Mold With Recessed Pedestal Pattern For Microneedle Arrays
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Solution Overview
Problem
Existing methods for producing molds with recessed pedestal patterns do not effectively prevent liquid flow during injection molding, which can lead to inefficiencies and inaccuracies in manufacturing microneedle arrays for drug delivery.
Innovation Solution
A production method involving an insert mold with a protruding needle pattern group and a mold with a protruding pedestal shape, where the two are held in an overlapping manner to form a cavity filled with resin, preventing liquid flow and enabling the creation of a mold with a recessed pedestal pattern that accurately replicates the needle pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mold is produced by injection molding without a liquid flow prevention configuration, then the production process is simple, but resin flows beyond the target location causing manufacturing defects
Solution Approach 1:
The mold is segmented into multiple components: a first mold, a second mold, and an insert mold with pedestal structures. This segmentation allows the liquid flow prevention function to be integrated into the insert mold rather than requiring complex modifications to the entire mold system, thus improving precision while controlling complexity
Solution Approach 2:
The insert mold with pedestal structures acts as an intermediary element between the first and second molds. It provides the liquid flow prevention function without requiring complex modifications to the main mold bodies, enabling precise pattern replication while maintaining relatively simple mold structures
2Reliability
If a mold with liquid flow prevention configuration is produced, then resin overflow is prevented, but the production process becomes more complex
Solution Approach 1:
The pedestal structures are prepared in advance as part of the insert mold before the injection molding process. This preliminary preparation ensures liquid flow prevention is already in place, improving reliability without adding complexity to the actual molding operation
Solution Approach 2:
The insert mold with pedestal structures is nested within the cavity formed by the first and second molds. This nesting approach integrates the liquid flow prevention mechanism into the existing mold structure, improving reliability while maintaining ease of manufacture through modular design
3Manufacturing precision
If the insert mold is held in an overlapping manner with the protruding pedestal shape, then a recessed pedestal pattern is formed preventing liquid flow, but the alignment process becomes more complex
Solution Approach 1:
The insert mold is designed with asymmetric features including protrusions that correspond to recesses in the first mold. This asymmetric design provides natural alignment cues that simplify the overlapping process while ensuring precise formation of the recessed pedestal pattern, improving manufacturing precision without significantly increasing alignment complexity
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 efficient and accurate production of molds with recessed pedestal patterns, preventing resin overflow and ensuring high productivity and accuracy in manufacturing microneedle arrays for drug delivery.
Implementation Method 1
an injection step of filling the cavity with a resin
Data Source
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AI summary
Provided are a production method of a mold having a recessed pedestal pattern for preventing a liquid flow and a manufacturing method of a pattern sheet. A production method of a mold having a recessed pedestal pattern, has: a step of preparing an insert mold having a protruding needle pattern group; a step of preparing a mold having a first mold provided with a protruding pedestal shape and a second mold; a holding step of holding the protruding pedestal shape of the first mold and the protruding needle pattern group of the insert mold in an overlapping manner; a clamping step of performing clamping with the first mold and the second mold to form a cavity; and an injection step of filling the cavity with a resin.