Membrane Emulsification Apparatus with Refiner for Droplet Control
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Solution Overview
Problem
Current emulsion manufacturing techniques struggle to achieve consistent droplet sizes due to fluctuating turbulence and high energy consumption, particularly when dealing with non-Newtonian fluids and materials like gels or solids, leading to inefficient productivity and equipment damage.
Innovation Solution
A membrane emulsification apparatus with a refiner that generates emulsions through a membrane with adjustable apertures, using a refiner with a tunable or fixed opening to converge and break up droplets into a refined emulsion with controlled droplet sizes ranging from 70 nm to 2 μm without the need for recirculation, utilizing a differential screw for adjustable openings and optional pumps for enhanced shear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional stirrers and homogenisers are used to generate emulsions, then emulsions can be produced, but droplet size consistency is poor and size distribution is wide
Solution Approach 1:
The patent employs a microfilter membrane with controlled pore sizes to replace conventional stirrers and homogenisers. The membrane's porous structure provides uniform aperture sizes that deterministically control droplet formation, eliminating the wide size distribution produced by turbulent mechanical mixing. Each pore acts as a template for generating monodisperse droplets.
Solution Approach 2:
The invention replaces the mechanical turbulence-based system (stirrers and homogenisers) with a pressure-driven flow system through a microfilter membrane. This substitution eliminates the fluctuating shear fields and random turbulence that cause poor droplet size control, replacing them with a stable, predictable flow regime through fixed geometric apertures.
2Productivity
If high speed stirrers are used for semisolid dispersions, then dispersion can be achieved, but energy consumption is high and productivity is low
Solution Approach 1:
The patent replaces high-speed mechanical stirrers with a pressure-driven flow system through a microfilter membrane. This eliminates the need for high-speed rotation and intense mechanical mixing, reducing energy consumption while maintaining or improving productivity through continuous flow operation.
Solution Approach 2:
The invention changes the operating parameters from high-speed mechanical mixing to controlled pressure-driven flow through fixed apertures. This parameter change enables processing of semisolid and non-Newtonian materials with lower energy input, as the flow through the membrane apertures is less sensitive to viscosity variations than mechanical stirring.
3Reliability
If homogenisers are used for high viscosity systems, then emulsion can be formed, but pressure drops are high and productivity is low
Solution Approach 1:
The microfilter membrane with its controlled porous structure provides a low-resistance pathway for high viscosity materials to pass through. The apertures are designed to accommodate viscous flow without creating excessive pressure drops, unlike the narrow clearance zones in homogenisers that choke on viscous materials.
Solution Approach 2:
The invention changes from clearance-based shear (homogenisers) to aperture-based flow (membrane). This parameter change allows high viscosity and non-Newtonian materials to pass through with minimal pressure drop, as the flow is governed by the aperture geometry rather than narrow clearance gaps that are sensitive to viscosity.
4Adaptability or versatility
If conventional emulsification equipment is used with gels or setting liquids, then emulsion can be produced, but equipment may become damaged
Solution Approach 1:
The microfilter membrane provides a gentle, non-mechanical separation interface that does not subject challenging materials like gels and setting liquids to intense mechanical stress. Materials pass through the porous structure without the high-shear zones that damage conventional equipment, extending equipment life while handling difficult formulations.
5Manufacturing precision
If membrane emulsification with refiner is used, then droplet size control is improved, but device complexity increases
Solution Approach 1:
The patent merges the emulsification function (membrane with apertures) and the droplet refinement function (refiner with opening) into a single integrated apparatus. The membrane generates the initial emulsion and the refiner immediately follows to refine droplet sizes, combining two functions that would traditionally require separate equipment into one compact unit.
Solution Approach 2:
The microfilter membrane serves multiple functions: it acts as the emulsification interface, provides droplet size control through its aperture distribution, and can be integrated with the refiner to provide both generation and refinement in one component system, reducing overall device complexity.
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 achieves high concentration, uniform emulsions with droplet sizes between 70 nm and 2 μm, reducing energy consumption and equipment stress, enabling efficient production of refined emulsions with low emulsifier use, suitable for various industrial applications.
Implementation Method 1
a membrane defining a plurality of apertures connecting a first volume on a first side of the membrane to a second volume on a second different side of the membrane, the apparatus being arranged to receive a first phase containing a liquid in the first volume and to receive a second phase in the second volume the apparatus being adapted to generate an emulsion through egression of the first phase into the second phase via the plurality of apertures
Implementation Method 2
a refiner arranged to receive the emulsion from the membrane; and wherein said refiner comprises an inlet and an outlet wherein an opening is adapted to converge flow of the emulsion and to break up droplets of the first phase in the emulsion
Implementation Method 3
utilizing a differential screw for adjustable openings
Data Source
AI summary
Membrane Emulsification Apparatus with Refiner There is described a membrane emulsification apparatus for dispersing a first phase in a second phase, comprising: •a membrane defining a plurality of apertures connecting a first volume on a first side of the membrane to a second volume on a second, different, side of the membrane, the apparatus being arranged to receive a first phase containing a liquid in the first volume and to receive a second phase in the second volume the apparatus being adapted to generate an emulsion through egression of the first phase into the second phase via the plurality of apertures; •the apparatus also comprising a refiner (1) arranged to receive the emulsion from the membrane; and wherein said refiner comprises an inlet (4/5) and an outlet (5/4) wherein an opening (8) adapted to converge flow of the emulsion and to break up droplets of the emulsion into a refined emulsion is located between the inlet and the outlet.