Microsphere Solvent Removal Using Gas-Driven Rotational Flow
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Solution Overview
Problem
Existing solvent removal processes for microsphere production are inefficient and complex, often requiring toxic solvents and extensive time, hindering mass production of high-quality microspheres.
Innovation Solution
A solvent removing apparatus and method that utilizes a tank body with fluid supply and exhaust parts to form a rotational flow in the emulsion, using gas bubbles and a filter to efficiently extract and evaporate solvents without a motor-driven stirrer, allowing for simpler configuration and continuous solvent removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a motor-driven impeller or stirrer is used to extract and remove solvent from emulsion, then solvent removal efficiency is improved, but device complexity increases
Solution Approach 1:
The patent replaces the motor-driven mechanical stirring system with a gas injection system that generates rotational flow through fluid dynamics. Gas bubbles are injected through nozzles to create a vortex that circulates the emulsion, eliminating the need for motors, impellers, and shafts while maintaining effective solvent removal capability
Solution Approach 2:
The invention uses pneumatic principles by injecting gas into the emulsion to generate rotational flow. The gas bubbles rise through the emulsion, creating a vortex pattern that enhances mass transfer and solvent extraction without requiring mechanical moving parts. This pneumatic-driven circulation system simplifies the device structure while improving productivity
2Manufacturing precision
If multiple filtering and cleaning steps are added to remove solvent completely, then product purity is improved, but device complexity and processing time increase
Solution Approach 1:
The patent implements continuous solvent removal through the rotational flow system. The vortex circulation continuously brings fresh emulsion into contact with the gas-liquid interface, enabling sustained and complete solvent extraction in a single continuous operation, eliminating the need for multiple sequential filtering and cleaning steps
Solution Approach 2:
The rotational flow system performs multiple functions simultaneously: it mixes the emulsion, enhances mass transfer, extracts solvent, and facilitates continuous processing. This multi-functional approach replaces what would traditionally require separate mixing equipment, filtration systems, and cleaning apparatus, thereby reducing overall device complexity while maintaining high product purity
3Productivity
If traditional solvent removal methods are used, then solvent extraction capability is improved, but processing time increases
Solution Approach 1:
The gas injection system creates dynamic vortex flow and turbulence in the emulsion, which enhances mass transfer coefficients and accelerates solvent extraction. The continuous circulation and renewed contact between phases created by the rotational flow significantly reduce the time required for complete solvent removal compared to static or slow-mixing traditional methods
Solution Approach 2:
The invention changes the flow dynamics parameters by creating high-velocity rotational flow through gas injection. This increases the interfacial area and mass transfer rate between the gas phase and emulsion, enabling rapid solvent extraction. The system operates under optimized flow conditions that maximize extraction efficiency while minimizing processing time
Data Source
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AI summary
This solvent-removing apparatus comprises: a tank body accommodating an emulsion comprising first source material in a continuous phase and second source material in a dispersed phase; a fluid supply unit for supplying fluid into the tank body to cause the emulsion to circulate; and a discharge unit for discharging the gas in the tank body to the outside.