Cold Process Formulation Aid for Low-Energy Emulsion Manufacturing
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Solution Overview
Problem
Conventional emulsion manufacturing processes require high energy, multiple vessels, and are sensitive to temperature and mixing rates, leading to batch-to-batch variations and challenges in dispersing polyacrylic acid derivatives without petroleum-derived solvents.
Innovation Solution
Cold process formulation aids (CPFAs) that combine a wax and a polymer with pendant ionic or ionizable groups, allowing for the formation of stable emulsions and hydrogels at low temperatures using a single vessel, and render polyacrylic acid derivatives directly soluble in cosmetically-acceptable esters and Caprylic/Capric Glycerides without petroleum-derived solvents by incorporating emulsifying waxes like polyglyceryl esters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional emulsion manufacturing processes are used with multiple vessels and heating, then emulsions can be formed, but energy consumption increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple process steps and vessels into a single cold process formulation aid system. The CPFA integrates emulsifying, thickening, and stabilizing functions in one product that can be added to a single vessel, eliminating the need for separate heating vessels and reducing energy consumption while maintaining emulsion stability.
Solution Approach 2:
The invention changes the temperature parameter from conventional high-temperature heating processes to low-temperature cold processing. The CPFA enables emulsion formation at ambient or refrigeration temperatures by altering the physical state and molecular structure of the polymer-wax complex, eliminating the need for thermal energy input.
2Stability of the object's composition
If conventional emulsion manufacturing processes are used with multiple vessels, then emulsions can be formed, but device complexity increases
Solution Approach 1:
The patent merges multiple separate vessels and process steps into a single-vessel operation using the cold process formulation aid. The CPFA consolidates the functions of emulsifiers, thickeners, and stabilizers that would otherwise require separate preparation and addition steps, simplifying the manufacturing device to a single mixing vessel.
Solution Approach 2:
The cold process formulation aid serves multiple functions simultaneously: it acts as an emulsifier to combine oil and water phases, a thickening agent to achieve desired viscosity, and a stabilizer to prevent phase separation. This multi-functionality eliminates the need for multiple specialized vessels and ingredients.
3Ease of operation
If polyacrylic acid derivatives are dispersed in petroleum-derived solvents, then they become easier to handle, but environmental harm increases
Solution Approach 1:
The invention changes the solvent parameter from petroleum-derived organic solvents to water-based aqueous systems. The CPFA is formulated as a water-soluble or water-dispersible product, eliminating petroleum solvents while maintaining ease of handling through proper molecular design of the polymer-wax complex that ensures solubility and stability in aqueous environments.
Solution Approach 2:
The patent converts the potential harm of petroleum solvent use into a benefit by developing a water-based system that is even more environmentally friendly. The aqueous formulation of the CPFA not only eliminates harmful petroleum derivatives but also provides additional benefits such as reduced flammability and improved safety.
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
CPFAs streamline the emulsion manufacturing process, reducing energy consumption, preventing wax crystallization, and ensuring reproducible emulsions with improved sensorial properties, while eliminating the need for petroleum-derived solvents.
Implementation Method 1
When one or a combination of CPFAs of the present invention is/are combined with an aqueous medium and other ingredients, an emulsion (or hydrogel) can be formed, often at temperatures not exceeding 30° C.
Implementation Method 2
When one or a combination of CPFAs of the present invention is/are combined with an aqueous medium and other ingredients, an emulsion (or hydrogel) can be formed
Implementation Method 3
PADs (and mixtures thereof) are combined specific minimum amount of one or a mixture of emulsifying waxes, which, in certain embodiments, are polyglyceryl esters, thereby rendering the PADs directly soluble in cosmetically-acceptable esters and CTG
Data Source
AI summary
Provided are cold process formulation aids (CPFAs), methods for their manufacture, and personal care products made using them. CPFAs include (i) a polymer having an aliphatic backbone and a plurality of pendant groups thereon that are pendant ionic or ionizable groups, or pendant groups having at least one permanent dipole that includes an acid, alcohol, thiol, ester, amine, amide, imide, imine, or nitrile moiety, and (ii) a wax selected from natural waxes and synthetic waxes, wherein if the wax is not micronized and is not self-emulsifying, the ratio, by weight, of the non-micronized wax to the polymer having an aliphatic backbone is from about 60:40 to 80:20, and if the wax is a micronized wax or a self-emulsifying wax, the ratio, by weight, of wax to polymer backbone is 70:30 to 98:2.