channels 25 and 25 has been described. However, the number of the liquid collection channels 25 is one or more as long as the number is one or more. It doesn't matter.

  Moreover, although Embodiment 1 and 2 mentioned above demonstrated the puncture needle 20, when manufacturing medical devices other than the puncture needle 20, it is also possible to apply this invention similarly.

  In the first and second embodiments described above, the case where the glass substrate 1 is used as the substrate has been described. However, a substrate other than the glass substrate 1 (for example, a substrate having good planar accuracy such as a silicon substrate) may be substituted. it can.

  The present invention can be applied when a plastic puncture needle used for blood glucose level measurement is injection molded.

It is sectional drawing which shows the resist application | coating process of the metal mold | die manufacturing method which concerns on Embodiment 1 of this invention. It is a figure which shows the convex formation process of the metal mold | die manufacturing method which concerns on the same Embodiment 1, Comprising: (a) is a top view of a resist convex mold | type, (b) is the cross section by the BB line of (a). FIG. It is sectional drawing which shows the concave mold formation process of the metal mold | die manufacturing method which concerns on the same Embodiment 1, Comprising: (a) is a state figure by which the ultraviolet curable resin was dripped at the resist convex mold, and was pressurized. ) Is a state diagram in which a concave mold is formed. It is sectional drawing which shows the transfer mold formation process of the metal mold | die manufacturing method which concerns on the same Embodiment 1, Comprising: (a) is a state figure by which the 2nd ultraviolet curable resin was dripped and pressurized on the concave mold, (B) is a state diagram in which a transfer mold is formed. It is sectional drawing which shows the core manufacturing process of the metal mold | die manufacturing method which concerns on the same Embodiment 1, Comprising: (a) is a state figure by which the transfer mold was immersed in the nickel electroforming bath, (b) is a transfer mold It is the state figure from which the nickel electrocast ingot was isolate | separated from. It is a perspective view of a puncture needle. It is a perspective view which shows the front-end | tip vicinity of the puncture needle shown in FIG. It is a figure which shows the convex formation process of the metal mold | die manufacturing method which concerns on Embodiment 2 of this invention, Comprising: (a) is a top view of a resist convex mold | type, (b) is a front view of a resist convex mold | type. .

Explanation of symbols

1 …… Glass substrate (substrate)
2 ... Photoresist 4 ... Resist convex 4a ... Rising surface 5 ... Transfer die 7 ... Mold core 8 ... Concave die 9 ... Nickel electroformed ingot 11 ... First UV curable resin 12 ... ... 2nd UV curable resin 13 ... 1st white plate glass 14 ... 2nd white plate glass 20 ... Needle for puncture (medical device)
21 …… Needle body (device body)
22 …… Puncture part 23 …… Uneven surface part 24 …… Spot shaped part 25 …… Liquid collection channel 26 …… Blood storage part T1 …… Photoresist thickness T2 …… Nickel electrocast ingot thickness

Claims (7)

A method for producing a mold core for use in molding a medical device made of plastic in which a liquid collection channel is formed in a device body,
A resist coating process for coating a photoresist on the substrate;
A first exposure step of exposing the photoresist applied in the resist coating step using a first reticle for forming a portion corresponding to the device body, and a portion corresponding to the liquid collection channel A resist exposure step of separately performing a second exposure step of exposing using a second reticle for forming
By developing the photoresist exposed in the resist exposure step, a convex shape forming step for forming a resist convex shape in which a portion corresponding to the device main body and the liquid collection flow path is formed;
A concave mold forming step of inverting the convex shape of the resist convex mold formed in the convex mold forming step to form a concave mold;
A transfer mold forming step of forming a transfer mold by inverting the concave shape of the concave mold formed in the concave mold forming step;
A core manufacturing step of manufacturing the mold core by inverting the convex shape of the transfer mold formed in the transfer mold forming step.   The portion corresponding to the slope of the device main body of the photoresist is formed in the convex forming step by using a gray scale mask as the first reticle in the first exposure step of the resist exposure step. Item 2. A mold core manufacturing method according to Item 1.   In the resist exposure process, by performing a third exposure process that exposes the photoresist using a binary mask as a third reticle, in the convex mold forming process, the photoresist corresponds to the device body. 3. The mold core manufacturing method according to claim 2, wherein a peripheral edge portion of the part is formed.   The mold core manufacturing method according to claim 1, wherein the convex material is an ultraviolet curable resin.   5. The mold core manufacturing method according to claim 1, wherein the concave material is an ultraviolet curable resin. In the core manufacturing process,
The mold core manufacturing method according to claim 1, wherein the mold core is manufactured by nickel electroforming.   A mold core manufactured by the mold core manufacturing method according to claim 1.

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