Multi-Hole Plate Microcarrier Emulsion Apparatus
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing production methods for microcarrier tablets face challenges in scaling up production to meet large market demand, with limited throughput and inefficiencies in material preparation and sterilization.
Innovation Solution
A method and apparatus for preparing microcarrier particles using a multi-hole plate to form liquid microspheres through a water-in-oil emulsion process, where the dispersed phase liquid containing synthetic polymers and natural biological macromolecules is sheared to create particles that are then cured and collected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional microcarrier production methods are used, then microcarrier tablets can be produced, but the throughput is limited and cannot meet large market demand
Solution Approach 1:
The production process is segmented into multiple functional modules: a multi-hole plate with numerous micro-wells for parallel emulsion formation, a continuous phase liquid flow system for shearing and emulsion formation, and a separate curing system. This segmentation enables simultaneous production of thousands of microcarrier particles, dramatically increasing throughput to meet large market demand.
Solution Approach 2:
The patent implements continuous production through continuous phase liquid flow that continuously shears dispersed phase liquid through the multi-hole plate, forming emulsions in real-time. The curing process also continues continuously, transforming liquid microspheres into solid microcarrier particles without interruption, thereby maintaining high productivity throughout the production cycle.
2Ease of manufacture
If conventional microcarrier production methods are used, then microcarriers can be manufactured, but material handling and sterilization operations become cumbersome
Solution Approach 1:
The patent merges multiple functions into the multi-hole plate structure: it serves as both the emulsion formation template and the molding cavity for microcarrier particles. The continuous phase liquid flow system combines shearing, emulsion formation, and particle shaping in a single integrated process, eliminating the need for separate material handling and sterilization steps for each component.
Solution Approach 2:
The system performs self-service through automatic emulsion formation where the continuous phase liquid automatically shears the dispersed phase liquid through the multi-hole plate without manual intervention. The curing process automatically transforms the liquid microspheres into solid particles, and the entire process can be sterilized as a single integrated unit, reducing material handling complexity.
3Manufacturing precision
If microcarrier particles are produced with high porosity and controlled size, then they are suitable for 3D cell culture, but the production process becomes more complex
Solution Approach 1:
The patent applies local quality by controlling the properties of different phases: the dispersed phase liquid contains synthetic polymers and natural biological macromolecules with specific local properties for porosity, while the continuous phase liquid contains organic solvent and nonionic surfactant with specific local properties for emulsion stability. The multi-hole plate provides uniform local shearing conditions across all micro-wells, ensuring consistent particle size and porosity throughout the batch.
Solution Approach 2:
The patent controls particle size and porosity by changing parameters: adjusting the diameter of micro-wells in the multi-hole plate, controlling the flow rates of dispersed and continuous phase liquids, and adjusting the composition ratios of polymers and surfactants. These parameter changes enable precise control over microcarrier particle size (50-500 μm) and porosity (>90%) without complicating the overall process.
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
This approach enables large-scale production of microcarrier particles with controlled size and porosity, suitable for three-dimensional cell culture, while improving efficiency and reducing material handling complexities.
Implementation Method 1
allowing a continuous phase liquid to flow, parallel to the multi-hole plate, on the other side of the multi-hole plate, shearing the dispersed phase liquid passing through the multi-hole plate to form liquid microspheres
Implementation Method 2
the dispersed phase liquid contains a synthetic polymer and/or natural biological macromolecules; and a curing agent
Data Source
AI summary
Provided herein is a method for preparing an emulsion, comprising the steps of allowing a dispersed phase liquid to flow from one side to the other side of a multi-hole plate through a plurality of micro-wells of the multi-hole plate while allowing a continuous phase liquid to flow, parallel to the multi-hole plate, on the other side of the multi-hole plate, shearing the dispersed phase liquid passing through the multi-hole plate to form liquid microspheres in the flowing continuous phase liquid. Further provided herein are an apparatus for preparing an emulsion and a process system for preparing microcarrier particles, which can be used for preparing emulsions and microcarrier particles on a large scale.