Patch production
Inventors
Chen, Xianfeng • Kendall, Mark Anthony Fernance • Prow, Tarl • Raphael, Anthony Paul
Assignees
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Publication Number
US-8734697-B2
Publication Date
2014-05-27
Expiration Date
Abstract
A method for use in producing a patch having a number of projections thereon. The method includes providing a distribution member and filling material on a mold surface, the mold including a number of cavities extending from the mold surface for defining the patch projections, filling the cavities with filling material, at least in part by urging filling material from the distribution member into the cavities, causing the filling material to solidify and separating the solidified filling material and the mold to thereby form the patch.
Core Innovation
The invention relates to a method for producing a patch having a number of projections thereon by forming the projections through mold casting. The method provides a distribution member and filling material on a mold surface of a mold, where the mold includes a number of cavities extending from the mold surface for defining the patch projections. The distribution member evenly disperses filling material across the mold surface so that the filling material evenly fills the mold.
The method fills the cavities with filling material at least in part by urging filling material from the distribution member into the cavities, and then causes the filling material to solidify. After solidification, the solidified filling material is separated from the mold to thereby form the patch. The approach is framed to support micro-scale, multilayer projections and scalable manufacture using mold configurations that include female mold and arrays.
The invention also covers producing projection patches with multiple materials through staged filling and solidification. In one approach, first filling material is applied to partially fill the cavities and solidified, followed by providing second filling material on the mold surface, filling the cavities with the second filling material, and solidifying again before separating the solidified filling material and the mold.
Claims Coverage
The partial content identifies two independent claims (clm-00001 and clm-00028). Both independently cover methods of producing a patch with projections using a mold with cavities and solidifying filling material, with clm-00028 specifically requiring sequential first then second filling and solidification in the cavities.
Evenly dispersing filling material with a distribution member across the mold surface
The method provides a distribution member and filling material on a mold surface of a mold, wherein the distribution member evenly disperses filling material across the mold surface so that the filling material evenly fills the mold.
Urging evenly dispersed filling material into mold cavities using the distribution member
The method fills the cavities with filling material, at least in part by urging filling material from the distribution member into the cavities.
Solidifying the cavity-filled filling material and separating to form the patch projections
The method causes the filling material to solidify and separates the solidified filling material and the mold to thereby form the patch.
Sequential cavity filling with a first filling material and solidification
The method provides a first filling material on a mold surface, partially fills the cavities with first filling material, and causes the first filling material to solidify.
Sequential cavity filling with a second filling material and solidification
The method provides a second filling material on the mold surface, fills the cavities with second filling material, and causes the second filling material to solidify.
Separating the solidified filling material and the mold to form the patch
The method separates the solidified filling material and the mold to thereby form the patch after the solidifying steps.
Across the identified independent claims, the core claim coverage is directed to producing a projection patch from a mold with cavities by distributing and urging filling material into the cavities and then solidifying and separating the molded material. The second independent claim further requires a staged sequence in which first filling material partially fills and solidifies before applying and solidifying second filling material, followed by separation to form the patch.
Stated Advantages
Scalable manufacturing of the patch with projections.
Reduced payload wastage, including for micron-scale multilayer projections.
Compatibility with temperature-sensitive bioactives.
Controllable payload delivery to skin strata.
Documented vaccination outcomes in vivo including reduced antigen dose.
Documented Applications
Vaccine delivery, including delivery of ovalbumin and influenza vaccine, with in-vivo vaccination results and ELISPOT/ELISA readouts referenced in the partial content.
Microneedle/needle patch penetration and mapping in mouse ear skin, with penetration depth and microscopy data referenced in the partial content.
Bioactive payload delivery to skin strata, including stratum corneum, viable epidermis, and dermis, as discussed in the partial content.
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