Flash NanoPrecipitation of organic actives via confined micromixing and block copolymer stabilization

This dissertation provides a method and the understanding required to produce nanoparticles of organic actives using Flash NanoPrecipitation . The process comprises mixing a solvent phase containing molecularly dissolved amphiphilic block copolymer and an organic active with an anti-solvent. One block of the copolymer precipitates to alter the nucleation and growth of the organic active while the other remains in solution for particle stabilization. A custom built confined impinging jets (CIJ) mixer provides optimum micromixing at the laboratory or full scale within milliseconds. Comparison to other reactor designs is provided. The resulting nanoparticles have functional surfaces tailored to meet the needs of pharmaceutical or specialty chemical formulations. Example β-carotene nanoparticles with a polyethylene oxide surface are produced at high concentration, high yield, low stabilizer content, and a size suitable for sterile filtration or larger.; The technical challenges in nanoparticle production are explained via the characteristic times for mixing, copolymer aggregation, and organic active particle formation. The time for Flash NanoPrecipitation is shown to depend strongly on the time for copolymer aggregation, and control of the organic nucleation versus growth is critical to achieve nanoparticles. Mixing operating lines explain the impact of solubility differences between the colloidal stabilizer and the organic active as function of mixing rate. Techniques to measure the solubility of the copolymer and ΔG° , ΔH°, and ΔS° of micellization are demonstrated.; An analytical CIJ mixer is developed by quantifying the characteristic time and physical mechanism of mixing. The methodology described to find an absolute mixing lifetime is also applied to a vortex mixer at a spectrum of flow ratios away from one. Dimensional analysis using the process Damköhler number, defined as the ratio of the mixing to the process time, is applied to precipitation to quantify the induction time through knowledge of the mixing lifetime. Copolymer aggregation without an organic active to kinetically frozen nanoparticles occurs by a “fusion only” mechanism. By analogy to classical precipitation kinetics, the interfacial free energy of a diblock copolymer nanoparticle is determined for the first time. The composite dissertation provides a clear picture of Flash NanoPrecipitation for future research and applications.