Microencapsulation
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Solution Overview
Problem
Existing microencapsulation methods fail to produce robust microcapsules with sustained retention of core materials and tailored release profiles, particularly for (meth)acrylate capsules, which often require separate deposition aids and lack surface charge or hydrophilic functional groups for enhanced adherence and stability.
Innovation Solution
A process involving amphiphilic block polymers with cationic or anionic charges and hydrophilic functional groups is used to form microcapsules, where pre-reacting monomers in water phases and oil phases creates a shell with improved surface properties, allowing for enhanced retention and tailored release characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional microencapsulation methods are used to form microcapsule shells, then the microcapsules can be produced, but they lack robust retention of core materials and require separate deposition aids
Solution Approach 1:
The patent modifies the chemical parameters of the shell polymer by incorporating functional groups (carboxylic acid, amine, quaternary ammonium) during the polymerization process. This changes the surface properties of the microcapsules to provide inherent adhesion and retention capabilities, eliminating the need for separate deposition aids while improving core material retention.
Solution Approach 2:
The patent creates composite shell structures by copolymerizing multifunctional monomers with hydrophilic monomers. The resulting shell combines the structural integrity of the polyacrylate/polymethacrylate matrix with the adhesive properties of functional groups, achieving both robust retention and reduced need for additional deposition aids.
2Ease of operation
If conventional (meth)acrylate capsules are produced, then they can be manufactured, but they lack surface charge and hydrophilic functional groups for enhanced adherence
Solution Approach 1:
The patent incorporates hydrophilic functional groups into the shell polymer structure during the initial polymerization process, before the microcapsules are applied to target surfaces. This preliminary functionalization ensures that the microcapsules possess inherent adhesion capabilities from manufacturing, simplifying subsequent application processes.
Solution Approach 2:
The patent changes the surface charge parameters of the microcapsules by incorporating charged functional groups (carboxylic acid for negative charge, amine and quaternary ammonium for positive charge). This modification enhances electrostatic interactions with target surfaces, improving adherence without requiring complex post-processing steps.
3Reliability
If robust microcapsules with sustained retention are desired, then the shell structure must be strengthened, but this increases manufacturing complexity
Solution Approach 1:
The patent combines multiple functions into a single polymerization step: shell formation, core material encapsulation, and surface functionalization all occur simultaneously during the emulsion polymerization process. This merging of operations achieves robust microcapsule formation with sustained retention capabilities while maintaining manufacturing simplicity.
Solution Approach 2:
The patent creates multi-functional shell polymers that simultaneously provide structural integrity for retention, surface charge for adhesion, and hydrophilic groups for stability. This universal shell design achieves multiple performance goals through a single manufacturing process, avoiding the need for separate processing steps.
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 resulting microcapsules exhibit improved retention and release characteristics, reduced need for deposition aids, and enhanced adherence to surfaces, making them suitable for various industrial and commercial applications.
Implementation Method 1
combining the first water phase with the second water phase and activating the initiator to form free radicals of the initiator and to pre-react the monomers forming a first prepolymer
Implementation Method 2
said block prepolymer being amphiphilic with hydrophobic segments and hydrophilic functional groups. The block polymer's hydrophobic segments and increasing molecular weight decrease solubility of the block polymer. This results in precipitating the block polymer and/or provides a means of moving or biasing the block polymer out from the water phase and/or toward an interface
Implementation Method 3
Interfacial polymerization is a process wherein a microcapsule wall, typically a polyamide, an epoxy resin, a polyurethane, a polyurea or the like is formed at an interface between two phases
Implementation Method 4
emulsifying the oil phase into the water phase using high shear agitation to form an emulsion of droplets of the oil phase of less than 100 microns dispersed in the water phase
Data Source
AI summary
An improved process of making a benefit agent delivery particle and an improved microcapsule made by such process are disclosed. The process comprises the steps of providing a first composition of water phase 1, water phase 2, water phase 3 and an oil phase, where a water phase multifunctional (meth)acrylate monomer is selected to have a hydrophilicity index of least 25, or even at least 30 and the oil phase multifunctional (meth)acrylate monomer has a hydrophilicity index of 25 or less, or even 20 or less. The water phases comprise water, initiator, a water-soluble or dispersible amine(meth)acrylate or hydroxyl(meth)acrylate, a multifunctional (meth)acrylate and one water phase comprises water, carboxyalkyl(meth)acrylate and a base or quaternary ammonium acrylate. Water phases are combined to prereact the hydroxy- or amine(meth)acrylate and the multifunctional (meth)acrylate to form a multifunctional hydroxyl-amine(meth)acrylate pre-polymer. The pre-polymer is combined with the remaining water phase and an emulsion is formed by emulsifying under high shear agitation, an oil phase comprising a multifunctional (meth)acrylate monomer and a benefit agent core material thereby forming a wall surrounding the benefit agent core material.