Spiked Microparticle Moulding for Low-Irritation Transdermal Delivery
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Solution Overview
Problem
Existing methods for producing microparticles are complex and costly, lacking a simple and efficient means to create microparticles with spikes that facilitate transdermal delivery of therapeutic or cosmetic agents while minimizing skin irritation.
Innovation Solution
A method involving a mould assembly with two moulds that define a micro-cavity, allowing pressure to form moulding material into microparticles, and a device using dies and cutting tools to produce microparticles with spikes extending in a two-dimensional plane, enabling easy removal and low-cost production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing methods are used to produce microparticles, then microparticles with spikes for transdermal delivery can be created, but the production process becomes complex and costly
Solution Approach 1:
The production process is segmented into distinct stages: providing a mold assembly with cavity and spike-forming features, injecting molding material into the cavity, curing the material, and removing the finished microparticle. This segmentation allows each stage to be optimized independently, simplifying the overall complex process while maintaining precise spike formation.
Solution Approach 2:
The mold assembly is pre-configured with specific cavity geometry and spike-forming features before production begins. The mold includes protrusions that correspond to the desired spike locations and shapes, allowing microparticles with precise geometric features to be formed in a single injection-curing cycle without requiring subsequent complex machining or shaping operations.
2Manufacturing precision
If complex production methods are used, then microparticle quality is improved, but production cost increases
Solution Approach 1:
The mold assembly is designed to be self-releasing, where the microparticle automatically detaches from the mold cavity after curing due to geometric features and surface properties. This eliminates the need for complex ejection mechanisms or manual removal processes, reducing both equipment cost and operational complexity while maintaining precise spike geometry throughout repeated production cycles.
Solution Approach 2:
The invention controls microparticle production by adjusting parameters such as injection pressure, curing temperature and time, and mold geometry. By optimizing these parameters, high-precision spike formation is achieved through the simple injection-curing process rather than through complex multi-step manufacturing methods, thereby reducing production costs while maintaining manufacturing precision.
3Productivity
If spike length is increased for better transdermal delivery, then delivery efficiency improves, but skin irritation and pain increase
Solution Approach 1:
The microparticle is designed with non-uniform spike distribution and varying spike lengths across its surface. Longer spikes are positioned in regions optimized for transdermal penetration where delivery efficiency is prioritized, while shorter spikes are located in areas where minimal skin interaction is desired. This local variation in spike quality allows the microparticle to achieve effective drug delivery while minimizing overall skin irritation and pain.
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
The method provides a simple and cost-effective way to produce microparticles with spikes for transdermal delivery, reducing skin irritation and enabling efficient transport of medical substances.
Implementation Method 1
Heat can be applied to the moulding material for softening the moulding material.
Implementation Method 2
the moulding material and the die are also pressed toward each other such that the moulding material passes through the orifice
Implementation Method 3
The microparticle is often removed from the mould assembly using a vacuum device.
Data Source
AI summary
A method of producing a microparticle includes providing a mould assembly, which comprises two moulds that comprise an upper mould and a lower mould, positioning the mould assembly in a closed position, wherein the two moulds define a micro-cavity to exert pressure on a moulding material within the micro-cavity to form the moulding material within the micro-cavity to form the moulding material into a microparticle, and positioning the mould assembly in an open position, wherein the microparticle adheres to one of the two moulds assembly.