Fabric Softener Active Composition Viscosity Control
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Solution Overview
Problem
Current fabric softener active compositions face challenges in achieving high softening performance, hydrolysis stability, suitable handling and processing in a liquid state, good odor, and compatibility with other components, particularly with low content or absence of flammable solvents, and require improved viscosity profiles and softening performance.
Innovation Solution
A fabric softener active composition comprising quaternary mono-, di-, or tri-ester ammonium compounds, fatty acid esters, fatty acids, and C18-C20 fatty alcohols, with specific weight ratios and formulations that allow for low dropping points, improved chemical stability, and reduced solvent content, enabling easy handling and pumping in a molten state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If quaternary ester ammonium compounds are used in pure state, then high softening performance is achieved, but handling and processing becomes difficult due to high viscosity and lumping tendency
Solution Approach 1:
The patent introduces fatty solvents (fatty acid esters, fatty acids, fatty alcohols) as intermediary substances to mediate between the quaternary ester ammonium compound and the final fabric softener formulation. These solvents reduce viscosity and improve handling while maintaining softening performance, avoiding the need to handle the pure compound directly.
Solution Approach 2:
The patent changes the physical state parameters of the quaternary ester ammonium compound by converting it from solid to liquid form through controlled hydrolysis and the addition of fatty solvents. This parameter change (from solid to liquid, from high viscosity to low viscosity) enables easier handling and processing while preserving the active compound's softening functionality.
2Ease of operation
If flammable solvents such as ethanol or isopropanol are added to reduce viscosity, then handling and processing becomes easier, but flash point decreases below 60°C requiring special safety measures
Solution Approach 1:
The patent replaces long-term safety concerns associated with flammable solvents with a short-term solution: using non-flammable fatty solvents that provide the same viscosity-reduction benefit without the fire hazard. This substitution eliminates the need for special safety measures while maintaining ease of handling.
Solution Approach 2:
The patent converts the potential harm of using any solvent (which could reduce flash point) into a benefit by carefully selecting fatty solvents with high flash points. The solvent addition, which could potentially create safety issues, is instead used to achieve both ease of handling and improved safety profile simultaneously.
3Object-affected harmful factors
If solvent content is reduced or eliminated, then safety and regulatory compliance improves, but viscosity control and handling become more difficult
Solution Approach 1:
The patent optimizes the concentration parameters of fatty solvents to achieve the minimum effective amount needed for viscosity control. By precisely controlling the solvent content and selecting specific fatty acid chain lengths, the patent maintains safe, regulated formulations while ensuring adequate fluidity for handling and processing.
Solution Approach 2:
The patent creates a composite solvent system combining multiple fatty acid esters, fatty acids, and fatty alcohols in specific ratios. This composite approach allows fine-tuning of viscosity properties while maintaining non-flammability and regulatory compliance, achieving a balance that single solvents cannot provide.
4Ease of operation
If melt temperature is increased to improve flow, then viscosity reduction is achieved, but chemical stability is compromised
Solution Approach 1:
The patent changes the temperature parameter from high melt temperatures to ambient or mildly elevated processing temperatures. By combining this temperature reduction with the addition of fatty solvents, the patent achieves adequate flow and viscosity control without compromising chemical stability, as the solvents work effectively at lower temperatures.
Data Source
AI summary
The present invention relates to a fabric softener active composition comprising: a component (a),said component comprising at least one or more quaternary mono-, di- or tri-ester ammonium compounds; a component (b), said component being a fatty acid ester or a mixture of fatty acid esters, wherein the component (b) content is in the range from 5 to 60% wt. based on the total weight of the fabric softener active composition; a component (c), said component being a fatty acid or a mixture of fatty acids, wherein the component (c) content is higher than 0 and lower than 5, preferably lower than 2% wt. based on the total weight of the fabric softener active composition a component (d), said component being a C18-C20 fatty alcohol, preferably a C18 fatty alcohol; and wherein the component (d) content is in the range from 2 to 12% wt. based on the total weight of the fabric softener active composition. Further disclosed are a method to obtain the fabric softener active composition; a fabric softener composition comprising the fabric softener active composition; a method to obtain the fabric softener composition, and a use of the fabric softener composition to soften and condition fabrics.