JP2022155255A - Projection-bearing body manufacturing method and projection-bearing body manufacturing device - Google Patents

Abstract

To provide a projection-bearing body manufacturing method and a projection-bearing body manufacturing device capable of solving a problem of a tradeoff occurring between a thickness and a width and forming a projection-bearing body having a desired shape.SOLUTION: Provided is a projection-bearing body manufacturing device EA for manufacturing projection-bearing bodies CB having projections CV formed thereon, comprising: material supporting means 20 for executing a material supporting step of supporting a base material BM by using a supporting member 22 having a supporting surface 22A in which recesses 22B corresponding to projections CV are formed; and pressing means 30 for executing a pressing step of forming the projections CV for forming a projection-bearing body CB from a plastic material PM by pressing the base material BM in a direction of facing the supporting surface 22A to fill the recesses 22B with the plastic material PM. The pressing means 30 includes a pressing member 32 formed with drain holes 32B opening to a pressing surface 32A that presses the base material BM, and fills the recesses 22B with the plastic material PM while draining, by way of the drain holes 32B, at least one of a fluid and the plastic material PM existing between the plastic material PM and the pressing surface 32A.SELECTED DRAWING: Figure 1

Description

The present invention relates to a projection holder manufacturing method and a projection holder manufacturing apparatus.

A technique for manufacturing a projection holder having needle-like projections is known (see Patent Document 1, for example).

JP 2019-170795 A

In the technology for manufacturing the protrusion holder disclosed in Patent Document 1, the pressing force for pressing the thermoplastic resin 3 (plastic material) is adjusted to adjust the thickness L (thickness) of the substrate of the microneedle 10 (protrusion holder). If you try to adjust, the plastic material will be pushed outward along the supporting surface of the intaglio 2 (supporting member), and the width of the substrate will increase. A problem arises that it becomes impossible to form a shaped protrusion holder.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing a protrusion holder and an apparatus for manufacturing a protrusion holder that can eliminate the trade-off between thickness and width and form a protrusion holder in a desired shape. That's what it is.

The present invention employs the configurations described in the claims.

According to the present invention, since at least one of the fluid and the plastic member existing between the plastic material and the pressing surface is discharged through the through hole, the recess is filled with the plastic material. It is possible to eliminate the trade-off relationship between and to form a projection holder having a desired shape.

(A) to (D) are an explanatory diagram of a projection holding body manufacturing apparatus according to an embodiment of the present invention and an explanatory diagram of the operation of the same apparatus. (E) to (G) are explanatory diagrams of modifications.

An embodiment of the present invention will be described below with reference to the drawings.
Note that the X-axis, Y-axis, and Z-axis in this embodiment are orthogonal to each other, and the X-axis and Y-axis are axes within a predetermined plane, and the Z-axis is an axis orthogonal to the predetermined plane. do. Furthermore, in the present embodiment, when viewed from the front in FIG. 1 parallel to the Y-axis, when the direction is indicated without designating the drawing, "up" is the direction of the arrow of the Z-axis and "down". is the opposite direction, "left" is the arrow direction of the X axis, "right" is the opposite direction, "front" is the direction parallel to the Y axis in FIG. 1, and "rear" is the opposite direction. Note that FIGS. 1B to 1G, which do not include arrows indicating directions, are views viewed from the same direction as FIG. 1A. In addition, FIG. 1(B) is a diagram in which the left half, which is bilaterally symmetrical about the center line CT, is omitted (FIGS. 1(B1) and (B2) are part of FIG. 1(B). ).

A projection holder manufacturing apparatus (hereinafter also simply referred to as "manufacturing apparatus") EA of the present invention is an apparatus for carrying out a method for manufacturing a projection holder CB having projections CV formed thereon, and includes a plastic material PM. A material supporting process for supporting the base material BM with a material conveying means 10 for carrying out a material conveying process for conveying the base material BM and a supporting member 22 having a supporting surface 22A formed with recesses 22B corresponding to the protrusions CV. and the base material BM is pressed toward the support surface 22A to fill the recesses 22B with the plastic material PM, and the protrusions CV are formed from the plastic material PM to form the protrusion holders CB. A pressing means 30 for performing a pressing process, a heating means 40 for performing a heating process for heating the plastic material PM, a positioning means 50 for performing a positioning process for positioning the support sheet BS with respect to the support surface 22A, and a projection holder. Separating means 60 for performing a separating step of separating the CB from the support member 22, cooling means 70 for performing a cooling step of cooling the plastic material PM, and immersing the plastic material PM in water WT as a leaching medium. A leaching means 80 for performing a leaching step in which the material PM is made into a porous body, and a surface direction deformation suppressing step for suppressing outward deformation of the plastic material PM along the support surface 22A when performing the pressing step. It is provided with a surface direction deformation suppressing means 90, and is arranged in the vicinity of the base material supplying means PS for performing the base material supplying step of supplying the BM.
The base material BM is formed by laminating a plastic material PM on one surface of the support sheet BS. In addition, the support sheet BS of the present embodiment is made of paper as a permeable member that is permeable to at least one of the fluid existing between the plastic material PM and the pressing surface 32A and the plastic material PM. It is Furthermore, the plastic material PM has thermoplasticity due to its main component being polylactic acid (PLA), and polyethylene glycol PG (see the enlarged view of FIG. 1(D)) as a leaching material that leaches into the water WT. contains. The plastic material PM of this embodiment is a mixture of two components, polylactic acid and polyethylene glycol PG, in a weight ratio of 5:5.

The material conveying means 10 is composed of a plurality of arms, and within its working range, a so-called multi-joint driving device capable of displacing what is supported by the tip arm 11A, which is the working part, to any position and any angle. It comprises a robot 11 and a holding plate 12 having a holding surface 12A supported by a distal arm 11A and capable of being held by suction by a decompression means (holding means) (not shown) such as a decompression pump or a vacuum ejector. 22A, and the base material BM is placed on the support member 22. As shown in FIG.

The material support means 20 includes a base 21 having a stepped portion 21A formed thereon, and a support member 22 which is fitted and supported in the stepped portion 21A and has a support surface 22A formed with a recessed portion 22B.

The pressing means 30 includes a direct-acting motor 31 as a driving device, and a pressing member 32 supported by an output shaft 31A thereof and having a through hole 32B communicating with a pressing surface 32A for pressing the base material BM. At least one of the air as a fluid and the plastic material PM existing between the PM and the pressing surface 32A is discharged through the vent hole 32B, and the recess 22B is filled with the plastic material PM. there is Incidentally, in this embodiment, the pressing member 32 is made of a transparent material.

The heating means 40 includes a heating device 41 such as a coil heater and a heating side of a heat pipe arranged inside the base 21 .

The positioning means 50 includes imaging means such as a camera and a projector, various sensors such as an optical sensor and an ultrasonic sensor, and the like. and a rotating motor 53 as a driving device that is supported by an output table 52A of the XY table 52 and supports the base 21 with an output shaft 53A, and linearly moves the support member 22 within the XY plane. Alternatively, the support member 22 is rotated in the XY plane while being curved.

The separating means 60 is composed of a plurality of arms, and is a so-called articulated robot as a driving device capable of displacing an object supported by the tip arm 61A, which is a working part, to any position and any angle within its working range. 61, and a holding plate 62 having a holding surface 62A which is supported by the tip arm 61A and can be held by suction by a decompression means (holding means) (not shown) such as a decompression pump or a vacuum ejector.

The cooling means 70 includes a cooling device 71 including a Peltier element provided inside the holding plate 62, a cooling side of a heat pipe, and the like.

The brewing means 80 comprises water WT and a container 81 for receiving the water WT.

The surface direction deformation suppressing means 90 is supported on the lower surface of the pressing member 32 and includes an annular projecting member 91 that is annular in a plan view looking down from above. The annular protruding member 91 is made of an elastically deformable member, and has the same inner edge shape as the outer edge shape of the plastic material PM. When pressed in the direction toward 22A, the plastic material PM is restrained from deforming outward along the support surface 22A.

The operation of the projection holding body manufacturing apparatus EA will be described.
First, a user of the manufacturing apparatus EA (hereinafter simply referred to as a "user"), an articulated robot, or a belt conveyor is assigned to the manufacturing apparatus EA in which each member is arranged at the initial position indicated by the solid line in FIG. 1(A). After feeding the base material BM onto the base material supply means PS as shown in FIG. Enter Then, the material conveying means 10 drives the articulated robot 11 and the decompression means (not shown) to move the holding plate 12 to bring the holding surface 12A into contact with the support sheet BS, and the holding surface 12A adsorbs and holds the base material BM. Then, after the base material BM is placed on the support surface 22A of the support member 22, the drive of the decompression means (not shown) is stopped to return the holding plate 12 to the initial position. Next, the pressing means 30 drives the direct-acting motor 31 to lower the pressing member 32, and as shown by the two-dot chain line in FIG. , the pressing member 32 is further lowered to press the base material BM in the direction toward the support surface 22A with the pressing member 32, and as shown in FIGS. The concave portion 22B is filled with the plastic material PM while being crushed. At this time, the plastic material PM is pushed outward along the support surface 22A and tries to be deformed. The air in the sheet BS permeates into the support sheet BS instead of escaping, thereby suppressing outward deformation along the support surface 22A. Furthermore, if the base material BM is further pressed in order to reduce the vertical thickness of the protrusion holder CB, as shown in FIG. This time, the plastic material PM is pulled out from the punching holes 32B via the support sheet BS. When the pressing member 32 presses the base material BM, the heating means 40 drives the heating device 41 to heat and soften the plastic material PM, thereby facilitating the filling of the recess 22B with the plastic material PM. After that, the positioning means 50 drives the detection device 51 to detect the position of the support sheet BS. The support member 22 is moved so that the concave portion 22B (projection portion CV) is arranged at the position of . As a result, the protrusions CV and the base FD for supporting the protrusions CV are formed from the plastic material PM, and the protrusion holders CB in which the protrusions CV are formed on the support sheet BS are formed. Next, after the pressing means 30 drives the direct-acting motor 31 and returns the pressing member 32 to the initial position, the heating means 40 stops driving the heating device 41 .

Then, the separating means 60 and the cooling means 70 drive the articulated robot 61 and the cooling device 71, and as shown in FIG. do. As a result, as shown in the enlarged view of FIG. 1(C), the plastic material PM shrinks to form a gap CL between it and the recess 22B, making it easier to remove the protrusion CV from the recess 22B. At this time, the cooling means 70 cools the plastic material PM while the separating means 60 presses the plastic material PM with the holding plate 62, so that the adhesion between the plastic material PM and the support sheet BS can be improved. Next, when the cooling means 70 stops driving the cooling device 71 and finishes cooling the plastic material PM, the separating means 60 drives the articulated robot 61 and the decompression means (not shown), and the holding surface 62A of the holding plate 62 protrudes from the holding surface 62A. After holding the holding bodies CB by suction and separating the projection holding bodies CB from the supporting member 22, the projection holding bodies CB are immersed in water WT as shown in FIG. 1(D). As a result, the polyethylene glycol PG contained in the plastic material PM is leached into the water WT, and as shown in the enlarged view of FIG. , and the plastic material PM becomes a porous body. After that, the separating means 60 drives the multi-joint robot 61 to transport the protrusion holding body CB with the hole HL formed thereon to the next process (not shown), stop the driving of the decompression means (not shown), and hold the protrusion holding body CB. The plate 62 is separated, the separated holding plate 62 is returned to the initial position, and the same operation as described above is repeated thereafter. As shown in FIG. 1(B2), the plastic material PM that has entered the punched hole 32B and protruded onto the support sheet BS is later scraped off or cut by a grinding device (not shown) or by a user to be removed. be done.

According to the embodiment as described above, at least one of the air and the plastic material PM existing between the plastic material PM and the pressing surface 32A is discharged through the vent hole 32B, and the plastic material PM is removed from the recess. 22B, the trade-off between the thickness and the width can be eliminated, and the projection holder CB having a desired shape can be formed.

The means and steps in the present invention are not limited in any way as long as they can perform the operations, functions or steps described for those means and steps. The process is not limited at all. For example, the material supporting process may be any process as long as it is a process of supporting a base material containing a plastic material with a support member having a support surface on which recesses corresponding to the protrusions are formed, and it is the common general knowledge at the time of filing. There is no limitation as long as it is within the technical scope in comparison (other means and processes are the same).

The material conveying means 10 may share the articulated robot 61 with the separating means 60 without adopting the articulated robot 11 to convey the base material BM. A suction pad or the like may be employed, and the apparatus EA for manufacturing a protrusion holder of the present invention may or may not be provided with the base material. The BM should be transported.

In the material supporting means 20, the base 21 may not have the stepped portion 21A, or decompression means such as a decompression pump or a vacuum ejector for holding the support member 22, or support member holding means such as a chuck motor may be provided. , the base 21 may be eliminated and only the support member 22 may be provided.
The support member 22 may be made of any material such as metal, resin, silicone material, rubber material, wood, paper, ceramics, etc. The number of the recesses 22B may be one or more, and the projection holding bodies CB may be provided. In order to facilitate the separation from the support member 22, the support surface 22A and the concave portion 22B may be coated, applied, or laminated with a peelability improving member such as fluorine or silicone.

The pressing means 30 moves the supporting member 22 without moving the pressing member 32 or while moving the pressing member 32, and presses the base material BM in the direction toward the supporting surface 22A to form the projections CV. Alternatively, the pressing member 32 may be translucent or non-transparent, and the articulated robot 11 and the holding plate 12 may be combined with the material conveying means 10 without adopting the direct-acting motor 31 and the pressing member 32. By sharing the multi-joint robot 61 and the holding plate 62 with the separating means 60, the base material BM is pressed in the direction toward the support surface 22A via the holding plate 12 and the holding plate 62 to press the protrusion CV. may be formed, the articulated robot 11 may be shared with the material conveying means 10 without adopting the linear motion motor 31, or the articulated robot 61 may be shared with the separating means 60, and the pressing member 32 The projections CV may be formed by pressing the base material BM in the direction toward the support surface 22A through the support surface 22A. It may be just the air in the sheet BS, it may be both the air and the plastic material PM, or it may be just the plastic material PM.
The through hole 32</b>B may have one or more holes communicating with the pressing surface 32</b>A, and may not extend outward from the pressing member 32 .

The heating means 40 may be arranged outside the base 21, inside the support member 22, or inside the pressing member 32, and heat the plastic material PM before being pressed by the pressing means 30. Alternatively, the plastic material PM may be heated while being pressed by the pressing means 30, or the plastic material PM may be heated after being pressed by the pressing means 30. It may or may not be provided in the manufacturing apparatus EA.

The positioning means 50 may move at least one of the support member 22 and the pressing member 32 linearly, curvilinearly, or rotationally within the XY plane. ), the pressing member 32 may be moved linearly or curvedly in the Y direction (X direction), or the support member 22 and the pressing member 32 may be linearly moved in the X direction or in directions other than the Y direction. Alternatively, the support member 22 and the pressing member 32 may be moved in a curved line, or the support member 22 and the pressing member 32 may be simply moved linearly or curvedly within the XY plane, or the support member 22 and the pressing member 32 may be rotationally moved within the XY plane. .
The detection device 51 may be one or two or more, and may detect the position of the support sheet BS with respect to the support surface 22A from the side of the pressing member 32. Alternatively, the position of the support sheet BS with respect to the support surface 22A may be detected by transmitting through the base 21 and the support member 22, or the support sheet BS may not be supported by the pressing member 32.
The positioning means 50 may position the plastic material PM with respect to the support surface 22A, may position both the support sheet BS and the plastic material PM with respect to the support surface 22A, or may position the projection holder of the present invention. It may or may not be provided in the manufacturing apparatus EA.

The separating means 60 may share the multi-joint robot 11 with the material conveying means 10 without adopting the multi-joint robot 61, and may be configured to separate the protrusion holder CB from the support member 22. It may be attached to the body CB, and tension may be applied to the peeling tape to separate the projection holding body CB from the support member 22. Alternatively, a vibrating means such as a vibrator or an ultrasonic vibration device may be used to remove the projection holding body CB. may be easily separated from the support member 22 by applying vibration to the projection holding body CB, the projection holding body CB may be centrifuged, or when the projection holding body CB is immersed in water WT, the The protrusion holder CB may be moved or vibrated to facilitate the leaching of the polyethylene glycol PG into the water WT. If it is not provided, the projection holder CB may be separated from the support member 22 by another device or manually.

The cooling means 70 may be provided with a cooling device 71 inside or near the pressing member 32, and the plastic material PM may be cooled while the base material BM is pressed by the pressing member 32, or the base material BM may be pressed. The plastic material PM may be cooled without cooling, may be provided outside the holding plate 62, may be provided inside the base 21 or the support member 22, or may be provided in a liquid such as water or a mixed liquid. Alternatively, the plastic material PM may be cooled by immersing it in a cooling medium such as an organic solvent such as ethanol or acetone or an oil such as mineral oil or synthetic oil. It may be configured to cool the plastic material PM by applying it to the water WT, or may be configured to cool the plastic material PM by sharing the water WT with the leaching means 80 without adopting the cooling device 71, or the protrusion holder of the present invention may or may not be provided in the manufacturing apparatus EA.

The leaching means 80 leaches a leaching material contained in the base material BM, such as a liquid such as water or a mixed liquid, an organic solvent such as ethanol or acetone, or an oil such as mineral oil or chemically synthesized oil, as a leaching medium. Anything can be adopted as long as it can be used, and the leaching medium may be moved, circulated, vibrated, or agitated to facilitate leaching of the leaching material into the leaching medium. It may or may not be provided in the manufacturing apparatus EA.

The surface direction deformation suppressing means 90 may adopt the annular convex member 91 supported on the upper surface of the support member 22 instead of adopting the annular convex member 91 supported on the lower surface of the pressing member 32. Two annular convex members 91 supported respectively on the lower surface of the pressing member 32 and the upper surface of the supporting member 22 may be employed. An annular projecting member 91 supported by another object may be employed, or if the outer edge shape of the support member 22 is the same shape as the outer edge shape of the plastic material PM, the pressing member 32 presses the base material BM on the support surface. 22A, the inner edge of the annular convex member 91 may slide along the outer edge of the plastic material PM and the outer edge of the support member 22, respectively. , may be composed of an elastically deformable member, or may be composed of an elastically non-deformable member.
When the support member 22 and the base 21 are elastically deformed, the annular convex member 91 may be made of an elastically deformable member, may be made of an elastically non-deformable member, or may be made of a pressing member. 32, or may be replaced with one having another inner edge shape in accordance with the outer edge shape of the base material BM, may be thicker than the base material BM, or may be thicker than the base material BM. The thickness may be the same as the thickness, or may be thinner than the thickness of the base material BM, and may or may not be provided in the projection holding body manufacturing apparatus EA of the present invention.

The base material supply means PS may be a simple stand, a belt conveyor, a self-propelled carriage, or the like, and may or may not be provided in the projection holding body manufacturing apparatus EA of the present invention. It doesn't have to be.

The projection holding body manufacturing apparatus EA is, for example, a gas such as a single gas or a composite gas, a liquid such as water or a mixed liquid, an organic solvent such as ethanol or acetone, or a fluid atmosphere such as oil such as mineral oil or chemically synthesized oil. Among them, the projections CV may be formed by pressing the base material BM in the direction toward the support surface 22A. In this case, the fluid discharged through the vent hole 32B is at least one of the fluid atmosphere and the plastic material PM.

The support sheet BS can be made of plastic materials such as cloth, non-woven fabric, resin, mesh material, wood, etc., as well as metal, resin, silicone material, rubber material, wood, paper, pottery, etc., in which through holes are formed. Any material may be adopted as long as at least one of the fluid and the plastic material PM existing between the PM and the pressing surface 32A can pass through.

Examples of the plastic material PM include materials that are deformed by applying energy such as heat and pressure and do not return to their original shape afterward, such as metals, clays, and resins. In the case of resins, examples include PET, polypropylene, and polyethylene. , Polyvinyl chloride, poly (lactide-co-glycolide) copolymer (PLGA), etc., may be anything as long as it has plasticity, may consist of a single component, or may consist of a plurality of components. It may be composed only of materials with plasticity, may be composed of materials with plasticity and materials without plasticity, may not have thermoplasticity, and may be leached. It does not have to contain any material.
The ratio of the plastic material PM to the leaching material may be any ratio other than 5:5, such as 8:2 or 1:9. Any standard such as mass ratio, volume ratio, molar ratio, etc. may be used.
The leaching material can be, for example, sodium chloride, potassium nitrate, alum, polyvinyl alcohol, etc., as long as it leaches into the leaching medium.
The base material BM may be composed only of the plastic material PM without the support sheet BS, or may be laminated with other materials in addition to the support sheet BS and the plastic material PM, or the amount of the plastic material PM may be may be the same amount as the capacity of the recess 22B, or may be greater than or equal to the capacity of the recess 22B.
The height of the protrusion CV may be 100 nm to 3 mm, 100 nm or less, or 3 mm or more. Especially when used as a so-called microneedle, the height of the projection CV is preferably 100 μm to 1.5 mm.
The tip of the protrusion CV may be sharp, not sharp, rounded, arrowhead-shaped, or bifurcated or trifurcated.
The shape of the protrusion CV may be a cone, a pyramid, a cylinder, a prism, or a combination thereof.

As shown in FIG. 1(E), the protrusion holding body CB may be formed by forming only the protrusions CV from the plastic material PM, and the protrusions CV may be directly supported by the support sheet BS. ), the protrusion CV and the base FD may be formed from the plastic material PM, and the base FD may be embedded (penetrated) in the support sheet BS, or as shown in FIG. 1(G). Thus, the projecting portion CV and the base FD may be formed from the plastic material PM and may not be supported by the support sheet BS.

The drive device in the above embodiment includes a rotating motor, a linear motor, a linear motor, a single-axis robot, an electric device such as a multi-joint robot having two or more joints, an air cylinder, a hydraulic cylinder, and a rodless robot. Actuators such as cylinders and rotary cylinders can be used, and combinations thereof directly or indirectly can also be used.
In the above embodiment, when a pressing means such as a pressing roller or a pressing head or a pressing member for pressing an object to be pressed is employed, a roller, a round bar, In addition to a blade material and a brush-like member, a material that blows gas such as air or gas may be adopted, and the pressing material may be made of a deformable member such as rubber, resin, sponge, etc. It may be composed of a non-deformable member such as metal or resin, or a support (holding) means or support (holding) member that supports (holds) a member to be supported (member to be held) is adopted. , gripping means such as mechanical chucks and chuck cylinders, Coulomb force, adhesives (adhesive sheets, adhesive tapes), adhesives (adhesive sheets, adhesive tapes), magnetic force, Bernoulli adsorption, suction adsorption, drive equipment, etc. A configuration for supporting (holding) may be employed.

EA...Protrusion holding body manufacturing apparatus 20...Material supporting means 22...Supporting member 22A...Supporting surface 22B...Recessed part 30...Pressing means 32...Pressing member 32A...Pressing surface 32B...Extraction hole 80...Exuding means BM...Base material CB... Protrusion holder CV...Protrusion PG...Polyethylene glycol (leaching material)
PM: plastic material WT: water (leaching medium)

Claims (3)

A method for manufacturing a protrusion holder having a protrusion, comprising:
a material supporting step of supporting a base material containing a plastic material with a support member having a support surface on which recesses corresponding to the protrusions are formed;
a pressing step of pressing the base material in a direction toward the supporting surface to fill the recesses with the plastic material, and forming the protrusions from the plastic material to form the protrusion holders;
In the pressing step, at least one of the fluid and the plastic material existing between the plastic material and the pressing surface is used by using a pressing member having a through hole communicating with the pressing surface that presses the base material. is discharged through the hole, and the plastic material is filled into the concave portion. the plastic material contains a leaching material that leaches into the leaching medium;
2. The method of manufacturing a protrusion holder according to claim 1, wherein the leaching step of making the plastic material porous is performed by immersing the plastic material in the leaching medium after the pressing step. An apparatus for manufacturing a projection holder having projections formed thereon,
material support means for supporting a base material containing a plastic material with a support member having a support surface on which recesses corresponding to the protrusions are formed;
pressing means for pressing the base material in a direction toward the support surface to fill the recesses with the plastic material, and forming the protrusions from the plastic material to form the protrusion holders;
The pressing means has a pressing member formed with a through-hole communicating with a pressing surface that presses the base material, and at least the fluid existing between the plastic material and the pressing surface and the plastic material An apparatus for manufacturing a projection holding body, characterized in that the plastic material is filled into the recess while one of the plastic materials is discharged through the hole.

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