Biodegradable Microneedle Manufacturing via Solid Fluidization
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Solution Overview
Problem
Current methods for manufacturing biodegradable microneedles face challenges in achieving uniformity and productivity due to viscosity changes from environmental factors and limited drug loading capabilities, leading to inconsistent drug delivery and potential drug denaturation.
Innovation Solution
A method involving forming a solid on a substrate, fluidizing it with a solvent, and shaping the fluidized solid, allowing for adjustable drug distribution and aspect ratio, which enables precise control over microneedle formation and enhances drug stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a viscous composition is used to manufacture biodegradable microneedles, then the microneedles can be formed by shaping, but the viscosity changes due to environmental factors (humidity and temperature) make it difficult to achieve uniformity and mass production
Solution Approach 1:
The patent changes the physical state parameter of the biodegradable material from viscous to solid form. By using solid particles instead of viscous composition, the manufacturing process becomes insensitive to environmental humidity and temperature variations, enabling consistent microneedle formation and mass production with high uniformity
Solution Approach 2:
The patent employs a disposable solid form of biodegradable material that is ejected as particles onto the substrate. This solid particle approach eliminates the need for precise viscosity control and environmental condition management required by viscous materials, simplifying the manufacturing process
2Productivity
If a viscous composition is ejected to form droplets for manufacturing biodegradable microneedles, then microneedles can be produced, but the drying degree varies according to ejection order causing viscosity variation and difficulty in mass production
Solution Approach 1:
The patent changes the material state from viscous to solid particles. Solid particles do not undergo drying-induced viscosity changes during ejection and deposition, allowing consistent microneedle formation regardless of ejection order or drying conditions, thereby enabling reliable mass production
Solution Approach 2:
The biodegradable material is pre-formed into solid particles before ejection. This preliminary solidification step eliminates subsequent drying variations that would otherwise cause viscosity changes, ensuring uniform microneedle properties across mass production batches
3Quantity of substance
If a mixed solution of biodegradable material and drug is used, then drugs can be loaded into microneedles, but the drug may be denatured or destroyed by interaction with the biodegradable material or solvent
Solution Approach 1:
The patent segments the drug and biodegradable material into separate components: solid biodegradable particles and liquid drug solution. The liquid drug solution is ejected onto the solid particles after deposition, minimizing contact time and interaction between incompatible substances, thereby preventing drug denaturation while achieving effective drug loading
Solution Approach 2:
The solid biodegradable particle structure is formed in advance before drug application. This preliminary formation creates a stable scaffold that receives the liquid drug subsequently, reducing the duration of drug-material interaction and preserving drug stability
4Adaptability or versatility
If solvents of different types are used for biodegradable material and drug, then drug loading is possible, but a separate surfactant is needed forming a mixed solution with high viscosity making accurate drug quantification difficult
Solution Approach 1:
The patent separates the biodegradable material (solid particles) from the drug (liquid solution with compatible solvent). This segmentation eliminates the need for surfactants and mixed solutions, allowing accurate drug quantification through direct ejection of the liquid drug solution onto the solid particle array
Solution Approach 2:
The patent uses a solvent that is compatible with both the solid biodegradable particles and the drug as an intermediary medium. This approach avoids the need for surfactants and complex mixed solutions, enabling accurate drug quantification and delivery
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 stabilizes drug activity, facilitates precise drug loading, and improves the uniformity and productivity of microneedle production, enabling effective drug delivery through controlled permeation into the skin.
Implementation Method 1
fluidizing the solid by adding a solvent to the solid
Implementation Method 2
fluidizing the solid by adding a solvent to the solid
Data Source
AI summary
The present invention relates to a method of manufacturing a microstructure, including: (a) forming a solid on a substrate; (b) fluidizing the solid by adding a solvent thereto; and (c) shaping the fluidized solid, and a microstructure manufactured using the method.