Solid Matrix Capsule Production via Temperature Control
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Solution Overview
Problem
Current methods for producing microcapsules suffer from poor control over capsule size and size distribution, as well as surface properties, which are crucial for pharmaceutical, fragrance, and flavor applications, and often involve high shear forces that can damage sensitive compounds.
Innovation Solution
A method involving the formation of a hydrophobic matrix in a liquid state at a higher temperature than storage, which is then cooled to solidify within an aqueous phase, allowing precise control over capsule size and distribution, and using surfactants to stabilize droplets, enabling the production of capsules with uniform size and surface properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spray drying, high speed rotation with high shearing forces, ultrasonication, mixing and/or shaking are used to produce microcapsules, then production throughput is improved, but capsule size control and surface property uniformity deteriorate
Solution Approach 1:
The patent replaces mechanical systems (spray drying, high speed rotation, ultrasonication, mixing, shaking) with a field-based approach using electric fields and temperature control. The continuous phase is heated to a specific temperature range (40-80°C) to control matrix solidification, and electric fields are applied to manipulate droplet formation and stabilization, eliminating the need for high shear forces while achieving precise capsule size control and uniform surface properties
Solution Approach 2:
The patent changes physical and chemical parameters of the continuous phase (temperature, pH, ionic strength) to control capsule formation. By adjusting the temperature of the continuous phase within 40-80°C and modifying pH and ionic strength, the patent achieves precise control over matrix solidification and droplet stabilization, resulting in uniform capsule size and surface properties without high mechanical stress
2Productivity
If high shear forces and temperatures are applied in prior art processes, then production efficiency is improved, but sensitive compounds and living material are damaged
Solution Approach 1:
The patent replaces mechanical systems (high shear forces, ultrasonication) with field-based approaches (electric fields, temperature control). The continuous phase is heated to 40-80°C and electric fields are applied to stabilize droplets and control solidification, eliminating high mechanical stress while maintaining production efficiency and protecting sensitive compounds and living material from damage
Solution Approach 2:
The patent performs preliminary stabilization of the continuous phase by heating to 40-80°C and adjusting pH and ionic strength before droplet formation. This preliminary action creates favorable conditions for gentle droplet stabilization and matrix solidification, preventing damage to sensitive compounds and living material during the encapsulation process
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 allows for the production of microcapsules with high precision in size and surface uniformity, increased throughput, and efficient encapsulation of sensitive compounds with minimal shear stress, enhancing their stability and viability for various applications.
Implementation Method 1
The first temperature is selected such that the hydrophobic matrix is liquid, i.e. in a liquid state of aggregation during step a. The hydrophobic matrix is configured such that it is solid at a storage temperature. The first operating temperature is higher than the storage temperature.
Implementation Method 2
cooling the emulsion or dispersion of the droplet phase in the continuous aqueous phase formed in step c. below the first operating temperature such that the hydrophobic matrix solidifies to form a solid matrix
Implementation Method 3
Providing in a second chamber a continuous aqueous phase at a second operating temperature, the continuous aqueous phase comprising water and optionally at least one first surfactant
Data Source
AI summary
Disclosed herein is a method for generating capsules with a solid matrix (7) as well as a capsule assembly comprising a plurality of capsules obtained by such a method. The method relies on temperature dependent step-emulsification of a droplet phase including a liquid hydrophobic matrix and a continuous aqueous phase.