Patent ID: 7618575
Filing Date: 2009-11-17
Classification: B29C,B29K,B29L,H01L

Abstract:
1. A method of molding a sheet of thermoplastic material into an array of microstructures, the method comprising: providing a pair of molds formed substantially of silicon or silicon alloy, the two molds each comprising a substantially planar wafer respectively shaped to define at least one first recess and at least two second recesses, the first recess bounded on two sides by first perimeter walls, and the second recesses bounded on one side by second perimeter walls; aligning the molds such that the first perimeter walls coincide with the second perimeter walls; placing a thermoplastic material between the pair of molds; heating the thermoplastic material; and bringing the molds together such that corresponding recesses and perimeter walls of the molds together define at least one cavity having a microstructure shape.