Concentrated dissolvable fabric softener sheets
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Solution Overview
Problem
Traditional fabric softeners in dissolvable sheet form face challenges due to poor compatibility between softening actives and water-soluble structurants, leading to active ingredient migration and instability, resulting in ineffective softening and practical storage issues.
Innovation Solution
The development of dissolvable fabric softener sheets with a high proportion of cationic and amphoteric polymer softening agents, combined with structurants like polyvinyl alcohol and starch, which remain stable and effective by forming a coacervate on textiles, preventing migration and ensuring consistent performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional fabric softening actives are used in dissolvable sheet form, then the product can be concentrated and compact, but the actives leach out from the sheet and form a greasy coating on the surface
Solution Approach 1:
The patent uses water-soluble structurants (starch, polyvinyl alcohol) as intermediary materials that form a solid matrix to immobilize the fabric softening actives. These structurants act as a mediator between the hydrophobic actives and water, preventing leaching while maintaining solubility of the sheet format. The structurants create a physical network that traps the actives within the sheet structure.
Solution Approach 2:
The invention creates a composite material system combining fabric softening actives with water-soluble structurants. This composite structure allows the hydrophobic actives to be embedded within a hydrophilic matrix, enabling the sheet to dissolve in water while preventing premature migration of the actives. The composite nature resolves the contradiction between concentration and stability.
2Reliability
If liquid fabric softeners are used, then they provide good coverage and contact with textile surfaces, but they are bulky and heavy due to high water content
Solution Approach 1:
The patent utilizes phase transition from liquid to solid format by removing water and creating a dissolvable sheet. The sheet transitions from solid storage form to dissolved state during use, providing the benefits of both concentrated format and liquid-like distribution. This phase transition eliminates the need for bulk water while maintaining effective coverage.
Solution Approach 2:
The invention leverages the hydraulic property of water solubility to transport the concentrated active ingredients from solid sheet form to liquid solution state during the wash cycle. The water-soluble structurants enable the actives to be carried by rinse water to the textiles, providing good coverage without the weight of pre-mixed liquid softener.
3Stability of the object's composition
If non-dissolvable sheets are used, then they are stable for storage, but they generate waste and can become entrapped in larger laundry items
Solution Approach 1:
The patent changes the key parameter of water solubility from low (non-dissolvable) to high (dissolvable) by selecting water-soluble structurants. This parameter change allows the sheet to maintain stability during storage through controlled solubility while dissolving completely during use, eliminating waste. The solubility parameter is tuned to provide stability when dry but complete dissolution when wet.
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 solution provides a lightweight, stable, and highly effective fabric softener that dissolves readily in water, offering softening and static reduction comparable or superior to conventional 2-in-1 detergent/fabric softener products, with improved storage and shipping efficiency and reduced waste generation.
Implementation Method 1
combined with structurants like polyvinyl alcohol and starch, which remain stable and effective by forming a coacervate on textiles, preventing migration and ensuring consistent performance
Data Source
AI summary
The present invention relates to formulations for a concentrated fabric softener, in the form of water-soluble sheets, which can conveniently be used alongside detergent in home laundry washing machines. The formulations comprise combinations of anionic surfactants with cationic and/or anionic polymers which together cooperate to provide a softening effect on textiles. This product format allows for a concentrated product that is comprised in a high proportion of active ingredients, and therefore occupies a much smaller volume and mass for the amount of active ingredient and softening power provided. The performance of the invention is equivalent or superior to comparable dosages of standard liquid 2-in-1 detergent/fabric softener combinations.