Flexible, porous, dissolvable solid sheet article containing direct-added microcapsules and process for making the same
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Solution Overview
Problem
Flexible and dissolvable sheets containing perfume microcapsules (PMCs) experience gelling issues and incomplete dissolution under stringent washing conditions, leading to undissolved residues, especially when multiple layers are assembled.
Innovation Solution
Directly add the microcapsule slurry into a wet pre-mixture before aeration and drying to form the sheet, utilizing the aeration and drying steps to protect and retain the microcapsules, preventing excessive water from dissolving the open-celled foam structure and ensuring complete dissolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If microcapsule slurry is added after sheet formation (Post-Added method), then microcapsule structural integrity is preserved, but excessive water in slurry dissolves open-celled foam structure causing gelling and incomplete dissolution
Solution Approach 1:
The microcapsule slurry is added to the wet pre-mixture before the aeration and drying steps that form the sheet structure. This preliminary incorporation allows the microcapsules to be embedded in the matrix before excessive water can dissolve the open-celled foam structure, preventing gelling while protecting microcapsule integrity through the suspended protection mechanism.
2Reliability
If microcapsule slurry is added to wet pre-mixture (Direct-Added method), then sheet dissolution is improved and gelling reduced, but microcapsules may rupture under heat, pressure and shear force during sheet-forming process
Solution Approach 1:
The viscous wet pre-mixture and air bubbles generated during aeration function as a protective cushion around the microcapsules before they are subjected to processing stresses. This beforehand cushioning suspends and protects the microcapsules against external pressure and shear forces during the sheet-forming and drying process, preventing premature rupture while maintaining dissolution properties.
3Quantity of substance
If multiple layers of sheets with Post-Added PMCs are assembled, then required dosage of surfactants is achieved, but gelling issue is exacerbated leading to undissolved residues
Solution Approach 1:
By incorporating microcapsule slurry into the wet pre-mixture before sheet formation, the dissolution profile is improved at the individual sheet level. When multiple layers are assembled, each layer maintains its dissolution capability, preventing the cumulative gelling effect that occurs with Post-Added method, thereby ensuring complete dissolution while achieving required surfactant dosage.
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 method enhances dissolution profile and reduces gelling, enabling effective delivery of long-lasting freshness and sensorial benefits without premature rupture of microcapsules.
Implementation Method 1
aerating said wet pre-mixture to form an aerated wet pre-mixture
Implementation Method 2
drying said formed sheet for a drying time of from 1 minute to 60 minutes at a temperature from 70° C. to 200° C.
Data Source
AI summary
Flexible, dissolvable, porous solid sheet articles which include direct-added microcapsules therein for delivering a benefit agent and a process for making such solid sheet articles.