U.S. patent application number 10/192474 was filed with the patent office on 2002-12-05 for microdevice and method of manufacturing a microdevice.
Invention is credited to Evans, John D., Lastovich, Alexander G., Pettis, Ronald J..
Application Number | 20020183688 10/192474 |
Document ID | / |
Family ID | 24470876 |
Filed Date | 2002-12-05 |
United States Patent
Application |
20020183688 |
Kind Code |
A1 |
Lastovich, Alexander G. ; et
al. |
December 5, 2002 |
Microdevice and method of manufacturing a microdevice
Abstract
A device for monitoring, sampling or delivering a substance
though the skin of a patient includes a support and a microdevice
having at least one skin penetrating member. The support has a
substantially flat bottom surface with the skin penetrating member
extending beyond the bottom surface. An outlet port extends through
the support to the bottom surface at a location between the skin
penetrating member and the outer edge of the support for drawing a
vacuum to enhance penetration of the skin. The device is produced
by positioning the microdevice in a recess formed in the support
and applying a bonding agent to wick into a gap formed between the
microdevice and the wall of the recess.
Inventors: |
Lastovich, Alexander G.;
(Raleigh, NC) ; Evans, John D.; (Marina del Rey,
CA) ; Pettis, Ronald J.; (Durham, NC) |
Correspondence
Address: |
BECTON, DICKINSON AND COMPANY
1 BECTON DRIVE
FRANKLIN LAKES
NJ
07417-1880
US
|
Family ID: |
24470876 |
Appl. No.: |
10/192474 |
Filed: |
July 10, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10192474 |
Jul 10, 2002 |
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09616771 |
Jul 14, 2000 |
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6440096 |
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Current U.S.
Class: |
604/27 |
Current CPC
Class: |
A61M 37/0015 20130101;
A61B 5/150022 20130101; A61B 5/15142 20130101; A61M 2037/003
20130101; A61B 17/205 20130101; A61B 5/150099 20130101; A61M
2037/0038 20130101; A61B 5/150984 20130101; A61B 5/14514 20130101;
A61M 2037/0023 20130101 |
Class at
Publication: |
604/27 |
International
Class: |
A61M 001/00 |
Claims
What is claimed is:
1. A method of forming a microdevice for delivering or withdrawing
a substance through the skin of a patient, comprising the steps of:
providing a support having a bottom face with a recessed area
having a dimension less than a dimension of said bottom face,
positioning a skin penetrating device in said recessed area of said
support, said skin penetrating device having a base and at least
one skin penetrating member, said base having a dimension less than
said dimension of said recessed area, and applying a bonding amount
of a bonding agent to at least one location between said support
and said base in said recessed area, said bonding agent having a
viscosity to wick between said base and said support.
2. The method of claim 1, wherein said base is a silicon wafer and
said skin penetrating member is a microneedle array.
3. The method of claim 1, wherein said base has a thickness of
about 250 microns.
4. The method of claim 1, wherein said recessed area has a depth
equal to or less than a thickness of said base.
5. The method of claim 1, wherein said recessed area has a bottom
surface parallel with said bottom face of said support and a side
face extending between said bottom face of said support and said
bottom surface of said recess, said method comprising positioning
said skin penetrating device on said bottom surface.
6. The method of claim 5, wherein said side face of said recessed
area is substantially perpendicular to said bottom face of said
support.
7. The method of claim 5, wherein said recessed area is dimensioned
to define a gap between said side face and said base of said skin
penetrating member, and said method comprises applying said bonding
agent to said gap.
8. The method of claim 1, wherein said support includes at least
one channel communicating with said recessed area, said method
comprising applying said bonding agent to said channel whereby said
bonding agent flows into said recessed area.
9. The method of claim 8, wherein said at least one channel is an
open channel on said bottom face of said support.
10. The method of claim 8, wherein said at least one channel has a
first end connected to said recessed area and a second end
connected to a reservoir formed in said support, said method
comprising applying said bonding agent to said reservoir whereby
said bonding agent flows through said at least one channel to said
recessed area.
11. The method of claim 1, wherein said support has a cavity
communicating with said recessed area.
12. The method of claim 11, wherein said support includes an
opening extending from a top face to said cavity.
13. The method of claim 10, wherein said support has at least one
port communicating with said bottom face, said at least one port
being spaced from said recessed area.
14. The method of claim 1, wherein said base of said penetrating
device is a silicon wafer and said at least one skin penetrating
member is an array of microneedles.
15. The method of claim 1, wherein said skin penetrating device
includes at least one passage extending through said base and being
in communication with said at least one skin penetrating
member.
16. A method of withdrawing a substance or delivering a substance
through the skin of a patient, said method comprising providing a
support having a central passage, a bottom face, a one skin
penetrating device on said bottom face, said central passage being
in communication with said skin penetrating device, positioning
said support on the skin of a patient with said bottom face of said
support and said at least one skin penetrating device contacting
said skin, reducing the pressure in an area between said support
and said skin to draw said skin toward said skin penetrating member
and to cause said skin penetrating device to penetrate said skin,
and withdrawing or delivering a substance through the skin of said
patient.
17. The method of claim 16, wherein said bottom face of said
support includes a recessed area having a dimension less than a
dimension of said bottom face, and wherein said skin penetrating
device includes a base fitted in said recessed area and coupled to
said support.
18. The method of claim 16, wherein said support has an outer edge
spaced from and surrounding said at least one skin penetrating
member and an annular flange coupled to said outer edge and
extending away from said support.
19. The method of claim 18, wherein said support further includes
an outlet port communicating with said bottom face of said support
between said annular flange and said skin penetrating member, and
said method comprises applying a vacuum source to said outlet port
to reduce the pressure between said support and said skin.
20. The method of claim 16, wherein said skin penetrating device
includes an axial passage in communication with said central
passage of said support.
21. The method of claim 16, wherein said at least one skin
penetrating device comprises an array of skin penetrating members,
said skin penetrating members being selected from the group
consisting of microtubes, microneedles, cannulas, blades and
lancets.
22. The method of claim 16, wherein said support includes a fluid
coupling communicating with said central passage, said method
comprising withdrawing or supplying a substance through said fluid
coupling to said central passage.
23. The method of claim 19, comprising coupling a vacuum source to
said outlet port and drawing a vacuum through said coupling.
24. A device for delivering or withdrawing a substance from a
patient, said device comprising: a support member having a bottom
face and a recessed area having a dimension less than a dimension
of said bottom face, a skin penetrating device having a base and at
least one skin penetrating member, said base being positioned
within said recessed area of said support, and a bonding material
attaching said skin penetrating device to said support member and
filling a space between said recessed area and said base of said
skin penetrating device.
25. The device of claim 24, wherein said base is a silicon wafer
and said skin penetrating member is a microneedle array.
26. The device of claim 24, wherein said base has a thickness of
about 250 microns.
27. The device of claim 24, wherein said recessed area has a bottom
surface parallel with said bottom face of said support and a side
face extending between said bottom face of said support and said
bottom surface of said recess.
28. The device of claim 27, wherein said side face of said recessed
area is substantially perpendicular to said bottom face of said
support.
29. The device of claim 24, wherein said support includes at least
one channel communicating with said recessed area for directing
said bonding material into said recessed area.
30. The device of claim 29, wherein said at least one channel is an
open channel on said bottom face of said support.
31. The device of claim 24, wherein said support has at least one
port communicating with said bottom face of said support between an
outer edge of said support and said skin penetrating device.
32. The device of claim 24, wherein said skin penetrating device
includes at least one passage extending through said base and being
in communication with said at least one skin penetrating
member.
33. The device of claim 32, wherein said support includes a port
and a central passage communicating with said skin penetrating
device for delivering or withdrawing a fluid through said
device.
34. The device of claim 24, wherein said support has an outer edge
spaced from and surrounding said skin penetrating device and a
flange extending from said outer edge away from said bottom face of
said support.
35. The device of claim 34, wherein said flange is dimensioned to
contact the skin of a patient and wherein said flange includes a
friction enhancing member.
36. The device of claim 35, wherein said friction enhancing member
is a ridge.
37. The device of claim 35, wherein said friction enhancing member
is a tacky material.
38. The device of claim 34, wherein said support further comprises
a port communicating with said bottom face of said support between
said flange and said skin penetrating device, and an outlet
coupling communicating with said port.
39. A device for delivering or withdrawing a substance from a
patient, said device comprising: a support member having a bottom
face, an outer edge, and a recessed area having a dimension less
than a dimension of said bottom face, said support having at least
one passage communicating with said bottom face between said
recessed area and said outer edge, a skin penetrating device having
a base and at least one skin penetrating member, said base being
positioned within said recessed area and coupled to said
support.
40. The device of claim 39, wherein said support includes a port
and a central passage communicating with said skin penetrating
device for delivering or withdrawing a fluid through said
device.
41. The device of claim 40, further comprising a flange on said
outer edge extending away from said bottom face.
42. The device of claim 41, wherein said flange is dimensioned to
contact the skin of a patient and includes a friction enhancing
member.
43. The device of claim 41, wherein said skin penetrating member is
a microneedle array.
44. A method of forming a microdevice, comprising the steps of:
providing a support having a bottom face with a recessed area
having a dimension less than a dimension of said bottom face and at
least one channel with said recessed area, positioning a
microdevice in said recessed area of said support, said microdevice
having a base with a dimension less than said dimension of said
recessed area, and applying a bonding amount of a bonding agent to
said channel, said bonding agent having a viscosity to wick along
said channel and between said base and said support.
45. The method of claim 44, wherein said at least one channel is an
open channel on said bottom face of said support.
46. The method of claim 45, wherein said at least one channel has a
first end connected to said recessed area and a second end
connected to a reservoir formed in said support, said method
comprising applying said bonding agent to said reservoir whereby
said bonding agent flows through said at least one channel to said
recessed area.
Description
[0001] This Application is a Continuation of application Ser. No.
09/616,771 filed Jul. 14, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates to a microdevice and to a
method of manufacturing the microdevice. The invention is further
directed to a method and device for withdrawing or delivering a
substance transdermally to a patient. The invention is also
directed to a method and apparatus for enhancing the penetration of
a microneedle array.
BACKGROUND OF THE INVENTION
[0003] Various devices have been proposed for sampling and
delivering of substances such as pharmaceutical agents and drugs
transdermally. Although the subcutaneous sampling and delivery
methods using a cannula are effective for many applications, the
pain normally induced by the cannula has prompted the development
of less painful delivery methods.
[0004] The skin is made up of several layers with the upper
composite layer being the epithelial layer. The outermost layer of
the skin is the stratum corneum that has well known barrier
properties to prevent molecules and various substances from
entering the body and analytes from exiting the body. The stratum
corneum is a complex structure of compacted keratinized cell
remnants having a thickness of about 10-30 microns. The stratum
corneum forms a waterproof membrane to protect the body from
invasion by various substances and the outward migration of various
compounds.
[0005] The natural impermeability of the stratum corneum prevents
the administration of most pharmaceutical agents and other
substances through the skin. Numerous methods and devices have been
proposed to enhance the permeability of the skin and to increase
the diffusion of various drugs through the skin to can be utilized
by the body. Typically, the delivery of drugs through the skin is
enhanced by either increasing the permeability of the skin or
increasing the force or energy used to direct the drug through the
skin.
[0006] Another method of sampling and delivering various substances
through the skin is by forming micropores or cuts through the
stratum corneum. By piercing the stratum corneum and delivering a
drug to the skin in or below the stratum corneum, many drugs can be
effectively administered. In a similar manner, some substances can
be extracted from the body through cuts or pores formed in the
stratum corneum. The devices for piercing the stratum corneum
generally include a plurality of micron size needles or blades
having a length to pierce the stratum corneum without passing
completely through the epidermis. Examples of these devices are
disclosed in U.S. Pat. No. 5,879,326 to Godshall et al.; U.S. Pat.
No. 5,250,023 to Lee et al., and WO 97/48440.
[0007] The above-noted devices that include micron-sized needles or
blades can be effective in delivering or sampling of substances in
the body. However, these needles and blades having a length a few
microns to a few hundred microns typically do not penetrate skin to
a uniform depth. The natural elasticity and resilience of the skin
will often result in the skin being deformed by the needles rather
than pierced. A microneedle array when pressed against the skin
often results in the outermost needles penetrating the skin while
the innermost needles do not penetrate or only penetrate to depth
less than the outermost needles.
[0008] The prior methods and devices for the transdermal sampling
and administration of substances have exhibited limited success.
Accordingly, a continuing need exists in the industry for an
improved device for the sampling and administration of various
drugs and other substances to the body.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a method and apparatus
for the transdermal sampling or delivery of a substance though the
skin of a patient. The invention is further directed to a method of
manufacturing and assembling a device for delivering or withdrawing
a substance through the skin of a patient. In particular, the
invention is directed to a method and apparatus for delivering a
pharmaceutical agent such as a drug or vaccine, to the stratum
corneum of the skin to a sufficient depth where the pharmaceutical
agent can be absorbed and utilized by the body.
[0010] Accordingly, a primary object of the invention is to provide
a device having a skin penetrating member and to a method of
penetrating the skin for sampling or delivering a substance through
the skin substantially without pain to the patient.
[0011] Another object of the invention is to provide a device
having a plurality of microtubes, needles, microneedles, blades or
lancets for piercing the stratum corneum of the skin for
withdrawing or delivering a substance though the skin of a
patient.
[0012] A further object of the invention is to provide a device
having at least one skin penetrating member and a device for
enhancing the penetration of the skin.
[0013] Another object of the invention is to provide a device for
sampling or delivering a substance to a patient where the device
has a support and a microneedle device bonded to the support.
[0014] A further object of the invention is to provide a device for
withdrawing or delivering a substance where the device includes a
skin penetrating device and a vacuum port for applying a vacuum to
enhance penetration of the skin by the skin penetrating device.
[0015] A still further object of the invention is to provide a
method for enhancing skin penetration by a skin penetrating device
in a target area by applying a vacuum to the surface of the target
area and the skin penetrating device.
[0016] Another object of the invention is to provide a method of
assembling a device comprising fitting a microdevice into a
recessed area in a support and applying a bonding agent to the
recess to wick between the microdevice and the support.
[0017] Still another object of the invention is to provide a method
of bonding a microdevice to a support, where the support includes a
recessed area and a channel having one end communicating with the
channel, the method comprising fitting the microdevice in the
recessed area and applying a bonding agent to the channel to flow
into a gap between the support and the microdevice.
[0018] These and other objects of the invention are substantially
attained by providing a method for forming a device for delivering
or withdrawing a substance through the skin of a patient. The
method comprises the steps of: providing a support having a bottom
face with a recessed area having a dimension less than a dimension
of said bottom face, positioning a skin penetrating device in said
recessed area of said support. The skin penetrating device has a
base and at least one skin penetrating member, the base has a
dimension less than said dimension of said recessed area. A bonding
agent is applied to at least one location between said support and
said base in said recessed area, where the bonding agent has a
viscosity to wick between the base and the support.
[0019] The objects and advantages of the invention are further
attained by providing a method of withdrawing a substance or
delivering a substance through the skin of a patient, said method
comprising providing a support having a central passage, a bottom
face, and a skin penetrating device on said bottom face, said
central passage being in communication with said skin penetrating
device, positioning said support on the skin of a patient with said
bottom face of said support and said skin penetrating device
contacting said skin, reducing the pressure in an area between said
support and said skin to draw said skin toward said skin
penetrating device and to cause said skin penetrating device to
penetrate said skin, and withdrawing or delivering a substance
through the skin of said patient.
[0020] Another object of the invention is to provide a device for
delivering or withdrawing a substance from a patient, said device
comprising: a support member having a bottom face and a recessed
area having a dimension less than a dimension of said bottom face,
a skin penetrating device having a base and at least one skin
penetrating member, said base being positioned within said recessed
area of said support, and a bonding material attaching said skin
penetrating device to said support member and filling a space
between said recessed area and said base of said skin penetrating
device.
[0021] The objects, advantages and other salient features of the
invention will become apparent from the following detailed
description which, taken in conjunction with the annexed drawings,
discloses preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The following is a brief description of the drawings in
which:
[0023] FIG. 1 is a perspective view of the sampling or delivery
device in accordance with a first embodiment of the invention;
[0024] FIG. 2 is an exploded cross-sectional view of the device of
FIG. 1;
[0025] FIG. 3 is a bottom view of the device of FIG. 1 showing the
support without the skin penetrating members;
[0026] FIG. 4 is a bottom view of the device of FIG. 1 showing the
skin penetrating member bonded to the support;
[0027] FIG. 5 is partial side elevational view in cross-section of
the support and the skin penetrating member fitted in the recess of
the support before bonding;
[0028] FIG. 6 is a partial side elevational view in cross-section
of the device showing the bonding agent for attaching the skin
penetrating device to the support;
[0029] FIG. 7 is a side view showing the device in contact with the
skin of a patient;
[0030] FIG. 8 is a side view of the device in a second
embodiment;
[0031] FIG. 9 is a perspective view of the device of the embodiment
of FIG. 8 showing the bottom side and the recess for receiving the
skin-penetrating device;
[0032] FIG. 10 is a bottom view of the device of FIG. 8 showing the
skin penetrating members;
[0033] FIG. 11 is a cross sectional side view of the device of FIG.
8 in contact with the skin of a patient; and
[0034] FIG. 12 is a cross sectional side view of FIG. 8 showing the
penetration of skin when a vacuum is applied to the inner area of
the device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] The present invention is directed to an intradermal device
for sampling, monitoring or delivering a substance through the skin
of a patient. More particularly, the invention is directed to a
sampling, monitoring or delivery device and to a method for
sampling or administering a substance into or below the stratum
corneum of the skin of a patient. The invention is further directed
to a method of manufacturing the sampling, monitoring or delivery
device.
[0036] As used herein, the term penetrate refers to entering a
layer of the skin without passing completely through. Piercing
refers to passing completely through a layer of the skin.
[0037] The device and method in one embodiment of the present
invention are suitable for use in administering various substances,
including pharmaceutical agents, to a patient, and particularly to
a human patient. As used herein, a pharmaceutical agent includes a
substance having biological activity that can be delivered through
the body membranes and surfaces, and particularly the skin.
Examples include antibiotics, antiviral agents, analgesics,
anesthetics, anorexics, antiarthritics, antidepressants,
antihistamines, antiinflammatory agents, antineoplastic agents,
vaccines, including DNA vaccines, and the like. Other substances
that can be delivered intradermally to a patient include proteins,
peptides and fragments thereof. The proteins and peptides can be
naturally occurring, synthesized or recombinantly produced.
[0038] The device and method are also suitable for withdrawing a
substance or monitoring the level of a substance in the body.
Examples of substances that can be monitored or withdrawn include
blood, interstitial fluid or plasma that can then be analyzed for
analytes, glucose, drugs and the like.
[0039] Referring to the drawings, the invention is directed to a
device 10, having a support 12 and a microdevice 14. The device 10
can be a monitoring device for monitoring a substance level in the
body, a sampling device for withdrawing a sample from the body, or
a delivery device for delivering a substance to the body.
[0040] Referring to FIGS. 1-7, support 12 in this embodiment has a
base 16 with a generally circular configuration. In further
embodiments, base 16 can have a non-circular configuration
depending on the intended use of the device. Base 16 includes a top
face 18 and a bottom face 20 and a central passage 22. As shown in
FIG. 2, central passage 22 extends completely through support 12 to
form a cavity within support 12.
[0041] A collar 24 extends from top face 18 and defines central
passage 22. Collar 24 includes a top end 26, defining an inlet
opening 28 to central passage 22. A flange 30 extends radially
outward from top end 26 of collar 24 to form a threaded coupling
member. In the embodiment of FIG. 1, the flange 30 and collar 24
form a female Luer-type fitting. Alternatively, collar 24 can be
dimensioned for coupling with a catheter tubing, pump, syringe or
other liquid interface.
[0042] Bottom face 20 of support 12 is substantially flat, as shown
in FIG. 2. A recessed area 32 is formed in bottom face 20 and is in
communication with central passage 22. Referring to FIGS. 2 and 3,
recessed area 32 is shown as having a generally square
configuration and includes a side face 34 and a bottom face 36.
Side face 34 in the embodiment illustrated is substantially
perpendicular to bottom face 20 of support 12. Bottom face 36 of
recessed area 32 is generally perpendicular to side face 34.
Generally, bottom face 36 of recessed area is parallel with bottom
face 20. In alternative embodiments, recessed area 32 and
microdevice 14 can have other shapes such as, for example, round or
oblong. Side face 34 can be inclined inwardly or outwardly with
respect to bottom face 20 of support 12.
[0043] Referring to FIG. 3, an open channel 38 formed in bottom
face 20 extends outward from recessed area 32 toward an outer edge
42 of support 12. In the embodiment illustrated, two channels 38
extend from opposite corners of recessed area 32 to circular
recesses 40. In an alternative embodiment, channels 38 can extend
completely to outer edge 42 of bottom face 20 or omitted
entirely.
[0044] Microdevice 14 in the illustrated embodiments of the
invention is a penetrating device suitable for use in monitoring,
sampling or delivering a substance though the skin of a patient. In
preferred embodiments, microdevice 14 includes a plurality of skin
penetrating members 44 extending outwardly from a base 46. As used
herein, the term skin penetrating member refers to a member that is
able to pierce or penetrate the skin to a desired depth. Skin
penetrating members 44 are shown as microneedles having a
substantially square cross-sectional shape and a beveled tip 48. An
axial passage 50 extends through each skin penetrating member 44
and base 46 so that axial passage 50 extends from the top face 52
to beveled tip 48. As shown in FIG. 4, skin penetrating members 44
are arranged in an array of substantially uniformly spaced apart
rows and columns. The spacing between the rows and columns can be
varied depending on the substance being delivered or withdrawn and
the area of the skin contacted with the device. When the skin
penetrating devices are microneedles, the microneedles are spaced
apart about 0.05 mm to about 5 mm.
[0045] Base 46 of microdevice 14 is dimensioned to fit within
recessed area 32 as shown in FIGS. 4 and 5. In a preferred
embodiment of the invention, side face 34 of recessed area 32 has a
height to define a depth of recessed area 32 that is less than a
thickness of base 46 of microdevice 14. As shown in FIGS. 5 and 6,
recessed area 32 has a depth approximately one-half the thickness
of base 46. In an alternative embodiment, recessed area 32 can have
a depth substantially equal to the thickness of base 46. In one
embodiment of the invention, base 46 has a thickness of about 250
microns.
[0046] In one embodiment of the invention, base 46 of microdevice
14 has a length and width slightly less than the length and width
of recessed area 32 to define a gap 54 between a side edge 56 of
base 46 and side face 34 of recessed area 32 as shown in FIG. 5. In
further embodiments, base 46 has an outer dimension substantially
equal to the dimension of recessed area 32. Device 10 is assembled
by positioning microdevice 14 in recessed area 32 with a
substantially uniform gap 54 formed around the perimeter of base
46. Top face 52 of base 46 preferably rests against bottom face 36
of recessed area 32 as shown in FIG. 5. In the embodiment of FIGS.
1-6, an adhesive is applied to recess 40 at the end of channel 38.
The adhesive preferably has a sufficiently low viscosity to flow
along channel 38 and wick into gap 54 by the surface tension of the
adhesive. The adhesive fills gap 54 and surrounds base 46 to attach
base 46 to support 12 and form a substantially fluid tight
seal.
[0047] It has been found that the adhesive wicks between bottom
face 36 of recessed area 32 and top face 52 of base 46 as shown in
FIG. 6 without the need to apply a force to the adhesive. The
adhesive 58 flows along top face 52 of base 46 into central passage
22 of support 12. The surface tension of adhesive 58 fills an area
between a vertical side wall 60 in central passage 22 and top face
52 of base 46. The adhesive flows along the surfaces of wall 60 and
top surface 52 until adhesive 58 attains a radius of curvature 62
within central passage 22 substantially equal to a radius of
curvature 64 of adhesive in gap 54. Therefore, to prevent adhesive
58 from flowing into axial passage 50 of skin penetrating members
44, the space 66 between side wall 60 in central passage 22 and the
innermost edge of axial passage 50 is greater than the width 68 of
gap 54. Adhesive 58 can be any suitable adhesive as know in the art
capable of bonding the materials together. In a preferred
embodiment of the invention, the adhesive is a UV curable
accelerated adhesive such as the adhesive sold under the trade name
Lock-Tite 3311.
[0048] In use, device 10 is placed against the skin 70 of a patient
as shown in FIG. 7 and pressed downwardly toward the skin 70 in the
direction of arrow 72 to cause skin penetrating members 44 to
pierce the surface of skin 70. Bottom face 20 of support 12 has a
dimension to form a sealing flange against the surface of skin 70
completely surrounding microdevice 14. In the embodiment
illustrated, a syringe 74 having a Luer collar 76 and is coupled to
flange 30 of collar 24 to form a fluid tight seal. Syringe 74 can
then be actuated to dispense a substance into or through inlet 28
to central passage 22 and through axial passages 50 of skin
penetrating members 44. Syringe 74 can be actuated to apply
sufficient force to deliver the substance through the skin of the
patient. Alternatively, syringe 74 can be used to extract or
withdraw a substance from the patient through the skin.
[0049] Bottom face 20 of support 12 can include a
friction-enhancing member such as a rib or a tacky material applied
to bottom face 20. Preferably, support 12 is formed from a
resilient material such that support 12 is able to conform to the
shape of skin 70. Bottom face 20 of support 12 forms a sealing
flange to contain fluid dispensed through skin penetrating member
44 to prevent leakage and to direct the fluid into the skin or to
withdraw a substance through the skin of the patient. In addition,
bottom face 20 frictionally grips the skin, thereby decreasing
relative motion between the support 12, skin penetrating members 44
and the skin 70. This decreases lateral sheer forces on the skin
penetrating members 44 to reduce the instance of breakage and
abrasion of the skin.
[0050] Support 12 is preferably made from a plastic material that
is non-reactive with the substance being delivered or withdrawn
from the patient. Suitable plastic materials include, for example,
polyethylene, polypropylene, polyesters, polyamines,
polycarbonates, and copolymers thereof as known in the art.
[0051] Microdevice 14 can also be made from suitable materials as
known in the art. In one embodiment of the invention, microdevice
14 includes a plurality of microneedles formed into an array formed
from spaced-apart rows and columns. The microneedles can be formed
from a silicon wafer that is machined or etched to form the
microneedle array. The microneedle array can also be formed from
stainless steel, tungsten steel, and alloys of nickel, molybdenum,
chromium, cobalt and titanium. In further embodiments, the
microneedles can be formed from ceramic materials, glass polymers
and other non-reactive metals. In further embodiments, microdevice
14 can be formed from needles that are mounted in a suitable
base.
[0052] The skin penetrating members have a length suitable to
achieve the desired depth of penetration in the skin. The length
and thickness of the skin penetrating members are selected based on
the substance being administered or withdrawn and the thickness of
the skin in the location where the device is to be applied. In
embodiments of the invention, the skin penetrating members can be
microneedles, microtubes, solid or hollow needles, lancets and the
like. Generally, the skin penetrating members have a length of
about 100 microns to about 2,000 microns and preferably, about 250
microns to 1,000 microns. The one embodiment, the skin penetrating
members are about 30-gauge to about 50-gauge needles, having a
length of about 500 microns to about 1,000 microns. In the
embodiment illustrated, the skin penetrating members have a
substantially square cross-sectional shape. Alternatively, the skin
penetrating members can be triangular, cylindrical, pyramid-shaped
or flat blades.
[0053] Microdevice 14 can have a width and length as necessary to
achieve the desired result. In one embodiment, microdevice 14 is
about one cm.sup.2 to about 10 Cm.sup.2. In further embodiments,
microdevice 14 can have a width and length of about one centimeter
to about five centimeters.
[0054] Generally, when the device is used as a delivery device, a
pharmaceutical agent or drug solution is introduced into the
central passage by a syringe or other fluid dispensing device. In
alternative embodiments, a dried or lyophilized drug or
pharmaceutical agent can be provided on the outer surfaces of the
skin penetrating members or in the axial passages of the skin
penetrating member. A diluent such as distilled water or saline
solution can then be injected through the central passage and
through the axial passage of the skin penetrating members to
dissolve and reconstitute the drug or pharmaceutical agent and then
deliver the drug to the patient.
[0055] Embodiment of FIGS. 8-12
[0056] A second embodiment of the invention is illustrated in FIGS.
8-12. In this embodiment, device 80 includes a support 82 and a
microdevice 84 having a plurality of skin penetrating members
86.
[0057] Support 82, as shown in FIGS. 8 and 9, has a substantially
frustoconical top surface 88 and a bottom surface 90. Support 82
has a peripheral outer edge 92 and an annular flange 94 extending
substantially perpendicular from bottom surface 90. A collar 96
extends from top surface 88 of support 82 in a generally axial
direction. Collar 96 includes a flange 98 extending outwardly from
a top end 100 of collar 96. An axial passage 102 extends through
collar 96 to bottom surface 90 of support 82 to form a central
opening 104 in bottom face 90.
[0058] A collar 106 extends from top surface 88 of support 82 and
is spaced from collar 96. Collar 106 includes a flange 108
extending radially outwardly at an outer end 105. An axial passage
110 extends through collar 106 to bottom surface 90 of support 82
to form an outlet port 112 in bottom surface 90.
[0059] As in the previous embodiment, bottom surface 90 includes a
recessed area 114 forming a ledge for receiving microdevice 84.
Channels 116 and a recess forming an adhesive reservoir 118 are
connected to recessed area 114 for directing an adhesive to
recessed area 114 to bond microdevice 84 to support 82. In further
embodiments, channels 116 and reservoir 118 can be omitted and the
microdevice bonded to the support by ultrasonic welding, thermal
welding or insert molding by molding the support directly onto the
microdevice. In use, device 80 is placed against the skin 120 as
shown in FIG. 11. Device 110 is positioned with flange 94
contacting skin 120 and encircling a target area 122. In one
embodiment, flange 94 has an axial length to lie in a plane that is
parallel with the tips 124 of skin penetrating members 86.
[0060] Device 80 is pressed against the skin 120 and a suitable
vacuum source is coupled to collar 106. In one embodiment, the
vacuum source is a syringe having a Luer lock collar threaded onto
flange 108 of collar 106. The plunger of the syringe can be
extracted to create a reduced pressure in the target area 122 which
pulls the skin upwardly into contact with skin penetrating members
86. Pulling the skin 70 upwardly by reducing the pressure in the
space between bottom wall 90 and skin 120 enables skin penetrating
members 86 to penetrate or pierce the skin substantially uniformly
across the width of microdevice 84. Generally, the vacuum source is
maintained during the sampling or delivery of a substance to
maintain penetration of the skin by the skin penetrating members.
In addition, maintaining the vacuum prevents movement of the device
with respect to the skin to prevent breakage of the skin
penetrating members and abrasion of the skin. In alternative
embodiments, a vacuum pump or other suitable device capable of
drawing a vacuum or reduced pressure can be coupled to collar
106.
[0061] After the skin penetrating members have adequately penetrate
or pierced the skin to a desired depth, a supply or sampling
container, such as a syringe 128, is coupled to collar 96 using a
Luer type fitting. When a substance is to be sampled or withdrawn
from the patient, the syringe plunger is withdrawn to reduce the
pressure in the central area of support 82 to withdraw a fluid
through the axial passage in the skin penetrating members.
Alternatively, a substance can be delivered to the patient by
directing the substance to the central passage of support 82 and
through the axial passage of skin penetrating member 86. A
substance can be delivered to a patient under pressure as an active
delivery system or without pressure as a passive delivery system.
The device is left in contact with the skin for sufficient time to
withdraw the desired substance or deliver the substance to the
patient. The time required is dependent on the substance being
delivered or withdrawn, the volume of the substance, and the target
area on the skin.
[0062] The device of the invention is generally designed to be a
disposable, single-use device. The device can be used safely and
effectively for intradermal delivery of a pharmaceutical agent or
other substance. The device is particularly suitable for
introducing a vaccine intradermally for efficiently delivering a
small amount of a vaccine antigen for presentation to the
Langerhans cells. The length, width and spacing of the microneedles
can vary depending on the pharmaceutical agent being administered
or required to penetrate the stratum corneum to the optimum depth
for the specific pharmaceutical agent being administered. When
delivering a vaccine, the microneedles are dimensioned to target
the optimum intradermal delivery site to promote the desired immune
response.
[0063] While various embodiments have been chosen to illustrate the
invention, it will be appreciated by those skilled in the art that
various additions and modifications can be made to the invention
without departing from the scope of the invention as defined in the
appended claims.
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