Pattern transfer device for mass transfer of micro-patterns onto medical devices
This invention is directed to a new method of mass-transfer/fabrication of micro-sized features/structures onto the inner diameter (ID) surface of a stent. This new approach is provided by technique of through mask electrical micro-machining. One embodiment discloses an application of electrical micro-machining to the ID of a stent using a customized electrode configured specifically for machining micro-sized features/structures.
1. An assembly, comprising:
a. an elongate electrically conductive electrode member having a first surface and at least a second surface, a first end, a second end and an intermediate workpiece mounting region which are continuous with each other;
b. a non-conductive coating disposed on at least one of the first surface and the second surface of the electrode member;
c. a micro-pattern of openings defined in and passing through the non-conductive coating; the micro-pattern of openings exposing, through the micro-pattern of openings, defined elongate slot portions in the intermediate workpiece mounting region of the electrode member, the micro-pattern being configured to impart a pattern corresponding to the elongate slots portions on a surface of a workpiece; and
d. a workpiece positioned adjacent the non-conductive coating at the intermediate workpiece mounting region of the electrode member.
2. The assembly of claim 1 , wherein the non-conductive coating is of a material capable of being vacuum deposited onto at least one of the first surface and the second surface of the electrode member.
3. The assembly of claim 1 , wherein the micro-pattern corresponds to a pattern of grooves adapted to be transferred to the workpiece.
4. The assembly of claim 1 , wherein the non-conductive coating is made of a material capable of being applied to the electrode member by one of dipping, spray coating, air brushing or lamination techniques.
5. The assembly of claim 1 , wherein the micro-pattern further comprises a plurality of grooves passing through the non-conductive coating, each of the plurality of grooves having a cross-sectional configuration selected from the group consisting of square, u-shaped, triangular, v-shaped, rectangular, keyway shaped.
6. The assembly of claim 1 , wherein the micro-pattern has a depth of approximately 0.5 μm-10 μm, a width of approximately 2 μm-40 μm.
7. A patterned masked electrode, comprising:
a. a generally cylindrical electrically conductive electrode member having continuous outer surface, the continuous outer surface having a first wall surface defined by a first portion of the continuous outer surface and at least a second wall surface defined by a second portion of the continuous outer surface, the electrode member further having a first end, a second end and a workpiece mounting region intermediate the first end and the second end;
b. a non-conductive coating on at least one of the first wall surface and the second wall surface and on the workpiece mounting region of the electrode member; and
c. a micro-pattern defined in the non-conductive coating passing through the non-conductive coating and exposing defined portions of the electrode member, the micro-pattern corresponding to a plurality of continuous elongate slots adapted to transfer electrical energy through the micro-pattern of a plurality of continuous elongate slots to a surface of a workpiece positioned on the workpiece mounting region.
8. The patterned masked electrode of claim 7 , wherein the non-conductive coating is of a material capable of being vacuum deposited onto the outer surface of the electrode member.
9. The patterned masked electrode of claim 7 , further comprising a workpiece concentrically engaged with the electrode member such that the non-conductive coating is intermediate the electrode member and the intraluminal stent.
10. The patterned masked electrode of claim 7 , wherein the non-conductive coating is made of a material capable of being applied to the electrode member by one of dipping, spray coating, air brushing or lamination techniques.
11. The patterned masked electrode of claim 7 , wherein the micro-pattern further comprises a plurality of grooves passing through the non-conductive coating, each of the plurality of grooves having a cross-sectional configuration selected from the group consisting of square, u-shaped, triangular, v-shaped, rectangular, keyway shaped.
12. The patterned masked electrode of claim 7 , wherein each of the plurality of elongate slots of the micro-pattern has a width between about 2 and about 40μ and a pattern resolution of between about 1-2μ between adjacent elongate slots of the plurality of elongate slots.
13. The assembly of claim 1 , wherein the electrode member further comprises a generally cylindrical shape having a continuous outer surface, the continuous outer surface having the first surface, the second surface, a first wall surface defined by a first portion of the continuous outer surface and at least a second wall surface defined by a second portion of the continuous outer surface.
14. The assembly of claim 1 , wherein the electrode member further comprises a generally ellipsoidal shape having a continuous outer surface, the continuous outer surface having the first surface, the second surface, a first wall surface defined by a first portion of the continuous outer surface and at least a second wall surface defined by a second portion of the continuous outer surface.