COSMETIC GEL BEAD MANUFACTURING METHOD AND APPARATUS

Abstract: Uniform crushable gel beads for topical delivery of biologically or cosmetically active agents in cosmetic, pharmaceutical, etc. formulations are produced by injection of a hot gelling agent liquid into a cold moving stream of oil contained in a conduit employing a T-piece. Cold oil can be recirculated and the beads separated with a screen. Preferred beads are agar beads containing an active agent retained in the bead by a restraining polymer. Desired organic solvent adjuvants can be adsorbed on oil-absorbent microspheres and included in the beads.

Description: COSMETIC GEL BEAD MANUFACTURING METHOD AND APPARATUS BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to novel methods and apparatus for manufacturing cosmetic gel beads. Gel beads, or capsules, or other manually crushable or frangible particles are useful as cosmetic or dermato logical delivery systems or vehicles for delivery of topically applied active agents to the skin. The invention is applicable to a wide variety of gel beads, capsules or other particles, referenced "beads " hereinafter, made from a variety of materials acceptable for biological use, provided that they can be gelled from solution by cooling and can be subsequently crushed, spread or otherwise dispersed on a desired body surface. Suitable gel materials include a wide range of homogenous or heterogenous gel-forming polymers such as polysaccharides. for example natural and synthetic celluloses, as well as polypeptides including proteinaceous materials, such for example as gelatin; agarose. A preferred gel material for use in the invention is agar. While the invention can beneficially employ the gel material itself as a useful end product, it is greatly preferred that the gel bead serve as a carrier for delivering an active agent to the skin or other body surface. Cosmetic products of interest include, for example, gels, creams and lotions, and it will be understood that such cosmetics may be applied to other body surfaces such as nails, teeth, exposed subcutaneous tissues or possibly even hair or hair and the scalp. While human topical application, especially for cosmetic purposes, is contemplated as the primary field of the invention, non-human animal applications of the inventive methods and apparatus will also be possible, and are included within the invention, as will be apparent to those skilled in the art. It will also be understood that while reference is made herein to cosmetics products, the gel beads of the invention, or produced by the inventive methods and apparatus disclosed herein may be incorporated, with advantage, in other formulations, for example, pharmaceutical or medicament preparations wherein one or more active ingredients, either ethical or over-the-counter, or both, is retained in and protected by the gel beads, as well as dermatoiogical, dermaceutical and neutraceutical products, if not included in the foregoing. 2. Description of Related Art Preferred gel beads, for employment in the invention, should be capable of being formulated into cosmetic products without significant loss of structural integrity and release of active ingredients, yet be able to release the active ingredients on the skin or other treated body surface, when crushed or otherwise broken or ruptured, for example by gentle rubbing on the skin with the fingers. Thus, gel beads used for these purposes, in order to protect the contained actives, should be sufficiently durable to survive the formulation process, which may employ homogenization, aqueous media, acidic pH conditions, temperatures elevated to 80 °C, or more, or employ other conditions that may tend to dissolve, disrupt or disperse the bead materials. The preferred gel material for use in this invention, agar. provides gel beads that have the advantages of being stable, once formed, and of being difficult to solubilize in aqueous media, even at elevated temperatures. Also, agar beads are sufficiently durable to remain stable for the relatively short period at elevated temperature, e.g. up to about 10 minutes, required for homogenization of cream or other emulsions, and may be stable for up to about 30 or 40 minutes. Furthermore, agar gel beads can be readily crushed and smeared on the skin to deliver an active retained in the bead. A drawback of agar beads loaded with an active ingredient is that they provide a sustained release system, releasing the active continuously from the moment of formulation. Such products are unsuitable when it is desired to protect the active from release into the cosmetic excipient. or the like, and to release the active primarily at the site of activation. Delrieu et al. U. S. Patent Number 5.961 ,990 dated October 5. 1999, ("Delrieu '990" hereinafter) a counterpart international application to which was published on 12 November 1998 under number WO 98/50000. teaches a particularly desirable gel bead composition which can be manufactured by the methods and apparatus of the present invention. The disclosures of the aforementioned United States patent and international patent publication are hereby incorporated herein by reference thereto. A preferred gel bead composition according to Delrieu "990 comprises a restraining polymer distributed in agar gel beads, which restraining polymer functions to retain a desired active ingredient or ingredients in the beads. The beads are soft and can be readily manually crushed to deliver the actives to the skin. They can retain useful actives and satisfactorily survive multiphase cosmetic formulation processes employing elevated temperatures and homogenization, without unacceptable deterioration or release of active. Agar gel beads complexed with a restraining polymer, pursuant to Delrieu '990 accordingly provide a valuable and desirable means for topical delivery of active ingredients in cosmetic or pharmaceutical compositions or the like. Delrieu '990 teaches a gel bead manufacturing process wherein a hot aqueous solution of agar and a suitable restraining polymer is injected through a tube immersed in a cold oil bath, generating a population of beads in the oil bath Alternatively, the hot agar solution may be dripped into the cold oil bath, from above, without immersion of the injection tube Active agents can be introduced variously when preparing the hot aqueous agar-polymer solution or subsequently at an intermediate temperature Although this method is effective, various difficulties may occur in scaling it up for commercial production, such as controlling bead size and shape within desired tolerances, maintaining a continuous or nearly continuous production flow and controlling the coolant temperature Oil in the vicinity of the outlet of the injection tube in the cold oil bath tends to be warmed by emerging coalescing drops of hot agar-polymer solution, interfering with quality bead formation which requires rapid cooling of the hot droplet Furthermore, the presence of certain organic solvent congeners of desired actives, for example fragrances may prevent bead formation or result in inferior beads SUMMARY OF THE INVENTION The invention, as claimed, is intended to provide a remedy The invention solves the problem of providing methods and apparatus capable of producing gel beads of consistent unitorm quality, especially, but not exclusively, agar-polymer beads as described in Delrieu "990 More particularly, the invention solves the problem of providing methods and apparatus capable ot producing gel beads of controlled size and shape, which methods are suitable for large scale, batch or nearly continuous production To solve the problem of producing uniform beads of a desired shape, from a bead solution including sufficient ot an organic solvent to inhibit bead formation, the invention provides a method ot preparing gel particles tor incorporation in a topically applied formulation, the method comprising a) forming a hot aqueous solution of a gelling agent, the solution being gellable at a lower temperature, and b) discharging the hot gelling agent solution through a discharge orifice into a cold hydrophobic liquid immiscible with the gelling agent solution, the cold hydrophobic liquid being maintained at a temperature below the gelling agent gelling point, and providing a moving stream of the cold hydrophobic liquid, and discharging the hot gelling agent solution through the discharge orifice into the moving stream of cold hydrophobic liquid to generate gel particles in the hydrophobic liquid stream The method can be effected by discharging the hot gelling agent through an injection tube, the injection tube terminating in the discharge orifice the discharge orifice being positioned in the moving stream of cold hydrophobic liquid. The cold hydrophobic liquid is preferably contained in a conduit, the injection tube extending into the conduit. Preferably also, the conduit has a recti-linear portion and the injection tube extends approximately perpendicularly into the recti-linear portion of the conduit. The invention also provides apparatus for performing the described inventive method, the apparatus comprising: a) a first source being a source of a hot aqueous solution of a gelling agent, the solution being gellable at a lower temperature; b) a second source being a source of a cold hydrophobic liquid immiscible with the gelling agent solution, the cold hydrophobic liquid being maintained at a temperature below the gelling agent gelling point; c) a discharge orifice for receiving the hot gelling agent solution from the second source and discharging the hot gelling agent solution into the cold hydrophobic liquid: and d) a conduit carrying a moving stream of the cold hydrophobic liquid, the discharge orifice being disposed to discharge the hot gelling agent solution into the moving stream of cold hydrophobic liquid to generate gel particles in the hydrophobic liquid stream. In another aspect the invention provides a gel bead for incorporation in topically applied formulations, the gel bead being crushable in the formulation to release an active agent and comprising: a) a structural gel material; b) an active agent; and c) an organic solvent adsorbent on oil absorbent microsphere particles. Preferably, the gel bead further comprises a restraining polymer to retain the active agent in the gel bead. While reference is made herein to the skin as a delivery target for active agents, it will be appreciated that the nails, hair, mouth, teeth wound tissue, or other accessible endogenous body surfaces can be similarly targeted, depending upon the active and the cosmetic or medicament vehicle into which the beads are formulated. BRIEF DESCRIPTION OF THE DRAWINGS Some illustrative embodiments of the invention, and the best mode contemplated of carrying out the invention, are described in detail below with reference to the accompanying drawings in which:- Figure 1 is a schematic view of a method of making gel beads according to the invention; and Figure 2 is a schematic view of apparatus for manufacturing gel beads by the method illustrated in Figure 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS All parts and proportions referenced in this description, unless otherwise stated, are on a weight or weight-for-weight basis. A particularly preferred embodiment of particulate cosmetic gel carrier, or gel bead comprises relatively small agar particles or agar beads having an average particle size measured in millimeters. The particles are small enough for cosmetic use, and preferably do not exceed 10 mm. in diameter, on average, but not so small as to penetrate the skin or skin pores, if the particles are to deliver an active agent topically. A minimum diameter of interest is, on average, about 0.05 mm. (50 microns). A preferred range of larger particle sizes is from about 1 to about 5 mm in diameter, on average, and a preferred range of smaller particle sizes is from about 0.2 mm to about 1 mm in diameter, on average. Preferred methods of producing the particles according to the invention yield uniform particles in a narrow band size and distribution and shape variation, so that it is preferred that at least 90 percent of the particles, more preferably 95 percent of the particles, lie within a desired average particle size bracket extending up to about 10 percent either side of a targeted average. If desired, for particular applications, a more uniform product can be obtained by mesh filtration. Some substances and materials usable in the practice of the invention are described in the following paragraphs. Others will be apparent to those skilled in the art. Gel-forming agents: A particularly preferred gel-forming agent for use in the practice of the invention is agar. also known as "agar-agar " . More properly referenced "agarose, " which is the neutral gelling fraction of agar (the other being a sulfated non-gelling fraction "agaropectin"), the term "agar" is nevertheless used herein in the same sense as "agarose". Agar is an example of a gel-forming polysaccharide commonly used as a medium for electrophoresis and chromatography. Agar is insoluble when dispersed as a dry solid in water at low temperatures, however, it becomes soluble when heated to temperatures over 70-90°C and forms a gel upon cooling. Agar is relatively expensive in comparison with some other commonly used gelling agents, but is particularly well suited for formulation with cosmetic vehicles, especially two-phase creams, gels and lotions which are usually homogenized at an elevated temperature. Agar gels are stable to both pH and moderate elevation of temperature. While agar is a particularly preferred gel for use in the practice of the invention, other gels meeting the requirements of the invention can be used. Such other gels should be capable of forming dimensionally stable, self-supporting gel-polymer complex particles that are stable under the conditions of formulation, if any, (the particles themselves may constitute the end product), packaging and storage, and which can be crushed, spread or otherwise dispersed on the skin or nails of an end user to increase the surface area of the particles and disperse contained active in situ. The beads are preferably not unduly tacky and do not adhere to one another on contact. Preferred gels are water-soluble polymers that are pH stable. Preferably also, they should be such as can yield polymer-complex beads that are stable, when exposed with mixing, to an aqueous environment at about 50 °C for at least 5 and preferably 15 minutes. Still more preferably, the polymer complex beads produced should be stable, when exposed with mixing, to an aqueous environment at about 80 °C. for at least 5. and preferably 15, minutes. Other such possible gels will be known or apparent to those skilled in the art. in the light of the disclosure herein, and may include: synthetic polymers, such as vinyl or acrylamide polymers, or copolymers: natural polymers, for example polysaccharides, or proteins or synthetically modified ones of such polymers; botanically derived gels; and may include gelling agents such as carbopol, a common, low-cost petroleum-derived, cosmetic gel. However carbopol ' s gelling characteristics depend on pH levels, so that it not a suitable protectant for many actives for example alpha hydroxy acids. It will be understood that the gel-forming agent selected for use in the practice of the invention should not only satisfy the particle or bead forming requirements described herein, but should also meet any requirements associated with the intended cosmetic, pharmaceutical, medicament, or other end use of the bead. Some other such gel-forming polymers are disclosed in Cini et al., supra, see for example, column 4, line 1 1 to column 6, line 30, the disclosure of which is hereby incorporated herein by reference thereto. Restraining polymer. The restraining polymer employed in practicing the invention has sufficient molecular weight to prevent egress of the restraining polymer from the agar gel, and has retention groups to bind the active agent to the restraining polymer for retention in the gel particles. Preferably also, it is water-soluble to a sufficient extent that a desired proportion can be co-dissolved with agar in an initial particle-forming step. The restraining polymer used is preferably selected according to the desired active agent or agents to have one or more retention groups which will bind the active agent. Polymers with an average molecular weight of about 100.000 daltons, and more, are unable to flow through a preferred agar gel matrix and are therefore generally suitable for use in the practice of the invention There is no particular upper limit to the molecular weight of the restraining polymer, although it is contemplated that the average molecular weight will not exceed several million, e g 5 million daltons, but preferably does not exceed 1 million daltons A preferred range for the average molecular weight is from about 75,000 to about 125.000 daltons Some preferred classes of restraining polv mer are cationic polysaccharides and polypeptides or proteins For example, some specific restraining polymers preferred for the practice of the invention are certain commercially available quaternized polysaccharides. especially celluloses, rich in quaternary groups, notably polyquaternium 24 available under the trademark QUATR1SOFT LM-200 (Union Carbide Corporation), polyquaternium 1 1. available for example under the trade name GAFQUAT 755N (ISP Europe), and the CRODACEL Q (trademark) range of alkyl quaternary cellulose polymers (Croda. Inc ) notably laurdimonium hydroxyethylcellulose. sold under the trademark CRODACEL QL, cocodimonium hvdrowethvlcellulose. sold under the trademai CRODACEL QM and steardimonium hydroxyethvlcellulose. sold under the trademark CRODACEL QS Preferred Actives Some examples ot particularly preterred actives for delivery by the gel carrier particles ot the invention are ascorbic acid (vitamin C), alpha-tocopherol (vitamin E), tocopherol acetate (vitamin E acetate), purified papain extract, beta-carotene, green tea extract rich in polyphenols, purified extracts of procyanidolic o gomers from grape seed or pine bark, monoazoic dye e g D&C orange, xanthenic dye (disodium salt), cinnamic acid and octv lmethoxycinnamate, pigments, perfumes and fragrances, including fragrances supplied in organic solvent vehicles One preferred class of actives is anionic, a particularly preferred restraining polymer to which the actives bind being a modified polysaccharides containing quaternary ammonium groups which are cationic and are able to form stable ionic bonds with many anionic actives Water Water is also a significant ingredient of the carrier particles of the invention, being the medium through which colloidal agar particles are dispersed to provide a semi-solid or nearly solid gel Other aqueous media, or possibly, polar alcohols or glycols, may substitute for water In preparing the agar beads of the invention, agar and other ingredients are mixed with water and injected through a needle as a warm solution or dispersion, at a speed controlled to generate drops, then cooled to set the gel Proportions The proportion of solids to water should be sufficient to dissolve or disperse the solids and to ensure they will remain in solution or dispersed until desired gel formation in the oil medium, after the droplets leave the injection needle. Preferably the solids comprise from about 0.5 to about 40 percent by weight of the solution or dispersion and more preferably from about 1.5 to about 25 percent by weight. The relative proportion of restraining polymer to agar can be as low as 1 : 10, but to obtain a satisfactory loading of active agent (which can, in certain instances, be the polymer itself, e.g. hyaluronic acid) a proportion of at least 1 : 1, up to about 10: 1 restraining polymer to agar, is desirable. Preferably, a proportion of from about 2: 1 to about 6: 1 is used. The proportion of active agent, assuming such to be additional to the restraining polymer, will usually be made as high as practical, without affecting the integrity of the particle or causing unacceptable instabilities in storage. The maximum practical loading of active, a desirable objective, will vary substantially, depending upon the nature of active agent and will usually be related to the quantity of restraining polymer. Depending upon the potency of the active, and other factors such as its physical form, the proportion of active agent to restraining polymer may range from about 0.01 : 1 to about 10: 1 , preferably from about 0.1 : 1 to about 5.0: 1. Preferably also, the active agent comprises from about 0.01 to about 20 percent of the solution, or dispersion, at the injection needle, more preferably about 0.1 to about 10 percent. The foregoing relative proportions are, as previously stated, based on weight, and are also based on the ingredients of the solution or dispersion at the injection needle. With proper manufacturing or production procedures, these proportions should largely be reflected in the end product agar complex gel beads themselves, but variations may occur. Cosmetic formulations. Cosmetic formulations, diluents or cosmetic vehicles are compositions applied externally to the skin, hair or nails for purposes of cleansing, beautifying, conditioning or protecting the body surface. Cosmetic formulations include but are not limited to water-in-oil or oil-in-water emulsions in cream or lotion form, sunscreens, toners, astringents, facial make-ups, powders, and skin cleansing compositions. The recipes for such compositions are well known to those skilled in the art and can be found in many publications in the field. A brief summary of some such cosmetic "diluents" that can be used in the practice of the invention appears in Wolf et al. U.S. Patent 5,449,519, for example at column 4. line 25 to column 6. line 56, the disclosure of which is hereby incorporated herein by reference thereto. The gel-complex particles of the invention are generally suitable for incorporation into such cosmetic compositions or "diluents" and the invention extends to the resultant gel-complex particle containing compositions which have beneficial properties arising from the presence of the gel- complex particles, for example new active ingredients, new concentrations of active ingredients, or simply better delivery of active ingredients with reduced loss of activity. The gel beads of the invention can be used in such cosmetic compositions in any desired concentration or proportion that will provide an effective amount of active agent upon application, for example from 0.1 to 90 percent by weight of the total composition, preferably from 1 to 50 percent, and more preferably from 5 to 25 percent by weight of the total composition. Manufacture. It is known to make agar gei beads by dissolving granular agar in deionized or distilled water heated to an elevated temperature sufficient to dissolve the agar. using a proportion of agar to water effective to form a gel at lower temperatures, cooling the hot agar solution to a suitable intermediate temperature above the gelling point of the agar solution, typically about 30 °C, and injecting the cooled solution through an injection needle, sized according to the desired agar bead size, into a hydrophobic liquid maintained at a temperature suitably below the agar gelling point for bead formation, at a rate of injection controlled to favor bead formation. The dissolved agar can be cooled to about 50 °C and injected into an oil medium, e.g. a paraffin bath, at about 2.5 °C, whereupon the agar gel beads solidify as they leave the injection needle. In the method of the invention, a suitable restraining polymer, and the active agent, if any, dissolved or dispersed in water or an aqueous solvent system, are mixed with the agar solution before injection into the hydrophobic liquid. Suitable restraining polymers, and many actives, are generally temperature stable and can be mixed with the agar granules and heated to the elevated temperature to provide a clear solution of all ingredients. Less stable actives, for example, enzymes, can be introduced to the agar- polymer solution at the intermediate temperature, preferably in aqueous solution or suspension. The temperatures of both the hot agar mixture and the cold hydrophobic liquid are chosen and adjusted according to the type of bead being produced, toward the goal of providing separable, pourable beads which can be crushed or spread on the skin. In particular, they are adjusted to ensure that the viscosity of the hot agar mixture is low enough to permit the mixture to be pumped through the injection needle. The viscosity will vary with different bead formulations, being increased by higher concentrations of ionic actives. If desired the active agent and the restraining polymer can be premixed to foster bonding of the active to the restraining polymer, in a preliminary step. Lipophilic acids, can if desired, be bonded to the restraining polymer in a preliminary mixing step employing a lipophilic solvent which is evaporated or otherwise removed prior to mixing with the agar solution. The resultant beads comprise a complex of active-loaded restraining polymer entrapped in an agar matrix. The beads are soft, clear, glossy, odor-free and esthetically appealing, pH-stable and temperature stable to temperatures up to about 80 °C. The hardness, or preferably softness of the beads is preferably carefully chosen, by appropriate selection of processing parameters, according to the bead components, so that the beads are hard enough to be conveniently handled, transferred from drums to formulation vessels, and the like, and hard enough to resist breakdown in mixers or homogenizers, yet soft enough to be crushed on the skin, and preferably sufficiently soft to be spread and "disappear". A principal parameter affecting the hardness is the agar concentration (higher concentrations form harder beads), but oily actives will soften the beads and the concentration and composition of the restraining polymer can also affect the hardness of the bead. These parameters are preferably selected and controlled to provide the desired hardness, which is that of a soft, pleasant crushable feel. In the manufacturing process according to the invention, agar granules, restraining polymer and stable active agent, if used, are dissolved and. if appropriate, dispersed, in a mixing step in deionized or distilled water, conducted at an elevated temperature, preferably between about 70 and about 100 °C, more preferably between about 85 and about 95 °C, or about 90°C. Upon heating, the suspension becomes a clear solution. Optionally, the solution or dispersion is cooled in a cooling step to an intermediate temperature above the gelling point of the solution or dispersion where less heat must be lost from the solution or dispersion to precipitate gelation. The intermediate temperature may range from about 40 to about 70 °C, preferably from about 50 to about 60 °C. Less stable actives, for example enzymes, dissolved or dispersed in water are incorporated in, and mixed with, the agar-polymer solution at the intermediate temperature to avoid detrimental effects of the higher temperature. Enzyme-containing solutions should be kept near to about 50 o C to avoid denaturing which may occur at temperatures around 60 °C. Preferably, the solution is temperature stabilized, at the intermediate temperature, for example, using a water jacket or bath, maintained at a temperature of about 50 o C. The liquid solution or dispersion is then injected into a stream of cold hydrophobic liquid, for example a paraffin oil maintained at a temperature below the gelling point of the solution or dispersion, namely below about 30 °C, preferably below about 25 °C. more preferably about 0 to 10 °C Because water and oil are immiscible the pumped solution of warm agar, polymer and active, form droplets when extruded into the oil The low temperature of the oil "freezes" the droplets in shape, causing the agar medium to gel into agar-polymer complex beads The hot agar solution is directly introduced to the cold oil at a rate such as to provide adequate cooling to provide bead formation The agar-polymer complex beads are then separated, washed to remove the paraffin oil, filtered and dried Large gel particles or beads, up to approximately 2 mm in diameter, can be colored, filled with actives and formulated in a transparent gel, the colorants and actives being incorporated in the injection solution or dispersion Different sized beads can be produced by adjusting the size of the needle diameter or the agitation speed of the oil bath, higher speeds producing smaller beads Some non-limiting examples of the practice of the invention will now be described by way of illustration EXAMPLE 1 Preparation of Agar Complex Beads using Polyquaternium 24 1 5 g of agar granules (OSI-France) with a gelling point of about 33 o C and 1 5 g of polyquaternium 24 [QUATRISOFT LM-200 trademark Union Carbide Corporation (Amerchol-France)] are mixed in 97 g of distilled water and heated to 90°C The suspension becomes a clear solution at this temperature and it is then allowed to cool to 50°C in a water bath The solution is then pumped through a needle by means of a peristaltic pump (Bioblock-France) and the needle is placed into a liquid paraffin oil bath maintained at 5°C while mixing (250 rpm) The pump flow rate is adjusted to 2 5 mi/minute and the liquid is injected into the oil bath Gel beads are formed in the oil phase and their size depends upon the inner diameter of the needle For this example, two different sized needles were used 0 45 x 12 mm or 0 8 x 50 mm (inner diameter x length) The gel beads are separated by filtration on a 0 2 mm screen and extensively washed with water In this example, 2mm diameter beads are typically formed Smaller beads are formed using higher mixing rates (e g 1200 rpm) while smaller needle diameters help maintain small diameter The gel beads formed are smooth, shiny and soft Surprisingly, the presence of the restraining polymer does not significantly alter the ability of the agar to gel and form stable beads when cooled in oil Many materials can be added to the gel system, including fragrances and colorants, so long as they do not prevent satisfactory gel formation However, care may be required with regard to liquids too much of which may impair the physical stability of the gel beads Preferably the proportion of liquid in the gel system additional to agar, restraining polymer and active agent is selected so that gelling is not prevented While excesses of water may result in soft or poorly defined beads that are acceptable for some purposes, certain organic solvents may prevent bead formation In particular, it is preferred to avoid excess proportions of organic solvents such as dipropylene glycol or butylene glycol that are often used in fragrances The following comparative Example A demonstrates this point Comparative Example A Non-gelling Agar Complex Composition Example 1 is repeated using 1 5 g ot agar granules, 7 5 g of CRODACEL QS (trademark, Croda, Inc ), containing 1 5 g PG-hydroxvethylcellulose stearyldimonium chloride. 97 g of water, or other quantity sufficient for bead formation in the absence of organic solvent, and 10 g dipropylene glycol No significant beading occurs Comparative Example B Other Non-gelling Agar Complex Compositions Comparative Example is repeated using solvated fragrance or butylene glycol in place of the dipropylene glycol Again, no significant beading occurs Comparative Example C Further Non-gelling Agar Complex Compositions Comparative Example A is repeated using pigments or active ingredients, as described herein Again, no significant beading occurs Since such solvents can perform useful functions in a gel bead system, for example as vehicles for fragrances, it would be desirable to solve the problem of forming a satisfactory gel in the presence of such solvents Pursuant to the present invention, this problem can be solved by providing the solvent or other material in its own carrier system to protect the gel medium from the effect of the solvent To this end, it has been discovered pursuant to this aspect of the invention that such gel-inhibiting solvents can be effectively trapped in porous inert particles, for example silica spheres, or porous microspheπcal inert polymers, such as polyethylene or polypropylene which particles provide an effective carrier system for the solvent and surprisingly, do not themselves interfere with gel formation Such particles are preferably at least one or two orders of magnitude smaller than the gel beads in which they are incorporated, being for example from about 0 5 to about 100 microns in diameter, preferably from about 1 to about 30 microns and more preferably from about 3 to about 12 microns in diameter. Suitable adsorbent silica particle products are supplied by obo Products, Inc. , South Plainfield, New Jersey, USA. Pursuant to this aspect, the invention provides a method of making gel beads, or other gelled product, especially a gelled product intended for incorporation into a cosmetics product, the method comprising adsorbing an active agent, for example a fragrance, in a gel-inhibiting solvent on porous silica particles, or the like and dispersing the solvent-laden particles in a gelling medium, the gelling medium comprising a solution or dispersion of a suitable gelling agent, for example, an aqueous solution of agar, the preferred gelling agent described herein. The gelling medium is then formed into the desired gelled product as described herein, or as otherwise apparent to those skilled in the art. Surprisingly, the properties of the active agent, for example fragrance become available when the beads are crushed on the skin. It will be understood by those skilled in the art that this aspect of the invention has general application to enable a wide variety of solvents or other liquids to be incorporated into a gelling system by loading the solvent into protective carrier particles. Example 2 Formation of Agar Beads with Solvent 10 g dipropylene glycol or a comparable fragrance are mixed in a beaker or other vessel, with 1.6 g oil- absorbent silica shells (Kobo Products, NJ, apparent density 0.5-1 .0 grams per cubic inch, oil absorbency from 550-700 g/l 10 g) to obtain a thick slurry or paste-like product. The thick product is dispersed in 7.5 g of CRODACEL QS (trademark, Croda, Inc.), containing 1.5 g PG- hydroxyethylcellulose stearyldimonium chloride, as described above in connection with the addition of active agents. A hot aqueous agar solution, containing 1.5 g of agar granules dissolved in 97 g. of water, or other quantity sufficient for bead formation in the absence of organic solvent, is added and the mixture is injected or dispersed in cold oil to yield well-formed, stable beads, with a good and consistent texture and size. Example 3 Agar Complex Beads Employing Quaternized Silk Hydrolysate Example 1 is repeated employing, as a restraining polymer, an equivalent amount of quaternized silk hydrolysate, PROMOIS (trademeark) S-CAQ (Seiwa Kasei Co., Ltd.). Comparable results are obtained. According to another embodiment of gel bead manufacturing method according to the invention it has been found that gel beads can advantageously be formed by entraining a liquid source of hot gel solution in a controlled flow of a cool oil stream, preferably moving with an approximately constant velocity. Referring to Figure 1 , in a preferred embodiment of the method, the hot gel solution is supplied in the direction of arrow A l to an injection tube 40 having an internal diameter ID1. Injection tube 40 is supported in a closed side branch 42 of a conduit 44 having an internal diameter ID2 through which cold oil flows in the direction of arrow A2. drawing gel solution from injection tube 40 with a venturi- like action. Injection tube 40 terminates in an orifice 41 which is preferably located approximately centrally of the cross-section of conduit 40 to provide a ring of cold oil around each emerging coalescing agar bead 48. Side branch 42 is shown as extending perpendicularly to conduit 44, which is preferred. This apparatus can provide uniform, high quality bead formation with a sharp cutoff of the forming bead from injection tube 40. However, other angles could be employed. For example, venturi 40 could open at an acute angle of up to 45°, delivering the gel solution in the direction of flow of the cold oil. Alternatively, the tip 46 could be turned to face in the oil flow direction. However, such configuration may impede efficient breaking off of beads 48 from the stream of gel solution. The bead size is related to the internal diameter ID1 of injection tube 40 and also to the oil flow rate, higher oil flow rates generating smaller beads and vice versa. Since rapid cooling of the gel solution is desirable to promote quality bead formation, both the flow rate of the oil and the diameter ID2 of conduit 44 are preferably greater than the respective flow rate of the gel solution and the diameter ID1 of injection tube 40. Preferably, diameter ID2 is at least twice that of ID1, more preferably at least five times and possibly as much as ten times as large. Preferred oil flow rates are also much higher than gel solution rates, for example at least twice as high, more preferably four to twenty times as high. For small beads oil flow rates may be 50 times higher. In general, the flow rate of the gel solution will depend upon its viscosity. Some exemplary dimensions and quantities include an injection tube 40 with an ID, of about 0.8 mm and an oil flow conduit 44 with an ID 2 of about 8 mm. ID, of injection tube 40 is selected according to the desired bead size, in this case close to 0.8 mm diameter and ID, of flow conduit 44 is selected to be substantially larger than ID,, preferably from about 2 to about 20 times the diameter of ID,, more preferably from about 6 to about 14 times the diameter of ID,. The cross sectional area of oil flow conduit 44 is, in the example given, accordingly about 100 times that of injection tube 40, and may range from about 4 to about 400 times that of injection tube 40, more preferably from about 30 to about 200 times that of injection tube 40. Employing an agar gelling agent solution, as described herein, the agar solution flow rate can preferably be from about 1 to about 20 ml/min, preferably about 2.5 to 6.2 ml/min. Oil flow rates will be faster and can vary between about 1 and about 1000 ml/min. preferably between about 10 and about 300 ml/min. The lower flow rates are useful for making larger beads of about 2.8 to about 4 mm diameter, and the higher flow rates are useful for making smaller beads of about 0.4 to about 0.7 mm diameter. Thus, the ratio of flow rates of the hot agar solution to the cold oil can vary widely, but preferred ratios are between about 1 :2 and 1 : 50 preferably between about 1 :4 and about 1 : 10 for the internal diameters given. Other flow rates can be in proportion to the diameters of injection tube 40 and conduit 44. Preferably, the cold oil flow velocity is somewhat greater than the flow velocity of the hot agar solution, to carry the forming beads away from injection tube 40, for example, in a proportion of from 1.2: 1 to about 10: 1 , preferably from about 2: 1 to about 5: 1. Figure 2 illustrates an apparatus suitable for relatively large scale manufacture of gel beads, employing the method illustrated in Figure 6. Referring to Figure 7, coolant fluid 50 recirculates from a chiller 52 to an immersion probe 54 immersed in an oil tank 56. Oil is drawn through a filter 58 by a gear pump 60 and delivered to conduit 44 mounted in a tee 62. Gel beads are removed from the emergent stream by a screen 64. Gel solution is mixed in a jacketed glass vessel 66 and delivered to injection tube 40 by a peristaltic pump 68. If desired, the gel beads can be removed from screen 64 to water bath 70. The methods and apparatus described herein are generally suitable for making gel beads having compositions such as those described herein and in Delrieu '990, as well as gel beads of other compositions, as will be apparent to those skilled in the art. While reference has been made to topical application of compositions containing the novel gel particle delivery systems of the invention, it will be understood that certain such gel delivery systems can, with benefit, be applied to tissues, e.g. wound tissue, and to other environments where the controllable release protection of actives, especially actives dispersed in an excipient, is important and where release of bound actives can be readily initiated. INDUSTRIAL APPLICABILITY The present invention is particularly suitable for application in the cosmetic industry providing novel consumer cosmetic products, for example, creams, gels and lotions containing gel-complex beads and the gel-complex beads themselves. While some illustrative embodiments of the invention have been described above, it is, of course, understood that various modifications and equivalents of the described embodiments will be apparent to those of ordinary skill in the art. Some equivalents will be readily recognized by those of ordinary skill while others may require no more than routine experimentation. Such modifications and equivalents are within the spirit and scope of the invention, which is limited and defined only by the appended claims.

Claims: Claims 1. A method of preparing gel particles for incorporation in a topically applied formulation, the method comprising: a) forming a hot aqueous solution of a gelling agent, the solution being gellable at a lower temperature: and b) discharging the hot gelling agent solution through a discharge orifice into a cold hydrophobic liquid immiscible with the gelling agent solution, the cold hydrophobic liquid being maintained at a temperature below the gelling agent gelling point; characterized by providing a moving stream of the cold hydrophobic liquid, and discharging the hot gelling agent solution through the discharge orifice into the moving stream of cold hydrophobic liquid to generate gel particles in the hydrophobic liquid stream. 2. A method according to claim 1 characterized by discharging the hot gelling agent through an injection tube, the injection tube terminating in the discharge orifice and characterized in that the discharge orifice is positioned in the moving stream of cold hydrophobic liquid. 3. A method according to claim 2 characterized by containing the cold hydrophobic liquid in a conduit and by the injection tube extending into the conduit. 4. A method according to claim 3 characterized in that the conduit has a recti-linear portion and the injection tube extends approximately perpendicularly into the recti-linear portion of the conduit. 5. A method according to claim 3 or 4 characterized in that the conduit has a cross-sectional area from about 4 to about 400 times the cross-sectional area of the injection tube. 6. A method according to claim 3 or 4 characterized in that the ratio of the flow rate of the hot gelling agent solution to the flow rate of the cold hydrophobic liquid is between about 1 :2 and 1 : 50. 7. A method according to claim 3 or 4 characterized in that the injection tube has an internal diameter of from about 0.05 to about 10 mm. 8. A method according to claim 3 or 4 characterized in that the conduit has a cross-sectional area from about 4 to about 400 times the cross-sectional area of the injection tube, the ratio of the flow rate of the hot gelling agent solution to the flow rate of the cold hydrophobic liquid is between about 1 :2 and 1 : 50 and the injection tube has an internal diameter of from about 0.05 to about 10 mm. 9. A method according to claim 1. 2. 3 or 4 characterized in that the gelling agent in the hot gelling agent solution is agar. 10. A method according to claim 1, 2, 3 or 4 characterized in that the hot gelling agent solution comprises a mixture of a gelling agent and a restraining polymer. 1 1. A method according to claim 10 characterized in that the hot gelling agent solution further comprises an active agent. 12. A method according to claim 1 1 characterized in that the gelling agent in the hot gelling agent solution is agar. 13. A method according to claim 1 characterized by pumping the hot gelling agent solution from a heated vessel containing a bulk supply of the hot gelling agent solution to the discharge orifice. 14. A method according to claim 1 characterized by recirculating the cold hydrophobic liquid through a cooled tank. 15. A method according to claim 14 characterized by recirculating a coolant between a chiller and the cooled tank to maintain a desired low temperature in the tank. 16. A method according to claim 1 characterized by flowing the hydrophobic liquid containing gel particles over a screen to separate the gel particles from the hydrophobic liquid. 17. A method according to claim 1 characterized by pumping the hot gelling agent solution from a heated vessel containing a bulk supply of the hot gelling agent solution to the discharge orifice, recirculating the cold hydrophobic liquid through a cooled tank, recirculating a coolant between a chiller and the cooled tank to maintain a desired low temperature in the tank and flowing the hydrophobic liquid containing gel particles over a screen to separate the gel particles from the hydrophobic liquid. 18. A method according to claim 1 characterized in that the gelling agent solution comprises an organic solvent adsorbed on oil-adsorbent microsphere particles. 19. Apparatus for performing the method of claim 1 comprising a) a first source being a source of a hot aqueous solution of a gelling agent, the solution being gellable at a lower temperature: b) a second source being a source of a cold hydrophobic liquid immiscible with the gelling agent solution, the cold hydrophobic liquid being maintained at a temperature below the gelling agent gelling point: and c) a discharge orifice for receiving the hot gelling agent solution from the second source and discharging the hot gelling agent solution into the cold hydrophobic liquid; characterized by further comprising: d) a conduit carrying a moving stream of the cold hydrophobic liquid, the discharge orifice being disposed to discharge the hot gelling agent solution into the moving stream of cold hydrophobic liquid to generate gel particles in the hydrophobic liquid stream. 20. Apparatus according to claim 19 characterized by further comprising: e) a heated vessel containing a bulk supply of the hot gelling agent solution; a pump to pump the hot gelling agent solution from the heated vessel to the discharge orifice; g) a cooled tank; h) recirculating apparatus to recirculate the cold hydrophobic liquid through the cooled tank; i) a chiller to cool the cooled tank; j) a screen to separate the gel particles from the hydrophobic liquid; and k) flow-directing apparatus direct the flow of hydrophobic liquid containing gel particles over the screen to separate the gel particles from the hydrophobic liquid. 21. A gel bead for incorporation in topically applied formulations, the gel bead being crushable in the formulation to release an active agent and comprising: a) a structural gel material; and b) an active agent; characterized by further comprising: c) an organic solvent adsorbent on oil absorbent microsphere particles. 22. A gel bead according to claim 21 characterized by further comprising a restraining polymer to retaining the active agent in the gel bead. AMENDED CLAIMS [received by the International Bureau on 5 April 2001 (05.04.01); original claims 1-5, 7, 8, 13, 16-21 amended; remaining claims unchanged (3 pages)] 1. A method of preparing gel particles (48) for incorporation in a topically applied formulation, the method comprising: a) forming a hot aqueous solution of a gelling agent, the solution being gellable at a temperature; below the temperature of the hot gelling agent solution; and b) discharging the hot gelling agent solution through a discharge orifice (41 ) into a cold hydrophobic liquid immiscible with the gelling agent solution, the cold hydrophobic liquid being maintained at a temperature below the gelling agent gelling point; characterized by providing a moving stream of the cold hydrophobic liquid, and discharging the hot gelling agent solution through the discharge orifice (41) into the moving stream of cold hydrophobic liquid wherein gel particles (48) are formed in the hydrophobic liquid stream from the gelling agent solution. 2. A method according to claim I characterized by discharging the hot gelling agent through an injection tube (40), the injection tube (40) terminating in the discharge orifice (41 ), and by constraining the moving stream of cold hydrophobic liquid in a conduit (44) characterized in that the discharge orifice (41) is positioned in the moving stream of cold hydrophobic liquid. 3. A method according to claim 2 characterized by containing the cold hydrophobic liquid in a conduit (44) and by the injection tube (40) extending into the conduit (44). 4. A method according' to claim 3 characterized in that the conduit (44) has a rectilinear portion and the injection tube (40) extends approximately perpendicularly into the rectilinear portion of the conduit (44). 5. A method according to claim 3 or 4 characterized in that the conduit (44) has a cross-sectional area from about 4 to about 400 times the cross-sectional area of the injection tube (40). 6. A method according to claim 3 or 4 characterized in that the ratio of the flow rate of the hot gelling agent solution to the flow rate of the cold hydrophobic liquid is between about 1:2 and 1 : 50. 7. A method according to claim 3 or 4 cbaracterized in that the injection tube (40) has an internal diameter of from about 0.05 to about 10 mm. 8. A method according to claim 3 or 4 characterized in that the conduit (44) has a cross-sectional area from about 4 to about 400 times the cross-sectional area of the injection tube (40), the ratio of the flow rate of the hot gelling agent solution to the flow rate of the cold hydrophobic liquid is between about 1 :2 and 1:50 and the injection tube (40) has an internal diameter of from about 0.05 to about 10 mm. 9. A method according to claim 1, 2, 3 or 4 characterized in that the gelling agent in the hot gelling agent solution is agar. 10. A method according to claim 1, 2, 3 or 4 characterized in that the hot gelling agent solution comprises a mixture of a gelling agent and a restraining polymer. 11. A method according to claim 10 characterized in that the hot gelling agent solution ftirther comprises an active agent. 12. A method according to claim 11 characterized in that the gelling agent in the hot gelling agent solution is agar. 13. A method according to claim 1 characterized by pumping the hot gelling agent solution from a heated vessel containing a bulk supply of the hot gelling agent solution to the discharge orifice (41). 14. A method according to claim 1 characterized by recirculating the cold hydrophobic liquid through a cooled tank. 15. A method according to claim 14 characterized by recirculating a coolant between a chiller and the cooled tank to maintain a desired low temperature in the tank. 16. A method according to claim 1 characterized by flowing the hydrophobic liquid containing gel particles (48) over a screen to separate the gel particles (48) from the hydrophobic liquid. 17. A method according to claim 1 characterized by pumping the hot gelling agent solution from a heated vessel containing a bulk supply of the hot gelling agent solution to the discharge orifice (41 ), recirculating the cold hydrophobic liquid through a cooled tank, recirculating a coolant between a chiller and the cooled tank to maintain a desired low temperature in the tank and flowing the hydrophobic liquid containing gel particles (48) over a screen to separate the gel particles (48) from the hydrophobic liquid. 18. A method according to claim 1 characterized in that the gelling agent solution comprises an organic solvent adsorbed on oil-adsorbent microsphere particles. 19. Apparatus for performing the method of claim 1 comprising a) a first source being a source of a hot aqueous solution of a gelling agent, the solution being gellable at a lower temperature; b) a second source being a source of a cold hydrophobic liquid immiscible with the gelling agent solution, the cold hydrophobic liquid being maintained at a temperature below the gelling agent gelling point; and c) a discharge orifice (41 ) for receiving the hot gelling agent solution from the second source and discharging the hot gelling agent solution into the cold hydrophobic liquid; characterized by further comprising: d) a conduit (44) carrying a moving stream of the cold hydrophobic liquid, the discharge orifice (41) being disposed to discharge the hot gelling agent solution into the moving stream of cold hydrophobic liquid to generate gel particles (48) in the hydrophobic liquid stream. 20. Apparatus according to claim 19 cbaracterized by further comprising: e) a heated vessel containing a bulk supply of the hot gelling agent solution; f) a pump to pump the hot gelling agent solution from the heated vessel to the discharge orifice (41); g) a cooled tank; h) recirculating apparatus to recirculate the cold hydrophobic liquid through the cooled tank; i) a chiller to cool the cooled tank; j) a screen to separate the gel particles (48) from the hydrophobic liquid; and k) flow-directing apparatus direct the flow of hydrophobic liquid containing gel particles (48) over the screen to separate the gel particles (48) from the hydrophobic liquid. 21. A gel bead for incorporation in topically applied formulations, the gel bead being crushable in the formulation to release an active agent and comprising: a) a structural gel material; and b) an active agent; ■ characterized by further comprising: c) an organic solvent absorbed on oil-absorbent microsphere particles. 22. A gel bead according to claim 21 characterized by further comprising a restraining polymer to retaining the active agent in the gel bead. STATEMENT UNDER ARTICLE 19(ii The International Search Report dated 6 February 2001 cited a single reference, Delrieu et al. U. S. patent No.5,961,990 ("Delrieu '990") as being relevant to applicant's inventive step. Delrieu '990 has commonly inventorship and ownership with the present application. Delrieu '990, as fully acknowledged in the precharacterizing clause of claims 1, 20 and 21, teaches formation of gel particles from a hot solution by injection into a cold hydrophobic liquid, for example a paraffin bath (see column 12, lines 38-39). Delrieu '990 neither teaches nor suggests providing a moving stream of the cold hydrophobic liquid and discharging the hot gelling agent into the moving stream as claimed in claim 1 and provided by the apparatus claimed in claim 19. Nor does Delrieu '990 teach or suggest a gel bead which includes an organic solvent absorbed on oil-absorbent microsphere particles as claimed in claim 21.

Inventors: DELRIEU PASCAL, DING LI, DELRIEU, PASCAL, DING, LI
Applicants: DELRIEU PASCAL, DING LI, KOBO PRODUCTS INC, DELRIEU, PASCAL, DING, LI, KOBO PRODUCTS INC.
Application year: 2000
Main classification: A61K9
IPC codes: A61K8, A61Q19, B01J2, B01J13