Multiple Impact Microprojection Applicator Design
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Solution Overview
Problem
Existing microneedle array applicators often cause discomfort or pain due to the high energy required for penetration, and they are complex and expensive, making them unsuitable for widespread use, especially in areas where cost and simplicity are concerns.
Innovation Solution
The development of an applicator with multiple energy-mass systems, each having a different time constant, which delivers the energy required for penetration in multiple, discrete impacts, reducing the force and strain on the skin and allowing sufficient delay for strain dissipation, thereby minimizing discomfort and improving penetration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single high-energy impact is used for microneedle penetration, then penetration depth and effectiveness are improved, but discomfort and pain to the patient increase
Solution Approach 1:
The patent divides the single high-energy impact into multiple lower-energy impacts by using multiple plunger elements (first plunger element and second plunger element) that release microprojections in sequence. The first plunger element delivers initial impacts, and the second plunger element delivers additional impacts, collectively achieving the required penetration depth while keeping each individual impact below the pain threshold.
Solution Approach 2:
The patent employs periodic action by timing the release of the second plunger element to occur after the first plunger element has delivered its impacts. This creates a sequential, periodic delivery pattern where microprojections are impacted at different times, allowing strain dissipation between impacts and reducing overall discomfort while maintaining effective penetration.
2Object-affected harmful factors
If multiple plunger elements with different time constants are used, then discomfort is reduced through multiple discrete impacts, but device complexity increases
Solution Approach 1:
The patent segments the applicator into distinct functional modules: a first plunger element with a first energy-mass system, a second plunger element with a second energy-mass system, and a common actuating member. Each plunger element can be independently controlled through the single actuating member, allowing complex multi-phase delivery without requiring multiple actuators, thus managing device complexity while achieving reduced discomfort.
Solution Approach 2:
The single actuating member serves multiple functions by controlling both the first and second plunger elements. When the actuating member is actuated, it simultaneously or sequentially releases both plunger elements, allowing one component to perform the work of multiple control systems and simplifying the overall device architecture despite the multiple impact phases.
3Reliability
If a disposable microneedle array is used, then sterility and integrity are maintained, but cost increases
Solution Approach 1:
The patent describes a disposable applicator design where the entire device including microprojections is discarded after a single use. This eliminates the need for complex sterilization and storage infrastructure, making the device suitable for low-resource settings. The disposable nature ensures sterility and integrity while the simplicity of the design aims to reduce manufacturing costs compared to reusable systems requiring maintenance and sterilization facilities.
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 achieves effective penetration with reduced discomfort and pain, using a simpler design that is more cost-effective and accessible, ensuring consistent drug delivery across patients and applications.
Implementation Method 1
The first plunger element impacts a subject by multiple, discrete impacts
Implementation Method 2
at least a first energy-mass system, the first plunger element having a first restrained position and a second extended position
Data Source
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AI summary
Applicators for a microprojection array capable of multiple impacts and methods of using the applicators are described.