Expanded Sodium Percarbonate Salt Liquid Loading
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Solution Overview
Problem
There is a need for a non-toxic carrier that can adsorb large amounts of liquid while maintaining product stability and water solubility, as traditional carriers like perborate salts are becoming less viable due to environmental regulations, and existing effervescent compositions face challenges with manufacturing time and shelf life stability.
Innovation Solution
A novel, water-soluble alkali percarbonate salt with lower bulk density and higher porosity, known as expanded sodium percarbonate salt (ESPC), which can adsorb up to 80% of its weight in liquids and exhibit effervescent characteristics, is developed, allowing for increased liquid loading and improved sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional carriers like perborate salts are used to adsorb large amounts of liquid, then liquid loading capacity is improved, but environmental compatibility deteriorates due to stricter environmental legislations
Solution Approach 1:
The patent changes the chemical composition parameters by replacing perborate salts with percarbonate salts, specifically using sodium percarbonate as the carrier. This substitution maintains the desired liquid loading capacity (50-80% by weight) while eliminating the environmental compatibility issues associated with borate-containing compounds, thus resolving the contradiction between liquid loading and environmental friendliness
Solution Approach 2:
The patent employs a disposable, water-soluble percarbonate carrier that can be easily discarded after use. The carrier is designed to dissolve completely in water, leaving no persistent environmental residue, which addresses the environmental compatibility concern while maintaining effective liquid delivery during its functional lifetime
2Quantity of substance
If water insoluble carriers like silicates are used to adsorb liquids, then liquid loading capacity is improved, but water solubility and effervescent characteristics deteriorate
Solution Approach 1:
The patent changes the solubility parameter by selecting water-soluble percarbonate salts instead of water-insoluble silicates. The sodium percarbonate carrier maintains high liquid loading capacity (50-80% by weight) while being completely water-soluble, which enables effervescent characteristics and eliminates the need for additional disintegrants, thus resolving the contradiction between liquid loading and water solubility
3Quantity of substance
If carriers with high porosity and low bulk density are used to adsorb liquids, then liquid loading capacity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses a simple, commercially available percarbonate salt carrier that requires minimal processing. The carrier is used in its native form without complex manufacturing steps, yet achieves high liquid loading capacity (50-80% by weight) through its inherent porosity and low bulk density, thus resolving the contradiction between liquid loading and manufacturing simplicity
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 ESPC enables the formulation of compositions that can deliver higher amounts of liquid ingredients, enhancing product stability and shelf life, while being environmentally friendly and suitable for various cleaning and personal care applications, with reduced hydrogen peroxide levels and improved powder flowability.
Implementation Method 1
The ability for a carrier to adsorb larger weights of liquid thereon at least depends upon its bulk density and porosity
Implementation Method 2
lower bulk density and higher porosity are considered desired characteristics of a good carrier
Implementation Method 3
The compound is used in compositions for delivering liquids as active and necessary ingredients
Implementation Method 4
effervescent characteristics
Data Source
AI summary
The present invention discloses a compound comprising an expanded percarbonate salt having less than about 24 wt. % hydrogen peroxide. Also disclosed in this invention is a composition including the above-mentioned compound and a liquid loaded thereon. Further, there is disclosed a method of manufacturing the above-described compound.