Automated Polymer Synthesis Apparatus Solid Building Block Transfer
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Solution Overview
Problem
Current automated polymer synthesizers face challenges in scalability and efficiency, particularly in handling solid building blocks for large-scale industrial synthesis of heteropolymers like peptides and nucleic acids.
Innovation Solution
The development of an apparatus that allows for fully automated iterative polymer synthesis by storing building blocks in solid form and dissolving them in a first reaction vessel, using an automated transport system and split valve device to manage solid material transfer, and controlling the process with a centralized unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If liquid solutions of building blocks are used in automated synthesizers, then the synthesis process can be automated, but scalability and efficiency at industrial scale are limited due to the need for tank farms and pre-activation reactors
Solution Approach 1:
The patent changes the physical state parameter of building blocks from liquid solution to solid form. This enables direct automated transfer of solid building blocks into the reaction vessel, eliminating the need for complex liquid handling systems, tank farms, and pre-activation reactors, thereby achieving both full automation and industrial scalability
Solution Approach 2:
The patent extracts and removes the complex liquid handling infrastructure (tank farms, pre-activation reactors, liquid dosing systems) from the automated synthesis system. By using solid building blocks that can be directly transferred and dissolved in the reaction vessel, the system eliminates these unnecessary components, simplifying the overall device complexity while maintaining automation
2Productivity
If solid building blocks are handled directly in automated synthesizers, then scalability is improved, but issues of clogging, non-quantitative transfer, and explosion hazards arise
Solution Approach 1:
The patent introduces a gas stream as an intermediary carrier to transport solid building blocks from the storage vessel to the reaction vessel. The solid building blocks are suspended in a gas flow, which prevents direct contact between the solid material and potential ignition sources, thereby eliminating explosion hazards while enabling reliable and quantitative transfer at industrial scale
Solution Approach 2:
The patent uses an inert gas atmosphere (nitrogen or carbon dioxide) to create a non-flammable environment during the handling and transfer of solid building blocks. This inert environment prevents oxidation and eliminates explosion hazards associated with powders in flammable solvents, while the gas flow ensures complete and quantitative transfer of solids, improving both reliability and scalability
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 efficient and automated large-scale synthesis of polymers, overcoming issues of clogging, non-quantitative transfer, and explosion hazards associated with handling powders in flammable solvents, while ensuring precise control and scalability.
Implementation Method 1
The building blocks are transferred from the storage vessels to the reaction vessel in a quantitative manner using a gas stream
Implementation Method 2
The reaction vessel (RV1) is equipped with a liquid inlet, which allows for the introduction of a liquid to dissolve the building block
Data Source
Figure 1~2c
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AI summary
The present invention discloses a method and apparatus for fully automated iterative polymer synthesis at a large scale.