Microneedle Drug Coating Jig Using Segmented Grooves
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for applying drugs to microneedles, particularly small needles, face challenges such as uneven drug distribution due to surface tension and vibration, leading to inefficiencies in mass production and high drug usage costs, especially for thermally unstable substances like proteins.
Innovation Solution
A method using a jig with drug liquid holding grooves that fix the liquid surface, allowing small needles to be immersed and coated uniformly, reducing the impact of surface tension and environmental vibrations, and enabling repeated application of the drug to achieve the desired amount on the microneedle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large drug liquid tank is used to immerse microneedles, then the liquid surface can be leveled, but the liquid surface is likely to be shaken due to vibration or wind causing uneven drug adhesion
Solution Approach 1:
The patent divides the single large drug liquid tank into multiple small individual tanks, each containing a single microneedle. This segmentation isolates each microneedle's immersion environment, preventing liquid surface shaking from affecting other needles and ensuring uniform drug adhesion without requiring a large tank size.
2Manufacturing precision
If the drug liquid tank is increased in size, then the liquid surface can be leveled, but a great amount of drug is required increasing costs
Solution Approach 1:
The patent segments the drug liquid into multiple small individual tanks, each containing minimal drug solution sufficient for immersing a single microneedle. This eliminates the need for large quantities of drug in a single large tank, significantly reducing drug consumption costs while maintaining proper liquid surface leveling in each small tank.
3Quantity of substance
If a small drug liquid tank is used, then drug quantity is reduced, but the liquid surface becomes convex due to surface tension causing uneven immersion
Solution Approach 1:
The patent segments the immersion process into multiple small individual tanks, where each tank's size is optimized for single microneedle immersion. This segmentation allows the use of small tank sizes (reducing drug quantity) while maintaining flat liquid surfaces through proper tank design, achieving both drug conservation and uniform drug application.
4Reliability
If thermally unstable drugs are mixed into microneedle material, then drug delivery is achieved, but manufacturing processes are limited and mass production is difficult
Solution Approach 1:
The patent applies the drug to the microneedle surface after the microneedle structure has been manufactured, rather than mixing the drug into the material during manufacturing. This preliminary action of coating the drug onto pre-formed microneedles allows thermally unstable drugs to be applied without exposure to high-temperature manufacturing processes, enabling mass production of microneedles with sensitive drugs.
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
This approach allows for efficient, uniform drug application to small microneedle needles, reducing waste and costs, while maintaining the stability of thermally sensitive drugs, facilitating mass production and effective drug delivery.
Implementation Method 1
the liquid surface is convex due to surface tension; therefore, when the small needles are immersed therein
Data Source
Figure 1
Figure 2a~2b
Figure 3~4
AI summary
Provided are a jig for uniformly applying a drug liquid to a microneedle, and a method of applying a drug to a microneedle using same. Grooves of a number corresponding to the number of rows of small needles of a microneedle are formed in the surface of a flat plate jig or of a roller-like jig, and a drug liquid is filled and held in the grooves. The drug liquid is applied to the microneedle by inserting the small needles of the microneedle into the surface of the drug liquid held in the narrow grooves, and immersing the small needles in the drug liquid. By this, the drug liquid is uniformly applied to the small needles of the microneedle without unevenness between the central section and the peripheral section of each microneedle, and thus the microneedles having good quality can be easily manufactured.