Bimodal Cationic Polymer for Fabric Softener Deposition
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Solution Overview
Problem
There is a need for novel cationic polymers and inverse dispersions that can improve the stability and effectiveness of home and personal care formulations, particularly in fabric softeners, by enhancing the deposition of softening and freshness active ingredients on textile fibers while minimizing residue and adhesion.
Innovation Solution
A cationic polymer is developed through polymerization of cationic monomers, nonionic monomers, crosslinkers, and chain transfer agents, resulting in a bimodal molecular weight distribution with specific sedimentation coefficients and a high percentage of water-soluble polymer components, which are used in inverse dispersions to create effective thickeners and deposition aids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a cationic polymer with high crosslinker concentration (500-5000 ppm) is used to improve thickening effectiveness, then the deposition efficiency improves, but the polymer stability and water-solubility deteriorate
Solution Approach 1:
The patent changes the concentration parameter of crosslinker from conventional 500-5000 ppm to a reduced range of 10-500 ppm, which resolves the contradiction by maintaining deposition efficiency while improving polymer stability and water-solubility. This parameter optimization allows the polymer to remain effective without excessive crosslinking that would cause precipitation.
Solution Approach 2:
The patent introduces a bimodal molecular weight distribution with distinct peaks (P1 at 100-1000 kDa and P2 at 1-10 MDa) to create local quality differentiation. The lower molecular weight component provides water-solubility and stability, while the higher molecular weight component provides thickening and deposition efficiency, thus resolving the contradiction between effectiveness and stability.
2Productivity
If a unimodal high molecular weight polymer is used to improve thickening performance, then the viscosity increases, but the water-solubility and storage stability deteriorate
Solution Approach 1:
The patent segments the polymer into two distinct molecular weight populations (bimodal distribution), with a first peak at 100-1000 kDa providing water-solubility and a second peak at 1-10 MDa providing thickening performance. This segmentation resolves the contradiction by distributing different functions across different molecular weight segments rather than relying on a single high molecular weight component.
Solution Approach 2:
The patent creates a composite polymer structure combining low and high molecular weight components in a single polymer system. The low molecular weight fraction (25-75% of total) ensures water-solubility and storage stability, while the high molecular weight fraction (75-25% of total) provides thickening performance, thus resolving the contradiction between performance and stability.
3Ease of manufacture
If conventional emulsion polymerization is used to simplify the manufacturing process, then the production ease improves, but the molecular weight distribution control deteriorates
Solution Approach 1:
The patent employs a two-stage polymerization process where the first stage produces low molecular weight polymer (peak P1) and the second stage produces high molecular weight polymer (peak P2). This preliminary action in stage 1 creates the foundation for achieving the desired bimodal distribution in the final product, resolving the contradiction between manufacturing simplicity and molecular weight control.
Solution Approach 2:
The patent uses periodic action through two distinct polymerization stages with different conditions. Stage 1 uses specific monomer ratios and crosslinker concentrations to produce the first molecular weight peak, while stage 2 uses different parameters to produce the second peak. This periodic approach enables precise molecular weight distribution control while maintaining reasonable manufacturing complexity.
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
The cationic polymers improve the stability and effectiveness of formulations, ensuring efficient deposition of active ingredients on textiles, reducing residue and adhesion, and providing high storage stability and convenient dosing in fabric softeners.
Implementation Method 1
the cationic polymer has an at least bimodal molecular weight distribution with at least one first peak (P1) with an average sedimentation coefficient of ≤10 Sved and with at least one second peak (P2) with an average sedimentation coefficient of ≥10,000 Sved
Data Source
AI summary
Provided herein is a cationic polymer obtainable by polymerization of at least one cationic monomer, at least one crosslinker and optionally further monomers, such as nonionic monomers, associative monomers, and/or chain transfer agents. The cationic polymer has an at least bimodal molecular weight distribution with at least one first peak (P1) and at least one second peak (P2), wherein the first peak has a rather low average sedimentation coefficient of ≤10 Sved and the second peak has a rather high average sedimentation coefficient of ≥10,000 Sved. The water-soluble polymer components of the cationic polymer are ≥25% by weight related to the total amount of cationic polymer. Further provided herein is a process for obtaining such a cationic polymer as well as to an inverse dispersion, a thickener or a deposition aid, including at least one of such cationic polymers.