SBIR Phase I: Mid-Infrared Diode Laser Sensor for Pharmaceutical Manufacturing

这个小企业创新研究第一阶段项目解决了制药制造中对端点监测溶剂干燥过程的实时手段的迫切需求。具体的创新是结合了一种新颖的、可广泛调谐的中红外二极管激光源和超灵敏的吸收技术，为感应流化床干燥器和喷雾涂布机中的微量有机溶剂蒸汽浓度提供了一种非接触手段。探头激光源利用差频产生（DFG）将可见光和近红外激光转换为中红外。它的连续调谐能力超过200厘米-1，使有机蒸汽的测量具有宽，红外吸收波段接近3.5微米。第一阶段的目标是使用DFG源来测量有机溶剂蒸气，确定分析仪的检测限，并为工业传感器创建初步设计。第一阶段计划将验证中红外溶剂监测器的技术和商业可行性。提议的溶剂干燥终点监测器将为制药行业提供实时数据，从而提高药品制造过程的效率和质量。该传感器可以消除离线残留溶剂分析的需要，这种分析通常会停止处理，并保留完成的产品等待放行。该技术有许多应用，包括有机污染物的环境监测、工业暖通空调控制、呼吸分析、医院空气和气体质量控制以及用于筛选酒精和其他有毒物质的传感器。

This Small Business Innovative Research Phase I project addresses an immediate need for a real-time means of endpoint monitoring solvent drying processes in pharmaceutical manufacturing. The specific innovation is the combination of a novel, broadly tunable, mid-infrared diode laser source with ultra-sensitive absorption techniques, to provide a non-contact means for sensing trace organic solvent vapor concentrations in fluidized bed dryers and spray coaters. The probe laser source utilizes Difference Frequency Generation (DFG) to convert visible and near-infrared laser light to the mid-infrared. Its ability to continuously tune over 200 cm-1 enables the measurement of organic vapors having broad, infrared absorption bands near 3.5 microns. The Phase I objectives are to use the DFG source to measure organic solvent vapors, determine analyzer detection limits, and create a preliminary design for an industrial sensor. The Phase I program will verify the technical and commercial feasibility of the mid-infrared solvent monitor. The proposed solvent drying endpoint monitors will provide the pharmaceutical industry with real-time data enabling improved drug manufacturing process efficiency and quality. The sensors may eliminate the need for off-line residual solvent analysis that often halts processing and holds completed product for release. There are numerous applications for the technology, including environmental monitoring of organic pollutants, industrial HVAC controls, breath analysis, hospital air and gas quality control and sensors to screen for alcohol and other toxics.