Microneedle Arrays With Bi-Fold Sheet Structure
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Solution Overview
Problem
There is a growing need for efficient and cost-effective methods to manufacture microneedle arrays for medical devices that can quickly and easily deploy microneedles into tissue substrates, such as the skin, while maintaining improved performance and economy of production.
Innovation Solution
A microneedle system comprising two arrays of microneedles formed from sheets that are folded out of plane and overlaid such that the second array extends through openings in the first sheet, allowing for relative displacement parallel to the sheets, with some microneedles folded about a parallel axis to the displacement direction, and featuring tapered tips and optional coatings for enhanced tissue penetration and drug delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If microneedles are manufactured using conventional methods, then manufacturing simplicity is maintained, but manufacturing precision and microneedle strength are insufficient
Solution Approach 1:
The microneedle structure is segmented into multiple parts: a shaft portion, a tip portion, and a base portion. The shaft portion includes a fold line that allows the tip portion to be folded relative to the base portion, creating a bi-fold configuration. This segmentation enables precise control over microneedle geometry and strength while maintaining manufacturability through standard sheet processing techniques.
Solution Approach 2:
The microneedle structure utilizes three-dimensional folding to achieve enhanced strength and geometry from a two-dimensional sheet. The tip portion is folded along a fold line that extends in a first direction, while another fold line extends in a second direction transverse to the first, creating a bi-fold configuration that provides structural reinforcement without complicating the manufacturing process.
2Ease of operation
If microneedles are deployed quickly and easily into tissue, then ease of operation is improved, but manufacturing precision and control may be compromised
Solution Approach 1:
The microneedle structure incorporates movable fold lines that allow the tip portion to be displaced relative to the base portion. This dynamic configuration enables the microneedle to transition from a compact stored state to an extended deployed state, facilitating easy insertion into tissue while maintaining precise control over the final microneedle geometry through the predetermined fold line locations.
Data Source
AI summary
The invention discloses a microneedle system comprising cooperating arrays of microneedles (12, 16) having particular geometries and orientations, and a method of manufacturing such a microneedle system which provides improved efficacy to the deployment and operation of devices employing the microneedle arrays manufactured according to the invention.