Solvent-Less Thermal Evaporative Extraction System

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Solution Overview

Problem

Current methods for extracting essential oils and volatile aroma components from plant biomass require solvents, which pose safety concerns and result in impure products needing additional processing, while existing solutions are limited by requiring extreme temperatures or being suitable only for batch processes.

Innovation Solution

A solvent-less thermal evaporative process that involves preheating and heating plant material under sub-atmospheric pressure, using a motive gas to drive out chemical compounds, and condensing them for recovery, allowing for continuous or batch operation without damaging temperature-sensitive constituents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If solvent-based extraction methods are used, then extraction efficiency is improved, but safety concerns increase and product purity decreases

Engineering Contradiction:

Improveextraction efficiencyVSAvoidsafety concerns and product impurity

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent removes the harmful solvent from the extraction system entirely. Instead of using hydrocarbon-based solvents or supercritical CO2, the invention uses a solvent-less thermal evaporative process where heat and vacuum directly extract the target compounds from plant material, eliminating the harmful factors associated with traditional solvents while maintaining extraction efficiency

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a vacuum environment as an intermediary medium that facilitates extraction without requiring chemical solvents. The vacuum condition enables water and volatile compounds to evaporate at lower temperatures, serving as the mediating mechanism that allows efficient extraction while avoiding the harmful effects of traditional solvents

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If high temperatures are used for extraction, then extraction efficiency is improved, but heat-sensitive constituents are damaged

Engineering Contradiction:

Improveextraction efficiencyVSAvoidthermal damage to heat-sensitive compounds

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent fundamentally changes the pressure parameter from atmospheric to sub-atmospheric (vacuum) conditions. This parameter change enables the extraction process to occur at significantly lower temperatures (below 100°C), which prevents thermal damage to heat-sensitive constituents while maintaining efficient extraction through the vacuum-enhanced evaporation mechanism

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If batch processing is used, then equipment simplicity is maintained, but processing time and productivity are reduced

Engineering Contradiction:

Improveequipment simplicityVSAvoidprocessing time

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent designs a flexible system that can dynamically adapt between batch and continuous operating modes. The equipment structure remains relatively simple, but the operational flexibility allows it to switch between batch processing (for smaller scales or specific product requirements) and continuous processing (for higher productivity), effectively resolving the contradiction between equipment simplicity and processing efficiency

Inventive Principle:

Principle #15Dynamics

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 process produces high-purity extracts with reduced downstream processing needs, is safer than solvent-based methods, and can operate at sub-atmospheric pressures to protect heat-sensitive compounds, achieving extracts with over 80% cannabinoids and minimal chlorophyll and waxes.

Implementation Method 1

heating the preheated feedstock to a second temperature at sub-atmospheric pressure in an evaporation chamber to form a heated feedstock

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

thermal evaporative process for the recovery of heat-sensitive constituents

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 3

flowing a heated motive gas through the evaporation chamber to drive the at least one chemical compound from the heated feedstock

Methodology Applied

Scientific EffectMass transfer: Diffusion

Implementation Method 4

condensing a portion of the pregnant motive gas to recover the at least one chemical compound

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS10765965B1Systems, methods, and equipment for chemical extraction

Publication Date: 2020.09.08 LOXLEY SYSTEMS LLC

AI summary

Novel thermal evaporative processes for the recovery of heat-sensitive constituents, raw essential oil concentrates, and other compounds from plant biomass material are disclosed, as are systems for implementing such processes. Particularly, the processes include a solvent-less process for either batch-wise or continuous removal and recovery of refined oils, such as volatile aroma components and heavier oils, from plant material.