Microsphere Solvent Extraction Layout for Continuous Production
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Solution Overview
Problem
Existing microsphere production methods using biodegradable polymers face challenges in mass-producing high-quality microspheres due to the use of toxic solvents like dichloromethane or chloroform, which require extensive time and effort for solvent removal, hindering efficient production.
Innovation Solution
A microsphere producing system and method that includes a first and second solvent extracting and removing part, spaced apart to efficiently extract and remove solvents from emulsions, allowing for continuous emulsion formation and solvent removal, with separate cleaning and drying processes to maximize efficiency and reduce production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If toxic solvents like dichloromethane or chloroform are used to dissolve biodegradable polymer and active agent, then dissolution efficiency is improved, but solvent removal time increases and production efficiency decreases
Solution Approach 1:
The solvent removal process is divided into multiple stages using a multi-chamber extraction system. The first chamber performs initial solvent extraction, the second chamber continues extraction, and the third chamber completes the removal process. This segmentation allows continuous processing without compromising dissolution efficiency, thereby maintaining both high-quality microsphere formation and improved production throughput.
Solution Approach 2:
The system enables continuous solvent removal through a multi-chamber extraction apparatus where emulsion passes sequentially through multiple extraction stages. Meanwhile, new emulsion continuously enters the first chamber, eliminating idle time between batches. This continuous action maintains dissolution efficiency while significantly increasing production efficiency compared to traditional batch processing.
2Object-affected harmful factors
If extensive solvent removal is performed to ensure complete toxin elimination, then product safety is improved, but production time increases
Solution Approach 1:
The extraction system divides solvent removal into three sequential chambers, each performing a portion of the total extraction task. This segmentation ensures thorough solvent elimination for product safety while distributing the time requirement across parallel processing stages, reducing total production time compared to single-chamber batch extraction.
Solution Approach 2:
The continuous flow system maintains constant solvent removal action through multiple chambers simultaneously processing different portions of emulsion. This ensures complete toxin elimination for safety while eliminating idle time between extraction stages, significantly reducing overall production time compared to traditional methods.
3Device complexity
If traditional batch processing is used for microsphere production, then process simplicity is maintained, but mass production capability is limited
Solution Approach 1:
The system segments the extraction process into multiple independent chambers connected in series, allowing each chamber to function as a separate processing unit. This modular segmentation enables easy scaling from batch to continuous processing while maintaining operational simplicity, thus achieving mass production capability without excessive complexity.
Solution Approach 2:
The multi-chamber system transforms traditional batch processing into continuous processing by maintaining constant emulsion flow through multiple extraction stages. New emulsion continuously enters the first chamber while processed microspheres exit the final chamber, enabling mass production while keeping the process conceptually simple and易于操作.
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 the mass-production of high-quality microspheres by optimizing solvent extraction and removal processes, reducing production time, and lowering costs compared to conventional batch processes.
Implementation Method 1
an emulsion generating part configured to continuously form an emulsion including the first raw material of a continuous phase and the second raw material of a dispersed phase
Implementation Method 2
a first solvent extracting and removing part configured to accommodate the emulsion formed from the emulsion generating part, and extract and remove the solvent from the dispersed phase of the emulsion
Data Source
AI summary
A system for producing a microsphere includes a first raw material storing to store a first raw material is stored, a second raw material storing part to store a second raw material including a solvent, a biodegradable polymer, and a drug, an emulsion generating part to continuously form an emulsion including the first raw material of a continuous phase and the second raw material of a dispersed phase, a first solvent extracting and removing part to accommodate the emulsion formed from the emulsion generating part, and extract and remove the solvent from the dispersed phase of the emulsion to form a microsphere, and a second solvent extracting and removing part spaced apart from the first solvent extracting and removing part, to accommodate the emulsion formed from the emulsion generating part, and extract and remove the solvent from the dispersed phase of the emulsion to form a microsphere.