Aerosol Composition Particle Size Control for Intensity and Longevity
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Solution Overview
Problem
Existing aerosol compositions face challenges in maintaining the intensity and longevity of active components like fragrances and insecticides due to larger particle sizes and higher spray rates, which lead to faster particle fallout and increased volatile organic content (VOC) from the inclusion of alcohol.
Innovation Solution
The aerosol composition features a specific formulation with a spray rate of 1.5 to 3.0 g/s and average particle size of 60 to 200 microns, utilizing a compressed gas propellant and water as a solvent carrier, with a low or zero VOC, to enhance the intensity and longevity of active components without alcohol, ensuring consistent spray and longer residence time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If larger aerosol particle sizes are used, then spray rate is improved, but particle fallout speed increases and wetting occurs
Solution Approach 1:
The patent applies parameter changes by optimizing the particle size distribution parameters within a specific range (Dv10: 30-60 μm, Dv50: 60-100 μm, Dv90: 100-200 μm) and controlling spray rate parameters (1.5-3.0 g/s) to achieve the desired balance between spray productivity and particle residence time in the air
2Speed
If alcohol is included to aid evaporation, then evaporation rate is improved, but volatile organic content increases
Solution Approach 1:
The patent extracts and eliminates alcohol from the composition formulation, achieving low or zero VOC levels. Instead, the invention relies on optimized particle size parameters and compressed gas propellants to provide the necessary evaporation and dispersal characteristics without harmful organic solvents
Solution Approach 2:
The patent replaces persistent harmful substances (alcohol) with temporary, benign alternatives (compressed gas propellants like nitrogen or CO2) that provide the needed evaporation effect but dissipate harmlessly, achieving low/zero VOC while maintaining functional performance
3Productivity
If higher spray rates are used, then intensity is improved, but particle size increases and fallout occurs
Solution Approach 1:
The patent simultaneously controls multiple parameters: spray rate (1.5-3.0 g/s), particle size distribution (Dv10: 30-60 μm, Dv50: 60-100 μm, Dv90: 100-200 μm), and composition formulation to achieve the counterintuitive result of high intensity with controlled, smaller particle sizes that resist fallout
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This formulation maintains fragrance intensity and odor elimination over a longer period, providing a more consistent and effective experience by controlling particle size and spray rate, while reducing VOC levels.
Implementation Method 1
a compressed gas propellant
Implementation Method 2
it had been believed that larger aerosol particle sizes of a fragrance or odor treating composition were not desirable or as advantageous as small particle sizes because the particles of composition would fall out of the air faster
Data Source
AI summary
An aerosol product is disclosed having a dispensing container, a dispensing actuator, a spray nozzle, and a composition including about 0.1% to about 2.5% by weight of an insecticide active component. The aerosol product has a flow rate of about 1.5 g/s to about 3.0 g/s and an average particle size of about 145 μm to about 200 μm.