Collapsible Microneedle Patch for Compact Transdermal Delivery
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Solution Overview
Problem
Conventional microneedle patches are fragile, sanitary-sensitive, and inefficient in transporting large molecules through the skin due to their bulky storage requirements and limited delivery capabilities, as they often require a disposable collar that occupies excessive space and generates waste.
Innovation Solution
A collapsible microneedle patch design featuring a base with a collapsible side wall and adhesive, where the microneedle array is affixed to the base and covered by a separable carrier, allowing for compact storage and deployment by collapsing the patch to bring the microneedle array closer to the target site.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional microneedle patches are used with disposable collars, then the patches can be stored and transported, but they occupy excessive space and generate excessive waste
Solution Approach 1:
The invention extracts and removes the disposable collar component from the microneedle patch system. The patch is designed to be applied directly to the skin without requiring a collar, eliminating the source of excessive waste while maintaining storage and transport capability through the collapsible design
Solution Approach 2:
The invention eliminates the need to discard collars by designing a system where the patch can be applied directly without a collar. The collapsible patch structure allows for compact storage and direct application, recovering the functionality previously provided by the collar without the waste associated with its disposal
2Ease of manufacture
If microneedle patches are stored in flat sheet-like configuration, then they are easy to manufacture, but they require excessive storage space
Solution Approach 1:
The invention applies a collapsible structure to the patch that allows it to transition from a flat, expanded configuration during manufacturing and storage to a compressed, compact configuration during transport and application. This dynamic structure reduces storage volume while maintaining manufacturing simplicity
Solution Approach 2:
The collapsible patch design allows the patch structure to nest or compress into a smaller volume, similar to a nested doll principle, where the patch can be collapsed inward to reduce its overall footprint for storage and transport while maintaining its functional integrity
3Reliability
If microneedle arrays are protected during transport, then they maintain sanitary characteristics, but they cannot be directly applied to target site
Solution Approach 1:
The invention segments the protection mechanism from the patch itself by using a separate removable carrier that holds the microneedle array during transport. The carrier can be easily removed at the point of application, providing sanitary protection during transport while enabling direct application readiness at the target site
Solution Approach 2:
The removable carrier acts as an intermediary between the microneedle array and the environment during transport, providing protective separation. At application time, this intermediary is easily removed, allowing the microneedle array to contact the target site directly without compromising either sanitary protection or application readiness
4Volume of stationary object
If patches are made collapsible to reduce storage space, then storage efficiency improves, but structural complexity increases
Solution Approach 1:
The collapsible patch utilizes flexible materials and thin-film construction that allow the patch to collapse and expand without requiring complex mechanical components. The flexibility of the shell and film structures enables volume reduction while maintaining structural integrity, avoiding the need for complex hinges, joints, or mechanical assemblies
Data Source
AI summary
A microneedle patch includes a base, at least one collapsible side wall extending from the base, and a lip disposed along the at least one collapsible sidewall and opposite the base. An adhesive is disposed along the base, and a microneedle array is affixed to the base.