Microparticle Nozzle Extension Tubes Shear Control
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Solution Overview
Problem
Conventional nozzles for producing microparticles suffer from poor uniformity in particle diameter, difficulty in controlling diameters, especially with high-concentration oil phase solutions, and low productivity due to surface tension issues and static water phase leading to aggregation and low yield.
Innovation Solution
A nozzle with extension tubes having outlet ports with reduced surface area and hydrophobic coatings, combined with a fluid shear device and temperature control system, to control microparticle formation and ensure uniformity, precision, and increased productivity by using shear force or vibrations to interrupt oil phase fluids and facilitate envelopment by a water phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional nozzle with openings is used for mass production of microparticles, then productivity is improved, but manufacturing precision deteriorates due to diverse microparticle diameters caused by different surface extensions or pressures in the openings
Solution Approach 1:
The invention divides the fluid passageway into multiple independent channels, each leading to a separate outlet port. This segmentation allows each channel to operate independently with controlled flow, eliminating the pressure variations that occur in conventional nozzles with multiple openings. The result is uniform microparticle diameter while maintaining mass production capability through multiple simultaneous outlets.
Solution Approach 2:
The invention applies local quality by ensuring each outlet port has identical geometric characteristics and flow conditions. By designing each channel with the same dimensions, orientation, and flow control mechanisms, the local quality at each outlet is standardized, producing microparticles with consistent diameters across all outlets simultaneously.
2Manufacturing precision
If the concentration of the oil phase solution is increased to reduce microparticle diameter variability, then manufacturing precision is improved, but productivity deteriorates because droplets must accumulate to be heavier for exiting the opening
Solution Approach 1:
The invention introduces dynamic flow control through independently adjustable channels, allowing the system to adapt to different oil phase concentrations. By dynamically adjusting flow rates in each channel, the system can handle high-concentration solutions that would otherwise require slow accumulation, while maintaining precise diameter control through coordinated multi-channel operation.
Solution Approach 2:
The invention combines multiple channel outputs to achieve both high concentration handling and rapid production. By merging the capabilities of multiple independently controlled channels, the system can process high-concentration oil phase solutions at higher overall rates than a single channel could achieve, while maintaining uniform microparticle diameters through synchronized operation.
3Device complexity
If a static water phase solution is used for enveloping droplets, then device complexity is reduced, but productivity deteriorates due to droplet aggregation and low yield
Solution Approach 1:
The invention transforms the static water phase into a dynamic flow system. By introducing controlled fluid motion in the water phase, droplets are continuously moved and separated, preventing aggregation. This dynamic approach maintains relatively simple device structure while dramatically improving microparticle yield through enhanced envelopment efficiency.
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 solution achieves more uniform microparticle diameters, precise control over particle size, and higher productivity, enabling the production of microparticles from high-concentration oil phase solutions, with improved yield and drug release characteristics.
Implementation Method 1
The oil phase solution flows out of the nozzle via the outlets and forms a droplet on each opening by surface tension
Implementation Method 2
the droplet exits the corresponding opening and falls into a water phase solution which envelops the droplet formed by the oil phase solution, assisting in curing and shaping of the droplet
Implementation Method 3
the surface area of each of the plurality of extension tubes at an outer periphery of the outlet port is reduced to make an oil phase fluid difficult to accumulate in each outlet port, thereby reducing adverse influence on the diameters of the microparticle products by the surface tension
Implementation Method 4
using shear force or vibrations to interrupt oil phase fluids and facilitate envelopment by a water phase
Implementation Method 5
using shear force or vibrations to interrupt oil phase fluids and facilitate envelopment by a water phase
Data Source
AI summary
A nozzle includes a nozzle body having a fluid passageway to which extension tubes are communicated. Each extension tube includes an end having an outlet port. The outlet ports are spaced from each other. An apparatus includes the nozzle, a fluid tank into which the extension tubes extends, a fluid shear device mounted in the fluid tank, and a temperature control system in which the fluid tank is mounted. A method includes filling a water phase fluid into the fluid tank. An oil phase fluid flows out of the nozzle body via the outlet ports. The water phase fluid is disturbed and flows out of the outlet ports to form semi-products of microparticles in the fluid tank. Each semi-product has an inner layer formed by the oil phase fluid and an outer layer formed by the water phase fluid. The outer layers of the semi-products are removed to form microparticles.