Silicon Vibrating Mesh Atomizer for Uniform Dry Powder Generation
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Solution Overview
Problem
Conventional spray-drying techniques using commercial atomizers produce dry powders with wide particle size distributions, leading to poor yield efficiency, bioavailability issues, and quality inconsistencies in pharmaceuticals, and require additional processing to achieve uniform sizes.
Innovation Solution
Utilizing a silicon-based vibrating mesh atomizer (Si-VMA) with an integrated heating chamber to control aerosol droplet size and evaporate liquid components, resulting in narrow droplet size distribution and uniform dry powders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional spray-drying techniques using commercial atomizers are used, then the process is simple and widely applicable, but the particle size distribution is wide leading to poor yield efficiency and quality inconsistencies
Solution Approach 1:
The patent segments the atomization process into multiple independent nozzles with precisely controlled aperture sizes. Each nozzle produces droplets of a specific size range, and by controlling the activation of individual nozzles, the system achieves narrow particle size distribution (span < 1.0) while maintaining high productivity through parallel operation of multiple nozzles.
Solution Approach 2:
The patent employs dynamic control of nozzle activation where specific nozzles are selectively activated based on the desired particle size range. This dynamic selection allows the system to optimize both precision (by using only the necessary nozzles for the target size) and productivity (by activating multiple nozzles simultaneously for high-volume production).
2Manufacturing precision
If conventional atomizers are used to produce dry powders, then the equipment is simple and easy to operate, but additional processing is required to achieve uniform particle sizes
Solution Approach 1:
The patent performs preliminary action by pre-configuring the atomizer with multiple nozzles of different aperture sizes before the drying process. Each nozzle is designed to produce droplets within a specific size range, so when the atomization occurs, the particle size distribution is already optimized for the target application, eliminating the need for post-processing size adjustment.
Solution Approach 2:
The patent changes the physical parameter of nozzle aperture size to directly control droplet size. By varying the aperture diameter (e.g., 10μm, 20μm, 30μm nozzles), the system produces droplets of corresponding sizes that dry into uniform particles, achieving precise particle size control through a single process parameter adjustment rather than multiple processing steps.
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 Si-VMA system achieves greater than 90% efficiency in controlling droplet sizes, producing uniform dry powders with reduced span, enhancing yield and quality in pharmaceuticals and other industries.
Implementation Method 1
a piezoelectric element (PZT) positioned behind the mesh membrane and configured to vibrate the mesh membrane at frequencies greater than 20 kHz
Implementation Method 2
an integrated heating chamber to control aerosol droplet size and evaporate liquid components
Data Source
AI summary
A variety of applications can include systems and methods related to vibrating mesh atomizers for dry powder generation. A spray-drying system can include a silicon vibrating mesh atomizer structured to receive a liquid and generate aerosol droplets; a heater at an outlet of the silicon vibrating mesh atomizer, where the heater is structured to evaporate liquid components of the aerosol droplets; and a collector to collect solid particles from the evaporation of the aerosol droplets. Variations of the silicon vibrating mesh atomizer or variations of associated heaters can be implemented to provide a controlled distribution of solid particles from an aerosol generated from a selected liquid.