Laminar Flow Packed Bed Emulsifier for Microparticle Size Control
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Solution Overview
Problem
Existing methods for producing emulsion-based microparticles using turbulent mixing techniques result in variable microparticle sizes, are sensitive to fluid flow and physical properties, and are not scalable, making it difficult to consistently produce microparticles with desired properties, especially when dealing with sensitive biological agents like proteins.
Innovation Solution
A laminar flow process using a packed bed emulsifier is employed to produce microparticles, which allows for a narrow and reproducible particle size distribution, enabling easy scaling from small to large volumes and maintaining consistent properties across batches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If turbulent mixing devices are used to form emulsions, then emulsion formation is achieved, but microparticle size distribution becomes wide and variable
Solution Approach 1:
The mixing process is segmented into discrete stages: first mixing the organic phase components, then separately preparing the aqueous phase, and finally combining them in a controlled manner. This segmentation allows precise control over emulsion formation and microparticle size distribution.
Solution Approach 2:
The patent changes the flow regime parameter from turbulent to laminar flow conditions. By operating at low flow rates where laminar flow predominates, the system achieves uniform microparticle size distribution while maintaining ease of emulsion formation. This parameter change is the core solution to the contradiction.
2Ease of manufacture
If turbulent mixing is used for emulsion formation, then mixing is achieved, but sensitivity to fluid flow and physical properties increases
Solution Approach 1:
Instead of using high-energy turbulent mixing to achieve emulsion formation, the patent inverts the approach by using low-energy laminar flow conditions. This inversion eliminates the sensitivity to fluid flow and physical properties that characterizes turbulent mixing, while still achieving effective emulsion formation and microparticle production.
3Ease of manufacture
If turbulent mixing processes are used, then emulsion formation is achieved, but scalability becomes difficult
Solution Approach 1:
The laminar flow mixing apparatus is designed to be universally applicable across different scales. The same basic apparatus can be used for both small-scale research and large-scale production, with only minor adjustments needed. This universality directly addresses the scalability problem by eliminating the need for completely different mixing systems at different scales.
4Ease of manufacture
If turbulent mixing is used, then emulsion formation is achieved, but batch to batch variation increases
Solution Approach 1:
The system incorporates feedback mechanisms to monitor and control flow rates, ensuring consistent laminar flow conditions across batches. This feedback control maintains uniform microparticle size distribution and composition from batch to batch, eliminating the variability inherent in turbulent mixing processes.
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 laminar flow process ensures consistent and precise microparticle production with a narrow size distribution, is insensitive to flow rates, and allows for efficient scaling, overcoming the limitations of turbulent mixing methods by producing high-quality microparticles across various batch sizes.
Implementation Method 1
a first phase and a second phase are passed through a packed bed emulsifier under laminar flow conditions producing an emulsion
Implementation Method 2
producing an emulsion that results in microparticles upon solvent removal
Implementation Method 3
After the external emulsion is formed, the organic solvent is removed from the emulsion, producing hardened microparticles
Data Source
AI summary
The apparatus and methods of the present invention are of use for the production of emulsion-based microparticles containing a biological or chemical agent. In particular, the apparatus provides a vessel; packing material situated inside such vessel and may further provide material capable of insertion into both ends of said vessel for enclosure of the packing material. In a particular embodiment, the apparatus is a packed bed apparatus. The methods include production of emulsion based microparticles containing a biological or chemical agent. The usefulness of the present invention is that the apparatus and methods of the present invention provide for a low-shear, non-turbulent, production of emulsion-based microparticles that provides a narrow, reproducible, particle size distribution, capable of use with both large and small volumes that is capable of being conveniently scaled up while providing predictable emulsion properties.