Process and apparatus for producing emulsion and microcapsules

• US 7,772,287 B2
• Filed: 11/28/2005
• Issued: 08/10/2010
• Est. Priority Date: 02/23/2001
• Status: Active Grant

• Current Assignee: Japan Science And Technology Agency
• Original Assignee: Japan Science And Technology Agency
• Inventors: Taniguchi, Tomohiro, Nishisako, Takashi, Torii, Toru, Higuchi, Toshiro
• Primary Examiner(s): Seidleck; James
• Assistant Examiner(s): Haider; Saira
• Application Number:
  US11/287,252
• Publication Number:
  US 20060079584A1
• Time in Patent Office: 1,716 Days
• Field of Search: 428402-40224, 4272133-21336, 264 4- 47
• US Class Current: 516/21
• CPC Class Codes: B01F 2215/0431 Numerical size values, e.g. diameter of a hole or conduit, area, volume, length, width, or ratios thereof
• CPC Class Codes: B01F 23/41 Emulsifying
• CPC Class Codes: B01F 23/4105 Methods of emulsifying
• CPC Class Codes: B01F 23/4143 Microemulsions
• CPC Class Codes: B01F 23/4144 Multiple emulsions, in particular double emulsions, e.g. water in oil in water; Three-phase emulsions
• CPC Class Codes: B01F 25/313 wherein additional components are introduced in the centre of the conduit
• CPC Class Codes: B01F 25/314 wherein additional components are introduced at the circumference of the conduit
• CPC Class Codes: B01F 25/31422 with a plurality of perforations in the axial direction only
• CPC Class Codes: B01F 33/3011 using a sheathing stream of a fluid surrounding a central stream of a different fluid, e.g. for reducing the cross-section of the central stream or to produce droplets from the central stream
• CPC Class Codes: B01F 33/3031 using electro-hydrodynamic [EHD] or electro-kinetic [EKI] phenomena to mix or move the fluids
• CPC Class Codes: B01F 35/71 Feed mechanisms with proportioning B01F35/80
• CPC Class Codes: B01F 35/712 for feeding fluids
• CPC Class Codes: B01F 35/71791 using ink jet heads or cartridges, e.g. of the thermal bubble jet or piezoelectric type
• CPC Class Codes: B01F 35/71805 using valves, gates, orifices or openings
• CPC Class Codes: B01J 13/04 by physical processes, e.g. drying, spraying
• CPC Class Codes: B01J 19/0093 Microreactors, e.g. miniaturised or microfabricated reactors laboratory containers with capillary fluid transport in microfabricated channels or chambers B01L3/5027
• CPC Class Codes: B01J 2219/00783 Laminate assemblies, i.e. the reactor comprising a stack of plates
• CPC Class Codes: B01J 2219/00853 Employing electrode arrangements
• CPC Class Codes: B01L 3/5027 by integrated microfluidic structures, i.e. dimensions of channels and chambers are such that surface tension forces are important, e.g. lab-on-a-chip B01L3/5023 takes precedence; micromixers B01F33/30; microreactors for synthesis B01J19/0093; microcapillary devices in general B81B1/00
• CPC Class Codes: Y10S 366/04 Micromixers: with application of energy to influence mixing/agitation, e.g. magnetic, electrical, e-m radiation, particulate radiation, or ultrasound
• CPC Class Codes: Y10S 516/924 : Significant dispersive or manipulative operation or step in making or stabilizing colloid system
• CPC Class Codes: Y10S 516/927 : in situ formation of a colloid system making or stabilizing agent which chemical reaction
• CPC Class Codes: Y10T 137/0329 : Mixing of plural fluids of diverse characteristics or conditions
• CPC Class Codes: Y10T 428/2984 : Microcapsule with fluid core [includes liposome]

Abstract

A process and apparatus for rapidly producing an emulsion and microcapsules in a simple manner is provided wherein a dispersion phase is ejected from a dispersion phase-feeding port toward a continuous phase flowing in a microchannel in such a manner that flows of the dispersion phase and the continuous phase cross each other, thereby obtaining microdroplets, formed by the shear force of the continuous phase, having a size smaller than the width of the channel for feeding the dispersion phase.

Claims

1. A process for producing a microdroplet emulsion of microdroplets, comprising

ejecting a dispersion phase from a dispersion phase feed channel toward the junction of flows of a first continuous phase and a second continuous phase flowing in first and second microchannels , the first and second continuous phases flowing towards the junction from first and second continuous phase feed ports positioned opposite to each other wherein the flow of the dispersion phase joins the flows of the first and second continuous phases to form a microdroplet emulsion in the flow of first and second continuous phases.

2. A process for producing microcapsules, comprising

feeding a content-forming phase to a first continuous phase and a second continuous phases flowing in first and second microchannels, the first and second continuous phases flowing towards the junction from first and second continuous phase feed ports positioned opposite to each other wherein the flow of the content-forming phase joins the flows of the first and second continuous phases to form a microdoplet emulsion;

and then

feeding a shell-forming phase to a third continuous phase and a fourth continuous phase flowing in third and fourth microchannels configured in an orientation to the first and second continuous phases to coat the microdroplet emulsion from the first and second continuous phase in the flow of the third and fourth continuous phase to form a microcapsule comprising the microdroplet emulsion coated with a shell.

3. An apparatus for producing an emulsion, comprising:

a first microchannel where a first continuous phase flows and a second microchannel where a second continuous phase flows, and

a dispersion phase feed channel configured to feed the dispersion phase toward the junction of flows of the first and second continuous phases such that the flow of the dispersion phase feed channel joins the flows of first and second continuous phases to form microdroplets in the flow of the first and second continuous phases by ejecting the dispersion phase from the dispersion phase feed channel toward the junction of flows of the first and second continuous phases wherein the first and second microchannels are configured to provide the first and second continuous phases towards the junction from first and second continuous phase feed ports positioned opposite to each other.

5. The apparatus for producing an emulsion according to claim 3, which comprises a plurality of dispersion phase feeds and wherein the plurality of the dispersion phase feeds each include a substrate, a driven plate, an elastic member disposed between the substrate and the driven plate, and an actuator for driving the driven plate wherein the plurality of dispersion phases feeds are configured to feed a plurality of dispersion phases at the same time.

7. The apparatus for producing an emulsion according to claim 3 further comprising films disposed on a portion of an inner wall surface of the first microchannel, the second microchannel, the a dispersion phase feed channel, or a combination thereof.

9. The apparatus according to claim 7, wherein the portion disposed with the film includes a junction of flows of the first and second continuous flows and the dispersion phase.

4. An apparatus for producing microcapsules, comprising:

a first microchannel where a first continuous phase flows and a second microchannel where a second continuous phase flows,

a dispersion phase feed channel configured to feed the dispersion phase toward the junction of flows of the first and second continuous phases such that the flow of the dispersion phase feed channel joins the flows of first and second continuous phases to form microdroplets in the flow of the first and second continuous phases by ejecting the dispersion phase from the dispersion phase feed channel toward the junction of flows of the first and second continuous phases;

a third microchannel where a third continuous phase flows and a fourth microchannel where fourth continuous phase flows wherein the third and fourth microchannels are configured in an orientation to the first and second continuous phases to coat microdroplets from the first and second continuous phase in the flows of the third and fourth continuous phase, wherein the first and second microchannels are configured to provide the first and second continuous phases towards the junction from first and second continuous phase feed ports positioned opposite to each other.

6. The apparatus for producing microcapsules according to claim 4, wherein the dispersion phase feed channel, the third microchannel and the fourth microchannel each include a substrate, a driven plate, an elastic member disposed between the substrate and the driven plate, and an actuator for driving the driven plate such that the dispersion phase feed channel, the third microchannel and the fourth microchannel are configured to feed the dispersion phase, the third continuous phase and the fourth continuous phase at the same time.

8. The apparatus for producing microcapsules according to claim 4 further comprising films disposed on a portion of an inner wall surface of the first microchannel, the second microchannel, the a dispersion phase feed channel, the third microchannel, the fourth microchannel, or a combination thereof.

10. The apparatus according to claim 8, wherein the portion disposed with the film includes a junction of flows of the first and second continuous flows and the dispersion phase.