Method of manufacturing solid solution perforator patches and uses thereof
First Claim
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1. A method of manufacturing a microneedle array, the method comprising:
- (a) preparing a positive master mold comprising a plurality of microneedles penetrating through a defining plate to extend from a bottom surface thereof, wherein the plurality of microneedles are spaced from one another at a predetermined distance;
(b) individually adjusting at least some of the plurality of microneedles by an actuator array individually moving the at least some microneedles through the defining plate to extend different distances from the bottom surface thereof, thereby providing a desired surface contour to the master mold;
(c) preparing a negative mold having a negative surface contour that is the reverse of the desired surface contour of the positive master mold by shaping a curable gel or thermoplastic material against the bottom surface of the defining plate having the adjusted microneedles;
(d) preparing a microneedle array having a surface contour that is the reverse of the negative surface contour of the negative mold by shaping a dissolvable polymer against the negative mold; and
(e) drying the microneedle array.
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Abstract
Methods for fabricating and manufacturing solid solution perforators (SSPs) using sharp metal or glass needles and/or subsequent molding and use are described. The methods entail making microneedles by various precision machining techniques and micromold structures from curable materials. Various designs of patch, cartridge and applicator are described. Also described are methods for adjusting the microneedle mechanical strength using formulation and/or post-drying processes.
138 Citations
14 Claims
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1. A method of manufacturing a microneedle array, the method comprising:
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(a) preparing a positive master mold comprising a plurality of microneedles penetrating through a defining plate to extend from a bottom surface thereof, wherein the plurality of microneedles are spaced from one another at a predetermined distance; (b) individually adjusting at least some of the plurality of microneedles by an actuator array individually moving the at least some microneedles through the defining plate to extend different distances from the bottom surface thereof, thereby providing a desired surface contour to the master mold; (c) preparing a negative mold having a negative surface contour that is the reverse of the desired surface contour of the positive master mold by shaping a curable gel or thermoplastic material against the bottom surface of the defining plate having the adjusted microneedles; (d) preparing a microneedle array having a surface contour that is the reverse of the negative surface contour of the negative mold by shaping a dissolvable polymer against the negative mold; and (e) drying the microneedle array. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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Specification