Microneedle Electrodeposition via Equipotential Array Positioning
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Solution Overview
Problem
The fabrication of microneedles for use in electrochemical sensors is not homogeneous, particularly when manufacturing a large number of microneedles, which affects their performance in detecting body analytes like glucose.
Innovation Solution
A method involving an array of raw microneedles positioned equidistant from a conductive element, immersed in a solution with an active element, and subjected to a potential or current to form a uniform and homogeneous film through electrodeposition, allowing for either metallization or functionalization of the microneedles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional electrodeposition methods are used to deposit active elements on microneedles, then the deposition process can be performed, but the resulting film is not uniform and homogenous across large numbers of microneedles
Solution Approach 1:
The patent applies equipotentiality by positioning all microneedle tips at the same distance from the conductive element, ensuring they are at equipotential during electrodeposition. This uniform positioning creates consistent electric field distribution across all microneedles, resulting in uniform and homogenous active element deposition even when manufacturing large numbers of microneedles simultaneously.
2Productivity
If electrodeposition is performed on arrays of microneedles, then productivity increases, but manufacturing precision decreases due to non-uniform deposits
Solution Approach 1:
The patent resolves this contradiction by establishing equipotential conditions for all microneedles in the array through uniform positioning relative to the conductive element. This allows simultaneous electrodeposition on multiple microneedles (high productivity) while maintaining uniform active element distribution across all tips (high manufacturing precision).
Solution Approach 2:
The patent introduces a spatial dimension control by positioning microneedles at a specific distance range (0.1mm to 10mm) from the conductive element. This dimensional parameter ensures uniform electric field exposure across the array, enabling both high throughput and consistent deposition quality.
3Manufacturing precision
If microneedles are positioned close to the conductive element for better deposition control, then manufacturing precision improves, but the risk of contact and short-circuiting increases
Solution Approach 1:
The patent maintains a safe distance (0.1mm to 10mm) between microneedles and the conductive element while still achieving equipotential conditions for effective electrodeposition. This distance prevents short-circuiting and contact hazards while ensuring uniform electric field distribution for high-quality active element deposition on all microneedle tips.
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 ensures a homogenous deposit of conductive or enzyme layers on microneedles, enhancing their performance as electrodes in electrochemical sensors and facilitating scalable manufacturing.
Implementation Method 1
applying a potential or a current between the conductive element, forming a cathode, and at least one raw microneedle of the array of raw microneedles forming an anode, causing an electrodeposition of a uniform and homogenous film comprising the active element on the raw microneedles of the anode
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
The invention relates to a method comprising the steps of: a) disposing an array (10) of raw microneedles (11) in front of a conductive element (12) so that the conductive element (12) is at equidistance of every raw microneedle (11) and not in contact with the tips of the raw microneedles (11); b) immersing the array (10) of raw microneedle(s) (11) and the conductive element (12) in a solution (13) comprising an active element (14), c) applying a potential (V) or a current (I) between the conductive element (12), forming a cathode, and at least one raw microneedle (11) of the array (10) of raw microneedles (11) forming an anode, causing an electrodeposition of a uniform and homogenous film comprising the active element (14) on the raw microneedles (11) of the anode.