US20070118070A1 - Device with anchoring elements for transdermal delivery or sampling of agents - Google Patents

Abstract

A percutaneous agent delivery or sampling device comprising a sheet having a plurality of microblades for piercing and anchoring to the skin for increasing transdermal flux of an agent and for improving the attachment of the device to the skin.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• A claim is made, under 35 USC 119(e), to the benefit of the filing of U.S. Patent Application Ser. No. 60/019,990 filed Jun. 18, 1996.
FIELD OF THE INVENTION
• The present invention relates to transdermal agent delivery and sampling. More particularly, this invention relates to the transdermal delivery of agents, such as peptides and proteins, as well as the transdermal sampling of agents, such as glucose, body electrolytes and substances of abuse, such as but not limited to alcohol and illicit drugs. The present invention uses skin-piercing microblades to enhance the transdermal flux of the agents during transdermal delivery or sampling and anchoring elements to assist in retaining the delivery or sampling device in the skin.
BACKGROUND OF THE INVENTION
• Interest in the percutaneous or transdermal delivery of peptides and proteins to the human body continues to grow with the increasing number of medically useful peptides and proteins becoming available in large quantities and pure form. The transdermal delivery of peptides and proteins still faces significant problems. In many instances, the rate of delivery or flux of polypeptides through the skin is insufficient to produce a desired therapeutic effect due to the binding of the polypeptides to the skin. In addition, polypeptides and proteins are easily degraded during and after penetration into the skin, prior to reaching target cells. Likewise, the passive flux of water soluble small molecules such as salts is limited.
• One method of increasing the transdermal delivery of agents relies on the application of an electric current across the body surface or on “electrotransport”. “Electrotransport” refers generally to the passage of a beneficial agent, e.g., a drug or drug precursor, through a body surface such as skin, mucous membranes, nails, and the like. The transport of the agent is induced or enhanced by the application of an electrical potential, which results in the application of electric current, which delivers or enhances delivery of the agent. The electrotransport of agents through a body surface may be attained in various manners. One widely used electrotransport process, iontophoresis, involves the electrically induced transport of charged ions. Electroosmosis, another type of electrotransport process, involves the movement of a solvent with the agent through a membrane under the influence of an electric field. Electroporation, still another type of electrotransport, involves the passage of an agent through pores formed by applying a high voltage electrical pulse to a membrane. In many instances, more than one of these processes may be occurring simultaneously to different extents. Electrotransport delivery generally increases agent delivery, particularly large molecular weight species (e.g., polypeptides) delivery rates, relative to passive or non-electrically assisted transdermal delivery. However, further increases in transdermal delivery rates and reductions in polypeptide degradation during transdermal delivery are highly desirable.
• One method of increasing the agent transdermal delivery rate involves pre-treating the skin with, or alternatively co-delivering with the beneficial agent, a skin permeation enhancer. The term “permeation enhancer” is broadly used herein to describe a substance which, when applied to a body surface through which the agent is delivered, enhances its electrotransport flux. The mechanism may involve a reduction of the electrical resistance of the body surface to the passage of the agent therethrough, an increase in the permeability of the body surface, the creation of hydrophilic pathways through the body surface, and/or a reduction in the degradation of the agent (e.g., degradation by skin enzymes) during electrotransport.
• There have been many attempts to enhance transdermal flux by mechanically puncturing the skin prior to transdermal drug delivery. See for example U.S. Pat. No. 5,279,544 issued to Gross et al., U.S. Pat. No. 5,250,023 issued to Lee et al., and U.S. Pat. No. 3,964,482 issued to Gerstel et al. These devices utilize tubular or cylindrical structures generally, although Gerstel does disclose the use of other shapes, to pierce the outer layer of the skin. Each of these devices provide manufacturing challenges, limited mechanical attachment of the structure to the skin, and/or undesirable irritation of the skin.
• As has been discussed, a variety of chemicals and mechanical means have been explored to enhance transdermal flux. However, there is still a need to provide a device suitable for increasing transdermal flux which device is low-cost and which can be manufactured reproducibly (i.e., without significant variation from device to device) in high volume production and to improve the attachment of the device to the skin.
DESCRIPTION OF THE INVENTION
• The present invention provides a reproducible, high volume production, low-cost device suitable for increasing transdermal flux and improving attachment to the skin with minimal to no skin irritation. The device generally comprises a structure that attaches to the skin more effectively than the prior art devices. The invention comprises a plurality of microblades for piercing and anchoring to the skin. The blades typically have a length of less than about 0.4 mm and a width and thickness which is even smaller. In spite of their small size, the blades can be made with an extremely reproducible size and shape so that the microslits formed by the blades puncturing the skin also have a very reproducible size and depth. Because the blades have a small thickness (i.e., small relative to the width and length of the blades), the blades produce less tissue damage for a given cross-section than a skin piercing microneedle having a circular cross-section. The device of the present invention pierces the stratum corneum of a body surface to form pathways through which a substance (e.g., a drug) can be introduced (i.e., delivery) or through which a substance (e.g., a body electrolyte) can be withdrawn (i.e., sampling).
• In one aspect of the invention, the device comprises a sheet having a plurality of openings therethrough, a plurality of microblades integral therewith and extending downward therefrom, and means for anchoring the device to a body surface. In the many different aspects of the invention, the device is anchored to the body surface in any of plurality of ways, including but not limited to, having an extension such as a prong or barb extending from at least some of the microblades, having an opening extending perpendicular through at least some of the microblades, covering essentially the entire surface area of the skin contacting surface of the device with adhesive except for one side of the microblades, orienting at least some of the plurality of microblades at an angle of 90° to the remainder of the plurality of microblades, orienting at least some of the plurality of microblades at an angle within a range of about 1° to about 89° with respect to the remainder of the plurality of microblades, providing a plurality of second openings through the sheet which make the device more shapeable with respect to the body surface. The device of the present invention can be used in connection with drug delivery, body analyte or drug sampling, or both. Delivery devices for use with the present invention include, but are not limited to, electrotransport devices, passive devices, osmotic devices and pressure-driven devices. Sampling devices for use with the present invention include, but are not limited to, “reverse” electrotransport devices as disclosed in Glikfeld et al., U.S. Pat. No. 5,279,543, passive devices, osmotic devices and negative pressure driven devices.
• The present invention also provides a high yield, low-cost method for producing, in extremely reproducible fashion, the device of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a perspective exploded view of one embodiment of an electrotransport agent delivery system with a blade array device according to one embodiment of the present invention;
• FIG. 2 is an enlarged perspective view of the skin proximal side of the blade array device in accordance with one embodiment of the present invention;
• FIG. 3 is a partial top plan view of a blade array pattern in accordance with one embodiment of the present invention for forming blades with anchoring elements;
• FIG. 4 is partial top plan view of yet another embodiment of the blade array pattern ofFIG. 3;
• FIG. 5 is an enlarged view of a portion of the blades of the blade array pattern ofFIG. 3;
• FIG. 6 is an enlarged view of a blade tip in accordance with one embodiment of the present invention;
• FIG. 7 is an enlarged view of a blade tip in accordance with another embodiment of the present invention;
• FIG. 8 is a diagrammatic representation of a method for producing blades of the present invention from the blade array pattern ofFIG. 3;
• FIG. 9 is an enlarged cross-sectional view of angled blades in accordance with one embodiment of the present invention;
• FIGS. 10, 11 and12 are yet other embodiments of the blades with anchoring elements of the present invention;
• FIG. 13 is a right side elevational view of another embodiment of a blade with an anchoring element;
• FIG. 14 is an end view of the blade ofFIG. 13;
• FIGS. 15 and 16 are another embodiment of the blade and an anchoring element;
• FIG. 17 is a right side elevational view of a blade with anchoring elements in accordance with one embodiment of the present invention;
• FIG. 18 is a cross-sectional view taken along line18-18 ofFIG. 17;
• FIG. 19 is a right side elevational view of another embodiment of a blade with an anchoring element;
• FIG. 20 is an enlarged partial top plan view of still another embodiment of the blade array pattern;
• FIG. 21 is an enlarged partial top plan view of yet another embodiment of the blade array pattern;
• FIG. 22 is a bottom plan view of the electrotransport agent delivery system ofFIG. 1;
• FIG. 23 is a right side elevational view of the electrotransport agent delivery system ofFIG. 1;
• FIG. 24 is a rear elevational view of the electrotransport agent delivery system ofFIG. 1;
• FIG. 25 is a cross-sectional view taken along line25-25 of the assembled electrotransport agent delivery system ofFIG. 23;
• FIG. 26 is a diagrammatic cross-sectional view of a passive agent delivery system in accordance with one embodiment of the present invention;
• FIG. 27 is a diagrammatic cross-sectional view of another embodiment of a passive agent delivery system in accordance with the present invention;
• FIG. 28 is a diagrammatic cross-sectional view of a sampling system in accordance with one embodiment of the present invention; and
• FIG. 29 is a diagrammatic cross-sectional view of another embodiment of the blades of the present invention.
MODES FOR CARRYING OUT THE INVENTION
• Turning now to the drawings in detail, one embodiment of thedevice2 of the present invention is generally shown inFIG. 1 for use withelectrotransport delivery device10.Device2 is used for the percutaneous administration or sampling of an agent. The terms “substance”, “agent” and “drug” are used interchangeably herein and broadly include physiologically or pharmacologically active substances for producing a localized or systemic effect or effects in mammals including humans and primates, avians, valuable domestic household, sport or farm animals, or for administering to laboratory animals such as mice, rats, guinea pigs, and the like. These terms also include substances such as glucose, electrolyte, alcohol, illicit drugs, etc. that can be sampled through the skin. The major barrier properties of the skin, such as resistance to drug penetration, reside with the stratum corneum. The inner division of the epidermis generally comprises three layers commonly identified as stratum granulosum, stratum Malpighi, and stratum germinativum. Once a drug penetrates below the stratum corneum, there is substantially less resistance to permeation through the underlying stratum granulosum, stratum Malpighi, and stratum germinativum layers for absorption and circulation of drug into the body. The device of the present invention is used to form microslits in the stratum corneum and produce a percolation area in the skin for improved transdermal delivery or sampling of an agent.
• Device2 comprises a plurality of microblades4 (i.e., a blade array) extending downward from one surface of a sheet or plate6 (seeFIG. 2 in whichdevice2 is in an inverted position to show the microblades). Themicroblades4 penetrate the stratum corneum of the epidermis when pressure is applied to the device to increase the administration of or sampling of a substance through a body surface. The term “body surface” as used herein refers generally to the skin, mucous membranes, and nails of an animal or human, and to the outer surface of a plant.
• Furthermore, thedevice2 of the present invention improves the attachment of the device to the skin so that the percolation areas and a continuous pathway are preserved during movement of the body surface. In the embodiment shown inFIG. 2, projections in the form ofbarbs50 on at least one of theblades4 assist in anchoring thedevice2 and any corresponding device or structure used in combination therewith to the skin.Barbs50 can be on any number of the blades from one blade to all blades. Other embodiments which assist to anchor the device to the skin will be discussed below.
• Themicroblades4 are generally formed from a single piece of material and are sufficiently sharp and long for puncturing the stratum corneum of the skin. In one embodiment, themicroblades4 and thesheet6 are essentially impermeable or are impermeable to the passage of an agent. Thesheet6 is formed with anopening8 between themicroblades4 for enhancing the movement of an agent therethrough. In the case of therapeutic agent (e.g., drug) delivery, the drug is released from a drug-containing reservoir (not shown inFIG. 2) through microslits formed by themicroblades4 cutting through the stratum corneum, migrating down the outer surfaces of the microblades and through the stratum corneum to achieve local or systemic therapy. In the case of agent (e.g., body analyte) sampling, the analyte (or interstitial fluid containing the analyte) migrates from the body through the microslits in the stratum corneum which are cut by themicroblades4. In one embodiment, theopening8 corresponds to the portion of thesheet6 occupied by each of the microblades prior to the blades being transpositioned into the downward depending position. The number ofmicroblades4 peropening8 can be any number, preferably however between 1 and about 30 blades per opening. Furthermore, the number of openings per device and the number of blades per device are independent. The device may have only one opening and one microblade. The agent can be administered at a controlled rate of release from the reservoir through an agent release rate controlling material (not shown) covering theopenings8.
• As is best shown inFIG. 2, themicroblades4 have a thickness which is much smaller than the width of the blades near their base, i.e., near the point where the blades are attached to theplate6. This blade geometry provides maximum drug percolation area with a minimum blade penetration area, and hence less tissue damage. The drug percolation area is the skin area in contact with the blades which provides for drug penetration in the skin. The microblades are shaped with the largest possible surface area with a minimal cross-sectional area so as to give the largest possible percolation area. Thin microblades are better than round protrusions for this purpose because for the same cross-section, a thin blade produces more percolation area and less tissue damage than a round protrusion. This is a crucial advantage over the prior art round elements such as needles and tubes. Thin microblades also require less insertion force than round protrusions. The width of each blade can be any of a range of widths. The widths can be different from blade to blade in the array pattern. Likewise, the width can be variable along the length of the blade, as will be described in more detail below. The width of the blade at the intersection of the blade and the body surface after the blade array has been inserted is preferably in the range of about 25 μm to about 500 μm, more preferably about 50 μm to about 400 μm, more preferably 100 μm to about 300 μm.
• In one embodiment, the microblades4 (FIG. 5) are also provided with slanted (i.e., angled)leading edges64 to further reduce the insertion force required to press the blades into the skin tissue. The angle of the leading edge is designated as α. The slanted leading edges produce a cut through the skin tissue that is equal to the full width of theblade4 while reducing the amount of metal that is in the skin tissue. In other words, a flat leading edge (i.e., α is 90°) produces a blade with a larger amount of blade material in the skin tissue than is produced by a blade having a slanted leading edge. The leading edges of each blade can all be the same angle or can be at different angles as shown inFIG. 5. The angle α of each leading edge can be any angle between about 10° to 90°, preferably between about 10° to 60°, more preferably about 10° to 40°. The leading edge can also be segmented into two sections at different angles. For example, the first segment can have an angle α between about 10° to 40° and then transition to a second segment having an angle between 20° to 60°. Alternatively, the leading edge of each blade can be arcuate (i.e., curved) in shape, having, for example, a convex or concave shape. In one embodiment, the leading edge is a curved tip across the entire width of the blade.
• Themicroblades4 are formed using a photo-etching process which is described in detail hereinafter. This process allows themicroblades4 to be reproducibly formed on a very small (i.e., tens of microns) scale. This process also allows themicroblades4 to be formed in shapes which help anchordevice2 to the skin. In one embodiment, themicroblades4 are provided with barbs50 (FIGS. 2, 3 and5) in some fashion so that thedevice2 and any corresponding device attached thereto stays attached to the skin after being applied with pressure. The degree of attachment and the number and size of the barbs is such as to retain the delivery or sampling device during the normal activity of the wearer, but not cause pain upon removal. As the microblades are pressed into the skin tissue for use, the leadingedge64 of each microblade cuts through and pushes aside the skin tissue. After the microblades have come to rest in the skin, the skin due to its elastic nature at least partially comes back together around the edges of the microblades, in this way thesurface66 on each microblade having abarb50 engages skin tissue and anchors the device in the skin. If the blade is left in the skin for an extended period of time (e.g., 24 hours), the skin tissue begins to heal together in the area behind thesurface66 of the barb thus improving the anchoring of the device. Only one barb per blade is shown in the figures but it is within the scope of the present invention that each blade can have a plurality of barbs extending therefrom. The microblades, in one embodiment, have a cross-section that is wider in the area of the skin distal end of the blade than in the area of the skin proximal end, thus providing additional anchoring of the distal end in the skin. For example, the blades can have an “arrowhead” shape. Furthermore, thebarbs50 shown in the figures are in the same plane as the blade, however the barbs can be oriented outside of that plane for example by a separate bending step or by using a shaped punch and die to produce a curve in the blade and barb. Curving the tips of the blade outside the plane of the blade generally provides better anchoring. Insertion of such blades causes the barbs to curve in the curve direction but retraction causes them to return to their prior position. The resulting curved cross-section of the blade can be, but is not limited to, angular, semi-circular, C-shaped, or banana-shaped to effect a larger cross-section of openings in the skin.
• The plurality ofmicroblades4 for puncturing the stratum corneum are present on oneface surface48 of thedevice2 in any predetermined arrangement, for example, as a cluster of blades spaced ir rows having any desired number, or in any spaced apart relation of one blade to each other. Thedevice2 of the embodiment shown inFIGS. 1 and 2 is produced by the pattern shown inFIG. 3. Each blade has a width and thickness that facilitates penetration of the stratum corneum without bending. In the embodiment ofFIG. 3, there are sixblades4 in eachopening8 insheet6. Eachopening8 in this embodiment is 1 mm long and 300 μm wide. Correspondingly, the width of each blade is between about 137.5 μm to about 175 μm and the length is about 250 μm. The required length of the blades is subject to variation of the body surface being penetrated and corresponds to the natural thickness of the stratum corneum, for one of the principle features of the invention is that the blades are to penetrate the stratum corneum into the epidermis. Usually, the blades will be about 25 μm to about 400 μm in length, with the length for most applications being between about 50 μm to about 200 μm.
• The pattern for any of the blade array devices of the present invention are produced with a photoetching process. A thin sheet orplate6 of metal such as stainless steel or titanium is etched photo-lithographically with patterns containing blade-like structures. In general, a thin laminate dry resist or wet resist is applied on a sheet about 7 μm to about 100 μm thick, preferably about 25 μm to about 50 μm thick. The resist is contact exposed using a mask having the desired pattern and is subsequently developed. These operations are conducted in much the same way that they are for the manufacture of a printed circuit board. The sheet is then etched using acidic solutions. After the pattern has been etched through the sheet, the sheet is placed on a die52 (shown schematically inFIG. 8) having a plurality ofopenings56 corresponding to theopenings8 in the sheet. Apunch54 having a plurality ofprotrusions58 corresponding to the openings in the sheet and die is initially located above the sheet and die. At the initial stage, theblades4 are in the same plane as the rest of thesheet6. Theprotrusions58 on thepunch54 are then pressed into theopenings56, thus bending theblades4 downward to be at an angle (e.g., substantially perpendicular) to the plane of the sheet. The finished structure providesblades4 with anadjacent opening8 for the passage of a substance therethrough when thedevice2 is applied to the skin.Rectangular openings8 are shown in the figures but the invention encompasses the use of any shape openings including, but not limited to, square, triangular, circular and elliptical.
• Thesheet6 in some areas can have additional etched openings80 (FIG. 4) to alleviate the curl created during punching and/or to provide for flexibility in the dense blade array patterns because in some embodiments the sheet becomes very stiff after punching. The openings can be any of a variety of shapes (e.g., rectangular, circular, elliptical, triangular, etc.) The openings also allow the sheet to be more easily curved to match the curvature of the body surface to which it is to be attached which improves anchoring of the device. The present invention maximizes the openings through the sheet but with a sufficient number of horizontal and vertical continuous portions in the sheet to prevent the sheet from being too flexible (i.e., flimsy). If the openings are made too long in any one dimension, the sheet will bend (i.e., crinkle). In addition, it is also possible to treat the devices after punching with heat or plastic deformation such that the radius of curvature of the sheet becomes equal to or somewhat smaller than the curvature of the body, where it is to be attached to enhance anchoring. The concave surface can be shaped to match the convex pattern of the body.
• Theblades4 can be patterned with resist on bothsides48,49 and subsequently etched simultaneously from both sides (FIG. 7) to achieve maximum pattern resolution for a given sheet thickness and to produce a knife-like edge that can not be achieved with conventional stamping and punching processes. Alternatively, theblades4 can be patterned and etched from one side (i.e., side49) only (FIG. 6). When etching from one side only, the etching process can be controlled to etch selective depths in theplate6 along the length of the blades (e.g., at the blade tips) to produce asingle angle60 at the tip of the blade which maximizes the sharpness of the knife-like edge of the blade. In this embodiment, the lithography process produces a portion of the blade that is thinner than the remainder of the thickness of the blade and of the sheet. The lithography process also can produce very small dimensioned elements for the anchoring and the penetration aspects of the invention.
• In another embodiment of the two-sided etching process, the blade array pattern of any of the embodiments of the present invention is etched into thetop surface49 ofsheet6. A second pattern equivalent to the area bounded by each of the openings8 (e.g., rectangular) is etched into thebottom surface48 such that each of the blades in the blade array pattern is thinner than the surroundingsheet6. As a result, thesheet6 forms a strong base and as thepunch54 deforms theblades4 downward, each of the blades plastically deforms so as to produce blades that are straighter and more truly perpendicular to the sheet.
• In one embodiment of the etching process, a dry resist (e.g., “Dynachem FL” available from Dynachem located in Tustin, Calif.) is applied 12.5 μm thick to one or both sides of the sheet and exposed in a standard manner. Then a suitable spray etcher (e.g., “Dynamil VRP 1 0/NM” available from Western Tech. Assoc. located in Anaheim, Calif.) is used to spray) a mixture of ferric chloride and hydrochloric acid onto the resist and sheet at 52° C. (125° F. for two minutes. A standard caustic stripper is used for the resist removal.
• In another embodiment of the etching process, a wet resist (e.g., “Shipley 111S” available from Shipley Corporation, located in Marlborough, Mass.) is applied 7.5 μm thick at about 20° C. (70° F.) to one or both sides of the sheet and exposed in a standard manner. Then a suitable etchant (e.g., ferric chloride) is sprayed onto the resist and sheet at 49° C. (120° F.). A standard caustic stripper is used for the resist removal.
• Generally, theblades4 are at an angle of about 90° to thesurface48 of thesheet6 after being punched, but they can be disposed at any angle forward or backward from the perpendicular position that will facilitate penetration of and attachment to the stratum corneum. In one embodiment (FIG. 9), the blades are all aligned at an angle between about 1° and about 89° degrees, preferably about 10° to about 60°, more preferably about 20° to 45° to facilitate the device being slid along and into the skin. The angled blades have two principal advantages. First, penetration of the blades is not opposed by the elasticity of the skin because the blades are slid horizontally into the skin as opposed to pressing vertically on the skin. Second, the angled blades act to anchor the device in the skin as any motion of the skin is less likely to dislodge the blades. In addition, other anchoring elements such as barbs, openings, etc. can be used with the angled blades to further enhance anchoring of the device.
• In one embodiment (FIG. 29), anchoring of the device is achieved by coating thesurface48 ofsheet6 and surface82 of eachblade4 with an adhesive. One method of producing this embodiment comprises spraying the adhesive on thedevice2 along the direction indicated byarrows84. In this embodiment, the agent is free to pass through theopenings8 and alongsurface86 of each blade unencumbered by the adhesive. It is also possible to apply the adhesive ononly surface48 and not on the blade surfaces82. This can be accomplished, for example, by applying the adhesive ontosurface48 after theblades82 have been punched by spraying the adhesive in a direction which is parallel to the axis of theblades82. It is further possible to apply the adhesive only on the blade surfaces82 and not on thesurface48 ofsheet6 in order to anchor the device, although this last design is the least preferred adhesive anchoring means.
• The sheet and blades can be made from materials that have sufficient strength and manufacturability to produce blades, such as, glasses, ceramics, rigid polymers, metals and metal alloys. Examples of metals and metal alloys include but are not limited to stainless steel, iron, steel, tin, zinc, copper, platinum, aluminum, germanium, nickel, zirconium, titanium and titanium alloys consisting of nickel, molybdenum and chromium, metals plated with nickel, gold, rhodium, iridium, titanium, platinum, and the like. An example of glasses include a devitrified glass such as “Photoceram” available from Corning in Corning, N.Y. Examples of rigid polymers include but are not limited to polystyrene, polymethylmethacrylate, polypropylene, polyethylene “Bakelite”, cellulose acetate, ethylcellulose, styrene/acrylonitrile copolymers stryrenetbutadiene copolymers, acrylonitrile/butadiene/styrene (ABS) copolymers, polyvinyl chloride and acrylic acid polymers including polyacrylates and polymethacrylates.
• Very dense patterns can be created with unit cells wherein a unit cell has a width A and a length B as illustrated inFIG. 3. In one embodiment (not shown), the pattern has the following characteristics: a unit cell area of 0.63 mm by 3.8 mm; the lineal length of a cut in a unit cell is approximately equal to 15 mm; and the open skin length per square centimeter is 625 mm.
• The microblades of the present invention make an elongated, thin microcut (i.e., a slit) in the skin surface because the blades have a small thickness (relative to their width and length) resulting in a minimal blade cross-sectional area for the portions of the blade in the skin. The geometry of themicroblades4 results in minimal blade volume in the skin with maximal blade surface area in the skin. The advantages of the present invention include, but are not limited to: (1) the thin blade geometry produces the maximum drug percolation area for a given cross-section of the blade; (2) minimal tissue damage occurs because the amount of blade material in the skin and hence the volume loading is minimized; (3) slanted leading edges (or equivalent pointed shapes) further minimize the amount of volume loading or tissue damage while preserving a large percolation area; (4) for a given volume loading, the larger the surface area, the larger the frictional retaining force in the skin; and (5) for a given desired percolation area, there are fewer blades necessary and therefore the force on each tip is higher making skin penetration easier.
• In other embodiments (FIGS. 10-16) other anchoring elements are used in the present invention. In the embodiments shown inFIGS. 10-14,prong68 is etched in the side of some or all of theblades4, and punched lightly so as to protrude outward from the plane of each of the blades, as illustrated inFIGS. 10 and 14. After the punching of the prongs, the blades may be repunched to regain their substantially vertical orientation. Hinges72 (FIG. 13) can be used to control the retention force of the barb for anchoring. The hinges allow for the retention force to be tailored independently of the size of the blade because the force required to bend or punch the prong is set independently of the size of the blades by the shape or size of the hinge. In other words, the force can be tailored by the amount of attachment of the prong to the plate, the greater the attachment, the greater the force.
• Prongs may protrude from either side of the blade, or both sides, if desired. The shape of each prong can be any of a variety of shapes such as triangular, square, etc. as shown inFIGS. 11 and 12. In another embodiment, a curved protrusion70 (FIGS. 15 and 16) is made by etching a slit in some or all of the blades followed by punching. The prongs and curved protrusions act to anchor the device in the skin similar to the manner described previously.
• In other embodiments other anchoring elements are used. In the embodiments ofFIGS. 17-19, theblade4 hasadditional openings74 extending through the blade to enhance anchoring. The edges forming the holes or other linear openings are etched through the blade. Alternatively, or in addition, numerous small pits (i.e., indentations) rather than holes can be etched in the surface of the blade. As described above, the elastic nature of the skin tissue causes the skin to move into the openings or pits. In the embodiments with openings, the skin tissue may heal and reconnect through the openings to provide even greater anchoring.
• In a further embodiment (FIG. 20), a plurality of blades in anopening8 are arranged at 90° to another plurality of blades in anopening8′ such that anchoring in two directions is obtained. In other words, the blades (not shown) associated with theopenings8 are oriented parallel to theedge76 of thedevice2 and the blades (not shown) associated with theopenings8′ are oriented parallel to theedge78 of the device. The blades associated with eachopening8 can be oriented at any angle with respect to the blades associated with eachopening8′. Alternatively, the blades within each opening can be along perpendicular sides of the openings. In a similar manner, the blades within each opening can be formed in a serrated pattern as illustrated inFIG. 21. This pattern allows the blades to have different, controllable angles with respect to each other defined by the angle of the punch used and the etched angle β of the pattern.
• The number of blades and openings of any of the embodiments of thedevice2 is variable with respect to the desired flux rate, agent being sampled or delivered, delivery or sampling device used (i.e., electrotransport, passive, osmotic, pressure-driven, etc.), and other factors as will be evident to one of ordinary skill in the art. In general, the larger the number of blades per unit area (i.e., the blade density), the more distributed is the flux of the agent through the skin because there are a greater number of agent-conveying pathways through the skin. Consequently, the smaller the number of blades per unit area, the more concentrated is the flux of the agent through the skin because there are fewer pathways. The present invention has a blade density of at least about 10 blades/cm²and less than about 1000 blades/cm², preferably at least about 600 blades/cm², more preferably at least about 800 blades/cm². In similar fashion, the number of openings per unit area through which the agent passes is at least about 10 openings/cm²and less than about 1000 openings/cm². In one embodiment, the present invention produces a percolation area of about 0.005 to 0.05 cm²/cm²of body surface, preferably about 0.01 cm²/cm²of body surface.
• One embodiment of the present invention relies on the application of an electric current across the body surface or “electrotransport”. Electrotransport refers generally to the passage of a beneficial agent, e.g., a drug or drug precursor, through a body surface such as skin, mucous membranes, nails, and the like. The transport of the agent is induced or enhanced by the application of an electrical potential, which results in the application of electric current, which delivers or enhances delivery of the agent or, for “reverse” electrotransport, samples or enhances sampling of the agent. The electrotransport of the agents into or out of the human body may be attained in various manners. One widely used electrotransport process, iontophoresis, involves the electrically induced transport of charged ions. Electroosmosis, another type of electrotransport process involved in the transdermal transport of uncharged or neutrally charged molecules (e.g., transdermal sampling of glucose), involves the movement of a solvent with the agent through a membrane under the influence of an electric field. Electroporation, still another type of electrotransport, involves the passage of an agent through pores formed by applying an electrical pulse, a high voltage pulse, to a membrane. In many instances, more than one of these processes may be occurring simultaneously to different extents. Accordingly, the term “electrotransport” is given herein its broadest possible interpretation, to include the electrically induced or enhanced transport of at least one charged or uncharged agent, or mixtures thereof, regardless of the specific mechanism(s) by which the agent is actually being transported.
• It will be appreciated by those working in the field that the present invention can be used in conjunction with a wide variety of electrotransport drug delivery systems, as the invention is not limited in any way in this regard. For examples of electrotransport drug delivery systems, reference may be had to U.S. Pat. No. 5,147,296 to Theeuwes et al., U.S. Pat. No. 5,080,646 to Theeuwes et al., U.S. Pat. No. 5,169,382 to Theeuwes et al., and U.S. Pat. No. 5,169,383 to Gyory et al., the disclosures of which are incorporated by reference herein in their entirety.
• Electrotransport devices generally use at least two electrodes which are in electrical contact with some portion of the skin, nails, mucous membranes, or other body surface. In the case of transdermal agent delivery, one of the two electrodes is commonly referred to as the “donor” or “active” electrode, and is the one from which the agent is delivered into the body. In the case of transdermal agent sampling, one of the two electrodes is referred to as the “receptor” electrode, and is the one into which the agent (e.g., body electrolyte) is collected upon being withdrawn from the body. The second electrode is typically termed the “counter” or “return” electrode, and serves to close the electrical circuit through the body. For example, when the agent to be delivered is a cation, i.e., a positively charged ion, the anode becomes the active or donor electrode, while the cathode serves to complete the circuit. Alternatively, if the agent to be delivered is an anion, i.e., a negatively charged ion, the cathode is the donor electrode. When the agent to be sampled is a cation, the cathode becomes the receptor electrode while the anode serves to complete the circuit. When the agent to be sampled is an anion, the anode becomes the receptor electrode while the cathode serves to complete the circuit. When the agent to be sampled has no net charge (e.g., glucose), then either the anode, or the cathode, or both electrodes, can serve as the receptor electrode. Both the anode and cathode may be donor electrodes if both anionic and cationic agents are delivered simultaneously. Electrotransport delivery systems generally require at least one reservoir or source of the agent to be delivered to the body. Electrotransport sampling systems likewise require at least one reservoir in which to collect the agent being sampled. Examples of such reservoirs include a pouch or cavity as described in U.S. Pat. No. 4,250,878 to Jacobsen, a porous sponge or pad as described in U.S. Pat. No. 4,141,359 to Jacobsen et al., and a pre-formed gel body as described in U.S. Pat. No. 4,383,529 to Webster, among others. The pertinent portions of which are incorporated herein by reference. Such reservoirs are electrically connected to, and positioned between, the anode or the cathode and the body surface. e.g., to provide a fixed or renewable source of one or more drugs in the case of agent delivery. In addition, electrotransport systems also typically have an electrical power source, e.g., one or more batteries, and an electrical controller designed to regulate the timing, amplitude and/or frequency of the applied electric current, and hence regulate the timing and rate of agent delivery/sampling. This power source component is electrically connected to the two electrodes. Optional electrotransport device components include a counter reservoir, adhesive coatings, insulating separation layers, and rate-controlling membranes.
• FIGS. 1 and 22-25 illustrate a representative electrotransport delivery/sampling device10 that may be used in conjunction with the present invention.Device10 comprises anupper housing16, acircuit board assembly18, alower housing20,anode electrode22,cathode electrode24,anode reservoir26,cathode reservoir28 and skin-compatible adhesive30.Upper housing16 haslateral wings15 which assist in holdingdevice10 on a patient's skin. Printedcircuit board assembly18 comprises anintegrated circuit19 coupled todiscrete components40 andbattery32.Circuit board assembly18 is attached tohousing16 by posts (not shown inFIG. 1) passing throughopenings13aand13b, the ends of the posts being heated/melted in order to heat stake thecircuit board assembly18 to thehousing16.Lower housing20 is attached to theupper housing16 by means ofadhesive layer30, theupper surface34 ofadhesive layer30 being adhered to bothlower housing20 andupper housing16 including the bottom surfaces ofwings15. Shown (partially) on the underside ofcircuit board assembly18 is abutton cell battery32. Other types of batteries may also be employed topower device10 depending on the need.
• Thedevice10 is generally comprised ofbattery32,electronic circuitry19,40,electrodes22,24, drug/receptor reservoir26,counter reservoir28, anddevice2, all of which are integrated into a self-contained unit. The outputs (not shown inFIG. 1) of thecircuit board assembly18 make electrical contact with theelectrodes24 and22 throughopenings23,23′ in thedepressions25,25′ formed inlower housing20, by means of electrically conductive adhesive strips42,42′.Electrodes22 and24, in turn, are in direct mechanical and electrical contact with thetop sides44′,44 ofdrug reservoirs26 and28. Thebottom side46 ofdrug reservoir28 contacts the patient's skin through theopening29 inadhesive layer30. Thebottom side46′ ofdrug reservoir26 contacts the patient's skin through the plurality ofopenings8 in thedevice2. The formulation ofreservoir26 is preferably a viscous gel that fills theopenings8 such that thereservoir26 is in direct contact with the skin when the blades have penetrated the stratum corneum. The contact between the reservoir and skin provides a path for the agent to be transported along. If thereservoir26 is not in direct contact with the skin initially, typically sweat accumulates in the confined area and provides an agent-transmitting pathway betweenreservoir26 and the skin.
• Device10 optionally has a feature which allows the patient to self-administer a dose of drug, or self-sample a body electrolyte, by electrotransport. Upon depression ofpush button switch12, the electronic circuitry oncircuit board assembly18 delivers a predetermined DC current to the electrode/reservoirs22,26 and24,28 for an interval of predetermined length. Thepush button switch12 is conveniently located on the top side ofdevice10 and is easily actuated through clothing. A double press of thepush button switch12 within a short time period, e.g., three seconds, is preferably used to activate the device, thereby minimizing the likelihood of inadvertent actuation of thedevice10. Preferably, the device transmits to the user a visual and/or audible confirmation of the onset of operation by means ofLED14 becoming lit and/or an audible sound signal from, e.g., a “beeper”. Agent is delivered/sampled through the patient's skin, e.g., on the arm, by electrotransport over the predetermined interval.Anodic electrode22 is preferably comprised of silver andcathodic electrode24 is preferably comprised of silver chloride. Bothreservoirs26 and28 are preferably comprised of polymeric gel materials.Electrodes22,24 andreservoirs26,28 are retained bylower housing20.
• In the case of therapeutic agent (i.e., drug) delivery, a liquid drug solution or suspension is contained in at least one of thereservoirs26 and28. Drug concentrations in the range of approximately 1×10⁻⁴M to 1.0 M or more can be used, with drug concentrations in the lower portion of the range being preferred.
• Thepush button switch12, the electronic circuitry oncircuit board assembly18 and thebattery32 are adhesively “sealed” betweenupper housing16 andlower housing20.Upper housing16 is preferably composed of rubber or other elastomeric material, e.g., injection moldable ethylene vinyl acetate.Lower housing20 is preferably composed of a plastic or elastomeric sheet material (e.g., polyethylene) which can be easily molded to formdepressions25,25′ and cut to formopenings23,23′. The assembleddevice10 is preferably water resistant (i.e., splash proof) and is most preferably waterproof. The system has a low profile that easily conforms to the body, thereby allowing freedom of movement at, and around, the wearing site. Thereservoirs26 and28 are located on the skin-contacting side of thedevice10 and are sufficiently separated to prevent accidental electrical shorting during normal handling and use.
• Thedevice10 adheres to the patient's body surface (e.g., skin) by means of an adhesive layer30 (which has upperadhesive side34 and body-contacting adhesive side36) and the anchoring elements on thedevice2 of any of the embodiments discussed above. Theadhesive side36 covers the entire underneath side of thedevice10 except where thedevice2 andreservoir28 are located. Theadhesive side36 has adhesive properties which assures that thedevice10 remains in place on the body during normal user activity, and yet permits reasonable removal after the predetermined (e.g., 24-hour) wear period. Upperadhesive side34 adheres to lowerhousing20 and retains the electrodes and reservoirs withinhousing depression25,25′ as well as retainsdevice2 tolower housing20 andlower housing20 toupper housing16.
• In one embodiment of the drug delivery or sampling device there is a bandage cover (not shown) on thedevice10 for maintaining the integrity of the device when it is not in use. In use, the bandage cover is stripped from the device before the device is applied to the skin.
• In other embodiments of the present invention, passive transdermal delivery or sampling devices are used withdevice2. Two examples of passive transdermal delivery or sampling devices are illustrated inFIGS. 26 and 27. InFIG. 26, passivetransdermal delivery device88 comprises areservoir90 containing agent.Reservoir90 is preferably in the form of a matrix containing the agent dispersed therein.Reservoir90 is sandwiched between abacking layer92, which is preferably impermeable to the agent, and a rate-controllingmembrane94. InFIG. 26, thereservoir90 is formed of a material, such as a rubbery polymer, that is sufficiently viscous to maintain its shape. If a lower viscosity material is used forreservoir90, such as an aqueous gel, backinglayer92 and rate-controllingmembrane94 would be sealed together about their periphery to prevent leakage. In a sampling configuration, thereservoir90 would initially not contain the agent. Located belowmembrane94 ismicroblade array device2. Thedevice88 adheres to a body surface by means of contactadhesive layer96 around the periphery of thedevice2 and by the anchoring elements of any of the embodiments described previously. Theadhesive layer96 may optionally contain agent. A strippable release liner (not shown) is normally provided along the exposed surface ofadhesive layer96 and is removed prior to application ofdevice10 to the body surface.
• Alternatively, as shown inFIG. 27, transdermaltherapeutic device98 may be attached to a body surface by means of a flexibleadhesive overlay100 and the anchoring elements used indevice2.Device98 is comprised of an agent-containing reservoir90 (for a delivery configuration) which is preferably in the form of a matrix containing the agent dispersed therein. In a sampling configuration, thereservoir90 would initially not contain the agent. Animpermeable backing layer102 is provided adjacent one surface ofreservoir90.Adhesive overlay100 maintains thedevice98 on the body surface in combination with the anchoring elements of any of the embodiments previously described fordevice2.Adhesive overlay100 can be fabricated together with, or provided separately from, the remaining elements of thedevice98. With certain formulations, theadhesive overlay100 may be preferable to the contact adhesive96 shown inFIG. 26. This is true, for example, where the agent reservoir contains a material (such as, for example, an oily surfactant permeation enhancer) which adversely affects the adhesive properties of thecontact adhesive layer96.Impermeable backing layer102 is preferably slightly larger thanreservoir90, and in this manner prevents the agents inreservoir90 from adversely interacting with the adhesive inoverlay100. Optionally, a rate-controlling membrane (not shown inFIG. 27) similar tomembrane94 in device88 (FIG. 26) can be provided on the skin/mucosa side ofreservoir90. A strippable release liner (not shown) is also normally provided withdevice98 and is removed just prior to application ofdevice98 to the body surface.
• The formulation for the passive transdermal devices may be aqueous or non-aqueous based. The formulation is designed to deliver the drug at the necessary fluxes. Aqueous formulations typically comprise water and about 1 to 2 weight percent of a hydrophilic polymer as a gelling agent, such as hydroxyethylcellulose or hydroxypropylcellulose. Typical non-aqueous gels are comprised of silicone fluid or mineral oil. Mineral oil-based gels also typically contain 1 to 2 weight percent of a gelling agent such as colloidal silicon dioxide.
• The reservoir matrix should be compatible with the delivered agent any excipients (e.g., flux enhancers, irritation preventing agents) and/or any carrier therefore. When using an aqueous-based system, the reservoir matrix is preferably a hydrophilic polymer, e.g., a hydrogel. When using a non-aqueous-based system, the reservoir matrix is preferably composed of a hydrophobic polymer. Suitable polymeric matrices are well known in the transdermal drug delivery art.
• When a constant drug delivery rate is desired, the drug is present in the matrix or carrier at a concentration in excess of saturation, the amount of excess being a function of the desired length of the drug delivery period of the system. The drug may, however, be present at a level below saturation without departing from this invention.
• In addition to the drug, the matrix or carrier may also contain dyes, pigments, inert fillers, permeation enhancers, excipients and other conventional components of pharmaceutical products or transdermal devices known in the art.
• The amount of drug present in the reservoir and the size of the reservoir is generally non-limited and is an amount equal to or larger than the amount of drug that, in its released form, is effective in bringing about the drugs physiological or pharmacological local or systemic effects.
• The preferred form in which an agent is delivered or sampled generally determines the type of delivery or sampling system to be used, and vice versa. That is, the selection of a “passive” system which delivers or samples the agent by diffusion or an electrically powered system which delivers or samples the agent by electrotransport will be mostly determined by the form of the agent. For example, with passive delivery systems, it has generally been recognized that the agent is preferably delivered in either its free base or acid form, rather than in the form of a water soluble salt. On the other hand, with electrotransport delivery devices, it has been recognized that the drugs should preferably be ionized and the drug salt should be soluble in water. It is generally believed that the pathways for passive and electrotransported transdermal drug delivery through intact skin are different, with passive delivery occurring through lipid regions (i.e., hydrophobic regions) of the skin and electrotransport delivery occurring through hydrophilic pathways or pores such as those associated with hair follicles and sweat glands. For the case of pierced skin, there is substantial passive flux through the microslits created by the microblades piercing the stratum corneum. The drug for passive delivery is generally hydrophobic, e.g., free base form, whereas the preferred form of a drug for electrotransport delivery is hydrophilic, e.g., water soluble salt form. For osmotic and pressure driven systems which deliver or sample drugs by connective flow carried by a solvent, the drug preferably has sufficient solubility in the carrier solvent. It will be appreciated by those working in the field that the present invention can be used in conjunction with a wide variety of osmotic delivery or sampling systems, as the invention is not limited to a particular device in this regard. Osmotic devices are disclosed for example in U.S. Pat. No. 4,340,048 to Eckenhoff, U.S. Pat. No. 4,655,766 to Theeuwes et al., and U.S. Pat. No. 4,753,651 to Eckenhoff, the disclosures of which are incorporated by reference herein in their entirety.
• This invention has utility in connection with the delivery of drugs within any of the broad class of drugs normally delivered through body surfaces and membranes, including skin. In general, this includes drugs in all of the major therapeutic areas including, but not limited to, anti-infectives such as antibiotics and antiviral agents, analgesics including fentanyl, sufentanil, buprenorphine and analgesic combinations, anesthetics, anorexics, antiarthritics, antiasthmatic agents such as terbutaline, anticonvulsants, antidepressants, antidiabetic agents, antidiarrheals, antihistamines, anti-inflammatory agents, antimigraine preparations, antimotion sickness preparations such as scopolamine and ondansetron, antinauseants, antineoplastics, antiparkinsonism drugs, antipruritics, antipsychotics, antipyretics, antispasmodics, including gastrointestinal and urinary anticholinergics, sympathomimetrics, xanthine derivatives, cardiovascular preparations including calcium channel blockers such as nifedipine, beta-blockers, beta-agonists such as dobutamine and ritodrine, antiarrythmics, antihypertensives such as atenolol, ACE inhibitors such as ranitidine, diuretics, vasodilators, including general, coronary, peripheral and cerebral, central nervous system stimulants, cough and cold preparations, decongestants, diagnostics, hormones such as parathyroid hormone, bisphosphoriates, hypnotics, immunosuppressives, muscle relaxants, parasympatholytics, pasympathomimetrics, prostaglandins, psychostimulants, sedatives and tranquilizers. The invention is also useful in conjunction with reducing or preventing sensitization occurring as a result of electrotransport delivery of proteins, peptides and fragments thereof, whether naturally occurring, chemically synthesized or recombinantly produced. The invention may additionally be used in conjunction with the delivery of nucleotidic drugs, including oligonucleotide drugs, polynucleotide drugs, and genes.
• The present invention has particular utility in the delivery of peptides, polypeptides, proteins, nucleotidic drugs, and other such species through body surfaces such as skin. These substances typically have a molecular weight of at least about 300 daltons, and more typically have a molecular weight of at least about 300 to 40,000 daltons. Specific examples of peptides and proteins in this size range include, without limitation, LHRH, LHRH analogs such as goserelin, buserelin, gonadorelin, napharelin and leuprolide, GHRH, GHRF, insulin, insultropin, calcitonin, octreotide, endorphin, TRH, NT-36 (chemical name: N-[[(s)-4-oxo-2-azetidinyl]carbonyl]-L-histidyl-L—prolinamide), lypressin, pituitary hormones (e.g., HGH, HMG, desmopressin acetate, etc), follicle luteoids, αANF, growth factors such as growth factor releasing factor (GFRF), βMSH, GH, somatostatin, bradykinin, somatotropin, platelet-derived growth factor, asparaginase, bleomycin sulfate, chymopapain, cholecystokinin, chorionic gonadotropin, corticotropin (ACTH), erythropoietin, epoprostenol (platelet aggregation inhibitor), glucagon, HCG, hirulog, hyaluronidase, interferon, interleukins, menotropins (urofollitropin (FSH) and LH), oxytocin, streptokinase, tissue plasminogen activator, urokinase, vasopressin, desmopressin, ACTH analogs, ANP, ANP clearance inhibitors, angiotensin II antagonists, antidiuretic hormone agonists, bradykinin antagonists, ceredase, CSI's, calcitonin gene related peptide (CGRP), enkephalins, FAB fragments, IgE peptide suppressors, IGF-1, neurotrophic factors, colony stimulating factors, parathyroid hormone and agonists, parathyroid hormone antagonists, prostaglandin antagonists, pentigetide, protein C, protein S, renin inhibitors, thymosin alpha-1, thrombolytics, TNF, vaccines, vasopressin antagonists analogs, alpha-1 antitrypsin (recombinant), and TGF-beta.
• As mentioned above, thedevice2 of the present invention can also be used with known sampling devices including, but not limited to, reverse iontophoresis, osmosis, passive diffusion, phonophoresis, and suction (i.e., negative pressure).FIG. 28 illustrates anosmotic sampling device104 in combination with any of the embodiments described previously fordevice2. Osmotic sampling devices can be used to sample any of a variety of agents (e.g., body analytes, licit and illicit drugs) through a body surface including, but not limited to glucose, body electrolytes, alcohol, blood gases, and illicit substances such as drugs of abuse. Theosmotic sampling device104 is attached to a body surface by means of a flexibleadhesive overlay100 and the anchoring elements ofdevice2.Device104 is comprised of asalt layer106 located between a semi-permeable orosmotic membrane94 and an optionalagent sensing element108. The optional agent sensing element can be any of a variety of chemically reactive sensors and indicators, for example the color indicating test strips associated with glucose testing. Theadhesive overlay100 can have a cut-out or transparent window in the area of the indicators so that the indicators can be readily viewed. In an alternate embodiment, the agent sensing element can be located between thedevice2 and the salt layer.
• The following example is merely illustrative of the present invention and should not be considered as limiting the scope of the invention in any way, as this example and other equivalents thereof will become apparent to those versed in the art and in light of the present disclosure, drawings, and the accompanying claims.
EXAMPLE
• The effect of the present design was evaluated on the skin resistance of a hairless guinea pig. A microblade array of two square centimeters was applied to ECG electrodes of five square centimeters. The blade array and electrodes were then applied to the skin of the animal. Resistance measurements were taken two minutes after application of the electrode to the skin of the animal. A decrease in resistance was observed indicating that penetration of the blades into the skin had occurred.
• The device was evaluated for its effect on electrotransport flux of a decapeptide in the hairless guinea pig. The following are specifications for the device: the device consisted of a sheet having a plurality of rectangular openings having six blades, three on each long side of a 860 μm by 250 μm rectangle resulting in a 0.22 mm²open area for each opening. Each set of three blades started at the opposite end of the rectangle as the opposing set of blades. All of the blades were about 200 μm long. All six blades had slanted leading edges and the blade at each end was barbed as well. The group of six blades were arranged in two slightly offset rows with ten groups in each row on the sheet. Each device was a two cm²piece ofstainless steel 25 μm thick etched and punched with eight pairs of offset rows or 160 groups of six blades for a total of 960 blades. There were 40 void areas per cm²and 240 blades per cm².
• For the study, a one compartment electrotransport system was used. It consisted of a cathode compartment containing a Dulbelco's phosphate buffered saline imbibing gel and a donor anode compartment containing two millimoles of decapeptide buffered at pH 7.5, 10% cholestyramine chloride and 3% hydroxyethylcellulose. After loading the gels in the system, the release liner was removed from the adhesive foam bottom of the electrotransport system. The device was carefully applied over a 1.6 cm diameter hole containing the donor gel with the microblades facing away from the gel. The electrotransport system was then placed on the skin of a lightly anesthetized hairless guinea pig. The systems were applied to the backs of the animals using gentle downward pressure while at the same time pushing bottom side of the system with the thumb of the technician. (The thumb trapped a roll of the animals' skin which allowed some upward pressure to be applied directly to the bottom side of the skin in contact with the device microblades). After two minutes the current and resistance measurements were observed and recorded. The electrotransport system was wrapped with Vetrap and the animals were returned to their cages for the duration of electrotransport (5 and 24 hours). Decapeptide flux was evaluated by measuring urinary excretion of this peptide. Only a modest effect of the device on decapeptide flux was observed in the first five hours of transport. Between five and twenty-four hours, the electrotransport flux of an ordinary electrotransport device dropped very significantly probably due to collapse of the pathways or possibly aggregation of the peptide in the pathways (the decrease in flux between five and twenty-four hours was reproducible). Use of the blade array device completely prevented this decrease in flux and resulted in an overall ten-fold increase in decapeptide flux over a twenty-four hour transport period.
• While the invention has been described in conjunction with the preferred specific embodiments thereof, it is to be understood that the foregoing description as well as the example are intended to illustrate and not limit the scope of the invention. Other aspects, advantages and modifications within the scope of the invention will be apparent to those skilled in the art to which the invention pertains.

Claims (52)

1. A device for piercing the stratum corneum of a body surface to form pathways through which an agent can be introduced or withdrawn, comprising:

a sheet having at least one opening therethrough and a plurality of blades extending downward therefrom, at least one of the plurality of blades having an anchor for anchoring the device to the body surface.

2. The device ofclaim 1 wherein the anchor is selected from the group consisting:

(i) a projection extending out from the at least one blade;

(ii) a barb;

(iii) at least one opening extending through the at least one blade;

(iv) an adhesive on a body contacting surface of the sheet and on at least one surface of at least one of the plurality of blades;

(v) each of the blades having an axis, the blades being oriented so that the blade axes are substantially parallel and the axes form an angle of about 1° to about 89° relative to the sheet;

(vi) each one of the plurality of blades defines essentially a plane and wherein the anchor comprises a portion of the plurality of blades being oriented at an angle of about 90° with respect to a remaining portion of the plurality of blades; and

(vii) each one of the plurality of blades defines essentially a plane and wherein the anchor comprises a portion of the plurality of blades being oriented at an angle within a range of about 1° to about 89° with respect to a remaining portion of the plurality of blades.

3. The device ofclaim 2, wherein the projection extends out from a plane defined by the at least one blade.

4. The device ofclaim 3, wherein the projection is a prong.

5. The device ofclaim 2, wherein the projection is integral with an edge of the at least one blade and in a plane defined by the at least one blade.

6. (canceled)

7. (canceled)

8. The device ofclaim 1, further comprising a sampling device connected to the piercing device and positioned to sample a substance from the body surface through the opening, the sampling device being selected from the group consisting of a reverse electrotransport device, a passive diffusion device, an osmotic device, and a negative pressure driven device.

9. The device ofclaim 8, wherein the sampled substance is selected from the group consisting of body electrolytes, illicit drugs and glucose.

10. The device ofclaim 1, wherein a portion of the plurality of blades are located along a periphery of an opening through the sheet.

11. The device ofclaim 1, wherein a portion of the plurality of blades are located along a periphery of a plurality of openings through the sheet.

12. The device ofclaim 11, further comprising a plurality of second openings through the sheet being spaced between the plurality of openings.

13. The device ofclaim 1, wherein the device has about 600 to about 1000 blades/cm2.

14. The device ofclaim 1, wherein the device has at least about 800 blades/cm2

15. The device ofclaim 1, wherein at least a portion of the plurality of blades have a length sufficient to pierce the stratum corneum of the body surface to a depth of at least about 25 μm.

16. The device ofclaim 1, wherein each of the plurality of blades is oriented approximately perpendicular to the sheet.

17. The device ofclaim 1, wherein each of the plurality of blades is oriented at an angle in the range of about 1° to about 89° to the sheet.

18. The device ofclaim 1, wherein each of the plurality of blades is oriented at an angle in the range of about 10° to about 60° to the sheet.

19. The device ofclaim 1, wherein at least a portion of the plurality of blades have a thickness in the range of about 7 μm to about 100 μm.

20. The device ofclaim 1, wherein at least a portion of the plurality of blades have a thickness in the range of about 25 μM to about 50 μm.

21. The device ofclaim 1, wherein the plurality of blades is composed of a material selected from the group consisting of metals, metal alloys, glasses, ceramics and rigid polymers.

22. The device ofclaim 1, wherein the sheet and the plurality of blades are substantially impermeable to the passage of the agent.

23. The device ofclaim 1, wherein the plurality of blades are thinner than the sheet.

24. A device for piercing the stratum corneum of a body surface to form pathways through which an agent can be introduced or withdrawn, comprising:

a sheet having a plurality of openings therethrough, at least one of said openings having a plurality of blades located along a periphery thereof and extending downward from the sheet, and an anchor for anchoring the device to the body surface.

25. The device ofclaim 24, wherein the anchor is selected from the group consisting:

(i) a projection extending out from at least one blade;

(ii) a barb on a blade;

(iii) at least one opening extending through at least one blade;

(iv) an adhesive on a body contacting surface of the sheet and on at least the plurality of blades;

(v) a portion of the plurality of blades being oriented at an angle of about 90° with respect to a remaining portion of the plurality of blades; and

(vi) each one of the plurality of blades defines essentially a plane and wherein the anchor comprises a portion of the plurality of blades being oriented at an angle within a range of about 1° to about 89° with respect to a remaining portion of the plurality of blades.

26. The device ofclaim 25, wherein the projection extends out from a plane defined by at least one blade.

27. The device ofclaim 26, wherein the projection is a prong.

28. The device ofclaim 25, wherein the projection is integral with an edge of the at least one blade and in a plane defined by the at least one blade.

29. The device ofclaim 24, wherein the anchor comprises a plurality of openings extending through at least one blade.

30. (canceled)

31. (canceled)

32. The device ofclaim 24, further comprising a sampling device connected to the piercing device and positioned to sample a substance from the body surface through the openings, the sampling device selected from the group consisting of a reverse electrotransport device, a passive device, an osmotic device, and a negative pressure driven device.

33. The device ofclaim 32, wherein the sampled substance is selected from the group consisting of body electrolytes, illicit drugs and glucose.

34. The device ofclaim 24, further comprising a plurality of second openings through the sheet being spaced between the plurality of openings.

35. The device ofclaim 24, wherein the device has about 600 to about 1000 blades/cm².

36. The device ofclaim 24, wherein the device has at least about 800 blades/cm².

37. The device ofclaim 24, wherein at least a portion of the plurality of blades have a length sufficient to pierce the stratum corneum of the body surface to a depth of at least about 25 μm.

38. The device ofclaim 24, wherein each of the plurality of blades is oriented approximately perpendicular to the sheet.

39. The device ofclaim 24, wherein each of the plurality of blades is oriented at an angle in the range of about 11 to about 89° to the sheet.

40. The device ofclaim 24, wherein each of the plurality of blades is oriented at an angle in the range of about 10° to about 60° to the sheet.

41. The device ofclaim 24, wherein the plurality of blades have a thickness in the range of about 7 μm to about 100 μm.

42. The device ofclaim 24, wherein the plurality of blades have a thickness in the range of about 25 micrometers to about 50 micrometers.

43. The device ofclaim 24, wherein each of the plurality of blades are composed of a material selected from the group consisting of metals, metal alloys, glasses, ceramics and rigid polymers.

44. The device ofclaim 24, wherein the sheet and the plurality of blades are substantially impermeable to the passage of the agent.

45. The device ofclaim 24, wherein the plurality of blades are thinner than the sheet.

46. A method for producing a device for piercing the stratum corneum of a body surface, the method comprising:

applying a layer of photo-resist to a first side of a sheet;

exposing the layer of photo-resist through a mask pattern for producing a plurality of blades;

etching exposed portions of the photo-resist and the sheet to produce the plurality of blades and openings through the sheet;

punching the plurality of blades through the openings such that the plurality of blades extend downward from the sheet; and

incorporating the device for piercing the stratum corneum into a delivery device or sampling device.

47. The method ofclaim 46, wherein the photo-resist is a resist selected from the group consisting of wet resist and dry resist.

48. The method ofclaim 46, wherein the etching step comprises spray etching.

49. The method ofclaim 46, wherein the punching step comprises:

placing the sheet on a die having a plurality of openings corresponding to the plurality of blades and openings of the sheet; and

bending the plurality of blades through the openings to be substantially perpendicular to the sheet with a punch having a plurality of protrusions corresponding to the plurality of openings in the die and the plurality of openings of the sheet.

50. A method of transdermally sampling an agent, comprising:

a. placing a device on a body surface through which the agent is to be withdrawn, the device including a sheet having at least one opening therethrough and a plurality of blades extending downward therefrom whereby agent transmitting pathways are formed through the stratum corneum at the body surface, and a reservoir in agent-transmitting relation with the opening;

b. withdrawing the agent through the pathways and said opening; and

c. collecting the agent in the reservoir.

51. The method ofclaim 50, wherein the sampled agent is selected from the group consisting of body analytes, electrolytes, blood gases, illicit drugs, licit drugs and glucose.

52. The method ofclaim 50, further comprising:

connecting a sampling device to a side opposite of a side of the sheet having the blades extending downward therefrom, the sampling device being selected from the group consisting of a reverse electrotransport sampling device, a passive sampling device, an osmotic sampling device, and a negative pressure driven sampling device.

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