Nanoparticle Synthesis Reactor with Zone-Controlled Temperature

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Solution Overview

Problem

Current methods for manufacturing nanoparticles face challenges such as contamination, broad size distribution, and limited size range, particularly in chemical synthesis and attrition methods, which hinder the production of high-purity, well-defined nanoparticles with specific properties.

Innovation Solution

An apparatus and method involving a solvent preparation module, particle synthesis module, and shell structure modules for continuous manufacture of nanoparticles, with degasser and solvent organizer units, analytical devices, and a particle isolation module using a flow centrifuge to ensure precise control over reaction conditions and purification, enabling the production of core-shell and core-shell-shell particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If chemical synthesis or attrition methods are used to manufacture nanoparticles, then production cost and output are improved, but contamination and broad size distribution occur

Engineering Contradiction:

Improveproduction outputVSAvoidsize distribution

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The continuous flow reactor is divided into multiple distinct zones: a mixing zone for reagent combination, a reaction zone for nanoparticle formation, and a growth zone for controlled size development. This spatial segmentation allows each zone to optimize for its specific function, achieving both high throughput and narrow size distribution through controlled residence times in each section.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention maintains constant temperature, pressure, and flow rate parameters throughout the continuous flow reactor. By controlling the residence time distribution and maintaining steady-state operating conditions, the system achieves narrow size distribution while operating continuously at high productivity, unlike batch processes where parameters vary over time.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If batch processing is used for nanoparticle manufacture, then equipment complexity is reduced, but size distribution broadens and purity decreases

Engineering Contradiction:

Improveequipment structureVSAvoidparticle size control

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The system operates as a continuous flow reactor where reactants continuously flow through the reaction zones without interruption. This continuous operation with steady-state conditions prevents the parameter variations inherent in batch processing, achieving narrow size distribution through consistent residence times while maintaining relatively simple equipment architecture.

Inventive Principle:

Principle #20Continuity of useful action

3Device complexity

If conventional purification methods are used, then device complexity is minimized, but contamination remains in the nanoparticle product

Engineering Contradiction:

Improvepurification systemVSAvoidproduct purity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The invention incorporates an integrated purification zone within the continuous flow reactor system that selectively removes contaminants and excess reagents from the nanoparticle suspension. This extraction function is built into the reaction pathway, allowing high-purity product output without requiring complex external purification equipment.

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of manufacture

If simple manufacturing processes are used, then production cost is reduced, but contamination and limited size range occur

Engineering Contradiction:

Improveprocess simplicityVSAvoidparticle size range

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The continuous flow reactor enables dynamic control of nanoparticle size by adjusting flow rates and residence times. The system can be easily reconfigured to produce particles across a wide size range by changing operational parameters rather than redesigning the equipment, maintaining process simplicity while achieving precise size control and narrow distribution.

Inventive Principle:

Principle #15Dynamics

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 allows for the high-output, high-purity, and low-cost manufacture of nanoparticles with precise control over size and properties, addressing contamination and size distribution issues, and enabling the production of complex structures like core-shell and core-shell-shell particles.

Implementation Method 1

a particle isolation module using a flow centrifuge to ensure precise control over reaction conditions and purification

Methodology Applied

Scientific EffectCentrifugal separation: Centrifugal Separation

Data Source

PatentEP2254695B1Apparatus and method for the manufacture of nanoparticles

Publication Date: 2019.05.01 FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV

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AI summary

An apparatus (10) and a method (200) for the manufacture of nanoparticles. The apparatus and the method allows for the nucleation and growth of nanoparticles at independent temperatures. The independent temperatures allow for the growth of nanoparticles in a controlled environment avoiding spontaneous nucleation and allowing particle sizes to be controlled and facilitating the manufacture of particles of a substantially uniform size. Furthermore the apparatus (10) allows for the manufacture of core-shell nanoparticles and core-shell-shell nanoparticles.