JP2016518997A - 遠心力を利用したマイクロ構造体の製造方法およびそれから製造されたマイクロ構造体 - Google Patents
遠心力を利用したマイクロ構造体の製造方法およびそれから製造されたマイクロ構造体 Download PDFInfo
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Abstract
Description
(a)下部基板上に粘性組成物を用意する段階;および
(b)前記粘性組成物に遠心力を印加(apply)し前記粘性組成物の引張(extension)を誘導してマイクロ構造体を製造する段階。
マイクロ構造体を製造するために本発明で利用される物質は粘性組成物である。本明細書において、用語、“粘性組成物”は本発明で利用される遠心力によって形状が変化してマイクロ構造体を形成できる能力を有する組成物を意味する。
選択的に、前記粘性組成物は主成分として生体適合性および/または生分解性物質を含むことができる。
本発明の一具体例によれば、本発明の段階(b)の引張は前記屈曲または凹凸の最高点(highest point)から前記遠心力の方向に前記マイクロ構造体の上端部を形成させる。これは前述の通り、基板上の高い部分と低い部分の位相差によるものである。
(a)粘性組成物吐出部を含む中空型構造体の内部空間上に粘性組成物を用意する段階;および
(b)前記中空型構造体の吐出部を通じて粘性組成物が吐出されるように粘性組成物に遠心力を印加(apply)し前記粘性組成物の引張(extension)を誘導してマイクロ構造体を製造する段階。
(a)前述した本発明の他の一形態により製造されたマイクロ構造体に金属蒸着する段階;
(b)前記金属蒸着されたマイクロ構造体を金属でメッキする段階;
および
(c)前記マイクロ構造体を除去して中空型マイクロ構造体を収得する段階。
(a)粘性組成物吐出部を含む中空型構造体の内部空間上に粘性組成物を用意する段階;および
(b)前記中空型構造体の吐出部を通じて粘性組成物が吐出されるように粘性組成物に遠心力を印加(apply)し前記粘性組成物の引張(extension)を誘導してマイクロ構造体を製造する段階;
(c)前記段階(b)での遠心力の印加がなされる途中、または遠心力の印加が終了した後に前記吐出部を通じてマイクロ構造体内部に薬物を注入する段階。
(a)粘性組成物吐出部を含む中空型構造体の内部空間上に粘性組成物を用意する段階;および
(b)前記中空型構造体の吐出部を通じて粘性組成物が吐出されるように粘性組成物に遠心力を印加(apply)し前記粘性組成物の引張(extension)を誘導してソリッドマイクロ構造体を製造する段階;
(c)前記段階(b)での遠心力の印加がなされる途中、または遠心力の印加が終了した後に前記吐出部を通じてソリッドマイクロ構造体内部に気体または流体を注入して空いた空間を形成させる段階(参照:図31)。
(a)本発明は、熱処理をしなくてもソリッドマイクロ構造体を製造することが可能な方法を提供する。これを通じて熱に敏感で容易に破壊または変性される多様な物質をマイクロ構造体に搭載することができる。これはマイクロニードルの適用可能分野をさらに拡張させる。
(b)本発明によれば、従来技術で利用していたモールドやフィラーのような他の構造体に接触せず非接触式でマイクロ構造体を製作することができる。これはマイクロ構造体の成形が終了した後、接触した構造体との分離過程または物理的破壊を通した切断過程により発生した損失および製作歩留まりの限界を克服できるようにする。
(c)本発明は、基板の平坦度や均一度にかかわらず高い歩留まりでマイクロ構造体を製造する方法を提供する。
(d)本発明は、滴下される粘性組成物の量、粘性組成物および基板の特性、回転半径、回転加速度、回転速度、回転持続時間などの調節を通じて多様な形状のマイクロ構造体を製造する方法を提供する。
(e)本発明は比較的迅速で簡便な工程で所望の形状およびディメンジョン(例えば、直径またはアスペクト比(aspect ratio))を有するマイクロ構造体を製造するようにする。このような特徴はマイクロ構造体の大量生産および品質管理がよくできるようにする。
(f)本発明において、下部基板および上部基板を利用する方法の場合には、一度の過程でより多くのマイクロ構造体の生産が可能となる利点がある。
ポリスチレン(Polystylene)基板(SPL Life Science)にカルボキシメチルセルロース(Carboxymethyl cellulose、Sigma − Aldrich、Inc.)をコーティングした後、40重量%ヒアルロン酸(Soliance)粘性溶液滴(drop)を形成させた。引き続き、前記基板を遠心分離機(Beckman coulter)に装着し、遠心分離機を5g/sで加速した後、900gの重力加速度にて3分の間運行した。それから、遠心分離機を9g/sの速度で減速した。前記遠心力の印加過程を通じて、高アスペクト比のマイクロ構造体を製造した(参照:図19):有効長さ1,500m、上端部直径45um、下端部直径300um。
29kDaヒアルロン酸(Hyaluronic acid)40%(w/v)溶液をディスペンサー(MUSASHI engineering、ML−5000XII)を利用して下部基板であるアルミニウム基板上に0.200MPaの圧力で0.220秒の間吐出して溶液滴を形成した後、遠心分離機(Hanil science industrial、Combi 514R)を利用して1mm間隔を置いた下部基板および上部基板である二つのアルミニウム基板の間で溶液滴を500gの遠心力で30秒の間回転させてマイクロ構造体を形成させた(参照:図20)。図20の左図は下部基板(内板)に形成されたマイクロ構造体であり、右図は上部基板(外板)に形成されたマイクロ構造体である。
実施例2によって製造したマイクロ構造体を電子顕微鏡(Field Emission Scanning Electron Microscope、JSM−7001F、JE0L Ltd.,Japan)で観察した。上部基板および下部基板の両方でマイクロ構造体が形成された(参照:図21)。
実施例2によって製造したマイクロ構造体パッチを人体の皮膚に適用した後、4時間経過後マイクロ構造体の吸収の可否を確認した。図22は前記実施例2で下部基板上に形成されたマイクロ構造体を利用した結果であり、図23は実施例2で上部基板上に形成されたマイクロ構造体を利用した結果である。両方とも、マイクロ構造体が溶解して体内で吸収されたことを確認した。
実施例2の方法を通じてマイクロ構造体を製造するにおいて、上部基板なしで下部基板のみを使用し、遠心力を400gまたは500gを印加して、生成されるマイクロ構造体の形状を観察した。500gの遠心力を印加した場合に生成されたマイクロ構造体のアスペクト比が400gを印加した場合に比べてより大きいことを確認し(参照:図24)、これは印加される遠心力の大きさを調節することによって、生成されるマイクロ構造体の形状を調節可能であることを示している。
下部基板および上部基板を利用した実施例2のマイクロ構造体製造方法において、既にマイクロ構造体が形成されている上部基板(参照:図25の上部基板)を利用してマイクロ構造体を製造した。上部基板上に既に形成されていたマイクロ構造体上に新しいマイクロ構造体が層をなし、多層マイクロ構造体を製造した(参照:図26)。これは多様な形状のマイクロ構造体を製造したり、複数の物質で構成されたマイクロ構造体を製造するのに遠心力を利用したマイクロ構造体製造方法を容易に適用できることを示している。
下部基板および上部基板を利用した実施例2のマイクロ構造体製造方法において、マイクロ構造体が形成された下部基板および上部基板の位置を相互変更して、実施例2のマイクロ構造体製造過程を追加的に遂行した(参照:図27)。これを通じて二つの形状のマイクロ構造体を一つの平面上に製作した(参照:図28)。これは複数回の製造過程を経て多様な形状のマイクロ構造体を一つの平面上に製作できることを示している。
Claims (26)
- 次の段階を含む、マイクロ構造体の製造方法:
(a)下部基板上に粘性組成物を用意する段階;および
(b)前記粘性組成物に遠心力を印加(apply)し前記粘性組成物の引張(extension)を誘導してマイクロ構造体を製造する段階。 - 前記粘性組成物は生体適合性または生分解性物質を含むことを特徴とする、請求項1に記載のマイクロ構造体の製造方法。
- 前記粘性組成物は滴(drop)形態(form)で前記基板上に位置することを特徴とする、請求項1に記載のマイクロ構造体の製造方法。
- 前記滴は前記粘性組成物の特性(properties)、前記下部基板の特性または前記粘性組成物の特性と下部基板の特性を変化させることによってその形状(shape)、大きさ、または前記下部基板との接触面積が調節されることを特徴とする、請求項3に記載のマイクロ構造体の製造方法。
- 前記方法は前記滴形態を構成する粘性組成物の量または濃度を調節して前記マイクロ構造体の形状を多様に調節することを特徴とする、請求項3に記載のマイクロ構造体の製造方法。
- 前記段階(b)は硬化(solidifying)が同時に起きるように実施することを特徴とする、請求項1に記載のマイクロ構造体の製造方法。
- 前記方法は、遠心力の調節を通じて長さ、直径およびアスペクト比(aspect ratio)で構成された群から選択される前記マイクロ構造体のすくなくとも一つのディメンジョン(dimension)を調節することを特徴とする、請求項1に記載のマイクロ構造体の製造方法。
- 前記下部基板は一定のパターンの屈曲または凹凸が形成された表面を有することを特徴とする、請求項1に記載のマイクロ構造体の製造方法。
- 前記段階(b)の引張は、前記屈曲または凹凸の最高点(highest point)から前記遠心力の方向に前記マイクロ構造体の上端部を形成させることを特徴とする、請求項8に記載のマイクロ構造体の製造方法。
- 前記遠心力の印加は調節された回転加速度で実施し、これによって前記粘性組成物の引張角度が調節され、これによって変形された形状を有するマイクロ構造体が製造されることを特徴とする、請求項1に記載のマイクロ構造体の製造方法。
- 前記方法は前記下部基板の平坦度(flatness)または均一度(uniformity)にかかわらず、マイクロ構造体を製造可能であることを特徴とする、請求項1に記載のマイクロ構造体の製造方法。
- 前記方法は前記段階(a)および(b)の間に次の段階(ab)を追加的に含むことを特徴とする、請求項1に記載のマイクロ構造体の製造方法:(ab)前記下部基板上に用意された前記粘性組成物を空洞を有する蓋基板で覆う段階。
- 前記段階(b)は追加的な上部基板を利用して実施し、前記上部基板は前記粘性組成物から空間的に離隔した上部に位置し、前記段階(b)での粘性組成物の引張は前記粘性組成物の一部が前記上部基板に結合するようにし、結局(whereby)、前記下部基板および前記上部基板の間に互いに連結されて形成されるかまたは前記下部基板および前記上部基板のそれぞれに結合されて両マイクロ構造体が分離された形態で形成されたマイクロ構造体が製造されることを特徴とする、請求項1に記載のマイクロ構造体の製造方法。
- 前記マイクロ構造体は前記下部基板および前記上部基板の間に互いに連結されて形成されたマイクロ構造体であり、前記方法は前記段階(b)の後に次の段階(c)を追加的に含むことを特徴とする、請求項13に記載のマイクロ構造体の製造方法:(c)前記下部基板および前記上部基板のうち少なくともいずれか一つを移動させて前記互いに連結されて形成されたマイクロ構造体を切断する段階。
- 前記切断は前記下部基板および前記上部基板のうち少なくともいずれか一つを特定方向に移動させてなされ、これを通じてマイクロ構造体が特定の角度を有するチップ(tip)が形成されることを特徴とする、請求項14に記載のマイクロ構造体の製造方法。
- 前記粘性組成物が親水性物質であり、前記下部基板および前記上部基板のうち少なくとも一つの表面が疎水性性質を有することを特徴とする、請求項13に記載のマイクロ構造体の製造方法。
- 第13項において、前記粘性組成物が疎水性であり、前記下部基板および前記上部基板のうち少なくとも一つの表面は親水性を有することを特徴とする、請求項13に記載のマイクロ構造体の製造方法。
- 次の段階を含むマイクロ構造体の製造方法:
(a)粘性組成物吐出部を含む中空型構造体の内部空間上に粘性組成物を用意する段階;および
(b)前記中空型構造体の吐出部を通じて粘性組成物が吐出されるように粘性組成物に遠心力を印加(apply)し前記粘性組成物の引張(extension)を誘導してマイクロ構造体を製造する段階。 - 前記中空型構造体は円筒状の中空型構造体であることを特徴とする、請求項18に記載のマイクロ構造体の製造方法。
- 前記請求項1または請求項19に記載されたマイクロ構造体の製造方法によって製造された、マイクロ構造体。
- 次を含む遠心力によってマイクロ構造体を製造するための装置:
(a)遠心分離機の回転軸に連結される回転アーム;および
(b)前記回転アームに連結されて粘性組成物を収容する下部基板。 - 前記装置は遠心分離機の回転軸を追加的に含むことを特徴とする、請求項21に記載の装置。
- 前記装置は前記遠心分離機の回転軸に回転力を付与するモーターを追加的に含むことを特徴とする、請求項22に記載の装置。
- 次の段階を含む中空型マイクロ構造体の製造方法:
(a) 請求項1または請求項19に記載されたマイクロ構造体の製造方法により製造されたマイクロ構造体に金属蒸着する段階;
(b)前記金属蒸着されたマイクロ構造体を金属でメッキする段階;
および
(c)前記マイクロ構造体を除去して中空型マイクロ構造体を収得する段階。 - 次の段階を含む薬物封入型マイクロ構造体の製造方法:
(a)粘性組成物吐出部を含む中空型構造体の内部空間上に粘性組成物を用意する段階;および
(b)前記中空型構造体の吐出部を通じて粘性組成物が吐出されるように粘性組成物に遠心力を印加(apply)し前記粘性組成物の引張(extension)を誘導してマイクロ構造体を製造する段階;
(c)前記段階(b)での遠心力の印加がなされる途中、または遠心力の印加が終了した後に前記吐出部を通じてマイクロ構造体内部に薬物を注入する段階。 - 次の段階を含む中空型マイクロ構造体の製造方法:
(a)粘性組成物吐出部を含む中空型構造体の内部空間上に粘性組成物を用意する段階;および
(b)前記中空型構造体の吐出部を通じて粘性組成物が吐出されるように粘性組成物に遠心力を印加(apply)し前記粘性組成物の引張(extension)を誘導してマイクロ構造体を製造する段階;
(c)前記段階(b)での遠心力の印加がなされる途中、または遠心力の印加が終了した後に前記吐出部を通じてマイクロ構造体内部に気体または流体を注入して空いた空間を形成させる段階。
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