Crosslinked Gel Preparation Using Ultrasonic Homogenization
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Solution Overview
Problem
Current methods for preparing crosslinked hyaluronic acid hydrogels face challenges in achieving uniform homogenization and crosslinking, leading to disparities in gel quality and requiring prolonged mechanical agitation, which is inefficient and prone to contamination, especially when dealing with high molecular weight polymers.
Innovation Solution
The process involves using a hermetic, deformable pouch to facilitate gentle and rapid homogenization and crosslinking, ensuring uniform conditions and minimizing environmental exposure, allowing for improved injectability and stability of the resulting gel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional batch processes are used for homogenization and crosslinking, then the process is simple to implement, but the homogenization time is prolonged and crosslinking uniformity is poor
Solution Approach 1:
The patent replaces conventional mechanical agitation with ultrasonic waves to achieve homogenization. The ultrasonic treatment (1-10 minutes) creates cavitation and micro-streaming that rapidly distributes the crosslinking agent uniformly throughout the hyaluronic acid solution, eliminating the need for prolonged mechanical mixing while achieving superior homogeneity and crosslinking uniformity.
Solution Approach 2:
The patent changes the physical state and distribution parameters by using ultrasonic energy to create micro-scale mixing zones throughout the solution. This parameter change from mechanical to acoustic energy enables rapid, uniform distribution of the crosslinking agent, achieving complete homogenization in 1-10 minutes compared to conventional prolonged mechanical agitation.
2Stability of the object's composition
If prolonged mechanical agitation is used for homogenization, then the polymer chains are well distributed, but the process is inefficient and prone to contamination
Solution Approach 1:
The patent substitutes mechanical agitation with ultrasonic homogenization. The ultrasonic waves (20-1000 W, 1-10 minutes) create cavitation bubbles that collapse and generate micro-jets, rapidly distributing polymer chains uniformly throughout the solution. This achieves complete homogenization in minutes rather than prolonged mechanical mixing, significantly improving process efficiency while maintaining excellent polymer chain distribution.
Solution Approach 2:
The patent utilizes the phase transition phenomenon of ultrasonic cavitation, where bubbles form and collapse rapidly in the liquid medium. This cavitation process creates intense local mixing and shear forces that efficiently distribute polymer chains without prolonged mechanical agitation, achieving rapid homogenization while minimizing contamination risk.
3Device complexity
If the process is carried out in an open system, then the equipment is simple, but the contamination risk increases
Solution Approach 1:
The patent implements a closed system where the hyaluronic acid solution and crosslinking agent are mixed and processed in a sealed container under controlled conditions. The ultrasonic homogenization and crosslinking occur within this closed environment, preventing contamination from external sources while maintaining process simplicity. The closed system eliminates exposure to airborne contaminants and environmental variables.
Solution Approach 2:
By replacing prolonged mechanical agitation with rapid ultrasonic treatment in a closed system, the patent minimizes the time the system needs to be open or accessible, thereby reducing contamination risk. The ultrasonic process (1-10 minutes) is so rapid that the closed system remains sealed throughout most of the critical processing steps.
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 results in a crosslinked gel with enhanced injectability and stability, reducing contamination risks and enabling the use of high molecular weight polymers, while minimizing exposure to external factors, thus improving the quality and consistency of the hydrogel.
Implementation Method 1
the cavity is made within a deformable pouch
Implementation Method 2
add an agent capable of inducing the crosslinking thereof
Data Source
Figure 1a~1e
Figure 2
Figure 3
AI summary
Process for preparing a crosslinked gel of at least one polymer or one of its salts, comprising at least the steps that consist in: a) providing an aqueous medium containing at least one polymer, b) forming a homogeneous gel from the medium from step a), c) bringing the gel obtained in step b) into contact with an effective amount of at least one crosslinking agent; d) crosslinking said mixture formed in step c); and e) recovering said crosslinked hydrogel, wherein at least said steps a) to d) are carried out within a hermetic cavity delimited at least partially by a deformable wall, the mixture present in the cavity being exposed, in step d), to conditions conducive to crosslinking.