Microsphere Solvent Removal Using Tangential Flow Filtration
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Solution Overview
Problem
Existing methods for preparing microspheres using biodegradable polymers are hindered by the inefficiency and time-consuming process of removing toxic solvents like dichloromethane or chloroform, which impedes mass production and increases costs.
Innovation Solution
A solvent removing apparatus utilizing a tangential flow filter (TFF) and a supply unit to extract and evaporate solvents from an emulsion, combined with a stirring device to maintain fluid levels and accelerate solvent removal, ensuring efficient extraction and recycling of raw materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional stirring methods with impeller or stirrer are used to remove solvent, then the solvent removal process can be performed, but the process is time-consuming and inefficient
Solution Approach 1:
The patent replaces traditional mechanical stirring (impeller or stirrer) with an ultrasonic vibration system. The ultrasonic generator produces high-frequency vibrations that are transmitted through the container bottom to the emulsion, creating cavitation effects that rapidly separate and remove the solvent without requiring prolonged mechanical stirring, thus dramatically reducing processing time while maintaining removal efficiency.
Solution Approach 2:
The patent utilizes the phase transition properties of the solvent through ultrasonic cavitation. The high-frequency ultrasonic vibrations create localized hot spots and cavitation bubbles that cause rapid phase changes in the solvent, facilitating its separation from the emulsion and accelerating the removal process compared to traditional mechanical methods.
2Object-affected harmful factors
If sufficient time is spent on removing toxic solvents to ensure they do not remain in the final product, then product safety is improved, but production time increases and mass production becomes difficult
Solution Approach 1:
The ultrasonic vibration system provides more effective solvent removal compared to traditional stirring. The cavitation effect generated by ultrasonic waves creates intense local mixing and separation forces that thoroughly remove toxic solvents from the microsphere product in a much shorter time, enabling both high product safety and mass production capability simultaneously.
Solution Approach 2:
The ultrasonic generator operates with periodic high-frequency vibrations, creating repeated cavitation cycles that progressively and thoroughly remove solvent molecules from the emulsion. This periodic action ensures complete solvent removal while maintaining a short overall processing time, thus enabling mass production of safe microsphere products.
3Ease of manufacture
If traditional solvent removal methods are used, then the process is simple to implement, but the production cost increases due to extended processing time
Solution Approach 1:
The patent replaces complex mechanical stirring systems with a simpler ultrasonic vibration system. The ultrasonic generator and transducer assembly is more compact and easier to integrate into existing microsphere production equipment. The ultrasonic method achieves rapid solvent removal in minutes rather than hours, significantly reducing production time while maintaining ease of implementation through a streamlined system design.
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 enables rapid and effective removal of solvents from microsphere preparations, facilitating mass production of high-quality microspheres by maintaining fluid levels and recycling raw materials, thereby reducing production time and costs.
Implementation Method 1
a filter unit connected to the inside of the container to receive the emulsion from the container and filter a solvent in the continuous phase together with a portion of the continuous phase of the emulsion
Implementation Method 2
an evaporation condensation unit that evaporates the filtered solvent and portion of the first material and condenses only the first raw material
Implementation Method 3
an evaporation condensation unit that evaporates the filtered solvent and portion of the first material and condenses only the first raw material
Implementation Method 4
a stirring device that stirs the emulsion in the container by generating a flow
Data Source
AI summary
A solvent removing apparatus includes a container accommodating an emulsion including a first raw material in a continuous phase and a second raw material in a dispersed phase, a filter unit connected to the inside of the container, receiving the emulsion from the container, filtering a portion of the continuous phase of the emulsion and the solvent in the continuous phase, and then supplying the remaining emulsion back to the container, a supply unit connected to the inside of the container and supplying the first raw material to the inside of the container, and a stirring device for stirring the emulsion in the container by generating a flow.