Microneedle Patch Applicator With Compressible Piston Drive
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Solution Overview
Problem
Existing microneedle configurations face challenges in consistently delivering active pharmaceutical ingredients (APIs) to appropriate depths with inconsistent application of force and suboptimal dosing.
Innovation Solution
An applicator device with a top portion, middle portion, and piston portion, utilizing a compressible member to ensure consistent and reliable application of medicament patches, including a mechanism to apply a predetermined force for proper skin penetration of microneedles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual application of microneedle patches is used, then the device is simple to operate, but the application force is inconsistent leading to poor delivery reliability
Solution Approach 1:
The patent applies parameter changes by using a spring mechanism with specific force characteristics (e.g., 6-15 lbs contribution to activation force) to standardize the application force. This transforms the variable manual pressure into a controlled mechanical force, ensuring consistent microneedle penetration depth and API delivery while maintaining a relatively simple applicator structure.
Solution Approach 2:
The spring-loaded mechanism automatically provides the necessary activation force without requiring the user to manually control the pressure. The compressible member self-regulates the force application, eliminating the inconsistency of manual pressing while keeping the device simple enough for easy operation.
2Manufacturing precision
If insufficient activation force is applied, then the applicator is gentle on the skin, but the microneedles do not penetrate to the required depth resulting in suboptimal API delivery
Solution Approach 1:
The patent specifies particular force parameters (6-15 lbs from flex arms, plus spring force) to achieve the precise activation needed for consistent microneedle penetration. This controlled force parameter ensures microneedles reach the target depth (delivering at least 70% of API to 300 μm depth) without excessive force that could cause skin damage.
Solution Approach 2:
The spring mechanism provides mechanical feedback through its compression and release, ensuring the activation force is applied consistently. The flex arms also contribute to force distribution, creating a feedback system that maintains optimal penetration depth while preventing over-activation.
3Reliability
If excessive activation force is applied, then the microneedles penetrate deeply, but the application becomes painful and inconsistent
Solution Approach 1:
The patent defines specific force ranges (6-15 lbs from flex arms, controlled spring force) that are sufficient for consistent microneedle penetration without exceeding the threshold for skin damage or pain. This parameter control ensures reliable delivery while minimizing harmful effects.
Solution Approach 2:
The spring mechanism acts as a cushioning element that pre-limits the maximum force applied. The compressible member absorbs excess energy and prevents sudden force spikes, ensuring consistent gentle activation that penetrates effectively without causing skin trauma or pain.
4Reliability
If the applicator uses a simple release mechanism, then the device is easy to manufacture, but it cannot ensure consistent force application across multiple patches
Solution Approach 1:
The patent uses standardized spring and flex arm components with defined force characteristics that can be manufactured with tolerances ensuring consistent 6-15 lbs force contribution. This approach maintains ease of manufacture while achieving reliable force consistency across multiple applications.
Solution Approach 2:
The applicator is divided into functional segments (top portion, middle portion with flex arms, bottom portion, piston portion, spring) that can be manufactured and assembled separately. This segmentation allows for easier manufacturing of individual components while ensuring consistent overall force application through the combined action of standardized parts.
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 applicator ensures that at least 70% of the API is delivered to a depth of 300 μm below the skin surface, improving delivery efficiency and consistency.
Implementation Method 1
a compressible member positioned between the middle portion and the piston portion. When the activation mechanism is activated, the piston portion is released from the top portion and the middle portion and moves downwards via force applied by the compressible member
Implementation Method 2
the applicator ensures that at least 70% of the API is delivered to a depth of 300 μm below the skin surface
Data Source
AI summary
An applicator for applying a medicament patch to a subject can include a top portion configured to be pressed downwards to activate an activation mechanism; a bottom portion configured to hold the medicament patch; a middle portion connected to the top portion and the bottom portion, the middle portion comprising a plurality of flex arms configured to contribute about 6-15 lbs to an activation force of the activation mechanism; a piston portion connected to the middle portion; and a compressible member positioned between the middle portion and the piston portion. When the activation mechanism is activated, the piston portion is released from the top portion and the middle portion and moves downwards via force applied by the compressible member. When the piston portion moves downwards, the medicament patch is released from the bottom portion and pushed downward by the piston portion onto a skin surface of the subject.