Optical Particle Size Distribution Control for Dispersion Stability
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Solution Overview
Problem
Existing methods fail to effectively optimize and control particle size distributions (PSDs) in liquid suspensions and solutions, leading to instability, reduced efficacy, and safety concerns in various applications, including medical and commercial products.
Innovation Solution
A method is provided to identify and optimize PSD profiles through measurement and adjustment of parameters, using techniques like single-particle optical sensing, to achieve a desired PSD signature that ensures product stability, efficacy, and safety by establishing tolerable limits and design spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing methods are used to control particle size distributions, then manufacturing simplicity is maintained, but product stability and efficacy deteriorate
Solution Approach 1:
The patent replaces traditional mechanical particle size analysis methods with optical sensing technology. The optical sensor detects particle size distribution by measuring light scattering properties, eliminating the need for complex mechanical sieving or centrifugation systems while providing real-time, non-intrusive measurement that maintains product stability without adding mechanical complexity.
Solution Approach 2:
The patent transforms the control approach by shifting from controlling individual particle sizes to controlling the overall particle size distribution profile. By measuring and adjusting the complete distribution curve rather than target-specific parameters, the system achieves better product stability and efficacy while simplifying the control strategy through profile-based optimization.
2Manufacturing precision
If particle size distribution is not optimized, then manufacturing simplicity is maintained, but product efficacy and safety deteriorate
Solution Approach 1:
The patent implements preliminary measurement of particle size distribution early in the manufacturing process using optical sensing. By detecting the distribution profile before final product formulation, the system can make proactive adjustments to prevent efficacy and safety issues rather than requiring time-consuming post-manufacturing optimization and testing.
Solution Approach 2:
The patent establishes a feedback loop where particle size distribution is continuously measured using optical sensors and the data is used to adjust manufacturing parameters in real-time. This closed-loop control system rapidly optimizes particle size distribution during production, achieving high manufacturing precision without extending overall manufacturing time.
3Measurement precision
If traditional measurement methods are used, then equipment simplicity is maintained, but measurement precision and reliability deteriorate
Solution Approach 1:
The patent replaces complex mechanical measurement systems with optical sensing technology. The optical sensor uses light scattering principles to measure particle size distribution non-contactly, providing high measurement precision without the mechanical complexity of traditional methods such as sieving, centrifugation, or microscopy-based analysis.
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 the production of stable and effective products by maintaining consistent PSD signatures, reducing the risk of adverse reactions and product failures, and extending shelf life, while ensuring safety and performance across different applications.
Implementation Method 1
measuring a particle size distribution of the dispersion using an optical sensor
Data Source
AI summary
A method for identifying an improved particle size distribution profile of a dispersion, the method including: (a) providing a dispersion comprising a liquid and particles dispersed in the liquid; (b) measuring a particle size distribution of the dispersion, resulting in a first particle size distribution profile; (c) adjusting at least one parameter associated with the dispersion; (d) measuring a dispersion characteristic, after adjustment of the at least one parameter; and (e) measuring the particle size distribution of the dispersion after adjustment of the at least one parameter, resulting in a second particle size distribution profile; wherein each of the first and second particle size distribution profiles comprises a plurality of data points of particle concentration values as a function of particle size.