Core-Shell Droplet Generation for Uniform High-Throughput Aerosols
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Solution Overview
Problem
Conventional techniques struggle to produce substantially uniform core-shell droplets or particles at a high rate, using a simple system, and at an affordable cost, which is necessary for applications such as medical delivery, ultrasonic diagnostics, encapsulation, and additive manufacturing.
Innovation Solution
A device comprising a first tubular member with a lumen and second tubular members extending through its sidewall, allowing fluids to form core-shell particles by flowing through the second tubular members, which are configured to create uniform particles with adjustable sizes and materials, and a system that includes fluid sources, controllers, and means for drying or polymerizing these particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional techniques are used to form core-shell particles, then the system complexity is low, but the manufacturing precision and uniformity of droplet sizes are insufficient
Solution Approach 1:
The device segments the particle formation process into distinct functional zones: a first tubular member for shell material delivery, multiple second tubular members for core material delivery, and a third tubular member for additional shell layers. Each tubular member has specific lumens configured for precise fluid injection, dividing the complex particle formation task into manageable, specialized components that collectively achieve high uniformity.
Solution Approach 2:
Different regions of the device are assigned specific functions to achieve local optimization: the first tubular member delivers shell material with specific flow characteristics, the second tubular members deliver core material at controlled rates, and the third tubular member adds outer shell layers. This local specialization of function allows each component to be optimized for its specific role, resulting in overall high manufacturing precision.
2Productivity
If conventional techniques are used to form core-shell particles, then the device structure is simple, but the productivity and rate of production are limited
Solution Approach 1:
The device merges multiple particle formation capabilities into a single integrated system. Multiple second tubular members with annular cross-sections are positioned within the first tubular member, allowing simultaneous formation of multiple core-shell particles or varied particle types in parallel. This consolidation of functions into one device dramatically increases production rate while maintaining controlled complexity through modular design.
Solution Approach 2:
The device is designed with universal capabilities to produce different types of core-shell particles by adjusting which second tubular members are active and their respective flow rates. The same device structure can produce particles with single or multiple shells, varying core materials, and different size distributions, making it a multi-functional production platform that maximizes productivity across diverse particle requirements.
3Manufacturing precision
If conventional techniques are used to form core-shell particles, then the cost is low, but the manufacturing precision and uniformity are insufficient
Solution Approach 1:
The device utilizes the inherent properties of the fluids being processed to achieve precise particle formation without requiring additional complex control systems. The shell material flowing through the first tubular member and core materials flowing through the second tubular members self-organize into uniform core-shell structures through controlled fluid dynamics and interfacial tension effects, eliminating the need for expensive post-processing or complex real-time adjustment mechanisms.
Solution Approach 2:
The device employs hydraulic and pneumatic principles to control fluid flow and particle formation. Pressurized fluids are used to drive materials through the tubular members at controlled rates, and fluid pressure differential is utilized to achieve precise droplet breakup and shell formation. This approach leverages readily available and cost-effective fluid power technology to achieve high manufacturing precision.
4Productivity
If multiple second tubular members are used to increase production rate, then the productivity improves, but the device complexity increases
Solution Approach 1:
The device implements a nested configuration where multiple second tubular members are positioned within the first tubular member, and potentially within the third tubular member. This nested doll arrangement allows multiple particle formation channels to be packed into a compact structure, increasing production rate while minimizing the overall device footprint and reducing the complexity of external connections and support structures.
Solution Approach 2:
The device transitions from a single-dimensional linear arrangement to a multi-dimensional nested structure. Second tubular members are positioned at different radial positions and orientations within the first tubular member, utilizing three-dimensional space efficiently. This dimensional arrangement allows parallel particle formation pathways without requiring proportional increases in device length or external 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
The device and system enable the production of uniformly sized core-shell particles and droplets, suitable for various applications, including medical delivery, ultrasonic diagnostics, encapsulation, and additive manufacturing, encapsulation, and additive manufacturing, food production, and recreational usage.
Implementation Method 1
A pressure of the first fluid may cause the second lumen to open and form a fluid film that spans the open second lumen
Implementation Method 2
The drying, photopolymerization, or pyrolysis means may be configured to transform at least one layer of the core-shell particle formed by the device from a liquid to a solid
Implementation Method 3
The drying, photopolymerization, or pyrolysis means may be configured to transform at least one layer of the core-shell particle formed by the device from a liquid to a solid
Implementation Method 4
The drying, photopolymerization, or pyrolysis means may be configured to transform at least one layer of the core-shell particle formed by the device from a liquid to a solid
Data Source
AI summary
Disclosed is a simple and cost-effective technique for generation of high-throughput aerosols of uniform-diameter submillimeter-size core-shell particles. An aerosol may be created by using, e.g., a first tube filled with liquid and having a small hole through a sidewall, then passing a fluid through the liquid via a second tube passing partially though the first tube at a location above the small hole, forming coaxial flow through the small hole. The diameter of generated core-shell particles scales with the inner and outer diameter of the gas tube nozzle, enabling control on the size of the produced particles. Further disclosed is a simple, scalable and cost-effective technique that enables microencapsulation of various materials. Including highly viscous materials, into sub-10 μm particles. A specially designed atomizing tube interacts with bubbles formed in a liquid comprising a plurality of immiscible liquid layers to generate aerosols of droplets which have layered core-shell structure.