Air-less Nebulizing Unit for Viscous Polysaccharide Micro-particles
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Solution Overview
Problem
Current methods for producing micro-particles of polysaccharides are limited by high production costs, restricted viscosity range, and health hazards from using irritants like isopropyl alcohol, and are not scalable for large-scale applications.
Innovation Solution
An air-less nebulizing unit is used to process viscous feeding solutions containing polysaccharides and biologically active substances, allowing for higher productivity and quality micro-particle production with adjustable nebulization parameters and a pneumatic circuit for pressurization, eliminating the need for compressed air and reducing operational risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If compressed air nebulization is used to process feeding solution, then nebulization can be achieved, but the technique fails for viscous solutions above 2 Pa·s and requires high pressure flows with extended facility dimensions
Solution Approach 1:
The invention extracts and eliminates compressed air from the nebulization system, using only hydraulic pressure from a pump to generate nebulization. This removes the limitation of compressed air on viscous solutions and eliminates the need for extended facility dimensions associated with high pressure air flows
Solution Approach 2:
The invention transitions from pneumatic nebulization (compressed air) to hydraulic nebulization (pump-driven pressure), allowing effective processing of viscous solutions through liquid pressure rather than gas pressure, thereby expanding the usable viscosity range without requiring large facility dimensions
2Loss of substance
If isopropyl alcohol is used for removing oil from emulsion, then oil removal is achieved, but operator health is compromised due to respiratory and eye irritation
Solution Approach 1:
The invention replaces toxic isopropyl alcohol with water, a non-toxic, inexpensive substance that effectively removes oil from the emulsion without harming operator health, eliminating the need for expensive safety equipment and health monitoring
Solution Approach 2:
The invention creates a safe working environment by using water instead of flammable and toxic solvents, eliminating health hazards to operators while maintaining effective oil removal capabilities
3Manufacturing precision
If shaft stirrer emulsification is used for microcapsule production, then micro-particles can be formed, but production is limited to a few grams/day with high production costs
Solution Approach 1:
The invention replaces the mechanical shaft stirrer system with a nebulization-based system that uses hydraulic pressure to create micro-droplets, dramatically increasing production capacity from grams per day to kilograms per day while maintaining micro-particle formation quality
Solution Approach 2:
The invention changes the fundamental operating parameters from low-speed mechanical stirring to high-velocity nebulization under hydraulic pressure, enabling scale-up of production while preserving the micro-particle formation mechanism
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the production of high-quality micro-particles from a wide range of viscosities, increasing productivity and reducing costs while ensuring a safer and more efficient process, capable of handling viscous solutions within comparable facility dimensions.
Implementation Method 1
pressurizing the feeding solution inside an air-less nebulizing unit and nebulizing the solution itself by means of such a unit so as to generate micro-drop jets impacting the surface of the gelifying liquid
Implementation Method 2
collecting the nebulized jets by gelification into a gelifying liquid
Data Source
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AI summary
The present invention relates to a method for the production of micro-particles of polysaccharides. The method includes preparing a feeding solution and a gelifying liquid to collect nebulized jets of the feeding solution. The feeding solution contains at least one polymer capable of forming micro-particle structures and at least one biologically active substance. The feeding solution is pressurized inside an air-less nebulizing unit and then nebulized through the unit itself so as to generate nebulized jets impacting the surface of the gelifying liquid.