Mesoporous Silica Particle Production via Sol-Gel Phase Separation
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Solution Overview
Problem
Current methods for producing mesoporous silica particles with macropores are complex and involve multiple steps, such as vacuum pumping, emulsification, and size classification, making them inefficient and material-intensive.
Innovation Solution
A simplified process using a sol-gel method where a water-soluble polymer and a metalorganic compound are mixed, leading to a gel with interconnected phases that are disintegrated into particles, allowing for controlled pore formation and calcination to create mesoporous and macroporous silica particles with uniform size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods (vacuum pumping, emulsification, size classification) are used to produce mesoporous silica particles with macropores, then particles with desired porosity can be obtained, but the process becomes complex and material loss increases
Solution Approach 1:
The invention divides the pore structure into two distinct segments: mesopores (2-50 nm) formed by surfactant templates and macropores (>50 nm) formed by phase separation between polymer-rich and polymer-poor phases. This segmentation allows independent control of each pore type through separate formation mechanisms, achieving complex porosity without complex processing steps
Solution Approach 2:
The polymer matrix is incorporated into the sol-gel system before hydrolysis and condensation occur. The polymer phase separation happens concurrently with silica network formation, pre-establishing the macropore structure before particle drying and calcination. This preliminary action eliminates the need for subsequent size classification and reduces material loss
2Quantity of substance
If traditional production methods are used, then mesoporous silica particles can be formed, but material loss increases due to size classification requirements
Solution Approach 1:
The invention changes the particle size parameter distribution by controlling the phase separation process during gel formation. By adjusting polymer concentration, molecular weight, and sol-gel conditions, a narrow particle size distribution is achieved inherently, eliminating the need for size classification and reducing material loss from discarding off-spec particles
3Manufacturing precision
If multiple processing steps are used to create macroporous mesoporous silica, then desired pore structure is achieved, but production efficiency decreases
Solution Approach 1:
The invention merges multiple functions into a single sol-gel process: mesopore formation via surfactant templating, macropore formation via polymer phase separation, particle formation, and pore structure development all occur concurrently during gelation and drying. This consolidation maintains precise pore structure control while dramatically improving production efficiency by eliminating sequential processing steps
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 process results in particles with a broad range of sizes and porosity, eliminating the need for size classification and reducing material loss, while enabling efficient drug loading and controlled release systems.
Implementation Method 1
mixing a metalorganic compound or a mixture of metalorganic compounds which contains hydrolyzable ligands to promote hydrolysis reaction
Implementation Method 2
solidifying the mixture through a sol-gel transition, whereby a gel is prepared which has two three dimensional interconnected phase domains
Implementation Method 3
removing the solvent by evaporation drying and/or heat-treatment
Implementation Method 4
calcining the particles to form the porous material
Data Source
Figure 1
AI summary
The present invention is directed to a process for producing inorganic particulate material, the material obtainable by such process, a modified release delivery system comprising the material and the use of the material for the administration of a bioactive agent.