Multi-component bio-active drug delivery and controlled release to the skin by microneedle array devices

1. A dissolvable microneedle array for transdermal insertion into a patient comprising:

a base portion;

a plurality of microneedles extending from the base portion, the plurality of microneedles including a first controlled release layer, the first controlled release layer comprising a first bioactive component and a first biocompatible polymer that interacts with the first bioactive component to provide a first controlled release profile of the first bioactive component, wherein the first bioactive component is complexed with or integrated to, or otherwise encapsulated by the first biocompatible polymer within the first controlled release layer,

the plurality of microneedles including a second controlled release layer, the second controlled release layer comprising a second bioactive component and a second biocompatible polymer that interacts with the second bioactive component to provide a second controlled release profile of the second bioactive component, wherein the second bioactive component is complexed with or integrated to, or otherwise encapsulated by the second biocompatible polymer within the second controlled release layer,

wherein the second bioactive component is different from the first bioactive component, the second biocompatible polymer is different from the first biocompatible polymer and the second release profile is different from the first release profile, and

wherein the first or second controlled release layers comprise one or more trigger signals selected from the group consisting of trigger signals based on thermal triggers, electric-field triggers, light triggers, and ultrasound triggers,

wherein the one or more trigger signals initiate a release of the first or second bioactive component from the first or second controlled release layer, respectively.

2. The microneedle array of claim 1 , wherein the first and second biocompatible polymers are different and the first controlled release layer exhibits a release profile that is different from the release profile of the second controlled release layer.

3. The microneedle array of claim 1 , wherein the first biocompatible polymer is selected from the group consisting of PLGA, P(L)LA, P(D,L)LA, PCL, PLCL.

4. The microneedle array of claim 3 , wherein the second biocompatible polymer is selected from the group consisting of PLGA, P(L)LA, P(D,L)LA, PCL, PLCL.

5. The microneedle array of claim 1 , wherein the second bioactive component is configured to be released from the microneedle array with an initial burst release kinetic activity and the first bioactive component is configured to have a delayed or triggered release relative to the second bioactive component.

6. A method of forming a microneedle array, comprising:

forming a sheet of material having a plurality of layers including a base portion and a plurality of microneedles extending from the base portion, wherein the plurality of microneedles comprise a first release layer comprising a first bioactive component and a second release layer comprising a second bioactive component;

combining the first bioactive component with a first biocompatible polymer dissolved and/or dispersed within the first controlled release layer to provide a controlled release of the first bioactive component when the microneedle array is inserted into the skin of a patient; and

combining the second bioactive component with a second biocompatible polymer dissolved and/or dispersed within the second controlled release layer to provide a controlled release of the second bioactive component when the microneedle array is inserted into the skin of a patient,

wherein the first release layer has a different release profile from the second release layer and the first and second bioactive components are different bioactive components,

wherein the second bioactive component is configured to be released from the microneedle array with an initial burst release kinetic activity and the first bioactive component is configured to have a delayed or triggered release relative to the second bioactive component, and

wherein the first biocompatible polymer is selected from the group consisting of PLGA, P(L)LA, P(D,L)LA, PCL, PLCL.

7. The method of claim 6 , wherein the first bioactive component is complexed with the first biocompatible polymer within the first controlled release layer.

8. The method of claim 6 , wherein the first bioactive component is integrated with the first biocompatible polymer within the first controlled release layer.

9. The method of claim 6 , wherein the first bioactive component is encapsulated by the first biocompatible polymer within the first controlled release layer.

10. The method of claim 6 , wherein the different bioactive components are combined with different sustained release polymers to provide different kinetic activities when the microneedle array is inserted into the skin of a patient.

11. The method of claim 10 , wherein the first and other biocompatible polymers are selected from the group consisting of PLGA, P(L)LA, P(D,L)LA, PCL, PLCL.