Cleansing Bar Formulation Using High Fatty Acid Structurant
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Solution Overview
Problem
Conventional soap-based cleansing products face challenges in processing due to their soft and sticky nature, making it difficult to manufacture using high throughput processes while maintaining mildness and foaming properties.
Innovation Solution
A cleansing composition comprising a surfactant and a structurant with a fatty acid mixture where the fatty acid is present in amounts greater than 88% by weight, allowing for reduced soap content, improved processing, and retention of desirable lathering properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional soap-based formulations are used, then good lather and skin feel are achieved, but processing becomes difficult due to soft and sticky nature
Solution Approach 1:
The patent changes the chemical composition parameters by reducing soap content to less than 12.5% and increasing synthetic surfactant content to greater than 87.5%, which fundamentally alters the physical properties of the bar from soft/sticky to processable hardness while maintaining mildness and lather properties
Solution Approach 2:
The patent creates a composite bar formulation combining synthetic surfactants (greater than 87.5%) with reduced soap content (less than 12.5%), achieving a synergistic effect where the synthetic surfactant provides structural integrity for processing while the soap provides beneficial skin properties and lather
2Object-affected harmful factors
If soap content is reduced to provide milder bars, then skin mildness improves, but processing difficulty increases due to softness
Solution Approach 1:
The patent adjusts the compositional parameters by limiting soap to less than 12.5% while using synthetic surfactants as the primary structure-building component, which maintains bar hardness for processing while reducing soap-related skin irritation
Solution Approach 2:
The synthetic surfactant acts as an intermediary that provides the structural framework for the bar, allowing reduced soap content to be maintained without compromising processing ability. The synthetic surfactant mediates between the need for mildness and the need for processability
3Strength
If fatty acid soap is used to structure the bar, then bar integrity is improved, but foaming properties may be negatively affected
Solution Approach 1:
The patent changes the surfactant composition parameters by using synthetic surfactants (greater than 87.5%) that are known to produce superior foam compared to traditional soap-based systems, while the reduced soap content (less than 12.5%) maintains sufficient bar integrity
Solution Approach 2:
The patent copies the structural function traditionally performed by soap with synthetic surfactants, achieving similar or superior bar integrity while gaining enhanced foaming performance. The synthetic surfactant replicates soap's structuring capability without its foam-limiting drawbacks
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 composition enables the production of bars with enhanced processing efficiency, mildness, and foaming capabilities, achieving a pH range of 4.0 to 7.0, and maintaining a Zein score of less than 0.4, indicating reduced skin irritation and improved lather performance.
Implementation Method 1
The structurant comprises a mixture of a fatty acid and a fatty acid soap. The fatty acid is present in an amount of greater than or equal to 88% by weight of the mixture
Implementation Method 2
The cleansing composition comprises a surfactant and a structurant... retention of desirable lathering properties
Implementation Method 3
achieve a pH range of 4.0 to 7.0, and maintaining a Zein score of less than 0.4, indicating reduced skin irritation
Data Source
AI summary
A cleansing composition comprises a surfactant and a structurant. The structurant comprises a mixture of a fatty acid and a fatty acid soap. The fatty acid is present in an amount of greater than or equal to 88% by weight of the mixture. preferably greater than or equal to 95% by weight of the mixture. more preferably greater than or equal to 99% by weight of the mixture.