Microneedle Patch Mold Alignment via Polymeric Female Die
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Solution Overview
Problem
The manufacturing of microneedle patches faces challenges due to misalignment issues in the metal mold process, leading to non-performing products with deviated microneedle positions, affecting user experience and administration accuracy.
Innovation Solution
A metal mold design with microneedle structures distributed in a single area on a bearing seat is used, along with a method involving a male die and female die formation, to ensure precise alignment and positional accuracy of the microneedle area, enhancing production yield and user experience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional metal mold is used for manufacturing microneedle patch, then production can proceed, but misalignment between female die and release mold occurs due to material properties, resulting in deviated microneedle positions
Solution Approach 1:
The invention applies preliminary action by pre-forming a female die from polymeric material that precisely matches the male die geometry before the actual microneedle patch manufacturing. This pre-formed female die serves as a template that ensures accurate positioning and alignment, preventing the misalignment issues that occur when conventional metal molds are used directly. The preliminary creation of the female die establishes the correct geometric relationships before production begins.
Solution Approach 2:
The invention introduces an intermediary element - the polymeric female die - that mediates between the male die and the final product. This intermediate female die acts as a buffer and alignment reference, ensuring that the release mold and other components align correctly during manufacturing. The female die translates the precise geometry of the male die into a form that can guide subsequent manufacturing steps without the misalignment problems of direct metal-to-metal contact.
2Productivity
If conventional manufacturing method is used, then production can continue, but yield rate is reduced due to non-performing products with misaligned microneedles
Solution Approach 1:
The invention implements feedback by using the female die as a reference template that provides continuous alignment information throughout the manufacturing process. The female die, once formed from the male die, serves as a master pattern that guides the positioning of the release mold and other components. Any deviations from the correct position are prevented because the female die physically constrains the alignment, providing real-time feedback during the manufacturing process rather than allowing errors to accumulate.
Solution Approach 2:
The invention applies copying by creating a precise replica (female die) of the male die geometry in polymeric material. This copy serves as the master template for subsequent manufacturing steps. The female die accurately replicates the microneedle patterns and spacing, ensuring that all subsequent operations are based on this verified correct geometry, thereby eliminating the variability and errors associated with direct metal mold usage.
3Measurement precision
If metal mold with distributed microneedle structures is used, then alignment accuracy is improved, but device complexity increases
Solution Approach 1:
The invention extracts the alignment-critical geometry from the complex metal mold system and isolates it into a separate, simplified polymeric female die. By taking out the essential positioning features and embedding them in the female die, the system separates the alignment function from the structural support function. This extraction allows the male die to remain relatively simple while the female die carries the precise geometric information needed for alignment, reducing overall system complexity.
Solution Approach 2:
The invention changes the material parameter from metal to polymer for the female die, which fundamentally alters the properties. The polymeric material is more compliant, easier to form with high precision, and less prone to the misalignment issues of rigid metal. This parameter change (material selection) enables achieving high positional accuracy without the complexity of precision metal machining and assembly, as the polymer can be formed more easily and maintains its geometric integrity.
Data Source
AI summary
A microneedle patch includes a microneedle structural layer, an adhesive layer, and a carrier layer. The adhesive layer is disposed between the microneedle structural layer and the carrier layer, and is connected to the microneedle structural layer and the carrier layer. The microneedle structural layer comprises a base layer and a plurality of microneedles, and the base layer has a first side and a second side opposite to the first side, and the first side faces the adhesive layer. The plurality of microneedles are spaced apart from each other and disposed on the second side, and include a plurality of first microneedles and at least one second microneedle. The at least one second microneedle is located at an edge of the microneedle structural layer, and the height of the at least one second microneedle is less than that of each first microneedle.