Microneedle Patch Applicator With Spring-Driven Depth Control
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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
1Ease of operation
If manual application of microneedle patches is used, then ease of operation is improved, but delivery consistency and penetration depth reliability deteriorate
Solution Approach 1:
The applicator device enables self-service application by the patient without requiring clinical personnel. The device includes a piston mechanism that automatically delivers the microneedle array when activated by the patient pressing a button, eliminating the need for manual clinical administration while maintaining consistent delivery performance
Solution Approach 2:
The patent replaces manual mechanical application with an automated piston-driven mechanical system. The piston is propelled by a spring mechanism that provides controlled force to penetrate the microneedles through the skin, substituting inconsistent manual pressure with a reliable mechanical force generation system
2Device complexity
If manual application of microneedle patches is used, then device complexity is reduced, but penetration depth control and API delivery precision deteriorate
Solution Approach 1:
The patent introduces a piston as an intermediary mechanical element between the activation button and the microneedle array. This piston mediator translates the user's button press into controlled mechanical force, ensuring consistent penetration depth and API delivery while maintaining a relatively simple overall device structure
Solution Approach 2:
The spring mechanism is pre-compressed and stored in a ready state within the applicator device. When activated, the pre-stored spring energy is released to propel the piston forward with consistent force, ensuring reliable penetration depth control without requiring complex real-time adjustment mechanisms
3Ease of operation
If inconsistent force application is used, then ease of operation is improved, but API delivery amount and depth consistency deteriorate
Solution Approach 1:
The patent replaces inconsistent manual force application with a spring-driven piston mechanism that generates consistent mechanical force. The spring is pre-compressed to a specific degree, ensuring that each activation delivers the same force magnitude to the microneedle array, thereby achieving consistent API delivery amounts
Solution Approach 2:
The patent controls the spring compression parameter to a specific range (pre-compressed state) to ensure consistent force generation. By standardizing this physical parameter, the device achieves reproducible API delivery quantities across multiple applications while remaining easy to operate
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
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.


