Microencapsulation Using Oxidized Unsaturated Alkyl Esters
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Solution Overview
Problem
Current microencapsulation techniques, such as in situ polymerization and interfacial polymerization, are unfavorable due to the use of formaldehyde and highly reactive monomers like acyl chlorides and isocyanates, which are not suitable for food, pharmaceutical, and cosmetic applications, necessitating a natural material-based encapsulation system.
Innovation Solution
A method involving the formation of microcapsules using unsaturated alkyl carboxylic acids and/or unsaturated alkyl esters with a minimum molecular weight of 200, capable of oxidation, along with a core material, where an oxidation catalyst is optionally added and oxygen is supplied to initiate oxidation, forming a core-shell structure within 96 hours, avoiding the use of harsh chemicals and allowing for the creation of microcapsules suitable for food and pharmaceutical use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If in situ polymerization is used to form microcapsules, then a poly(urea formaldehyde) or poly(melamine formaldehyde) shell can be formed around a water insoluble droplet, but formaldehyde is used which is a known carcinogen and not suitable for food, pharmaceutical, and cosmetic applications
Solution Approach 1:
The invention changes the chemical parameters of the shell-forming agents by replacing formaldehyde-based monomers with isocyanate-free alternatives such as polyols and carboxylic acids. This parameter change allows the formation of encapsulation shells without carcinogenic substances while maintaining the structural integrity and protective function of the microcapsules, making them suitable for food, pharmaceutical, and cosmetic applications
Solution Approach 2:
The invention extracts and removes the harmful formaldehyde component from the encapsulation process. By eliminating formaldehyde and using alternative reagents like polyols and carboxylic acids that react to form non-toxic polyesters or polyurethanes, the harmful factor is completely removed while the capsule formation function is preserved
2Reliability
If interfacial polymerization is used to form microcapsules, then a polyurea, polyurethane, polyamide, polyamine or polycarbonate shell can be formed around a water or oil droplet, but highly reactive monomers like acyl chlorides and isocyanates are used which prevent use in products that come into contact with humans and animals
Solution Approach 1:
The invention changes the reactivity parameters of the shell-forming agents by replacing highly reactive isocyanates and acyl chlorides with less reactive but equally effective alternatives such as carboxylic acids and polyols. These modified parameters reduce the harmful reactivity while maintaining the ability to form protective encapsulation shells through controlled polymerization reactions
Solution Approach 2:
The invention extracts and removes the highly reactive and toxic monomers (isocyanates and acyl chlorides) from the interfacial polymerization process. By using alternative reagents that are safe for human and animal contact, the harmful factors are eliminated while the capsule shell formation capability is maintained through modified chemical reactions
3Reliability
If gelatin-based coacervation is used for microencapsulation, then a gelatin shell can be formed around a water insoluble droplet, but animal-derived gelatin is used which is not suitable for animal-free products
Solution Approach 1:
The invention extracts and removes the animal-derived gelatin from the coacervation process. By replacing gelatin with plant-based or synthetic polymers such as polyols, carboxylic acids, or their ester derivatives, the animal-derived harmful factor is eliminated while the encapsulation function is maintained through similar phase separation and shell formation mechanisms
Solution Approach 2:
The invention uses composite materials composed of plant-based or synthetic polymers (such as polyols combined with carboxylic acids or their esters) to replace animal-derived gelatin. These composite materials provide similar or improved encapsulation properties while being suitable for animal-free and vegan applications
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 produces microcapsules with controlled size and morphology, suitable for pharmaceutical, food, and cosmetic applications, without the use of toxic chemicals like formaldehyde or isocyanates, enabling the encapsulation of active ingredients and phase change materials, and providing a gelatin-free alternative.
Implementation Method 1
supplying oxygen to the dispersion and initiating oxidation of said one or more alkyl carboxylic acids and/or one or more unsaturated alkyl esters
Data Source
AI summary
The present invention relates to microencapsulation of core materials utilizing one or more unsaturated alkyl carboxylic acids and/or one or more unsaturated alkyl esters which are capable of oxidation and microcapsule formation. The unsaturated alkyl carboxylic acid(s) may specifically include drying oils and/or drying oil components. The unsaturated alkyl ester(s) may specifically include a glycerol ester of a fatty acid.