Combined synthesis and in situ coating of nanoparticles in the gas phase

Combined gas phase synthesis and coating of sodium chloride (NaCl) and lactose nanoparticles has been developed using an aerosol flow reactor. Nano-sized core particles were produced by the droplet-to-particle method and coated in situ by the physical vapour deposition of L-leucine vapour. The saturation of L-leucine in the reactor determined the resulting particle size and size distribution. In general, particle size increased with the addition of L-leucine and notable narrowing of the core particle size distribution was observed. In addition, homogeneous nucleation of the vapour, i.e. formation of pure L-leucine particles, was observed depending on the saturation conditions of L-leucine as well as the core particle characteristics. The effects of core particle properties, i.e. size and solid-state characteristics, on the coating process were studied by comparing the results for coated NaCl and lactose particles. During deposition, L-leucine formed a uniform coating on the surface of the core particles. The coating stabilised the nanoparticles and prevented the sintering of particles during storage.