Polydioxanone Particle Manufacturing via Perfluoroalcohol Solvation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing polymer particles, such as emulsion, dispersion, seed, and suspension polymerization, face challenges in achieving uniform particle size, stability, and reproducibility, particularly for biocompatible polydioxanone particles intended for use in the body.
Innovation Solution
A method involving dissolving polydioxanone in perfluoroalcohol and mixing it with a polymer emulsion containing polyethylene oxide-polypropylene oxide-polyethylene oxide terpolymer, acid, and surfactant, followed by aging and washing, to produce polydioxanone particles with controlled size and high biocompatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If emulsion polymerization is used to manufacture polymer particles, then particle size uniformity is improved, but particle diameter is limited to below 1 μm and surfactant adsorption causes foaming and deterioration of physical properties
Solution Approach 1:
The patent uses a specific emulsion polymerization process with controlled surfactant selection and concentration to mediate between the need for particle uniformity and the desire for larger particle size. The surfactant acts as an intermediary that enables larger particle formation while maintaining uniformity, resolving the contradiction between size limitation and uniformity requirements.
2Length of moving object
If dispersion polymerization is used with organic solvents, then particle size can be increased to 1 μm or smaller, but particle size distribution varies sensitively with reaction environment and process reproducibility deteriorates
Solution Approach 1:
The patent systematically optimizes and controls multiple reaction parameters including solvent composition, monomer concentration, initiator type and amount, and temperature to achieve reproducible particle size distribution. By establishing specific parameter ranges and control protocols, the patent resolves the sensitivity issue and improves process reliability while maintaining the ability to produce particles of desired size.
3Manufacturing precision
If seed polymerization is used to manufacture micrometer scale particles with uniform size distribution, then particle size control is improved, but process complexity increases and manufacturing time extends due to multiple steps
Solution Approach 1:
The patent employs a multi-stage polymerization process where particles are formed in sequential steps with each stage building upon the previous one. This segmentation allows for precise size control at each stage while systematically managing the overall process complexity through structured progression from seed formation to final particle development.
4Length of moving object
If suspension polymerization is used to manufacture polymer particles, then large particle size range (0.1-1000 μm) is achieved, but particle size distribution becomes very broad and additional apparatus is required to reduce particle size distribution
Solution Approach 1:
The patent utilizes dynamic control of stirring speed, temperature, and addition rate during suspension polymerization to maintain uniform particle size distribution across a broad size range. By continuously adjusting process parameters during reaction, the patent achieves both wide size range and narrow distribution without requiring additional size reduction apparatus.
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 method allows for the production of polydioxanone particles with uniform size and high biocompatibility, suitable for use in the body, improving skin vitality and elasticity, and can be used as a filler to enhance skin volume for several months.
Implementation Method 1
a polymer emulsion containing a polyethylene oxide-polypropylene oxide-polyethylene oxide terpolymer
Implementation Method 2
a solution of polydioxanone dissolved in a perfluoroalcohol with a concentration of 1.0-5.0 wt%
Implementation Method 3
a surfactant and an acid in an amount that the pH of the polymer emulsion is 1.5-4.5
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to a method for manufacturing polydioxanone particles (PDO) for a filler, more particularly to a method for manufacturing polydioxanone particles, which includes a step of mixing a solution of polydioxanone dissolved in a perfluoroalcohol with a polymer emulsion containing a polyethylene oxide-polypropylene oxide-polyethylene oxide terpolymer at a predetermined ratio to generate polydioxanone particles and then recovering the polydioxanone particles through aging and washing. The polydioxanone particles manufactured by the manufacturing method of the present invention can be favorably used as an injection for regenerating skin tissues.