Viscous Polymer Extrusion for Microneedle Manufacturing

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Solution Overview

Problem

Existing methods for manufacturing microstructures with microneedles for transdermal delivery often fail to achieve the desired properties of sufficient diameter, length, and hardness, and may degrade active ingredients, necessitating a simpler and cost-effective approach.

Innovation Solution

A method involving the use of viscous compositions on substrates, where the substrates are brought into contact, elongated, solidified, and cut to form microstructures, with optional air blowing to control viscosity and shape, allowing for the incorporation of active ingredients without heat treatment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional methods are used to manufacture microstructures with microneedles, then the microstructures can be produced, but they fail to achieve sufficient diameter, length, and hardness

Engineering Contradiction:

Improvemicroneedle dimensions (diameter, length) and hardnessVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the physical state of the polymer material from solid to viscous liquid during manufacturing, allowing the material to be extruded and formed into microneedles with precise dimensions. By controlling the viscosity and temperature parameters, the method achieves sufficient diameter, length, and hardness while simplifying the manufacturing process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces complex mechanical forming processes with a simpler extrusion method through a nozzle. The viscous polymer composition is pushed through a nozzle to form microneedles, eliminating the need for complex molding or machining operations while achieving precise dimensional control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If existing manufacturing methods are used, then microstructures can be produced, but active ingredients may be degraded

Engineering Contradiction:

Improveintegrity of active ingredientsVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent eliminates heat treatment steps from the manufacturing process, using only mechanical extrusion and drying. This mechanical approach preserves the chemical integrity of heat-sensitive active ingredients while maintaining manufacturing feasibility

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent skips the heat treatment step entirely, moving directly from viscous composition extrusion to drying and solidification. This rapid process avoids thermal degradation of active ingredients while completing manufacturing efficiently

Inventive Principle:

Principle #21Skipping (Rushing through)

3Ease of manufacture

If conventional manufacturing methods are used, then microstructures can be produced, but the process is complex and costly

Engineering Contradiction:

Improvemanufacturing simplicity and cost-effectivenessVSAvoidmicroneedle properties (diameter, length, hardness)

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces complex multi-step manufacturing processes with a single extrusion operation through a nozzle. The viscous polymer composition is extruded directly into the desired microneedle shape, simplifying the process while maintaining precision through control of extrusion parameters

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses controlled changes in temperature and viscosity parameters to achieve precise microneedle formation. By adjusting these parameters during extrusion, the method produces microneedles with consistent dimensions and hardness in a simple, cost-effective process

Inventive Principle:

Principle #35Parameter changes

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 enables the production of microstructures with controlled dimensions and hardness, ensuring effective skin penetration and preserving the integrity of active ingredients, while being simpler and more cost-effective than existing methods.

Implementation Method 1

moving the first substrate, the second substrate, or both so as to allow the first viscous composition to be elongated

Methodology Applied

Scientific EffectViscous flow:

Implementation Method 2

blowing air directly or indirectly to the first viscous composition to solidify the first viscous composition

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

cutting the solidified first viscous composition at predetermined positions between the first substrate and the second substrate to provide a microstructure

Methodology Applied

Scientific EffectFracture: Fracture Mechanics

Data Source

PatentUS8545741B2Method of manufacturing microstructure

Publication Date: 2013.10.01 RAPHAS

AI summary

Provided are methods of manufacturing microstructures, in which at least one viscous composition each containing at least one active ingredient is disposed directly or indirectly on a first substrate and/or a second substrate and the viscous composition(s) is elongated between the first and second substrates. The methods are simpler and more cost-effective.