IMPROVED MICROCAPSULES AND METHOD FOR THE PRODUCTION AND USE THEREOF

Abstract

A method for producing microcapsules with core material and shell material includes following steps: a) providing an aqueous two-phase system comprising at least one salt, which is at least partially not dissolved in this two-phase system and a core material, which is one phase of the two-phase system, and b) adding two solutions i) and ii) in the presence of at least one polymer soluble in solution i) and/or ii), wherein solution i) contains at least one salt of a cation of the salt from step a) and solution ii) contains at least one salt of an anion of the salt from step a). Microcapsules can be obtained or obtainable by the above method, and the microcapsules can be used in products and compositions.

Claims

1. A method for producing microcapsules with core material and shell material comprising following steps, a) providing an aqueous two-phase system comprising at least one salt, which is at least partially not dissolved in this two-phase system and a core material, which is one phase of the two-phase system, b) adding two solutions i) and ii) in the presence of at least one polymer, which is at least partially solved in solution i) and/or ii), wherein solution i) contains at least one salt of a cation of the salt from step a) and solution ii) contains at least one salt of an anion of the salt from step a).

2. The method according to claim 1, characterized in that the salt of step a) is selected from the group consisting of calcium carbonate, calcium phosphate, calcium sulfate, calcium oxalate, magnesium carbonate, strontium carbonate, strontium sulphate, strontium oxalate, barium carbonate, barium sulfate, calcium fluoride, (modified) silica or mixtures thereof, preferably calcium carbonate, magnesium carbonate, barium carbonate or mixtures thereof, particularly preferably calcium carbonate.

3. The method according to claim 1, characterized in that the salt in solution i) of step b) is selected from the group consisting of lithium carbonate, sodium carbonate, sodium oxalate, potassium carbonate, potassium oxalate, rubidium carbonate, cesium carbonate, sodium sulfate, potassium sulfate, magnesium sulfate, trisodium phosphate, tripotassium phosphate, amine fluoride, potassium fluoride or mixtures thereof, preferably lithium carbonate, sodium carbonate, potassium carbonate or mixtures thereof, particularly preferably potassium carbonate.

4. The method according to claim 1, characterized in that the salt in solution ii) of step b) is selected from the group consisting of calcium formate, barium formate, magnesium formate, calcium acetate, barium acetate, magnesium acetate, calcium propanoate, barium propanoate, magnesium propanoate, calcium chloride, strontium chloride, strontium sulfate, strontium phosphate or mixtures thereof, preferably calcium formate, barium formate, calcium acetate, barium acetate or mixtures thereof, particularly preferably calcium formate and/or calcium acetate.

5. The method according to claim 1, characterized in that the soluble polymer of step b) is selected from the group consisting of celluloseether like carboxymethyl cellulose or salts thereof, preferably sodium carboxymethyl cellulose or polyelectrolytes like gum arabic, chitosan, xanthan gum, alginate, carrageen or pectine, more preferred the soluble polymer consist of carboxymethyl cellulose.

6. The method according to claim 1, characterized in that the core material is at least one hydrophobic ingredient or at least one template microcapsule.

7. The method according to claim 6, characterized in that the hydrophobic ingredient is selected from the group consisting of alcohols, perfume oils, care substances, natural and/or synthetic oils, silicone oils, pesticides, biocides, pigments, phase change materials (PCM), fertilizer, adhesives, insecticides, solvents, lubricants, dyes and cooling substances or mixtures thereof.

8. The method according to claim 6, characterised in that the template microcapsule comprises a shell material (inner shell material), which comprises a natural polymer, a resin or a mixture thereof.

9. The method according to claim 8, characterised in that the resin is obtained by the condensation of thermosetting resins and a subsequent formation of microcapsules using aldehydes, preferably formaldehyde and optionally, wherein the shell material of the microcapsule has been treated with an oxidizing agent preferred with H2O2 prior to curing of the shell material further optionally supplemented by silica or a silica derivative.

10. The method according to claim 8, characterised in that the resin is obtained by reacting a) at least one aromatic alcohol or ethers or esters thereof and b) at least one aldehyde component that comprises at least two carbon atoms per molecule, and c) in the presence of at least one homopolymer or copolymer of 2-acrylamido-2-methyl-propane sulfonic acid or salts thereof.

11. The method according to claim 8, characterised in that the natural polymer is selected from the group consisting of gum arabic, chitosan, gelantine, pectine, chitin, glycogen, cellulose, xanthan gum or mixtures thereof.

12. Microcapsules obtained by a method according to claim 1.

13. Microcapsules comprising a shell material of a salt obtained by a method according to claim 1, and core material comprising at least one hydrophobic ingredient selected from the group consisting of alcohols, perfume oils, care substances, natural and/or synthetic oils, silicone oils, pesticides, biocides, pigments, phase change materials (PCM), fertilizer, adhesives, insecticides, solvents, lubricants, dyes and cooling substances or mixtures thereof, or at least one template microcapsule/s comprising a shell material (inner shell material) which comprises a natural polymer, a resin or a mixture thereof and a core material which comprises at least one hydrophobic ingredient selected from the group consisting of alcohols, perfume oils, care substances, natural and/or synthetic oils, silicone oils, pesticides, biocides, pigments, phase change materials (PCM), fertilizer, adhesives, insecticides, solvents, lubricants, dyes and cooling substances or mixtures thereof.

14. Microcapsules according to claim 12, whereas the microcapsules have a hydrodynamic diameter d(90%) between 5 and 150 .Math.m, preferred between 10 and 120 .Math.m, more preferred between 10 and 100 .Math.m, with a standard deviation of ± 30 .Math.m.

15. A composition comprising microcapsules according to claim 12.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0018] FIG. 1 is a microscopic image of CaCO.sub.3 microcapsules obtained by drying slurry on a carrier plate - the shell structure is shown by the fragments after targeted mechanical destruction of some microcapsules. (by confocal LASER-scan microscopy).

[0019] FIG. 2 is a microscopic image of dry-stable CaCO.sub.3 microcapsules produced by a method according to the invention; shown here are microcapsules dried onto filter paper.

[0020] FIG. 3 is a microscopic image dried capsules on a microscope slide. The surface of the capsules shows a clear structure.

[0021] FIG. 4 is a microscopic image of microcapsules 20 seconds after addition of 1% acetic acid. CO.sub.2 gas bubbles (large bubbles in foreground) are formed by the reaction of calcium carbonate with acetic acid. The structuring of the capsules surface is significantly reduced.

[0022] FIG. 5 is a microscopic image of a microcapsule 180 seconds after addition of 1% acetic acid. CO.sub.2 development has continued to increase (increasing bubble sizes). The capsule shells have been completely dissolved. Only free oil droplets are still present here; collapsed cascades are visible.

[0023] FIG. 6 is a graphic showing the results of a thermal analysis of microcapsules encapsulating octane showing core material loss as a function of temperature.

DETAILED DESCRIPTION OF THE INVENTION

[0024] The present invention provides an improved method for producing environmentally friendly microcapsules. Moreover, the present invention provides microcapsules obtainable by the method according to the invention, in particular multilayer microcapsules which are suitable for all kinds of industrial application, in particular in personal care and home care products. The microcapsules preferably comprise at least one hydrophobic compound (e.g. oil) or at least one template microcapsule as core material.

[0025] In one embodiment of the invention a method is disclosed for producing microcapsules with core material and shell material comprising following steps, [0026] a) providing an aqueous two-phase system comprising at least one salt, which is at least partially not dissolved in this two-phase system and a core material, which is one phase of the two-phase system, [0027] b) adding two solutions i) and ii) in the presence of at least one polymer, which is at least partially solved in solution i) and/or ii), wherein solution i) contains at least one salt of a cation of the salt from step a) and solution ii) contains at least one salt of an anion of the salt from step a).

[0028] The two-phase system in step a) of the present invention is known as Pickering emulsion/suspension. A “two-phase system” is according to the invention a liquid-liquid system, wherein the two liquids are immiscible or at least partially immiscible and therefore separating from each other by differences in density and/or chemical nature (e.g. hydrophobic or hydrophilic character), or a liquid-solid system wherein the two phases are immiscible due to their differing aggregate states.

[0029] A “Pickering emulsion” is an emulsion that is stabilized by solid particles (e.g. colloidal silica or calcium carbonate) which adsorb onto the liquid-liquid interface between two phases. If one phase is a solid, e.g. microparticles/microcapsules which are suspended in a liquid phase, the solid stabilizing particles (e.g. colloidal silica or calcium carbonate) adsorb onto the liquid-solid interface; it can be named as a “Pickering suspension”.

[0030] Step b) represents the step of growth/thickening of the shell material (by a crystallization process of the salt).

[0031] The term “phase” describes a spatial region in which material properties, such as density, refractive index, the aggregate state or chemical composition, are homogeneous. A phase is any homogeneous part of a system.

[0032] In an embodiment of the invention the method is characterised in that the two solutions i) and ii) in step b) are added in parallel.

[0033] The shell material of suitable microcapsules according to the invention can be selected from natural, semi-synthetic or synthetic materials or a mixture thereof.

[0034] Natural shell materials are inorganic materials e.g. salts like carbonates, especially calcium carbonate or other natural shell materials like gum arabic, agar-agar, agarose, maltodextrins, alginic acid or its salts, e.g. sodium or calcium alginate, fats and fatty acids, cetyl alcohol, collagen, chitosan, lecithin, gelatin, albumin, shellac, polysaccharides such as starch or dextran, polypeptides, protein hydrolysates, sucrose and waxes.

[0035] Semi-synthetic shell materials are chemically modified celluloses, especially cellulose esters and ethers of cellulose, e.g. cellulose acetate, ethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose and carboxymethyl cellulose, as well as starch derivatives, especially starch ethers and esters.

[0036] Synthetic shell materials are (co)polymers such as polyacrylates, polymethacrylates, polyamides, polyvinyl alcohol or polyvinyl pyrrolidone.

[0037] In an embodiment, the salt in step a) is at least 50 wt% not dissolved in the two-phase system at room temperature, preferably at least 75 wt%, more preferred at least 90 wt%, most preferred at least 95 wt%, based on the used amount of inorganic material in step a).

[0038] “Room temperature” means by the disclosure of the present invention a temperature of 20° C. (293.15 Kelvin).

[0039] In a further embodiment, the salt in step a) has solubility in water of less than (<) 100 mg/L at room temperature, preferred less then (<) 50 mg/L.

[0040] In a preferred embodiment the salt of step a) is selected from the group consisting of calcium carbonate, calcium phosphate, calcium sulfate, calcium oxalate, magnesium carbonate, strontium carbonate, strontium sulphate, strontium oxalate, barium carbonate, barium sulfate, calcium fluoride, (modified) silica or mixtures thereof, preferably calcium carbonate, magnesium carbonate, barium carbonate or mixtures thereof, particularly preferably calcium carbonate.

[0041] In a more preferred embodiment the salt in step a) is calcium carbonate.

[0042] Most preferred is a mixture of hydrophilic and hydrophobic calcium carbonate.

[0043] “Hydrophilic” surfaces (e.g. of calcium carbonate particles) have a strong affinity to water and spreading of water on such surfaces are preferred. The degree of hydrophilicity of the substance can be measured by measuring the contact angle between the liquid and solid phases - for example the average water contact angle (WCA). Hydrophobic materials are known as non-polar materials with a low affinity to water, which makes them water repelling. A contact angle of less than 90° indicates hydrophilic interaction where as an angle greater than 90° indicates a hydrophobic interaction.

[0044] The water contact angle (WCA) can be measured with a Kruess DSA-100 contact angle analyzer. The measurements can be performed on the prepared powders compressed into discs using 5 .Math.L water droplet volumes and the contacted angle can be determined from the profile of the droplets that are fully separated from the pump syringe needle tip.

[0045] In a preferred embodiment the particle size of the calcium carbonate is between 0.001 .Math.m and 1 .Math.m, more preferred between 0.01 .Math.m and 0.5 .Math.m, most preferred between 0.06 and 0.2 .Math.m.

[0046] In another embodiment the salt in solution i) or in solution ii) of step b) is at least 40 wt% soluble at room temperature, preferred at least 65 wt%, more preferred at least 80 wt%, most preferred at least 95 wt%, based on the used amount of salt in solution i).

[0047] In a preferred embodiment, the salt in solution i) or in solution ii) of step b) has a solubility in water of more than (>) 1 g/L at room temperature, preferred more then (>) 5 g/L, more preferred more then (>) 10 g/L.

[0048] According to a more preferred embodiment of the invention the salt in solution i) is selected from the group consisting of lithium carbonate, sodium carbonate, sodium oxalate, potassium carbonate, potassium oxalate, rubidium carbonate, cesium carbonate, sodium sulfate, potassium sulfate, magnesium sulfate, trisodium phosphate, tripotassium phosphate, amine fluoride, potassium fluoride or mixtures thereof, preferably lithium carbonate, sodium carbonate, potassium carbonate or mixtures thereof, particularly preferably potassium carbonate.

[0049] In a more preferred embodiment the salt in solution ii) is selected from the group consisting of calcium formate, barium formate, magnesium formate, calcium acetate, barium acetate, magnesium acetate, calcium propanoate, barium propanoate, magnesium propanoate, calcium chloride, strontium chloride, strontium sulfate, strontium phosphate or mixtures thereof, preferably calcium formate, barium formate, calcium acetate, barium acetate or mixtures thereof, particularly preferably calcium formate and/or calcium acetate.

[0050] Suitable polymers of step b) are selected from the group consisting of celluloseether like carboxymethyl cellulose or salts thereof, preferably sodium carboxymethyl cellulose or polyelectrolytes like gum arabic, chitosan, xanthan gum, alginate, carrageen or pectine or mixtures thereof. Preferably the soluble polymer consists of carboxymethyl cellulose.

[0051] Suitable sodium carboxymethyl cellulose according to the invention has an average molecular weight between 10.000 g/mol and 500.000 g/mol, preferably between 75.000 g/mol and 300.000 g/mol.

[0052] Preferred sodium carboxymethyl cellulose has a viscosity at room temperature below 100 cP in a 2% aqueous solution.

[0053] More preferred the sodium carboxymethyl cellulose has a substitution degree of 0.82 to 0.95, most preferred of 0.75 to 0.90.

[0054] Steps a) and b) of the method according to the invention are preferably performed under stirring. In a preferred embodiment the stirring speed in step b) is adjusted between 600 and 3000 rpm, preferably between 1000 and 2000 rpm and is reduced to 300 to 500 rpm before step b) occurs. For step b) it is preferred to have a stirring speed between 300 to 500 rpm. The indicated stirring speeds herein refer to a 1 liter batch e.g. in a common laboratory dissolver. The person skilled in the art knows how to adjust the stirring speed according to the reaction vessel used (e.g. larger reaction vessel requires higher stirring speeds).

[0055] In a preferred embodiment of the invention, the core material is at least one hydrophobic ingredient or at least one template microcapsule.

[0056] In a preferred embodiment of the present invention the core material comprises at least one template microcapsule. The template microcapsule is preferably a core-shell microcapsule, comprising e.g. at least one hydrophobic ingredient. The use of template microcapsules as core material according to the invention enables the production of multilayer microcapsules. The shell material of the template microcapsules/s preferably contains a resin, a natural polymer or a mixture thereof. The shell of the template microcapsule forms the inner shell of the microcapsule according to the invention.

[0057] The hydrophobic substance is preferably selected from the group comprising alcohols, perfume oils, care substances, natural and/or synthetic oils, silicone oils, pesticides, biocides, pigments, phase change materials (PCM), fertilizer, adhesives, insecticides, solvents, lubricants, dyes and cooling substances or mixtures thereof.

[0058] “Hydrophobic ingredient” means according to the invention any ingredient or material or substance or mixtures thereof which is/are mostly of hydrophobic nature. Hydrophobes tend to be nonpolar and, thus, prefer other neutral molecules and nonpolar solvents. Because water molecules are polar, hydrophobes do not dissolve well or not at all among them.

[0059] The template microcapsule comprises core material, which denotes the inner core material of the microcapsules according to the invention and shell material, which denotes the inner shell material of the microcapsules according to the invention, wherein the shell material preferably comprises a natural polymer, a resin or a mixture thereof.

[0060] In a preferred embodiment the inner core material can be a hydrophobic ingredient.

[0061] In a further preferred embodiment the natural polymer of the inner shell material is selected from the group consisting of gum arabic, chitosan, gelantine, pectine, chitin, glycogen, cellulose, xanthan gum or mixtures thereof.

[0062] In a more preferred embodiment the inner shell material is a resin. The resin preferably can be produced (version A) by a condensation of thermosetting resins and a subsequent formation of microcapsules using aldehydes, preferably formaldehyde. A process for the preparation of such microcapsules is disclosed e.g. in WO 2009/015872 A1, which is expressly incorporated herein by reference.

[0063] It is also preferred to use a resin which can be produced (version B) by reacting [0064] a) at least one aromatic alcohol or ethers or esters thereof and [0065] b) at least one aldehyde component that comprises at least two carbon atoms per molecule, and [0066] c) in the presence of at least one homopolymer or copolymer of 2-acrylamido-2-methyl-propane sulfonic acid or salts thereof.

[0067] Suitable (in version B) as an aromatic alcohol a) are compounds selected from phenol, cresol (o-, m- and p-cresol), naphthol (α- and β-naphthol), thymol, pyrocatechol, resorcinol, hydroquinone and 1,4-naphthohydroquinone, phloroglucinol, pyrogallol, or hydroxyhydroquinone.

[0068] Suitable (in version B) as an aldehydic component b) are compounds selected from valeraldehyde, capronaldehyde, caprylaldehyde, decanal, succindialdehyde, cyclohexanecarboxaldehyde, cyclopentanecarboxaldehyde, 2-methyl-1-propanal, 2-methylpropionaldehyde, acetaldehyde, acrolein, aldosterone, antimycin A, 8′-apo-β-carotene-8′-al, benzaldehyde, butanal, chloral, citral, citronellal, crotonaldehyde, dimethylaminobenzaldehyde, folinic acid, fosmidomycin, furfural, glutaraldehyde, glyceraldehyde, glycolaldehyde, glyoxal, glyoxylic acid, heptanal, 2-hydroxybenzaldehyde, 3-hydroxybutanal, hydroxymethylfurfural, 4-hydroxynonenal, isobutanal, isobutyraldehyde, methacrolein, 2-methylundecanal, mucochloric acid, N-methylformamide, 2-nitrobenzaldehyde, nonanal, octanal, oleocanthal, orlistat, pentanal, phenylethanal, phycocyanin, piperonal, propanal, propenal, protocatechuic aldehyde, retinal, salicylaldehyde, secologanin, streptomycin, strophanthidin, tylosin, vanillin, or cinnamaldehyde.

[0069] In a preferred embodiment (in version B) the molar ratio of the aromatic alcohol a) to the aldehydic component b), which comprises at least two carbon atoms per molecule, is between 1:2 and 1:3.5, preferably between 1:2.4 and 1:2.8, and is particularly preferably between 1:2.6.

[0070] In a further embodiment of the method according to the invention at least one surfactant may be used during the production of the template microcapsules. Preferably, the surfactant is selected from the group consisting of sulfonated lignin, natural dispersants like quillaja saponin, lecithins, gum arabic, pectin, carrageenan, chitosan, chondroitin sulfate, cellulose gum, physically or chemically modified starch, whey protein, pea protein, egg white protein, silk protein, gelatin of fish, proteins of porcine or bovine origin, ester gum, fatty acids or mixtures thereof, sulfonated lignin is preferred.

[0071] This process according to version B is described in detail in WO 2011/110368 A1, and consequently this document is incorporated in its totality into the disclosure content of the present invention by way of reference.

[0072] In a further embodiment of the method according to the invention at least one surfactant may be used during the production of the template microcapsules (version A or B). Preferably, the surfactant is selected from the group consisting of sulfonated lignin, natural dispersants like quillaja saponin, lecithins, gum arabic, pectin, carrageenan, chitosan, chondroitin sulfate, cellulose gum, physically or chemically modified starch, whey protein, pea protein, egg white protein, silk protein, gelatin of fish, proteins of porcine or bovine origin, ester gum, fatty acids or mixtures thereof, preferably is sulfonated lignin.

[0073] Suitable as protective colloids in the production of microcapsules are AMPS-copolymers described in detail in WO 2010/102830 A1 which is incorporated into the disclosure content of the present invention by way of reference. Examples of AMPS-copolymers are AMPS/hydroxyethylmethacrylate-copolymer, AMPS/hydroxyethylacrylate-copolymer, AMPS/hydroxypropylmethacrylate-copolymer, AMPS/hydroxypropylacrylate-copolymer, AMPS/hydroxybuylmethacrylate-copolymer, AMPS/hydroxybutylacrylate-copolymer, AMPS/polyethylene glycol monomethacrylate-copolymer, AMPS/polypropylene glycol monomethacrylate-copolymer, AMPS/polypropylene glycol monoacrylate-copolymer, AMPS/methoxy-polyethylene glycol monomethacrylate-copolymer, AMPS/methoxy-polyethylene glycol monoacrylate-copolymer, AMPS/hydroxyethylmethacrylate-copolymer, AMPS/hydroxyethylacrylate-copolymer, AMPS/hydroxypropylmethacrylate-copolymer, AMPS/hydroxypropylacrylate-copolymer, AMPS/hydroxybutylmethacrylate-copolymer, AMPS/hydroxybutylacrylate-copolymer, AMPS/polyethylene glycol monomethacrylate-copolymer, AMPS/polypropylene glycol monomethacrylate-copolymer, AMPS/polypropylene glycol monoacrylate-copolymer, AMPS/methoxy-polyethylene glycol monomethacrylate-copolymer, AMPS/methoxy-polyethylene glycol monoacrylate-copolymer.

[0074] Particularly a microcapsule according to the invention is most preferred, wherein the inner shell material (the shell material of the template microcapsule) comprises a synthetic polymer, especially preferred an aminoplastic and/or phenoplastic resin and the shell material (the outer shell material of the microcapsules) comprises at least one biopolymer, especially preferred comprises gum arabic and chitosan.

[0075] In a preferred embodiment, microcapsules produced by a method according to the invention have a low content of synthetic polymer(s).

[0076] The “content of synthetic polymer(s)” (abbreviated to: CSP) is the ratio of synthetic polymer(s) to encapsulated core material. It describes the amount of synthetic polymer (e.g. in gram, g) used/needed to encapsulate a certain amount of core material (e.g. in gram, g) -the quotient of synthetic polymer (abbreviated to: SP) to core material (abbreviated to: CM).

[0077] As an example, commercially available phenolplastic microcapsules for laundry need at least 30 g synthetic polymer(s) (SP) to encapsulate 100 g of core material (CM) (to deliver stable microcapsules, which are stable even in harsh conditions like softener or detergents); CSP = 0.3. In one method according to the invention the produced multilayer microcapsules need less than 15 g synthetic polymer(s) (SP) per 100 g core material (CM), preferably less than 10 g synthetic polymer(s) per 100 g core material; CSP = 0.1.

[0078] As a consequence, producing microcapsules by a method according to the invention reduces the content of synthetic polymer(s) by 30%, preferred by 60%, more preferred by 75%, most preferred by 80%.

[0079] Microcapsules according to one preferred embodiment have a content of synthetic polymer(s) (CSP) less than or equal to (≤) 0.15, wherein the CSP is the quotient of the amount of synthetic polymer(s) encapsulating an amount of core material.

[0080] In a more preferred embodiment the multilayer microcapsules have a CSP of less than or equal to (≤) 0.15, preferred less than (<) 0.1, more preferred less than (<) 0.08.

[0081] The value for CSP can be determined by any method known by a skilled person in the art. Preferably the value for CSP can be determined in a first step, wherein the amount of synthetic polymer (SP) is determined by subtracting the amount of not reacted / unreacted monomers or other educts that were used to create (inner) shell material comprising synthetic polymer(s) during the production process of the microcapsules from the amount of monomers or other educts that were originally used to create (inner) shell material comprising synthetic polymer(s) during the production process of the microcapsules. In a second step, the amount of core material (CM) is determined by subtracting the amount of free / not encapsulated core material (core material which is not encapsulated during the production process of the microcapsules) from the amount of core material originally used to be encapsulated as core material during the production process. The quotient of SP and CM delivers the value for CSP.

[0082] In an embodiment the method according to the invention may comprise a further step c) wherein the slurry obtained after step b) is dried to provide dried microcapsules.

[0083] The drying process may be any technology which is state of the art, preferably spray drying, freeze drying, drum drying and/or pulse combustion drying, more preferred spray drying.

[0084] In a preferred embodiment, microcapsules are obtained or are obtainable by a method according to the invention.

[0085] Microcapsules according to any of the embodiments are stable in storage after drying for at least 14 days, preferably for at least 28 days, particularly preferably for at least 36 days at storage temperatures from 20 to 45° C. and at a relative air humidity of 30 to 70 %.

[0086] In a preferred embodiment of the invention the microcapsules are characterized in that the shell material comprises at least 40 wt.-% of a salt according to one of the embodiments and at least 0.1 wt.-% of a water-soluble polymer selected from the group consisting of celluloseether like carboxymethyl cellulose or salts thereof, preferably sodium carboxymethyl cellulose or polyelectrolytes like gum arabic, chitosan, xanthan gum, alginate, carrageen or pectine, more preferred the soluble polymer consist of carboxymethyl cellulose.

[0087] In a further preferred embodiment of the invention, the shell material comprises at least 40 wt.-% of a salt selected from the group consisting of calcium carbonate, magnesium carbonate, barium carbonate or mixtures thereof, particularly preferably calcium carbonate and at least 0.1 wt.-% of a soluble polymer is a cellulose, preferably is carboxymethyl cellulose, more preferably sodium carboxymethyl cellulose.

[0088] Typically, the microcapsules according to the invention have a hydrodynamic diameter d(90%) of between 1 .Math.m and 5.000 .Math.m, preferably between 5 .Math.m and 1.000 .Math.m, more preferably between 5 and 150 .Math.m, even more preferably between 10 and 120 .Math.m, most preferred between 10 and 100 .Math.m, with a standard deviation of ± 30 .Math.m (measured via DLS in deionized water at room temperature, volume-weighted evaluation).

[0089] The size of the microcapsules according to the invention could be adjusted by the mixing intensity of the emulsion or dispersion, especially by stirring (depending on the rounds per minute, rpm). Especially the size of multilayer microcapsules can be adjusted by producing and/or using correspondingly small template microcapsules.

[0090] The ratio of core material to shell material in step a) of the method according to the invention is preferably between 1:10 and 10:1, more preferred between 1:4 and 4:1, most preferred between 2:3 and 3:2.

[0091] In an embodiment according to the invention, the microcapsules open and release the core material at a pressure of at least 5 N, preferably at a pressure of at least 10 N, particularly preferably at a pressure of at least 50 N, extremely preferably at a pressure of at least 100 N.

[0092] In another embodiment the microcapsules according to the invention have a pH-depending opening mechanism. The microcapsules are opened and release the core material at a pH less (<) than 7.0, preferably at a pH less (<) than 6.0.

[0093] The present invention also relates to the use of microcapsules obtained or obtainable by the invention or to composition and products comprising them. Such compositions or products may be either solid or liquid product. According to a particular embodiment, liquid products are preferred. Preferred products and composition are used in the “home- or personal- care” industry, e.g. laundry or cleansing compositions.

[0094] The invention will now be further described by way of examples. It will be appreciated that the invention as claimed is not intended to be limited in any way by these examples.

PARTICULARLY PREFERRED EMBODIMENTS OF THE INVENTION

[0095] 1. A method for producing microcapsules with core material and shell material comprising following steps, [0096] a) providing an aqueous two-phase system comprising at least one salt, which is at least partially not dissolved in this two-phase system and a core material, which is one phase of the two-phase system, [0097] b) adding two solutions i) and ii) in the presence of at least one polymer, which is at least partially solved in solution i) and/or ii), wherein solution i) contains at least one salt of a cation of the salt from step a) and solution ii) contains at least one salt of an anion of the salt from step a).

[0098] 2. The method according to embodiment 1, characterized in that the salt in step a) is at least 50 wt% not dissolved at room temperature in the two-phase system of step a), preferred at least 75 wt%, more preferred at least 90 wt%, most preferred at least 95 wt%, based on the used amount of inorganic material in step a).

[0099] 3. The method according to embodiment 1 or 2, characterized in that the salt in step a) has a solubility in water of less than (<) 100 mg/L at room temperature, preferred less then (<) 50 mg/L.

[0100] 4. The method according to any one of the embodiments 1 to 3, characterized in that the salt of step a) is selected from the group consisting of calcium carbonate, calcium phosphate, calcium sulfate, calcium oxalate, magnesium carbonate, strontium carbonate, strontium sulphate, strontium oxalate, barium carbonate, barium sulfate, calcium fluoride, (modified) silica or mixtures thereof, preferably calcium carbonate, magnesium carbonate, barium carbonate or mixtures thereof, particularly preferably calcium carbonate.

[0101] 5. The method according to any one of the embodiments 1 to 4, characterized in that the salt in solution i) or in solution ii) of step b) is at least 40 wt% soluble at room temperature, preferred at least 65 wt%, more preferred at least 80 wt%, most preferred at least 95 wt%, based on the used amount of salt in solution i).

[0102] 6. The method according to any one of the embodiments 1 to 5, characterized in that the salt in solution i) or in solution ii) of step b) has a solubility in water of more than (>) 1 g/L at room temperature, preferred more then (>) 5 g/L, more preferred more then (>) 10 g/L.

[0103] 7. The method according to any one of the embodiments 1 to 6, characterized in that the salt in solution i) of step b) is selected from the group consisting of lithium carbonate, sodium carbonate, sodium oxalate, potassium carbonate, potassium oxalate, rubidium carbonate, cesium carbonate, sodium sulfate, potassium sulfate, magnesium sulfate, trisodium phosphate, tripotassium phosphate, amine fluoride, potassium fluoride or mixtures thereof, preferably lithium carbonate, sodium carbonate, potassium carbonate or mixtures thereof, particularly preferably potassium carbonate.

[0104] 8. The method according to to any one of the embodiments 1 to 6, characterized in that the salt in solution ii) of step b) is selected from the group consisting of calcium formate, barium formate, magnesium formate, calcium acetate, barium acetate, magnesium acetate, calcium propanoate, barium propanoate, magnesium propanoate, calcium chloride, strontium chloride, strontium sulfate, strontium phosphate or mixtures thereof, preferably calcium formate, barium formate, calcium acetate, barium acetate or mixtures thereof, particularly preferably calcium formate and/or calcium acetate.

[0105] 9. The method according to any one of the embodiments 1 to 8, characterized in that the soluble polymer of step b) is selected from the group consisting of celluloseether like carboxymethyl cellulose or salts thereof, preferably sodium carboxymethyl cellulose or polyelectrolytes like gum arabic, chitosan, xanthan gum, alginate, carrageen or pectine, more preferred the soluble polymer consist of carboxymethyl cellulose.

[0106] 10. The method according to embodiment 9, characterized in that the sodium carboxymethyl cellulose has an average molecular weight between 10.000 g/mol and 500.000 g/mol, preferred between 75.000 g/mol and 300.000 g/mol.

[0107] 11. The method according to embodiment 9 or 10, characterized in that the sodium carboxymethyl cellulose has a viscosity at room temperature between 10 and 200 cP, more preferred between 15 and 100 cP in a 2% aqueous solution.

[0108] 12. The method according to any one of the embodiments 9 to 11, characterized in that the sodium carboxymethyl cellulose has a substitution degree of 0.50 to 0.95, most preferred of 0.75 to 0.90.

[0109] 13. The method according to embodiment 1 to 12, characterized in that the core material is at least one hydrophobic ingredient or at least one template microcapsule.

[0110] 14. The method according to any one of the embodiments 1 to 13, characterized in that the hydrophobic ingredient is selected from the group consisting of alcohols, perfume oils, care substances, natural and/or synthetic oils, silicone oils, pesticides, biocides, pigments, phase change materials (PCM), fertilizer, adhesives, insecticides, solvents, lubricants, dyes and cooling substances or mixtures thereof.

[0111] 15. The method according to embodiment 13, characterised in that the template microcapsule comprises a shell material (inner shell material), which comprises a natural polymer, a resin or a mixture thereof.

[0112] 16. The method according to embodiment 15, characterised in that the resin is obtained by the condensation of thermosetting resins and a subsequent formation of microcapsules using aldehydes, preferably formaldehyde and optionally, wherein the shell material of the microcapsule has been treated with an oxidizing agent preferred with H.sub.2O.sub.2 prior to curing of the shell material optionally supplemented by silica or a silica derivative.

[0113] 17. The method according to embodiment 15 or 16, characterised in that the resin is obtained by reacting [0114] a) at least one aromatic alcohol or ethers or esters thereof and [0115] b) at least one aldehyde component that comprises at least two carbon atoms per molecule, and [0116] c) in the presence of at least one homopolymer or copolymer of 2-acrylamido-2-methyl-propane sulfonic acid or salts thereof.

[0117] 18. The method according to embodiment 17, characterised in that the at least one aromatic alcohol of a) is selected from phenol, the cresols (o-, m- and p-cresol), the naphthols (α- and β-naphthol), thymol, pyrocatechol, resorcinol, hydroquinone and 1,4-naphthohydroquinone, phloroglucinol, pyrogallol, or hydroxyhydroquinone.

[0118] 19. The method according to embodiment 17 or 18, characterised in that the aldehydic component b) is selected from valeraldehyde, capronaldehyde, caprylaldehyde, decanal, succindialdehyde, cyclohexanecarboxaldehyde, cyclopentanecarboxaldehyde, 2-methyl-1-propanal, 2-methylpropionaldehyde, acetaldehyde, acrolein, aldosterone, antimycin A, 8′-apo-β-carotene-8′-al, benzaldehyde, butanal, chloral, citral, citronellal, crotonaldehyde, dimethylaminobenzaldehyde, folinic acid, fosmidomycin, furfural, glutaraldehyde, glyceraldehyde, glycolaldehyde, glyoxal, glyoxylic acid, heptanal, 2-hydroxybenzaldehyde, 3-hydroxybutanal, hydroxymethylfurfural, 4-hydroxynonenal, isobutanal, isobutyraldehyde, methacrolein, 2-methylundecanal, mucochloric acid, N-methylformamide, 2-nitrobenzaldehyde, nonanal, octanal, oleocanthal, orlistat, pentanal, phenylethanal, phycocyanin, piperonal, propanal, propenal, protocatechuic aldehyde, retinal, salicylaldehyde, secologanin, streptomycin, strophanthidin, tylosin, vanillin, or cinnamaldehyde.

[0119] 20. The method according to any one of the preceding embodiments 17 to 19, characterised in that the molar ratio of the at least one aromatic alcohol a) to the at least one aldehydic component b), which comprises at least two carbon atoms per molecule, is between 1:2 and 1:3.5, preferably between 1:2.4 and 1:2.8, and is particularly preferably 1:2.6.

[0120] 21. The method according to any one of the preceding embodiments 15 to 20 characterised in that a surfactant is used.

[0121] 22. The method according to embodiment 21, characterised in that the surfactant is selected from the group consisting of sulfonated lignin, natural dispersants like quillaja saponin, lecithins, gum arabic, pectin, carrageenan, chitosan, chondroitin sulfate, cellulose gum, physically or chemically modified starch, whey protein, pea protein, egg white protein, silk protein, gelatin of fish, proteins of porcine or bovine origin, ester gum, fatty acids or mixtures thereof, preferably is sulfonated lignin

[0122] 23. The method according to embodiment 15 characterised in that the natural polymer is selected from the group consisting of gum arabic, chitosan, gelantine, pectine, chitin, glycogen, cellulose, xanthan gum or mixtures thereof.

[0123] 24. The method according to any one of the preceding embodiments characterised in that it comprises a further step of drying the slurry obtained in step c) to obtain dried microcapsules.

[0124] 25. Microcapsules obtained by a method according to any one of the embodiments 1 to 24.

[0125] 26. Microcapsules according to embodiment 25, characterised in that the microcapsules have a content of synthetic polymer(s) (CSP) less than or equal to (≤) 0.15, wherein the CSP is the quotient of the amount of synthetic polymer(s) encapsulating an amount of core material.

[0126] 27. Microcapsule slurry obtainable by the method of any one of the embodiments 1 to 23 or dried microcapsules obtainable by the method of embodiment 24.

[0127] 28. Microcapsules according to any one of the embodiments 25 to 27, characterized in that the microcapsules shell material comprises at least 40 wt.-% of a salt according to any one of the embodiments 2 to 8 and at least 0.1 wt.-% of a soluble polymer according to any one of the embodiments 9 to 12.

[0128] 29. Microcapsules according to any one of the embodiments 25 to 28, whereas the microcapsules have a hydrodynamic diameter d(90%) between 5 and 150 .Math.m, preferred between 10 and 120 .Math.m, more preferred between 10 and 100 .Math.m, with a standard deviation of ± 30 .Math.m.

[0129] 30. Microcapsules according to any one of the embodiments 25 to 29, whereas the microcapsules are stable in storage after drying for at least 14 days, preferably for at least 28 days, particularly preferably for at least 36 days at storage temperatures from 20 to 45° C. and at a relative air humidity of 30 to 70 %.

[0130] 31. Microcapsules according to any one of the embodiments 25 to 30, characterized in that they open and release the core material at a pressure of at least 5 N, preferably at a pressure of at least 10 N, particularly preferably at a pressure of at least 50 N, extremely preferably at a pressure of at least 100 N.

[0131] 32. Microcapsules according to any one of the embodiments 25 to 31, characterized in that they release the core material at a pH less (<) than 7.0, preferably at a pH less (<) than 6.0.

[0132] 33. Microcapsules comprising a shell material of a salt obtained by a method according to any one of the embodiments 1 to 24, and core material comprising at least one hydrophobic ingredient according to embodiment 14, or at least one template microcapsule/s comprising a shell material (inner shell material) according to any one of the embodiments 13 to 19 and a core material which comprises at least one hydrophobic ingredient according to embodiment 14.

[0133] 34. A composition comprising dried microcapsules as defined in embodiment 25, or microcapsules slurry as defined in embodiment 27, wherein the core material comprises at least one hydrophobic ingredient according to embodiment 14.

[0134] 35. A product that comprises dried microcapsules as defined in embodiment 25, or microcapsules slurry as defined in embodiment 27, in liquid or powder form.

EXAMPLES

Example 1

[0135] The process of microencapsulation of at least one hydrophobic substance by a method according to the invention, based on a Pickering emulsion process, can be described as two basic steps:

1. Creating a Two-Phase System

[0136] 1 g of precipitated calcium carbonate and 3 g fine precipitated calcium carbonate are dispersed in 80 ml of demineralized water in a 200 mL beaker (9000 rpm with the disperser/lab dissolver e.g. Ultra Turaxx®). When the calcium carbonate is well dispersed, the homogenization speed/intensity is slowly decreased to 3600 rpm. Then, 18.50 g of the water-immiscible core material (e.g. any hydrophobic compounds, perfume, fragrance oil etc.) is added dropwise to the dispersion. After 30 minutes the Pickering emulsion is ready and the emulsion formation is completed.

2. Growth/Thickening of the CaCO.SUB.3 Shell (Crystallization Process)

[0137] The emulsion from the first step is provided and heated to 40° C. The speed of the homogenizer is now at 400 rpm. Two solutions are then added to this emulsion in parallel. Solution 1 consists of 88.20 g deionized water, 9.8 g K.sub.2CO.sub.3 and 2 g of water-soluble carboxymethyl cellulose (CMC, with a substitution degree of more then 0.75, preferred more than 0.82). The second solution consists of 90 g deionized water and 10 g calcium chloride. Both solutions are added parallel and stepwise within the time span of 75 minutes.

[0138] Both the use of other inorganic compounds (and combinations thereof) and/or water-immiscible core material (and combinations thereof) are included in the disclosure of this invention.

Proof of Drying Stability

[0139] The drying stability of the microcapsules can be demonstrated by light microscopy. The following FIG. 1 clearly shows the dried microcapsules after spraying the slurry onto filter paper (see FIG. 1 and FIG. 2).

Proof of pH-Dependent Opening

[0140] The inorganic microcapsules were brought into contact with 1% acetic acid. The behavior of the capsules in this medium was evaluated by light microscopy. [0141] Step 1: Fixation of the capsules on a microscope slide [0142] Microscopic image see FIG. 3 [0143] Observation: Dry capsules can be clearly identified in both observation ranges. The surface of the capsules shows a clear structure. [0144] Step 2: Addition of 1% acetic acid [0145] Step 2.1: Observation 20 seconds after addition of 1% acetic acid [0146] Microscopic image see FIG. 4 [0147] Observation: CO.sub.2 gas bubbles are formed by the reaction of calcium carbonate with acetic acid. The structuring of the capsules surface is significantly reduced in both observation areas. [0148] Step 2.2: Observation 180 seconds after addition of 1% acetic acid [0149] Microscopic image see FIG. 5 [0150] Observation after 180 seconds: CO.sub.2 development has continued to increase. In observation range 1 the capsule shells have been completely dissolved. Only free oil droplets are still present here. In observation area 2 collapsed cascades are visible.

Leakage Test

[0151] A thermal analysis of microcapsules (shell material: CaCO.sub.3, core material: octane with coumarin) was performed. As comparison test a thermal analysis of pure octane without encapsulation was also performed. For the measurements a PERKINELMER TGA 8000™ Thermogravimetric analyzer was used. The test temperature program was for both samples the following: [0152] 1.) Holding for 1.0 min at 30° C., [0153] 2.) Heat from 30° C. to 80° C. at 5.00° C./min, [0154] 3.) Holding heat for 180.0 min at 80° C. min

[0155] Purging gas was nitrogen with a purge gas rate of 20.0 mL/min.

[0156] FIG. 6 shows the thermogramm for octane and CaCO.sub.3 microcapsules with a core material comprising octane. In the first step, part of the water and non-encapsulated octane evaporates. The subsequent isothermal storage at 80° C. corresponds to the leakage test, whereby any remaining water and non-encapsulated water will initially escape.

[0157] At the beginning of the actual leakage test, the capsule content is approx. 12.0 % from the 40th minute and decreases to 10.6 % at the end of the test. The calculated wall fraction of the microcapsules is 8.6 %, which means encapsulated octane is still present even after storage of the microcapsules under these drastic conditions.

Example 2 - Multi-Layer Microcapsules

[0158] The process of microencapsulation of at least one further microcapsule (template microcapsule) via a Pickering emulsion with a salt which is at least partially not dissolved in the aqueous two-phase system, based on an emulsion/suspension process, can be described in two main steps - the formation of the further microcapsules (template microcapsules) or the simple provision of such template microcapsules followed by the encapsulation with at least one salt which is at least partially not dissolved in the aqueous two-phase system.

A) First Step - Formation of a First Microcapsule (Template Microcapsule)

Version A: Aminoplastic Resin Method

[0159] The formation of the first capsule (template microcapsule) is based on the process described in patent WO2009/015872 A1. As protective colloids, biodegradable polymers carrying sulfonic acid groups are preferred, especially the sodium, calcium and ammonium salts of lignosulfonic acid.

[0160] The microcapsule composition is obtainable by the condensation of thermosetting resins and subsequent formation of microcapsules using aldehydes, preferably formaldehyde and optionally, wherein the shell material of the capsule has been treated with an oxidizing agent (e.g. H.sub.2O.sub.2) prior to curing of the shell material optionally supplemented by silica or a silica derivative.

Version B: Formaldehyde-Free Phenolic Resin Method

[0161] The formation of the first capsule (template microcapsule) is produced according to the process described in patent WO2011/110368 A2.

[0162] Those microcapsule’s shells comprise a resin which is prepared by reacting a) at least one compound selected from the group consisting of a1) amines and a2) aromatic or heteroaromatic compounds which are unsubstituted or substituted by one or more substituents from the group C.sub.1-C.sub.20 alkyl, OH, OR, COOH, SH, SR, NHCOR, OCOR, halogen, aromatic, wherein R represents a C.sub.1-C.sub.10 alkyl group, with b) at least one aldehydic component containing at least two C atoms per molecule, in the presence of c) at least one copolymer containing units of 2-acrylamido-2-methyl-propanesulfonic acid or its salts (AMPS) and/or 2-acrylamido-2-methyl-propanephosphonic acid or its salts (AMPP) and units of one or more (meth)acrylates. Preferred is a1) selected from the group consisting of urea, melamine and benzoguanamine and a2) is selected from the group consisting of one or more aromatic or heteroaromatic alcohols and/or one or more aromatic or heteroaromatic carboxylic acids, more preferably selected from the group consisting of pyrocatechol, resorcinol, hydroquinone and 1,4-naphthohydroquinone, phloroglucinol, pyrogallol, hydroxyhydroquinone, most preferably resorcinol and phloroglucin and the b) the least one aldehydic component is selected from the group consisting of valeraldehyde, caproic aldehyde, caprylic aldehyde, decanal, succindialdehyde, cyclohexane carbaldehyde, cyclopentane carbaldehyde, 2-methyl-1-propanal, 2-methylpropionaldehyde, acetaldehyde, acrolein, aldosterone, antimycin A, 8′-Apo-ß-caroten-8′-al, benzaldehyde, butanal, chloral, citral, citronellal, crotonaldehyde, dimethylaminobenzaldehyde, folic acid, fosmidomycin, furfural, glutaraldehyde, glyceraldehyde, glycolaldehyde, glyoxal, glyoxylic acid, Heptanal, 2-hydroxybenzaldehyde, 3-hydroxybutanal, hydroxymethylfurfural, 4-hydroxynonenal, isobutanal, isobutyraldehyde, methacrolein, 2-methylundecanal, mucochloric acid, N-methylformamide, 2-nitrobenzaldehyde, nonanal, octanal, oleocanthal, orlistat, pentanal, phenylethanal, phycocyanin, piperonal, propanal, propenal, protocatechualdehyde, retinal, salicylaldehyde, secologanin, streptomycin, strophanthidin, tylosin, vanillin, cinnamic aldehyde and c) is selected from the group consisting of biopolymer or a terpolymer, which is more preferably composed of units of AMPS or AMPP, preferably AMPS, and one or more (meth)acrylates.

[0163] Preferred are template microcapsules according to one of the two mentioned methods from version A or version B. According to the invention, template microcapsules from both methods can also be used as a mixture or independently of each other for the further encapsulation according to the invention’s method. In general, all capsules, particles or template microcapsules can be encapsulated by the method according to the invention.

B) Second Step - Encapsulation of the First Microcapsule (Template Microcapsule) by a Method According to the Invention

[0164] The process of microencapsulation of at least one template microcapsules by a method according to the invention, based on a Pickering suspension process, can be described as two basic steps:

1. Creating a Two-Phase System

[0165] 1 g of precipitated calcium carbonate and 3 g of fine precipitated calcium carbonate are dispersed in 80 ml of demineralized water in a 200 mL beaker (9000 rpm with the disperser e.g. Ultra Turaxx®). When the calcium carbonate is well dispersed, the homogenization speed/intensity is slowly decreased to 3600 rpm. Then, the core material, here template microcapsules, are added stepwise to the dispersion. After 30 minutes the Pickering suspension is ready.

2. Growth/Thickening of the CaCO.SUB.3 Shell (Crystallization Process)

[0166] The two-phase system (suspension) from the first step is provided and heated to 40° C. The speed of the homogenizer is now at 400 rpm. Two solutions are then added to this suspension in parallel. Solution 1 consists of 88.20 g deionized water, 9.8 g K.sub.2CO.sub.3 and 2 g of water-soluble carboxymethyl cellulose (CMC, with a substitution degree of more then 0.75, preferred more than 0.82). The second solution consists of 90 g deionized water and 10 g calcium formate. Both solutions are added parallel and stepwise within the time span of 15 minutes

[0167] Both the use of other inorganic compounds (and combinations thereof) and/or other core materials (and combinations thereof) are included in the disclosure of this invention.