Baffle Plate Flow Distribution for Disposable Plasma Spray Drying
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Solution Overview
Problem
Existing spray drying systems are impractical for use by untrained operators and lack the capability to aseptically manufacture dried plasma for medical applications, particularly in remote or emergency settings, and current methods fail to provide a stable, easily accessible dried plasma product.
Innovation Solution
A spray drying disposable device with a spray drying head and chamber that includes a nozzle assembly, plenum, and baffle plate, capable of atomizing plasma into droplets and evaporating them into dried particles, while maintaining aseptic conditions and allowing for rapid rehydration, suitable for use by minimally trained personnel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex spray drying systems are used to maintain aseptic conditions and ensure plasma integrity, then manufacturing precision and reliability are improved, but device complexity and ease of operation deteriorate
Solution Approach 1:
The system is divided into a reusable spray drying apparatus and a disposable drying chamber assembly. The disposable chamber contains all critical aseptic components (filters, heating elements, drying chamber) that are discarded after single use, eliminating the need for complex cleaning and sterilization procedures while maintaining aseptic conditions throughout the process.
Solution Approach 2:
The drying chamber is designed as a disposable component that is discarded after a single use. This eliminates the need for complex sterilization and maintenance systems, reducing overall device complexity while ensuring aseptic manufacturing through the single-use nature of the chamber and its components.
2Reliability
If complex spray drying systems are used to ensure plasma integrity, then reliability is improved, but ease of operation deteriorates
Solution Approach 1:
By separating the disposable chamber from the reusable apparatus, the system allows minimally trained operators to simply load the disposable chamber and initiate the automated drying process. The complex aseptic maintenance functions are encapsulated within the disposable chamber, making the overall system easy to operate while maintaining plasma integrity.
Solution Approach 2:
The disposable chamber is pre-assembled with all necessary aseptic components (filters, heating elements, drying chamber) ready for immediate use. The system automatically maintains aseptic conditions and plasma integrity without requiring operator intervention or specialized training, as the disposable chamber performs these functions self-contained.
3Duration of action of stationary object
If frozen storage methods are used for plasma, then availability is improved for long periods, but loss of time occurs during thawing in emergencies
Solution Approach 1:
The system uses spray drying to transform liquid plasma into dried plasma powder through rapid evaporation of the solvent. This phase transition creates a stable, long-lasting dried product that can be stored indefinitely at ambient temperatures without requiring freezing or thawing, eliminating the time loss associated with thawing frozen plasma in emergency situations.
4Productivity
If rapid spray drying is used to produce dried plasma, then productivity is improved, but manufacturing precision and reliability may deteriorate
Solution Approach 1:
The disposable chamber contains controlled microenvironment components including filtered air supply, regulated heating elements, and controlled drying gas flow that act as intermediaries to ensure consistent and reliable plasma drying. These controlled intermediaries maintain plasma integrity during rapid drying by preventing contamination and ensuring uniform drying conditions throughout the process.
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 enables the production of dried plasma that can be stored and rehydrated quickly, providing easy access to plasma in emergency situations, and is suitable for aseptic manufacture by a wide range of operators, overcoming the limitations of existing systems.
Implementation Method 1
the pressurized aerosol gas flows in a vortex pattern, wherein, when in use, the pressurized aerosol gas atomizes the plasma entering the drying chamber to obtain atomized plasma droplets
Implementation Method 2
the drying gas jet provides drying gas to the drying chamber, wherein, when in use, the drying gas resides in the plenum with uniform air pressure, wherein the plenum supports the nozzle assembly
Implementation Method 3
the drying gas jet provides drying gas to the drying chamber, wherein, when in use, the drying gas resides in the plenum with uniform air pressure
Implementation Method 4
a baffle plate forming the floor of the plenum having one or more drying gas jets, wherein drying gas jet provides drying gas to the drying chamber
Data Source
AI summary
The present invention includes a spray drying disposable device for use in a spray drying system. The disposable has a spray drying head and a plasma drying chamber. The head has a spray dry nozzle assembly in fluid communication with the plasma source and the pressurized aerosol gas source. The pressurized gas flows in a vortex pattern that atomizes plasma droplets in the chamber. The head also includes a plenum has uniform air pressure of the drying gas. A baffle plate forms the floor of the plenum having drying gas jets that supply drying gas to the chamber. The atomized plasma droplets evaporate in the presence of the drying gas emitted from the jets to obtain dried plasma particles and humid air. A capture filter captures the dried plasma particles and allows the humid air to pass. The humid air passes through the gas outlet and the exhaust port.