Esterquat Quaternization Using Glycerol for Non-Flammable Softeners

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Solution Overview

Problem

Existing processes for producing esterquats, particularly those using isopropyl alcohol as a solvent, result in inflammable products with suboptimal safety and performance, and alternative methods like triglycerides lead to unwanted subproducts and impurities.

Innovation Solution

A process where glycerol is used as the sole solvent for the quaternization reaction in esterquat production, replacing isopropyl alcohol and improving the safety and performance of the final esterquat product by eliminating inflammability and enhancing textile softening properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If isopropyl alcohol is used as solvent for quaternization, then the esterquat has good solubility and reaction efficiency, but the final product becomes inflammable and unsafe

Engineering Contradiction:

Improvesolubility and reaction efficiencyVSAvoidinflammability

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the solvent parameter from isopropyl alcohol to glycerol, fundamentally altering the fire safety property while maintaining solvent functionality. Glycerol's high boiling point and non-volatile nature eliminate inflammability, yet it still provides adequate solubility for the quaternization reaction to proceed efficiently.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the conventional isopropyl alcohol solvent with glycerol, which can be obtained as a byproduct from biodiesel production or other industrial processes. This substitution uses a readily available, non-flammable alternative that eliminates safety hazards while maintaining process efficiency.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Adaptability or versatility

If triglycerides are used instead of fatty acids for esterification, then the process uses alternative feedstocks, but unwanted subproducts like incompletely hydrolysed mono- and diglycerides and glycerine are formed

Engineering Contradiction:

Improvealternative feedstock usageVSAvoidproduct purity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent extracts and removes the problematic subproducts (incompletely hydrolysed mono- and diglycerides and glycerine) from the reaction system. By using glycerol as the quaternization solvent, the process eliminates these unwanted byproducts that would otherwise contaminate the final esterquat product, thereby improving product purity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of using triglycerides as the starting material (which leads to subproduct formation), the patent inverts the approach by using fatty acids directly for esterification. This reverses the conventional triglyceride-based route and avoids the formation of incompletely hydrolysed intermediates, achieving cleaner product formation.

Inventive Principle:

Principle #13The other way round (Inversion)

3Object-affected harmful factors

If glycerol is used as sole solvent for quaternization, then the final esterquat becomes non-inflammable with improved safety, but the solvent polarity and dissolution capability may be reduced

Engineering Contradiction:

ImproveinflammabilityVSAvoidsolvent polarity and dissolution capability

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses glycerol as an intermediary solvent that mediates between the reactants in the quaternization reaction. Despite its different polarity compared to isopropyl alcohol, glycerol effectively dissolves the reactants and facilitates the reaction, serving as a functional intermediary that achieves both safety and reactivity requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 process yields a non-inflammable esterquat with improved textile softening performance and higher viscosity, offering safer handling and increased active matter content perception compared to conventional methods.

Implementation Method 1

the quaternization reaction b) is performed using glycerol as sole solvent

Methodology Applied

Scientific EffectSolvation: Solvation

Implementation Method 2

reaction of fatty acids with tertiary alkanolamines, to form an ester linkage between the carboxylic group of the fatty acid and the hydroxyl group of the alkanolamine

Methodology Applied

Scientific EffectEsterification: Chemical Bonding

Implementation Method 3

The quaternization is generally performed with alkyl halides or with dialkyl sulphates

Methodology Applied

Scientific EffectQuaternization: Chemical Bonding

Data Source

PatentEP4282854A1Process for the production of esterquats

Publication Date: 2023.11.29 UNIÓN DERIVÁN SA

AI summary

The present invention relates to a process for the production of esterquats characterized in that the quaternization step is performed using glycerol as the sole solvent. The invention also relates to the esterquat obtainable by such process and to a textile softener composition comprising it. The esterquat obtainable by the process of the invention is not inflammable and has improved softening properties.