Foam Breaker and Air Supply for Microsphere Solvent Removal
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Solution Overview
Problem
The existing methods for manufacturing microspheres using biodegradable polymers are hindered by the need for extensive solvent removal, particularly for toxic solvents like dichloromethane or chloroform, which increases production time and impedes mass production.
Innovation Solution
A solvent removing apparatus is designed with a container holding an emulsion, an impeller for stirring, and a foam breaker positioned above the impeller to reduce foam. The apparatus includes specific geometric configurations and components like a rotation shaft, compressed air supply, and air discharge units to enhance solvent extraction and evaporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional solvent removal methods using impeller and stirrer are used, then the emulsion can be stirred, but the solvent removal efficiency is insufficient and production time increases
Solution Approach 1:
The apparatus divides the solvent removal function into multiple components: impeller for bulk stirring, foam breaker for foam management, and air supply system for enhanced evaporation. This segmentation allows each component to address specific aspects of solvent removal efficiently.
Solution Approach 2:
The patent introduces a compressed air supply unit that supplies air to the emulsion surface, utilizing pneumatic action to enhance solvent evaporation. The air flow increases the rate of solvent removal from the emulsion, directly addressing the productivity issue.
2Reliability
If extensive solvent removal is performed to eliminate toxic solvents, then product safety is improved, but production time increases and mass production is impeded
Solution Approach 1:
The apparatus maintains continuous solvent removal through simultaneous operation of impeller stirring, foam breaking, and air supply. This continuous action ensures complete solvent elimination for product safety while minimizing total processing time for mass production.
Solution Approach 2:
The patent optimizes operational parameters including impeller speed, air flow rate, and foam breaker position to maximize solvent removal efficiency. By carefully controlling these parameters, the system achieves rapid and complete solvent elimination.
3Ease of operation
If foam is generated during emulsion stirring, then mixing is achieved, but foam accumulation hinders effective solvent removal
Solution Approach 1:
The foam breaker component specifically targets and removes foam from the emulsion surface during stirring. By extracting the foam phase, the system prevents foam accumulation that would otherwise hinder solvent removal, maintaining both mixing effectiveness and solvent removal efficiency.
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 apparatus effectively accelerates solvent evaporation and extraction, improving the efficiency of microsphere production by reducing residual solvent levels and enhancing encapsulation rates, thus facilitating high-quality microsphere manufacturing on a larger scale.
Implementation Method 1
an impeller rotating in the container to stir the emulsion
Implementation Method 2
a foam breaker spaced apart from the impeller on an upper portion of the impeller, positioned below a surface of the emulsion to be submerged in the emulsion when the emulsion is calm, and configured to rotate to reduce foam generated during stirring of the emulsion
Implementation Method 3
a compressed air supply unit for supplying compressed air to the surface of the emulsion in the container
Data Source
Figure 1~2
Figure 3~4(g)
Figure 5~7
AI summary
A solvent removing apparatus comprises a container containing an emulsion comprising a first raw material of a continuous phase and a second raw material of a dispersed phase, an impeller rotating in the container to stir the emulsion, and a foam breaker spaced apart from the impeller on an upper portion of the impeller, positioned below a surface of the emulsion to be submerged in the emulsion when the emulsion is calm, and configured to rotate to reduce foam generated during stirring of the emulsion; and when a depth from the surface (LS) of the emulsion to a center of the foam breaker (FB) is defined as Hfb, and a depth from the surface (LS) to a bottom surface of the container (100) is defined as Hliquid, wherein Hfb / Hliquid satisfies 0.2 to 0.5.