Solid Core Coacervated Capsules Leakage Prevention
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Solution Overview
Problem
Existing coacervated capsules in the flavor and fragrance industry face issues with leakage of the core material during storage, lack of stability in surfactant solutions, and poor mechanical properties, especially when exposed to higher temperatures or harsh environments.
Innovation Solution
Development of coacervated capsules with a core comprising a mixture of hydrogenated oil, hydrogenated fat, or cocoa butter, combined with a flavor or fragrance material, having a melting point between 30°C and 40°C, encapsulated within a protein-based coating layer, optionally including a non-protein polymer, to form a stable and resistant microcapsule structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a liquid core is used in coacervated capsules, then the processing steps are easier to achieve, but leakage of the core from the shell occurs during storage
Solution Approach 1:
The core material undergoes a phase change from liquid to solid by controlling the melting point to be between 20°C and 40°C. This parameter change ensures the core is solid at room temperature (preventing leakage) but becomes liquid during processing (enabling easy manufacturing), thus resolving the contradiction between ease of manufacture and storage stability.
Solution Approach 2:
The invention utilizes phase transition of the core material based on temperature. The core is solid at storage temperature (room temperature) to prevent leakage, and transitions to liquid at processing temperature (above melting point) to facilitate processing. This phase transition approach simultaneously achieves both ease of manufacture and storage reliability.
2Stability of the object's composition
If a waxy solid core is used to slow liquid movement, then viscosity increases, but leakage is not fully prevented
Solution Approach 1:
The invention optimizes the melting point parameter of the core material to a specific range (20°C-40°C) to ensure it is solid at room temperature. This parameter control provides both the desired viscosity for stability and complete leakage prevention, overcoming the insufficient protection offered by conventional waxy solids.
3Adaptability or versatility
If gelatin capsules are dispersed in polyhydric alcohol mixtures, then the capsule membrane strength decreases, but high breaking strength is desired
Solution Approach 1:
The capsule wall is constructed from a composite material consisting of gelatin and a non-protein polymer with opposite electric charge. This composite structure enhances the mechanical strength and chemical resistance of the membrane, allowing it to maintain high breaking strength even when dispersed in polyhydric alcohol mixtures, while retaining compatibility with cosmetic bases.
Solution Approach 2:
The non-protein polymer acts as an intermediary component that reinforces the gelatin matrix and provides resistance against polyhydric alcohols. This intermediary material prevents the plasticizing effect of polyhydric alcohols on gelatin, thereby maintaining membrane strength while enabling compatibility with cosmetic formulations.
4Adaptability or versatility
If coacervate systems are used at higher temperatures or in harsh environments, then stability is compromised, but stability in challenging conditions is desired
Solution Approach 1:
The dual-polymer composite wall structure (protein + non-protein polymer) provides enhanced thermal stability and resistance to harsh environments including surfactant solutions. The synergistic interaction between the two polymers with opposite charges creates a more robust membrane that maintains integrity at higher temperatures and in challenging conditions, while the system remains adaptable to various 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
The capsules demonstrate improved stability and mechanical resistance, maintaining the integrity of the core material even in challenging conditions such as high temperatures and surfactant solutions, with enhanced loading capacity of active ingredients.
Implementation Method 1
the core comprising a mixture of (I) a fatty component comprising (i) hydrogenated oil or (ii) hydrogenated fat or (iii) cocoa butter or (iv) a mixture thereof, and (II) a material to be encapsulated comprising a flavor and/or fragrance material, the mixture having a Tm of between about 30°C and about 40°C such that it is a solid at 20°C
Implementation Method 2
Coacervation, also called aqueous phase separation, is a very well known technique for encapsulating hydrophobic liquids. The process provides oil-containing microcapsules, the encapsulating material being a gelled hydrophilic colloid that is impervious to the oil and deposited evenly and densely around the oil.
Implementation Method 3
The encapsulating material is a protein which may be complexed with another colloid having an opposite electric charge. Complex coacervation method is widely practiced in commercial processes
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a coacervated capsule comprising: (a) from 10 to 99% by weight of the capsule of a core comprising a mixture of (I) a fatty component comprising (i) hydrogenated oil or (ii) hydrogenated fat or (iii) cocoa butter or (iv) a mixture thereof and (II) a material to be encapsulated comprising a flavor and/or fragrance material, the mixture having a Tm of between about 30°C and about 40°C such that it is a solid at 20°C, wherein the weight ratio of fatty component to material to be encapsulated is from to 10:90 to 70:30, and (b) from 90 to 1% by weight of the capsule of a coating layer comprising essentially a protein, and optionally a non-protein polymer.