Alginate Moulded Articles Production via Calcium Sulfate Suspension
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Solution Overview
Problem
Existing methods for producing large-sized, homogeneous alginate moulded articles with high wet strength and whiteness are hindered by issues such as inhomogeneous calcium ion incorporation, reliance on physiologically unacceptable additives, and difficulty in achieving uniform thickness and cuttability.
Innovation Solution
A process involving the mixing of an aqueous alginate solution with calcium sulfate in the presence of a mineral acid, followed by drying, which eliminates the need for foam-forming agents, surface-active agents, and borate buffers, while allowing for the production of thick, porous alginate layers with added carboxymethylcellulose and hyaluronic acid for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If calcium chloride is added to Na alginate solution to produce thicker layers, then the desired product thickness is achieved, but the solution viscosity increases and homogeneous incorporation of calcium ions becomes difficult, resulting in incoherent agglomerates
Solution Approach 1:
The patent uses calcium sulfate as an intermediary substance instead of directly adding calcium chloride to the alginate solution. The calcium sulfate is first dispersed in water to form a suspension, which then reacts with the alginate solution to gradually form calcium alginate. This intermediary approach prevents sudden viscosity increases and allows homogeneous incorporation of calcium ions throughout the thick layer, avoiding incoherent agglomerates while achieving the desired product thickness.
2Loss of time
If complexing agents are added to retard precipitation of calcium alginate, then immediate precipitation is delayed, but adequate retardation is not achieved on larger scales and the process becomes difficult to control
Solution Approach 1:
The patent extracts and eliminates complexing agents from the process entirely. Instead of using chemical additives to retard precipitation, the method relies on the physical dispersion of calcium sulfate in water and its controlled reaction with alginate solution. This extraction of harmful substances simplifies the process, makes it easily controllable on any scale, and allows adequate gelling time without requiring complexing agents or surface-active agents.
3Manufacturing precision
If surface-active agents are used to achieve adequate dispersion of components, then homogeneous dispersion is achieved, but intolerances and skin reactions may occur
Solution Approach 1:
The patent converts the potential harm of using surface-active agents into a benefit by completely eliminating them from the process. Instead of relying on chemical surfactants for dispersion, the method uses the natural properties of calcium sulfate suspension and alginate solution, combined with gentle mixing, to achieve homogeneous dispersion without any substances that could cause skin intolerance or allergic reactions.
4Shape
If calcium carbonate is used to form gas during production, then foam structure is created, but pore sizes cannot be controlled and pronounced inhomogeneities result
Solution Approach 1:
The patent replaces calcium carbonate with calcium sulfate, which does not produce gas during the reaction. This substitution eliminates the uncontrolled foam formation and associated inhomogeneities. The calcium sulfate suspension provides a stable, controllable matrix that reacts with alginate to form uniform calcium alginate structures without generating gas bubbles that would create unpredictable pore sizes and structural inhomogeneities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process enables the creation of large-sized, highly homogeneous, and cuttable alginate moulded articles with high wet tenacity and whiteness, suitable for cosmetic and medical applications, without the use of undesirable additives, and allows for the incorporation of active ingredients for controlled release.
Implementation Method 1
mixing an aqueous alginate solution with calcium sulfate in the presence of at least one mineral acid
Implementation Method 2
crosslinked in the presence of a foam-forming agent by the addition of polyvalent metal ions
Implementation Method 3
drying the mixture
Data Source
AI summary
The invention relates to a process for the production of alginate-containing porous or sponge-like moulded articles, and to the moulded articles obtainable thereby and their use.