Needle-like Array Sheet Manufacturing via Two-Layer Molding
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Solution Overview
Problem
Current methods for manufacturing needle-like array sheets face challenges in achieving high productivity and low costs due to difficulties in bonding water-soluble and poorly soluble resins, requiring sterile facilities, and lengthy drying times that can decompose medicines and increase facility costs.
Innovation Solution
A two-layer molding method involving a first and second needle-like array-forming solution, where the first solution is dried in a wet state to form needle-like distal ends, and the second solution is used to create a sheet part molding product that is inserted and bonded with the distal ends, allowing for high-temperature drying and reduced facility costs by shortening drying times and eliminating the need for extensive sterile facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If water-soluble and poorly soluble resins are bonded together to form needle-like array sheets, then the structural integrity and functionality are improved, but the bonding difficulty increases due to resin incompatibility
Solution Approach 1:
The patent uses a multi-layer molding approach where a first resin layer (water-soluble or poorly soluble) and a second resin layer (different solubility characteristics) are formed separately in a mold and then bonded together. The intermediary step of separate formation allows compatibility management, while the bonding process achieves structural integrity. This resolves the contradiction by enabling bonding of incompatible resins through controlled sequential processing.
2Productivity
If complete drying is performed at high temperature to shorten manufacturing time, then productivity is improved, but the medicine may decompose
Solution Approach 1:
The patent segments the drying process into two distinct stages: (1) initial drying at high temperature to remove bulk moisture and shorten manufacturing time, and (2) final low-temperature drying to preserve medicine stability. This segmentation allows high-temperature processing for productivity while protecting the medicine from thermal decomposition, thus resolving the contradiction between manufacturing speed and product quality.
3Reliability
If extensive sterile facilities are used to ensure product safety, then reliability is improved, but facility costs increase
Solution Approach 1:
The patent extracts the critical sterile processing steps from the entire manufacturing process by identifying only the specific stages that require sterile conditions (namely, when the medicine-containing solution is handled). Non-critical stages can be performed in less expensive facilities. This selective approach maintains product safety while reducing overall facility costs by eliminating the need for extensive sterile environments throughout the entire manufacturing process.
4Manufacturing precision
If long drying time is used to ensure complete moisture removal, then product quality is improved, but productivity decreases
Solution Approach 1:
The patent implements periodic action through a two-stage drying process with distinct temperature and time parameters. The first stage uses high temperature for rapid moisture removal, and the second stage uses lower temperature for complete drying. This periodic approach achieves thorough drying while significantly reducing total manufacturing time compared to single-stage low-temperature drying, thus resolving the contradiction between drying completeness and productivity.
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 productivity by shortening manufacturing time, ensuring firm bonding of the needle-like distal ends and sheet part molding product, and allows for high-temperature drying without medicine decomposition, thereby reducing facility costs and maintaining product safety.
Implementation Method 1
a first liquid drying step of interrupting drying of the first needle-like array-forming solution in a wet state and forming a needle-like distal end part
Implementation Method 2
a sheet part molding product forming step of peeling a sheet part molding product from the second mold after the second needle-like array-forming solution is dried and solidified
Implementation Method 3
bonding the needle-like distal end part and the protrusion of the sheet part molding product together, and forming a needle-like array sheet
Data Source
AI summary
A method of manufacturing a needle-like array sheet includes supplying a first needle-like array-forming solution consisting of an aqueous solution on a first mold having a first recess; interrupting drying in a wet state and forming a needle-like distal end part; supplying a second needle-like array-forming solution consisting of an aqueous solution on a second mold having a second recess; peeling a sheet part molding product, which is dried and solidified and has a protrusion corresponding to the second recess, after the sheet part molding product is formed; inserting the protrusion of the sheet part molding product into the first recess of the first mold; drying and solidifying the needle-like distal end part and the sheet part molding product after inserting the protrusion, bonding the needle-like distal end part and the protrusion of the sheet part molding product together, and forming a needle-like array sheet having the needle-like array.