Three-Phase Cosmetic Capsule via Co-Extrusion
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Solution Overview
Problem
Existing cosmetic capsule manufacturing processes are limited in encapsulating multiple types of active ingredients and achieving a unique visual appearance, with existing technologies only allowing for aqueous or oily encapsulation and lacking in visual differentiation.
Innovation Solution
Development of capsules with a three-phase structure, comprising an internal oily or aqueous phase, an intermediate gelled phase, and an external gelled envelope, using three-way co-extrusion and calcium bath gelling to create capsules with distinct external phases for enhanced visual appeal and encapsulation capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-phase capsule structure is used, then the manufacturing process is simple, but the capsule can only encapsulate one type of active ingredient and lacks visual differentiation
Solution Approach 1:
The capsule is divided into three distinct phases: an internal phase (aqueous or oily), an intermediate gelled phase, and an external gelled envelope. This segmentation allows each phase to encapsulate different active ingredients or provide different functions, thereby increasing versatility while maintaining a systematic manufacturing approach through three-way co-extrusion
Solution Approach 2:
The capsule structure follows a nested configuration where the internal phase is surrounded by the intermediate gelled phase, which in turn is encapsulated by the external gelled envelope. This nested structure enables multiple active ingredients to be contained within concentric layers, providing both functional versatility and visual differentiation through distinct phases
2Stability of the object's composition
If an intermediate gelled phase is added to separate internal and external phases, then the stability and suspension are improved, but the manufacturing complexity increases
Solution Approach 1:
The intermediate gelled phase acts as a mediator between the internal phase (containing active ingredients) and the external gelled envelope. This intermediate layer provides a stable suspension medium that prevents direct contact between the internal and external phases, ensuring compositional stability while the three-way co-extrusion process manages the manufacturing complexity by simultaneously forming all three phases
Solution Approach 2:
The intermediate phase undergoes gelation transition to form a stable gel structure that provides suspension stability. This phase transition from liquid to gel state creates a rigid yet porous matrix that maintains the encapsulated structure, while the controlled gelation process integrates into the overall manufacturing sequence
3Illumination intensity
If coloring agents are incorporated in the external phases, then the visual appearance is enhanced, but the manufacturing precision requirements increase
Solution Approach 1:
Coloring agents are incorporated selectively into specific external phases (5A and/or 5B) rather than uniformly distributed throughout the entire capsule. This local quality approach allows different regions of the capsule to have distinct visual characteristics, enhancing visual appearance while the three-way co-extrusion process maintains precise phase separation to prevent mixing of colored and non-colored phases
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 three-phase capsule structure allows for the encapsulation of multiple active ingredients and provides a unique visual appearance with distinct external phases, enhancing the cosmetic product's attractiveness and preserving the integrity of the encapsulated ingredients.
Implementation Method 1
Falling into the bath causes the capsule to gel by diffusion of calcium into the external phase which becomes the gelled membrane
Implementation Method 2
Three fluids arrive through three different paths from a nozzle and form a three-phase drop
Data Source
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AI summary
Method for manufacturing a series of capsules (1A) comprising a core (3), and a gelled shell (5) completely encapsulating the core and comprising at least two outer phases (5A, 5B), the gelled shell having an outer surface comprising at least two separate portions (7A, 7B) formed respectively by the two outer phases, comprising the following steps:- conveying a first flow (F1) for forming the core, and a second flow (F2) of at least the two outer phases for forming the gelled shell, each outer phase containing a liquid polyelectrolyte capable of gelling, at least one of the two outer phases comprising a colouring agent, the second flow surrounding the first flow around an axis (D2); - sequentially forming a plurality of liquid bodies (57) comprising a drop (107) and a peripheral film (109) coating the drop and having the two outer phases, the film having on the outer surface thereof at least two separate portions (109A, 109B) formed by the two outer phases; and - immersing each liquid body in a gelling solution (100) capable of reacting with the polyelectrolyte of each of the two outer phases, and retrieving the plurality of capsules. Series of capsules, cosmetic composition containing the capsules and cosmetic treatment using the composition.