Thermoplastic Microparticle Shells for High-Throughput Pulsatile Release
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Solution Overview
Problem
Existing methods for synthesizing microparticles with pulsatile release are limited by minimum particle size, low production throughput, and inconsistency, requiring multiple components and manual alignment, which hinder scalability and efficiency.
Innovation Solution
A one-component method for producing microparticles with pulsatile release, involving the creation of an open-topped thermoplastic shell that is filled with a guest agent and sealed by heating above the polymer's glass transition or melting temperature, eliminating the need for separate base and cap fabrication and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional two-component microparticle synthesis methods are used, then particle sealing can be achieved, but production throughput is low and minimum particle size is limited
Solution Approach 1:
The patent merges the base and cap components into a single monolithic microparticle structure formed by sintering a green body within a mold. This eliminates the need for separate component fabrication, manual alignment, and assembly steps, thereby dramatically increasing production throughput while reducing process complexity.
Solution Approach 2:
The invention segments the microparticle production process into distinct stages: forming the green body with embedded cavity, sintering to create the monolithic structure, and post-processing. This segmentation allows for optimized control of each stage while enabling high-throughput continuous manufacturing.
2Ease of manufacture
If flexible molds are used for microparticle production, then ease of manufacture is improved, but sealing of very small particles becomes difficult
Solution Approach 1:
The patent changes the physical state and mechanical properties of the mold material by heating it above its glass transition temperature during the sintering process. This thermal parameter change allows the mold to become sufficiently rigid to maintain precise dimensional control and achieve proper sealing of small particles, while remaining flexible enough for easy manufacture and particle ejection at room temperature.
3Reliability
If force is applied to very small particles during sealing, then sealing can be achieved, but particle fracture is induced
Solution Approach 1:
The patent utilizes phase transitions of both the polymer material and mold material. The green body transitions from a soft, formable state to a rigid, sintered structure through heat treatment. Simultaneously, the mold transitions from a flexible state to a rigid sealing state when heated above its glass transition temperature, enabling effective sealing without excessive force that would fracture small particles.
4Manufacturing precision
If manual inspection and alignment steps are included, then particle quality can be controlled, but production time increases
Solution Approach 1:
The patent implements self-alignment through the mold design, where the cavity structure automatically positions the green body components correctly during insertion. The monolithic formation process inherently ensures proper alignment and sealing without requiring manual inspection or adjustment steps, enabling continuous high-speed production while maintaining consistent particle quality.
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
Enables high-throughput, continuous production of smaller microparticles with improved shape and stability, allowing for delivery via smaller needles and enhanced scalability, while maintaining pulsatile release kinetics.
Implementation Method 1
sealed by heating above the polymer's glass transition or melting temperature
Implementation Method 2
heating above the polymer's glass transition or melting temperature
Data Source
AI summary
Disclosed herein are closed polymeric microparticles comprising an outer shell and an inner volume, wherein the outer shell has a bottom and a domed top end, and comprises at least one polymer, further wherein the inner volume comprises at least one guest agent, wherein the guest agent is a therapeutic agent, a prophylactic agent, a nutraceutical agent, or a diagnostic agent. The present disclosure also provides methods for the production of as well as methods for treatment using said microparticles.