Fatty Alkyl Ester Surfactant for Liquid Dose Stringing Control
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Solution Overview
Problem
Formulating high non-ionic surfactant levels into water-soluble unit dose articles is challenging due to liquid stringing and dripping issues, which lead to seal failures and premature rupture, especially at high line speeds.
Innovation Solution
Incorporating a fatty alkyl ester alkoxylate non-ionic surfactant while controlling the level of alkoxylated alcohol non-ionic surfactant, which reduces stringing and dripping, enabling faster line speeds and maintaining product integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high levels of non-ionic surfactant are added to liquid laundry detergent formulations, then body soil cleaning effectiveness is improved, but liquid stringing and dripping occurs during manufacturing
Solution Approach 1:
The patent changes the chemical parameters of the non-ionic surfactant by specifying a particular molecular structure (Formula I) with defined alkyl chain lengths (R1: 8-18 carbons, R2: 1-6 carbons) and ethoxylate units (x: 1-30). This structural parameter change reduces liquid stringing and dripping while maintaining cleaning effectiveness at high surfactant levels (2-30% by weight).
Solution Approach 2:
The patent creates a composite surfactant system by combining the specific non-ionic surfactant (Formula I) with anionic surfactants (15-55% by weight) and optional secondary non-ionic surfactants (15% or less). This composite formulation achieves both high cleaning performance and reduced liquid stringing during high-speed manufacturing.
2Productivity
If high line speeds are used in manufacturing water-soluble unit dose articles, then productivity is improved, but seal failures and premature rupture occur due to liquid dripping
Solution Approach 1:
By modifying the surfactant molecular structure parameters (specifically the balance between hydrophobic alkyl chains R1 and R2 and hydrophilic ethoxylate units x), the formulation reduces liquid dripping at high line speeds, preventing seal contamination and maintaining seal integrity during high-speed manufacturing.
Solution Approach 2:
The patent converts the potential harm of liquid stringing and dripping into a benefit by formulating a surfactant system that actually reduces liquid adhesion to the nozzle. The controlled liquid release pattern ensures consistent dosing without contaminating seal areas, enabling both high productivity and reliable sealing.
3Reliability
If higher non-ionic surfactant levels are formulated, then cleaning performance is improved, but manufacturing into water-soluble unit dose articles becomes challenging
Solution Approach 1:
The patent changes the chemical parameters of the non-ionic surfactant to a specific molecular architecture (Formula I) with controlled hydrophobic-hydrophilic balance. This parameter optimization enables the formulation to maintain high cleaning performance at 2-30% concentrations while exhibiting reduced liquid stringing, making it easier to manufacture into water-soluble unit dose articles at high line speeds.
Solution Approach 2:
The patent formulates a composite detergent system combining the optimized non-ionic surfactant (Formula I) with anionic surfactants and optional adjuncts. This composite approach achieves superior cleaning performance while the specific non-ionic surfactant structure prevents manufacturing issues, enabling easy formulation into water-soluble unit dose articles.
Data Source
Figure 1
AI summary
A water-soluble unit dose article containing a non-soap anionic surfactant, a non-ionic surfactant and a method of use thereof.