Coated Microneedle Array for Targeted Dermal Material Delivery

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods of drug and bioactive material delivery, such as intradermal injection, face challenges including cross-contamination, injection phobia, and inability to target key cells in the outer skin layers effectively.

Innovation Solution

A device with projections coated with a non-liquid coating, featuring a convex effective profile and varying cone angles, penetrates the skin to deliver material directly to dermal cells, inducing a bystander response and immunological reaction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If intradermal injection is used to deliver material to skin layers, then material can be delivered to dermal cells, but cross-contamination through needle-stick injuries and injection phobia occur

Engineering Contradiction:

Improvematerial delivery to dermal cellsVSAvoidcross-contamination and injection phobia

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The injection device is segmented into multiple projections (at least 500) that can penetrate the skin simultaneously, replacing the single needle approach. This segmentation eliminates needle-stick injuries to healthcare workers while maintaining effective material delivery to dermal cells through distributed projection tips

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The traditional mechanical syringe and needle system is replaced with a projection array system that uses elastic recovery and spring-loaded mechanisms to achieve skin penetration without requiring manual needle insertion, thereby eliminating injection phobia and cross-contamination risks

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Quantity of substance

If needle and syringe are used for intradermal injection, then material can be delivered to skin, but the large scale and method of administration cannot target key cells in the outer skin layers

Engineering Contradiction:

Improvematerial delivery to skinVSAvoidtargeting precision to key cells in outer skin layers

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The projection array implements local quality by varying the spacing, dimensions, and distribution of projections to match the specific arrangement of target cells in the skin. This allows precise targeting of key cells in the outer skin layers while delivering material effectively to the intended location

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The device utilizes parameter changes in projection spacing and dimensions based on the target cell arrangement. By adjusting these parameters, the system achieves precise targeting of key cells in the outer skin layers, overcoming the limitation of traditional large-scale injection methods

Inventive Principle:

Principle #35Parameter changes

3Productivity

If projections with convex effective profile are used, then material delivery efficiency is improved, but device complexity increases due to coating requirements

Engineering Contradiction:

Improvematerial delivery efficiencyVSAvoidcoating process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The convex effective profile is created through preliminary action by forming projections with predetermined non-convex geometries before coating. The coating process then simply adds material to achieve the final convex shape, simplifying the overall manufacturing process while maintaining delivery efficiency

Inventive Principle:

Principle #10Preliminary action

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

The device efficiently delivers materials to dermal cells, inducing an improved immunological response while avoiding nerve stimulation and ensuring precise targeting.

Implementation Method 1

at least the tip of at least one of the coated projections has a convex effective profile... The convex effective profile concentrates stress at the tip of the projection during penetration

Methodology Applied

Scientific EffectStress concentration:

Implementation Method 2

at least a portion of at least one of the projections being coated with a non-liquid coating including the material

Methodology Applied

Scientific EffectDirect contact delivery:

Data Source

PatentUS12491351B2Delivery device

Publication Date: 2025.12.09 VAXXAS PTY LTD

AI summary

A device for delivery of material to a biological subject, the device including a base and a number of projections extending from the base, each projection including a tip for penetrating tissue of the biological subject, at least a portion of at least one of the projections being coated with a non-liquid coating including the material. At least the tip of at least one of the coated projections may have a convex effective profile. The device may be for delivery of material to a dermal layer of the biological subject. In another aspect an applicator for applying the device to the biological subject applies a preload force to the tissue such that the force at least partially compresses a subcutaneous tissue layer of the biological subject prior to application of the device, and applies the device with a predetermined velocity, wherein tissue stiffness is maintained and/or the projections penetrate the tissue to a predetermined depth.