Hybrid Atomization-Drying Process for Porous Particle Formation
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Solution Overview
Problem
Existing methods for producing porous particles from non-solubilized matrices in a melt state require excessive use of solvents and post-processing steps, leading to high energy consumption and long processing times.
Innovation Solution
A hybrid process combining atomization via drying-cooling using a water-in-oil type emulsion of a non-solubilized and molten matrix composition, where the emulsion is atomized under high pressure and temperature, followed by immediate cooling to remove solvents and form particles with a pore structure without the need for additional solvent removal processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional drying processes are used to remove solvents from solubilized matrices, then porous particles can be obtained, but excessive solvent usage and long processing times are required
Solution Approach 1:
The invention utilizes phase transition of water from liquid to vapor through flash evaporation. The emulsion is atomized into droplets that undergo rapid water evaporation, forming porous particles directly without conventional drying. This phase transition mechanism eliminates the need for prolonged drying processes while maintaining porous structure formation.
Solution Approach 2:
The emulsion is prepared in advance with the matrix solubilized in water, and the porous structure is formed during the atomization process itself rather than through subsequent drying steps. The preliminary emulsion formulation enables the porous structure to develop during the rapid evaporation phase transition, eliminating post-processing drying time.
2Manufacturing precision
If conventional drying processes are used to remove solvents from solubilized matrices, then porous particles can be obtained, but high energy consumption is required
Solution Approach 1:
The invention exploits the phase transition from liquid to vapor through flash evaporation during atomization. This natural phase transition occurs rapidly as water evaporates from the atomized emulsion droplets, forming porous particles without requiring energy-intensive conventional drying processes. The phase transition itself drives the solvent removal and porous structure formation.
Solution Approach 2:
The invention replaces mechanical drying systems (heaters, dryers, prolonged heating processes) with a flash evaporation mechanism driven by atomization and phase transition. This substitution eliminates the need for sustained thermal energy input while achieving the same porous particle formation, dramatically reducing energy consumption.
3Ease of manufacture
If solubilized matrix formulations are used, then particles can be formed through drying, but excessive organic solvents must be used
Solution Approach 1:
The invention changes the solvent parameter from organic solvents to water as the solubilizing medium. The matrix is solubilized in water to form an emulsion, which is then atomized and undergoes flash evaporation. This parameter change eliminates the need for excessive organic solvents while maintaining ease of particle formation through the water-based emulsion system.
Solution Approach 2:
The invention substitutes water-based emulsion formulation with organic solvent-based formulations. By using water as the continuous phase in the emulsion and leveraging flash evaporation during atomization, the process achieves particle formation without requiring excessive organic solvents, reducing environmental impact and cost.
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 reduces solvent usage and energy consumption, while achieving particles with a pore structure efficiently, reducing processing times and maintaining the desired morphological characteristics.
Implementation Method 1
discrete particles that result from the action of shear forces induced by a high pressure gas flow
Implementation Method 2
allowing the formation of a pore structure by evaporation of the solvent
Implementation Method 3
through the action of shear forces induced by a high pressure gas flow, which is at a temperature high enough
Implementation Method 4
cooling said discrete particles, immediately after having removed the solvent composition, obtaining discrete particles in a solid state
Data Source
AI summary
The invention relates to a method for producing particles with pore structures, by means of a hybrid process of atomization via drying-cooling, from a water-in-oil-type emulsion of a composition of a non-solubilized and in melt state matrix. The production method comprises: i) forming a water-in-oil-type emulsion consisting of a composition of a solvent that is aqueous or soluble in water (dispersed phase) and a composition of a non-solubilized and in melt state matrix (continuous phase); ii) forming discrete particles from the emulsion via atomization, using a flow of gas at high pressure and temperature; iii) immediately removing the solvent via evaporation; and iv) subsequently cooling the formed discrete particles, resulting in porous particles that are substantially free from solvents.