Angled Mold Support Unit for Uniform Microstructure Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing microstructure manufacturing methods face issues with non-uniform filling of molds due to vacuum-induced bubble formation and centrifugal force causing composition concentration in rotational radial direction, leading to decreased elasticity and inaccurate drug delivery.
Innovation Solution
A mold support unit with angled support regions and a loading plate that allows molds to be positioned at varying angles, combined with a centrifugal force-based rotation system, ensuring uniform filling of compositions into molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If centrifugal force is used to fill molds, then filling speed is improved, but composition concentrates in rotational radial direction causing non-uniform distribution
Solution Approach 1:
The support plate is designed with asymmetric angle configurations for different support regions. The first support region has an upper surface disposed at a first angle, while the second support region has an upper surface disposed at a second angle different from the first angle. This asymmetric angular arrangement compensates for the radial concentration effect of centrifugal force, ensuring uniform composition distribution across all molds during high-speed rotation.
2Quantity of substance
If more compositions are loaded into the mold to ensure accurate filling, then filling completeness is improved, but base part thickness increases reducing elasticity
Solution Approach 1:
Different support regions are configured with different angles to optimize local composition distribution. The first support region has an upper surface disposed at a first angle, and the second support region has an upper surface disposed at a second angle different from the first angle. This local differentiation ensures that each region receives the appropriate amount of composition for accurate filling without excessive accumulation, maintaining base part thickness within optimal elastic limits.
3Quantity of substance
If vacuum is used to fill molds, then filling is achieved, but bubbles are generated in the composition reducing uniformity
Solution Approach 1:
The patent replaces the vacuum-based filling method with a centrifugal force-based method. By rotating the support plate at high speed, centrifugal force drives the composition into the molds, achieving complete filling without creating bubbles. This mechanical substitution eliminates the harmful bubble formation while maintaining filling effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables uniform distribution of compositions across the entire mold area, enhancing manufacturing uniformity and quantitative drug loading for accurate microneedle insertion and delivery.
Implementation Method 1
the mold support unit rotates around a second rotation axis by centrifugal force of the rotation unit rotating around the first rotation axis
Data Source
AI summary
A mold support unit is provided. The mold support unit supports molds for manufacturing microstructures, and includes a support plate in which a plurality of support regions on which the molds are placed are formed to be spaced apart from each other, wherein the support regions include a first support region in which an upper surface on which the mold is placed is disposed at a first angle; and a second support region in which an upper surface on which the mold is placed is disposed at a second angle different from the first angle.