Capsule with Intermediate Phase for Polyelectrolyte Shell Formation
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Solution Overview
Problem
Existing methods for encapsulating liquids in capsules with gelled shells struggle with formulations containing ions, high alcohol concentrations, or low pH levels, making it difficult to form capsules with narrow shells that effectively release their contents.
Innovation Solution
The method involves creating capsules with a liquid core containing an intermediate phase and internal drops, where the volume ratio of the core to the gelled shell is greater than 2, and the shell is formed by coating the liquid bodies with a polyelectrolyte solution that gels upon contact with a gelling solution, allowing for the formation of capsules with a thin, mechanically strong shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the coextrusion method with double wall is used to form capsules, then the shell thickness is narrow, but the method becomes tedious when encapsulating preparations that interact with polyelectrolyte liquid containing ions, high alcohol concentration, or low pH
Solution Approach 1:
The patent introduces an intermediate phase as a mediator between the internal phase and the polyelectrolyte solution. This intermediate phase acts as a protective barrier that prevents harmful interactions between the internal phase (containing ions, alcohol, or low pH) and the polyelectrolyte liquid, thereby enabling the successful formation of narrow-shelled capsules without degradation of the shell material
Solution Approach 2:
The capsule structure employs a composite design with multiple distinct phases: an internal phase, an intermediate phase, and a polyelectrolyte shell. This composite structure allows each layer to perform its specific function - the intermediate phase protects the polyelectrolyte from degradation while the shell provides the desired narrow thickness, resolving the contradiction between manufacturing ease and precision
2Productivity
If the volume ratio of core to gelled shell is increased to maintain thin shell for effective release, then the release effectiveness is improved, but the mechanical strength of the capsule may be reduced
Solution Approach 1:
The patent utilizes a gelled polyelectrolyte shell that forms a thin yet mechanically functional layer. The gel structure provides flexibility and adequate mechanical strength even at reduced thickness, enabling the shell to maintain structural integrity while allowing effective release of the internal phase when the capsule is subjected to physiological conditions
3Productivity
If the gelled shell is made thinner to ensure effective disintegration and release, then the release effectiveness is improved, but the mechanical retention capability may be reduced
Solution Approach 1:
The patent optimizes the parameters of the gelled shell including its thickness, cross-linking density, and polyelectrolyte concentration to achieve the desired balance. By carefully controlling these parameters, the shell maintains sufficient mechanical retention to hold the liquid core during handling while being thin enough to disintegrate effectively under physiological conditions for controlled release
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 approach enables the encapsulation of a wide variety of liquids while maintaining a thin shell for effective release, providing mechanical strength and controlled release of contents, even in challenging formulations.
Implementation Method 1
a gelled shell comprising a gelled polyelectrolyte completely encapsulating the liquid core at the periphery thereof
Implementation Method 2
pass from a liquid state in solution to a significantly more viscous state to form a gel
Data Source
AI summary
Each capsule comprises a liquid core (14) and a gelled shell (16) comprising a gelled polyelectrolyte completely encapsulating the liquid core (14) at the periphery thereof. The gelled shell (16) is suitable for retaining the liquid core (14) when the capsule (12) is immersed in a gas.The liquid core (14) comprises an intermediate drop (18) of an intermediate phase, the intermediate phase being placed in contact with the gelled shell (16), and at least one internal drop (20) of an internal phase placed in the intermediate drop (18). The ratio of the volume of the core (14) to the volume of the gelled shell (16) is greater than 2, advantageously is greater than 50.