Microsphere Collection Unit Using Gravity Deposition
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Solution Overview
Problem
Conventional methods for preparing biodegradable microspheres, such as those using poly(lactic/glycolic acid) (PLGA), face issues with microsphere deformation and aggregation during centrifugal collection, leading to inefficiencies in production and drug release models due to the need for batch processes and manual operation.
Innovation Solution
A continuous microsphere preparation method and device that employs a collection unit with a tank and removable plate to facilitate deposition, allowing for continuous collection and prevention of microsphere deformation and aggregation, integrating emulsification, solidification, and collection steps into a single automated process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If centrifugal collection method is used to collect microcapsules, then collection efficiency is improved, but microsphere deformation and aggregation occur
Solution Approach 1:
The patent replaces the mechanical centrifugal collection system with a gravity-based deposition system. The collection unit utilizes gravitational force to allow microcapsules to naturally settle and deposit on the tank bottom, eliminating the need for centrifugal force that causes deformation and aggregation. This substitution of mechanical force with gravitational force resolves the contradiction between collection efficiency and microsphere shape consistency.
Solution Approach 2:
The collection unit enables microcapsules to self-collect through gravitational deposition without requiring external mechanical intervention. The system allows the microcapsules to naturally settle and accumulate on the tank bottom through their own weight, eliminating the need for centrifugal separation. This self-service mechanism maintains microsphere integrity while achieving efficient collection.
2Adaptability or versatility
If batch process with manual operation is used, then process flexibility is maintained, but production scalability is limited
Solution Approach 1:
The patent implements a continuous collection process where the collection unit operates continuously as the emulsification and solidification processes proceed. The tank continuously receives the emulsion mixture, and microcapsules continuously deposit on the bottom through gravity. This continuous operation eliminates batch processing limitations and enables scalable production while maintaining process flexibility through the removable plate design.
Solution Approach 2:
The collection unit incorporates a removable plate that can be taken out for cleaning or maintenance. This segmentation allows the collection system to be easily serviced without disrupting the entire production process, maintaining operational flexibility while enabling continuous large-scale production. The removable plate divides the collection space and facilitates easy access for maintenance activities.
3Stability of the object's composition
If PLGA polymer is used to form microcapsule wall, then biodegradability is achieved, but capsule hardness is insufficient causing deformation
Solution Approach 1:
The patent uses a composite emulsion system combining PLGA polymer with surfactants and other formulation components to create microcapsules that maintain biodegradability while achieving sufficient structural integrity. The composite nature of the emulsion mixture allows the PLGA to provide biodegradability while the overall formulation ensures adequate hardness to prevent deformation during collection, resolving the contradiction between biodegradability and mechanical strength.
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
Enables continuous production of microspheres without manual intervention, improving production scalability and maintaining consistent drug release profiles, as demonstrated by stable release kinetics of Olanzapine and Granisetron microspheres, with enhanced product quality and reduced initial drug effect.
Implementation Method 1
the microspheres are deposited around the first plate
Implementation Method 2
the microspheres are deposited around the first plate, and the solution is caused to pass through or over the first plate
Data Source
AI summary
A method and a device for continuously preparing microspheres, and a collection unit thereof are provided. The collection unit for collecting microspheres in the solution comprises a tank and a first plate. The first plate is removably disposed in the tank. The first plate, when lay across the tank, has its two ends came in contact with the sidewall of the tank so as to divide the tank into a first chamber and a second chamber. The tank has an outlet located in the second chamber. After the solution with microspheres are input to the first chamber of the tank, the microspheres are deposited around the first plate, and the solution is caused to pass through or over the first plate to the second chamber and output from the outlet.