Fabric Conditioner Viscosity and Flocculation Control
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Solution Overview
Problem
Dilute fabric conditioner compositions face challenges in achieving high viscosity without flocculation, as increasing viscosity often compromises stability and leads to flocculation issues during use.
Innovation Solution
A combination of ester-linked quaternary ammonium compounds with specific fatty acid chain distributions and a non-ionic alkoxylated material as a flocculation prevention agent, maintaining viscosity while preventing flocculation upon addition to water.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the concentration of quaternary softening active is increased to enhance product thickness and consumer appeal, then the viscosity and perceived richness of the product is improved, but the cost of the product increases significantly and this approach is prohibitive for commercial dilute fabric conditioners
Solution Approach 1:
The patent changes the chemical parameters of the quaternary ammonium compound by selecting specific fatty acid chain compositions (20-35% saturated C18 chains and 20-35% monounsaturated C18 chains) to achieve enhanced viscosity at lower concentrations, thereby reducing cost while maintaining product thickness
Solution Approach 2:
The patent creates a composite system by combining the specifically structured quaternary ammonium compound with a non-ionic alkoxylated flocculation prevention agent, where the synergistic interaction between these components achieves both high viscosity and cost-effectiveness in dilute formulations
2Shape
If a polymer thickener is added to increase viscosity, then the product thickness is improved, but the product becomes non-biodegradable, technically difficult to manufacture, and prone to separation and redeposition problems
Solution Approach 1:
The patent replaces expensive, problematic polymer thickeners with a more economical and reliable approach using specifically structured quaternary ammonium compounds that provide viscosity enhancement without the drawbacks of polymer additives, including biodegradability and formulation stability issues
Solution Approach 2:
The patent achieves viscosity enhancement through changes in the chemical structure and composition of the quaternary ammonium compound itself, rather than adding separate thickening agents, thereby avoiding the stability and environmental issues associated with polymer thickeners
3Reliability
If the processing temperature is increased during manufacture to reduce flocculation, then the occurrence of flocs upon use is reduced, but the viscosity of the formulation decreases
Solution Approach 1:
The patent incorporates a flocculation prevention agent (non-ionic alkoxylated material) into the formulation during manufacturing, which preemptively prevents floc formation during subsequent use, eliminating the need for post-manufacturing temperature adjustments that would compromise viscosity
Solution Approach 2:
The non-ionic alkoxylated flocculation prevention agent acts as an intermediary substance that mediates between the quaternary ammonium compound and water, preventing direct interaction that would cause flocculation, thereby maintaining both anti-flocculation properties and viscosity without high-temperature processing
4Reliability
If the amount of fatty alcohol is decreased to reduce flocculation, then the level of floc formation is reduced, but the product viscosity decreases
Solution Approach 1:
The patent changes the concentration parameters of fatty alcohol to optimized levels that balance flocculation prevention with viscosity maintenance, and compensates for any viscosity loss through the synergistic effect of the specifically structured quaternary ammonium compound and flocculation prevention agent
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 results in a thick, stable dilute fabric conditioner with reduced flocculation and maintained viscosity, enhancing product performance and consumer acceptance.
Implementation Method 1
the combination of a specific quaternary active with a flocculation prevention agent, which is a non-ionic surfactant, enables the formation of a thick 'dilute' fabric conditioner composition, which does not flocculate upon use
Implementation Method 2
We have now surprisingly found that the combination of a specific quaternary active with a flocculation prevention agent enables the formation of a thick 'dilute' fabric conditioner composition
Data Source
AI summary
An aqueous fabric conditioner composition comprising (a) from 2 to 9 wt % of a fabric softening active, by weight of the total composition, wherein the fabric softening active is an ester-linked quaternary ammonium compound having fatty acid chains comprising from 20 to 35 wt % of saturated C18 chains and from 20 to 35 wt % of monounsaturated C18 chains, by weight of total fatty acid chains; and (b) from 0.01 to 0.5 wt %, by weight of the total composition, of a floc prevention agent, which is a non-ionic alkoxylated material having an HLB value of from 8 to 18, wherein the aqueous fabric conditioner composition has a viscosity of greater than 50 cps, preferably from 55 to 200 cps as measured on a cup and bob viscometer; the viscosity being continuously measured under shear at 106 s″1 for 60 seconds, at 25° C. and wherein the composition leads to little or no floc formation upon addition to water.