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1

METHOD AND DEVICE FOR
INTRADERMALLY DELIVERING A
SUBSTANCE

FIELD OF THE INVENTION 5

The present invention is directed to a method and device for delivering a substance intradermally to a patient. The invention is also directed to a microneedle delivery device for containing and delivering a unit dose of a substance intradermally to a patient.

BACKGROUND OF THE INVENTION

15

Subcutaneous delivery devices using a cannula are effective for many applications. However, the pain normally induced by the cannula has prompted the development of less painful delivery methods. Recently, a number of intradermal devices employing microneedles have been 2o designed. The microneedles have a length selected to penetrate the skin to a depth where a drug or pharmaceutical agent can be delivered to a patient.

In humans, the skin is made up of several layers, with the upper composite layer being the epithelial layer. The outer- 25 most layer of the skin, the stratum corneum, has well known barrier properties to prevent molecules and various substances from entering the body and analytes from exiting the body. Bouwstra, et al., (2001) Skin Pharmacol Appl Skin Physiol, 14 Suppl 1:52-62. 30

The stratum corneum is a complex structure of compacted keratinized cell remnants having a thickness of about 10-30 microns which forms a waterproof membrane to protect the body from invasion by various substances and from the outward migration of various compounds. 35

The natural impermeability of the stratum corneum prevents the administration of most pharmaceutical agents and other substances through the skin. Numerous methods and devices have been proposed to enhance the permeability of the skin and to increase the diffusion of various drugs 40 through the skin to be utilized by the body. Typically, increasing either the permeability of the skin or the force or energy used to drive therapeutics through the skin enhances delivery of drugs through the skin. Bouwstra, et al., supra.

45

Another method of delivering various substances through the skin is by forming micropores or microcuts through the stratum corneum. By penetrating or piercing the stratum corneum and delivering a drug to the skin in or below the stratum corneum, many drugs can be administered effec- 5Q tively. The devices for piercing the stratum corneum generally include a plurality of micron-sized needles or blades having a length selected to pierce the stratum corneum without passing completely through the epidermis. Examples of these devices are disclosed in U.S. Pat. No. 5,879,326 to Godshall et al, U.S. Pat. No. 5,250,023 to Lee et al, and WO 97/48440.

The above-noted devices that include micron-sized needles or blades deliver the substances to the body by allowing the substances to flow through pores or channels in 60 the device. Many of these prior devices do not provide a controlled delivery of a substance to the patient.

The prior methods and devices for the intradermal administration of substances have exhibited limited success. Accordingly, a continuing need exists for an improved 65 device for administration of various drugs and other substances to the body.

2

SUMMARY OF THE INVENTION

The present invention is directed to a method and device for the delivery of a substance though the skin of a patient. More particularly, the invention is directed to a method and device for delivering a pharmaceutical agent, such as a drug or vaccine, below the stratum corneum of the skin to a depth at which the pharmaceutical agent can be absorbed and utilized by the body. The invention is further directed to a method of manufacturing and assembling a device for intradermally delivering a substance through the skin of a patient.

Accordingly, a primary object of the invention is to provide a low profile device to provide an increased comfort level to the patient, wherein the device has a skin penetrating member for introducing the substance to the patient.

A further object of the invention is to provide a device for penetrating the skin for delivering a unit dose of a substance through the skin substantially without pain to the patient.

Another object of the invention is to provide a device having at least one micro skin penetrator, (e.g., microtube, microneedle, microblade or lancet) for piercing the stratum corneum of the skin to deliver a substance to a patient.

A further object of the invention is to provide a delivery device having at least one skin penetrating member and a chamber for containing a substance to be delivered to a patient.

Still another object of the invention is to provide an intradermal delivery device having an indicator for indicating that a sufficient amount of a substance, for example, a premeasured dose, has been delivered from a chamber intradermally to a patient and an arrangement for producing a dispensing enhancing pressure in the chamber throughout the dispensing operation.

Another object of the invention is to provide a device for delivering a substance to a patient, wherein the device has a support with an internal supply channel having a very low dead volume and a micro skin penetrator device bonded to the support in fluid communication with the supply channel for delivering the substance to the patient.

A further object of the invention is to provide a delivery device having a plurality of micro skin penetrating members, wherein the device includes at least one elastic wall for producing a dispensing enhancing pressure in an internal chamber containing a substance to deliver to the patient and for indicating when a sufficient amount of the substance has been dispensed.

Another object of the invention is to provide an intradermal delivery device having an internal chamber with an arrangement for filling and pressurizing the internal chamber.

Another object of the invention is to provide for the intradermal delivery device a liquid source for supplying a liquid substance to the internal cavity by a force sufficient to pressurize the housing and produce the dispensing enhancing pressure throughout the dispensing operation.

A yet further object of the invention is to provide a method for intradermally delivering a substance to a patient comprising providing a delivery device which has a housing with an internal cavity and at least one skin penetrating device in fluid communication with the cavity, wherein the housing is pressurizable for maintaining a dispensing enhancing pressure in the cavity, the delivery device is positioned on a target area on the skin of a patient, and sufficient force is applied to cause the skin penetrating device to penetrate the skin of the patient. A substance is 3

introduced into the cavity of the housing, the substance producing the dispensing enhancing pressure in the cavity.

These and other objects of the invention are substantially achieved by providing an intradermal delivery device comprising a housing having an internal cavity dimensioned to 5 receive a substance for delivery to a patient, a skin penetrating device in fluid communication with the cavity, and a resiliently biased movable member in fluid communication with the cavity. The resiliently biased movable member produces a dispensing enhancing pressure in the cavity for 1° dispensing the substance from the cavity to the skin penetrating member and indicates the delivery of a sufficient amount of the substance to the patient.

The objects and advantages of the invention are further attained by providing an intradermal delivery device com- 15 prising a housing having at least a portion made of an expandable material with sufficient elasticity to produce a dispensing enhancing pressure when the cavity is filled with a substance and to indicate that the cavity has not yet delivered a sufficient amount of the substance. A skin 20 penetrating device is coupled to the housing and is in fluid communication with the cavity.

The present invention is directed to a device for delivering a substance into the skin of a patient. More particularly, the invention is directed to an intradermal delivery device and to 25 a method for administering a substance below the stratum corneum of the skin of a patient where the substance is absorbed and utilized by the body.

As used herein, the term "penetrate" refers to entering an 3Q object, such as a layer of the skin, without passing completely through. The term "pierce" refers to passing completely through an object, such as a layer of the skin.

The device and method of the present invention are suitable for use in administering various substances, includ- 35 ing pharmaceutical agents, to a patient, and particularly to a human patient. As the term is used herein, a pharmaceutical agent includes a substance having biological activity that can be delivered through the body membranes and surfaces, particularly the skin. Examples of pharmaceutical agents 40 include antibiotics, antiviral agents, analgesics, anesthetics, anorexics, antiarthritics, antidepressants, antihistamines, anti-inflammatory agents, antineoplastic agents, vaccines, including DNA vaccines, and the like. Other substances that can be delivered intradermally to a patient include proteins, 45 peptides and fragments thereof. The proteins and peptides can be naturally occurring, synthesized or recombinantly produced.

The delivery device of the present invention is constructed for penetrating selected layers of the dermis of a 50 patient to attain the desired depth of penetration. The desired depth of penetration is determined by the substance being delivered and the desired rate of absorption by the body. Less penetration speeds the uptake of the substance by the body, and greater penetration slows delivery. It is contem- 55 plated that the skin penetrating member has a length of about 50 microns to about 1,500 microns. It is also contemplated that an array of such skin penetrating members can be used. The penetrating members have a length designed to pierce the stratum corneum without inducing pain by impacting 60 nerve endings. By delivering a substance below the stratum corneum, the substance can be absorbed and utilized by the body substantially without pain or discomfort to the patient. Preferably, the skin penetrating members have a length and diameter to penetrate the skin to a depth where the patient 65 experiences little or no pain, for example, below the stratum corneum and above the nerve endings.

4

The present invention is directed to an intradermal delivery device for delivering a substance into the skin of a patient where the device is able to maintain a dispensing enhancing pressure for delivering the substance. More particularly, the invention is directed to a unit dose delivery device for the sustained delivery of a substance through the skin of a patient.

The objects, advantages and other salient features of the invention will become apparent from the following detailed description which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings:

FIG. 1 is a top view of a delivery device in accordance with a first embodiment of the invention;

FIG. 2 is a front elevational view of the device of FIG. 1;

FIG. 3 is a bottom view of the device of FIG. 1, showing a skin penetrating device;

FIG. 4 is an enlarged partial cross-sectional view of the device of FIG. 2, showing the skin penetrating device 3 bonded to a housing;

FIG. 5 is an enlarged cross-sectional view taken along the line 5—5 in FIG. 1, showing a cavity in the housing and a diaphragm in a normal, relaxed state;

FIG. 6 is a cross-sectional view similar to FIG. 5 but showing the cavity filled with a substance and the diaphragm in a stretched state for producing an indication of an insufficient amount dispensed and a dispensing enhancing pressure;

FIG. 7Ais a cross-sectional side view of a delivery device in accordance with a second embodiment of the invention, wherein the device has an expandable diaphragm forming a top wall;

FIG. 7B is a top view of the device of FIG. 7A;

FIG. 8 is a cross-sectional side view similar to FIG. 7A but with the cavity filled with a substance and the diaphragm in the stretched state;

FIG. 9 is a top view of a delivery device in accordance with a third embodiment of the invention showing an inlet port and an expandable diaphragm in a top wall;

FIG. 10 is a bottom view of the delivery device of FIG.

9;

FIG. 11 is an enlarged cross-sectional view taken alone the line 11—11 in FIG. 9;

FIG. 12 is a top view of a delivery device in accordance with a fourth embodiment of the invention, showing an expandable top wall and an inlet port coupled to a side of a housing;

FIG. 13 is a bottom view of the device of FIG. 12, showing a microneedle array; and

FIG. 14 is an enlarged cross-sectional view taken along the line 14—14 in FIG. 12, showing a microneedle array and an internal chamber.

DETAILED DESCRIPTION OF THE
PREFERRED EMBODIMENTS

As can be seen from FIGS. 1-6, a first embodiment of a delivery device according to the present invention, which is designated generally by the reference numeral 10, comprises a housing 12 and a skin penetrating device 14. Housing 12 is dimensioned to contain a substance to be delivered to a patient and to be removably attached to the surface of the skin. Skin penetrating device 14 is associated with housing 12 to penetrate the skin of the patient and deliver the

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