Microfluidic Particle Formation Device for Uniform Size Control
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Solution Overview
Problem
Current methods for producing fine particles, such as mechanical grinding and thermo-electrospinning, struggle with achieving uniform size distribution and efficient mass production, leading to increased post-treatment needs and limitations in commercial-scale production.
Innovation Solution
An apparatus utilizing a particle formation mechanism with a unit-structure that merges continuous and dispersed phase solutions in a merging volume, allowing for controlled formation and mass production of spherical fine particles through microfluidic channels, enabling easy control of particle size and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods (mechanical grinding, high-speed spraying) are used for mass production of fine particles, then productivity is improved, but manufacturing precision deteriorates due to large size distribution
Solution Approach 1:
The invention divides the particle formation process into multiple independent micro-channels, each producing particles of uniform size. By segmenting the continuous phase and dispersed phase into multiple streams that merge in a controlled manner, the system achieves both mass production (through multiple channels operating simultaneously) and uniform particle size (through controlled merging in each channel)
Solution Approach 2:
The invention transitions from conventional single-channel or bulk processing to a multi-channel microfluidic system. By adding the dimension of multiple parallel micro-channels with controlled merging, the system simultaneously achieves high throughput (productivity) and precise size control (manufacturing precision) that cannot be achieved in single-channel systems
2Productivity
If conventional methods are used for producing fine particles, then productivity is improved, but device complexity increases due to required post-treatment classification processes
Solution Approach 1:
The invention performs size control during the particle formation process itself, rather than requiring post-formation classification. By controlling the merging of continuous and dispersed phases in micro-channels during formation, particles are produced with uniform size distribution from the start, eliminating the need for subsequent classification equipment and processes
3Ease of manufacture
If prilling method or spraying method is used for capsule-type fine particles, then ease of manufacture is improved, but manufacturing precision deteriorates due to difficulty in achieving uniform size
Solution Approach 1:
The invention uses hydraulic principles by controlling the flow and merging of liquid phases (continuous phase and dispersed phase) through micro-channels. This hydraulic control during the formation process enables precise size control while maintaining relative process simplicity, overcoming the limitations of conventional prilling and spraying methods
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 simplifies the process of producing fine particles, allowing for commercial-scale mass production of uniformly sized spherical particles, enhancing productivity and manufacturing reliability across various technical fields.
Implementation Method 1
the continuous phase solution and the dispersed phase solution are merged in the merging volume, wherein fine particles are formed via the merging between the continuous phase solution and the dispersed phase solution in the merging volume
Data Source
AI summary
Apparatus for producing fine particles having a particle formation mechanism and a particle-outlet micro-channel may include a unit-structure including first and second portions adjacent to each other; and a first inlet defined in the first portion at a first height. A continuous phase solution is injected into the first inlet; and a second inlet is defined in the first portion at a second height different from the second height. A dispersed phase solution is injected into the second inlet. A merging volume is defined in the second portion and is defined at third height equal to either the first height and the second height, or has a value therebetween. The continuous phase solution and the dispersed phase solution are merged in the merging volume, wherein fine particles are formed. A first micro-channel and a second micro-channel branching from the merging volume communicates with the first inlet and the second inlet, respectively.