Patent ID: 7422651

Claim:
A method for forming a membrane comprising the steps of: applying a coating of membrane material over a selected portion of a substrate, the substrate imparting a pattern to an area of the membrane material; positioning a support member in contact with an outer perimeter outside of the area of the membrane material, wherein the support member extends around an entire perimeter of the membrane and has a height which is greater than a height of a top surface of the membrane, so that the support member and the membrane form a well; adding additional material into the well; curing the membrane material to bond the support member to the membrane, wherein, when bonded to the membrane, the support member, which has a rigidity which is greater than and consists of a material different from the membrane, maintains at least a portion of the membrane in a substantially taut condition to prevent that portion of the membrane from folding onto itself; and removing the membrane from the substrate.