Microneedle-array manufacturing apparatus, microneedle-array manufacturing method, and product having the microneedle array
Inventors
Yamada, Shinya • CHIYAMA, Masateru • Akita, Kensaku • Ueno, Takako • IDE, Yuko • NAGAI, Sachi • AKAO, Osanobu • Ono, Ichiro • Takada, Kanji
Assignees
Interested in licensing this patent?
MTEC can help explore whether this patent might be available for licensing for your application.
Publication Number
US-10639823-B2
Publication Date
2020-05-05
Expiration Date
Abstract
A product having a microneedle array is provided wherein the composition distribution has been adjusted with good accuracy. A droplet-delivery apparatus of a microneedle-array manufacturing apparatus is configured capable of delivering, to each recessed part, droplets of a raw-material liquid in a prescribed amount that is less than the capacity of the recessed part. An aligning apparatus can align the relative position of the droplet-delivery apparatus and a mold such that the droplets from the droplet-delivery apparatus are caused to land in each of the recessed parts. The droplet-delivery apparatus delivers a plurality of the droplets to each of the recessed parts; and the aligning apparatus aligns the relative position of the droplet-delivery apparatus and the mold such that a second droplet lands in each of the recessed parts on the center part side of a first droplet.
Core Innovation
A microneedle-array manufacturing method reads alignment marks on a surface of a mold and identifies positions of a plurality of first recessed parts of the mold. Based on the identified positions, the method adjusts an angle formed by a first direction in which the recessed parts are disposed in an array and a second direction in which nozzles are disposed in an array that is inclined relative to the first direction. The adjustment is performed by rotating the mold around a center axis of a stage, where the center axis extends in a vertical direction perpendicular to the first and second directions.
The method performs a first filling step in which the recessed parts are filled with a first raw-material liquid by causing at least one nozzle to deliver a plurality of droplets. Each droplet is delivered in an amount that is less than the capacity of the first recessed part so that the droplets land in the recessed parts such that a second droplet lands on a center part side of a first droplet. After the filling, a drying step dries the first raw-material liquid of the recessed parts, thereby forming a microneedle array comprising a plurality of microneedles.
In implementations, positions of recessed parts can be determined for a matrix along a first direction and an intersecting direction, with the angle adjustment performed relative to the first direction and the intersecting direction. The nozzles can be operated so that at least two nozzles simultaneously deliver droplets into at least two recessed parts, while maintaining a droplet amount less than the capacity of each recessed part so droplets land to place a second droplet on a center part side of a first droplet.
In further implementations, a microneedle-array manufacturing method arranges a plurality of molds including a first mold and an independent adjacent second mold and simultaneously fills recessed parts of both molds with the first raw-material liquid using droplet amounts less than each recessed part's capacity.
Claims Coverage
The document provides three independent microneedle-array manufacturing methods that share the same core workflow: reading alignment marks, identifying recessed-part positions, adjusting nozzle inclination by rotating the mold or molds around a center axis, sub-capacity droplet filling so a later droplet lands on a center part side of an earlier droplet, and drying to form microneedles.
Alignment marks-based recessed-part positioning with nozzle-angle adjustment
Reading alignment marks on a surface of a mold; identifying positions of a plurality of first recessed parts of the mold by using the alignment marks; adjusting an angle formed by a first direction and a second direction, by rotating, based on the positions of the plurality of first recessed parts, the mold around a center axis of a stage on which the mold is disposed.
Sub-capacity droplet filling with center-side landing of a second droplet
A first filling step in which the plurality of first recessed parts are filled with a first raw-material liquid by causing at least one of the plurality of nozzles to deliver a plurality of droplets in an amount that is less than the capacity of the first recessed part such that a second droplet lands in each recessed part on a center part side of a first droplet; and a drying step in which the first raw-material liquid is dried thereby forming a microneedle array comprising a plurality of microneedles.
Adjacent independent molds with simultaneous sub-capacity filling
Arranging a plurality of molds including at least a first mold and a second mold that is independent of and separate from the first mold on a stage such that the first mold and the second mold are adjacent; reading alignment marks on surfaces of the first and second molds; identifying positions of the plurality of first recessed parts of the first and second molds by using the alignment marks; adjusting an angle by rotating the first and second molds around a center axis of the stage; a first filling step in which recessed parts of the first and second molds are simultaneously filled with a first raw-material liquid by causing a plurality of droplets in an amount less than the capacity of the first recessed part such that a second droplet lands on a center part side of a first droplet in each recessed part; and a drying step in which the first raw-material liquid is dried thereby forming a microneedle array.
Matrix-arranged recessed parts with simultaneous multi-nozzle delivery
Reading alignment marks on a surface of a mold; identifying positions of a plurality of first recessed parts disposed in a matrix along a first direction and an intersecting direction; adjusting an angle formed by the first direction and a second direction along which nozzles are disposed in an array and which is inclined relative to the first and intersecting directions, by rotating the mold around a center axis of a stage; a first filling step in which the plurality of first recessed parts are filled by simultaneously at least two nozzles delivering droplets of the first raw-material liquid in an amount less than the capacity of the first recessed part such that a second droplet lands in each recessed part on a center part side of a first droplet; and a drying step in which the first raw-material liquid is dried thereby forming a microneedle array.
Across the independent claims, the inventive coverage centers on reading alignment marks to identify recessed-part positions, adjusting the nozzle inclination by rotating the mold or molds around a vertical center axis based on those positions, and performing droplet filling with an amount less than each recessed part's capacity so that a second droplet lands on a center part side of a first droplet, followed by drying to form microneedles.
Stated Advantages
Not explicitly described in patent.
Documented Applications
Not explicitly described in patent.
Interested in licensing this patent?