Flexible Microneedle Array with Spring Elements for Contoured Skin

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Solution Overview

Problem

Conventional microneedle arrays struggle to maintain precise penetration in contoured and flexible skin surfaces, leading to premature movement and reduced effectiveness in transdermal drug delivery and biological sample collection, especially on areas that stretch or flex during normal movement.

Innovation Solution

A flexible microneedle array design featuring a substrate with interconnected spring elements and apertures, allowing the microneedles to conform and remain inserted on contoured skin surfaces, with a drug storage element and collection reservoir for extended use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a rigid, planar microneedle array substrate is used, then manufacturing precision and structural stability are improved, but adaptability to contoured skin surfaces and maintenance of penetration position deteriorate

Engineering Contradiction:

Improvemicroneedle penetration precisionVSAvoidadaptability to contoured skin surfaces

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent replaces the rigid, planar substrate with a flexible substrate that can conform to contoured skin surfaces. The flexible substrate maintains microneedle array integrity while adapting to curved anatomical surfaces, resolving the contradiction between manufacturing precision and adaptability to contoured surfaces.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent introduces a movable or adjustable mechanism that allows the microneedle array to dynamically adapt to skin movement and contour changes. This dynamic adjustment capability enables the array to maintain optimal penetration position on both flat and contoured surfaces throughout the treatment duration.

Inventive Principle:

Principle #15Dynamics

2Stability of the object's composition

If a rigid, planar microneedle array substrate is used, then structural stability is improved, but ability to maintain penetration position on flexible skin deteriorates

Engineering Contradiction:

Improvesubstrate structural stabilityVSAvoidmaintenance of microneedle penetration position

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The flexible substrate replaces the rigid structure, allowing the microneedle array to conform to skin movement while maintaining relative positional stability of individual needles. This flexibility ensures reliable penetration maintenance on dynamic, flexible skin surfaces.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The substrate is divided into multiple segments or flexible elements that can independently deform to accommodate skin contours and movement. This segmentation allows each portion of the array to maintain its penetration position while the overall structure adapts to skin flexibility.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If a flexible microneedle array substrate is used, then adaptability to contoured skin surfaces is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveadaptability to contoured skin surfacesVSAvoidsubstrate structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent employs a flexible substrate with integrated spring elements that provide the necessary adaptability to contoured surfaces. While the structure is more complex than a rigid substrate, the use of standardized flexible materials and modular spring components keeps manufacturing complexity manageable while achieving superior adaptability.

Inventive Principle:

Principle #30Flexible shells and thin films

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 flexible microneedle array maintains stable penetration and fluid communication over extended periods, enhancing transdermal drug delivery and biological sample collection, even on areas that stretch or flex, while minimizing discomfort and improving patient compliance.

Implementation Method 1

a flexible substrate which comprises a plurality of apertures, each of which are defined by (i) a plurality of substrate elements which are integral with the base portions of the microneedles, and (ii) at least one spring element connecting at least two of the substrate elements

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS7785301B2Tissue conforming microneedle array and patch for transdermal drug delivery or biological fluid collection

Publication Date: 2010.08.31 YUZHAKOV VADIM V

AI summary

Microneedle arrays are provided for use on a contoured or flexible tissue surface. In one embodiment, the microneedle array includes a plurality of microneedles, each having a base portion, a tip end portion distal to the base portion, and body portion therebetween; and a flexible substrate which comprises a plurality of apertures, each of which are defined by (i) a plurality of substrate elements which are integral with the base portions of the microneedles, and (ii) at least one spring element connecting at least two of the substrate elements. The spring element may include a curved element, such as a C-shaped, U-shaped, or S-shaped element. Apertures may be defined, for example, by two substrate elements, which connected to three or four spring elements. A skin patch is provided for therapeutic or diagnostic applications, which includes the microneedle array and an adhesive material.