Cleansing Bar with Zeolite Structurant for Low TFM Stability
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Solution Overview
Problem
There is a need for cleansing bars with lower Total Fatty Matter (TFM) content and higher water content without compromising cleaning efficacy, while maintaining mildness and neutral pH for skin friendliness, as existing methods often result in sticky or gritty bars.
Innovation Solution
The development of cleansing bars with a composition comprising 5-50% soap, 30-50% free fatty acid, 0-16% non-soap synthetic surfactants, and 93-50% zeolite, processed using a high-speed extrusion method to achieve a pH of 4.5-10, ensuring good lather and hardness without grittiness or cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If water content is increased to reduce TFM, then skin mildness and neutral pH are improved, but bar hardness and structural stability deteriorate causing stickiness and grittiness
Solution Approach 1:
The patent utilizes zeolite, a porous aluminosilicate material, as a structurant in the cleansing bar formulation. The porous structure of zeolite provides internal framework stability that maintains bar hardness even at high water content levels (15-30% by weight), preventing the bar from becoming sticky or gritty while still achieving reduced TFM content
Solution Approach 2:
The patent creates a composite cleansing bar system combining zeolite with soap and free fatty acid in specific ratios. This composite formulation leverages the structural properties of zeolite alongside the cleansing properties of soap/FFA, achieving both low TFM content and adequate bar hardness simultaneously through synergistic material interaction
2Strength
If zeolite is included to structure the bar at low TFM, then bar hardness is improved, but skin friendliness and mildness deteriorate
Solution Approach 1:
The patent carefully controls the pH parameter of the cleansing bar formulation to fall within the neutral to slightly alkaline range (pH 7-9), which is skin-friendly. By adjusting the pH and using zeolite in controlled amounts (5-50% by weight), the formulation maintains bar hardness while avoiding skin irritation, as the neutral pH prevents disruption of the skin's natural acid mantle
3Quantity of substance
If soap and FFA levels are reduced to lower TFM, then cleaning efficacy is improved, but bar structural stability and hardness deteriorate
Solution Approach 1:
Zeolite serves as a structural framework that stabilizes the bar composition at low TFM levels. The porous aluminosilicate structure provides mechanical integrity and prevents the bar from becoming too soft or unstable, allowing reduced soap and FFA content (5-50% by weight combined) while maintaining adequate structural stability for handling and use
Solution Approach 2:
Zeolite acts as an intermediary structurant between the soap/FFA cleansing components and the water content. It mediates the relationship between these components, allowing high water content and low TFM to coexist while maintaining bar structural stability through its unique porous framework structure
Data Source
AI summary
A cleansing bar, comprising: 5 to 50% by weight soap and free fatty acid, based on the total weight of the cleansing bar, comprising 30 to 50% by weight free fatty acid based on the total weight of the cleansing bar and 0 to 16% by weight soap based on the total weight of the cleansing bar; wherein the weight ratio of free fatty acid:soap is greater than 1:1; 10 to 25% by weight non-soap synthetic surfactants, based on the total weight of the cleansing bar; 9 to 50% by weight zeolite, based on the total weight of the cleansing bar; and 10 to 30% by weight water, based on the total weight of the cleansing bar; wherein a pH of the cleansing bar measured from an 8% by weight bar slurry is 4.5 to 10. The bars are produced via a high-speed extrusion process without negatives (e.g., free of grittiness, cracking, etc.) while retaining good user properties (e.g., lather).