Thin-Film Ionic Gelation Coating of Insoluble Solids
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Solution Overview
Problem
Existing microencapsulation processes for insoluble solids using ionic gelation result in thick shells that hinder controlled release and modify surface chemistry, leading to health hazards and limited applications due to high macromolecule concentrations and agglomeration issues.
Innovation Solution
A process that coats insoluble solids with a concentration of macromolecules less than 10% using ionic gelation, allowing for a thin film formation that maintains surface chemistry flexibility and prevents agglomeration, enabling controlled release and redispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high concentration of macromolecules (≥10%) is used in ionic gelation process, then microcapsule formation is achieved, but thick shell (>10 nm) is generated that insulates core from external agents and causes health problems
Solution Approach 1:
The patent changes the concentration parameter of macromolecules from ≥10% to <10%, specifically optimizing to 5-8%, which fundamentally alters the shell thickness and prevents the formation of thick insulating layers while maintaining microcapsule structure stability
Solution Approach 2:
The patent applies partial action by using lower than conventional macromolecule concentrations, achieving sufficient coating with 5-8% instead of the traditional ≥10%, thereby avoiding excessive shell thickness and associated health issues
2Reliability
If high concentration of macromolecules (≥10%) is used, then microcapsule shell is formed, but core-shell type microcapsules are generated with thick shell that limits controlled release
Solution Approach 1:
By changing the macromolecule concentration parameter to 5-8% (lower than conventional ≥10%), the patent achieves thinner shells that allow faster and more controlled release of core components while maintaining structural integrity
3Ease of operation
If macromolecule concentration is reduced to <10%, then thin film coating is achieved with improved handling, but coating efficiency may be compromised
Solution Approach 1:
The patent optimizes the macromolecule concentration parameter to a specific range of 5-8%, which balances coating thickness control with improved handling properties, achieving thin films that prevent agglomeration while maintaining manufacturing precision
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 process achieves efficient coating with less than 20% macromolecule retention, allowing for controlled release and improved handling, reducing health risks and enhancing application versatility.
Implementation Method 1
forming a matrix of charged macromolecules on the surface of water insoluble solids to generate microspheres by controlled adsorption of the macromolecules onto the solid surface
Implementation Method 2
Microencapsulation processes of insoluble solids such as ionic gelation, acid precipitation, coacervation and layer-by-layer processes usually employ methods based on ionic interactions
Implementation Method 3
Microencapsulation by ionic gelation consists of the extrusion or emulsification of an ionically charged macromolecule in the form of droplets, in a solution of a counterion, generating in its contact the immediate gelation of the droplet external part
Implementation Method 4
the counterions persist in their diffusion towards the interior of the particle inducing its total gelation
Data Source
AI summary
The invention relates to a process for coating water-insoluble solids by ionic gelation employing negatively-charged macromolecules and a source of polyvalent cations as film-forming materials, wherein the coating material represents not more than 10% (w/w) with regard to the total weight of the coated solid. The coated insoluble solids may be subsequently dried to generate surface-modified dry particles for use as active ingredients and/or excipients in the manufacture of pharmaceutical compositions or food products.