Reaction Device Concentration Gradient Continuous Microsphere Production

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Solution Overview

Problem

The existing microsphere production process faces challenges with solution saturation during the extraction step, preventing continuous production due to the cumbersome and difficult-to-reproduce nature of the current methods.

Innovation Solution

A reaction device with a first injection port and a supply device that creates a concentration gradient within the reactor body using a continuous phase, allowing for the directional flow of the extraction agent to concentrate extracted substances, thereby maintaining a gradient that facilitates continuous production and avoids saturation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the double emulsification method is used for microsphere production, then microspheres can be formed with encapsulated biological drugs, but the extraction solution becomes saturated during production preventing continuous manufacturing

Engineering Contradiction:

Improvemicrosphere formation reliabilityVSAvoidcontinuous production capability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The extraction process is segmented into multiple extraction chambers arranged in series, where each chamber contains fresh extraction solution. This segmentation prevents saturation by dividing the extraction task across multiple independent units, allowing continuous flow of emulsion droplets through progressively fresher extraction solutions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The extraction solution is pre-positioned in each extraction chamber before the emulsion droplets arrive. This preliminary placement ensures that fresh extraction solution is always available at the point of extraction, eliminating the need to wait for solution replacement and enabling continuous production.

Inventive Principle:

Principle #10Preliminary action

2Quantity of substance

If frequent injections are used to administer biological drugs, then the drugs can be delivered to patients, but the treatment burden increases and patient compliance decreases

Engineering Contradiction:

Improvedrug delivery frequencyVSAvoidpatient compliance

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The patent creates sustained-release microspheres that continuously release encapsulated biological drugs over extended periods (weeks to months). This continuous release mechanism replaces frequent discrete injections, maintaining therapeutic drug levels in the body without requiring repeated patient visits for injection.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent changes the release rate parameter of the drug delivery system by encapsulating drugs in biodegradable polymer microspheres. This transforms the delivery pattern from frequent high-dose injections to continuous low-dose release, extending the effective duration of action from days to months.

Inventive Principle:

Principle #35Parameter changes

3Duration of action of moving object

If chemical modification (PEGylation) is used to prolong drug half-life, then in vivo duration is extended, but the specific activity is reduced due to shielding effects requiring increased dosage

Engineering Contradiction:

Improvedrug half-lifeVSAvoiddrug specific activity

Core Design Contradiction:

Duration of action of moving objectVSQuantity of substance

Solution Approach 1:

The patent uses biodegradable polymer microspheres as an intermediary carrier to deliver biological drugs. This intermediary protects the drug from rapid clearance while maintaining its biological activity, avoiding the shielding effect problem of PEGylation. The polymer matrix allows controlled release without interfering with the drug's active sites.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 continuous production of microspheres by maintaining a concentration gradient, preventing precipitation and adhesion issues, and allowing for reproducible and scalable production of microspheres and liposomes.

Implementation Method 1

the continuous phase flows directionally within the reactor body to create or maintain a parametric gradient within the reactor body

Methodology Applied

Scientific EffectConcentration gradient: Diffusion

Implementation Method 2

extracting the organic solvent in it to solidify the polymer dispersed phase into spheres

Methodology Applied

Scientific EffectExtraction: Liquid-Liquid Extraction

Data Source

PatentUS20230149879A1Reaction device, microsphere preparation device and extraction method and liposome drug loading method

Publication Date: 2023.05.18 HANGZHOU BIODETECH BIOTECHNOLOGY CO

AI summary

Disclosed is a reaction device, comprising: a reactor body (100) and a supply device (200), wherein the reactor body (100) has a first end (106) and a second end (107) and is used for accommodating a reaction liquid, with a first injection port (101) being provided between the first end (106) and the second end (107), and a discharge port (109) being provided at the second end (107); and the supply device (200) is in communication with the first injection port (101) to inject a continuous phase, wherein the continuous phase directionally flows in the reactor body (100) to form or maintain a parameter gradient in the reactor body (100). By means of injecting the continuous phase into the first injection port (101) on the reactor body (100), the solution presents a certain parameter gradient on two sides of the first injection port (101) in the reactor body (100).