Microneedle array with active ingredient

Abstract

Microneedle arrays for introducing an active ingredient through a skin surface of a subject can include a base layer, a plurality of microneedles projecting from the base layer, and an active ingredient. Each of the microneedles comprises an elongate body having a proximal portion and a distal portion, in which the proximal portion is attached to the base layer. Each of the microneedles comprises at least one dissolvable polymer. The active ingredient is incorporated in the elongate body, and the active ingredient is present only in the distal portion and at least internally in the distal portion.

What is claimed is: 
     
         1 . A microneedle array comprising microneedles that project from a base layer thereof, the base layer and the microneedles being formed from a dissolvable polymer as a single, continuous structure, the microneedles further comprising an active ingredient carried by a distal portion of the microneedles, the base layer and a proximal portion of the microneedles having substantially no active ingredient. 
     
     
         2 . The microneedle array of  claim 1 , wherein the active ingredient is incorporated within a matrix of the dissolvable polymer along the distal portion of the microneedles. 
     
     
         3 . The microneedle array of  claim 1 , wherein the active ingredient comprises a neurotoxin. 
     
     
         4 . The microneedle array of  claim 3 , wherein the neurotoxin comprises a botulinum toxin. 
     
     
         5 . The microneedle array of  claim 4 , wherein the botulinum toxin is selected from the group consisting of Botulinum toxin serotype A (BoNT/A), Botulinum toxin serotype B (BoNT/B), Botulinum toxin serotype C1 (BoNT/C1), Botulinum toxin serotype D (BoNT/D), Botulinum toxin serotype E (BoNT/E), Botulinum toxin serotype F (BoNT/F), Botulinum toxin serotype G (BoNT/G), Botulinum toxin serotype H (BoNT/H), Botulinum toxin serotype X (BoNT/X), and mosaic Botulinum toxins and/or variants thereof. 
     
     
         6 . The microneedle array of  claim 1 , wherein the dissolvable polymer comprises hyaluronic acid, crosslinked hyaluronic acid, hydrophobically modified hyaluronic acid, or any combination thereof. 
     
     
         7 . The microneedle array of  claim 1 , wherein the dissolvable polymer comprises at least one of a glycosaminoglycan, a polysaccharide, collagen, elastin, fibroin, starch, glucomannan, hyaluronic acid, crosslinked hyaluronic acid, hydrophobically modified hyaluronic acid, or any combination thereof. 
     
     
         8 . The microneedle array of  claim 1 , wherein the distal portion comprises a first distal portion adjacent the proximal portion and a second distal portion longitudinally separated from the proximal portion by the first distal portion, and the first distal portion and the second distal portion have different active ingredient concentrations. 
     
     
         9 . The microneedle array of  claim 1 , wherein the proximal portion has a length in a range from 1% to 99% of a length of the distal portion. 
     
     
         10 . The microneedle array of  claim 1 , wherein the distal portion tapers longitudinally from the proximal portion to terminate in a tip having a width in a range from 1 μm to 30 μm. 
     
     
         11 . A microneedle array comprising:
 a base layer comprising a first dissolvable polymer;   a plurality of microneedles projecting from the base layer, each of the microneedles comprising an elongate body having:
 a proximal portion comprising the first dissolvable polymer and being attached to the base layer, and 
 a distal portion comprising a second dissolvable polymer and an active ingredient homogenously incorporated therewithin, 
   wherein the proximal portion and the base layer have substantially no active ingredient.   
     
     
         12 . The microneedle array of  claim 11 , wherein the first dissolvable polymer and the second dissolvable polymer are same. 
     
     
         13 . The microneedle array of  claim 11 , wherein the first dissolvable polymer comprises hyaluronic acid, crosslinked hyaluronic acid, hydrophobically modified hyaluronic acid, or any combination thereof. 
     
     
         14 . The microneedle array of  claim 11 , wherein the first dissolvable polymer comprises at least one of a glycosaminoglycan, a polysaccharide, collagen, elastin, fibroin, starch, glucomannan, hyaluronic acid, crosslinked hyaluronic acid, hydrophobically modified hyaluronic acid, or any combination thereof. 
     
     
         15 . The microneedle array of  claim 11 , wherein the active ingredient comprises a neurotoxin. 
     
     
         16 . The microneedle array of  claim 15 , wherein the neurotoxin comprises a botulinum toxin. 
     
     
         17 . The microneedle array of  claim 16 , wherein the botulinum toxin is selected from the group consisting of Botulinum toxin serotype A (BoNT/A), Botulinum toxin serotype B (BoNT/B), Botulinum toxin serotype Cl (BoNT/C1), Botulinum toxin serotype D (BoNT/D), Botulinum toxin serotype E (BoNT/E), Botulinum toxin serotype F (BoNT/F), Botulinum toxin serotype G (BoNT/G), Botulinum toxin serotype H (BoNT/H), Botulinum toxin serotype X (BoNT/X), and mosaic Botulinum toxins and/or variants thereof. 
     
     
         18 . The microneedle array of  claim 11 , wherein the distal portion comprises a first distal portion adjacent the proximal portion and a second distal portion longitudinally separated from the proximal portion by the first distal portion, and
 wherein the first distal portion comprises a first amount of the active ingredient homogeneously incorporated therewithin and the second distal portion comprises a second amount of the active ingredient homogeneously incorporated therewithin.   
     
     
         19 . The microneedle array of  claim 11 , wherein the proximal portion has a length in a range from 1% to 99% of a length of the elongate body. 
     
     
         20 . The microneedle array of  claim 11 , wherein the elongate body tapers longitudinally from the proximal portion to the distal portion, the distal portion terminating in a tip having a width in a range from 1 μm to 30 μm.