Microneedle Array Manufacturing via Precision Droplet Dispensing
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Solution Overview
Problem
Existing microneedle-array manufacturing methods face challenges in achieving accurate composition distribution due to errors in fill amounts and layer thickness variations, leading to inconsistent pharmaceutical agent delivery in microneedle arrays.
Innovation Solution
A microneedle-array manufacturing apparatus and method utilizing a droplet-delivery apparatus and aligning apparatus to precisely deliver and align droplets of raw-material liquid into recessed parts of a mold, allowing for controlled filling and drying to form microneedles with accurate composition distribution, including the option to use multiple layers with different compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a squeegee and stamper are used to alternately and repetitively fill and dry needle raw material in recessed parts, then the manufacturing process can be completed, but errors in fill amounts and layer thickness variations occur leading to poor composition distribution accuracy
Solution Approach 1:
The patent replaces the mechanical squeegee-based filling system with a droplet-delivery apparatus that uses piezoelectric actuators to precisely control droplet ejection. This substitution eliminates the mechanical contact and variability inherent in squeegee operations, achieving both ease of manufacture through automated droplet dispensing and high manufacturing precision through controlled droplet placement in each recessed part
Solution Approach 2:
The patent changes the filling parameter from continuous mechanical squeegee movement to discrete droplet delivery with precise volume control. By controlling the droplet volume to be less than the capacity of each recessed part and using multiple droplets for multi-layer formation, the system achieves accurate composition distribution while maintaining manufacturing feasibility through programmable delivery sequences
2Adaptability or versatility
If multiple layers with different compositions are formed using squeegee method, then microneedles with varied pharmaceutical content can be created, but large errors occur in the amount of pharmaceutical agent
Solution Approach 1:
The patent segments the filling process into discrete droplet deliveries for each layer and each recessed part. Instead of applying material continuously with a squeegee, the system delivers individual droplets or droplet sequences to specific locations, enabling precise control over the amount of pharmaceutical agent in each layer while maintaining the ability to create multiple layers with different compositions
Solution Approach 2:
The patent incorporates a control system that manages the droplet-delivery apparatus to precisely control the number, volume, and placement of droplets for each layer. This feedback-controlled approach ensures that the pharmaceutical agent amount is accurately delivered in each layer, eliminating the large errors that occur with the squeegee method while maintaining versatility in multi-layer composition design
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 solution enables precise adjustment and control of composition distribution in microneedle arrays, ensuring consistent and accurate delivery of pharmaceutical agents, thereby improving the reliability and effectiveness of microneedle-based drug administration.
Implementation Method 1
a droplet-delivery apparatus capable of delivering, to each of the recessed parts, droplets of the raw-material liquid in a prescribed amount that is less than the capacity of the recessed part
Implementation Method 2
an aligning apparatus capable of aligning the relative position of the droplet-delivery apparatus and the mold such that the droplets from the droplet-delivery apparatus land in each of the recessed parts
Implementation Method 3
a method is known in which a mold having a plurality of recessed parts is filled with a needle raw material using a squeegee and then dried to harden it
Data Source
AI summary
A product having a microneedle array is provided wherein the composition distribution has been adjusted with good accuracy. A droplet-delivery apparatus of a microneedle-array manufacturing apparatus is configured capable of delivering, to each recessed part, droplets of a raw-material liquid in a prescribed amount that is less than the capacity of the recessed part. An aligning apparatus can align the relative position of the droplet-delivery apparatus and a mold such that the droplets from the droplet-delivery apparatus are caused to land in each of the recessed parts. The droplet-delivery apparatus delivers a plurality of the droplets to each of the recessed parts; and the aligning apparatus aligns the relative position of the droplet-delivery apparatus and the mold such that a second droplet lands in each of the recessed parts on the center part side of a first droplet.