Core-Shell Microcapsule Formation via Computer-Controlled Syringe Pumps
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Solution Overview
Problem
Existing microcapsule formation processes struggle to consistently produce core-shell microcapsules with precise control over temperature, volumetric flow rate, and pressure, especially when using heated or melted materials.
Innovation Solution
The development of computer-controlled microcapsule formation systems that use heated and melted materials, with syringe pumps operating up to 250°C, to form core-shell microcapsules with precise control over temperature, volumetric flow rate, and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional encapsulation processes are used, then microcapsules can be formed, but precise control over temperature, volumetric flow rate, and pressure is difficult to achieve
Solution Approach 1:
The patent applies parameter changes by implementing computer-controlled regulation of temperature, volumetric flow rate, and pressure parameters. The system uses programmable controllers to dynamically adjust these parameters, enabling precise control throughout the microcapsule formation process. This resolves the contradiction by transforming manual or semi-automatic parameter control into automated precise control.
Solution Approach 2:
The patent implements feedback control through sensors that continuously monitor temperature, flow rate, and pressure, with the data fed back to the computer control system. This closed-loop feedback mechanism enables real-time adjustments to maintain precise control parameters, resolving the contradiction between control precision and system complexity by providing automated regulation.
2Stability of the object's composition
If heated or melted materials are used for microcapsule formation, then material properties can be optimized, but temperature control becomes more challenging
Solution Approach 1:
The patent applies parameter changes by implementing computer-controlled temperature regulation throughout the material handling system. Heating elements and temperature sensors are integrated into the syringe pump system, allowing precise maintenance of material temperature between 0°C and 250°C. This ensures consistent material properties (viscosity, flow characteristics) while resolving the temperature control challenge through automated regulation.
Solution Approach 2:
The patent applies preliminary action by pre-heating materials to the required temperature before microcapsule formation begins. The system prepares melted materials in advance, maintaining them at optimal temperatures through heated containers and syringes. This preliminary temperature preparation ensures material property consistency during the actual encapsulation process.
3Productivity
If rapid microcapsule formation is achieved, then productivity increases, but control over formation parameters may be compromised
Solution Approach 1:
The patent applies continuity of useful action by implementing continuous computer-controlled regulation of all formation parameters during rapid microcapsule production. The system maintains precise control over temperature, flow rate, and pressure even at high production speeds through automated feedback loops. This resolves the contradiction by enabling rapid formation without sacrificing precision through automated continuous control.
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 rapid and consistent formation of microcapsules with outer diameters less than 1 millimeter, using materials like melted plastic, with improved temperature and viscosity control throughout the process.
Implementation Method 1
one or more container heaters in mechanical contact with the first and second containers. In some systems, the one or more container heaters are operable to heat the core and shell materials to a temperature between 0° C. and 250° C.
Implementation Method 2
one or more syringe heaters in mechanical contact with the first and second pairs of syringe pumps. In some systems, the one or more heaters are operable to heat the core and shell materials while the core and shell materials are pumped by the syringe pumps.
Implementation Method 3
a vibration source operable to vibrate the encapsulation cell. In some systems, the encapsulation cell includes an inner nozzle concentrically disposed within an outer nozzle. In some systems, the inner and outer nozzles are operable to form a microcapsule using the core material and the shell material while the encapsulation cell is vibrated by the vibration source.
Data Source
AI summary
Some microcapsule forming systems include a first container containing a core material; a second container containing a shell material; one or more heaters in mechanical contact with the first and second containers; a first pair of syringe pumps operable to pump the heated core material from the first container to an encapsulation cell; a second pair of syringe pumps operable to pump the heated shell material from the first container to the encapsulation cell; a controller for controlling the one or more heaters and the first and second pair of syringe pumps; the encapsulation cell comprising a first nozzle disposed concentrically within a second nozzle, the first nozzle operable to form a sphere using the heated and pumped core material and the second nozzle operable to form a shell surrounding the sphere using the heated and pumped shell material to form a microcapsule.