Microneedle Array, Molding for Manufacturing a Microneedle Array, and Method for Manufacturing a Microneedle Array

Abstract

A microneedle array has a plurality of microneedles, said microneedles being supported by a substrate. In order to improve the properties of the microneedle array, the substrate is in the form of a grid structure or comprises a grid structure.

Claims

1. A microneedle array, comprising: a plurality of microneedles; and a support layer supporting the plurality of microneedles, wherein the support layer is formed as a grid structure or comprises a grid structure.

2. The microneedle array according to claim 1, wherein the grid structure connects the plurality of microneedles with each other.

3. The microneedle array according to claim 1, wherein the grid structure has a plurality of crossing points which are at least partially connected with the plurality of microneedles.

4. The microneedle array according to claim 1, wherein a plurality of bars of the grid structure are perpendicular to each other.

5. The microneedle array according to claim 1, wherein a material forming the plurality of microneedles surrounds at least one crossing point of a prefabricated grid structure.

6. The microneedle array according to claim 1, wherein the grid structure is prefabricated.

7. The microneedle array according to claim 1, wherein the grid structure is produced by linearly applying a material that essentially comprises PVP.

8. The microneedle array according to claim 1, wherein the grid structure has a plurality of fibers which are essentially made from textiles.

9. The microneedle array according to claim 1, wherein the grid structure is produced by a material forming the plurality of microneedles.

10. A molding for manufacturing a microneedle array, comprising: a base body having a plurality of depressions, wherein a plurality of channels are provided for forming a grid structure on an upper side of the base body.

11. The molding according to claim 10, wherein at least one of the plurality of depressions is connected with one of the plurality of channels.

12. The molding according to claim 10, wherein at least one of the plurality of depressions is connected with at least one of the plurality of channels.

13. The molding according to claim 10, wherein at least one of the plurality of channels connects its neighboring plurality of depressions with each other.

14. A method for manufacturing a microneedle array, the method comprising: metering one or several materials into depressions of a molding; and linearly applying a material to an upper side of the molding in order to form a grid structure.

15. The method according to claim 14, wherein linearly applying the material is realized such that at least a part of one line crosses the depressions provided in the molding.

16. The method according to claim 14, wherein linearly applying the material is realized such that at least a part of one nodal point formed by the grid structure is arranged in the area of the depressions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In the drawings:

[0028] FIG. 1 shows a schematic plan view of a microneedle array according to a first preferred embodiment,

[0029] FIG. 2 shows a schematic plan view of a microneedle array according to a second preferred embodiment,

[0030] FIG. 3 shows a schematic sectional view of a microneedle in longitudinal direction,

[0031] FIG. 4 shows a schematic plan view of a microneedle array according to a third preferred embodiment,

[0032] FIG. 5 shows a schematic plan view of a microneedle array according to a fourth preferred embodiment, and

[0033] FIG. 6 and FIG. 7 show schematic sectional views of dies for manufacturing microneedle arrays according to the invention.

DETAILED DESCRIPTION

[0034] In the drawings, different embodiments of microneedle arrays are shown schematically. For convenience, the microneedles 10 are illustrated as squares.

[0035] In the exemplary embodiment shown in FIG. 1, a grid structure with bars 12, 14 is formed. The bars 12, 14 forming the grid structure are arranged perpendicular to each other. Here, the bars are arranged such that a part of the crossing points 16 is arranged above the microneedles 10. Further crossing points 18 are respectively arranged between the microneedles 10.

[0036] As can be seen in FIG. 2, the bars can of course also have a width that is slightly larger than the base area of the microneedles 10.

[0037] The microneedles 10 are preferably pyramidal and in particular have a rectangular, preferably square cross-section. The depressions of the die are correspondingly formed.

[0038] In the sectional view shown in FIG. 3, a microneedle 10 is shown. The microneedle is made in a lower area 20 forming the tip of the needle by a material comprising in particular the active ingredient. In particular, the needle tip can also be formed with multiple layers, wherein in particular different materials are metered successively. Moreover, a bar 12 of a grid structure is shown. A further material 22 is provided for connecting the needle tip 20 with the bar 12 of the grid structure. Said material encloses the bar 12 in the area of the upper side of the needle 10 in a drop shape.

[0039] Similar grid structures are shown in FIGS. 4 and 5, wherein said grid structures are arranged such that the microneedles are located in the spaces of the grid structure. In this respect, these are grid structures that are embedded or inserted in a support layer, respectively. Furthermore, said grid structures can also be made of a different material.

[0040] When filling individual cavities to form the microneedles, it is also possible to provide in particular the further material 22 in such a quantity that the material of adjacent areas flows together or joins together, respectively. Thus, a gird structure is formed.

[0041] Alternatively, a material can be linearly applied to the upper side 26 of the base body or the die 28, respectively, in order to form a grid structure, wherein this is preferably realized such that the lines cross above the cavities or depressions 24, respectively.

[0042] FIG. 6 and FIG. 7 show schematically simplified illustrations of possible configurations of dies.

[0043] In the simple configuration shown in FIG. 6, pyramidal depressions 24 are provided which, from an even surface 26 of the die, extend inwards or, in FIG. 6, downwards, respectively. The microneedles 10 are produced by filling the cavities 24. In particular, by filling with a further material 22 (compare FIG. 3), a grid structure can be produced by bonding material of neighboring cavities together on the upper side 26 of the die 28.

[0044] Additionally or alternatively, a prefabricated grid structure may be arranged on the upper side 26.

[0045] In another embodiment of a die 30 (FIG. 7), in addition to the cavities 24 provided in the die 30 for forming the microneedles 10, depressions 34 are formed in an upper side 32 of the die. Said depressions 34 are formed to be linear or channel-shaped and connect neighboring cavities 24 with each other. By filling the depressions 34, in particular with a further material 22, a grid structure can be produced in a simple manner. If necessary, a prefabricated grid structure can be inserted into the channel-shaped depressions 34 for stiffening while improving the structure and quality, the grid structure being then at least partially enclosed by the further material 22.