Glass-Coated Wire Laser Cutting for Asymmetric Microparticles

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Solution Overview

Problem

Current methods for producing non-spherical/asymmetric fine particles are limited by complexity and scalability, making large-scale commercial production challenging due to reliance on chemical reactions and small quantity outputs.

Innovation Solution

A method involving the production of glass-coated metal wires through heating and drawing, followed by laser cutting with a pulse width shorter than the heat propagation time, to create non-spherical/asymmetric fine particles with controlled dimensions and shapes, enabling efficient large-scale production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If conventional methods (optofluidic technique, printing soft lithography, micro-molding, stretching-induced deformation) are used to produce non-spherical/asymmetric fine particles, then particle shape control is improved, but manufacturing complexity and production time increase significantly

Engineering Contradiction:

Improvenon-spherical/asymmetric particle shapeVSAvoidmanufacturing process complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The invention extracts the core functionality of shape control from complex multi-step processes and implements it through a single laser cutting step. By removing unnecessary process steps (chemical reactions, multiple molding operations, stretching procedures), the patent achieves non-spherical particle formation with significantly reduced manufacturing complexity while maintaining shape control precision

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces complex mechanical and chemical manufacturing systems with a laser-based energy field system. Instead of using mechanical molding, chemical reactions, or stretching apparatus, the patent employs laser cutting to directly form non-spherical particles, thereby reducing device complexity while achieving the desired shape control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Shape

If conventional methods are used to produce non-spherical/asymmetric fine particles, then particle shape control is improved, but productivity and output quantity decrease

Engineering Contradiction:

Improvenon-spherical/asymmetric particle shapeVSAvoidmass production capability

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The invention implements continuous laser cutting of glass-coated metal wires to produce non-spherical particles in a continuous manufacturing process. This eliminates the batch-wise production limitations of conventional methods, enabling sustained high-rate particle generation while maintaining consistent shape control throughout the production run

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The invention changes the fundamental production approach from batch chemical/mechanical processes to continuous laser-based processing. By adjusting laser parameters (power, speed, pulse duration) and wire feeding rate, the system achieves both shape control and high productivity, with output quantity no longer limited by small-scale batch processing constraints

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If spherical fine particles are used, then manufacturing simplicity is maintained, but functional performance and biological application effectiveness are limited

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidfunctional performance in biological applications

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention intentionally introduces asymmetry and non-spherical shapes into fine particles to enhance their functional performance in biological applications. The varied shapes (rod-like, disk-like, irregular forms) provide improved cell uptake efficiency, enhanced circulation time, and better targeting capability compared to conventional spherical particles, thereby improving reliability in drug delivery and diagnostic applications

Inventive Principle:

Principle #4Asymmetry

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 allows for the economical production of non-spherical/asymmetric fine particles in large quantities, suitable for bioassay and security applications, with enhanced physical and chemical properties compared to conventional spherical particles.

Implementation Method 1

cutting the at least one of the glass-coated metal wires positioned on the wire holder, in a traverse direction at predetermine distances in a non-contact machining process using a laser having a pulse width shorter than the heat propagation time of the glass-coated metal wires

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

drawing the metal-filled glass tube while melting a lower portion of the glass tube by heating

Methodology Applied

Scientific EffectHeating and melting: Melting

Data Source

PatentEP3632597B1Method for preparing nonspherical/asymmetric microparticles by using glass-coated fine wire

Publication Date: 2023.11.01 UNIVERSITY INDUSTRY COOPERATION GROUP OF KYUNG HEE UNIVERSITY

Figure 1a
Figure 1b~2a
Figure 2b~3a

AI summary

Disclosed are: a method capable of preparing, in large-scaled quantity, nonspherical/asymmetric fine particles in which the physical factors (for example, size, shape, structure, etc.) of a fine wire (for example, glass-coated metal wires) are controlled, by mersing a convergence of nano technology (NT) and laser machining technology; and a use thereof applicable to various fields including bioassay and security.