Liquid Detergent Thickening with Polyacrylate Copolymer
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Solution Overview
Problem
Existing processes for manufacturing liquid laundry detergent compositions with amine-neutralized linear alkyl benzene sulfonate (LAS) using alkali swellable polyacrylate copolymers face instability and phase separation issues during large-scale production, particularly when following standard mixing procedures.
Innovation Solution
A modified process involving the mixing of alkali swellable polyacrylate copolymer with water and sufficient amine, followed by the addition of LAS acid to form the anionic surfactant, while controlling pH and using hydrotropes like monopropylene glycol, ensures stable composition formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard mixing procedures are followed for manufacturing liquid laundry detergent compositions with amine-neutralized LAS using alkali swellable polyacrylate copolymers, then the composition can be produced, but instability and phase separation occur during large-scale production
Solution Approach 1:
The patent applies preliminary action by pre-mixing the polyacrylate copolymer with water and sufficient amine before adding LAS acid. This preparatory step ensures the polymer is properly solvated and the amine is available to neutralize the acid, preventing phase separation during large-scale production. The pre-mixing step is critical for maintaining composition stability.
Solution Approach 2:
The patent changes the pH parameter dynamically during the manufacturing process. By controlling the addition of LAS acid to the pre-mixed polymer-amine solution, the pH is gradually adjusted while maintaining stability. The final composition achieves a pH of 8-10, which optimizes both stability and thickening performance.
2Quantity of substance
If LAS acid is added to the thickened mixture to form anionic surfactant by neutralisation, then the desired detergent composition is achieved, but viscosity peaks and gelation may occur
Solution Approach 1:
The patent prepares the polymer-amine pre-mix before adding LAS acid, ensuring the system is ready to accommodate the acid without sudden viscosity spikes. This preliminary preparation allows for controlled neutralisation and prevents gelation.
Solution Approach 2:
The patent employs dynamic control of the neutralisation process by gradually adding LAS acid to the pre-mixed polymer-amine solution while monitoring viscosity. This dynamic approach allows the system to adapt and maintain stability throughout the acid addition process, preventing unwanted gelation.
3Ease of manufacture
If conventional neutralisation of LAS acid with caustic is used, then Sodium LAS is formed, but the composition becomes unstable when combined with amine-based pH adjustment
Solution Approach 1:
The patent merges the neutralisation function and pH adjustment function into a single integrated process. By using amine to neutralize LAS acid directly in the presence of the polymer, the process eliminates the need for separate caustic neutralisation and amine pH adjustment steps, preventing the instability that arises from combining pre-neutralized Sodium LAS with amine.
Solution Approach 2:
The patent inverts the conventional approach by neutralizing LAS acid with amine directly in the polymer-containing solution rather than pre-neutralizing with caustic and then adjusting pH with amine. This reversal of the neutralisation sequence prevents composition instability.
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 process enables the production of stable, high-viscosity liquid detergents suitable for large-scale manufacturing, avoiding energy-intensive mixing and maintaining composition stability, with the ability to control viscosity peaks and prevent gelation.
Implementation Method 1
Mixing the alkali swellable polyacrylate copolymer with water
Implementation Method 2
neutralisation of linear alkylbenzene sulfonic acid during the process by one or more amines
Implementation Method 3
thicken a liquid detergent composition containing amine neutralised anionic surfactant
Data Source
AI summary
A process to manufacture a liquid detergent composition thickened with a linear and or cross linked alkali swellable polyacrylate copolymer wherein the composition comprises anionic surfactant comprising linear alkylbenzene sulfonate formed by neutralisation of linear alkylbenzene sulfonic acid during the process by one or more amines, the process comprising the steps of: a) Mixing the alkali swellable polyacrylate copolymer with water, then b) Further mixing at least one amine with the mixture of step a) the amount of amine being more than sufficient to neutralise the linear alkyl benzene sulfonic acid, and then c) Adding the linear alkylbenzene sulfonic acid to the thickened mixture of step b) thereby to form the corresponding anionic surfactant by neutralisation.