A microfluidic emulsion droplet generation system and methods of use thereof are provided. The system may include a microfluidic substrate having a flow path configured and arranged for emulsion droplet generation, at least one textured surface in the flow path configured and arranged for inducing surface-mediated coalescence of emulsion droplets; and at least one channel junction in the flow path for emulsion droplet formation.

A microfluidic emulsion droplet generation system and methods of use thereof are provided. The system may include a microfluidic substrate having a flow path configured and arranged for emulsion droplet generation, at least one textured surface in the flow path configured and arranged for inducing surface-mediated coalescence of emulsion droplets; and at least one channel junction in the flow path for emulsion droplet formation.

In the present invention, two adjacent supply lines for supplying two immiscible fluids are spirally disposed on a substrate where microchannels for microsphere production based on a droplet-based highly controlled method for mass-production of microspheres (HCMMM) are formed, and microsphere forming parts each comprising microchannels are arranged between and along the two supply lines, whereby a much larger amount of microspheres can be produced. Further, the two supply lines are disposed in a spiral configuration, and the microsphere forming parts can be disposed by branching microchannels from the two supply lines on inner and outer sides of the spiral configuration, whereby the limited space on a wafer normally having a circular shape can be maximally used to form multiple microsphere forming parts.

Powderized solid-state electrolytes and electroactive materials as well as related methods of manufacturing and use are disclosed. In one embodiment, an ionically conductive powder comprises a plurality of ionically conductive particles. The ionically conductive particles may comprise an ionically conductive salt dissolved in a thermoplastic polymer, with optional components (e.g.,electroactive and/or inorganic solid particles) dispersed within. Related methods of producing these ionically conductive powders are also disclosed including, but are not limited to, low-temperature milling, spray drying, and aerosol polymerization. Embodiments related to using the resultant ionically conductive powders in a spray deposition process are also described.

A method and apparatus for freezing a liquid droplet includes dispensing, by a liquid dispenser, a droplet of liquid into a fluid chamber containing a freezing liquid. The droplet of liquid is allowed to dwell in the freezing liquid for at least a predetermined dwell time so that the droplet of liquid freezes to a frozen droplet. The method and apparatus further includes injecting, by a gas injector, a stream of gas transversely to a surface of the freezing liquid at about where the frozen droplet is located along the surface of the freezing liquid contained in the fluid chamber so that the frozen droplet sinks in the freezing liquid.

A method and apparatus for freezing a liquid droplet includes dispensing, by a liquid dispenser, a droplet of liquid into a fluid chamber containing a freezing liquid. The droplet of liquid is allowed to dwell in the freezing liquid for at least a predetermined dwell time so that the droplet of liquid freezes to a frozen droplet. The method and apparatus further includes injecting, by a gas injector, a stream of gas transversely to a surface of the freezing liquid at about where the frozen droplet is located along the surface of the freezing liquid contained in the fluid chamber so that the frozen droplet sinks in the freezing liquid.

The invention provides methods for the preparation of particles including one or more agents, e.g., therapeutic or diagnostic agents. The particles can be formed by creating droplets of a first liquid, e.g., including an agent, and removing the first liquid, e.g., through its dispersal in a second liquid and/or evaporation, to solidify the droplets. Advantageously, the process of forming the particles does not significantly alter the structure or activity of the agents and may enhance the stability of the agents. For example, the particles may be stored for long periods of time without significant loss of activity, and in some embodiments, without the need for refrigeration. These particles may be used to generate stabilized pharmaceutical compositions for storage or other logistical purposes, pharmaceutical suspensions, pharmaceutical powder formulations (e.g., inhalable powders, injectable powders), creams or other topical pastes, nutraceuticals, or cosmetics.

The invention provides methods for the preparation of particles including one or more agents, e.g., therapeutic or diagnostic agents. The particles can be formed by creating droplets of a first liquid, e.g., including an agent, and removing the first liquid, e.g., through its dispersal in a second liquid and/or evaporation, to solidify the droplets. Advantageously, the process of forming the particles does not significantly alter the structure or activity of the agents and may enhance the stability of the agents. For example, the particles may be stored for long periods of time without significant loss of activity, and in some embodiments, without the need for refrigeration. These particles may be used to generate stabilized pharmaceutical compositions for storage or other logistical purposes, pharmaceutical suspensions, pharmaceutical powder formulations (e.g., inhalable powders, injectable powders), creams or other topical pastes, nutraceuticals, or cosmetics.

Cryogranulation systems with improved dispenser assemblies are provided for use in manufacturing frozen pellets of pharmaceutical substances in a fluid medium. Methods of cryogranulating the pharmaceutical substance in the fluid medium are also provided. In particular embodiments, the dispenser assembly is used with suspensions or slurries of pharmaceutical compositions including biodegradable substances, such as proteins, peptides, and nucleic acids. In certain embodiments, the pharmaceutical substance can be adsorbed to any pharmaceutically acceptable carrier particles suitable for making pharmaceutical powders. In one embodiment, the pharmaceutical carrier can be, for example, diketopiperazine-based microparticles. The dispenser assembly improves the physical characteristics of the cryopellets formed and minimizes product loss during processing.

Cryogranulation systems with improved dispenser assemblies are provided for use in manufacturing frozen pellets of pharmaceutical substances in a fluid medium. Methods of cryogranulating the pharmaceutical substance in the fluid medium are also provided. In particular embodiments, the dispenser assembly is used with suspensions or slurries of pharmaceutical compositions including biodegradable substances, such as proteins, peptides, and nucleic acids. In certain embodiments, the pharmaceutical substance can be adsorbed to any pharmaceutically acceptable carrier particles suitable for making pharmaceutical powders. In one embodiment, the pharmaceutical carrier can be, for example, diketopiperazine-based microparticles. The dispenser assembly improves the physical characteristics of the cryopellets formed and minimizes product loss during processing.