Atmospheric Pressure Particle Coating Through Rapid Precipitation
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Solution Overview
Problem
Existing methods for producing nanoparticle coatings on carrier particles face challenges in controlling particle size, agglomeration, and scalability, particularly with supercritical anti-solvent techniques that require high pressure environments, leading to safety concerns and limited scalability.
Innovation Solution
A method involving mixing a supercritical fluid with a solution to form particles at atmospheric pressure, allowing for rapid precipitation and coating onto carrier particles within a chamber, which reduces the need for high-pressure equipment and enables a continuous process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If supercritical anti-solvent technique is used to produce API nanoparticles with controlled particle shape and size distribution, then particle quality is improved, but high pressure requirements limit scalability and jeopardize safety
Solution Approach 1:
The patent changes the pressure parameter from high pressure (supercritical state) to atmospheric pressure by using a different mechanism - mixing supercritical CO2 with a saturated solution and allowing rapid precipitation when the solution contacts the supercritical fluid at atmospheric pressure. This maintains particle quality while eliminating safety concerns
Solution Approach 2:
Instead of introducing the saturated solution into a high-pressure chamber containing supercritical CO2 (conventional approach), the patent inverts the process by introducing supercritical CO2 into a chamber at atmospheric pressure containing the saturated solution. This reversal eliminates the need for high-pressure chambers while achieving the same particle precipitation effect
2Quantity of substance
If high pressure environment is maintained in the chamber to keep supercritical fluid in supercritical state, then particle precipitation is achieved, but equipment costs increase and scalability is limited
Solution Approach 1:
The patent extracts the supercritical CO2 from the high-pressure chamber environment and introduces it into an atmospheric pressure chamber. The supercritical fluid's particle-precipitating function is retained, but the high-pressure containment requirement is removed, simplifying equipment needs and enabling scalability
Solution Approach 2:
The saturated solution acts as an intermediary that enables particle precipitation at atmospheric pressure. When supercritical CO2 contacts the saturated solution at atmospheric pressure, rapid precipitation occurs without requiring the CO2 to remain in supercritical state, thus eliminating high-pressure equipment requirements
3Loss of substance
If API nanoparticles are produced and then coated onto carrier particles using separate processes, then particle isolation is achieved, but product yield is reduced due to inefficient collection
Solution Approach 1:
The patent merges the particle production and coating operations into a single integrated process. Carrier particles are introduced into the same chamber where API nanoparticles precipitate from the saturated solution, allowing direct coating without separate isolation and transfer steps, thereby improving yield and reducing complexity
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
This approach achieves a homogeneous nanoparticle coating with improved process yield and efficiency, reducing equipment costs and safety risks while maintaining particle properties, enabling scalable production.
Implementation Method 1
Mixing a supercritical fluid such as supercritical carbon dioxide with a solution comprising dissolved material for forming particles prior to introducing the formed mixture to a precipitation chamber
Implementation Method 2
A rapid pressure drop as the mixture is sprayed into the chamber may cause droplets of the solution to be formed as the supercritical fluid depressurizes
Implementation Method 3
Due to the below supercritical pressure (for example, atmospheric pressure) in the chamber, the droplets may then rapidly dry (for example, prior to contacting the one or more items within the chamber) to form particles
Data Source
AI summary
A method of producing a particle coating on one or more items is provided. The method comprises mixing a supercritical fluid with a solution comprising dissolved material for forming particles. The method further comprises spraying the mixture into a precipitation chamber (316) to precipitate particles, wherein the chamber is at a pressure below a supercritical pressure of the supercritical fluid. The method comprises conveying items to be coated from an inlet of the chamber to an outlet of the chamber. The method also comprises capturing the precipitated particles on items within the chamber.