Spin encapsulation apparatus and method of use

An encapsulation apparatus for forming capsules containing particles to be coated, said apparatus comprising in combination:

• a) spinning means for forming beads and for projecting them centrifugally outward, said spinning means being adjustably rotatable at a preselected first rotational speed;
• b) collection basins adapted for substantially surrounding said spinning means, and being adjustably rotatable at a preselected second rotational speed;
• c) said collection basins being rotatable independently from said spinning means and positioned to collect said beads projected from said spinning means;
• and
• d) said first and second rotational speeds being selected so as to minimize the impact of said beads against a gelling solution in said collection basins;
• wherein there are two or more collection basins of different sizes;
• and
• wherein said collection basins are adjacently vertically disposed relatively to each other, such that the sizes of said collection basins gradually increase.

An encapsulation apparatus comprising in combination:

• a) a cup-shaped member that is rotatably mounted about an axis for spinning a fluid suspension therein, said cup-shaped member having an open end and a closed end,
• said closed end being a mixing chamber for receiving a suspension of the particles to be encapsulated and an encapsulating solution,
• said mixing chamber extending into an upper chamber bound by a conical sidewall terminating at an upper end of the block,
• said conical sidewall of said upper chamber forming an angle in a range between 10.degree. and 90.degree. degrees with a central axis of the mixing chamber,
• said cup-shaped member being positioned within a block connected to a first rotor for connection to a first motor providing a first rotational speed;
• the first rotor coupled to said cup-shaped member for rotating said member at she first rotational speed;
• b) one or more collection basins rotatably mounted about said cup-shaped member, said collection basins comprising;
• a collection basin block;
• an annular gelation chamber;
• an annular collection chamber;
• and
• a trough;
• wherein the block is connected to a second rotor for connection to a second motor providing said second rotational speed;
• wherein the annular gelation chamber is defined within the block having a substantially flat upper rim extending generally horizontally and radially from a central axis into a vertical or lateral sidewall, said sidewall extending into a first conical or beveled edge of the annular collection chamber;
• wherein the collection chamber is defined by the first beveled edge and a second beveled edge generally symmetrical to the first beveled edge with respect to a central geometric axis of the trough and wherein the second beveled edge extends radially into a substantially flat lower rim or edge parallel to said upper rim, said lower rim extending inward toward the block of the rotary cup;
• wherein the trough is conically shaped;
• said gelation chamber being adapted for containing a gelling solution, said gelation chamber being radially spaced from said open end of the cup-shaped member;
• and
• the second rotor coupled to said collection basing for rotating said collection basins at the second rotational speed,
• said collection basins being rotatable independently from said cup-shaped member and positioned to collect said beads projected from said rotary cup;
• and
• said first and second rotational speeds being selected so as to minimize the impact of said beads against a gelling solution present in said gelation chamber of said collection basins.

An encapsulation apparatus comprising in combination:

• a cup-shaped member that is rotatably mounted about an axis for spinning a fluid suspension therein, said cup-shaped member having an open end and a closed end;
• a first drive coupled to said cup-shaped member for rotating said member at a first speed;
• a basin rotatably mounted about said cup-shaped member, said basin including a chamber adapted for containing a gelling solution, said chamber being radially spaced from said open end of the cup-shaped member;
• and
• a second drive coupled to said basin for rotating said basin at a second speed,
• said apparatus further including a second basin that is rotatably mounted above said first basin, said second basin including a chamber, said cup-shaped member being movable from a first position where its said open end is radially spaced from said first basin chamber to a second position where its said open end is radially spaced from said second basin chamber.

Microcapsules containing biological tissue, cells, cell lines, solid or semisolid particle materials coated with a uniform, thin, continuous and semipermeable coating having a thickness from about 20 to about 200.mu. and a high degree of control and reproducibility of said coating at a rapid production of said microcapsules produced by an encapsulation process comprising steps:

• a) preparing a suspension comprising a material to be coated and a coating gellable polymer;
• b) delivering said suspension into a mixing chamber of a rotary cup of a spinning disk apparatus;
• c) forming beads of the suspension by rotating the rotary cup of the spinning disk apparatus at a preselected first rotational speed suitable to propel the suspension by a centrifugal force from the mixing chamber along a textured inner wall of a conical sidewall of the rotary cup conical sidewall thereby forming the beads;
• d) projecting said beads centrifugally outwardly from the conical sidewall into a collection basin containing a gelling solution wherein said collection basin is rotating at a preselected second rotational speed selected to minimize an impact of the beads against the gelling solution;
• e) gelling the gellable coating polymer;
• and
• f) recovering coated microcapsules from a collection chamber of said collection basin.