Method for producing microcapsules

1. A process for producing microcapsules and controlling their particle size, comprising the following steps:

(a) providing a first, aqueous formulation comprising at least one prepolymer;

(b) providing a second, nonaqueous formulation comprising an active to be encapsulated;

(c) mixing the aqueous phase and the nonaqueous phase in the presence of at least one emulsifier and/or stabilizer to form an emulsion;

(d) polymerizing the at least one prepolymer present in the emulsion from step (c) to obtain a dispersion of microcapsules enclosing the active;

(e) hardening and crosslinking the microcapsules obtained in step (d), and optionally

(f) removing and drying the microcapsules from the dispersion,

wherein

(i) the emulsion is formed in step (c) in the presence of at least one 1,2-diol and

(ii) the particles from the process have a single average particle size distribution of from 10 to 35 microns.

2. The process as claimed in claim 1 , wherein the prepolymer is selected from the group consisting of optionally alkylated mono- and polymethylolurea or mono- and polymethylolmelamine precondensates, partially methylated mono- and polymethylol-1,3,5-triamino-2,4,6-triazine precondensates, mono- and polyalkylolbenzoguanamine and mono- and polyalkylolglycoluril precondensates, poly[N-(2,2-dimethoxy-1-hydroxy)]polyamines, dialdehydes and resorcinol and mixtures thereof.

3. The process as claimed in claim 1 , wherein the active to be encapsulated is at least one aroma, at least one fragrance or at least one biogenic principle.

4. The process as claimed in claim 1 , wherein the emulsifier is a 1,2-diol selected from the group consisting of pentane-1,2-diol, hexane-1,2-diol, octane-1,2-diol, decane-1,2-diol, dodecane-1,2-diol and mixtures thereof.

5. The process as claimed in claim 4 , wherein the 1,2-diol is a mixture of hexane-1,2-diol and octane-1,2-diol.

6. The process as claimed in claim 1 , wherein the diol is used in amounts of about 0.1% to about 10% by weight based on the emulsion.

7. The process as claimed in claim 1 , wherein the stabilizer is selected from the group consisting of sulfonated acrylic copolymers, copolymers of acrylamides and acrylic acid, copolymers of alkyl acrylates and N-vinylpyrrolidone, sodium polycarboxylates, sodium polystyrenesulfonates, vinyl ether- and methyl vinyl ether-maleic anhydride copolymers, and ethylene-, isobutylene- or styrene-maleic anhydride copolymers and mixtures thereof.

8. The process as claimed in claim 1 , wherein the emulsifier and stabilizer are each used in a total amount of about 1% to about 10% by weight based on the emulsion.

9. The process as claimed in claim 2 wherein polycondensation of an amine-formaldehyde precondensate is triggered by adjusting the pH of the emulsion to about 1.0 to about 5.8.

10. The process as claimed in claim 1 , wherein the microcapsules are hardened or crosslinked by adjusting the temperature of the dispersion to about 50 to about 90° C.

11. The process as claimed in claim 1 , wherein the microcapsules are hardened by adding melamine to the dispersion.

12. The process as claimed in claim 1 , wherein the entire reaction is conducted with vigorous stirring.

13. The process as claimed in claim 1 , wherein a formaldehyde scavenger is added to the dispersion after the capsules have been hardened.