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Plasma polymerization for encapsulating particlesRelated Patent Categories: Chemical Apparatus And Process Disinfecting, Deodorizing, Preserving, Or Sterilizing, Chemical Reactor, Bench ScalePlasma polymerization for encapsulating particles description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060045822, Plasma polymerization for encapsulating particles. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] The present invention relates to the encapsulation of particles, and more specifically to particle encapsulation using a plasma polymerization process. [0002] Particle encapsulation, in which a particle is surrounded or coated by at least one layer of a surface, has many beneficial uses. Unfortunately, current methods of encapsulation generally require a number of technical steps and result in encapsulated products with poor stability. In addition, most methods result in low product yields, due, in part, to the limited tolerance of the starting materials to industrial operating conditions and the numerous technical difficulties associated with the encapsulation process, with product recovery and inadequate recycling from the reaction systems. [0003] Particle encapsulation, for example, offers a method in which a particle may be introduced to an environment in a more controlled manner. The control is generally imposed by varying different aspects of the coating, such as its composition. Such control generally falls into one of two categories: temporal control and distribution control. Temporal control introduces the particle to the environment over an extended time period or at a pre-specified time. Here, the aim is to match the rate of particle introduction to the rate of particle elimination from the environment. Thus, the particle concentration appears to be regulated and often for a much longer time. This technique is particularly beneficial when introducing a particle into a biologic system for therapeutic purposes, because the overall therapeutic index is improved. [0004] Distribution control, on the other hand, provides for the introduction of a particle at at least one specific environmental location. Such control may be desired when the particle is not required or presents/encounters problems when introduced to the entire environment. In biologic systems, distribution control may reduce or eliminate the occurrence of undesirable side effects. [0005] Current approaches to particle encapsulation include layer-by-layer assembly of polyelectrolytes, emulsion-solvent evaporation processes, formation of hydrogel films, and the preparation of systems based on thiolated polymers, sol-gel carriers, and granulation techniques. While current approaches do provide satisfactory results for introducing particles to an environment; these approaches are complex, involve a number of technical steps, generate large amounts of waste products, and are often inadequate in truly controlling the introduction of the particle into the environment. [0006] Clearly, then, there remains a need to provide for more efficient compositions, systems and methods for introducing particles to an environment in which the particle introduction may be better controlled temporally and/or site-specifically. SUMMARY OF THE INVENTION [0007] The present invention solves the current problem associated with inefficient systems and methods of introducing particles to an environment. The present invention provides for a novel plasma polymerization approach for controlling the introduction and release of a particle to an environment. [0008] Generally, and in one form, the present invention provides for the encapsulation of one or more particles using plasma enhanced chemical vapor depositions (PECVD). The PECVD coats particles with at least one layer of a coating material. PECVD is capable of controlling coating of the particle. In addition, the coating material controls particle introduction into an environment. The coating material and, hence, control of particle introduction into an environment, is dependent on the encapsulation process as well as the composition of the coating of the present invention. In one embodiment, the coating material is a polymeric film comprising at least one carbonaceous compound. The carbonaceous compound is a degradable or nondegradable carbon-containing compound capable of being polymerized on a surface of a particle and, as such, encapsulating the particle. [0009] The present invention also provides for a system for encapsulating one or more particles comprising one or more particles, a rotatable reaction chamber in a plasma enhanced chemical reactor to accept one or more particles, and at least one carbonaceous compound to be used in the rotatable reaction chamber, wherein the carbonaceous compound is polymerized onto a surface of one or more particles forming a polymer film encapsulating one or more particles. The particle may be a pharmaceutical composition (e.g., drug), food, semiconductor material, amino acid, protein, carbonaceous compound, nucleic acid, vitamins, mineral, elemental molecule, fatty acid, lipid, photolabile compound, as examples. The carbonaceous compound is a carbon-containing monomer capable of polymerizing into a degradable or nondegradable polymer. [0010] Reaction conditions that promote polymerization and/or encapsulation generally include power input, peak power, coating time, duty cycle, flow rate of the carbonaceous compound, reactor pressure, and quantity of particles. By altering one or more of the reaction conditions, polymerization is controlled. By controlling polymerization, one can ultimately control the release and rate of release of the encapsulated constituents into an environment. Aspects of the coating or polymer film that may be controlled include film growth, thickness, number, density and quality of one or more monomeric functional groups, hydrophilicity or hydrophobicity, wettability, linearity, cross-linking, and various combinations thereof. [0011] In another form, the present invention is a method for encapsulating one or more particles comprising the step of polymerizing a carbonaceous compound onto a surface of one or more particles to form a polymer film encapsulating one or more particles, wherein the carbonaceous compound is polymerized in a rotatable reaction chamber of a plasma reactor using radio frequency power. [0012] In still another form, the present invention provides for methods and systems for controlling release of one or more particles into an environment, the system comprising one or more particles, a rotatable reaction chamber in a plasma enhanced chemical reactor to accept one or more particles, and at least one carbonaceous compound to be used in the rotatable reaction chamber, wherein the carbonaceous compound is polymerized onto a surface of one or more particles forming a polymer film encapsulating one or more particles, and wherein reaction conditions used in the rotatable reaction chamber control polymer film formation and release of one or more particles into the environment. Particles are released from the encapsulating polymer film by a number of processes that include dissolution of the particle, degradation of the polymer film, and/or passage of the particle through the polymer film. [0013] In yet another form the present invention provides for compositions prepared by systems and methods of the present invention. Compositions include organic and inorganic compositions, such as pharmaceutical compositions, as examples. [0014] Those skilled in the art will further appreciate the above-noted features and advantages of the invention together with other important aspects thereof upon reading the detailed description that follows in conjunction with the drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0015] For more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures, wherein: [0016] FIG. 1 depicts a schematic diagram of a plasma reactor in accordance with one aspect of the present invention; [0017] FIG. 2 depict FT-IR absorption spectra obtained for pulsed plasma polymerization of allyl alcohol at 1/5 ms/ms and peak powers of 100 W and 25 W; [0018] FIG. 3 depict FT-IR absorption spectra obtained for pulsed plasma polymerization of allyl alcohol at 1/5 ms/ms and 25 W for coating times of 60 and 30 minutes; [0019] FIG. 4 depict FT-IR absorption spectra obtained for CW plasma polymerization of allyl alcohol at powers of 10 W and 25 W; [0020] FIG. 5 depict release rates of acetylsalicylic acid coated with of polyallylalcohol as a function of power input; [0021] FIG. 6 depict release rates of acetylsalicylic acid coated with polyallylalcohol as a function of coating time; Continue reading about Plasma polymerization for encapsulating particles... 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