Nozzle System for Continuous Micro- and Nanoparticle Size Control
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Solution Overview
Problem
Current methods for producing micro- and nanoparticles lack the ability to control particle size in a continuous process, often resulting in unsatisfactory size distribution and limited scalability for industrial applications.
Innovation Solution
A specially designed nozzle system where reactants are brought into contact at the outlet, with flow parameters and the addition of surface-active substances allowing precise control of particle size through laminar and turbulent flow conditions, enabling the production of particles with narrow size distribution and adjustable diameters from a few nanometers to several micrometers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional precipitation methods are used to produce micro- and nanoparticles, then particles can be formed, but the particle size distribution is broad and size control is poor
Solution Approach 1:
The invention divides the single precipitation process into two separate stages: first forming nuclei in one reactor, then growing particles in a second reactor. This segmentation allows independent control of nucleation and growth processes, resulting in narrow size distribution and precise particle size control while maintaining high production quantity.
Solution Approach 2:
The invention performs preliminary nucleation in the first reactor before the growth stage in the second reactor. By pre-forming nuclei with controlled size and distribution, the subsequent growth process can uniformly increase particle size without creating broad size distribution, thus achieving both size control and uniformity.
2Productivity
If batch processing is used for particle production, then particles can be synthesized, but the process is not scalable for industrial applications
Solution Approach 1:
The invention employs continuous flow reactors instead of batch processing, where reactants continuously flow through the system and particles are continuously formed and grown. This continuous operation enables industrial scalability while maintaining precise particle size control through steady-state reaction conditions and consistent flow parameters.
Solution Approach 2:
The invention uses dynamic control of flow rates, residence times, and temperature profiles in the continuous reactors to optimize both scalability and particle size control. By adjusting operational parameters in real-time, the system can produce different particle sizes while maintaining narrow size distribution at industrial production levels.
3Quantity of substance
If simple nozzle mixing is used to bring reactants into contact, then particles can be formed, but the mixing efficiency is insufficient for narrow size distribution
Solution Approach 1:
The invention introduces a controlled intermediary mixing zone between the nozzle and the reaction chamber, where initial mixing occurs under controlled conditions before particles enter the main reaction and growth zone. This intermediary stage ensures uniform reactant distribution and consistent nucleation, leading to narrow size distribution without requiring overly complex nozzle designs.
Solution Approach 2:
The mixing process is segmented into multiple stages: initial mixing in the nozzle, further mixing in a controlled zone, and then particle growth in the reactor. This segmentation of the mixing and reaction process allows each stage to be optimized independently, achieving narrow size distribution with manageable device complexity.
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
Enables the production of high-quality, monodisperse nanoparticles with precise size control, suitable for various applications, including cosmetics, pharmaceuticals, and electronics, by adjusting flow rates, pressures, and detergent concentrations, achieving consistent and scalable results.
Implementation Method 1
with laminar flows the throughput per channel is in the range of a few liters per minute
Implementation Method 2
at higher flow rates, they are close to the limit of turbulent flow
Implementation Method 3
The particle diameter can be additionally influenced by adding special surface-active substances in different concentrations to these liquids
Implementation Method 4
The basic idea of the process is to bring together the reactants from which the particles are to be formed in the outlet area of a specially designed nozzle
Data Source
AI summary
2.1 The invention relates to a method and a technical process for the production of small particles, which are synthesised in a preferably continuous method, and the size of which can be precisely set in the process. This occurs using specific nozzles, at the outlet of which two reactants are brought into contact in such a manner that small particles are produced. The size of the particles is predetermined primarily via the flow parameters of the fluids at the outlet of the nozzle. The particle diameter can also be influenced via the addition of special surface-active materials in different concentrations to said fluids, or via the changing of the concentration or temperature of the reaction solutions. 2.2 The invention also relates to a uniform technical process and is also based on specifically constructed nozzles. In this way, the circumstance arises wherein the diameter of the obtained particles can be predetermined by changing the flow parameters of the reaction solutions, by changing their surface characteristics, their concentration or temperature. 2.3 A method of this type can be used for the production of metallic or non-metallic micro- and nanoparticles for highly diverse applications.