JP6635876B2 - Concave pattern mold, method for producing concave pattern mold, and method for producing pattern sheet - Google Patents

Description

  The present invention relates to a concave pattern mold, a method for manufacturing a concave pattern mold, and a method for manufacturing a pattern sheet, and in particular, a concave pattern mold used for manufacturing a pattern sheet having needle-like convex portions, and a method for manufacturing a concave pattern mold. And a method for manufacturing a pattern sheet using the concave pattern mold.

  As a method for administering a drug or the like from the surface of a living body, that is, skin or mucous membrane, a needle-like convex portion containing a drug and having a high aspect ratio (hereinafter, also referred to as “microneedle” or “microneedle”) is formed. A method of injecting a drug by inserting a needle-like convex portion into the skin using a percutaneous absorption sheet has been performed.

  Many methods for forming a projection pattern sheet have been proposed. For example, in the following Patent Document 1, a microneedle is manufactured by forming an intaglio having an inverted shape of the original from an original, filling the intaglio with a material for forming microneedles, drying and curing the intaglio. Is described.

JP 2015-136422 A

  In the method of manufacturing a microneedle described in Patent Document 1, the material of the mold (intaglio) has not been specifically studied. When filling the needle-shaped recess with liquid accurately, the head is pressed against the mold, but if the mold is not easily deformed, a gap is created between the head and the mold, and the liquid can be filled accurately. I didn't. Further, if the mold is not easily deformed, the liquid shrinks due to rapid drying of the liquid, so that bubbles may be included at the tip of the needle-shaped convex portion. In addition, since the mold is placed on the substrate for positioning and filling the needle-shaped concave portion with the liquid, positioning accuracy of the mold is required. Therefore, a material having a low adhesiveness to the substrate and a slipperiness is required on the back side of the mold.

  Thus, in the process of manufacturing a pattern sheet, it is required that the surface on which the needle-shaped concave portion of the mold is provided and the back surface thereof have different properties, but this point has not been studied. .

  The present invention has been made in view of such circumstances, the accuracy of filling the liquid into the needle-shaped concave portion, and a concave pattern mold with improved mold positioning accuracy, a method of manufacturing a concave pattern mold, and It is an object of the present invention to provide a method for manufacturing a pattern sheet using the concave pattern mold.

  In order to achieve the above object, the present invention provides a concave pattern mold in which a plurality of needle-shaped concave portions are arranged in an array, wherein the concave pattern mold comprises a first resin and a second resin different from the first resin. And a laminated body of two or more layers including a resin, and the back surface side of the needle-shaped concave portion in the thickness direction of the concave pattern mold is made of the first resin having lower adhesiveness than the second resin, and has a needle-like shape. The concave side provides a concave pattern mold made of a second resin having higher elongation than the first resin.

  According to the present invention, the concave pattern mold is a laminated body including the first resin and the second resin, and the needle-shaped concave side is made of the second resin having a higher elongation than the first resin. In the step of drying the liquid, even if the drying proceeds and the liquid shrinks, the mold can be deformed along the contracted needle-shaped convex portions. Therefore, it is possible to prevent bubbles from being contained in the needle-shaped convex portions.

  In addition, since the opposite side of the surface having the needle-shaped concave portion is formed of the first resin having lower adhesiveness than the second resin, when the concave pattern mold placed on the substrate is moved, , Can be easily moved and positioned. Therefore, positioning can be performed quickly, and productivity can be improved. As described above, by forming a concave pattern mold using resins having different characteristics in the thickness direction of the concave pattern mold, a design that is more suitable for manufacturing a pattern sheet than a concave pattern mold made of one type of resin. It can be.

  In addition, when the adhesiveness is low, in the adhesiveness between the concave pattern mold and the contact material, when the concave pattern mold is allowed to stand on the contact material and the concave pattern mold end is pulled, there is no large resistance to slip. About stickiness. The elongation can be defined by (amount of change in elastic deformation) / (dimension before deformation), and the second resin is 300% or more and the first resin is 200% or less, preferably 100% or less. % Or less of the resin is preferably used.

  In another aspect of the present invention, it is preferable that no interface of the resin of the laminate exists on the surface in the acicular concave portion.

  According to this aspect, since the resin interface of the laminate does not exist on the surface in the acicular concave portion, the manufactured pattern sheet can be stably peeled.

  According to another aspect of the present invention, it is preferable that the laminate is a two-layer laminate of the first resin and the second resin.

  According to this aspect, by forming the concave pattern mold into a two-layer laminate, one material is applied and dried to form a resin layer, and then the other material is applied on the resin layer and dried. , A concave pattern mold can be manufactured. Therefore, it is possible to easily manufacture the concave pattern mold.

  According to another aspect of the present invention, the first resin and the second resin are preferably silicone resins.

  According to this aspect, since the concave pattern mold is made of a silicone resin, it is possible to manufacture a pattern sheet that maintains safety even when the pattern sheet is a drug.

  In order to achieve the above object, the present invention provides a step of applying a first resin solution containing a first resin having a lower tackiness than a second resin on a substrate, A step of applying a second resin solution containing a second resin having a higher elongation than the first resin, a step of pressing a mold having needle-like projections on the second resin solution, Production of a concave pattern mold having a step of forming a second resin film by curing the second resin solution while pressing the mold against the resin solution, and a step of peeling the mold from the second resin film Provide a way.

  In order to achieve the above object, the present invention provides a step of applying a second resin solution containing a second resin having higher elongation compared to the first resin on a mold having a needle-like convex portion, A step of curing the second resin solution while pressing the second resin solution with the substrate from the opposite side of the mold to form a second resin film having a needle-like concave portion, and peeling the mold and the substrate A method for manufacturing a concave pattern mold, comprising: a step of applying a first resin having a lower adhesiveness than a second resin to a side of a second resin film opposite to a surface having a needle-shaped recess. provide.

  In order to achieve the above object, the present invention provides a medicine filling step of filling the needle-shaped recess of the concave pattern mold with a medicine, and a base liquid for applying a base liquid to the surface of the concave pattern mold after the medicine filling step. Provided is a method for manufacturing a pattern sheet, comprising: an application step; a drying step of drying a base liquid to form a pattern sheet; and a peeling step of peeling the pattern sheet from a concave pattern mold.

  According to the present invention, by manufacturing a pattern sheet using the concave pattern mold, it is possible to accurately manufacture a needle-shaped convex portion of the pattern sheet, which is an inverted type of the needle-shaped concave portion of the concave pattern mold. .

  According to the concave pattern mold of the present invention, the needle-shaped concave side of the concave pattern mold is made of a highly extensible material, and the rear side of the needle-shaped concave part is made of a material having low adhesiveness, so that the pattern having the needle-shaped convex parts is formed. In the manufacture of the sheet, the shape of the needle-shaped protrusions can be formed stably, and the positioning of the mold can be performed with high accuracy, so that the productivity can be improved.

FIG. 4 is a process chart showing a procedure for manufacturing a mold having a protruding pattern. FIG. 4 is a process chart showing a procedure for manufacturing a mold having a protruding pattern. FIG. 4 is a process chart showing a procedure for manufacturing a mold having a protruding pattern. FIG. 4 is a process chart showing a procedure for manufacturing a mold having a protruding pattern. FIG. 4 is a process chart showing a procedure for manufacturing a mold having a protruding pattern. FIG. 4 is a process chart showing a procedure for manufacturing a mold having a protruding pattern. FIG. 4 is a process chart showing a procedure for forming a concave pattern mold. FIG. 4 is a process chart showing a procedure for forming a concave pattern mold. FIG. 4 is a process chart showing a procedure for forming a concave pattern mold. FIG. 4 is a process chart showing a procedure for forming a concave pattern mold. It is a flowchart showing another procedure of forming a concave pattern mold. It is a flowchart showing another procedure of forming a concave pattern mold. It is a flowchart showing another procedure of forming a concave pattern mold. It is a flowchart showing another procedure of forming a concave pattern mold. FIG. 4 is a process chart showing a procedure for forming a pattern sheet. FIG. 4 is a process chart showing a procedure for forming a pattern sheet. FIG. 4 is a process chart showing a procedure for forming a pattern sheet. It is a flowchart showing the procedure of peeling a pattern sheet. It is a flowchart showing another procedure of forming a pattern sheet. It is a flowchart showing another procedure of forming a pattern sheet. It is a flowchart showing another procedure of forming a pattern sheet.

  Hereinafter, a method for manufacturing a concave pattern mold and a pattern sheet according to the present invention will be described with reference to the accompanying drawings. In addition, in this specification, "-" is used in the meaning including the numerical value described before and after it as a lower limit and an upper limit. Hereinafter, an example using a silicone resin will be described as an example of the resin, but the present invention is not limited to this.

<Method of manufacturing concave pattern mold>
[Step of manufacturing first mold]
The first mold 20 includes a concave pattern 22 that is a reverse mold of the mold 40 for manufacturing a mold 40 having a projecting pattern 42 that is a reverse mold of a concave pattern mold (hereinafter, also referred to as a “mold”) 58. Type. The first mold 20 is manufactured using a resin from the original plate 10 on which the protruding patterns 12 are formed.

  First, as shown in FIG. 1, an original plate 10 on which projection patterns 12 are formed in an array is prepared. The method of producing the original plate 10 on which the protruding patterns 12 are formed is not particularly limited, but for example, it can be produced as follows. By processing a metal substrate such as Ni by mechanical cutting using a cutting tool such as a diamond tool, a plurality of protrusion patterns 12 can be formed on the surface of the original plate 10.

  As another method, after applying a photoresist on a Si substrate, exposure and development are performed. Then, by performing etching by RIE (Reactive Ion Etching) or the like, the protruding pattern 12 is formed on the surface of the original plate 10. When etching such as RIE is performed to form the protruding pattern 12 on the surface of the original plate 10, the protruding pattern may be formed by performing etching in an oblique direction while rotating the Si substrate. It is possible.

  Next, as shown in FIGS. 2 and 3, a plurality of first molds 20 having a concave pattern 22 are manufactured using the original plate 10. The method of manufacturing the first mold 20 can be performed using a resin by the following method. In the first method, a silicone resin obtained by adding a curing agent to PDMS (polydimethylsiloxane, for example, Silgard 184 manufactured by Dow Corning Co.) is poured into the master 10, heated at 100 ° C., cured, and then cured from the master. A first mold 20 having a concave pattern 22, which is a reversal type of the projecting pattern, is manufactured.

  The second method is a method in which an ultraviolet curable resin which is cured by irradiating ultraviolet rays is poured into the master 10, and the first mold 20 is peeled off from the master 10 after irradiating the ultraviolet rays in a nitrogen atmosphere. In the third method, a solution obtained by dissolving a plastic resin such as polystyrene or PMMA (polymethyl methacrylate) in an organic solvent is poured into an original plate 10 coated with a release agent and dried to volatilize the organic solvent. This is a method in which the first mold 20 is peeled off from the original plate 10 after being cured.

  The material for forming the first mold 20 is a resin, and it is preferable to use an ultraviolet curable resin or a thermoplastic resin. By using an ultraviolet curing resin or a thermoplastic resin, the first mold 20 can be easily manufactured, and the protruding patterns 12 of the original plate 10 can be formed stably.

[Process of manufacturing the first collective mold]
Next, as shown in FIG. 4, the plurality of first molds 20 manufactured from the original plate 10 are joined, the surface 24 of the first mold 20 on which the concave pattern 22 is formed is enlarged, and the first collective mold 30 is formed. To produce

  The first collective mold 30 can be manufactured by joining a plurality of first molds 20. The joining of the first mold 20 can be performed by, for example, an adhesive. Since the first collective mold 30 is a mold of the mold 40 having the protruding pattern 42 manufactured in the next step, the first collective mold 30 is kept in a state where the flatness of the surface 24 on which the concave pattern 22 is formed is secured. Preferably, the collective mold 30 is formed. If the flatness of the surface 24 on which the concave pattern 22 is formed is not ensured, a step is formed in a mold, a mold, and a pattern sheet manufactured in a subsequent step, which is not preferable.

  The method of manufacturing the first collective mold 30 while securing the planarity of the concave pattern 22 is not particularly limited. For example, the surface 24 of the first mold 20 on which the concave pattern 22 is formed faces downward on the substrate. After being arranged at a position in contact with the substrate, it is cured with an adhesive, so that the planarity of the first collective mold 30 can be ensured. As described above, by securing the planarity of the first collective mold 30 using the substrate, it is possible to suppress the occurrence of steps, deformation, and the like between the first collective mold 30 and the adhesive between the first molds 20. The flatness of the first collective mold 30 can be ensured.

  The production of the first collective mold 30 may or may not be performed. When the first collective mold 30 is not manufactured, a mold having a protruding pattern is manufactured from the first mold 20. However, it is preferable to manufacture the first collective mold 30 because a large-area mold can be manufactured by one electroforming process. Also in the subsequent steps, the production of the mold using the large-area mold and the production of the pattern sheet from the mold are preferable, so that the productivity of the pattern sheet can be improved.

[Step of manufacturing a mold having a projecting pattern]
FIG. 5 is a diagram illustrating a process of manufacturing the mold 40 having the projecting pattern 42 using the first collective mold 30. The mold 40 is preferably manufactured by an electroforming process.

  In the electroforming process, first, a conductive process is performed on the first collective mold 30. Metal (for example, nickel) is sputtered on the first mold 20 of the first collective mold 30, and the metal is attached to the surface of the first mold 20 of the first collective mold 30 and the concave pattern 22.

  Next, the first collective mold 30 that has been subjected to the conductive treatment is held on the cathode. The metal pellet is held in a metal case to serve as an anode. The cathode holding the first assembly mold 30 and the anode holding the metal pellets are immersed in the electroforming solution and energized, so that the metal is embedded in the concave pattern 22 of the first assembly mold 30 and peeled off. A mold 40 having a protruding pattern 42 is manufactured (FIG. 6).

  Further, the production of the mold 40 having the protruding pattern 42 is not limited to the electroforming process, but may be performed by supplying a resin to the first collective mold and curing the resin.

  The mold 40 having the protruding pattern 42 is not limited to the method shown in FIGS. 1 to 6, and can be manufactured by the same method as the method of manufacturing the original plate 10. However, the cost of producing the master 10 increases as the pattern becomes finer and more complex. Therefore, when producing a large mold, the number of the projecting patterns 42 increases, which increases the cost. Also, there is a concern that the shape of the projecting pattern 42 is different. Therefore, as shown in FIG. 1 to FIG. 6, by manufacturing a plurality of first molds 20 from the master 10 and manufacturing the mold 40, the mold 40 can be manufactured at low cost.

[Step of forming concave pattern mold]
Next, a method of manufacturing a concave pattern mold using the mold 40 manufactured as described above will be described. 7 to 10 are process diagrams showing a procedure for forming a concave pattern mold.

  First, a substrate 50 is prepared, and a first resin solution containing a first resin having a lower tackiness than a second resin is applied to the substrate 50 after curing. As a material of the substrate 50, metal, glass, ceramic, silicon, or the like can be used. The method for applying the first resin solution is not particularly limited, and examples thereof include application using a spin coater or a bar. After applying the first resin solution, the first resin solution is heated and cured to form the first resin film 52 (FIG. 7). As a method for heating the first resin solution, an aluminum heater, an infrared heater, a ceramic heater, an IH (Induction Heating) heater, or the like can be used. In some cases, the next step can be performed without curing the first resin solution without curing.

  Next, as shown in FIG. 8, after curing, a second resin solution 54 containing a second resin, which has higher elongation than the first resin, is applied to the first resin film 52. The method of applying the second resin solution 54 can be performed by the same method as the method of applying the first resin solution.

  Next, the pressure of the second resin solution 54 applied on the first resin film 52 is reduced, and the second resin solution 54 is defoamed. The defoaming of the second resin solution 54 is performed by putting the second resin solution 54 in a decompression device (not shown) together with the substrate 50 and the like, and reducing the pressure in the decompression device.

  The defoaming of the second resin solution 54 can be confirmed visually or by image recognition using a CCD (Charge-Coupled Device) camera. By defoaming the second resin solution 54, the air contained in the second resin solution 54 can be removed, so that the shape at the time of molding can be stabilized.

  Next, as shown in FIG. 9, the mold 40 is pressed against the second resin solution 54 on the substrate 50, and the second resin solution 54 is heated and cured in the pressed state, thereby forming the second resin film. 56 is formed. As a method of heating the second resin solution 54, a method similar to the method of heating the first resin solution can be used.

  Next, as shown in FIG. 10, the substrate 50 is peeled from the first resin film 52 and the mold 40 is peeled from the second resin film 56, so that the projection pattern 42 of the mold 40 is an inverted mold. The concave pattern mold 58 in which the concave portions are arranged in an array can be formed. The formed concave pattern mold 58 is formed of different materials on the needle-shaped concave side of the mold and on the back side thereof. The substrate 50 and the mold 40 can be separated by providing an air ejection mechanism (not shown) and supplying air by the air ejection mechanism.

  Note that, in the above description, the method of applying the first resin solution, heating and curing to form the first resin film, and then applying the second resin solution has been described. However, the present invention is not limited to this. After the application of the first resin solution, the second resin solution may be applied, and the mold may be pressed and heated to simultaneously cure the first resin solution and the second resin solution.

<Resin>
Next, the resin used in the present embodiment will be described. In the concave pattern mold 58 of the present embodiment, the surface on which the needle-shaped concave portions are formed is made of a highly extensible material, and the back surface on which the needle-shaped concave portions are not formed is made of a low-adhesive material. In order to form the concave pattern mold 58 in such a configuration, in the above-described manufacturing process, the first resin contained in the first resin solution and the second resin contained in the second resin solution are made of different materials. . As a material to be used, a silicone resin can be used. For example, MED6019 manufactured by Nusil Co., Ltd. can be used as the first resin on the back side of the concave pattern mold 58. Further, as the second resin on the needle-shaped concave side of the concave pattern mold 58, MED6015 and MED4044 manufactured by Nusil can be used.

<Concave pattern mold>
By forming the concave pattern mold 58 using the above-described material, a two-layer laminate structure in which the surface side on which the needle-shaped concave portions are formed has high extensibility and the back surface side has low adhesiveness can be obtained. it can. The configuration of the concave pattern mold is not limited to two layers, and may be a laminate structure of three or more layers.

  In the concave pattern mold 58, by forming the needle-like concave portion side with a highly extensible material, a resin solution can be accurately filled in the needle-like concave portion when forming a pattern sheet. The filling of the needle-shaped concave portion with the resin solution is performed by pressing the nozzle against the mold. By making the material on the needle-shaped concave side of the mold a highly extensible material, when the nozzle is pressed against the mold, the mold is not deformed and a gap is not formed between the nozzle and the mold. Therefore, the resin solution discharged from the nozzle can be reliably supplied into the needle-shaped recess.

  In addition, by using a low-adhesive material on the back side of the mold, the mold can be easily moved when positioning the mold when forming the pattern sheet, so that the position after the mold is arranged can be easily corrected. Can be done.

  Further, when the pattern sheet is formed, even if the resin solution shrinks due to drying, the needle-shaped concave portion side is made of a highly extensible material, so that the shape of the needle-shaped concave portion is deformed in accordance with the contraction of the resin solution. Therefore, it is possible to prevent bubbles from being generated in the needle-shaped protrusions of the formed pattern sheet. Therefore, it is possible to stabilize the shape of the needle-shaped protrusions of the pattern sheet.

  Further, it is preferable that the surface of the needle-shaped concave portion of the concave pattern mold is formed by exposing a highly extensible material. Since the surfaces of the acicular concave portions are all formed of a highly extensible material, there is no interface between the plurality of resins of the mold in the middle of the acicular convex portions of the manufactured pattern sheet. Peeling can be performed stably.

≪Other manufacturing methods≫
11 to 14 are diagrams illustrating another method of manufacturing the concave pattern mold. First, as shown in FIG. 11, the second resin solution 154 is applied on the mold 40. As the second resin solution, the above-described material having high elongation can be used. Further, the method of applying the second resin solution 154 can be performed in the same manner. Further, when the mold 40 has a plurality of regions in which the protruding patterns 42 are formed, the slit nozzles can be applied to each region having the protruding patterns 42 with the width of the protruding patterns 42. By applying the second resin solution to each region having the protruding pattern 42, the second resin solution can be applied only to the position where the mold is manufactured, so that unnecessary application of the second resin solution can be performed. Can be prevented.

  Next, the substrate 50 is pressed against the second resin solution on the mold 40, and the second resin solution is heated and cured in the pressed state to form the second resin film 156 (FIG. 12). . Thereafter, the mold 40 and the substrate 50 are peeled off, thereby manufacturing the second resin film 156 in which the needle-shaped concave portions, which are the inverse types of the projecting patterns 42 of the mold 40, are formed (FIG. 13).

  Next, as shown in FIG. 14, a low-adhesive material 160 is applied to the back surface of the second resin film 156 opposite to the surface on which the needle-shaped concave portions are formed. As the material 160 having low adhesiveness, a resin similar to the above-described first resin can be applied. This makes it possible to manufacture a mold 158 having a high elongation property on the needle-like concave side and a low adhesive property on the back side. The first resin may be applied by applying a first resin solution containing the first resin, followed by heating and curing.

  In the present invention, "adhesiveness" can be measured by a ball tack test.

<Method of manufacturing pattern sheet>
Next, a method of manufacturing a pattern sheet using the concave pattern mold 58 will be described. FIGS. 15 to 17 are diagrams showing the steps of manufacturing a pattern sheet.

  As shown in FIG. 15, the needle-shaped concave portion 62 of the mold 58 is filled with a solution 72 containing a drug (drug filling step). As a filling method, only the needle-shaped recess 62 may be filled by bringing the tip of the nozzle into contact with the mold 58. Alternatively, a solution containing a drug may be filled in the needle-shaped concave portion by applying a solution containing a drug on the mold and bringing a blade into contact with the mold.

  Next, as shown in FIG. 16, a solution (base solution) 74 containing no drug is applied onto the solution 72 containing the drug by a dispenser (base solution application step). In addition to coating by a dispenser, bar coating, spin coating, coating by spraying, and the like can be applied.

  Next, as shown in FIG. 17, a solution 72 containing a drug and a solution 74 containing no drug are dried and solidified to form a pattern sheet including a layer 76 containing a drug and a layer 78 containing no drug. 80 are formed (drying step). Drying and solidification can be performed by blowing air onto the dissolving solution 72 containing a drug and the dissolving solution 74 containing no drug (hereinafter, also referred to as “dissolving solutions 72 and 74”) supplied to the mold 58. . The pattern sheet 80 means a state after subjecting the solutions 72 and 74 to a desired drying treatment. The water content of the pattern sheet 80 and the like are appropriately set. In addition, since it becomes difficult to peel off when the moisture content of the pattern sheet becomes too low by drying, it is preferable to leave the moisture content in a state where elasticity is maintained.

  A pattern sheet on the surface of which a needle-like convex portion formed of a drug-containing layer 76 composed of a drug-containing solution 72 and a drug-free layer 78 composed of a drug-free solution 74 is formed After forming 80, the process proceeds to a peeling step of peeling the pattern sheet 80 from the mold 58.

  The method of peeling the pattern sheet 80 from the mold 58 is not particularly limited. It is desired that the needle-shaped convex portion does not bend or break during peeling. For example, as shown in FIG. 18, after attaching a sheet-like base material 82 having an adhesive layer formed on a pattern sheet 80, a suction cup (not shown) is set on the base material 82. A method of vertically pulling up while suctioning with air can be applied. By vertically pulling up, it is possible to prevent the needle-shaped convex portion from being bent or broken during peeling. Moreover, you may peel off so that the base material 82 may turn from an edge part.

  Another method of manufacturing a pattern sheet will be described with reference to FIGS. Up to the drug filling step, the same method can be used. Next, as shown in FIG. 19, the mold frame 90 is set in a region of the mold 58 where the needle-shaped concave portions are not formed. In the present embodiment, since the mold 58 needle-shaped concave side is formed of the second resin film 56 having higher adhesiveness than the first resin film 52, the installed mold 90 moves during the work. Can be prevented.

  Next, as shown in FIG. 20, a solution (base solution) 92 containing no drug is applied on the solution 72 containing the drug in the mold 90 (base solution application step). After the application, as shown in FIG. 21, a solution 72 containing a drug and a solution 74 containing no drug are dried and solidified to form a pattern composed of a layer 76 containing a drug and a layer 94 containing no drug. The sheet 96 is formed (drying step). The substrate liquid applying step and the drying step can be performed by the same method as described above.

  After that, the pattern sheet 96 is peeled from the mold 58. As described above, the pattern sheet 96 can be divided and manufactured by installing the mold 90 before applying the solution 92 containing no drug.

  It is preferable to use a water-soluble material as a material of the dissolving liquids 72 and 74 forming the pattern sheet 80. It is preferable to use a biocompatible resin as the material of the resin polymer contained in the solution used for producing the pattern sheet. Examples of such a resin include sugars such as glucose, maltose, pullulan, sodium chondroitin sulfate, sodium hyaluronate and hydroxyethyl starch, proteins such as gelatin, and biodegradable polymers such as polylactic acid and lactic acid / glycolic acid copolymer. It is preferred to use. Although the concentration varies depending on the material, the concentration is preferably such that the resin polymer is contained in the solution containing no drug in an amount of 10 to 50% by mass. The solvent used for dissolution may be any solvent other than warm water as long as it has volatility, and alcohols such as ethanol may be used. Then, in the solution of the resin polymer, it is possible to dissolve the drug to be supplied into the body together depending on the application. The polymer concentration of the solution containing the drug (when the drug itself is a polymer, the concentration of the polymer excluding the drug) is preferably 0 to 30% by mass.

  When a water-soluble polymer (eg, gelatin) is used, the solution may be prepared by dissolving a water-soluble powder in water and adding the drug after dissolution, or adding The powder of the conductive polymer may be added and dissolved. When it is difficult to dissolve in water, it may be dissolved by heating. The temperature can be appropriately selected depending on the type of the polymer material. However, it is preferable to heat at a temperature of about 20 to 40 ° C., if necessary. The viscosity of the solution of the resin polymer is preferably 200 mPa · s or less, more preferably 50 mPa · s or less, for the solution containing the drug. The dissolving solution containing no drug preferably has a pressure of 2000 mPa · s or less, more preferably 500 mPa · s or less. By appropriately adjusting the viscosity of the solution of the resin polymer, the solution can be easily injected into the needle-shaped concave portion of the mold. For example, the viscosity of the solution of the resin polymer can be measured with a capillary viscometer, a falling ball viscometer, a rotary viscometer or a vibration viscometer.

  The drug contained in the solution is not limited as long as it has a function as a drug. In particular, it is preferable to select from peptides, proteins, nucleic acids, polysaccharides, vaccines, pharmaceutical compounds belonging to water-soluble low molecular weight compounds, or cosmetic components.

  In the present embodiment, the pattern sheet 80 is manufactured by filling and applying a solution 72 containing a drug and a solution 74 containing no drug, and then drying and solidifying the solution. However, the present invention is not limited to this. For example, the needle-shaped recess 62 of the mold 58 is filled with a solution 72 containing a drug, dried, and then a layer 76 containing a drug is formed. Then, the pattern sheet 80 can be manufactured by applying a solution 74 containing no drug, drying and solidifying the solution.

  The shape of the protrusion of the pattern sheet 80 to be manufactured is not particularly limited as long as the tip is tapered. For example, the shape may be a cone, or a pyramid such as a triangular pyramid or a quadrangular pyramid. it can. Further, it can be formed by a tapered needle portion and a frustum portion connected to the needle portion.

  The protruding height of the protruding pattern is in the range of 100 μm or more and 2000 μm or less, and preferably 200 μm or more and 1500 μm or less.

  Since the pattern sheet 80 having the projecting pattern to be manufactured is a copy of the mold 40 having the projecting pattern 42, the pattern sheet manufactured by setting the shape of the projecting pattern 42 of the mold 40 to a desired shape 80 can be formed into a desired shape.

Reference Signs List 10 original plate 12 projecting pattern 20 first mold 22 concave pattern 24 surface on which concave pattern is formed 30 first collective mold 40 mold 42 projecting pattern 50 substrate 52 first resin film 54, 154 second resin solution 56, 156 second resin film 58, 158 concave pattern mold (mold)
62 Needle-shaped concave portion 72 Dissolution solution containing drug (dissolution solution)
74, 92 Drug-free solution (solution)
76 Drug-containing layer 78, 94 Drug-free layer 80, 96 Pattern sheet 82 Substrate 90 Formwork 160 Low tack material

Claims (6)

A concave pattern mold in which a plurality of needle-shaped concave portions are arranged in an array,
The concave pattern mold is a two-layer laminate of a first resin and a second resin different from the first resin,
In the thickness direction of the concave pattern mold, the back surface side of the needle-like concave portion is made of a first resin having lower adhesiveness than the second resin,
A concave pattern mold made of a second resin having a higher extensibility than the first resin on the needle-like concave side.   The concave pattern mold according to claim 1, wherein an interface of the resin of the laminate does not exist on a surface in the acicular concave portion. 3. The concave pattern mold according to claim 1, wherein the first resin and the second resin are silicone resins. A step of applying a first resin solution containing a first resin having a lower tackiness than the second resin on a substrate;
A step of applying a second resin solution containing the second resin, which has a higher elongation than the first resin, on the first resin;
Pressing a mold having a needle-shaped convex portion on the second resin solution;
Curing the second resin solution while the mold is pressed against the second resin solution to form a second resin film;
Removing the mold from the second resin film. A step of applying a second resin solution containing a second resin having a higher elongation than the first resin on a mold having needle-like convex portions;
Curing the second resin solution in a state where the second resin solution is pressed by the substrate from the opposite side of the mold to form a second resin film having a needle-shaped recess;
Peeling the mold and the substrate;
Applying a first resin having a lower adhesiveness than the second resin to a side of the second resin film opposite to a surface having the needle-shaped concave portions. A drug filling step of filling the needle-shaped concave portion of the concave pattern mold according to any one of claims 1 to 3 with a drug,
A base liquid application step of applying a base liquid to the surface of the concave pattern mold after the drug filling step,
Drying the base liquid, a drying step of forming a pattern sheet,
A method for manufacturing a pattern sheet, comprising: a separating step of separating the pattern sheet from the concave pattern mold.

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