Abstract: A process for preparing ultrafine powders of biological macromolecules comprises atomizing liquid solutions of the macromolecules, drying the droplets formed in the atomization step, and collecting the particles which result from drying. By properly controlling each of the atomization, drying, and collection steps, ultrafine dry powder compositions having characteristics particularly suitable for pulmonary delivery for therapeutic and other purposes may be prepared.

Abstract: A method and apparatus are provided for atomizing a liquid under dispersal conditions suitable for spray drying at a commercial plant scale. In one embodiment, a liquid atomizer has a structural body adapted for connection with a spray dryer and a plurality of atomizing nozzles. Each of the atomizing nozzles includes a liquid nozzle adapted to disperse a supply of liquid and a gas nozzle adapted to disperse a supply of gas. In another embodiment, a process for producing a powder blend of at least two target substances in a single processing step is provided.

Abstract: A method and an apparatus are provided for efficiently manufacturing microspheres having a uniform particle diameter. The apparatus comprises: case 1 having a lower body 1a and an upper body 1b. A seal ring 3, a first plate 4 which is comprised of a transparent plate such as a glass plate or a plastic plate, an annular spacer 5, an intermediate plate 6 which is comprised of a silicon substrate or the like, an annular spacer 7, a second plate 8 and a seal ring 9 are inserted in this order into a concave portion 2 formed in the lower body 1a. The upper body 1b is superposed thereon. Further, the upper body 1b is attached to the lower body 1a with bolts or the like.

Abstract: A procedure for the continuous manufacture of powdered materials starting from solid raw materials in powder form based on synchronizing feed or loading of raw materials or reagents into a tube which constitutes the reactor itself, with the output of the material itself obtained, carrying out the extraction in the lower part, all this carried out in continuous fashion, i.e., as the material is introduced into the tube the synthesis takes place and the product or resulting material is extracted from the reaction without the need to stop the reactor.

Abstract: Methods for preparing dry powders having hydrophobic and hydrophilic components comprise combining solutions of the components and spray drying them simultaneously in a spray dryer. The hydrophilic and hydrophobic component are separately dissolved in separate solvents and directed simultaneously through a nozzle, usually a coaxial nozzle, into the spray dryer. The method provides dry powders having relatively uniform characteristics.

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: The present invention relates to a method for forming particles of a substance, comprising the step of introducing into a mixing chamber (8), in which the temperature and pressure are controlled, a fluid gas (4) and at least one vehicle system (1) comprising at least one substance in solution or suspension such that droplet formation and extraction of the vehicle occur substantially simultaneously by the action of the fluid gas (4). Turbulence is induced in at least one of said fluid gas (4) and said vehicle system (1) so as to create a controlled disorder in the flow of the at least one of the fluid gas (4) or the vehicle system (1) in order to control the particle formation in said mixing chamber (8), said controlled disorder being created by at least one flow perturbation means (11).

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: Method for making polymer particulates, such as spherical powder and whiskers, by melting a polymer material under conditions to avoid thermal degradation of the polymer material, atomizing the melt using gas jet means in a manner to form atomized droplets, and cooling the droplets to form polymer particulates, which are collected for further processing. Atomization parameters can be controlled to produce polymer particulates with controlled particle shape, particle size, and particle size distribution. For example, atomization parameters can be controlled to produce spherical polymer powders, polymer whiskers, and combinations of spherical powders and whiskers. Atomizing apparatus also is provided for atoomizing polymer and metallic materials.

Abstract: The invention provides a method and apparatus for forming particles of a substance, comprising (a) introducing into a particle formation chamber, the temperature and pressure in which are controlled, a first supercritical fluid (SCF) and a solution or suspension of the substance in a vehicle, (b) simultaneously introducing an impinging flow of a second supercritical fluid (SCF), at an angle to, and directed at, the direction of flow of the first supercritical fluid, so as to increase the amount of kinetic energy transferred to the solution or suspension; and (c) using either or both of the first and the second supercritical fluids to disperse the solution or suspension, and to extract the vehicle from it, substantially simultaneously and substantially immediately on introduction of the fluids into the particle chamber.

Abstract: Metal-carbon composite powders and methods for producing metal-carbon composite powders. 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: Microparticles comprising or consisting of a therapeutic agent have a particle density of at least 80% of the solid agent and a shape factor of 1 to 5. The microparticles may be produced by spray drying and may be used in needleless injection.

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 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: Method for producing pressure die-cast or injection moulded articles having a unit for producing salt grains, a press for forming salt filler cores by compressing the said salt grains, a pressure die-casting machine for making the said articles by injecting a material in the liquid state into a mould having at least one salt filler core, and a salt removal and washing unit designed to remove the salt filler cores that have been trapped within the said articles; the said unit for producing salt grains being designed to atomize a saline solution which is supersaturated with salt into a plurality of drops so as subsequently to cause the salt present in solution/suspension in each drop of solution to solidify into a corresponding salt grain.

Abstract: Methods for preparing dry powders having hydrophobic and hydrophilic components comprise combining solutions of the components and spray drying them simultaneously in a spray dryer. The hydrophilic and hydrophobic component are separately dissolved in separate solvents and directed simultaneously through a nozzle, usually a coaxial nozzle, into the spray dryer. The method provides dry powders having relatively uniform characteristics.

Abstract: A production method for producing granulated materials comprises sampling step for sampling at predetermined time intervals diffracted and/or scattered light from growing particles under granulation in a granulation tank as measured particle size distribution data by applying beam light to the growing particles, calculating step for calculating the size of particle from the measured particle size distribution data by applying a specific algorithm, comparison step for comparing the particle size from the measured particle size distribution data with that from the particle size distribution objective data prepared in advance, and correction step for adding change to basic feedback control for granulation process in accordance with the result of the comparison step.

Abstract: A process for producing atomized powder, such as a metal powder, using a recirculating atomization gas, such as helium, and the apparatus used for producing the atomized powder

Abstract: The invention provides a method and apparatus for forming particles of a substance, comprising (a) introducing into a particle formation chamber, the temperature and pressure in which are controlled, a first supercritical fluid (SCF) and a solution or suspension of the substance in a vehicle; (b) simultaneously introducing an impinging flow of a second supercritical fluid (SCF), at an angle to, and directed at, the direction of flow of the first supercritical fluid, so as to increase the amount of kinetic energy transferred to the solution or suspension; and (c) using either or both of the first and the second supercritical fluids to disperse the solution or suspension, and to extract the vehicle from it, substantially simultaneously and substantially immediately on introduction of the fluids into the particle chamber.

Abstract: A process for preparing ultrafine powders of biological macromolecules comprises atomizing liquid solutions of the macromolecules, drying the droplets formed in the atomization step, and collecting the particles which result from drying. By properly controlling each of the atomization, drying, and collection steps, ultrafine dry powder compositions having characteristics particularly suitable for pulmonary delivery for therapeutic and other purposes may be prepared.

Abstract: An apparatus (46) for reconditioning a protective surface (30) of an optically-read digital recording disc (20) includes a turntable (48) configured to receive a center hole (24) of the disc (20) and a first motor (52), coupled to the turntable (48), for rotating the turntable (48) and the disc (20) at a first rotational speed. The apparatus further includes a buffing element (50) for removing an amount of material from the protective surface (30) as the turntable rotates the disc (20) and a second motor (54), coupled to the buffing element (50) for rotating the buffing element (50) at a second rotational speed. A timing element (56) synchronizes the first and second motors (52, 54) to substantially simultaneously cease rotation of the turntable (48) and the buffing element (50) following removal of an amount of material from the disc (20).

Abstract: The present invention is directed to particles, including liquid droplets and dry particulates, having a narrow particle size distribution made from a liquid feed stock. In particular, the invention is directed to producing particles of a desired median diameter and narrow particle size distribution without the need for additional separation processing. The process of the present invention can be tailored to produce substantially monodisperse particles or multimodal particles having well defined and controllable particle size distributions. The present invention is particularly well suited for producing particles for pulmonary administration.

Abstract: Methods for preparing dry powders having hydrophobic and hydrophilic components comprise combining solutions of the components and spray drying them simultaneously in a spray dryer. The hydrophilic and hydrophobic component are separately dissolved in separate solvents and directed simultaneously through a nozzle, usually a coaxial nozzle, into the spray dryer. The method provides dry powders having relatively uniform characteristics.

Abstract: A method for the agglomeration of alumina particles, the method comprising the steps of: adding a quantity of pseudo-boehmite to the alumina particles; and spray drying the mixture so formed to produce agglomerated granules.

Abstract: In insulator including alumina as a main component, a Na component in the insulator is set in the range of 0.07 to 0.5 wt % as Na2O. While the Na component content is as high as to have conventionally been regarded to be beyond the common sense, with this range of the Na component content, insulation resistance, mechanical strength and the like at high temperature are unexpectedly not reduced and an insulator with performances comparable to those of an insulator from conventional low soda alumina lower in Na component content than the above described range can be obtained. As a result, medium soda alumina and regular soda alumina that are much lower in cost than conventionally used low soda alumina can be used instead of the low soda alumina, so that dramatic reduction in production costs of insulator 2 for a spark plug 100 and in addition, of the spark plug 100 using the insulator 2 are realized.

Abstract: Microspheres are prepared by a process comprising the steps of (i) spray-drying a solution or dispersion of a wall-forming material in order to obtain intermediate microspheres and (ii) reducing the water-solubility of at least the outside of the intermediate microspheres. Suitable wall-forming materials include proteins such as albumin and gelatin. The microsphere have walls of 40-500 nm thick and are useful in ultrasonic imaging. The control of median size, size distribution and degree of insolubilisation and cross-linking of the wall-forming material allows novel microsphere preparations to be produced. In particular, the microspheres may be 15-20 &mgr;m, targeted to selected areas of the body or of prolonged life in the circulation.

Abstract: A process for the preparation of a powder coating composition, wherein 5-90% by weight of at least one monomeric compound selected from glycidyl group-containing unsaturated compounds and methylglycidyl group-containing unsaturated compounds is copolymerized with 95-10% by weight of an ethylenically unsaturated monomer in methanol to obtain a resin solution. The resin solution is spray-dried to obtain a powdery resin. Alternatively, the resin solution is fed to an extruder having a die and a plurality of vent ports and extruded through the die, while removing volatile matters through the vent ports, to obtain extrudates. The extrudates are pulverized to obtain a powdery resin.

Abstract: In a process for granulating and disintegrating molten slags, in particular blast furnace slags, with water, a compressed water jet is directed into the slag and the slag is ejected as the jacket of the compressed water jet. The device for carrying out the process comprises a slag vessel for molten slag including an outlet opening for the molten slag, wherein a lance opens into the axis of the slag outlet opening such that the molten slag is ejected by compressed water or vapor introduced through the lance.

Abstract: Plant for producing pressure die-cast or injection moulded articles having a unit for producing salt grains, a press for forming salt filler cores by compressing the said salt grains, a pressure die-casting machine for making the said articles by injecting a material in the liquid state into a mould having at least one salt filler core, and a salt removal and washing unit designed to remove the salt filler cores that have been trapped within the said articles; the said unit for producing salt grains being designed to atomize a saline solution which is supersaturated with salt into a plurality of drops so as subsequently to cause the salt present in solution/suspension in each drop of solution to solidify into a corresponding salt grain.

Abstract: A composite filtration medium web of fibers containing a controlled dispersion of a mixture of sub-micron and greater than sub-micron diameter polymeric fibers is described. The filtration medium is made by a two dimensional array of cells, each of which produces a single high velocity two-phase solids-gas jet of discontinuous fibers entrained in air. The cells are arranged so that the individual jets are induced to collide in flight with neighboring jets in their region of fiber formation, to cause the individual nascent fibers of adjacent jets to deform and become entangled with and partially wrap around each other at high velocity and in a localized fine scale manner before they have had an opportunity to cool to a relatively rigid state. The cells are individually adjusted to control the mean diameters, lengths and trajectories of the fibers they produce.

Abstract: The invention relates to a method and apparatus for the production of double-walled hollow sections by means of internal high-pressure forming, a first hollow section being inserted into a second hollow section, after which the double-walled hollow section thus formed is subjected to high internal fluid pressure in such a way in an internal high-pressure forming die that the double-walled hollow section is expanded. During this process, an air gap is formed between the first, inner, hollow section and the second, outer, hollow section.

Abstract: Provided is a compressed anti-solvent technique for manufacture of drug-containing powders for pulmonary delivery. The drug is processed in a cosolvent system including two or more mutually soluble organic solvents. Also provided are powders manufacturable by the manufacture method, including powders of substantially pure drug and powders including a biocompatible polymer for pulmonary sustained drug release applications. Also provided are packaged products including drug-containing powder in a container that is receivable by and operable with a dry powder inhaler to produce an aerosol including dispersed drug-containing particles when the inhaler is actuated.

Abstract: A process for producing pulverous, i.e., powdered, preparations from sparingly soluble solid materials is disclosed. The process utilizes dimethyl ether under conditions of elevated temperature and pressure to dissolve the solid material. Upon release of the pressure, the solid material precipitates as a fine powder and the gaseous dimethyl ether is released or drawn off.

Abstract: A method of producing magnesium chloride granules with a particle size in the range from 0.4 to 3.0 mm suitable for fluidization, air drying and chlorinating to anhydrous state, by preparing a feed solution of MgCl2 having a 30-55% by weight of MgCl2, feeding the solution and keeping it at high temperatures from the feeding tank to the nozzles, atomisation of the feed solution into the bed of already dried particles by pressure or compressed air, passing preheated air upwardly through the bed, maintaining the particles in a fluidizing state and a bed temperature between 100-170° C., continuously recovering entrained particles in a cyclone, discharging magnesium chloride particles continuously, classifying discharged material and recycling of any undersized fraction and crushed oversize fraction together with fines from the cyclone to the fluid bed for further granulation.

Abstract: Ceramic powder (50) may be disposed within a flexible mold (30 and 130) to form a dense ceramic wafer (60) by hydrostatic pressing. The ceramic powder (50) may include various types of pyroelectric material or bolometric material. One or more substrates (20 and 24) may be disposed within the flexible mold (30 and 130) to form the desired dense ceramic wafer (60). The flexible mold (30 and 130) may be placed in one or more vacuum sealed bags (38) prior to hydrostatic pressing. Also, a vibration table (70) may be used to minimize any void spaces in the ceramic powder (50) prior to hydrostatic pressing.

Abstract: The present invention provides a novel group of particles for air filter inspection which solves problems caused by volatilization and scattering of those particles at the downstream side of the air filter in use, enables an air filter inspection with superior stability and reproducibility, and may be produced by using a comparative inexpensive manufacturing device, and manufacturing methods as well as inspection methods of such a group of particles. The group of particles for air filter inspection consists of a plurality of aggregate particles having a particle size of not less than 0.1 &mgr;m, each aggregate particle being constituted by solid primary particles having an average particle size of less than 55 nm.

Abstract: Polymer microparticles suitable for gel chromatography are formed by spraying a composition of a thermally-gelling polymer in an aqueous medium into ambient air and allowing the atomized composition to gel in the air. The gelled microparticles have a gel strength sufficient to preserve the structural integrity of the gelled microparticle upon collection thereof.

Abstract: The present invention provides fibril system fibers which may be employed in filter applications and in artificial leather applications, and also provides an industrially superior manufacturing method for such fibril system fibers, and a spinning nozzle. The fibril fibers of the present invention include at least one macromolecular polymer having a film forming ability, and they have a structure in which fibrillated fibers having a diameter of 10 micrometers or less branch from main fibers having a width within a range of 0.1 micrometers-500 micrometers, and a length within a range of 10 micrometers-10 cm.

Abstract: Systems, apparatus combinations and methods for producing a powder coating are provided wherein a stream of a powder coating precursor including at least one resin and at least one additional powder coating ingredient is contacted with a process fluid effective to reduce the viscosity of the powder coating precursor to allow processing of the powder coating precursor at a lower temperature.

Abstract: Relatively viscous glass is fiberized in a rotary fiberization process at relatively high disk speeds and through relatively large diameter holes to form long, fine diameter glass fibers which preferably are rapidly solubilized in biological fluids. The method of forming the long, fine diameter glass fibers includes maintaining a ratio of the velocity of the external surface of the peripheral wall of the fiberizing disk to the velocity of the glass passing through the fiberizing orifices within a specific range (the disc/glass velocity ratio); maintaining a ratio of the velocity of the air exiting the air ring to the velocity of the glass passing through the fiberizing orifices within a specific range (the air-ring/glass velocity ratio); and maintaining a ratio of the BTU content of the fuel expended forming the hot attenuating combustion gases to the BTU content of a pound of molten glass being fiberized within a specific range (the attenuating combustion gases/glass heat content ratio).

Abstract: A process for producing pulverous, i.e., powdered, preparations from sparingly soluble solid materials is disclosed. The process utilizes dimethyl ether under conditions of elevated temperature and pressure to dissolve the solid material. Upon release of the pressure, the solid material precipitates as a fine powder and the gaseous dimethyl ether is released or drawn off.

Abstract: The present invention relates to a process for the preparation of a mixture of cellulosic fibers and microfibers. Said process comprises: the preparation of a cellulosic solution (C); the extrusion of said solution (C) through the hole or holes of a die (1); the disintegration of said solution (C) when it comes out of said hole or holes by projecting a liquid or gas fluid (F) in a direction making an angle lower than or equal to 75 degrees with the axis of said die (1); said fluid (F) being neutral or appropriate to regenerate or precipitate, only partially, the cellulose; the reception in a cellulose regeneration or precipitation bath, of the dispersion generated at the disintegration step; the recovery of the mixture of fibers and microfibers, more or less bonded, obtained in said bath. Said process provides for the preparation of mixtures rich in microfibers (with a fineness lower than 1 dtex, particularly between 0.5 and 0.3 dtex).

Abstract: In order to produce aluminium oxide beads, an acid aluminium oxide sol or an acid aluminium oxide suspension is converted into droplets by a vibrating nozzle plate and pre-solidified after the formation of a bead shape by laterally blowing gaseous ammonia and then coagulated in an ammonia solution.

Abstract: A composite filtration medium web of fibers containing a controlled dispersion of a mixture of sub-micron and greater than sub-micron diameter polymeric fibers is described. The filtration medium is made by a two dimensional array of cells, each of which produces a single high velocity two-phase solids-gas jet of discontinuous fibers entrained in air. The cells are arranged so that the individual jets are induced to collide in flight with neighboring jets in their region of fiber formation, to cause the individual nascent fibers of adjacent jets to deform and become entangled with and partially wrap around each other at high velocity and in a localized fine scale manner before they have had an opportunity to cool to a relatively rigid state. The cells are individually adjusted to control the mean diameters, lengths and trajectories of the fibers they produce.

Abstract: An improved method and apparatus for producing flexible fibers (30) of superconducting material includes a crucible (12) for containing a charge of the superconducting material. The material is melted in the crucible (12) and falls in a stream (18) through a bottom hole (16) in the crucible (12). The stream (18) falls through a protecting collar (22) which maintains the stream (18) at high temperatures. The stream (18) is then supplied through a downwardly directed nozzle (26) where it is subjected to a high velocity of a heated gas (36′) which breaks the melted superconducting material into ligaments which solidify into the flexible fibers (30). The fibers (30) are collected by directing them against a collection filter (32).

Abstract: Atomized particles within a desired size range (e.g., 1 micron to about 5 microns) are produced from two immiscible fluids, a first fluid source containing the formulation to be atomized, and a second fluid source which is contained in a pressure chamber surrounding at least the area where the first liquid is to be provided. Upon presentation of the first fluid source to the second, the second fluid is forced out of an opening positioned in front of the flow path of the formulation. The first and second fluids interact dynamically to form a stable capillary microjet, which in turn results in the formation of a focusing funnel at the opening. Formulation passing through this a focusing funnel will atomize upon exiting the opening of the pressurized chamber without physically contacting the perimeter of the opening.

Abstract: The present invention relates to an atomization apparatus and method for the formation of substantially uniform, at least nearly spherical particles, particularly for the formation of metal particles. 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 in an upward direction. This produces uniform droplets having an initial velocity sufficient to increase the residence time of the droplets in an inert atmosphere. The parabolic trajectory of the droplets over a 2 m vertical displacement is approximately five times longer than a freefall, thus significantly increasing the cooling time without increasing the cooling chamber height. Further the kinetic energy of each droplet is much lower throughout its trajectory which serves to improve the formation of spherical shaped particles and to lower the impact velocity.

Abstract: An improved method for injection molding fine particulate inorganic materials that first spray dries a fine particulate inorganic material and then mixes the dried particulate inorganic material with a binder system to form a compounded material. The compounded material is then injected, at a low pressure into a mold to form a green part. The green part is then debinded to remove most of the binder system and the debinded green part is then sintered to form the final molded part.

Abstract: Method for producing salt grains in which the salt is dissolved in a liquid solvent inside a mixing tank so as to form a saline solution which is supersaturated with salt and which is then atomized inside a drying tower where a stream of hot air circulates; the atomizing process being designed to produce a plurality of drops of saline solution, all of approximately the same size, and the stream of hot air being designed to evaporate the liquid solvent contained in each drop so as to cause the salt present in the said drop to solidify into a salt grain of essentially spherical shape; given that the dimensions of the salt grains depend on the dimensions of the drops of saline solution, it is possible to obtain salt grains of the desired size by producing drops of saline solution of a suitable size during the atomizing process.

Abstract: A super-low temperature plastic powder manufacturing method for continuous production of thermo-plastic powder with granule sizes smaller than 10 microns. The method includes the steps of material melting wherein coarse granular thermo-plastic material is melted to form a plastic solution, high air pressure blowing for separation wherein high pressure air is injected to impact the plastic solution to cool and harden it gradually into micro-granules and to thereby reduce its adhesive strength, super-low temperature liquid nitrogen impacting for brittling wherein super low temperature liquid nitrogen is used to reduce the temperature of the plastic micro-granules, and low temperature calendaring. The reduced temperature greatly reduces elongation, impact strength, and fracture resistance of the plastic micro-granules for easier processing.