Fabric Softener Ester Quat Composition for Solvent-Free Stability

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Solution Overview

Problem

Existing fabric softener actives face challenges in achieving high softening performance and storage stability in aqueous dispersions without the need for volatile solvents, as they often require solvents due to high melting points and limited thermal stability, leading to issues with viscosity changes and settling during storage.

Innovation Solution

A fabric softener composition comprising at least 50% bis-(2-hydroxypropyl)-dimethylammonium methylsulphate fatty acid ester with a specific molar ratio of fatty acid to amine, average chain length, and iodine value, allowing for handling and processing without solvents, while maintaining low melting points and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ester quats with high melting points are used to achieve high softening performance, then softening performance is improved, but handling and processing becomes difficult without volatile solvents

Engineering Contradiction:

Improvesoftening performanceVSAvoidhandling and processing

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent modifies the chemical structure parameters of the ester quat by using specific alkanolamines with hydroxyl groups and controlling the esterification degree, which lowers the melting point and enables solvent-free handling while maintaining softening performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces specific structural features (hydroxyl groups from alkanolamine) that act as internal mediators to reduce intermolecular forces and lower melting point, eliminating the need for external volatile solvent mediators

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If ester quats are processed with volatile solvents to improve handling, then ease of operation is improved, but storage stability deteriorates due to viscosity changes and settling at elevated temperatures

Engineering Contradiction:

ImprovehandlingVSAvoidstorage stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The patent extracts and eliminates the volatile solvent component from the system entirely, replacing it with a solvent-free ester quat composition that maintains both handling ease and storage stability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the previously harmful high melting point property into a benefit by using it to indicate proper molecular structure, while the resulting lower melting point structure simultaneously provides both ease of handling and storage stability

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Duration of action of moving object

If aqueous dispersions of ester quats are stored at elevated temperatures to test stability, then duration of action is extended, but storage stability deteriorates with unacceptable rise in viscosity or settling

Engineering Contradiction:

Improvestorage durationVSAvoiddispersion stability

Core Design Contradiction:

Duration of action of moving objectVSStability of the object's composition

Solution Approach 1:

The patent incorporates structural features (hydroxyl groups, specific chain lengths) that beforehand cushion against thermal aggregation and hydrolysis, preventing viscosity rise and settling during extended storage at elevated temperatures

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Ease of manufacture

If fabric softener actives are delivered with 5 to 15% volatile solvent content to enable processing, then ease of manufacture is improved, but safety deteriorates due to volatility and flammability

Engineering Contradiction:

ImproveprocessingVSAvoidvolatility and flammability

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes the volatile solvent component entirely from the formulation, replacing it with a solvent-free ester quat composition that maintains processability while eliminating safety hazards

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the previously problematic volatility and flammability into benefits by using the ester quat's inherent properties (lower melting point, liquid state) to enable processing without any volatile solvent, thus eliminating safety risks

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 achieves high softening performance and good storage stability in aqueous dispersions with minimal viscosity change, enabling solvent-free processing and improved handling characteristics.

Implementation Method 1

good storage stability in aqueous dispersion with little change in dispersion viscosity

Methodology Applied

Scientific EffectThermal stability:

Implementation Method 2

stable viscosity

Methodology Applied

Scientific EffectViscosity stability:

Data Source

PatentUS20110239378A1Heat Stable Fabric Softener

Publication Date: 2011.10.06 PROCTER & GAMBLE CO

AI summary

A fabric softener composition, comprising 1% to 49% by weight of a bis-(2-hydroxypropyl)-dimethylammonium methylsulphate fatty acid ester having a molar ratio of fatty acid moieties to amine moieties of from 1.85 to 1.99, wherein the average chain length of the fatty acid moieties is from 16 to 18 carbon atoms and the iodine value of the fatty acid moieties, calculated for the free fatty acid, is from 0.5 to 50.