Microneedle Applicator Energy-Storing Element Design
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Solution Overview
Problem
Existing microneedle arrays face challenges in delivering drugs uniformly across patients due to variability in skin permeability enhancement, which can result in inconsistent therapeutic dosing, and prior applicator designs suffer from dimensional distortion and energy loss over time, leading to poor penetration and drug delivery inefficiencies.
Innovation Solution
A microneedle applicator featuring a rigid planar plate member with a blocking element and energy-storing element, where the blocking element moves between two positions to release the plunger, and an actuating member applies force to move the blocking element, ensuring consistent energy release and minimizing dimensional distortion, thereby improving reproducibility and drug delivery efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If microneedle arrays are pressed by hand into skin, then the application process is simple, but variations in force, velocity, and skin tension result in variations in permeability enhancement and inconsistent drug delivery
Solution Approach 1:
The patent replaces the manual mechanical pressing system with an energy-storing element (spring) that mechanically propels the plunger. This substitution eliminates human variability in force application while maintaining operational simplicity through a single activation motion. The spring-based mechanical system provides consistent force, velocity, and skin tension throughout the penetration process.
2Reliability
If energy-storing elements are used in applicators, then consistent energy release is achieved, but dimensional distortion and creep occur over time leading to energy loss
Solution Approach 1:
The patent changes the material parameter of the energy-storing element from conventional spring materials to a foam material with specific mechanical properties. This foam material exhibits reduced dimensional distortion and creep over time while maintaining consistent energy release characteristics. The parameter change in material composition directly addresses the shelf life issue without sacrificing energy consistency.
3Reliability
If microneedle arrays are made disposable to avoid sterilization issues, then sterility and integrity are maintained, but manufacturing cost increases
Solution Approach 1:
The patent embraces the disposable concept by designing an applicator with a foam energy-storing element that is cost-effective to manufacture and replace. The foam material allows for inexpensive production of single-use applicators, making the disposable model economically viable. This approach maintains sterility and integrity while controlling manufacturing costs through material selection.
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 applicator ensures consistent and reproducible drug delivery by maintaining stored energy and preventing dimensional distortion, enhancing the uniformity of drug administration across patients and extending the applicator's shelf life.
Implementation Method 1
an energy-storing element positioned between the lower surface of the plate member and the distal end of the plunger
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
Applicators (10, 100) for a microprojection array having a plate member (12) having at least one opening (22, 82); a blocking or retaining element (14) or flexure element (64) in contact with the upper surface of the plate member and being capable of moving between a first position and a second position; a plunger (16) on which at least one microprojection can be retained, the blocking or retaining element or flexure element retaining the plunger, an energy- storing element (20); and an actuating member (18, 68) having an external surface for application of a force, and having at least one surface in mechanical communication with the blocking or retaining element or flexure element, wherein the actuating member moves the blocking or retaining element or flexure element from its first position to its second position when a force is applied to the external surface of the actuating member, thereby to affect release of the energy- storing element.