Static Mixer Nanoparticle Precipitation Control
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Solution Overview
Problem
Conventional nanoprecipitation methods for generating polymeric nanoparticles face challenges in controlling average particle size and size distribution, and scaling up these processes to large-scale production is difficult.
Innovation Solution
A process involving a static mixer is used to create a mixed flowing stream of an anti-solvent, into which a polymer solution is introduced to form polymeric nanoparticles through precipitation, allowing for control of particle size and distribution by adjusting flow rates and other parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional nanoprecipitation methods are used, then nanoparticles can be generated, but the average particle size and size distribution cannot be controlled predictably
Solution Approach 1:
The patent employs a dynamic mixing system where the anti-solvent is continuously circulated through a static mixer at controlled flow rates. This dynamic approach allows real-time adjustment of mixing intensity and contact time between polymer solution and anti-solvent, enabling predictable control over nanoparticle size and distribution. The continuous circulation creates consistent hydrodynamic conditions that govern nucleation and growth processes.
Solution Approach 2:
The patent systematically varies key process parameters including anti-solvent flow rate, polymer solution concentration, and mixing time to control nanoparticle characteristics. By establishing quantitative relationships between these parameters and final particle size, the method achieves predictable size control. The circulation rate of anti-solvent and injection rate of polymer solution are specifically tuned to achieve desired particle dimensions.
2Productivity
If conventional nanoprecipitation processes are scaled up, then production volume increases, but process control and consistency become difficult
Solution Approach 1:
The patent divides the nanoprecipitation process into distinct functional zones: a static mixer section for controlled mixing, a circulation loop for anti-solvent recycling, and a collection section for nanoparticle recovery. This segmentation allows each zone to be optimized independently and facilitates scaling by replicating or enlarging specific sections without compromising overall process consistency.
Solution Approach 2:
The patent implements a continuous circulation system where the anti-solvent is continuously pumped through the static mixer and returned to the reservoir. This continuous action maintains steady-state operating conditions even at large scales, ensuring consistent mixing quality and nanoparticle formation throughout the process. The continuous flow regime eliminates batch-to-batch variations inherent in conventional methods.
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 method enables the production of nanoparticles with a low polydispersity index and predictable average particle sizes, facilitating scalable production and improved pharmaceutical applications.
Implementation Method 1
the process solvent diffuses rapidly into the anti-solvent while the polymer aggregates into a plurality of nanoparticles
Implementation Method 2
introducing an anti-solvent into a static mixer to create a mixed flowing stream
Implementation Method 3
a polymer solution comprising a polymer dissolved in a process solvent is brought into contact with another solvent (also known as anti-solvent) in which the process solvent is miscible but the polymer is not. As a result, the process solvent diffuses rapidly into the anti-solvent while the polymer aggregates into a plurality of nanoparticles
Data Source
AI summary
In one aspect, the present invention provides a process for forming polymeric nanoparticles, which comprises using a static mixer to create a mixed flowing stream of an anti-solvent, e.g., by introducing a liquid anti-solvent into a static mixer, and introducing a polymer solution into the mixed flowing anti-solvent stream such that controlled precipitation of polymeric nanoparticles occurs. The nanoparticles can then be separated from the anti-solvent stream.