Microneedle Casting via Porous Membrane Vacuum Filling
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Solution Overview
Problem
Existing microneedle casting methods face challenges in achieving high-precision, rapid replication of micro-nano structures with uniform casting, accurate control, and low solution consumption, particularly in mass production, due to limitations in mold material compatibility, filling consistency, and residual gas removal.
Innovation Solution
A microneedle casting system comprising a vacuum chamber, motion platform, liquid-filling needle assembly, and controller, which enables precise movement and controlled filling of a casting solution into a microneedle mold under vacuum conditions, using a pressure-reducing valve for efficient solution delivery and a motion platform for even distribution, ensuring high-precision and rapid replication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum filling method is used to fill microneedle mold, then filling consistency and residual gas removal are improved, but mold material requirements become more stringent and process complexity increases
Solution Approach 1:
The patent introduces a porous membrane as an intermediary layer between the mold cavity and vacuum chamber. This membrane allows gas molecules to pass through during evacuation while blocking liquid casting material, thereby simplifying the process by eliminating the need for complex mold structure modifications and reducing vacuum pressure requirements.
Solution Approach 2:
The patent extracts the gas removal function from the mold structure itself and transfers it to a dedicated porous membrane component. This separation allows the mold to focus on shaping while the membrane handles gas evacuation, reducing overall system complexity and improving filling consistency.
2Productivity
If high negative pressure is applied during vacuum filling, then gas removal efficiency is improved, but risk of mold deformation and liquid material instability increases
Solution Approach 1:
The patent applies different properties to different parts of the system: the porous membrane provides selective permeability (gas permeable, liquid impermeable) at the interface between mold and vacuum chamber, allowing moderate vacuum pressure to effectively remove gas without requiring extreme negative pressure that would deform the mold.
3Ease of manufacture
If conventional pressure filling method is used, then process simplicity is maintained, but ability to fill high depth-to-width ratio microneedle structures deteriorates
Solution Approach 1:
The patent replaces the mechanical pressure-driven filling system with a vacuum-driven system using a porous membrane. This substitution enables the filling of deep microneedle structures by utilizing pressure differential across the membrane rather than direct mechanical pressing, achieving better filling of high depth-to-width ratio structures while maintaining operational simplicity.
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 system achieves high-precision and rapid replication of micro-nano structures with reduced solution consumption and improved consistency, allowing for efficient mass production while maintaining a high negative pressure state to ensure accurate mold filling and minimize residual gas.
Implementation Method 1
evacuating the vacuum chamber and maintaining a vacuum state of the vacuum chamber
Implementation Method 2
maintaining a high negative pressure state to ensure accurate mold filling and minimize residual gas
Data Source
AI summary
A microneedle casting system includes a vacuum chamber, a motion platform, a first motion assembly, a liquid-filling needle assembly, a second motion assembly, and a controller. The motion platform is arranged in the vacuum chamber; the first motion assembly includes a first transmission component and a first drive component that are connected to each other; the liquid-filling needle assembly includes a liquid-dispensing tip and a liquid-filling needle shaft; the second motion assembly includes a second transmission component and a second drive component which are connected to each other, the liquid-filling needle is connected to the second transmission component, and, driven by the second drive component, the second transmission component drives the liquid-filling needle to move in a second direction; and the first drive component or/and the second drive component are communicatively connected to the controller.