Double Emulsion Micro-Particle Preparation via Membrane and Micro-Sieve
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Solution Overview
Problem
Conventional methods for preparing micro-particles using double emulsion techniques face challenges in achieving uniform size and narrow size distributions, particularly when encapsulating hydrophilic drugs, due to turbulence and shear forces that can lead to batch variations and degradation of sensitive active agents like proteins and peptides.
Innovation Solution
The method involves passing a first phase containing an active agent and a second phase through a membrane or interwoven fiber to form a stable primary emulsion, followed by passing this emulsion through a micro-sieve in a continuous phase to create a secondary emulsion, which helps in achieving uniform micro-particle size and narrow size distributions by minimizing mechanical agitation and turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional dispersion techniques (turbulent flow conditions) are used to prepare emulsion, then mixing efficiency is improved, but micro-particle size distribution becomes wide and batch variations increase
Solution Approach 1:
The patent replaces conventional mechanical dispersion techniques (propeller mixers, turbine mixers, colloid mills) that create turbulent flow with a membrane-based emulsification system. The membrane uses capillary pressure and surface tension effects to form uniform emulsion droplets without mechanical turbulence, thereby achieving narrow size distribution while maintaining production efficiency.
Solution Approach 2:
The patent changes the fundamental parameter of flow condition from turbulent to laminar. By using membrane emulsification with controlled pressure differentials and laminar flow conditions, the system achieves uniform droplet formation. The membrane pore size, pressure differential, and flow rate are controlled parameters that directly determine emulsion droplet size and distribution.
2Productivity
If high shear forces are applied during emulsification, then emulsion formation is accelerated, but sensitive active agents (proteins, peptides) undergo deactivation and degradation
Solution Approach 1:
The patent replaces high-shear mechanical mixing with a membrane-based process that relies on capillary pressure and interfacial tension. This substitution eliminates the harmful mechanical shear forces that deactivate proteins and peptides while maintaining efficient emulsion formation through controlled pressure differentials across the membrane.
Solution Approach 2:
The membrane acts as an intermediary device that facilitates emulsion formation without direct mechanical contact with the phases. It mediates the interface between oil and water phases, using surface properties and capillary effects to form stable emulsions while protecting sensitive active agents from mechanical degradation.
3Adaptability or versatility
If volatile organic solvents are used to dissolve polymer and form oil phase, then encapsulation of hydrophilic drugs is achieved, but solvent removal requires extended stirring time and the process becomes complex
Solution Approach 1:
The patent changes the solvent system from volatile organic solvents to non-volatile oils or water-immiscible liquids. This parameter change eliminates the need for solvent evaporation steps, simplifying the process. The oil phase can be directly used as the continuous phase or removed by simple decantation/centrifugation, reducing process complexity while maintaining the ability to encapsulate hydrophilic drugs through the membrane emulsification mechanism.
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 approach results in reproducible, stable micro-particles with narrow size distributions and improved control over emulsion globule size, enhancing the encapsulation efficiency of hydrophilic drugs and protecting sensitive active agents from degradation.
Implementation Method 1
passing the first phase and the second phase through a membrane to form the stable primary emulsion
Implementation Method 2
passing the primary emulsion through a micro-sieve in a continuous phase to form the secondary emulsion
Data Source
AI summary
Methods for preparing micro-particles using a double emulsion technique combining a membrane and a micro-sieve are provided. Particularly the present invention relates to method for preparing micro-particles comprising: preparing a first phase comprising an active agent; preparing a second phase comprising a carrier and a solvent; passing the first phase and the second phase through a membrane to form a primary emulsion; passing the primary emulsion through a micro-sieve in a continuous phase to form a secondary emulsion; and removing the solvent to form the micro-particles.