Adhesive Patch Tool Set for Parallel Embossing and Cutting
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Solution Overview
Problem
Adhesive matrix material in transdermal patches often comes into contact with the environment, leading to contamination and improper drug administration due to exposure and adherence to objects, which affects the integrity and efficacy of the patch.
Innovation Solution
A transdermal adhesive layering design where the backing layer covers the adhesive matrix layer, with a compressed edge area to prevent exposure, and a tool set for manufacturing patches that includes embossing and cutting tools to create a sealed perimeter, ensuring minimal adhesive matrix material is exposed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the adhesive matrix layer is fully covered by the backing layer, then exposure of adhesive matrix material to the environment is prevented, but manufacturing complexity increases due to additional processing steps
Solution Approach 1:
The adhesive matrix material is compressed at the edges during the manufacturing process before the patch is applied to the skin. This preliminary compression creates a sealed edge that prevents exposure of the adhesive matrix material to the environment during subsequent handling and application, eliminating the need for additional covering steps
Solution Approach 2:
The physical state of the adhesive matrix material at the edges is changed through compression, altering its density and structure to create a sealed perimeter. This parameter change prevents the adhesive material from adhering to external objects while maintaining its functional properties in the central application area
2Object-affected harmful factors
If the adhesive matrix material is compressed at the edges, then exposure and contamination are prevented, but manufacturing precision requirements increase
Solution Approach 1:
The compression process is designed to be self-regulating, where the adhesive matrix material itself provides resistance that naturally limits the compression force. This self-service mechanism ensures consistent edge sealing without requiring highly precise external control of compression parameters
Solution Approach 2:
The potentially problematic adhesive matrix material at the edges is effectively removed from the functional system by compressing it into a sealed, non-adhesive state. This extracted material no longer poses contamination risks while the central portion retains its full adhesive functionality for drug delivery
3Object-affected harmful factors
If the backing layer completely covers the adhesive matrix layer, then adhesive matrix material exposure is prevented, but the patch size increases
Solution Approach 1:
Different regions of the adhesive matrix layer are given different properties: the central area maintains its normal adhesive characteristics for drug delivery, while the edge regions are compressed to create a non-adhesive sealed perimeter. This local differentiation prevents exposure without requiring an extended backing layer
Solution Approach 2:
Instead of expanding the patch area in two dimensions by extending the backing layer, the solution addresses the exposure problem by modifying the third dimension (depth/density) at the edges through compression. This dimensional approach seals the edges without increasing the overall patch footprint
Data Source
AI summary
A tool set for manufacturing adhesive patches, by processing laminate web. The tool set includes a cutting tool having a cutting face lying in a cutting plane, and an embossing tool having a pressing face lying in a pressing plane, where the cutting plane and the pressing plane are parallel. The embossing tool is configured to press an edge area shape of the adhesive patch to be manufactured, and the cutting tool is configured to cut out the adhesive patch to be manufactured by cutting in edge area or outside the edge area. Furthermore, a method of manufacturing adhesive patches. The method essentially includes a feeding step, a pressing step and cutting step. Lastly an adhesive layering having a backing layer and an adhesive matrix layer. The backing layer having a larger size than the adhesive matrix layer.