Microneedle Array With Lateral Orifice For Clogging Prevention
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Solution Overview
Problem
Conventional microneedle arrays face issues with medical solution delivery efficiency due to clogging and material strength limitations, particularly when using photo-curable resin, and the difficulty in forming horizontal holes at the fine tip parts, which complicates manufacturing and biosafety.
Innovation Solution
A microneedle array design featuring a longitudinal passage and a horizontal hole with an orifice on the lateral side, formed between two divisional elements, which communicates with the longitudinal passage, facilitating efficient medical solution delivery and manufacturing by preventing clogging and enhancing tip strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a horizontal hole is formed at the tip part of the microneedle using stereolithography, then clogging is prevented and medical solution delivery efficiency is improved, but manufacturing complexity increases and production time becomes excessively long
Solution Approach 1:
The microneedle is divided into two separate substrates (first substrate and second substrate) that are bonded together. The horizontal hole is formed in the first substrate before bonding, avoiding the need for complex post-bonding hole formation. This segmentation allows for simpler, faster manufacturing while maintaining the anti-clogging function.
Solution Approach 2:
The horizontal hole is formed in the first substrate before the bonding process with the second substrate. This preliminary action simplifies the manufacturing process by performing the hole formation operation on a standalone component rather than on the assembled microneedle structure, thereby reducing production time and complexity.
2Reliability
If a horizontal hole is formed at the fine tip part of the microneedle, then clogging is prevented, but manufacturing difficulty increases due to the fine-shaped tip
Solution Approach 1:
By dividing the microneedle into two substrates, the horizontal hole formation is performed on the first substrate alone, which has a larger, more accessible structure. This avoids the difficulty of forming holes in the fine tip region of a complete microneedle assembly.
Solution Approach 2:
The first substrate acts as an intermediary component that carries the horizontal hole feature. This intermediary structure facilitates easier manufacturing by separating the hole formation process from the final microneedle tip geometry, allowing standard manufacturing techniques to be used.
3Ease of manufacture
If photo-curable resin is used as the microneedle material, then manufacturing is enabled, but tip strength is insufficient and biosafety requirements are not met
Solution Approach 1:
The microneedle assembly uses composite construction with the first substrate made of photo-curable resin and the second substrate made of a different material. This composite approach allows the resin component to provide manufacturing advantages while the combined structure achieves the required tip strength and biosafety.
Solution Approach 2:
Dividing the microneedle into two substrates allows each component to be optimized for its specific function. The first substrate can be manufactured using photo-curable resin with the horizontal hole, while the second substrate can be made from materials providing the necessary mechanical strength and biosafety properties.
Data Source
AI summary
The purpose of the present invention is to provide a microneedle array and a microneedle manufacturing method, which improves medical solution delivery efficiency and facilitates manufacturing. The microneedle array is provided with a first divisional element, a second divisional element to be bonded to the first divisional element, a longitudinal passage formed between the first divisional element and the second divisional element bonded to each other; and a horizontal hole, having an orifice on a lateral side and formed in a direction parallel to a bonding surface of the first divisional element with the second divisional element, and communicating to the longitudinal passage.