Cyclic Surfactant Microneedle Formulation Bubble Stability
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Solution Overview
Problem
The production of microneedles using mold-based methods often results in defective products due to air bubbles aggregating and rupturing within the mold, leading to voids and reduced yield rates, especially when incorporating poorly soluble or insoluble active components.
Innovation Solution
A microneedle formulation combining surfactants with cyclic structures and microneedle scaffold materials to enhance bubble stability, improve solubility of active components, and stabilize the production process, thereby reducing defect rates and increasing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mold-based methods are used for microneedle production, then production efficiency is improved, but air bubbles aggregate and rupture causing voids and defective products
Solution Approach 1:
The patent introduces a surfactant as an intermediary substance in the microneedle formulation. This surfactant acts as a mediator between the hydrophobic air bubbles and the hydrophilic formulation matrix, reducing surface tension and preventing bubble aggregation and rupture during the molding process, thereby eliminating voids and defective products while maintaining production efficiency
2Manufacturing precision
If centrifugation and vacuuming methods are used to eliminate bubbles, then small bubbles are removed, but bubbles are re-introduced during material filling and static drying processes
Solution Approach 1:
The patent applies preliminary action by incorporating the surfactant into the formulation before the molding process. This pre-treatment ensures that the formulation is already protected against bubble aggregation from the outset, preventing the need for repeated bubble elimination steps and avoiding re-introduction of bubbles during subsequent filling and drying operations
3Reliability
If poorly soluble or insoluble active components are added to microneedle formulations, then therapeutic efficacy is improved, but defect rates increase due to bubble aggregation
Solution Approach 1:
The surfactant serves as a dual-function intermediary: it not only prevents bubble aggregation to maintain manufacturing quality but also enhances the solubility of poorly soluble active components through micellization, allowing both therapeutic efficacy and manufacturing precision to be improved simultaneously
4Quantity of substance
If conventional surfactants are used in microneedle formulations, then solubility of active components is improved, but bubble stability is not enhanced and defect rates remain high
Solution Approach 1:
The patent applies parameter changes by selecting surfactants with specific molecular characteristics (hydrophilic-lipophilic balance, molecular weight, cyclic structure) that optimize both solubility enhancement and bubble stabilization properties, transforming the formulation parameters to achieve superior performance in both solubility and bubble stability
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 use of surfactants with cyclic structures in the microneedle formulation effectively prevents bubble aggregation and rupture, significantly improving the yield rate and product quality by reducing needle deficiency and unflatness rates.
Implementation Method 1
The present disclosure utilizes a combination of surfactant with cyclic structure with microneedle scaffold material to enhance the stability of bubbles in microneedle formulations
Implementation Method 2
dissolving the aforementioned formulation amount of microneedle scaffold material and surfactant with cyclic structure in deionized water, stirring uniformly
Data Source
AI summary
The present disclosure discloses a microneedle formulation, a microneedle patch, and preparation methods thereof. The microneedle formulation includes the following components in mass percentage: 15-55% of microneedle scaffold material, 0.05-5% surfactant with cyclic structure, 0-15% of active components, and the remaining being deionized water. The microneedle patch is prepared from the aforementioned microneedle formulation.