Microstructure Mold Filling Using Negative Pressure Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of microarrays is complex, expensive, and prone to issues such as incomplete filling of mold openings, cavities, air pockets, and contamination, leading to application problems and insufficient drug dosage.
Innovation Solution
A method involving a planar mold element with open mold openings, use of negative pressure and capillary action to draw formulations into the openings, and controlled volume changes through compression and expansion to ensure complete filling, followed by drying and demolding to form microstructures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional silicone molds with conical or pyramidal openings are used, then the manufacturing process is simple, but the mold openings are not sufficiently filled leading to cavities and air pockets
Solution Approach 1:
The mold element transitions from a static conical/pyramidal shape to a dynamic structure that changes shape during filling. The mold openings are compressed during formulation intake, then relaxed to expand, creating a dynamic volume change that drives complete filling through negative pressure generation.
Solution Approach 2:
The invention changes the volume parameter of the mold opening dynamically. By compressing the mold element to reduce volume and then releasing to expand volume, the system creates pressure differentials that drive complete formulation intake, transforming the filling mechanism from passive to active.
2Manufacturing precision
If simple pouring methods are used to fill mold openings, then the operation is easy, but incomplete filling occurs at the tips of conical or pyramidal openings
Solution Approach 1:
The mold element transitions from a static conical/pyramidal shape to a dynamic structure that changes shape during filling. The mold openings are compressed during formulation intake, then relaxed to expand, creating a dynamic volume change that drives complete filling through negative pressure generation.
Solution Approach 2:
The mold openings are pre-compressed before formulation intake to reduce their volume, then released to expand and create negative pressure that draws formulation into the tips. This preliminary compression action ensures that the filling process reaches the tips completely.
3Productivity
If traditional manufacturing methods are used, then the process is established, but production is complex and expensive with contamination risks
Solution Approach 1:
The mold element performs multiple functions: it contains the formulation, generates negative pressure for filling, and facilitates demolding. The elastic material itself creates the suction effect through its compression and relaxation, eliminating the need for separate vacuum systems and reducing contamination risks.
Solution Approach 2:
The invention extracts the vacuum generation function from external equipment and embeds it within the mold element itself. By making the mold element elastic and compressible, the negative pressure is generated internally during the filling process, simplifying the system and reducing contamination points.
4Quantity of substance
If conical or pyramidal mold openings are used, then the mold design is simple, but insufficient formulation reaches the tips resulting in inadequate drug dosage
Solution Approach 1:
The mold element transitions from a static conical/pyramidal shape to a dynamic structure that changes shape during filling. The mold openings are compressed during formulation intake, then relaxed to expand, creating a dynamic volume change that drives complete filling through negative pressure generation.
Solution Approach 2:
The mold openings are pre-compressed before formulation intake to reduce their volume, then released to expand and create negative pressure that draws formulation into the tips. This preliminary compression action ensures that the filling process reaches the tips completely.
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 method enhances scalability and reduces production costs while ensuring consistent and complete filling of microstructures, minimizing defects and contamination, thereby improving the quality and efficiency of microarray production.
Implementation Method 1
The volume of the mold opening is increased by expanding the mold element. The at least one mold opening is thereby opened up towards the environment to a greater extent. The intake of the first formulation into the mold opening can thereby be promoted.
Implementation Method 2
The intake of the first formulation into the mold opening can thereby be promoted. In particular, the capillary action can be utilized for the intake of the first formulation into the mold opening.
Implementation Method 3
The volume of the mold opening is reduced by at least partially compressing the mold element.
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2a~2b
AI summary
The invention relates to a method for producing microstructures (120), the method comprising the following steps: providing a planar mould element (10), which comprises at least one mould opening (12) for the microstructure (120) to be produced, wherein the at least one mould opening (12) has a first opening (14) and a second opening (18); providing a first formulation (22) at the second opening (18); generating a negative pressure in the mould opening (12); and taking up the first formulation (22) through the second opening (18) into the mould opening (12) on account of the negative pressure in the mould opening (12). The invention further relates to a system (100) for producing microstructures.