Microneedle Applicator Locking Mechanism for Consistent Insertion Depth
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Solution Overview
Problem
Existing microneedle applicators face challenges in consistently and effectively inserting needles to the desired depth in the skin, maintaining proper contact, and applying consistent force for drug delivery, limiting the efficacy of transdermal and topical drug delivery methods.
Innovation Solution
The development of an applicator with a locking mechanism that allows the microneedle device to be actuated and locked in an extended position, ensuring consistent treatment and delivery, featuring a plunger and deformable sheet mechanism that facilitates easy application and secure locking, enabling gentle hand pressure for actuation and maintaining the actuated state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If microneedles are pressed against the skin to pierce the stratum corneum, then drug delivery through the skin is enabled, but consistent insertion depth and reliable contact maintenance during administration are difficult to achieve
Solution Approach 1:
The microneedles are pre-loaded in a retracted position within the applicator housing. Before application, the microneedles are in a safe, protected state. During application, a plunger is depressed to advance the microneedles into the skin surface, ensuring consistent insertion depth without requiring manual manipulation of individual needles. This preliminary positioning resolves the contradiction by automating the insertion process.
Solution Approach 2:
An applicator device with a plunger mechanism serves as an intermediary between the user and the microneedles. The plunger translates user pressure into controlled microneedle advancement, maintaining reliable contact with the skin during drug delivery. This intermediary mechanism ensures consistent insertion depth while simplifying operation, as the user only needs to press the plunger without directly handling the microneedles.
2Reliability
If microneedles are held in contact with the skin during administration, then drug delivery is maintained, but the ability to apply consistent force for delivery is compromised
Solution Approach 1:
The applicator design allows the microneedles to self-maintain contact with the skin through the plunger mechanism. Once the plunger is depressed to insert the microneedles, the mechanism maintains constant force application during the drug delivery period without requiring continuous user intervention. This self-service capability ensures both reliable contact maintenance and consistent force application simultaneously.
3Adaptability or versatility
If the applicator is designed for multiple uses, then device versatility is improved, but the microneedle arrays must be reused which reduces reliability
Solution Approach 1:
The applicator is segmented into reusable and disposable components. The applicator housing and plunger mechanism are designed for multiple uses, while the microneedle arrays are configured as replaceable cartridges or single-use inserts. This segmentation allows the versatile applicator to maintain reliability by enabling replacement of the microneedle component after each use, preventing performance degradation from reuse.
Data Source
AI summary
An applicator and method for applying a microneedle device to skin. The applicator can include a microneedle device and a housing configured to house the microneedle device. The housing can have a first surface configured to be positioned toward the skin. The applicator can include (i) an unactuated state in which the microneedle device is located within the housing and does not extend beyond the first surface of the housing, and (ii) an actuated state in which at least a portion of the microneedle device extends beyond the first surface of the housing. The applicator can further include a locking mechanism configured to lock the applicator in the actuated state. The method can include positioning the first surface of the housing of the applicator adjacent the skin; actuating the applicator to cause the applicator to change to the actuated state; and locking the applicator in the actuated state.