Frozen Pellet Freezing With Concave Wells for Uniform Spherical Beads
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Solution Overview
Problem
Existing methods for producing freeze-dried pellets, such as lyophilised beads, face challenges in achieving uniform size distribution, mechanical stability, and contamination due to liquid nitrogen use, leading to inhomogeneous batches and structural inconsistencies.
Innovation Solution
A method involving applying a predefined liquid composition to concave receiving structures on a cooled carrier, which are then frozen to form spherical pellets, followed by lyophilization, ensuring controlled freezing and consistent shape and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid nitrogen is used for freezing, then rapid cooling is achieved, but contamination and inhomogeneous size distribution occur
Solution Approach 1:
The patent introduces a carrier substance (such as silicone oil or another cryogenic liquid) as an intermediary between the liquid nitrogen and the droplets. This carrier allows the droplets to be cooled rapidly by thermal contact with the cryogenic liquid while preventing direct contact with liquid nitrogen, thus avoiding contamination and the inhomogeneous cooling that occurs during boiling. The carrier substance transfers heat efficiently without causing the droplets to sink or merge.
2Temperature
If liquid nitrogen is used for freezing, then rapid cooling is achieved, but mechanical stability and structural consistency deteriorate
Solution Approach 1:
The carrier substance acts as a mediator that provides uniform thermal contact with the droplets during freezing. This ensures that heat is removed consistently from all parts of the droplet, resulting in homogeneous internal structure and consistent mechanical properties. Without the carrier, direct contact with liquid nitrogen causes uneven cooling and structural inconsistencies.
3Manufacturing precision
If concave receiving structures are used, then spherical shape and size uniformity are improved, but device complexity increases
Solution Approach 1:
The carrier is segmented into multiple individual receiving structures (such as wells or cavities) that are arranged in an array. Each receiving structure is a discrete unit with a concave shape designed to hold a specific volume of liquid composition. This segmentation allows for precise control of pellet size and shape while maintaining a relatively simple overall device structure that can be manufactured using standard techniques.
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 method produces uniformly sized, mechanically stable, and contamination-free spherical pellets with minimal variation, facilitating easy handling and storage without loss, suitable for pharmaceutical and diagnostic use.
Implementation Method 1
freezing the liquid composition, thereby generating a plurality of frozen pellets
Implementation Method 2
the receiving surface of the receiving structure has a concave shape
Implementation Method 3
spherical shapes or spheres cannot be obtained due to the gravitational force acting on the volumes resting on the (ultra)cold plate
Implementation Method 4
freeze-dried pellets
Data Source
Figure 1~2
Figure 3
AI summary
In various embodiments a method for the manufacture of frozen pellets is provided, comprising: (a) applying a predefined quantity of a liquid composition to a respective receiving surface of a plurality of receiving structures, (b) freezing the liquid composition, thereby generating a plurality of frozen pellets, wherein the receiving surface of the receiving structure has a concave shape; and wherein said liquid composition comprises one or more saccharide. In various further embodiments a product is provided, in the form of a plurality of frozen pellets, obtainable by the method of any one of the preceding claims.