Microcapsule Volatile Diffuser Preventing Evaporation
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Solution Overview
Problem
The current mosquito coil manufacturing process using wet extrusion and drying is inadequate for new generation insecticides with higher volatility, leading to significant evaporation of active ingredients and potential market withdrawal due to non-compliance with biocidal product regulations.
Innovation Solution
A diffuser with a coil-shaped body formed from microcapsules containing volatile substances, where the outer shell is made of thermally activated materials like gum arabic, xanthan gum, or polyethylene, which melts or collapses between 80° C. and 150° C., preventing evaporation during drying and releasing the substances during combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional wet extrusion and drying process is used, then manufacturing simplicity is maintained, but significant evaporation of volatile active ingredients occurs during drying
Solution Approach 1:
The patent uses microcapsules with thin film shells made of gelatin or other suitable materials to enclose the volatile active ingredients. These flexible thin film shells prevent evaporation during the drying process while being simple to incorporate into the extrusion manufacturing process, thus resolving the contradiction between manufacturing simplicity and prevention of substance loss.
Solution Approach 2:
The patent embeds microcapsules containing active ingredients within the matrix of the diffuser body during extrusion. This nesting approach allows the volatile substances to be protected inside capsules while being integrated into the overall product structure, preventing evaporation without complicating the manufacturing process.
2Loss of substance
If microencapsulation is used to prevent evaporation, then active ingredient retention is improved, but mechanical stress during extrusion damages the capsules
Solution Approach 1:
The patent modifies the parameters of the microcapsules by using specific materials like gelatin with appropriate molecular weights and cross-linking densities. These parameter changes enhance the mechanical strength and elasticity of the capsule shells, enabling them to withstand the mechanical stress of extrusion while still preventing active ingredient evaporation.
Solution Approach 2:
The patent employs composite capsule structures combining gelatin with reinforcing agents or cross-linking materials to create shells that are both mechanically robust enough to survive extrusion and sufficiently intact to prevent evaporation. This composite approach resolves the contradiction between capsule strength and retention efficiency.
3Loss of time
If high temperature drying is applied, then drying time is reduced, but active ingredient evaporation increases
Solution Approach 1:
The patent applies microencapsulation as a preliminary protective action before the drying process. The microcapsule shells are formed around the active ingredients prior to drying, creating a protective barrier that allows subsequent high-temperature drying to proceed rapidly without causing significant evaporation of the volatile substances.
Solution Approach 2:
The patent utilizes the phase transition properties of the microcapsule shell materials, which remain stable and maintain their barrier function at elevated drying temperatures. This allows the system to withstand the phase changes associated with high-temperature drying while protecting the active ingredients inside, thus reducing drying time without increasing evaporation.
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 microcapsule-based diffuser effectively reduces or avoids evaporation of active ingredients during drying, ensuring compliance with regulatory limits and maintaining the efficacy of high-volatility insecticides, while providing a stable and efficient release mechanism during use.
Implementation Method 1
the outer shell is made of a material that is thermally activated, such that it melts, expands or collapses above a preset temperature, diffusing the volatile substances in the ambient air
Implementation Method 2
the outer shell is made of a material that is thermally activated, such that it melts, expands or collapses above a preset temperature
Implementation Method 3
drying generally takes place over a considerably long period of time, closer to days than hours, at a very low temperature of 40-80° C. to prevent the evaporation of the active ingredients
Data Source
AI summary
The diffuser of volatile substances by combustion comprises a body (1) that includes said volatile substances, wherein said body is formed from microcapsules (2) that house said volatile substances. Preferably, each microcapsule (2) comprises an outer shell that houses the volatile substances therein. It makes it possible to provide a diffuser of volatile substances by combustion wherein the evaporation of the volatile substances is reduced or fully prevented during the drying in the manufacturing process thereof.