Abstract: A process, method and/or system for preparing polymer-coated nanoparticles and/or other ultrafine particles utilizing a supercritical fluid, e.g., supercritical carbon dioxide (SC CO2), as an antisolvent that may be added to a solution of a polymer and an organic solvent in which insoluble nanoparticles or the like are suspended. The coating process occurs when the supercritical fluid (e.g., SC CO2) and the nanoparticle-containing suspension are combined to cause the suspended nanoparticles to precipitate as coated nanoparticles. Processing parameters for optimizing and/or enhancing the efficacy and/or efficiency of the coating process, method and/or system and for controlling the coating and/or agglomeration of coated particles are also described. The process, method and/or system has wide ranging applicability, e.g., for coating and/or encapsulation of pharmaceuticals, cosmetics, food products, chemicals, agrochemicals, pesticides, polymers, coatings, catalysts and the like.

Abstract: A method of prilling or spray drying comprising calculating and controlling the viscosity of a shear-thinnable fluid stream at a particle-forming section of a dispersion device. The method comprises measuring the static head of fluid in the dispersion device, providing a pressurized blanket of inert gas over the fluid, mechanically agitating the fluid in the dispersion device, calculating the viscosity at the particle-forming section and controlling the viscosity by adjusting the speed of mechanical agitation.

Abstract: Method of manufacturing resin particles capable of manufacturing resin particles of controlled particle size stably and efficiently by removing bubbles from the surface of a molten kneaded product as the raw material for resin particles thereby sufficiently ensuring action sites for a surfactant on the surface of the molten kneaded product, is provided. The method includes a coarsely-pulverizing step of pressurizing a mixture of a molten kneaded product containing a synthetic resin and an aqueous medium containing a surfactant to 15 MPa to 120 MPa thereby removing bubbles attached to the molten kneaded product containing the synthetic resin, and a finely-granulating step of finely granulating, by a high pressure homogenizer method, an aqueous slurry containing coarse particles of a molten kneaded product passing through a pressure proof nozzle in the coarsely-pulverizing step and in a state where bubbles attached to the surface are removed.

Abstract: An object of the present invention is to provide a resin microparticle for a toner raw material that has a small particle diameter and a narrow particle diameter distribution and has a low odor. There are provided a resin microparticle for a toner raw material characterized in that all of the following requirements (i) to (iii) are satisfied: Requirement (i): A particle diameter of 50% volume (D50) satisfies the relationship 0.05 ?m?D50?1 ?m; Requirement (ii): A particle diameter of 10% volume (D10) and a particle diameter of 90% volume (D90) satisfy the relationship D90/D10?7; and Requirement (iii): The content of an organic solvent is not more than 70 ppm.

Abstract: The Invention is a reinforced plastic sonar dome having a low acoustical insertion loss combined with sufficient mechanical strength. Acoustical and structural fibers are stochastically mixed and formed into a blended yarn. The blended yarn is woven into a blended fabric. The blended fabric is ordered into a stack having multiple layers of blended fabric. The blended fabric is incorporated into a polymer resin while the polymer resin is in liquid form using a vacuum assist. The acoustical fibers and the vacuum assist modify the acoustical properties of the resulting composite sonar dome.

Abstract: The method of the present invention can 1) produce spherical and scaly ultrafine particles without pulverization, 2) obtain spherical ultrafine particles having a sharp spherical particle diameter distribution without requiring a sieving step, 3) produce spherical ultrafine particles extremely approximating a true circle and possessing a particle diameter of 100 nm˜50,000 nm allowing selection of a size suitable for the particular purpose of use and 4) produce spherical ultrafine particles on a commercial scale at low cost. There is also provided spherical ultrafine particles produced by the above production process. The spherical ultrafine particles of the present invention are characterized by a form having circularity of 0.9 to 1.0 and a particle diameter of 0.01 ?m to 10 ?m without pulverization. The spherical ultrafine particles can be produced by the method of the present invention using as a nozzle a base having special through holes and hole density.

Abstract: The present provides a method for preparing resin fine particles of a homogeneous particle size used in the fields of chemistry, medicine, electronic material or the like, resin fine particles, and a production apparatus for resin fine particles. The present invention provides a method for preparing a resin fine particle, which comprises discharging a liquid comprising a polymerizable monomer as a dispersion phase into a continuous phase; splitting the liquid comprising the polymerizable monomer by applying mechanical vibration to form a liquid droplet; and polymerizing the liquid droplet in a state without splitting or integrating the liquid droplet, said method comprising recognizing a state of said liquid being split into a liquid droplet, and a condition of said discharging and/or said mechanical vibration of the liquid being determined by feedback from a result of the recognition.

Abstract: The invention relates to a method and a device for the production of spherical particles, whereby a molten prepolymer or precondensate is transformed into droplets by means of a drip nozzle, the droplets are subjected to a countercurrent with a gas in a precipitation column until at least partial crystallization is achieved and are then subjected to an additional post-crystallization phase. In order to economically produce higher quality particles at a high flow rate, the molten prepolymer is transformed into droplets by means of a vibrating nozzle plate and/or direct vibration of the molten prepolymer or polymer and resulting droplets are subjected to an air and gas countercurrent.

Abstract: A microcapsule composition comprising a core material in a matrix of polymorphic shell material, releases said core material in an aqueous environment in accordance with zero order linear release profile. A preferred composition comprises a core material having a degree of water solubility entrapped in a beta crystalline matrix of water insoluble shell material which matrix may, optionally, be surrounded by a contiguous core material-free layer of water insoluble shell material. Also disclosed is a process for the preparation of microcapsules comprising subjecting a flowable mixture of core material and a first amount of water insoluble shell material to a pressure force to form a pressure-treated mixture, and passing said pressure-treated mixture through a spray nozzle into a chilling zone to form a solidified composition.

Abstract: Considerable energy savings may be realized by recovering heat from hot PET pellets exiting a solid state polymerization reactor, and using this heat to heat cool pellets entering the crystallizer or solid state polymerization reactor. The heat may be transferred from hot to cool pellets employing a heat exchanger.

Abstract: A prilling method comprising the steps of: providing a molten first component, mixing at least a second component with the molten first component, reacting the components to form a shear-thinnable mixture; and prilling the shear-thinnable mixture wherein the prilling comprises mechanically agitating in the prill head to shear thin the shear-thinnable mixture sufficiently to permit prilling. The inventive method can be used to produce fertilizer product comprising ammonium sulfate nitrate.

Abstract: Apparatus for the granulation of a predetermined substance provided in fluid, semi-fluid and similar state, comprising a prilling tower.

Abstract: Disclosed is a method of manufacturing a spherical seamless capsule formed by encapsulating a filler material such as a medicine with a capsule shell material such as gelatin. A concentric multiple nozzle is positioned above the liquid surface of a curing liquid such that the tip of the nozzle faces down. A concentric columnar composite flow which is discharged from this concentric multiple nozzle and which is composed of a filler material and a capsule shell material outside the filler material is immersed in the curing liquid, and cut in the curing liquid to form a droplet. The capsule shell material of the droplet is cured by the curing liquid, and thereby a seamless capsule is formed. Since, the droplet is not dropped into the curing liquid, no deformation of the droplet caused by collision against the liquid surface occurs. The tip of the multiple nozzle is positioned above the liquid surface of the curing liquid.

Abstract: A method of manufacturing particles, especially nanoparticles, by way of precipitation from solution on a rotating surface (1) of a rotating surface reactor is disclosed. Nanoparticles with a tight size distribution may be manufactured in bulk and without the problems of agglomeration that are associated with traditional stirred-tank reactors. Use of a rotating surface reactor allows precipitation of nanoparticles from viscous, supersaturated solutions by way of homogeneous nucleation aided by strong micromixing.

Abstract: Chemical-mechanical planarization slurries and methods for using the slurries wherein the slurry includes abrasive particles. The abrasive particles have a small particle size, narrow size distribution and a spherical morphology and the particles are substantially unagglomerated.

Abstract: Energy devices such as batteries and methods for fabricating the energy devices. The devices are small, thin and lightweight, yet provide sufficient power for many handheld electronics.

Abstract: A process for making granular solids involving: (a) providing a substantially anhydrous preparation, which is solid at room temperature and contain at least one cosmetic feed material; (b) liquifying the substantially anhydrous preparation to form a melt; (c) providing a vibrating casting plate used for droplet formation; (d) introducing the melt onto the vibrating casting plate to form melt droplets thereon; (e) providing a cooling medium; and (f) contacting the melt droplets with the cooling medium which is passed countercurrently to the melt droplets, thus forming the granular solids, and wherein the granular solids have a monodisperse particle size distribution and are substantially free of particles having a diameter of less than 0.3 mm.

Abstract: A process for making spherically-shaped sterol preparations involving: (a) providing a liquid sterol preparation; (b) forming the liquid sterol preparation into liquid sterol droplets; and (c) solidifying the liquid sterol droplets to form the spherically-shaped sterol preparations.

Abstract: Processes for preparing surfactant granules, wherein the processes comprise: (a) passing a water-containing surfactant preparation through a casting plate, wherein the casting plate vibrates, such that droplets of the preparation are formed; and (b) contacting the droplets with a gaseous drying agent; are described.

Abstract: Methods and devices are disclosed that use focused acoustic energy to generate solid particles containing at least one compound of interest. Focused acoustic radiation serves to eject droplets containing a compound of interest dissolved in a solvent. The droplets are subjected to a condition that allows for the compound of interest to precipitate out of solution, thereby generating solid particles. The particles are typically of controlled size, composition, and/or structure. Often, particles of substantially identical size are generated.

Abstract: The invention relates to a process and an apparatus for forming molten drops of precursors of thermoplastic polyesters or copolyesters as molten monomer, oligomer, monomer/glycol mixture or after partial polycondensator [sic] and melting to give a molten precursor, in which the precursor formed into drops is introduced into a gaseous medium, and the gaseous medium, after entry of the precursor formed into drops into the gaseous medium, accelerates the crystallization process by holding the drop-form precursor at a temperature above 100° C. and below its melting point for a limited time until crystallization of the drop at the surface of the precursor is complete. To this end, the apparatus has a fall tower, through which the gaseous medium flows in countercurrent from bottom to top, while the drops fall in the vertical direction from top to bottom into a collecting funnel with a precrystallized surface.

Abstract: Metal-carbon composite powders and methods for producing metal-carbon composite powers. The powders have a well-controlled microstructure and morphology and preferably have a small average particle size. The method includes forming the particles from an aerosol of powder precursors. The invention also includes novel devices and products formed from the composite powders.

Abstract: The invention relates to a method and a device for the production of spherical particles, whereby a molten prepolymer or precondensate is transformed into droplets by means of a drip nozzle, the droplets are subjected to a countercurrent with a gas in a precipitation column until at least partial crystallization is achieved and are then subjected to an additional post-crystallization phase. In order to economically produce higher quality particles at a high flow rate, the molten prepolymer is transformed into droplets by means of a vibrating nozzle plate and/or direct vibration of the molten prepolymer or polymer and resulting droplets are subjected to an air and gas countercurrent.

Abstract: Chemical-mechanical planarization slurries and methods for using the slurries wherein the slurry includes abrasive particles. The abrasive particles have a small particle size, narrow size distribution and a spherical morphology and the particles are substantially unagglomerated.

Abstract: A method of making a spherical seamless capsule formed by encapsulating a filler material such as a medicine with a capsule shell material shell such as gelatin. A liquid capsule shell material is stored in a tank at a low temperature, and supplied to a concentric multiple nozzle while it temperature is raised to a predetermined temperature upon being gradually heated while being transferred to the concentric multiple nozzle. This prevents deterioration in the capsule shell material and excessive decrease in its viscosity. When the liquid filler material and the capsule shell material flow out of the concentric multiple nozzle, their flows are cut by imparting a vibration thereto, to form a droplet in which the filler material and the capsule shell material are disposed at the center and on the outside, respectively. Such droplets are dropped into a curing liquid while in a dispersed state to cure the surface of the capsule shell material.

Abstract: A process for producing a mixture of particulates using compressed gas and sonication. The process is particularly useful to mix reactive particulates, such as thermites.

Abstract: The current invention, Supercritical Antisolvent Precipitation with Enhanced Mass Transfer (SAS-EM) provides a significantly improved method for the production of nano and micro-particles with a narrow size distribution. The processes of the invention utilize the properties of supercritical fluids and also the principles of virbrational atomization to provide an efficient technique for the effective nanonization or micronization of particles. Like the SAS technique, SAS-EM, also uses a supercritical fluid as the antisolvent, but in the present invention the dispersion jet is deflected by a vibrating surface that atomizes the jet into fine droplets. The vibrating surface also generates a vibrational flow field within the supercritical phase that enhances mass transfer through increased mixing. Sizes of the particles obtained by this technique are easily controlled by changing the vibration intensity of the deflecting surface, which in turn is controlled by adjusting the power input to the vibration source.

Abstract: A process for making particles, the process including generating an aerosol stream which includes droplets of a precursor liquid dispersed in a carrier gas, the precursor liquid including a liquid vehicle and a precursor material, separating the precursor liquid into two portions during the generating step, a first portion exiting the generator in the droplets of the aerosol stream and a second portion exiting as effluent at least a portion of which is recycled to the generator, and also during the generating step adding additional liquid vehicle to at least one of the carrier gas supply, the precursor liquid supply, and the aerosol generator, to at least partially compensate for the tendency of the precursor liquid to become more concentrated in the precursor material over time, and then removing at least a portion of the liquid vehicle from the droplets and forming particles in the aerosol stream.

Abstract: The present invention relates to a process for formulating one or more pharmaceutical active principles in the form of granules, characterized in that the various ingredients to be granulated are introduced continuously and this mixture is granulated using a device comprising a chamber and at least one rotary stirring arm, and in the presence of an effective amount of a binder solution, until the said granules are obtained.

Abstract: The current invention, Supercritical Antisolvent Precipitation with Enhanced Mass Transfer (SAS-EM) provides a significantly improved method for the production of nano and micro-particles with a narrow size distribution. The processes of the invention utilize the properties of supercritical fluids and also the principles of virbrational atomization to provide an efficient technique for the effective nanonization or micronization of particles. Like the SAS technique, SAS-EM, also uses a supercritical fluid as the antisolvent, but in the present invention the dispersion jet is deflected by a vibrating surface that atomizes the jet into fine droplets. The vibrating surface also generates a vibrational flow field within the supercritical phase that enhances mass transfer through increased mixing. Sizes of the particles obtained by this technique are easily controlled by changing the vibration intensity of the deflecting surface, which in turn is controlled by adjusting the power input to the vibration source.

Abstract: A method and device for generating solid particles using focused acoustic energy are provided. A solution of a compound of interest is provided in a solvent, which may be an aqueous fluid, a nonaqueous fluid, or a supercritical fluid. Focused acoustic energy is used to eject a droplet of the solution, which is then directed into or through an antisolvent that upon admixture with the solution droplet causes the compound in the droplet to precipitate. In a preferred embodiment, the solvent is an aqueous or organic liquid, and the antisolvent is a supercritical fluid.

Abstract: A method and device for generating pharmaceutical agent particles using focused acoustic energy are provided. A solution of the pharmaceutical agent is provided in a solvent, which may be an aqueous fluid, a nonaqueous fluid, or a supercritical fluid. Focused acoustic energy is used to eject a droplet of the solution, which is then directed into or through an antisolvent that upon admixture with the solution droplet causes the pharmaceutical agent in the droplet to precipitate. In a preferred embodiment, the solvent is an aqueous or organic liquid, and the antisolvent is a supercritical fluid.

Abstract: A granular solid with monodisperse particle size distribution is disclosed, which may be obtained by melting an essentially anhydrous composition, which is solid at room temperature and made from at least one cosmetic ingredient. A flow of the melt is dispersed into droplets by means of a casting plate and vibration and said droplets contacted with a cooling medium, which causes the solidification thereof.

Abstract: Processes for preparing surfactant granules, wherein the processes comprise: (a) passing a water-containing surfactant preparation through a casting plate, wherein the casting plate vibrates, such that droplets of the preparation are formed; and (b) contacting the droplets with a gaseous drying agent; are described.

Abstract: An apparatus for forming metal spheres includes a droplet generator, a buffering chamber, and a cooling drum. The droplet generator generates a droplet from a molten metal mass. The buffering chamber receives the droplet from the droplet generator, and diminishes internal kinetic energy of the droplet without solidifying the droplet. The cooling drum receives the droplet from the buffering chamber, and cools the droplet to the extent that the droplet solidifies into a metal sphere. The apparatus can further include a collector arrangement that receives the metal spheres from the cooling drum and makes the metal spheres available for collection.

Abstract: A process for making spherically-shaped sterol preparations involving: (a) providing a liquid sterol preparation; (b) forming the liquid sterol preparation into liquid sterol droplets; and (c) solidifying the liquid sterol droplets to form the spherically-shaped sterol preparations.

Abstract: The invention relates to a process and an apparatus for forming molten drops of precursors of thermoplastic polyesters or copolyesters as molten monomer, oligomer, monomer/glycol mixture or after partial polycondensator [sic] and melting to give a molten precursor, in which the precursor formed into drops is introduced into a gaseous medium, and the gaseous medium, after entry of the precursor formed into drops into the gaseous medium, accelerates the crystallization process by holding the drop-form precursor at a temperature above 100° C. and below its melting point for a limited time until crystallization of the drop at the surface of the precursor is complete. To this end, the apparatus has a fall tower, through which the gaseous medium flows in countercurrent from bottom to top, while the drops fall in the vertical direction from top to bottom into a collecting funnel with a precrystallized surface.

Abstract: The process comprises forming drops of a liquid to be configured, introducing said drops into a configurator liquid at high temperature in order to produce the coagulation of the drops and to obtain granules; to this effect, the jet of configuration liquid is subjected to the action of periodical pulses which are symmetrical to the axis of the effluent jet of configuration liquid thereby obtaining a controlled disintegration of the liquid into drops. The device for implementing such process includes a pulse chamber (2) with an elastic membrane (4) which produces pressure pulses to the liquid thereby disintegrating the liquid into drops (10) which fall into a receiver (12) and which, together with a configuration liquid flow, are introduced into a column (13) containing the configuration liquid at high temperature. The process and device enable to obtain granulated products such as caviar-like product, granulated meat products, chemical, pharmaceuticals and the like.

Abstract: A method of making spherical bodies from powder, which comprises (1) preparing an adjusted powder so as to have at least one powder characteristic selected from the group consisting of an average particle size, a powder particle size distribution and a BET specific surface area, (2) preparing nuclei having a particle size larger than that of the adjusted powder, (3) rotating the nuclei, and (4) adding the adjusted powder and a solvent to the rotating nuclei so that particles of the adjusted powder accumulate on the nuclei to form granular bodies. Also disclosed is a spherical body having a core or nucleus formed in the spherical body, an adjusted powder composition for forming a spherical body, and a method for manufacturing spherical sintered bodies of silicon nitride.

Abstract: This invention describes a method of producing polymer powders from solution in a compatible solvent using a new device referred to as a microdroplets on demand generator (MODG). The embodiment of this invention is the MODG apparatus and its relevance as a method to extensive application in materials science and technology. Proof of concept is demonstrated using poly(ethylene) glycol polymer microparticles generated with the MODG and captured in a microparticle levitation device.

Abstract: The present invention relates to an apparatus and method for the formation of nearly spherical particles, particularly for the formation of metal or metal alloy particles with an induced duplex microstructure. The present invention provides an atomization apparatus having a nozzle positioned at the bottom of a cooling chamber. Rayleigh wave instability may be induced by imparting vibrations to a stream of molten material, which is released under positive pressure upward into a cooling chamber where the stream breaks up into substantially spherical droplets. This produces a plurality of uniform droplets, each droplet having an initial velocity sufficient to follow a unique upward parabolic trajectory above the aperture. These parabolic trajectories carry the individual droplets to a chill body disposed within the cooling chamber, with which they impact while they are at least partially molten.

Abstract: A method and device for generating solid particles using focused acoustic energy are provided. A solution of a compound of interest is provided in a solvent, which may be an aqueous fluid, a nonaqueous fluid, or a supercritical fluid. Focused acoustic energy is used to eject a droplet of the solution, which is then directed into or through an antisolvent that upon admixture with the solution droplet causes the compound in the droplet to precipitate. In a preferred embodiment, the solvent is an aqueous or organic liquid, and the antisolvent is a supercritical fluid.

Abstract: The invention relates to a method for capsulating microbial, plant and animal cells or biological and chemical substances, using a nozzle to obtain small, especially spherical particles by vibrating an immobilisation mixture. According to said method, the immobilisation mixture, especially a laminar fluid jet taking the form of an immobilisation mixture, is divided into equal parts by superimposition of an external vibration. In a device especially well suited to carry out this method a metallic counter-element (18) which is mounted down-stream from the nozzle (16) at a distance (a) to, and on the outside of, the nozzle axis (A) is connected to a high-voltage source (30). The counter-element is to be embodied by a metal ring (18) through whose through hole (20) the nozzle axis (A) extends. The metal ring (18) is radially connected to an insulated support (22, 24).

Abstract: A system and method for making very small (e.g., 1 millimeter diameter) spherical shaped devices is disclosed. The system includes a supply system for providing predetermined amounts of raw material into a chamber, which is used for melting the raw material. The melted raw material is then provided to a dropper for measuring predetermined amounts of the melted raw material (droplets) and releasing the droplets into a drop tube, where they are cooled and solidified into spherical shaped silicon devices. The system includes a container of silicon powder in which the solidified spherical shaped devices are received from the drop tube, the container including a stirring mechanism for agitating the silicon powder. The system also includes a separating device for separating the powder from the solidified spherical shaped devices after the devices have been received into the container.

Abstract: A system and method for making very small (e.g., 1 millimeter diameter) spherical shaped devices is disclosed. The system includes a supply system for providing predetermined amounts of raw material into a chamber, which is used for melting the raw material. The melted raw material is then provided to a dropper for measuring predetermined amounts of the melted raw material (droplets) and releasing the droplets into a drop tube, where they are cooled and solidified into spherical shaped silicon devices. The system includes a container of silicon powder in which the solidified spherical shaped devices are received from the drop tube, the container including a stirring mechanism for agitating the silicon powder.

Abstract: A method of forming particles comprises accelerating a stream comprising a liquid; and vibrating the stream, to form particles. The particle may have a diameter that is smaller than the diameter of the nozzle used to form the stream, allowing for the formation of micro- and nano-sized particle.

Abstract: Composite fibers useful for preparing diaphragms are prepared by (a) mixing a PTFE or PTFE copolymer dispersion or powder with a finely divided inorganic material and a fiber forming material, (b) shear heating the resulting mixture to a temperature at which sheared to PTFE or PTFE copolymer becomes flowable without showing signs of decomposition while removing the dispersion medium, if a PTFE or PTFE copolymer dispersion is used, (c) cooling the mixture to below 70° C., (d) mix shearing the mixture at below 70° C. to form composite fibers.

Abstract: Provided is an aerosol method, and accompanying apparatus, for preparing powdered products of a variety of materials involving the use of an ultrasonic aerosol generator (106) including a plurality of ultrasonic transducers (120) underlying and ultrasonically energizing a reservoir of liquid feed(102) which forms droplets of the aerosol. Carrier gas (104) is delivered to different portions of the reservoir by a plurality of gas delivery ports (136) delivering gas from a gas delivery system. The aerosol is pyrolyzed to form particles, which are then cooled and collected. The invention also provides powders made by the method and devices made using the powders.

Abstract: The current invention, Supercritical Antisolvent Precipitation with Enhanced Mass Transfer (SAS-EM) provides a significantly improved method for the production of nano and micro-particles with a narrow size distribution. The processes of the invention utilize the properties of supercritical fluids and also the principles of virbrational atomization to provide an efficient technique for the effective nanonization or micronization of particles. Like the SAS technique, SAS-EM, also uses a supercritical fluid as the antisolvent, but in the present invention the dispersion jet is deflected by a vibrating surface that atomizes the jet into fine droplets. The vibrating surface also generates a vibrational flow field within the supercritical phase that enhances mass transfer through increased mixing. Sizes of the particles obtained by this technique are easily controlled by changing the vibration intensity of the deflecting surface, which in turn is controlled by adjusting the power input to the vibration source.

Abstract: Uniform sized and shaped spheres are formed by applying a minute periodic disturbance to a low viscosity liquid material. Pressure forces the material through at least one orifice in a crucible as a steady laminar stream. The stream enters an enclosed controlled temperature solidification environment which contains at least one heat transfer medium. A charging means is applied to the stream as the stream exits the crucible and breaks into a plurality of spheres to deflect the spheres as they pass through an electric field. The enclosed controlled temperature solidification environment cools and substantially solidifies the spheres.