Prefilming Atomizer Thin Film Gas Impingement
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Solution Overview
Problem
Conventional spray drying technologies face challenges in producing particles with precise control over particle size and distribution, particularly for pulmonary drug delivery, where achieving small particle sizes and low moisture content is difficult and costly, and often requires additional processing steps.
Innovation Solution
The method involves forming a liquid into a thin film and impinging it with a flowing gas to create droplets with diameters less than 35 micrometers, using an atomizer with a constriction and a gas channel positioned to impinge the film at a right angle, enhancing atomization efficiency and control over particle size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional spray drying is used to produce small particles for pulmonary delivery, then particle size can be reduced, but manufacturing precision and control over particle size distribution deteriorate
Solution Approach 1:
The liquid feed is divided into a thin film structure before atomization, creating multiple discrete droplets from a single liquid stream. This segmentation approach enables precise control over droplet size and distribution, resolving the contradiction between achieving small particle sizes and maintaining manufacturing precision.
Solution Approach 2:
The liquid is transformed from a bulk phase into a thin film dimension, increasing surface area and enabling more uniform atomization. This dimensional transformation allows for better control over droplet formation and particle size distribution while maintaining small particle sizes.
2Stability of the object's composition
If conventional spray drying is used to achieve low moisture content, then particle stability is improved, but loss of time and additional processing steps are required
Solution Approach 1:
The liquid is prepared as a thin film before entering the drying zone, pre-conditioning it for efficient evaporation. This preliminary preparation enables rapid moisture removal in a single pass, achieving low moisture content without requiring additional processing steps or extended drying time.
3Length of moving object
If conventional spray drying is used to produce small particles, then particle size is reduced, but device complexity and capital costs increase
Solution Approach 1:
The thin film formation function is extracted as a separate, simple component before the atomization zone. This extraction allows the main atomization system to focus solely on droplet formation, simplifying the overall device structure while enabling production of small particles with controlled size distribution.
4Manufacturing precision
If conventional spray drying is used to achieve desired particle characteristics, then particle quality is improved, but productivity decreases due to additional processing steps
Solution Approach 1:
Multiple functions including thin film formation, atomization, and drying are merged into a single integrated process zone. This combination eliminates the need for separate processing steps, maintaining high particle quality while significantly improving productivity and reducing processing time.
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 allows for the production of uniform, small droplets and particles with improved size distribution, reducing the need for additional processing and minimizing capital and operating costs, while ensuring the desired particle characteristics for pharmaceutical applications.
Implementation Method 1
spreading the liquid into a thin film in the channel; and impinging the thin film with a flowing gas to atomize the liquid into droplets
Data Source
AI summary
A method of forming droplets comprises flowing a liquid through a channel; spreading the liquid into a thin film in the channel; and impinging the thin film with a flowing gas to atomize the liquid into droplets. The droplets may then be dried to produce dried particles, such as particles comprising a pharmaceutical active agent. The droplets formed by the disclosed process have improved size and/or size distribution characteristics.