U.S. patent application number 14/945479 was filed with the patent office on 2016-05-26 for systems for encapsulation of actives within droplets and other compartments.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Alireza Abbaspourrad, Marco Caggioni, Chang-Hyung Choi, David A Weitz, John Christopher Wesner, Taotao Zhu.
Application Number | 20160144329 14/945479 |
Document ID | / |
Family ID | 54782825 |
Filed Date | 2016-05-26 |
United States Patent
Application |
20160144329 |
Kind Code |
A1 |
Wesner; John Christopher ;
et al. |
May 26, 2016 |
Systems for Encapsulation of Actives within Droplets and other
Compartments
Abstract
The present invention generally relates to microparticles and,
in particular, to systems and methods for encapsulation within
microparticles. In one aspect, the present invention is generally
directed to microparticles containing entities therein, where the
entities contain an agent that can be released from the
microparticles, e.g., via diffusion. In some cases, the agent may
be released from the microparticles without disruption of the
microparticles. The entities may be, for instance, polymeric
particles, hydrogel particles, droplets of fluid, etc. The entities
may be contained within a fluid that is, in turn, encapsulated
within the microparticle. The agent may be released from the entity
into the fluid, and then from the fluid through the microparticle.
In such fashion, the release of agent from the microparticle may be
controlled, e.g., over relatively long time scales. Other
embodiments of the present invention are generally directed to
methods of making such microparticles, methods of using such
microparticles, microfluidic devices for making such
microparticles, and the like.
Inventors: |
Wesner; John Christopher;
(Liberty Township, OH) ; Caggioni; Marco;
(Cincinnati, OH) ; Zhu; Taotao; (West Chester,
OH) ; Weitz; David A; (Bolton, MA) ;
Abbaspourrad; Alireza; (Ithaca, NY) ; Choi;
Chang-Hyung; (Belmont, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
54782825 |
Appl. No.: |
14/945479 |
Filed: |
November 19, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62083729 |
Nov 24, 2014 |
|
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|
Current U.S.
Class: |
425/5 |
Current CPC
Class: |
A61Q 13/00 20130101;
A61K 8/8129 20130101; A61K 8/11 20130101; B01F 2003/0838 20130101;
B01J 13/06 20130101; C09K 15/08 20130101; A61K 9/5089 20130101;
A61K 2800/412 20130101; B01F 2003/0834 20130101; B01F 2005/0034
20130101; C11B 9/0046 20130101; A61K 8/86 20130101; B01F 5/02
20130101; B01F 13/0062 20130101; A61K 2800/56 20130101; Y10T
428/2984 20150115; B01F 3/0807 20130101; B01F 5/045 20130101; B01J
13/14 20130101 |
International
Class: |
B01J 13/06 20060101
B01J013/06 |
Claims
1. An apparatus for producing microparticles, comprising: a first
reservoir containing a first liquid, wherein the first liquid is an
emulsion comprising a dispersed phase and a continuous phase, the
first reservoir being in fluid communication with a plurality of
first conduits having exits; a second reservoir containing a second
liquid, the second reservoir being in fluid communication with a
plurality of second conduits, the second conduits at least partly
surrounding the first conduits; a third reservoir containing a
third liquid, the third reservoir being in fluid communication with
second conduits; and a plurality of third conduits disposed at
least in part within the second conduits downstream of the exits of
the first conduits, the third conduits positioned to receive the
first liquid exiting the first conduits, the second liquid and the
third liquid.
2. The apparatus of claim 1, wherein the first reservoir is in
switchable fluid communication with the plurality of first conduits
and further comprising a fourth reservoir containing a fourth
liquid, wherein the fourth liquid is an emulsion comprising a
dispersed phase and a continuous phase, the fourth reservoir being
in switchable fluid communication with the plurality of first
conduits.
3. The apparatus of claim 1, wherein the dispersed phase of the
first liquid is substantially miscible with the second liquid and
the dispersed phase of the fourth liquid is substantially
immiscible with the second liquid.
Description
FIELD
[0001] The present invention generally relates to microparticles
and, in particular, to systems and methods for encapsulation within
microparticles.
BACKGROUND
[0002] Microparticles such as microcapsules have great potential
for applications involving encapsulation, delivery, and release of
agents in fields such as agriculture, health care, cosmetics and
detergents, construction chemicals, and food and beverages. A
variety of physical and chemical methods, including spray-drying,
coextrusion, interfacial polymerization, and complex coacervation,
have been used for high-throughput preparation of microparticles.
For example, using various microfluidic technologies, a variety of
agents have been encapsulated into emulsions, which are then
solidified to form solid microparticles or other types of
particles, for instance, by interfacial polycondensation, freezing,
or polymerization. However, improvements in particle technologies
are still needed.
[0003] In formulated products containing high levels of surfactants
as well as microparticles with oil based payloads, the presence of
the surfactants tends to increase the likelihood of the migration
of the payload out of the micro particles and decrease the useful
shelf life of the product. Microparticles having greater payload
stability when disposed in an environment having a high
concentration of surfactants are desired.
SUMMARY
[0004] The present invention generally relates to microparticles
and, in particular, to systems and methods for encapsulation within
microparticles. The subject matter of the present invention
involves, in some cases, interrelated products, alternative
solutions to a particular problem, and/or a plurality of different
uses of one or more systems and/or articles.
[0005] In one aspect, the present invention is generally directed
to a method. In some cases, the method is a method of release of
agent from a particle, such as a microparticle. In one set of
embodiments, the method includes an act of exposing, to an
environment, a plurality of microparticles comprising a shell and a
fluid within the shell, the fluid comprising a plurality of
entities containing an agent, and causing release of at least about
50 wt % of the agent from the plurality of microcapsules without
disruption of the shell.
[0006] The present invention, in another aspect, is generally
directed to a composition. In one set of embodiments, the
composition comprises a plurality of microparticles comprising a
shell and a fluid within the shell, the fluid comprising a
plurality of entities containing an agent, where at least 50 wt %
of the agent is releasable from the microparticles without
disruption of the shell. According to another set of embodiments,
the composition comprises a plurality of microparticles comprising
a shell and a fluid within the shell, the fluid comprising a
plurality of entities containing an agent, where the plurality of
entities within the shell has a volume of at least 50% of the
volume of the shell.
[0007] In one aspect, a composition includes a plurality of
microparticles. Each microparticle includes a single core which
contains a liquid emulsion having a dispersed phase and a
continuous phase; and a shell surrounding the single core. The
shell has a mean wall thickness of between about 0.1 .mu.m, and
about 10 .mu.m.
[0008] In one aspect, a composition includes a plurality of
microparticles. Each microparticle includes a single core which
contains a liquid emulsion having a dispersed phase and a
continuous phase; and a shell surrounding the single core. The
shell has a mean wall thickness of between about 0.1 .mu.m, and
about 10 .mu.m. The core comprises an aqueous phase, an oil phase,
and a surfactant.
[0009] In another aspect, the present invention encompasses methods
of making one or more of the embodiments described herein, for
example, microfluidic droplets encapsulating entities.
[0010] In one aspect, the method is directed to the production of
microparticles and includes the steps of: providing a first liquid
to a system of microfluidic devices, introducing a stream of the
first liquid into a stream of a second liquid, introducing a stream
of a third liquid which surrounds the second liquid, and forming
droplets within the third liquid. The first liquid includes an
emulsion having a dispersed phase and a continuous phase as it is
introduced into the second liquid. The continuous phase of the
first liquid is substantially immiscible in the second liquid. The
droplets comprise a core including the first liquid and a shell
comprised of the second liquid.
[0011] In one aspect, an apparatus for producing microparticles
includes: a first reservoir containing a first liquid, a second
reservoir containing a second liquid, and a third reservoir
containing a third liquid. The first liquid includes an emulsion.
The emulsion includes a dispersed phase and a continuous phase. The
continuous phase of the emulsion is substantially immiscible in the
second fluid. The first reservoir is in fluid communication with
the first conduits of a plurality of microfluidic devices. The
first conduits have exits. The second reservoir in is fluid
communication with second conduits. The second conduits at least
partially surround the first conduits. The third reservoir is in
fluid communication with the second conduits. The apparatus also
includes third conduits disposed, at least in part, within the
second conduits, downstream of the exits of the first conduits.
[0012] In still another aspect, the present invention encompasses
methods of using one or more of the embodiments described herein,
for example, microfluidic droplets encapsulating entities.
[0013] Other advantages and novel features of the present invention
will become apparent from the following detailed description of
various non-limiting embodiments of the invention when considered
in conjunction with the accompanying figures. In cases where the
present specification and a document incorporated by reference
include conflicting and/or inconsistent disclosure, the present
specification shall control. If two or more documents incorporated
by reference include conflicting and/or inconsistent disclosure
with respect to each other, then the document having the later
effective date shall control.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Non-limiting embodiments of the present invention will be
described by way of example with reference to the accompanying
figures, which are schematic and are not intended to be drawn to
scale. In the figures, each identical or nearly identical component
illustrated is typically represented by a single numeral. For
purposes of clarity, not every component is labeled in every
figure, nor is every component of each embodiment of the invention
shown where illustration is not necessary to allow those of
ordinary skill in the art to understand the invention. In the
figures:
[0015] FIGS. 1A-1D illustrate methods useful for forming
microparticles, in accordance with one embodiment of the
invention;
[0016] FIG. 2 illustrates the production of a particle suspension,
in another embodiment of the invention;
[0017] FIG. 3 illustrates the structure of a microparticle, in yet
another embodiment of the invention; and
[0018] FIG. 4 illustrates a device for producing particle
suspensions, in still another embodiment of the invention.
[0019] FIG. 5 illustrates data associated with the relative
stability of microcapsules having a hydrogel continuous phase and
control microcapsules having an aqueous continuous phase.
[0020] FIG. 6 provides a schematic illustration of an apparatus
according to one embodiment of the invention.
DETAILED DESCRIPTION
[0021] The present invention generally relates to microparticles
and, in particular, to systems and methods for encapsulation within
microparticles. In one aspect, the present invention is generally
directed to microparticles containing entities therein, where the
entities contain an agent that can be released from the
microparticles, e.g., via diffusion. In some cases, the agent may
be released from the microparticles without disruption of the
microparticles. The entities may be, for instance, polymeric
particles, hydrogel particles, droplets of fluid, etc. The entities
may be contained within a fluid that is, in turn, encapsulated
within the microparticle. The agent may be released from the entity
into the fluid, and then from the fluid through the microparticle.
In such fashion, the release of agent from the microparticle may be
controlled, e.g., over relatively long time scales. Other
embodiments of the present invention are generally directed to
methods of making such microparticles, methods of using such
microparticles, microfluidic devices for making such
microparticles, and the like.
[0022] One aspect of the invention is now described with reference
to FIG. 3. In this example figure, a microparticle 10 comprises a
shell 15 surrounding a fluid 20. Within fluid 20 are a plurality of
entities 25. The entities may be, for example, polymeric particles,
hydrogel particles, droplets of an immiscible fluid, or the like.
The entities may also contain an agent 30 to be released from
microparticle 10. To be released, agent 30 must travel from
entities 25 through fluid 20 and shell 15. In some cases, shell 15
may be kept intact or undamaged during the release of agent 30.
Thus, agent 30 may diffuse out of entities 25, through fluid 20,
and through shell 15, before being released from microparticle 10.
Accordingly, the microparticles, in certain embodiments, can
provide for the controlled rate of release of agent 30.
[0023] In one embodiment, the fluid 20 comprises an emulsion
comprising a continuous phase and a dispersed phase. The entities
may comprise the dispersed phase of the emulsion. In such
embodiments, the continuous phase may constitute an aqueous phase
and the dispersed phase may constitute an oil phase. The fluid may
further comprise a surfactant. In one embodiment, the first fluid
may comprise a suspo-emulsion comprising a continuous phase and
particles suspended in the continuous phase.
[0024] Exemplary emulsions may be created by dispersing an oil
phase material in an aqueous phase with mechanical agitation.
Exemplary forms of mechanical agitation include: shaking, mixing,
agitators, sonication, colloid mills, rotors, rotor-stator, static
mixers, flow-through static mixers, homogenizers, high-shear
microfluidic collision processors, a Microfluidizer.RTM., vortex
mixers, a speed mixer, and a high shear homogenizer. Exemplary
emulsions include an emulsion of 0.1-0.4 wt % Permulen TR-2
surfactant in perfume oil, and an emulsion of .alpha.-pinene in a
solution of 2.5% (v/v) PVA and 2% (w/w) Tween 80.
[0025] Exemplary continuous phase materials for the first liquid
include: water, glycerine, formamide, dimethyl formamide, dimethyl
sulfoxide, polyethylene glycol, propylene glycol, and fluorinated
oils.
[0026] In some cases, the release profile may be relatively slow,
e.g., having a characteristic time of release of hours or days. In
addition, in certain embodiments, the rate of release of agent from
the microparticle may not necessarily be controlled by the amount
of agent contained within the microparticle; for example, diffusion
of the agent through the fluid may be rate-limiting, and the
entities may act as a reservoir to contain agent prior to diffusion
through the fluid. In contrast, in other particles loaded with
agent, the amount and rate of agent released from the particle is
usually a function of the amount of agent contained within the
particle.
[0027] In some cases, the microparticles may be exposed to an
environment to which the agent is to be released. The agent may be
caused to be released from the microparticles via a variety of
techniques. The release of agent may occur without disrupting the
microparticles, e.g., by damaging the shell of the microparticles
to release the agent from within. In one set of embodiments, the
agent may be released by agitating the microparticles. In another
set of embodiments, the microparticles may be exposed to a fluid,
such as oil (e.g., a hydrocarbon oil, crude oil, petroleum, etc.),
or to water. In some cases, the agent may diffuse through the
microparticles to be released at the surface of the microparticles
into the surrounding environment, e.g., if the microparticles are
contained in a fluid, such as an oil or water.
[0028] The microparticles may be produced by a variety of
techniques. For example, FIG. 4 describes one non-limiting system
for producing such microparticles. In this figure, a fluid 20
containing entities 25 suspended therein flows through a first
channel 30. As discussed below, fluid 20 becomes encapsulated
within microparticles. In addition, first channel 30 has an exit
opening 34 contained within channel 40. Also contained in channel
40 is fluid 45, which will be used to produce the shell of the
microparticle, and fluid 50, which will contain the microparticles.
In this figure, fluid 45 flows around channel 30 towards exit
opening 34 of channel 30, where it surrounds fluid 20 emerging out
of the exit opening. In turn fluid 45 is surrounded by fluid 50.
Fluids 45 and 50 may be substantially immiscible in certain
embodiments. At exit opening 34, multiple emulsion droplets may be
formed, containing fluid 20, surrounded by droplets of fluid 45,
contained within continuous fluid 50. Fluid 45 may also be hardened
or reacted to form a shell surrounding fluid 20 by, for example,
exposing the formed droplet to appropriate electromagnetic
radiation. See also Int. Pat. Apl. Pub. Nos. WO 2006/096571 or WO
2013/006661, each incorporated herein by reference in its entirety,
for other examples.
[0029] The above discussion illustrates non-limiting examples of
certain embodiments of the present invention generally directed to
fluids encapsulated within microparticles. However, other
embodiments are also possible. Accordingly, more generally, various
aspects of the invention are directed to various systems and
methods for encapsulation within microparticles
[0030] For instance, in one aspect, the microparticles may comprise
a plurality of entities therein containing one or more agents. Any
suitable entities able to contain an agent and remain as separate
entities when contained within a fluid may be used. The entities
may be solid, or fluid in some embodiments.
[0031] In one set of embodiments, for example, the entities may be
a second fluid that is substantially immiscible within the fluid
within the microparticles. However, the entities may be
substantially prevented from merging or coalescing together using
surfactant or other suitable techniques. Thus, the entities are
able to remain as discrete or separate entities within the fluid.
Thus, for example, if the fluid within the microparticles is
aqueous (e.g., a "water" phase), the fluid forming the entities may
be a non-aqueous fluid that is substantially immiscible within the
aqueous fluid (e.g., an "oil" phase), or vice versa.
[0032] In one embodiment, the entities may comprise a fluid which
is substantially miscible in the shell of the microparticles.
[0033] It should be understood that the "water" phase is not
limited to only pure water, but may be any fluid miscible in water,
and/or the fluid may be water but contain other substances
dissolved or suspended therein, etc. Similarly, the "oil" phase
need not be a hydrocarbon oil, but may be any fluid that is
substantially immiscible in water. Accordingly, the terms "oil" and
"water" are used as terms of convenience, as is typically expressed
by those of ordinary skill in the art.
[0034] The entities contained within the microparticles need not be
fluid. In another set of embodiments, the entities may be
particles, for example, polymeric particles or hydrogel particles,
etc. Any of a wide variety of particles may be used, for example,
that can be contained or suspended in a fluid that is to be
encapsulated within a microparticle. For example, the entities may
comprise hydrogels such as agarose, polyacrylamide,
poly(N-isopropylacrylamide), or the like, or polymers such as
polystyrene, polypropylene, polyethylene, polycaprolactone,
polyisoprene, poly(lactic acid), polycaprolactone, poly(lactic
acid), polyacrylonitrile, polyimide, polyamide, and/or mixtures
and/or co-polymers of these and/or other polymers. The polymeric
particles may be formed using microfluidic techniques known to
those of ordinary skill in the art, or using other techniques that
are not necessarily microfluidic. In some cases, the particles are
nanoparticles e.g., having an average diameter of less than 1
micrometer.
[0035] Any suitable number of entities may be contained within a
microparticle. In some embodiments, however, there may be a
relatively large number of entities contained within a
microparticle, e.g., if the entities are relatively small relative
to the size of the microparticles. In some cases, entities with
relatively high loading densities may be achieved, as discussed
herein, by starting with a fluid having a relatively high loading
density of such entities.
[0036] The entities may be relatively small in some embodiments.
For example, the entities may have an average diameter of less than
about 1 micrometer, less than about 500 nm, less than about 300 nm,
less than about 200 nm, less than about 100 nm, less than about 50
nm, less than about 30 nm, less than about 20 nm, or less than
about 10 nm, etc. The entity may be spherical or non-spherical. The
average diameter of a non-spherical entity may be taken as the
diameter of a perfect sphere having the same volume as the
non-spherical entity.
[0037] In another set of embodiments, the entities may have an
average diameter that is less than about 30%, less than about 20%,
less than about 15%, less than about 10%, less than about 5%, less
than about 3%, less than about 2%, less than about 1%, less than
about 0.5%, less than about 0.3%, less than about 0.2%, less than
about 0.1%, or less than about 0.05% of the average diameter of the
microparticle containing the entities. The diameter or volume of
the entities may be determined directly, e.g., using optical or
electron microscopy, and or estimated, e.g., based on the overall
volume of entities contained within the microparticles.
[0038] In one set of embodiments, the microparticles may each
contain, on average, at least about 100, at least about 200, at
least about 300, at least about 500, at least about 1000, at least
about 2000, at least about 3000, at least about 5000, at least
about 10,000, at least about 20,000, at least about 300,000, or at
least about 500,000 entities therein. The microparticles may also,
in some cases, exhibit a relatively uniform distribution of
entities per microparticles.
[0039] In some cases, the entities may exhibit a core loading
within microparticle such that the entities take up at least about
1%, at least about 50%, at least about 60%, at least about 70%, at
least about 75%, at least about 80% at least about 85%, at least
about 90%, at least about 95%, at least about 97%, at least about
98%, at least about 99%, at least about 99.5%, or at least about
99.7% of the volume of the interior of the microparticle (i.e., not
including the volume of the shell). Such relatively high loadings
of entities are surprising and not routinely achievable in many
microfluidic prior art techniques. In one embodiment, the core of
the microparticle comprises about 20% continuous phase and about
80% dispersed phase.
In one embodiment, the core loading of the dispersed phase may be
between about 1% and about 80% of the volume of the interior of the
particle. In one embodiment, the core loading of the dispersed
phase may be between about 50% and about 70% of the volume of the
interior of the particle.
[0040] The entities may, in some cases, be relatively monodisperse.
For example, the entities within a microparticle may have an
overall average diameter and a distribution of diameters such that
no more than about 5%, no more than about 2%, or no more than about
1% of the particles or droplets have a diameter less than about 90%
(or less than about 95%, or less than about 99%) and/or greater
than about 110% (or greater than about 105%, or greater than about
101%) of the overall average diameter of the plurality of entities.
However, in other cases, the entities may not necessarily be
relatively monodisperse.
[0041] The entities may contain one or more than one agent, in any
suitable distribution. For example, a microparticle may contain a
first entity containing a first agent and a second entity
containing a second agent, or an entity containing both first and
second agents, or the like. If more than one microparticle is
present, the microparticles may independently contain the same or
different agents, at the same or different concentrations, etc.
[0042] Any suitable concentration of agent may be present within
the entities. For instance, the agent may be present within the
entities at a concentration of at least about 0.001 M, at least
about 0.003 M, at least about 0.005 M, at least about 0.01 M, at
least about 0.03 M, at least about 0.05 M, at least about 0.1 M, at
least about 0.3 M, at least about 0.5 M, at least about 1 M, etc.
The type or concentration of agent used may depend, for example, on
the particular application.
[0043] Thus, the systems and methods described herein can be used
in a plurality of applications. For example, fields in which the
microparticles described herein may be useful include, but are not
limited to, food, beverage, health and beauty aids, paints and
coatings, chemical separations, agricultural applications, and
drugs and drug delivery. For instance, a precise quantity of a
fluid, drug, pharmaceutical, or other agent can be contained in an
entity. Non-limiting examples include biochemical species such as
nucleic acids such as siRNA, RNAi and DNA, proteins, peptides, or
enzymes. Additional agents that may be used include, but are not
limited to, colloidal particles, magnetic particles, nanoparticles,
quantum dots, fragrances, perfumes, proteins, indicators, dyes,
fluorescent species, chemicals, biocides, or the like.
[0044] Exemplary perfume materials may comprise a material selected
from the group consisting of prop-2-enyl 3-cyclohexylpropanoate,
(4aR,5R,7aS,9R)-octahydro-2,2,5,8,8,9a-hexamethyl-4h-4a,9-methanoazuleno(-
5,6-d)-1,3-dioxole,
(3aR,5aS,9aS,9bR)-3a,6,6,9a-tetramethyl-2,4,5,5a,7,8,9,9b-octahydro-1H-be-
nzo[e][1]benzofuran, 4-methoxybenzaldehyde, benzyl
2-hydroxybenzoate, 2-methoxynaphthalene,
3-(4-tert-butylphenyl)propanal,
3a,6,6,9a-tetramethyl-2,4,5,5a,7,8,9,9b-octahydro-1H-benzo[e][1]benzofura-
n, 3,7-dimethyloct-6-en-1-ol, 3,7-dimethyloct-6-enenitrile,
3-(4-tert-butylphenyl)butanal, 3-(4-propan-2-ylphenyl)butanal,
(E)-1-(2,6,6-trimethyl-1-cyclohexa-1,3-dienyl)but-2-en-1-one,
decanal, (E)-1-(2,6,6-trimethyl-1-cyclohex-3-enyl)but-2-en-1-one,
(5E)-3-methylcyclopentadec-5-en-1-one, 2,6-dimethyloct-7-en-2-ol,
ethyl 2-methylpentanoate, ethyl 2-methylbutanoate,
1,3,3-trimethyl-2-oxabicyclo[2,2,2]octane,
2-methoxy-4-prop-2-enylphenol,
3a,4,5,6,7,7a-hexahydro-4,7-methano-1H-indenyl acetate,
3-(3-propan-2-ylphenyl)butanal,
a,4,5,6,7,7a-hexahydro-1H-4,7-methanoinden-1-yl propanoate,
(2E)-3,7-dimethylocta-2,6-dien-1-ol,
(12E)-1-oxacyclohexadec-12-en-2-one,
[2-[1-(3,3-dimethylcyclohexyl)ethoxy]-2-methylpropyl]propanoate,
hexyl acetate, 2-(phenylmethylidene)octanal, hexyl
2-hydroxybenzoate,
(E)-4-(2,6,6-trimethyl-1-cyclohex-2-enyl)but-3-en-2-one,
(E)-4-(2,6,6-trimethyl-1-cyclohexenyl)but-3-en-2-one,
(E)-3-methyl-4-(2,6,6-trimethyl-1-cyclohex-2-enyl)but-3-en-2-one,
1-(2,3,8,8-tetramethyl-1,3,4,5,6,7-hexahydronaphthalen-2-yl)ethanone,
propan-2-yl 2-methylbutanoate,
(1R,2S,5R)-5-methyl-2-propan-2-ylcyclohexan-1-ol,
(E)-2-ethyl-4-(2,2,3-trimethyl-1-cyclopent-3-enyl)but-2-en-1-ol,
2,4-dimethylcyclohex-3-ene-1-carbaldehyde,
3,7-dimethylocta-1,6-dien-3-ol, 3,7-dimethylocta-1,6-dien-3-yl
acetate,
1-((3R,3aS,7R,8aS)-2,3,4,7,8,8a-hexahydro-3,6,8,8-tetramethyl-1H-3a,7-met-
hanoazulen-5-yl)-ethanone, methyl
3-oxo-2-pentylcyclopentaneacetate, 2-methylundecanal,
2-[2-(4-methyl-1-cyclohex-3-enyl)propyl]cyclopentan-1-one,
1-(5,5-dimethyl-1-cyclohexenyl)pent-4-en-1-one,
2-cyclohexylidene-2-phenylacetonitrile, 2-phenylethanol,
3,7-dimethyloctan-3-ol, 5-heptyloxolan-2-one,
(2-tert-butylcyclohexyl)acetate, (E)-4-methyldec-3-en-5-ol,
(4-tert-butylcyclohexyl)acetate,
decahydro-2,2,6,6,7,8,8-heptamethyl-2H-indeno(4,5-b)furan,
17-oxacycloheptadec-6-en-1-one, pentyl 2-hydroxybenzoate, benzyl
acetate, 4-phenylbutan-2-one, 2-methoxynaphthalene,
1,7,7-trimethylbicyclo[2.2.1]heptan-2-one,
1,1,2,3,3-pentamethyl-2,5,6,7-tetrahydro-inden-4-one,
1H-3a,7-Methanoazulene, octahydro-6-methoxy-3,6,8,8-tetramethyl,
[(Z)-hex-3-enyl]acetate, [(Z)-hex-3-enyl]2-hydroxybenzoate,
(9Z)-cycloheptadec-9-en-1-one, chromen-2-one, cyclohexyl
2-hydroxybenzoate, ethyl 3-methyl-3-phenyloxirane-2-carboxylate,
3-ethoxy-4-hydroxybenzaldehyde,
1,4-dioxacycloheptadecane-5,17-dione, 16-oxacyclohexadecan-1-one,
diethyl cyclohexane-1,4-dicarboxylate,
1-(5,5-dimethyl-1-cyclohexenyl)pent-4-en-1-one,
[(2E)-3,7-dimethylocta-2,6-dienyl]acetate,
3-(1,3-benzodioxol-5-yl)-2-methylpropanal,
1,3-benzodioxole-5-carbaldehyde,
6-(pent-3-en-1-yl)tetrahydro-2H-pyran-2-one,
[(1R,2S)-1-methyl-2-[[(1R,3S,5S)-1,2,2-trimethyl-3-bicyclo[3.1.0]hexanyl]-
methyl]cyclopropyl]methanol,
(Z)-3,4,5,6,6-pentamethyl-hept-3-en-2-one, dodecanal,
3,7-dimethylnona-2,6-dienenitrile, (2S)-2-aminopentanedioic acid,
methyl 2,4-dihydroxy-3,6-dimethylbenzoate,
2,6-dimethyloct-7-en-2-ol,
4-(4-hydroxy-4-methylpentyl)cyclohex-3-ene-1-carbaldehyde,
1-naphthalen-2-ylethanone, 4-methyl-2-(2-methylprop-1-enyl)oxane,
1H-Indene-ar-propanal, 2,3-dihydro-1,1-dimethyl-(9CI), nonanal,
octanal, 2-phenylethyl 2-phenylacetate,
3-methyl-5-phenylpentan-1-ol, 4-methyl-2-(2-methylpropyl)oxan-4-ol,
1-oxacycloheptadecan-2-one,
1-(spiro[4.5]dec-7-en-7-yl)pent-4-en-1-one,
2-(4-methyl-1-cyclohex-3-enyl)propan-2-ol,
1-methyl-4-propan-2-ylidenecyclohexene,
(4-methyl-1-propan-2-yl-1-cyclohex-2-enyl)acetate,
1,2-dimethylcyclohex-3-ene-1-carbaldehyde, undec-10-enal,
[(4Z)-1-cyclooct-4-enyl]methyl carbonate,
8-methyl-1,5-benzodioxepin-3-one, nona-2,6-dienal,
(5Z)-cyclohexadec-5-en-1-one, 2,6,10-trimethylundec-9-enal,
prop-2-enyl hexanoate,
(E)-1-(2,6,6-trimethyl-1-cyclohex-2-enyl)but-2-en-1-one,
3-phenylprop-2-en-1-ol, 3,7-dimethylocta-2,6-dienal,
3,7-dimethyloct-6-enyl acetate,
[2-(2-methylbutan-2-yl)cyclohexyl]acetate,
3a,4,5,6,7,7a-hexahydro-4,7-methano-1H-inden-5-yl 2-methyl
propanoate, 2-pentylcyclopentan-1-ol, (E)-dec-4-enal,
2-pentylcyclopentan-1-one, 2-methoxy-4-propylphenol, methyl
2-hexyl-3-oxocyclopentane-1-carboxylate, phenoxybenzene, ethyl
3-phenylprop-2-enoate,
(E)-2-ethyl-4-(2,2,3-trimethyl-1-cyclopent-3-enyl)but-2-en-1-ol,
3-(4-ethylphenyl)-2,2-dimethyl-propanal,
4-methyl-2-(2-methylpropyl)oxan-4-ol, 2-methyldecanenitrile,
5-hexyloxolan-2-one, 5-(diethoxymethyl)-1,3-benzodioxole,
7-hydroxy-3,7-dimethyloctanal,
(E)-4-(2,5,6,6-tetramethyl-1-cyclohex-2-enyl)but-3-en-2-one,
[(1R,4S,6R)-1,7,7-trimethyl-6-bicyclo[2.2.1]heptanyl]acetate,
6-butan-2-ylquinoline, 2-methoxy-4-prop-1-en-2-ylphenol,
(NE)-N-[(6E)-2,4,4,7-tetramethylnona-6,8-dien-3-ylidene]hydroxylamine,
(4-propan-2-ylcyclohexyl)-methanol, 2,6-dimethylhept-5-enal,
(1R,2S,5R)-5-methyl-2-propan-2-ylcyclohexan-1-ol, ethyl
2-(2-methyl-1,3-dioxolan-2-yl)acetate, 1-phenylethyl acetate,
1-(3,5,5,6,8,8-hexamethyl-6,7-dihydronaphthalen-2-yl)ethanone,
6-butyloxan-2-one,
2,4-dimethyl-2-(5,6,7,8-tetrahydro-5,5,8,8-tetramethyl-2-naphthalenyl)-1,-
3-dioxolane, (2R,4S)-2-methyl-4-propyl-1,3-oxathiane,
4-(4-hydroxyphenyl)butan-2-one, 3-methyl-5-phenylpentan-1-ol,
4-((1R,5S)-6,6-dimethylbicyclo[3.1.1]hept-2-en-2-yl)-3,3-dimethylbutan-2--
one, 3-methylbut-2-enyl acetate, dec-9-en-1-ol,
5-(3-methylphenyl)pentan-1-ol, 3,7-dimethyloctan-3-ol,
1-methoxy-4-[(E)-prop-1-enyl]benzene,
4-hydroxy-3-methoxybenzaldehyde,
9-acetyl-2,6,6,8-tetramethyltricyclo(5.0.3.1.01,5)undec-8-ene,
2,5-dioxacyclohexa-decane-1,6-dione and mixtures thereof;
[0045] In one embodiment, the agent may comprise a material
selected from the group consisting of a small molecule dye, a
polymeric dye, a dye clay conjugate, a pigment or mixtures
thereof;
[0046] In one embodiment, the agent may comprise a silicone. The
silicone may comprise a material selected from the group consisting
of non-functionalized siloxane polymers, functionalized siloxane
polymers, silicone resins, silicone solvents, cyclic silicones and
mixtures thereof.
[0047] In such embodiments, the functionalized siloxane polymers
may comprise aminosilicones, amidosilicones, silicone polyethers,
silicone-urethane polymers, quaternary ABn silicones, amino ABn
silicones, and mixtures thereof.
[0048] In such embodiments, the non-functionalized siloxane polymer
may comprise polydimethylsiloxane, dimethicone, dimethiconol,
dimethicone crosspolymer, phenyl trimethicone, alkyl dimethicone,
lauryl dimethicone, stearyl dimethicone, phenyl dimethicone,
phenylpropyl substituted dimethicone and mixtures thereof.
[0049] In one embodiment, the silicones may comprise Si--O moieties
and may be selected from (a) non-functionalized siloxane polymers,
(b) functionalized siloxane polymers, and combinations thereof. The
molecular weight of the organosilicone is usually indicated by the
reference to the viscosity of the material. In one aspect, the
organosilicones may have a viscosity at 25 deg. C. of from about 1
cPs to about 2,000,000 cPs, or from about 5 cPs to about 800,000
cPs, or even from about 10 cPs to 300,000 cPs, or even from about
50 cPs to about 50,000 cPs. In one aspect, suitable organosilicones
or mixtures thereof may have a viscosity at 25 deg. C. of from
about 10 cPs to about 10,000 cPs, or from about 50 cPs to about
1,000 cPs, or even from about 80 cPs to about 600 cPs.
[0050] Silicone materials and silicone resins in particular, might
conveniently be identified according to a shorthand nomenclature
system known to those of ordinary skill in the art as "MDTQ"
nomenclature. Under this system, the silicone is described
according to presence of various siloxane monomer units which make
up the silicone. Briefly, the symbol M denotes the monofunctional
unit (CH3)3SiO0.5; D denotes the difunctional unit (CH3)2SiO; T
denotes the trifunctional unit (CH3)SiO1.5; and Q denotes the
quadra- or tetra-functional unit SiO2. Primes of the unit symbols
(e.g. M', D', T', and Q') denote substituents other than methyl,
and must be specifically defined for each occurrence.
[0051] Suitable organosilicones may be linear, branched or
cross-linked. In one aspect, the organosilicones may comprise a
silicone resin. Silicone resins are highly cross-linked polymeric
siloxane systems. The cross-linking is introduced through the
incorporation of trifunctional and tetrafunctional silanes with
monofunctional or difunctional, or both, silanes during manufacture
of the silicone resin. As used herein, the nomenclature SiO"n"/2
represents the ratio of oxygen and silicon atoms. For example,
SiO1/2 means that one oxygen is shared between two Si atoms.
Likewise SiO2/2 means that two oxygen atoms are shared between two
Si atoms and SiO312 means that three oxygen atoms are shared are
shared between two Si atoms.
[0052] In one aspect, the organosilicone may comprise
polydimethylsiloxane, dimethicone, dimethiconol, dimethicone
crosspolymer, phenyl trimethicone, alkyl dimethicone, lauryl
dimethicone, stearyl dimethicone, phenyl dimethicone, phenylpropyl
substituted dimethicone and mixtures thereof.
[0053] In one aspect, the organosilicone may comprise a cyclic
silicone. The cyclic silicone may comprise a cyclomethicone of the
formula [(CH3)2SiO]n where n is an integer that may range from
about 3 to about 7, or from about 5 to about 6.
[0054] In one aspect, the organosilicone may comprise a
functionalized siloxane polymer. Functionalized siloxane polymers
may comprise one or more functional moieties selected from the
group consisting of amino, amido, alkoxy, hydroxy, polyether,
carboxy, hydride, mercapto, sulfate phosphate, and/or quaternary
ammonium moieties. These moieties may be attached directly to the
siloxane backbone through a bivalent alkylene radical, (i.e.,
"pendant") or may be part of the backbone. Suitable functionalized
siloxane polymers include materials selected from the group
consisting of aminosilicones, amidosilicones, silicone polyethers,
silicone-urethane polymers, quaternary ABn silicones, amino ABn
silicones, and mixtures thereof.
[0055] Non-limiting examples of suitable silicones are Pulpaid
(Registered trademark) 3500, Pulpaid (Registered trademark) 3600,
Xiameter (Registered trademark) ACP-0001, Xiameter (Registered
trademark) PMX-0245 and Xiameter (Registered trademark) PMX-0246,
Dow Corning (Registered trademark) FS 1266 from Dow Corning;
Silfoam (Registered trademark) SD 860, Silfoam (Registered
trademark) SD 168, Silfoam (Registered trademark) SD 850, Silfoam
(Registered trademark) SD 650, Silfoam (Registered trademark) SE
36, Silfoam (Registered trademark) SE 39, Silfoam (Registered
trademark) SC 1092, Silfoam (Registered trademark) SC 1132, Silfoam
(Registered trademark) SC 129, Silfoam (Registered trademark) SC
132, Silfoam (Registered trademark) SE 47, Silfoam (Registered
trademark) SRE and Silfoam (Registered trademark) SE 90, from
Wacker Corp.; Tego 3062 from Goldschmidt; AF-140TG and
Tri-Lube-60-PR from Tri-Chem Industries; and Antifoam 2226 from
Basildon Chemicals.
[0056] In one embodiment, the agent may be selected from mineral
oils, soybean oils, petrolatum, and lanolin. In one embodiment, the
agent may include sensates. Exemplary sensates include a
composition of menthol and menthyl lactate.
[0057] Additional exemplary benefit agents are described in patent
application publication 2014/0342972, "Encapsulate" published Nov.
20, 2014 and incorporated herein, in its entirety, by
reference.
[0058] In certain aspects, the entities may be contained within a
fluid within the microparticles. The fluid may be any suitable
fluid that can contain the entities, e.g., suspended within the
fluid. In some cases, the fluid may be immiscible with the fluids
forming the entities, e.g., where the entities comprise fluids.
Non-limiting examples of suitable fluids include water or other
aqueous fluids (such as cell or biological media, salt solutions,
alcohol, etc.), or hydrophobic fluids. Examples of hydrophobic
liquids include, but are not limited to, oils such as hydrocarbons,
silicone oils, mineral oils, fluorocarbon oils, organic solvents
etc.
[0059] In certain embodiments, the fluid may be one in which the
agent within the entities does not easily dissolve or other pass
through, e.g., to reach the shell of the microparticle. If the
agent has relatively low solubility within the fluid, then
relatively large amounts or concentrations of agent may be
contained within the entities, relative to the fluid. Thus, for
example, even if there is a relatively low concentration of agent
that can be contained within the fluid, the microparticle may
exhibit surprisingly high amounts of the agent therein, if one were
to assume that the microparticle were only filled with the fluid.
In addition, in some cases, the rate-limiting step for the release
of agent from the microparticle may be controlled by the rate of
dissolution of the agent within the fluid, rather than by the
maximum concentration of agent within the fluid, since much of the
agent may be stored within the entities instead of within the fluid
itself.
[0060] As used herein, two fluids are immiscible, or not miscible,
with each other when one is not soluble in the other to a level of
at least 10% by weight at the temperature and under the conditions
at which the emulsion is produced. For instance, two fluids may be
selected to be immiscible within the time frame of the formation of
the fluidic droplets.
[0061] The microparticle may also contain a shell surrounding the
fluid and the entities, in certain aspects. The shells can comprise
a polymer in some embodiments. Examples include, but are not
limited to, ethoxylated trimethylolpropane triacrylate (ETPTA),
polystyrene, polycaprolactone, polyisoprene, poly(lactic acid),
polystyrene (PS), polycaprolactone (PCL), polyisoprene (PIP),
poly(lactic acid), polyethylene, polypropylene, polyacrylonitrile,
polyimide, polyamide, poly(normal-butyl acrylate)-poly(acrylic
acid), and/or mixtures and/or co-polymers of these and/or other
polymers.
[0062] In one embodiment, the shell material may comprise,
poly(vinyl alcohol), poly(vinyl acetate), poly(vinyl pyrrolidone),
poly(vinyl acetate phthalate), vinyl acetate neodecanoic acid
co-polymer, vinyl acetate ethylene co-polymer, vinyl acetate
crotonic acid neodecanoate co-polymer, vinyl acetate crotonic acid
co-polymer, vinyl acetate butyl maleate co-polymer, cellulose
acetate, cellulose acetate phathalate, ethyl cellulose, hydroxyl
propyl methyl cellulose phathalate, cellulose acetate butyrate,
vinyl pyrrolidone vinyl acetate co-polymer, poly(styrene-co-maleic
acid) isobutyl ester, poly(styrene-co-butadiene),
poly(styrene-co-acrylic) and mixtures thereof.
[0063] Further non-limiting examples of shell materials may
comprise Vinavil.RTM. VIN, Vinavil.RTM. 6915, Vinavil.RTM. 03V,
Vinavil EVA.RTM. 04 and Vinaflex.RTM. CR50 from Vinavil S.p.A.,
Italy; Luviset.RTM. CAN, Luviset.RTM. CA66 and Luviskol.RTM. VA 37
E from BASF, Germany; Sureteric.RTM. and Ethocel, Et from Colorcon,
U.S.A.; Mowiol.RTM. grades from Sigma-Aldrich; Antaron-Ganex.RTM.
V-220 F and Antaron-Ganex.RTM. WP-660 from ISP Chemicals, or
mixtures thereof.
[0064] In one aspect, said core and/or said shell may comprise a
viscosity regulator.
[0065] In one aspect, said viscosity regulator may comprise a
water-soluble solvent, a water-insoluble solvent, silicones,
perfume raw materials and/or mixtures thereof.
[0066] The microparticles described herein may have any suitable
average cross-sectional diameter. Those of ordinary skill in the
art will be able to determine the average cross-sectional diameter
of a single and/or a plurality of particles, for example, using
laser light scattering, microscopic examination, or other known
techniques. The average cross-sectional diameter of a single
particle, in a non-spherical particle, is the diameter of a perfect
sphere having the same volume as the non-spherical particle. The
average cross-sectional diameter of a particle (and/or of a
plurality or series of particles or droplets) may be, for example,
less than about 1 mm, less than about 500 micrometers, less than
about 200 micrometers, less than about 100 micrometers, less than
about 75 micrometers, less than about 50 micrometers, less than
about 25 micrometers, less than about 10 micrometers, or less than
about 5 micrometers, or between about 50 micrometers and about 1
mm, between about 10 micrometers and about 500 micrometers, or
between about 50 micrometers and about 100 micrometers in some
cases. The average cross-sectional diameter may also be at least
about 1 micrometer, at least about 2 micrometers, at least about 3
micrometers, at least about 5 micrometers, at least about 10
micrometers, at least about 15 micrometers, or at least about 20
micrometers in certain cases. In some embodiments, at least about
50%, at least about 75%, at least about 90%, at least about 95%, or
at least about 99% of the particles or droplets within a plurality
of particles or droplets has an average cross-sectional diameter
within any of the ranges outlined in this paragraph.
[0067] Certain applications may use a plurality of particles, at
least some of which contain a fluid and entities such as those
described herein. Some embodiments of the invention advantageously
employ microparticles with relatively consistent properties. For
example, in some embodiments, a plurality of particles is provided
wherein the distribution of thicknesses of the outermost layer
among the plurality of particles is relatively uniform. In some
embodiments, a plurality of particles is provided having an overall
thickness, measured as the average of the average thicknesses of
each of the plurality of particles. In some cases, the distribution
of the average thicknesses can be such that no more than about 5%,
no more than about 2%, or no more than about 1% of the particles or
droplets have an outermost layer with an average thickness thinner
than 90% (or thinner than 95%, or thinner than 99%) of the overall
average thickness and/or thicker than 110% (or thicker than 105%,
or thicker than about 101%) of the overall average thickness of the
outermost layer.
[0068] In one embodiment, the microparticles may comprise
relatively thick shells. Exemplary shell thicknesses for such
embodiments include thicknesses ranging from between about 0.1
.mu.m to about 10 .mu.m. In such embodiments, the shell wall
thicknesses of a population of the particles may have a mean of
between about wtmm .mu.m to about wthmM .mu.m.
[0069] In one set of embodiments, the microparticles may comprise
relatively thin outer shells. Techniques for forming relatively
thin outer shells include those discussed in U.S. Provisional
Application Ser. No. 61/980,541, filed Apr. 16, 2014, entitled
"Systems and Methods for Producing Droplet Emulsions with
Relatively Thin Shells"; or in U.S. Pat. Apl. Pub. No.
2014-0220350, entitled "Multiple Emulsions and Techniques for the
Formation of Multiple Emulsions," published Aug. 7, 2014, each
incorporated herein by reference in its entirety.
[0070] Thus, in some embodiments, the shell may have an average
thickness (i.e., between the first fluid and the second fluid) of
less than about 1 micrometer, less than about 500 nm, less than
about 300 nm, less than about 200 nm, less than about 100 nm, less
than about 50 nm, less than about 30 nm, less than about 20 nm, or
less than about 10 nm. The thickness may be determined optically or
visually, or in some cases, estimated based on the volumes and/or
flow rates of fluid entering or leaving a conduit. If the droplet
is non-spherical, then average thickness or diameters may be
determined using the diameter of a perfect sphere having the same
volume as the non-spherical droplet(s).
[0071] The volumes or thicknesses of a layer of fluid in a droplet
may be determined or estimated (e.g., before and/or after
distortion) using any suitable technique, e.g., visually or
optically. In some cases, the volumes or thickness of a layer of
fluid may be estimated statistically, e.g., by determining the
amount of fluid present in the microparticles.
[0072] In addition, in some embodiments, the thickness may be
determined as a percentage of the diameter of the overall droplet
within the carrying fluid. For example, the thickness of the shell
of the microparticle may be than about 20%, less than about 15%,
less than about 10%, less than about 5%, less than about 3%, less
than about 1%, less than about 0.5%, less than about 0.3%, or less
than about 0.1% of the diameter of the overall droplet.
[0073] In addition, in some embodiments, the shell may comprise a
relatively small percentage by volume of the overall microparticle.
For example, the shell may comprise less than about 20%, less than
about 15%, less than about 10%, less than about 5%, less than about
3%, less than about 1%, less than about 0.5%, less than about 0.3%,
or less than about 0.1% of the overall droplet. In another set of
embodiments, the shell may have a thickness such that the
difference between the average diameter of the shell and the
average diameter of the interior of the shell (including fluid and
any entities therein) is less than about 20% of the average
diameter of the overall droplet, and in some cases, less than about
15%, less than about 10%, less than about 5%, less than about 3%,
less than about 1%, less than about 0.5%, less than about 0.3%, or
less than about 0.1% of the average diameter of the overall
microparticle.
[0074] In some embodiments, the shell may have an average thickness
of less than about 0.05, less than about 0.01, less than about
0.005, or less than about 0.001 times the average cross-sectional
diameter of the microparticle, or between about 0.0005 and about
0.05, between about 0.0005 and about 0.01, between about 0.0005 and
about 0.005, or between about 0.0005 and about 0.001 times the
average cross-sectional diameter of the microparticle. In some
embodiments, the shell may have an average thickness of less than
about 1 micron, less than about 500 nm, or less than about 100 nm,
or between about 50 nm and about 1 micron, between about 50 nm and
about 500 nm, or between about 50 nm and about 100 nm One of
ordinary skill in the art would be capable of determining the
average thickness of the shell, for example, by examining scanning
electron microscope (SEM) images of the microparticle.
[0075] It should also be understood that in some cases, the
interior of the shell (including fluid and any entities therein) is
relatively large, e.g., a large percentage of the volume of the
microparticle is taken up by the interior, which may result in the
shell having a relatively thin thickness. Thus, for example, on a
volume basis, the interior may take up at least about 80% of the
volume of the microparticle, and in some cases, at least about 85%,
at least about 90%, at least about 95%, at least about 97%, at
least about 98%, at least about 99%, at least about 99.5%, or at
least about 99.7% of the volume of the microparticle. In some
cases, the diameter of the interior may be at least about 80% of
the diameter of the microparticle, and in some cases, at least
about 85%, at least about 90%, at least about 95%, at least about
97%, at least about 98%, at least about 99%, at least about 99.5%,
or at least about 99.7% of the diameter of the microparticle.
[0076] In one set of embodiments, the interior comprises at least
about 50% of the volume of the microparticle, and in some cases, at
least about 60%, at least about 70%, at least about 75%, at least
about 80%, or at least about 85% of the volume of the
microparticle. In some cases, the volume of the interior may also
be no more than about 90%, no more than about 85%, no more than
about 80%, no more than about 75%, no more than about 70%, no more
than about 65%, no more than about 60%, or no more than about 55%
of the volume of the microparticle. Combinations of any of these
are also possible, e.g., the interior may comprise between about
50% and about 80% of the volume of the microparticle.
[0077] The microparticles may have relatively uniform
cross-sectional diameters in certain embodiments. The use of
particles with relatively uniform cross-sectional diameters can
allow one to control viscosity, the amount of species delivered to
a target, and/or other parameters of the delivery of fluid and/or
species from the particles. In some embodiments, the particles are
relatively monodisperse, or the plurality of particles has an
overall average diameter and a distribution of diameters such that
no more than about 5%, no more than about 2%, or no more than about
1% of the particles or droplets have a diameter less than about 90%
(or less than about 95%, or less than about 99%) and/or greater
than about 110% (or greater than about 105%, or greater than about
101%) of the overall average diameter of the plurality of
particles.
[0078] In some embodiments, the microparticles has an overall
average diameter and a distribution of diameters such that the
coefficient of variation of the cross-sectional diameters of the
particles or droplets is less than about 10%, less than about 5%,
less than about 2%, between about 1% and about 10%, between about
1% and about 5%, or between about 1% and about 2%. The coefficient
of variation can be determined by those of ordinary skill in the
art, and may be defined as:
c v = .sigma. .mu. ##EQU00001##
wherein .sigma. is the standard deviation and .mu. is the mean.
[0079] In some aspects, the microparticles may be exposed to an
environment to which the agent is to be released. The environment
may be any suitable environment, and can be, e.g., a liquid or a
gas. The agent may be releasable from the microparticles, in some
embodiment, without significantly damaging or disrupting the
microparticles, e.g., by damaging the shell of the microparticles
to cause release of the agent. Thus, for instance, the agent may be
diffuse across the outer shell of the microparticles to be released
externally of the microparticles.
[0080] The agent may exit the microparticles passively, or the
microparticles may be treated in some way to cause release of the
agent. For instance, in one set of embodiments, the agent may be
released by agitating the microparticles, e.g., intermittently or
continuously. In another set of embodiments, the microparticles may
be exposed to a fluid, such as oil or water. For example the agent
may be soluble in oil or water, such that upon reaching the surface
of the microparticle, the agent can readily enter the fluid.
[0081] In some embodiments, relatively high amounts of agent may be
released from the microparticles into the surrounding environment,
e.g., without damaging the microparticles. For instance, at least
about 30 wt %, at least about 50 wt %, at least about 60 wt %, at
least about 70 wt %, at least about 75 wt %, at least about 80 wt
%, at least about 85 wt %, at least about 90 wt %, or at least
about 95 wt % of the agent may be released from the microparticles
upon exposure to a suitable surrounding environment.
[0082] As mentioned, in accordance with certain embodiments, the
rate of release of agent from the microparticles may be controlled,
e.g., based on the ability of the agent to exit the entities
contained within the microparticles and pass through the internal
fluid and the shell of the microparticles. Thus, as discussed
herein, the amount of loading of entities within the
microparticles, and the rate at which the agent is released from
the microparticles, may not necessarily be coupled to each other.
Thus, for example, the fluid surrounding the entities may act as a
rate-limiting step (e.g., if the agent is not fully soluble within
the fluid), and the entities may thus act as a "reservoir" to
contain the agent prior to release from the microparticles.
[0083] Some aspects of the present invention are generally directed
to systems and methods for forming such microparticles. In one set
of embodiments, for example, various microfluidic conduits can be
positioned to create the multiple emulsion droplets, e.g., in
series. In some cases, e.g., by controlling the flow of a fluid
through a conduit, surprisingly thin inner layers of fluid may be
created.
[0084] In one set of embodiments, a first conduit may be used to
inject a first fluid into a second fluid that is immiscible with
the first fluid. The first fluid may contain entities therein, e.g.
suspended therein. The first fluid may comprise an emulsion having
continuous and dispersed phases. The dispersed phase may be
immiscible in the continuous phase but substantially miscible in
the second fluid, or polymers which may be formed from the second
fluid. In some cases, the entities may also contain an agent for
subsequent release from the microparticles. The entities may be
contained within the first fluid in any suitable amount or
concentration, including those described above with respect to the
final amount or concentration within the microparticles.
[0085] The first conduit may end at an exit opening. The first
conduit may gradually or suddenly reach the diameter of the exit
opening. In one set of embodiments, a tapered region may be used.
The length of the tapered region may be any suitable length as
determined in the direction of average fluid flow within the
channel; for example, the length can be less than about 1 mm, less
than about 500 micrometers, less than about 300 micrometers, less
than about 100 micrometers, less than about 50 micrometers, less
than about 30 micrometers, less than about 10 micrometers, etc.
[0086] In some embodiments, the first conduit may have a
cross-sectional dimension of less than about 1 mm, less than about
500 micrometers, less than about 200 micrometers, less than about
100 micrometers, less than about 75 micrometers, less than about 50
micrometers, or other dimensions as discussed herein. In some
cases, the cross-sectional area of the first conduit may vary. In
some cases, the first conduit is substantially smaller than the
second conduit at the point where the first conduit opens into a
second conduit. For instance, the first conduit may have a
cross-sectional area of the exit opening that is no more than about
75%, no more than about 50%, no more than about 45%, no more than
about 40%, no more than about 35%, no more than about 30%, no more
than about 25%, no more than about 20%, no more than about 15%, no
more than about 10%, or no more than about 5% of the
cross-sectional area of the second conduit at that location.
[0087] Upon exiting the exit opening of the first conduit, the
first fluid (containing entities, e.g., as discussed above) may
encounter a second fluid and a third fluid contained within a
second conduit. The second fluid may be immiscible with the first
fluid and/or the third fluid, in some cases. Thus, the second fluid
may be caused to form droplets surrounding the first fluid (and
entities) contained within the third fluid. The second and third
fluids may be introduced into the second conduit in directions
substantially opposed to each other. The droplets may be formed
prior to entering the third conduit or while the combination of
fluids is passing through the third conduit.
[0088] In some embodiments, the second conduit may have a
cross-sectional dimension of less than about 1 mm, less than about
500 micrometers, less than about 200 micrometers, less than about
100 micrometers, less than about 75 micrometers, less than about 50
micrometers, or other dimensions as discussed herein. The
cross-sectional area of the second conduit may be substantially
constant, or may vary. For instance, the second conduit may be
tapered.
[0089] The droplets may then exit the second conduit through an
entrance opening of a third conduit, e.g., to be polymerized, or
for subsequent use, etc. Thus, for example, one or more of the
fluids may be hardened as discussed below to form a particle. The
particle may have the same dimensions as the droplet prior to
hardening.
[0090] In some embodiments, the third conduit may have a
cross-sectional dimension of less than about 1 mm, less than about
500 micrometers, less than about 200 micrometers, less than about
100 micrometers, less than about 75 micrometers, less than about 50
micrometers, or other dimensions as discussed herein. The
cross-sectional area of the third conduit may be substantially
constant, or may vary. For instance, the third conduit may be
tapered. In some cases, the third conduit is substantially smaller
than the second conduit at the entrance opening to the third
conduit. For instance, the third conduit may have a cross-sectional
area of the exit opening that is no more than about 75%, no more
than about 50%, no more than about 45%, no more than about 40%, no
more than about 35%, no more than about 30%, no more than about
25%, no more than about 20%, no more than about 15%, no more than
about 10%, or no more than about 5% of the cross-sectional area of
the third conduit at that location. In some cases, the third
conduit may have a diameter that changes moving away from the
entrance opening, although in other cases, the diameter of the
third conduit may be substantially constant.
[0091] Some benefit agents and/or shell material solutions might
have a high viscosity after dissolution or dispersion, so certain
additives as viscosity regulators might be added to the core and/or
the shell as processing aid to facilitate the flow of such benefit
agents and/or shell materials through the conduits. Such viscosity
regulators may comprise water-soluble solvents, water-insoluble
solvents, perfume raw materials, silicones and/or mixtures thereof.
Non-limiting examples include ethanol, propanol, isopropanol,
n-propanol, n-butanol, t-butanol, propylene glycol,
1,3-propanediol, ethylene glycol, diethylene glycol, dipropylene
glycol, 1,2,3-propanetriol, propylene carbonate, phenylethyl
alcohol, 2-methyl 1,3-propanediol, hexylene glycol, glycerol,
sorbitol, polyethylene glycols, 1,2-hexanediol, 1,2-pentanediol,
1,2-butanediol, 1,4 butanediol, 1,4-cyclohexanedimethanol, pinacol,
1,5-hexanediol, 1,6-hexanediol, 2,4-dimethyl-2,4-pentanediol,
2,2,4-trimethyl-1,3-pentanediol (and ethoxylates),
2-ethyl-1,3-hexanediol, phenoxyethanol (and ethoxylates), glycol
ethers such as butyl carbitol and dipropylene glycol n-butyl ether,
ester solvents such as dimethyl esters of adipic, glutaric, and
succinic acids, hydrocarbons such as decane and dodecane,
camethylcyclopentasiloxane, cyclohexasiloxane,
ethyl-2-methylbutanoate, ethyl-2-methylbutyrate, isopropyl
myristate, thyl-2-methyl pentanoate, hexyl acetate, allyl caproate
and mixtures thereof.
[0092] In one set of embodiments, the outer, second fluid
surrounding the droplets may be hardened to form microparticles,
e.g., containing the first fluid and the entities. For instance, in
one set of embodiments, light, such as ultraviolet light, may be
used to facilitate polymerization of a polymer. In another set of
embodiments, the third fluid may contain a chemical that can react
with the second fluid (e.g., at its surface) to harden the second
fluid. In yet another set of embodiments, certain changes, such as
temperature changes, may be used to induce hardening of the second
fluid to form microparticles.
[0093] For example, in some embodiments, a fluid may be dried,
gelled, and/or polymerized, and/or otherwise solidified, e.g., to
form a solid, or at least a semi-solid. The solid that is formed
may be rigid in some embodiments, although in other cases, the
solid may be elastic, rubbery, deformable, etc. In some cases, for
example, an outermost layer of fluid may be solidified to form a
solid shell at least partially containing an interior containing a
fluid and/or a species. Any technique able to solidify at least a
portion of a fluidic droplet can be used. For example, in some
embodiments, a fluid within a fluidic droplet may be removed to
leave behind a material (e.g., a polymer) capable of forming a
solid shell. In other embodiments, a fluidic droplet may be cooled
to a temperature below the melting point or glass transition
temperature of a fluid within the fluidic droplet, a chemical
reaction may be induced that causes at least a portion of the
fluidic droplet to solidify (for example, a polymerization
reaction, a reaction between two fluids that produces a solid
product, etc.), or the like. Other examples include pH-responsive
or molecular-recognizable polymers, e.g., materials that gel upon
exposure to a certain pH, or to a certain species. In some
embodiments, a fluidic droplet is solidified by increasing the
temperature of the fluidic droplet. For instance, a rise in
temperature may drive out a material from the fluidic droplet
(e.g., within the outermost layer of a multiple emulsion droplet)
and leave behind another material that forms a solid. Thus, in some
cases, an outermost layer of a multiple emulsion droplet may be
solidified to form a solid shell that encapsulates entities
contained within a fluid.
[0094] In one embodiment, for light curable wall materials such as
acrylate and acrylamide based monomer/oligomers, photoinitiators
may include benzyl ketones, monomeric hydroxyl ketones, polymeric
hydroxyl ketones, alpha-amino ketones, acyl phosphine oxides,
metallocenes, benzophenone, benzophenone derivatives, and many
others as described in (US 20140261508 A1),
Exemplary photoinitiators include: Benzoin Ethyl Ether,
2-hydroxy-2-Methylphenylpropanone, Irgacure 369, Irgacure LEX 201,
Irgacure 819, Darocur 4265, Irgacure 184, Irgacure 2959, and the
visible light initiator: Irgacure 784, Camphorquinone(GENOCURE*
CQ).
[0095] Acrylate and acrylamide can also be cured thermally by
adding thermal initiator as described in patent publication: WO
2011084141 A2(Appleton). The initiators are energy activated
meaning free radicals are generated when the initiators are
subjected to heat or other energy input.
[0096] Exemplary initiators include peroxy initiators, azo
initiators, peroxides, and compounds such as
2,2'-azobismethylbutyronitrile, dibenzoyl peroxide. More
particularly, and without limitation the free radical initiator can
be selected from the group of initiators comprising an azo or
peroxy initiator, such as peroxide, dialkyl peroxide, alkyl
peroxide, peroxyester, peroxycarbonate, peroxyketone and
peroxydicarbonate, 2,2'-azobis(isobutylnitrile),
2,2'-azobis(2,4-dimethylpentanenitrile),
2,2'-azobis(2,4-dimethylvaleronitrile),
2,2'-azobis(2-methylpropanenitrile),
2,2'-azobis(methylbutyronitrile),
1,1'-azobis(cyclohexanecarbonitrile),
1,1'-azobis(cyanocyclohexane), benzoyl peroxide, decanoyl peroxide;
lauroyl peroxide; benzoyl peroxide, di(n-propyl) peroxydicarbonate,
di(sec-butyl) peroxydicarbonate, di(2-ethylhexyl)
peroxydicarbonate, 1,1-dimethyl-3-hydroxybutyl peroxyneodecanoate,
a-cumyl peroxyneoheptanoate, t-amyl peroxyneodecanoate, t-butyl
peroxyneodecanoate, t-amyl peroxypivalate, t-butyl peroxypivalate,
2,5-dimethyl 2,5-di(2-ethylhexanoyl peroxy) hexane, t-amyl
peroxy-2-ethyl-hexanoate, t-butyl peroxy-2-ethylhexanoate, t-butyl
peroxyacetate, di-t-amyl peroxyacetate, t-butyl peroxide, di-t-amyl
peroxide, 2,5-dimethyl-2,5-di-(t-butylperoxy)hexyne-3, cumene
hydroperoxide, 1,1-di-(t-butylperoxy)-3,3,5-trimethyl-cyclohexane,
1,1-di-(t-butylperoxy)-cyclohexane,
1,1-di-(t-amylperoxy)-cyclohexane,
ethyl-3,3-di-(t-butylperoxy)-butyrate, t-amyl perbenzoate, t-butyl
perbenzoate, ethyl 3,3-di-(t-amylperoxy)-butyrate, and the like.
Blends of initiators can also be employed.
[0097] Commercially available initiators, such as Vazo initiators,
typically indicate a decomposition temperature for the initiator.
In one embodiment, the initiator is selected to have a
decomposition point of about 50.degree. C. or higher. Multiple
initiators may be employed, either as a blend in the oil phase, or
in either of the oil or water phases. In one embodiment, initiators
are selected to stagger the decomposition temperatures at the
various steps, pre-polymerization, wall formation and hardening or
polymerizing of the capsule wall material. For example, a first
initiator in the oil phase can decompose at 55.degree. C., to
promote prepolymer formation; a second can decompose at 60.degree.
C. to aid forming the wall material. Optionally a third initiator
can decompose at 65.degree. C. to facilitate polymerization of the
capsule wall material. The total amount of initiator can be
typically as low as 0.1 weight percent or as high as 10 weight
percent.
[0098] In certain aspects of the present invention, as discussed,
the microparticles are prepared in a microfluidic system.
"Microfluidic," as used herein, refers to a device, apparatus, or
system including at least one fluid channel having a
cross-sectional dimension of less than about 1 millimeter (mm), and
in some cases, a ratio of length to largest cross-sectional
dimension of at least 3:1. One or more channels of the system may
be a capillary tube. In some cases, multiple channels are provided,
and in some embodiments, at least some are nested, as described
herein. The channels may be in the microfluidic size range and may
have, for example, average inner diameters, or portions having an
inner diameter, of less than about 1 millimeter, less than about
300 micrometers, less than about 100 micrometers, less than about
30 micrometers, less than about 10 micrometers, less than about 3
micrometers, or less than about 1 micrometer, thereby providing
droplets having comparable average diameters. The cross-section of
one or more of the channels may, have a height that is
substantially the same as a width at the same point. In
cross-section, the channels may be rectangular or substantially
non-rectangular, such as circular or elliptical.
[0099] As used herein, the term "fluid" generally refers to a
substance that tends to flow and to conform to the outline of its
container, i.e., a liquid, a gas, a viscoelastic fluid, etc. In one
embodiment, the fluid is a liquid. Typically, fluids are materials
that are unable to withstand a static shear stress, and when a
shear stress is applied, the fluid experiences a continuing and
permanent distortion. The fluid may have any suitable viscosity
that permits flow. If two or more fluids are present, each fluid
may be independently selected among essentially any fluids
(liquids, gases, and the like) by those of ordinary skill in the
art, by considering the relationship between the fluids.
[0100] A variety of materials and methods, according to certain
aspects of the invention, can be used to form articles or
components such as those described herein, e g, channels such as
microfluidic channels, chambers, etc. For example, various articles
or components can be formed from solid materials, in which the
channels can be formed via micromachining, film deposition
processes such as spin coating and chemical vapor deposition, laser
fabrication, photolithographic techniques, etching methods
including wet chemical or plasma processes, 3D printing, and the
like. See, for example, Scientific American, 248:44-55, 1983
(Angell, et al).
[0101] In one set of embodiments, various structures or components
of the articles described herein can be formed from glass or a
polymer, for example, an elastomeric polymer such as
polydimethylsiloxane ("PDMS"), polytetrafluoroethylene ("PTFE" or
Teflon.RTM.), epoxy, norland optical adhesive, or the like. For
instance, according to one embodiment, microfluidic channels may be
formed from glass tubes or capillaries. In addition, in some cases,
a microfluidic channel may be implemented by fabricating the
fluidic system separately using PDMS or other soft lithography
techniques (details of soft lithography techniques suitable for
this embodiment are discussed in the references entitled "Soft
Lithography," by Younan Xia and George M. Whitesides, published in
the Annual Review of Material Science, 1998, Vol. 28, pages
153-184, and "Soft Lithography in Biology and Biochemistry," by
George M. Whitesides, Emanuele Ostuni, Shuichi Takayama, Xingyu
Jiang and Donald E. Ingber, published in the Annual Review of
Biomedical Engineering, 2001, Vol. 3, pages 335-373; each of these
references is incorporated herein by reference). In addition, in
some embodiments, various structures or components of the articles
described herein can be formed of a metal, for example, stainless
steel.
[0102] Other examples of potentially suitable polymers include, but
are not limited to, polyethylene terephthalate (PET), polyacrylate,
polymethacrylate, polycarbonate, polystyrene, polyethylene,
polypropylene, polyvinylchloride, cyclic olefin copolymer (COC),
polytetrafluoroethylene, a fluorinated polymer, a silicone such as
polydimethylsiloxane, polyvinylidene chloride, bis-benzocyclobutene
("BCB"), a polyimide, a fluorinated derivative of a polyimide, or
the like. Combinations, copolymers, or blends involving polymers
including those described above are also envisioned. The device may
also be formed from composite materials, for example, a composite
of a polymer and a semiconductor material.
[0103] In some embodiments, various structures or components of the
article are fabricated from polymeric and/or flexible and/or
elastomeric materials, and can be conveniently formed of a
hardenable fluid, facilitating fabrication via molding (e.g.
replica molding, injection molding, cast molding, etc.). The
hardenable fluid can be essentially any fluid that can be induced
to solidify, or that spontaneously solidifies, into a solid capable
of containing and/or transporting fluids contemplated for use in
and with the fluidic network. In one embodiment, the hardenable
fluid comprises a polymeric liquid or a liquid polymeric precursor
(i.e. a "prepolymer"). Suitable polymeric liquids can include, for
example, thermoplastic polymers, thermoset polymers, waxes, or
mixtures or composites thereof heated above their melting point. As
another example, a suitable polymeric liquid may include a solution
of one or more polymers in a suitable solvent, which solution forms
a solid polymeric material upon removal of the solvent, for
example, by evaporation. Such polymeric materials, which can be
solidified from, for example, a melt state or by solvent
evaporation, are well known to those of ordinary skill in the art.
A variety of polymeric materials, many of which are elastomeric,
are suitable, and are also suitable for forming molds or mold
masters, for embodiments where one or both of the mold masters is
composed of an elastomeric material. A non-limiting list of
examples of such polymers includes polymers of the general classes
of silicone polymers, epoxy polymers, and acrylate polymers. Epoxy
polymers are characterized by the presence of a three-membered
cyclic ether group commonly referred to as an epoxy group,
1,2-epoxide, or oxirane. For example, diglycidyl ethers of
bisphenol A can be used, in addition to compounds based on aromatic
amine, triazine, and cycloaliphatic backbones. Another example
includes the well-known Novolac polymers. Non-limiting examples of
silicone elastomers suitable for use according to the invention
include those formed from precursors including the chlorosilanes
such as methylchlorosilanes, ethylchlorosilanes,
phenylchlorosilanes, dodecyltrichlorosilanes, etc.
[0104] Silicone polymers are used in certain embodiments, for
example, the silicone elastomer polydimethylsiloxane. Non-limiting
examples of PDMS polymers include those sold under the trademark
Sylgard by Dow Chemical Co., Midland, Mich., and particularly
Sylgard 182, Sylgard 184, and Sylgard 186. Silicone polymers
including PDMS have several beneficial properties simplifying
fabrication of various structures of the invention. For instance,
such materials are inexpensive, readily available, and can be
solidified from a prepolymeric liquid via curing with heat. For
example, PDMSs are typically curable by exposure of the
prepolymeric liquid to temperatures of about, for example, about
65.degree. C. to about 75.degree. C. for exposure times of, for
example, about an hour, about 3 hours, about 12 hours, etc. Also,
silicone polymers, such as PDMS, can be elastomeric and thus may be
useful for forming very small features with relatively high aspect
ratios, necessary in certain embodiments of the invention. Flexible
(e.g., elastomeric) molds or masters can be advantageous in this
regard.
[0105] One advantage of forming structures such as microfluidic
structures or channels from silicone polymers, such as PDMS, is the
ability of such polymers to be oxidized, for example by exposure to
an oxygen-containing plasma such as an air plasma, so that the
oxidized structures contain, at their surface, chemical groups
capable of cross-linking to other oxidized silicone polymer
surfaces or to the oxidized surfaces of a variety of other
polymeric and non-polymeric materials. Thus, structures can be
fabricated and then oxidized and essentially irreversibly sealed to
other silicone polymer surfaces, or to the surfaces of other
substrates reactive with the oxidized silicone polymer surfaces,
without the need for separate adhesives or other sealing means. In
most cases, sealing can be completed simply by contacting an
oxidized silicone surface to another surface without the need to
apply auxiliary pressure to form the seal. That is, the
pre-oxidized silicone surface acts as a contact adhesive against
suitable mating surfaces. Specifically, in addition to being
irreversibly sealable or bonded to itself, oxidized silicone such
as oxidized PDMS can also be sealed irreversibly to a range of
oxidized materials other than itself including, for example, glass,
silicon, silicon oxide, quartz, silicon nitride, polyethylene,
polystyrene, glassy carbon, and epoxy polymers, which have been
oxidized in a similar fashion to the PDMS surface (for example, via
exposure to an oxygen-containing plasma). Oxidation and sealing
methods useful in the context of the present invention, as well as
overall molding techniques, are described in the art, for example,
in an article entitled "Rapid Prototyping of Microfluidic Systems
and Polydimethylsiloxane," Anal. Chem., 70:474-480, 1998 (Duffy et
al.), incorporated herein by reference.
[0106] Different components can be fabricated of different
materials. For example, a base portion including a bottom wall and
side walls can be fabricated from an opaque material such as
silicon or PDMS, and a top portion can be fabricated from a
transparent or at least partially transparent material, such as
glass or a transparent polymer, for observation and/or control of
the fluidic process. Components can be coated so as to expose a
desired chemical functionality to fluids that contact interior
channel walls, where the base supporting material does not have a
precise, desired functionality. For example, components can be
fabricated as illustrated, with interior channel walls coated with
another material, e.g., as discussed herein. Material used to
fabricate various components of the systems and devices of the
invention, e.g., materials used to coat interior walls of fluid
channels, may desirably be selected from among those materials that
will not adversely affect or be affected by fluid flowing through
the fluidic system, e.g., material(s) that is chemically inert in
the presence of fluids to be used within the device. A non-limiting
example of such a coating is disclosed below; additional examples
are disclosed in Int. Pat. Apl. Ser. No. PCT/US2009/000850, filed
Feb. 11, 2009, entitled "Surfaces, Including Microfluidic Channels,
With Controlled Wetting Properties," by Weitz, et al., published as
WO 2009/120254 on Oct. 1, 2009, incorporated herein by
reference.
[0107] In some embodiments, certain microfluidic structures of the
invention (or interior, fluid-contacting surfaces) may be formed
from certain oxidized silicone polymers. Such surfaces may be more
hydrophilic than the surface of an elastomeric polymer. Such
hydrophilic surfaces can thus be more easily filled and wetted with
aqueous solutions.
[0108] In some embodiments, a bottom wall of a microfluidic device
of the invention is formed of a material different from one or more
side walls or a top wall, or other components. For example, in some
embodiments, the interior surface of a bottom wall comprises the
surface of a silicon wafer or microchip, or other substrate. Other
components may, as described above, be sealed to such alternative
substrates. Where it is desired to seal a component comprising a
silicone polymer (e.g. PDMS) to a substrate (bottom wall) of
different material, the substrate may be selected from the group of
materials to which oxidized silicone polymer is able to
irreversibly seal (e.g., glass, silicon, silicon oxide, quartz,
silicon nitride, polyethylene, polystyrene, epoxy polymers, and
glassy carbon surfaces which have been oxidized). Alternatively,
other sealing techniques may be used, as would be apparent to those
of ordinary skill in the art, including, but not limited to, the
use of separate adhesives, bonding, solvent bonding, ultrasonic
welding, etc.
[0109] Thus, in certain embodiments, the design and/or fabrication
of the article may be relatively simple, e.g., by using relatively
well-known soft lithography and other techniques such as those
described herein. In addition, in some embodiments, rapid and/or
customized design of the article is possible, for example, in terms
of geometry. In one set of embodiments, the article may be produced
to be disposable, for example, in embodiments where the article is
used with substances that are radioactive, toxic, poisonous,
reactive, biohazardous, etc., and/or where the profile of the
substance (e.g., the toxicology profile, the radioactivity profile,
etc.) is unknown. Another advantage to forming channels or other
structures (or interior, fluid-contacting surfaces) from oxidized
silicone polymers is that these surfaces can be much more
hydrophilic than the surfaces of typical elastomeric polymers
(where a hydrophilic interior surface is desired). Such hydrophilic
channel surfaces can thus be more easily filled and wetted with
aqueous solutions than can structures comprised of typical,
unoxidized elastomeric polymers or other hydrophobic materials.
[0110] In one set of embodiments, one or more of the channels
within the device may be relatively hydrophobic or relatively
hydrophilic, e.g. inherently, and/or by treating one or more of the
surfaces or walls of the channel to render them more hydrophobic or
hydrophilic. Generally, the fluids that are formed into droplets in
the device are substantially immiscible, at least on the time scale
of forming the droplets, and the fluids will often have different
degrees of hydrophobicity or hydrophilicity. Thus, for example, a
first fluid may be more hydrophilic (or more hydrophobic) relative
to a second fluid, and the first and the second fluids may be
substantially immiscible. Thus, the first fluid can from a discrete
droplet within the second fluid, e.g., without substantial mixing
of the first fluid and the second fluid (although some degree of
mixing may nevertheless occur under some conditions). Similarly,
the second fluid may be more hydrophilic (or more hydrophobic)
relative to a third fluid (which may be the same or different than
the first fluid), and the second and third fluids may be
substantially immiscible.
[0111] Accordingly, in some cases, a surface of a channel may be
relatively hydrophobic or hydrophilic, depending on the fluid
contained within the channel. In one set of embodiments, a surface
of the channel is hydrophobic or hydrophilic relative to other
surfaces within the device. In addition, in some embodiments, a
relatively hydrophobic surface may exhibit a water contact angle of
greater than about 90.degree., and/or a relatively hydrophilic
surface may exhibit a water contact angle of less than about
90.degree..
[0112] In some cases, relatively hydrophobic and/or hydrophilic
surfaces may be used to facilitate the flow of fluids within the
channel, e.g., to maintain the nesting of multiple fluids within
the channel in a particular order.
[0113] In some aspects, as previously discussed, emulsions such as
those described herein may be prepared by controlling the
hydrophilicity and/or hydrophobicity of the channels used to form
the emulsion. In one set of embodiments, the hydrophilicity and/or
hydrophobicity of the channels may be controlled by coating a
sol-gel onto at least a portion of a channel. For instance, in one
embodiment, relatively hydrophilic and relatively hydrophobic
portions may be created by applying a sol-gel to portions of the
channel surfaces, which renders those portions relatively
hydrophobic. The sol-gel may comprise an initiator, such as a
photoinitiator. Portions (e.g., channels, and/or portions of
channels) may be rendered relatively hydrophilic by filling the
channels with a solution containing a hydrophilic moiety (for
example, acrylic acid), and exposing the portions to a suitable
trigger for the initiator (for example, light or ultraviolet light
in the case of a photoinitiator). For example, the portions may be
exposed by using a mask to shield portions in which no reaction is
desired, by directing a focused beam of light or heat onto the
portions in which reaction is desired, or the like. In the exposed
portions, the initiator may cause the reaction (e.g.,
polymerization) of the hydrophilic moiety to the sol-gel, thereby
rendering those portions relatively hydrophilic (for instance, by
causing poly(acrylic acid) to become grafted onto the surface of
the sol-gel coating in the above example).
[0114] As is known to those of ordinary skill in the art, a sol-gel
is a material that can be in a sol or a gel state, and typically
includes polymers. The gel state typically contains a polymeric
network containing a liquid phase, and can be produced from the sol
state by removing solvent from the sol, e.g., via drying or heating
techniques. In some cases, the sol may be pretreated before being
used, for instance, by causing some polymerization to occur within
the sol.
[0115] In some embodiments, the sol-gel coating may be chosen to
have certain properties, for example, having a certain
hydrophobicity. The properties of the coating may be controlled by
controlling the composition of the sol-gel (for example, by using
certain materials or polymers within the sol-gel), and/or by
modifying the coating, for instance, by exposing the coating to a
polymerization reaction to react a polymer to the sol-gel coating,
as discussed below.
[0116] For example, the sol-gel coating may be made more
hydrophobic by incorporating a hydrophobic polymer in the sol-gel.
For instance, the sol-gel may contain one or more silanes, for
example, a fluorosilane (i.e., a silane containing at least one
fluorine atom) such as heptadecafluorosilane, or other silanes such
as methyltriethoxy silane (MTES) or a silane containing one or more
lipid chains, such as octadecylsilane or other
CH.sub.3(CH.sub.2).sub.n-silanes, where n can be any suitable
integer. For instance, n may be greater than 1, 5, or 10, and less
than about 20, 25, or 30. The silanes may also optionally include
other groups, such as alkoxide groups, for instance,
octadecyltrimethoxysilane. In general, most silanes can be used in
the sol-gel, with the particular silane being chosen on the basis
of desired properties such as hydrophobicity. Other silanes (e.g.,
having shorter or longer chain lengths) may also be chosen in other
embodiments of the invention, depending on factors such as the
relative hydrophobicity or hydrophilicity desired. In some cases,
the silanes may contain other groups, for example, groups such as
amines, which would make the sol-gel more hydrophilic. Non-limiting
examples include diamine silane, triamine silane, or
N-[3-(trimethoxysilyl)propyl]ethylene diamine silane. The silanes
may be reacted to form oligomers or polymers within the sol-gel,
and the degree of polymerization (e.g., the lengths of the
oligomers or polymers) may be controlled by controlling the
reaction conditions, for example by controlling the temperature,
amount of acid present, or the like. In some cases, more than one
silane may be present in the sol-gel. For instance, the sol-gel may
include fluorosilanes to cause the resulting sol-gel to exhibit
greater hydrophobicity, and other silanes (or other compounds) that
facilitate the production of polymers. In some cases, materials
able to produce SiO.sub.2 compounds to facilitate polymerization
may be present, for example, TEOS (tetraethyl orthosilicate).
[0117] It should be understood that the sol-gel is not limited to
containing only silanes, and other materials may be present in
addition to, or in place of, the silanes. For instance, the coating
may include one or more metal oxides, such as SiO.sub.2, vanadia
(V.sub.2O.sub.5), titania (TiO.sub.2), and/or alumina
(Al.sub.2O.sub.3).
[0118] In some instances, the microfluidic channel is present in a
material suitable to receive the sol-gel, for example, glass, metal
oxides, or polymers such as polydimethylsiloxane (PDMS) and other
siloxane polymers. For example, in some cases, the microfluidic
channel may be one which contains silicon atoms, and in certain
instances, the microfluidic channel may be chosen such that it
contains silanol (Si--OH) groups, or can be modified to have
silanol groups. For instance, the microfluidic channel may be
exposed to an oxygen plasma, an oxidant, or a strong acid to cause
the formation of silanol groups on the microfluidic channel.
[0119] The sol-gel may be present as a coating on the microfluidic
channel, and the coating may have any suitable thickness. For
instance, the coating may have a thickness of no more than about
100 micrometers, no more than about 30 micrometers, no more than
about 10 micrometers, no more than about 3 micrometers, or no more
than about 1 micrometer. Thicker coatings may be desirable in some
cases, for instance, in applications in which higher chemical
resistance is desired. However, thinner coatings may be desirable
in other applications, for instance, within relatively small
microfluidic channels.
[0120] In one set of embodiments, the hydrophobicity of the sol-gel
coating can be controlled, for instance, such that a first portion
of the sol-gel coating is relatively hydrophobic, and a second
portion of the sol-gel coating is relatively hydrophilic. The
hydrophobicity of the coating can be determined using techniques
known to those of ordinary skill in the art, for example, using
contact angle measurements such as those discussed herein. For
instance, in some cases, a first portion of a microfluidic channel
may have a hydrophobicity that favors an organic solvent to water,
while a second portion may have a hydrophobicity that favors water
to the organic solvent. In some cases, a hydrophilic surface is one
that has a water contact angle of less than about 90.degree. while
a hydrophobic surface is one that has a water contact angle of
greater than about 90.degree..
[0121] The hydrophobicity of the sol-gel coating can be modified,
for instance, by exposing at least a portion of the sol-gel coating
to a polymerization reaction to react a polymer to the sol-gel
coating. The polymer reacted to the sol-gel coating may be any
suitable polymer, and may be chosen to have certain hydrophobicity
properties. For instance, the polymer may be chosen to be more
hydrophobic or more hydrophilic than the microfluidic channel
and/or the sol-gel coating. As an example, a hydrophilic polymer
that could be used is poly(acrylic acid).
[0122] The polymer may be added to the sol-gel coating by supplying
the polymer in monomeric (or oligomeric) form to the sol-gel
coating (e.g., in solution), and causing a polymerization reaction
to occur between the polymer and the sol-gel. For instance, free
radical polymerization may be used to cause bonding of the polymer
to the sol-gel coating. In some embodiments, a reaction such as
free radical polymerization may be initiated by exposing the
reactants to heat and/or light, such as ultraviolet (UV) light,
optionally in the presence of a photoinitiator able to produce free
radicals (e.g., via molecular cleavage) upon exposure to light.
Those of ordinary skill in the art will be aware of many such
photoinitiators, many of which are commercially available, such as
Irgacur 2959 (Ciba Specialty Chemicals) or
2-hydroxy-4-(3-triethoxysilylpropoxy)-diphenylketone (SIH6200.0,
ABCR GmbH & Co. KG).
[0123] The photoinitiator may be included with the polymer added to
the sol-gel coating, or in some cases, the photoinitiator may be
present within the sol-gel coating. For instance, a photoinitiator
may be contained within the sol-gel coating, and activated upon
exposure to light. The photoinitiator may also be conjugated or
bonded to a component of the sol-gel coating, for example, to a
silane. As an example, a photoinitiator such as Irgacur 2959 may be
conjugated to a silane-isocyanate via a urethane bond, where a
primary alcohol on the photoinitiator may participate in
nucleophilic addition with the isocyanate group, which may produce
a urethane bond.
[0124] It should be noted that only a portion of the sol-gel
coating may be reacted with a polymer, in some embodiments of the
invention. For instance, the monomer and/or the photoinitiator may
be exposed to only a portion of the microfluidic channel, or the
polymerization reaction may be initiated in only a portion of the
microfluidic channel. As a particular example, a portion of the
microfluidic channel may be exposed to light, while other portions
are prevented from being exposed to light, for instance, by the use
of masks or filters, or by using a focused beam of light.
Accordingly, different portions of the microfluidic channel may
exhibit different hydrophobicities, as polymerization does not
occur everywhere on the microfluidic channel. As another example,
the microfluidic channel may be exposed to UV light by projecting a
de-magnified image of an exposure pattern onto the microfluidic
channel. In some cases, small resolutions (e.g., 1 micrometer, or
less) may be achieved by projection techniques.
[0125] Additional details of such coatings and other systems may be
seen in Int. Pat. Apl. Ser. No. PCT/US2009/000850, filed Feb. 11,
2009, entitled "Surfaces, Including Microfluidic Channels, With
Controlled Wetting Properties," by Weitz, et al., published as WO
2009/120254 on Oct. 1, 2009, and International Patent Application
Serial No. PCT/US2009/000850, filed Feb. 11, 2009, entitled
"Surfaces, Including Microfluidic Channels, With Controlled Wetting
Properties," by Abate, et al., each incorporated herein by
reference.
[0126] In one embodiment, it may be desirable to slow the release
of the active agent by the process of diffusion. In such an
embodiment, the release of the active agent may be facilitated by
mechanical rupture of the microparticles, by thermal breakdown of
the shell and hydrogel, or by dissolving the shell and hydrogel of
the core of the microparticles.
[0127] While microparticles with the first liquid pre-emulsion
enable high encapsulation efficiency of the hydrophobic payload,
the density mismatch between the payload and the aqueous continuous
phase of the first liquid may result in the dispersed payload
rising and directly contacting the inner surface of the polymeric
shell. This contact may enable the payload to move into the
hydrophobic polymer, leading to a rapid leakage and hence limiting
the long-term storage of the payload. To achieve long-term storage
of the payload, the continuous phase of the first liquid may be
modified by the addition of a hydrogel precursor and a
photo-initiator to enable the conversion of the continuous phase
within the microparticles to a hydrogel, enabling it to act as a
physical barrier and preventing direct exposure of the innermost
dispersed phase payload with the polymeric shell. As an example a
continuous phase of the first liquid may be composed of an aqueous
solution of 15% polyethylene glycol diacrylate (PEG-DA,
M.sub.n=700) with a photo-initiator. In the presence of
electromagnetic radiation, the PEG-DA precursor solution can be
rapidly polymerized, and/or cross-linked, transforming into an
hydrogel.
[0128] Certain aspects of the invention are generally directed to
techniques for scaling up or "numbering up" devices such as those
discussed herein. For example, in some cases, relatively large
numbers of devices may be used in parallel, for example at least
about 10 devices, at least about 30 devices, at least about 50
devices, at least about 75 devices, at least about 100 devices, at
least about 200 devices, at least about 300 devices, at least about
500 devices, at least about 750 devices, or at least about 1,000
devices or more may be operated in parallel. In some cases, an
array of such devices may be formed by stacking the devices
horizontally and/or vertically. The devices may be commonly
controlled, or separately controlled, and can be provided with
common or separate sources of various fluids, depending on the
application.
[0129] Those of ordinary skill in the art will be aware of other
techniques useful for scaling up or numbering up devices or
articles such as those discussed herein. For example, in some
embodiments, a fluid distributor can be used to distribute fluid
from one or more inputs to a plurality of outputs, e.g., in one
more devices. For instance, a plurality of articles may be
connected in three dimensions. In some cases, channel dimensions
are chosen that allow pressure variations within parallel devices
to be substantially reduced. Other examples of suitable techniques
include, but are not limited to, those disclosed in International
Patent Application No. PCT/US2010/000753, filed Mar. 12, 2010,
entitled "Scale-up of Microfluidic Devices," by Romanowsky, et al.,
published as WO 2010/104597 on Nov. 16, 2010, incorporated herein
by reference in its entirety.
[0130] The following documents are incorporated herein by reference
in their entirety for all purposes: International Patent
Application Serial No.: PCT/US2015/025921, filed: Apr. 15, 2015,
Title: Systems and methods for producing droplet emulsions with
relatively thin shells; Inventors: David Weitz, Esther Amstad,
Laura R. Arriaga; International Patent Publication Number WO
2004/091763, filed Apr. 9, 2004, entitled "Formation and Control of
Fluidic Species," by Link et al.; International Patent Publication
Number WO 2004/002627, filed Jun. 3, 2003, entitled "Method and
Apparatus for Fluid Dispersion," by Stone et al.; International
Patent Publication Number WO 2006/096571, filed Mar. 3, 2006,
entitled "Method and Apparatus for Forming Multiple Emulsions," by
Weitz et al.; International Patent Publication Number WO
2005/021151, filed Aug. 27, 2004, entitled "Electronic Control of
Fluidic Species," by Link et al.; International Patent Publication
Number WO 2008/121342, filed Mar. 28, 2008, entitled "Emulsions and
Techniques for Formation," by Chu et al.; International Patent
Publication Number WO 2010/104604, filed Mar. 12, 2010, entitled
"Method for the Controlled Creation of Emulsions, Including
Multiple Emulsions," by Weitz et al.; International Patent
Publication Number WO 2011/028760, filed Sep. 1, 2010, entitled
"Multiple Emulsions Created Using Junctions," by Weitz et al.;
International Patent Publication Number WO 2011/028764, filed Sep.
1, 2010, entitled "Multiple Emulsions Created Using Jetting and
Other Techniques," by Weitz et al.; International Patent
Publication Number WO 2009/148598, filed Jun. 4, 2009, entitled
"Polymersomes, Phospholipids, and Other Species Associated with
Droplets," by Shum, et al.; International Patent Publication Number
WO 2011/116154, filed Mar. 16, 2011, entitled "Melt
Emulsification," by Shum, et al.; International Patent Publication
Number WO 2009/148598, filed Jun. 4, 2009, entitled "Polymersomes,
Colloidosomes, Liposomes, and other Species Associated with Fluidic
Droplets," by Shum, et al.; International Patent Publication Number
WO 2012/162296, filed May 22, 2012, entitled "Control of Emulsions,
Including Multiple Emulsions," by Rotem, et al.; International
Patent Publication Number WO 2013/006661, filed Jul. 5, 2012,
entitled "Multiple Emulsions and Techniques for the Formation of
Multiple Emulsions," by Kim, et al.; and International Patent
Publication Number WO 2013/032709, filed Aug. 15, 2012, entitled
"Systems and Methods for Shell Encapsulation," by Weitz, et al.
In one embodiment, illustrated in FIG. 6, an apparatus 1000 for
producing microcapsules may include: a first reservoir 100
containing a first liquid, wherein the first liquid may comprise an
emulsion comprising in turn, a dispersed phase and a continuous
phase. The first reservoir may be disposed in fluid communication
with a plurality of first conduits forming a portion of a plurality
of microfluidic devices 600, each of the first conduits having an
exit. The apparatus also comprises a second reservoir 200
containing a second liquid, the second reservoir may be disposed in
fluid communication with a plurality of second conduits forming a
portion of the plurality of microfluidic devices 600. Each of the
second conduits at least partly surrounds one of the first
conduits. The first and second fluids are substantially immiscible.
The apparatus further comprises a third reservoir 300 containing a
third liquid, the third reservoir disposed in fluid communication
with second conduits. The second and third fluids being
substantially immiscible. The apparatus further comprising a
plurality of third conduits disposed at least in part within the
second conduits downstream of the exits of the first conduits as
part of the plurality of microfluidic devices, the third conduits
positioned to receive the first liquid exiting the first conduits,
the second liquid and the third liquid.
[0131] The volume of the reservoirs may range from as little as
about 2 ml, to as much as about 6,000 L depending upon the volume
of product desired to be produced.
[0132] In such an embodiment, the first reservoir may be disposed
in switchable fluid communication with the first conduits and the
apparatus may further comprise a fourth reservoir 400 containing a
fourth liquid, wherein the fourth liquid is an emulsion comprising
a dispersed phase and a continuous phase, the fourth reservoir 400
disposed in switchable fluid communication with the first conduits
by the activation of valve 500.
[0133] In one embodiment, the dispersed phase of the first liquid
is substantially miscible with the second liquid and the dispersed
phase of the fourth liquid is substantially immiscible with the
second liquid.
Test Methods
[0134] It is understood that the test methods that are disclosed in
the Test Methods Section of the present application should be used
to determine the respective values of the parameters of Applicants'
invention as such invention is described and claimed herein.
Furthermore, it is obvious to those skilled in the art that
encapsulated benefit agents need to be isolated from the product
before using the methods below and isolation will depend not only
on the type and form of the product but also on the encapsulated
benefit agent shell nature. For example, encapsulated benefit
agents comprised in a liquid product might be isolated by
centrifugation and redisperse in a non-solvent for the encapsulated
benefit agent shell, whilst for encapsulated benefit agents
comprised in solid products, a solvent for the binder and
non-solvent for the encapsulated benefit agent shell might be
use.
[0135] (1) Mean Diameter of a Population of Encapsulated Benefit
Agents:
[0136] A population of encapsulated benefit agents is characterized
by a mean diameter (D) obtained using scanning electron microscopy
and computerized image analysis with the ImageJ software program
version 1.46r (Rasband, W. S., ImageJ, U. S. National Institutes of
Health, Bethesda, Md., USA, http://imagej.nih gov/ij/, 1997-2012.).
[0137] i. A sample of a population of encapsulated benefit agents
of about 30 mg is adhered to a bioadhesive stub (e.g., 12.5 mm
diameter Aluminium Pin Stub G301, mounted with 12 mm diameter Leit
Adhesive Carbon tab, as available from Agar Scientific, Essex, UK),
avoiding agglomerations to obtain a single, uniform layer of
encapsulated benefit agents on the stub. [0138] ii. A Hitachi
TM-1000 Table Top Scanning Electron Microscope (Hitachi
High-Technologies Europe GmbH, Germany) is used to take about 10
images per stub using a magnification of about 100.times., in order
to obtain images of about 500 randomly selected encapsulated
benefit agents. [0139] iii. From the 10 images taken, at least 3
images are selected for ImageJ analysis, while ensuring that
sufficient images are selected to depict a monolayer of at least
300 encapsulated benefit agents, in total. [0140] iv. Each of the 3
or more images is opened in ImageJ. The images are calibrated and
the scale used is in micrometers (.mu.m). Each image is converted
to 8-bit grayscale pixel depth, and then automatically thresholded
by the software's auto threshold button to create a binary image,
whereby pixels representing the encapsulated benefit agents become
the foreground objects and regions-of-interest, which are separated
from the background pixels. The area (in sq..mu.m) of each
region-of-interest object representing an encapsulated benefit
agent, is then measured with ImageJ by selecting "Area" on the "Set
Measurement" menu, and within "Area" select "Exclude Edge
Particles" and "circularity". Then for "circularity" enter the
range of values from about 0.4 to about 1 on the "Analyze
Particles" menu. [0141] v. The obtained areas (A, in sq..mu.m) are
recorded and used to calculate the diameter of the encapsulated
benefit agents according to following formula:
[0141] d.sub.i=.PI.(4A.sub.i/.pi.) [0142] wherein d.sub.i is the
diameter in micrometers and A.sub.i the area obtained from ImageJ
for a given encapsulated benefit agent. [0143] vi. Then, diameters
(d.sub.i) are rank-ordered from largest to smallest size and the
mean encapsulated benefit agent size is obtained using following
formula:
[0143] D _ = i = 1 n d i n ##EQU00002## [0144] wherein D is the
mean encapsulated benefit agent diameter in micrometers, d.sub.i
are the individual diameters of the encapsulated benefit agent as
calculated above in micrometers and n the total number of
encapsulated benefit agent analyzed, using a minimum of 300
encapsulated benefit agents to obtain such mean. Additionally, the
5.sup.th, 50.sup.th and 95.sup.th percentile values are also
calculated for these diameter datapoints.
[0145] (2) Coefficient of Variation of the Diameters of a
Population of Encapsulated Benefit Agents:
[0146] A population of encapsulated benefit agents is characterized
by a diameter coefficient of variation (CoV) corresponding to the
ratio between the diameter distribution of said population of
encapsulated benefit agents (ie the standard deviation) and the
mean encapsulated benefit agent diameter. CoV is obtained as
follow: [0147] i. First, the Standard Deviation (STD) of the mean
encapsulated benefit agents' diameter is obtained using following
formula:
[0147] S T D = i = 1 n ( d i - D _ ) 2 n ##EQU00003## [0148]
wherein STD is the standard deviation of diameters in micrometers,
D is the mean encapsulated benefit agent diameter in micrometers,
d.sub.i are the individual diameters of the encapsulated benefit
agents in micrometers as calculated above, and n is the total
number of encapsulated benefit agents analyzed, using a minimum of
300 encapsulated benefit agents to obtain such STD. [0149] ii.
Finally, the coefficient of variation (CoV) of the diameters of a
population of encapsulated benefit agents is obtained using
following formula:
[0149] CoV = S T D 100 D _ ##EQU00004## [0150] wherein CoV is the
coefficient of variation of the diameters of a population of
encapsulated benefit agents in %, STD and D are the standard
deviation and the mean diameter in micrometers, respectively, as
calculated above.
[0151] (3) Mean Shell Thickness:
[0152] The mean shell thickness is determined by preparing
cross-sections of targeted encapsulated benefit agents and
measuring the shell thickness under a Scanning Electron Microscope
(such as model JSM-6400, available from JEOL Ltd, Tokyo, Japan).
Approximately 200 mg of encapsulated benefit agent sample (as dry
powder) is mixed with about 1 mL of Optimal Cutting Temperature
solution (OCT). In the case of non water-soluble shell materials,
the OCT solution can be composed of 10.24% poly vinyl alcohol,
4.26% Poly ethylene glycol and 85.5% non-reactive ingredients.
Whereas, for water-soluble shell materials, the OCT solution can be
comprised of Poly Propylene Glycol, Poly Ethylene Glycol, Glycerin,
Vegetable oil and/or Mineral oil. This OCT solution containing the
encapsulated benefit agents suspended in it is immediately frozen
by using liquid Nitrogen (-196.degree. C.) and is placed inside a
cryostat microtome cooled to -20.degree. C. The cryostat microtome
is used to cut sample cross-sections of the frozen suspension, at
about 10 .mu.m in thickness. Sections are mounted on room
temperature glass microscope slides, where they will
instantaneously melt and adhere. After the sections are air-dried
at room temperature, they are coated with gold by sputter coating
and observed and photographed using a scanning electron microscope
(SEM) (such as the JEOL SEM model JSM-6400, available from JEOL
Ltd, Tokyo, Japan). From the micrographs obtained of the
cross-sections, the shell thickness of 30 encapsulated benefit
agents is measured, by selecting 10 encapsulated benefit agents in
each of 3 different diameter size fractions. The 3 different
diameter size fractions are determined by the 5.sup.th, 50.sup.th
and 95.sup.th percentile values calculated from the diameter
datapoints, as measured under method (1) above. The 3 diameter size
fractions are defined (in micrometers) as being: the 5.sup.th
percentile value+/-10% of its value; the 50.sup.th percentile
value+/-10% of its value; and the 95.sup.th percentile value+/-10%
of its value. For each of the 30 encapsulated benefit agents
selected, the shell thickness is measured at least at 4 different
locations spaced equi-distantly around each shell's circumference,
i.e., at 0.degree., 90.degree., 180.degree. and 270.degree.,
yielding 120 thickness measurements in total. The mean shell
thickness (S) of each capsule is calculated using the at least 4
shell thickness measurements for the respective capsule.
[0153] (4)
[0154] Microcapsule Stability: [0155] In-situ polymerized
microcapsules encapsulating .alpha.-pinene are collected, rinsed,
and monitored with different time intervals in a closed system with
five microcapsules dispersed in 3 mL of DI water after being
transferred to a quartz cuvette cell. The cuvette cell is sealed
during the leakage study. UV-VIS spectroscopy is used to monitor
the leakage profile of various systems in a controlled environment
for comparative purposes. Representative systems are selected and
the as-prepared and treated microcapsules are transferred to
ethanol, to quantitatively determine the amount of .alpha.-pinene
remaining after each condition tested. The dispersed phase
retention fraction is determined according to the stability test
after a period of five days. The retention fraction is the % w/w of
the .alpha.-pinene indicated by the test as remaining in the
microcapsules.
[0156] The following examples are intended to illustrate certain
embodiments of the present invention, but do not exemplify the full
scope of the invention.
Example 1
[0157] This example illustrates encapsulation of an active embedded
within secondary compartments to achieve control of the release
profile. In this example, a perfume is encapsulated as an
illustrative example. Perfume is often a mixture of polar and
non-polar components (e.g. fragrant essential oils or aroma
compounds). Thus, it can be challenging to encapsulate the perfume
in polymer shells which is dispersed in water phase due to their
significant solubility in a broad range of solvents, and even in
most shell materials (monomer).
[0158] This example presents a method to encapsulate pre-emulsified
perfume in hydrophobic polymer shells, achieving high loading
efficiencies, e.g., over 50%. In this particular example, to first
form double emulsions (water-in-oil-in-water), three phases were
injected into a microcapillary device: 10% PVA (polyvinyl alcohol)
in aqueous phase as the continuous phase, ethoxylated
trimethylolpropane triacrylate (ETPTA) with a photoinitiator (1%)
as the middle phase, and pre-emulsified perfume as an inner phase.
See FIG. 1A.
[0159] The pre-emulsified perfume was prepared by simple mixing of
perfume and surfactant solution. To ensure long-term stability of
pre-emulsified perfume, two kinds of surfactants were used, Tween
80 (15.2) and polyvinyl alcohol (PVA), with different hydrophilic
lipophilic balances (HLB). For example, in some experiments,
pre-emulsified perfume used as an inner phase included 50% perfume,
2.5% PVA, 1% Tween 20 and 46.5% water (all percentages are by
weight).
[0160] FIG. 1B shows that double emulsions were uniformly formed
under jetting conditions, and these droplets were collected in a
vial. The double emulsions were exposed to UV light, forming
polymer shells containing pre-emulsified perfume (FIGS. 1C and 1D).
To demonstrate successful encapsulation of perfume inside, the
perfume was stained with Nile Red as a tracer. Overall, high
loading efficiencies (e.g., greater than about 50%) of perfume in
the polymer shells was achieved by encapsulating pre-emulsified
perfume.
Example 2
[0161] In this example, an antioxidant was encapsulated as another
illustrative example. See FIG. 2.
[0162] Preparation of THBQ in monomer solution. Antioxidant
(tert-butyl hydroquinone, TBHQ, 600 mg) was dissolved in EtOH (1
mL) in a glass vial. To a vial containing a hydrophobic monomer
(pentaerythritol triacrylate, PETA, 3 g), and a photoinitiatior
(2-hydroxy-2-methylpropiophenone, HMP, 30 mg), the EtOH solution of
TBHQ was added. The solution (2 g) was left under vacuum for 6
hours to remove EtOH and a transparent and viscous fluid of monomer
with TBHQ dissolved inside was found.
[0163] Preparation of water in oil emulsion. To the resulting
solution, 8 mL aqueous solution of PVA (10 wt %) was added and the
resulting mixture was then placed on vortex for 1 min. After
initial mixing, the turbid emulsion was subject to tip sonication
under an ice bath for 15 min (40% power, 5 s sonication, 2 s
interval).
[0164] Synthesis of secondary particle dispersion in water. After
sonication, the emulsion was transferred into a syringe (5 mL) and
then pumped out at 1 mL/min through a plastic tube to a collection
vial. UV light was applied to the outlet of the tube (1 cm above
the tube) and as a result, the drops from the emulsion were
photo-irradiated and the polymerization of PETA was initiated in
the oil phase.
[0165] Washing secondary particles. After photo-polymerization,
three cycles of centrifuge/re-dispersion was used to remove
impurities from the particles dispersion. The pH of the dispersion
containing particles (1 mL) was adjusted to 5 using buffer
phosphate solution and centrifuged for 2 minutes using 14000 rpm.
After the supernatant was carefully removed, 1 mL of buffer
solution was added and the resulting dispersion was sonicated for
10 minutes to re-disperse the particles into solvent. This process
was repeated 3 times.
[0166] Preparation of secondary particles encapsulated droplet. To
an aqueous dispersion of secondary particles (1 mL), a polymer
solution (9 mL) containing monomer (polyethylene glycol diacrylate,
PEGDA Mw 575, 40 wt %), crosslinker (ethoxylated trimethylolpropane
triacrylate, ETPTA, MW 912, 5 wt %), and photoinitiator (HMP, 1 wt
%) was added. The resulting solution was mixed using vortex for 5
min before subjecting to microfluidic setup as the dispersed phase
(see FIG. 1A). A dodecane solution containing 5 wt % of surfactant
(EM90, Evonik) was used as the continuous phase.
Example 3
[0167] .alpha.-pinene encapsulated ETPTA microcapsules were
prepared with and without a hydrogel network continuous phase in
the microcapsules. These microcapsules were rinsed with DI water
the continuous aqueous phase carrying the microcapsules was
removed. Upon removal of the surrounding water, drastic difference
in microcapsule morphology were observed over time. The aqueous
phase of fragrance emulsion is replaced by air as the water
evaporates for the control microcapsule. No apparent difference is
observed for the PEG hydrogel microcapsule. A uniform hydrogel
network in PEG hydrogel microcapsule was observed upon breakage. As
shown in FIG. 5, the control microcapsules have a dispersed phase
retention fraction of less than about 40% w/w after 5 days while
the hydrogel continuous phase microcapsules have a dispersed phase
retention fraction of about 50% w/w.
[0168] The various embodiments set forth above may be used as part
of the formulation of a range of consumer products. Such consumer
products include, but are not limited to, products for treating
hair (human, dog, and/or cat), including, bleaching, coloring,
dyeing, conditioning, shampooing, styling; deodorants and
antiperspirants; personal cleansing; cosmetics; skin care including
application of creams, lotions, and other topically applied
products for consumer use including fine fragrances; and shaving
products, products for treating fabrics, hard surfaces and any
other surfaces in the area of fabric and home care, including: air
care including air fresheners and scent delivery systems, car care,
dishwashing, fabric conditioning (including softening and/or
freshening), laundry detergency, laundry and rinse additive and/or
care, hard surface cleaning and/or treatment including floor and
toilet bowl cleaners and cleaning implements, granular or
powder-form all-purpose or "heavy-duty" washing agents, especially
cleaning detergents; liquid, gel or paste-form all-purpose washing
agents, especially the so-called heavy-duty liquid types; liquid
fine-fabric detergents; hand dishwashing agents or light duty
dishwashing agents, especially those of the high-foaming type;
machine dishwashing agents, including the various tablet, granular,
liquid and rinse-aid types for household and institutional use;
liquid cleaning and disinfecting agents, including antibacterial
hand-wash types, cleaning bars, mouthwashes, denture cleaners,
dentifrice, car or carpet shampoos, bathroom cleaners including
toilet bowl cleaners; hair shampoos and hair-rinses; shower gels,
fine fragrances and foam baths and metal cleaners; as well as
cleaning auxiliaries such as bleach additives and "stain-stick" or
pre-treat types, substrate-laden products such as dryer added
sheets, dry and wetted wipes and pads, nonwoven substrates, and
sponges; as well as sprays and mists all for consumer or/and
institutional use; and/or methods relating to oral care including
toothpastes, tooth gels, tooth rinses, denture adhesives, and tooth
whitening.
[0169] While several embodiments of the present invention have been
described and illustrated herein, those of ordinary skill in the
art will readily envision a variety of other means and/or
structures for performing the functions and/or obtaining the
results and/or one or more of the advantages described herein, and
each of such variations and/or modifications is deemed to be within
the scope of the present invention. More generally, those skilled
in the art will readily appreciate that all parameters, dimensions,
materials, and configurations described herein are meant to be
exemplary and that the actual parameters, dimensions, materials,
and/or configurations will depend upon the specific application or
applications for which the teachings of the present invention
is/are used. Those skilled in the art will recognize, or be able to
ascertain using no more than routine experimentation, many
equivalents to the specific embodiments of the invention described
herein. It is, therefore, to be understood that the foregoing
embodiments are presented by way of example only and that, within
the scope of the appended claims and equivalents thereto, the
invention may be practiced otherwise than as specifically described
and claimed. The present invention is directed to each individual
feature, system, article, material, kit, and/or method described
herein. In addition, any combination of two or more such features,
systems, articles, materials, kits, and/or methods, if such
features, systems, articles, materials, kits, and/or methods are
not mutually inconsistent, is included within the scope of the
present invention.
[0170] All definitions, as defined and used herein, should be
understood to control over dictionary definitions, definitions in
documents incorporated by reference, and/or ordinary meanings of
the defined terms.
[0171] The indefinite articles "a" and "an," as used herein in the
specification and in the claims, unless clearly indicated to the
contrary, should be understood to mean "at least one."
[0172] The phrase "and/or," as used herein in the specification and
in the claims, should be understood to mean "either or both" of the
elements so conjoined, i.e., elements that are conjunctively
present in some cases and disjunctively present in other cases.
Multiple elements listed with "and/or" should be construed in the
same fashion, i.e., "one or more" of the elements so conjoined.
Other elements may optionally be present other than the elements
specifically identified by the "and/or" clause, whether related or
unrelated to those elements specifically identified. Thus, as a
non-limiting example, a reference to "A and/or B", when used in
conjunction with open-ended language such as "comprising" can
refer, in one embodiment, to A only (optionally including elements
other than B); in another embodiment, to B only (optionally
including elements other than A); in yet another embodiment, to
both A and B (optionally including other elements); etc.
[0173] As used herein in the specification and in the claims, "or"
should be understood to have the same meaning as "and/or" as
defined above. For example, when separating items in a list, "or"
or "and/or" shall be interpreted as being inclusive, i.e., the
inclusion of at least one, but also including more than one, of a
number or list of elements, and, optionally, additional unlisted
items. Only terms clearly indicated to the contrary, such as "only
one of" or "exactly one of," or, when used in the claims,
"consisting of," will refer to the inclusion of exactly one element
of a number or list of elements. In general, the term "or" as used
herein shall only be interpreted as indicating exclusive
alternatives (i.e. "one or the other but not both") when preceded
by terms of exclusivity, such as "either," "one of," "only one of,"
or "exactly one of." "Consisting essentially of," when used in the
claims, shall have its ordinary meaning as used in the field of
patent law.
[0174] As used herein in the specification and in the claims, the
phrase "at least one," in reference to a list of one or more
elements, should be understood to mean at least one element
selected from any one or more of the elements in the list of
elements, but not necessarily including at least one of each and
every element specifically listed within the list of elements and
not excluding any combinations of elements in the list of elements.
This definition also allows that elements may optionally be present
other than the elements specifically identified within the list of
elements to which the phrase "at least one" refers, whether related
or unrelated to those elements specifically identified. Thus, as a
non-limiting example, "at least one of A and B" (or, equivalently,
"at least one of A or B," or, equivalently "at least one of A
and/or B") can refer, in one embodiment, to at least one,
optionally including more than one, A, with no B present (and
optionally including elements other than B); in another embodiment,
to at least one, optionally including more than one, B, with no A
present (and optionally including elements other than A); in yet
another embodiment, to at least one, optionally including more than
one, A, and at least one, optionally including more than one, B
(and optionally including other elements); etc.
[0175] When the word "about" is used herein in reference to a
number, it should be understood that still another embodiment of
the invention includes that number not modified by the presence of
the word "about."
[0176] It should also be understood that, unless clearly indicated
to the contrary, in any methods claimed herein that include more
than one step or act, the order of the steps or acts of the method
is not necessarily limited to the order in which the steps or acts
of the method are recited.
[0177] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0178] Every document cited herein, including any cross referenced
or related patent or application and any patent application or
patent to which this application claims priority or benefit
thereof, is hereby incorporated herein by reference in its entirety
unless expressly excluded or otherwise limited. The citation of any
document is not an admission that it is prior art with respect to
any invention disclosed or claimed herein or that it alone, or in
any combination with any other reference or references, teaches,
suggests or discloses any such invention. Further, to the extent
that any meaning or definition of a term in this document conflicts
with any meaning or definition of the same term in a document
incorporated by reference, the meaning or definition assigned to
that term in this document shall govern.
[0179] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *
References