Microstructure Formation Using Negative Pressure

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Solution Overview

Problem

Existing methods for manufacturing microstructures like microneedles face challenges such as loss during separation, restricted surface characteristics, and the need for high-heat or solvent treatments, which can destroy drugs or skin care ingredients, and are not suitable for mass production or quick manufacturing.

Innovation Solution

A method involving the application of negative pressure to a viscous composition placed on a substrate, allowing for the formation of microstructures with controlled dimensions and hardness without heat or solvent treatments, enabling efficient drug delivery and mass production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If conventional methods (contact and stretching, air blowing, three-dimensional downward flow) are used to manufacture microstructures, then microstructures can be formed, but there is loss during separation procedure and surface characteristics are restricted

Engineering Contradiction:

Improveloss during separationVSAvoidmanufacturing process complexity

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

The invention extracts and eliminates the problematic contact and separation steps from the manufacturing process. By using a non-contact method where a viscous solution is directly deposited onto a substrate and then stretched, the separation procedure that causes loss is completely removed from the process flow.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the mechanical contact-based stretching system with a non-contact stretching system. The viscous solution is stretched using aerodynamic or electromagnetic forces rather than mechanical contact, eliminating the need for physical separation and reducing material loss.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If high-heat treatment or solvent treatment is applied to manufacture microstructures, then the microstructure can be formed, but drugs or skin care ingredients are destroyed

Engineering Contradiction:

Improvemicrostructure formationVSAvoiddestruction of drugs or skin care ingredients

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The invention substitutes thermal and chemical processing methods with mechanical and aerodynamic methods. The microstructure is formed through controlled stretching and deposition processes that do not require high heat or solvent treatment, thereby preserving the integrity of sensitive pharmaceutical ingredients.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the processing parameters from high-temperature and high-solvent conditions to controlled stretching parameters and ambient conditions. By adjusting the stretching rate, substrate temperature, and deposition conditions, the microstructure is formed without exposing sensitive materials to destructive thermal or chemical environments.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If existing microneedle manufacturing methods are used, then microneedles can be manufactured, but the process is not suitable for mass production or quick manufacturing

Engineering Contradiction:

Improvemass production capabilityVSAvoidmanufacturing cycle time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The invention performs preliminary actions by pre-preparing the viscous solution with appropriate rheological properties and pre-configuring the substrate. This allows for rapid stretching and formation of microstructures without time-consuming separation or post-processing steps, enabling quick manufacturing suitable for mass production.

Inventive Principle:

Principle #10Preliminary action

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 allows for the rapid and efficient production of microstructures with desired dimensions and hardness, suitable for drug delivery, while preserving the integrity of sensitive ingredients and facilitating mass production.

Implementation Method 1

applying negative pressure to the viscous composition to induce an extension of the viscous composition, thereby forming a microstructure

Methodology Applied

Scientific EffectNegative pressure: Pressure Gradient

Data Source

PatentUS9974936B2Method for manufacturing microstructure using negative pressure and microstructure manufactured therefor

Publication Date: 2018.05.22 JUVIC INC

AI summary

The present invention is directed to a method for manufacturing a microstructure, the method comprising: (a) placing a viscous composition on a substrate; and (b) applying negative pressure to the viscous composition to induce an extension of the viscous composition, thereby forming a microstructure, and a microstructure manufactured therefor. According to the present invention, a microstructure can be formed without performing a heat treatment by applying a negative pressure. Consequently, it is possible to mount on a microstructure various materials that are sensitive to heat and easily damaged or degenerated. According to the present invention, a microstructure can be manufactured in a non-contacting manner, that is, without being contacted with conventionally used another structure such as a mold or filler. This leads to overcome a loss caused during a process of separating a microstructure in contact or a cutting process involving a physical destruction after the completion of molding a microstructure and limit on the production yield.