Nano-Seeding Crystallization for Controlled Microparticle Production

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Solution Overview

Problem

Existing methods for producing micro-particles, such as dry-milling, face challenges like high energy consumption, low yields, formation of encrustations, and difficult-to-control particle sizes and surface properties, complicating consistent quality and production efficiency.

Innovation Solution

A nano-seeding process involving the use of a homogenous supersaturated solution and nano-particles with a size between 10 nm and 999 nm, stabilized by polymers or surfactants, to generate micro-particles by contacting the solution with seeding material of the same substance, followed by optional isolation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If dry-milling is used to produce microparticles, then microparticles can be generated, but energy consumption is high and yields are low

Engineering Contradiction:

Improvemicroparticle production yieldVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The invention changes the fundamental parameters of the process by using supersaturated solutions and nanoseeding instead of mechanical dry-milling. This chemical approach operates at lower energy levels while achieving higher yields through controlled crystallization rather than mechanical size reduction

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the mechanical dry-milling system with a chemical crystallization system using supersaturated solutions and nanoseeding. This substitution eliminates the high energy consumption associated with mechanical grinding while maintaining microparticle production efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If dry-milling is used to produce microparticles, then microparticles can be generated, but formation of encrustations occurs complicating production

Engineering Contradiction:

Improvemicroparticle production consistencyVSAvoidencrustation formation

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The invention introduces nanoseeding material as an intermediary that controls crystal nucleation and growth. This intermediary prevents uncontrolled crystal formation and encrustations by providing defined nucleation sites, ensuring consistent microparticle production without the harmful encrustation byproducts of dry-milling

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If dry-milling is used to produce microparticles, then microparticles can be generated, but particle sizes and surface properties are difficult to control

Engineering Contradiction:

Improveparticle size controlVSAvoidprocess control complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention implements feedback control through the nanoseeding process where the nanoseeding material acts as a template that directs crystal growth. This self-regulating mechanism provides precise control over particle size and surface properties without requiring complex external control systems, simplifying the overall process while improving manufacturing precision

Inventive Principle:

Principle #23Feedback

4Productivity

If conventional processes are used to produce microparticles, then microparticles can be generated, but the process is complex and costly

Engineering Contradiction:

Improvemicroparticle production efficiencyVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention merges multiple steps into a single integrated process by combining supersaturation, nanoseeding, and crystallization into one operation. This consolidation eliminates the need for separate micronization and processing steps, reducing both device complexity and production costs while maintaining high productivity

Inventive Principle:

Principle #5Merging (Combining)

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 process is more cost-effective, efficient, and produces micro-particles with controlled sizes and improved flowability, eliminating the need for micronization and reducing the amount of seeding material required, while maintaining yield and quality.

Implementation Method 1

a) providing a homogenous supersaturated solution of a substance in a crystallization medium... c) bringing the homogenous supersaturated solution in contact with the seeding material

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Implementation Method 2

providing a seeding material characterized by a nano-particle size of a d50 between 10 nm and 999 nm... comprising at least one stabilizer

Methodology Applied

Scientific EffectNucleation: Nucleation

Data Source

PatentUS12350373B2Nano-seeding

Publication Date: 2025.07.08 BAYER AG

AI summary

What is described herein relates to a method for generating micro-particles comprising the steps ofa) providing a homogenous supersaturated solution of a substance in a crystallization mediumb) providing a seeding material characterized by a nano-particle size of a d50 between 10 nm and 999 nm comprising at least one stabilizer, wherein said seeding material is of the same substance as the substance of the homogenous supersaturated solution of step a)c) bringing the homogenous supersaturated solution in contact with the seeding material,optionally isolating micro-particles.