Monolithic Swirl Nozzle for Pharmaceutical Aerosolization

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Solution Overview

Problem

Current swirl nozzles face challenges in effectively aerosolizing pharmaceutical drugs due to mechanical fragility and high shear rates, requiring improved manufacturing methods for delivering sensitive drugs while handling high pressures and temperatures.

Innovation Solution

A monolithic swirl nozzle is fabricated using photoactivatable materials, such as polymers, ceramics, or composites, through additive manufacturing, allowing for precise activation of voxels and forming nozzles with small features capable of handling high pressures and viscosities, with features like multiple inlets and outlets and a swirl chamber for efficient aerosolization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stress or pressure

If mechanically tough materials such as metals are used for high-pressure operation, then pressure resistance is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvepressure resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

Stress or pressureVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from traditional metals to photoactivatable polymers, and changes the manufacturing approach from conventional machining to selective activation. This allows the nozzle to achieve high pressure resistance through optimized polymer composition and cross-linking density rather than relying on metal strength, while significantly simplifying manufacturing processes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite materials by combining photoactivatable polymer matrix with reinforcing agents or functional particles during the selective activation process. This creates a composite structure that achieves metal-level strength and pressure resistance while maintaining the manufacturing advantages of polymer-based materials.

Inventive Principle:

Principle #40Composite materials

2Productivity

If high shear rates are used for aerosolization, then droplet formation is improved, but drug mechanical fragility is worsened

Engineering Contradiction:

Improveaerosolization efficiencyVSAvoiddrug integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces high-shear mechanical mixing with a swirl-flow mechanism where centrifugal forces generated by a swirl chamber create aerosolization. This substitution reduces the harmful mechanical shear forces that damage fragile drugs while still achieving effective droplet formation through the swirl-induced flow patterns.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the aerosolization mechanism from high-shear mixing to controlled swirl flow, adjusting the flow parameters and chamber geometry to achieve droplet formation through centrifugal separation rather than mechanical shearing, thereby protecting drug integrity.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If monolithic design is used, then structural stability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidfeature precision

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent replaces traditional mechanical manufacturing processes with selective photoactivation, where a light-based system builds the monolithic structure layer by layer. This substitution enables precise control of feature dimensions and geometries at the micro-scale while maintaining the structural integrity of the single-piece design, resolving the contradiction between monolithic stability and manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 monolithic swirl nozzle achieves efficient aerosolization with lower fluidic resistance, shorter spray times, and structural stability, capable of handling high pressures and viscosities, making it suitable for pharmaceutical drug delivery with improved manufacturing precision and efficiency.

Implementation Method 1

forming the swirl nozzle by selectively activating voxels in the photoactivatable material

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

a device which exploits a radial acceleration from a vortex in the nozzle to form a circulating, thin liquid cone, which breaks up into droplets

Methodology Applied

Scientific EffectVortex: Vortex Ring

Implementation Method 3

radial acceleration from a vortex in the nozzle to form a circulating, thin liquid cone

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Data Source

PatentUS20240082857A1A swirl nozzle and methods of fabricating the same

Publication Date: 2024.03.14 BONSENS AB

AI summary

A method for forming a monolithic swirl nozzle configured to aerosolize a pharmaceutical drug. The swirl nozzle comprises an inlet for receiving the pharmaceutical drug to be aerosolized; a swirl chamber connected to the inlet and configured to aerosolize the pharmaceutical drug provided by the inlet; and an outlet connected to the swirl chamber and configured to discharge the aerosolized pharmaceutical drug. The method comprises providing a photoactivatable material and forming the swirl nozzle by selectively activating voxels in the photoactivatable material.