Pneumatic Atomization for Sub-Micron Particle Production
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Solution Overview
Problem
Current methods for producing sub-micron particles from biological materials often involve inconvenient temperature ranges, prolonged processing times, and mechanical stress, which can affect the quality and yield of the product, particularly in achieving small particle sizes with narrow size distribution and retained biological activity.
Innovation Solution
A particle generating apparatus comprising an atomization means, a drying chamber, an ionizer, and an electrostatic collector, which includes a solution container, a pump, a scale, and a pneumatic or ultrasonic atomizer to produce droplets, followed by a drying process to achieve particles of specific sizes, and charging with negative ions for collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spray drying is used to produce sub-micron particles, then particle size can be reduced, but temperature range becomes inconvenient and may affect biological activity
Solution Approach 1:
The patent replaces the thermal spray drying process with a pneumatic atomization system that uses compressed gas to generate and dry particles. This mechanical substitution eliminates the need for high-temperature processing while achieving the same particle size reduction, thereby preserving biological activity in the particles.
Solution Approach 2:
The invention changes the controlling parameter from temperature (in spray drying) to gas pressure and flow rate (in pneumatic atomization). By adjusting these parameters, the system achieves precise control over particle size without subjecting biological materials to damaging temperature ranges.
2Reliability
If freeze-drying is used to produce sub-micron particles, then particle quality can be maintained, but processing time becomes prolonged
Solution Approach 1:
The pneumatic atomization process skips the lengthy freezing and sublimation steps required in freeze-drying. By using rapid evaporation in a controlled airflow environment, the system achieves particle production in a fraction of the time while maintaining product quality through gentle, non-thermal processing.
Solution Approach 2:
The invention utilizes rapid liquid-to-vapor phase transition of the solvent in the atomized droplets, replacing the slow solid-ice-to-vapor transition in freeze-drying. This accelerated phase change enables quick particle formation without prolonged processing times, while the controlled environment preserves material quality.
3Manufacturing precision
If milling is used to reduce particle size, then small particle size can be achieved, but mechanical stress affects biological activity
Solution Approach 1:
The patent replaces mechanical milling with pneumatic atomization, substituting mechanical impact and shear forces with gentle gas-driven droplet formation and evaporation. This eliminates mechanical stress on biological materials while achieving the desired sub-micron particle size through controlled fluid dynamics.
Solution Approach 2:
The invention introduces a gas stream as an intermediary medium to transfer energy and form particles, replacing direct mechanical contact. The gas acts as a mediator that carries the liquid solution through atomization and drying without subjecting the biological material to damaging mechanical forces.
4Productivity
If conventional atomization is used, then particle production can be achieved, but particle size distribution becomes broad
Solution Approach 1:
The system employs dynamic control of gas flow rates, pressure, and atomization parameters to optimize droplet formation and drying. By continuously adjusting these dynamic parameters, the system maintains narrow particle size distribution while achieving high production rates, overcoming the trade-off between productivity and precision.
Solution Approach 2:
The patent incorporates feedback control mechanisms that monitor particle size distribution in real-time and adjust atomization parameters accordingly. This closed-loop control ensures consistent, narrow size distribution is maintained throughout the particle production process, preventing broad distribution even at high production rates.
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 apparatus effectively produces particles with sizes between 10 and 700 nm, achieving high yield and retaining biological activity, with controlled particle size distribution and efficient processing, addressing the limitations of existing methods.
Implementation Method 1
The atomization means includes at least one of a pneumatic atomizer and an ultrasonic atomizer configured to atomize the solution to produce a droplet flow comprising a plurality of droplets of the solution
Implementation Method 2
The atomization means includes at least one of a pneumatic atomizer and an ultrasonic atomizer configured to atomize the solution to produce a droplet flow comprising a plurality of droplets of the solution
Implementation Method 3
a drying chamber configured to expose the droplet flow to a drying flow so as to produce a dried particle flow having particles of a size less than a predetermined threshold size
Implementation Method 4
at least one ionizer arranged to expose the particle flow received from the drying chamber, wherein the at least one ionizer produces an ionized flow of negative ions configured to charge the particles to produce a charged particle flow
Implementation Method 5
an electrostatic collector configured to deflect the incoming charged particles of the charged particle flow towards a surface, where, deflected particles form a layer on the surface
Data Source
AI summary
Embodiments of the present disclosure include, for example, systems, apparatuses, devices, and methods for producing a population of particles. In some embodiments, such particles include particles corresponding to an active, pharmaceutical ingredient.