Biodegradable Microcapsule Composition for Stable Hydrophobic Encapsulation
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Solution Overview
Problem
Existing microcapsules made from polymeric materials pose environmental risks due to microplastic pollution and struggle to balance stability and biodegradability, affecting the release and retention of hydrophobic active ingredients.
Innovation Solution
The development of biodegradable microcapsules using a combination of polysaccharides and proteins, crosslinked with polyisocyanates, to form a stable capsule shell that encapsulates hydrophobic active ingredients, ensuring efficient encapsulation and targeted release while being environmentally friendly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional microcapsule preparation methods are used, then microcapsules can be produced, but the process requires multiple separate steps (core formation, wall material application, drying) which reduces productivity and increases manufacturing complexity
Solution Approach 1:
The patent combines core formation, wall material application, and drying steps into a single spray drying operation. The core material solution is sprayed directly into the drying chamber where solvent evaporation occurs simultaneously with wall material deposition, eliminating the need for separate batch-wise operations and significantly improving productivity while reducing process complexity
Solution Approach 2:
The patent prepares the core material as a pre-formulated solution with appropriate solvent and concentration before the spray drying process. This preliminary preparation allows the core to be formed directly during the spray drying operation rather than requiring separate core formation steps, thereby streamlining the overall process
2Manufacturing precision
If conventional batch-wise methods are used, then microcapsules can be produced with controlled properties, but the process is time-consuming and difficult to scale up
Solution Approach 1:
The patent replaces conventional mechanical batch processing with a continuous spray drying system. The spray drying process uses fluid dynamics and heat transfer mechanisms to achieve continuous production while maintaining precise control over microcapsule properties through parameters such as spray rate, drying temperature, and airflow patterns, thereby reducing production time without sacrificing manufacturing precision
Solution Approach 2:
The patent utilizes parameter changes during the spray drying process to control microcapsule properties. By adjusting drying temperature, spray concentration, and airflow rate, the process achieves precise control over wall thickness, core material distribution, and microcapsule size while operating in continuous mode rather than batch-wise, significantly reducing production time
3Reliability
If multiple processing steps are used, then microcapsule quality can be controlled, but the process generates more waste and requires more extensive equipment
Solution Approach 1:
The patent implements a continuous spray drying process where core material solution is continuously sprayed and dried in a single pass. This continuous operation eliminates the material handling, transfer, and intermediate drying steps required in conventional batch processes, reducing material waste while maintaining microcapsule quality through consistent process parameters throughout continuous operation
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate steps from the conventional multi-step process. By removing separate core formation, wall application, and drying steps, the spray drying process reduces material waste associated with intermediate handling and equipment while maintaining quality control through direct observation and adjustment of the single-step process
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
The polysaccharide-protein-polyisocyanate microcapsules provide stable encapsulation with controlled release and good biodegradability, reducing environmental impact by minimizing microplastic pollution and maintaining effective performance.
Implementation Method 1
spray drier which forms the core material by evaporation of a solvent
Implementation Method 2
spray drier which forms the core material by evaporation of a solvent
Implementation Method 3
atomizer for forming the core material in a spray drier
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The present invention relates to a process for the preparation of biodegradable microcapsules, in particular biodegradable protein- and/or polysaccharide-based microcapsules, as well as dispersions of such microcapsules (microcapsule slurry) that enclose at least one hydrophobic active ingredient. In addition, the present invention relates to biodegradable microcapsules obtainable by the process according to the invention. In another aspect, the present invention relates to the use of the microcapsules and dispersions as an ingredient in consumer products.