Capsule Fabrication via Porous Membrane Nozzles for Uniform Size
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing encapsulation technologies face challenges in mass production due to wide size distribution, low encapsulation yields, limited size adjustment, and high costs, making them unsuitable for industrial applications, and current methods struggle to produce capsules with uniform physical properties and high thermal conductivity.
Innovation Solution
A method involving the formation of droplets of a dispersed phase solution containing a phase transition material and carbon nanomaterial, passing through a porous membrane with nozzle units, followed by migration into a mobile phase material for polymer shell formation, allowing for the creation of capsules with a core-shell structure and high thermal conductivity through continuous polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional encapsulation methods (emulsion formation with outer wall coating) are used, then capsules can be formed with various sizes, but the size distribution is wide and uniformity is poor
Solution Approach 1:
The invention divides the capsule fabrication process into discrete stages: droplet formation through nozzle units, outer wall formation in a first mobile phase, and core material filling in a second mobile phase. This segmentation enables precise control over capsule size and composition while maintaining high production rates through continuous processing.
2Manufacturing precision
If microencapsulation method with simultaneous pressing of emulsion and outer wall is used, then uniform capsule size and high encapsulation degree are achieved, but productivity decreases due to single capsule fabrication
Solution Approach 1:
The invention implements continuous droplet generation through nozzle units and continuous polymerization in mobile phases, transforming the batch-wise single-capsule fabrication into a continuous mass production process. This maintains uniform capsule formation while dramatically increasing throughput.
3Ease of manufacture
If density gradient method is used for capsule formation, then capsules can be manufactured, but selectivity is low due to mixture of mononuclear and multinuclear capsules
Solution Approach 1:
The invention changes the fundamental parameter from density gradient to interfacial polymerization. By controlling the chemical reaction at the interface between dispersed phase and mobile phase, uniform mononuclear capsules are formed with precise size control, eliminating the multinuclear capsule problem inherent in density gradient methods.
4Adaptability or versatility
If conventional encapsulation processes are used, then various materials can be encapsulated, but encapsulation yields are low and costs are high
Solution Approach 1:
The invention applies different mobile phases with specific properties to different stages of capsule formation. The first mobile phase optimizes outer wall formation while the second mobile phase optimizes core material filling, thereby improving overall encapsulation yield and reducing costs through targeted process optimization.
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 enables the mass production of capsules with uniform sizes and high thermal conductivity, overcoming previous limitations by achieving high yield and economical efficiency without the need for density gradients or curing processes, suitable for various thermal energy storage applications.
Implementation Method 1
forming droplets of a dispersed phase solution including a phase transition material, a carbon nanomaterial, and a first monomer by allowing the dispersed phase solution to pass through nozzle units provided at a porous membrane
Implementation Method 2
forming droplets of a dispersed phase solution
Implementation Method 3
forming polymer shells respectively at interfaces between the droplets and the mobile phase material by polymerization between the first monomer and the second monomer
Implementation Method 4
capsules each having a core-shell structure and excellent thermal conductivity... including a carbon nanomaterial
Data Source
AI summary
Provided is a method of fabricating capsules. The method includes: forming droplets of a dispersed phase solution including a phase transition material, a carbon nanomaterial, and a first monomer by allowing the dispersed phase solution to pass through nozzle units provided at a porous membrane in a reaction tank including the porous membrane; migrating the droplets into a mobile phase material including a second monomer; and forming polymer shells at interfaces between the droplets and the mobile phase material by polymerization between the first monomer and the second monomer.