Method Of Synthesizing Zirconium Phosphate Particles

• US 20090208399A1
• Filed: 04/29/2009
• Published: 08/20/2009
• Est. Priority Date: 12/28/2004
• Status: Active Grant

• Current Assignee: Renal Solutions, Inc. (Fresenius Medical Care AG)
• Original Assignee: Renal Solutions, Inc. (Fresenius Medical Care AG)
• Inventors: Wong, Raymond
• Granted Patent: US 7,736,507 B2
• Time in Patent Office: Days
• US Class Current: 423/309
• CPC Class Codes: A61K 33/42 Phosphorus; Compounds thereof
• CPC Class Codes: B01J 20/0211 Compounds of Ti, Zr, Hf
• CPC Class Codes: B01J 20/0292 Phosphates of compounds other than those provided for in B01J20/048
• CPC Class Codes: B01J 2220/62 In a cartridge
• CPC Class Codes: B01J 27/16 containing oxygen , i.e. acids, anhydrides and their derivates with N, S, B or halogens without carriers or on carriers based on C, Si, Al or Zr; also salts of Si, Al and Zr
• CPC Class Codes: B01J 37/031 Precipitation
• CPC Class Codes: B01J 39/12 Compounds containing phosphorus
• CPC Class Codes: C01B 25/372 of titanium, vanadium, zirconium, niobium, hafnium or tantalum
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]

Abstract

Zirconium phosphate particles are synthesized by providing a solution of zirconium oxychloride in an aqueous solvent, adding at least one oxygen-containing additive to the solution, the oxygen-containing additive being selected to form a complex with zirconium ions in the solution of zirconium oxychloride and thereby reduce hydration of the zirconium ions, and combining this solution with phosphoric acid or a phosphoric acid salt to obtain zirconium phosphate particles by sol gel precipitation.

Claims

1-27. -27. (canceled)

28. A method of making zirconium phosphate particles comprising:

(a) combining at least one fluorine-containing additive with zirconium oxychloride in an aqueous solvent to form a solution wherein the fluorine-containing additive forms a complex with zirconium ions in the solution, and

(b) combining the solution obtained in (a) with phosphoric acid or a phosphoric acid salt to obtain zirconium phosphate particles by sol gel precipitation.

29-35. -35. (canceled)

36. A composition comprising a water-soluble zirconium-containing polymer in an aqueous solution, wherein the polymer is formed by combining, in an aqueous solvent, zirconium oxychloride with at least one oxygen-containing additive that is capable of forming a complex with zirconium ions.

37. The composition of claim 36, wherein the oxygen-containing additive is an inorganic sulfate, an inorganic carbonate, an alcohol, a carboxylate, a ketone, an aldehyde, an organic sulfate, or combinations thereof.

38. The composition of claim 36, wherein the oxygen-containing additive is sulfuric acid, sodium sulfate, sodium carbonate, isopropanol, glycerol, sodium lauryl sulfate, sodium sulfate, glycerol, isopropanol, sodium carbonate, sodium lauryl sulfate (SDS), tartaric acid, polyvinyl alcohol, 2-amino-2-methyl-propanol, hydroxypropyl cellulose, tetrasodium N-(1,2-dicarboxyethyl)-N-octadecyl sulfosuccinamate, octylphenoxypolyethoxy(9-10) ethanol, polyethoxylated(20) oleyl alcohol, ethylenediamine alkoxylate block copolymer or combinations thereof.

39. The composition of claim 36, wherein the oxygen-containing additive is a combination of sodium sulfate and glycerol, a combination of sodium sulfate and sodium lauryl sulfate, a combination of sodium sulfate and tartaric acid, or a combination of sodium sulfate and tetrasodium N-(1,2-dicarboxyethyl)-N-octadecyl sulfosuccinamate, or combinations thereof.

40. Zirconium phosphate particles comprising the following characteristics:

a particle size distribution of less than 20% in the range of >

60-120 microns, more than 80% in the range of 30-60 microns, and less than 10% in the range of less than 30 microns,

an ammonia capacity of 15-20 mg NH₄—

N/gm ZP, and

an Na⁺ content of 3.8-6.2 wt %, based on the weight of the zirconium phosphate particles.

41. The zirconium phosphate particles of claim 40, wherein the ammonia capacity is 16-17 mg NH₄—

N/gm ZP.

42. A dialysis cartridge comprising a cartridge that contains the zirconium phosphate particles of claim 40.

43. The dialysis cartridge of claim 42, wherein said zirconium phosphate particles are present as a layer and said dialysis cartridge further comprises at least one other layer of sorbent material.

44. The dialysis cartridge of claim 42, wherein said dialysis cartridge has a plurality of filter media sections comprising an activated carbon section, an immobilized enzyme section, a powdered alumina section, a zirconium phosphate section, and a sodium zirconium carbonate or a mixture of hydrous zirconium oxide of the acetate form and sodium zirconium carbonate section, in any order.

45. The dialysis cartridge of claim 42, wherein said dialysis cartridge has a plurality of filter media sections including an arrangement, starting from a first end and ending at a second end, an activated carbon section, an immobilized enzyme section, a powdered alumina section, a zirconium phosphate section, and a sodium zirconium carbonate or a mixture of hydrous zirconium oxide of the acetate form and sodium zirconium carbonate section.