Co-extruded Hybrid Encapsulation for Sensitive Ingredients
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Solution Overview
Problem
Current encapsulation techniques often require heat, solvents, or specific conditions that can damage sensitive materials and limit the variability and efficiency of encapsulation, particularly for sensitive ingredients.
Innovation Solution
A method involving the coextrusion of a crosslinkable inorganic-organic hybrid polymer precursor around the ingredient, followed by rapid crosslinking, typically using UV radiation, to create encapsulation structures without temperature changes or solvent exposure, allowing for gentle and efficient encapsulation with high variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional encapsulation techniques (extrusion, spray drying, rotating disc) are used, then encapsulation can be achieved, but heat and solvents must be applied which can damage sensitive materials
Solution Approach 1:
The invention changes the temperature parameter from elevated (conventional) to ambient or low temperature, and eliminates solvent usage entirely. The crosslinkable precursor material is applied at ambient temperature and crosslinked in situ without solvents, thereby protecting sensitive materials from thermal and chemical damage while achieving complete encapsulation.
Solution Approach 2:
The invention replaces thermal and chemical encapsulation mechanisms with a photochemical or catalytic crosslinking mechanism. Instead of using heat to cure the encapsulation material or solvents to facilitate coating, the patent uses UV radiation or other energy sources to initiate crosslinking of the precursor material directly on the substrate, eliminating harmful thermal and solvent effects.
2Productivity
If emulsion process/coacervation is used, then high economic efficiency is achieved, but encapsulation efficiency and purity are low
Solution Approach 1:
The invention applies segmentation by first forming a complete encapsulation shell around the substrate using the crosslinkable precursor material, then subsequently filling the enclosed space with the active substance. This two-stage approach ensures complete encapsulation and high purity, as the shell is formed first to prevent contamination, followed by controlled filling, achieving both high productivity and high purity.
3Reliability
If silica-based materials are used for encapsulation, then encapsulation can be achieved, but strongly basic conditions are required which can contaminate or destroy active components
Solution Approach 1:
The invention changes the pH parameter from strongly basic (required for silica-based materials) to neutral or mild conditions. The crosslinkable precursor material system operates effectively at ambient pH or with mild catalysis, eliminating the need for strongly basic conditions that would damage or contaminate sensitive active components while still achieving complete encapsulation.
4Adaptability or versatility
If conventional encapsulation methods are used, then encapsulation is achieved, but the process is active substance-specific and limited in variability
Solution Approach 1:
The invention achieves universality by using a single crosslinkable precursor material system that can encapsulate diverse active substances including liquids, pastes, and solids across different pH ranges and sensitivities. The same basic process—applying the precursor material and initiating crosslinking—works for a wide variety of substrates and active ingredients, providing high adaptability without requiring multiple specialized processes.
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 method enables encapsulation with high efficiency and purity, avoiding contamination and temperature changes, and allows for the creation of stable capsules with thin walls and variable geometries, suitable for a wide range of applications.
Implementation Method 1
rapid crosslinking, typically using UV radiation
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to a method for encapsulating a liquid or pasty substance in a cross-linked encapsulation material, characterized in that the liquid or pasty substance and an inorganic-organic hybrid material which is at least partially subjected to inorganic condensation or which can be subjected to organic polymerization are used as a cross-linkable precursor material of the encapsulation material and are co-extruded through a nozzle such that the cross-linkable precursor material surrounds the liquid or pasty substance, the co-extruded material being then passed through a zone in which the precursor material is cross-linked. According to preferred embodiments, the precursor material for the encapsulation material can be produced by hydrolytic condensation from or using silanes of the formula RaR'bSiX4-a-b, wherein R, R' and X are the same or different and wherein R is a group that can be bound to the silicon via carbon and that can be organically cross-linked under the effect of heat or actinic radiation, R' is a group that is bound to the silicon via carbon and that cannot be organically cross-linked, X is a group that can be hydrolyzed under conditions of hydrolysis or that can be separated from the silicon, or it is OH, a is 1 or 2, b is 0 or 1 and a+b is 1 or 2. Optionally inorganic hollow spheres or hollow fibers can be produced by burning the organic components of the capsules or fibers obtained in this manner and evaporating their content.