Projection-Bearing Sheet Forming with Integrated Resin Pressing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing process for microneedles with needle-like projections requires multiple steps and is inefficient, particularly in placing thermoplastic resin on a support surface and then a sheet-like object, which hampers productivity.
Innovation Solution
A method and device that prepare a base material with a plastic layer on a bearing sheet, transfer it to a support member with recesses, press the plastic material into these recesses to form projections, and then leach out the plastic to create a porous structure, simplifying the process into fewer steps and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the existing two-step process is used (placing thermoplastic resin on support surface, then placing sheet-like object on resin), then the projections can be formed, but the manufacturing process becomes complex and productivity decreases
Solution Approach 1:
The invention combines the thermoplastic resin and sheet-like object into a single integrated base material where the resin is stacked on one surface of the sheet. This eliminates the need for separate placement steps, reducing process complexity while maintaining projection formation capability.
Solution Approach 2:
The base material is prepared in advance with the plastic material already stacked on the bearing sheet surface. This preliminary preparation allows the material to be ready for direct transfer and pressing, eliminating intermediate steps and improving manufacturing efficiency.
2Manufacturing precision
If multiple separate steps are used for material transfer, support, and pressing, then each step can be optimized, but the overall manufacturing time increases
Solution Approach 1:
The material transfer step, support step, and pressing step are merged into a single integrated operation. The base material is transferred directly to the support member and pressed in one continuous motion, eliminating the time losses associated with multiple separate steps while maintaining placement accuracy through the integrated design.
Solution Approach 2:
The manufacturing process is designed to maintain continuous useful action by combining transfer, support, and pressing into a single uninterrupted operation. The base material moves continuously from transfer to pressing without idle transitions, maximizing productivity while preserving precision through the coordinated design of the integrated step.
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 approach reduces the manufacturing time by integrating material transfer, support, and pressing into a single step, enhancing the capacity for producing projection-bearing bodies with projections on a bearing sheet, such as microneedles, by using a device with units for material transfer, support, heating, positioning, cooling, and leaching.
Implementation Method 1
a pressing step of pressing the base material in a direction toward the support surface to fill the plastic material in the recess
Implementation Method 2
a material transfer step of transferring the base material prepared in the base material preparing step, the material transfer step placing the base material on a support member having a support surface in which a recess corresponding to the projection is formed
Data Source
AI summary
A device EA that manufactures a projection-bearing body having a structure in which projections CV are formed on a bearing sheet BS comprises: a material transfer unit 10 that executes a material transfer step of transferring a base material BM containing a plastic material PM; a material support unit 20 that executes a material support step of supporting the base material BM transferred by the material transfer unit 10, by a support member 22 having a support surface 22A in which recesses 22B corresponding to the projections CV are formed; and a press unit 30 that executes a pressing step of pressing the base material BM in a direction toward the support surface 22A to fill the plastic material PM in the recesses 22B and forming the projections CV from the plastic material PM. In the base material BM, the plastic material PM is stacked on one surface of the bearing sheet BS. When transferring the base material BM, the material transfer unit 10 places the base material BM on the support member 22, with the plastic material PM in contact with the support surface 22A.