High Caustic Laundry Emulsion Stabilization Using Low HLB Surfactants
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Solution Overview
Problem
Existing liquid detergents face challenges in maintaining emulsion stability and viscosity under high alkalinity conditions, leading to phase separation or viscosity changes, which affect their performance and manufacturing costs.
Innovation Solution
A liquid detergent composition comprising an alkalinity source, a rheology modifier, sequestering agents, and nonionic surfactants, including specific alkylpolysaccharides and acrylic copolymers, to stabilize the emulsion and maintain viscosity without requiring a pre-mix process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high levels of alkalinity source are used to achieve effective soil removal, then cleaning performance is improved, but emulsion stability deteriorates causing phase separation or viscosity collapse
Solution Approach 1:
A stabilizing system comprising a blend of polymers (acrylic acid crosslinked copolymer and polyacrylic acid) acts as an intermediary between the high alkalinity source and the emulsion components. This stabilizing system mediates the interaction, allowing high levels of alkalinity (40-95 wt.%) to be present while preventing phase separation and viscosity collapse through the synergistic polymer blend.
Solution Approach 2:
The patent uses a composite stabilizing system combining two different polymer materials (acrylic acid crosslinked copolymer and polyacrylic acid) to achieve enhanced stabilization效果. This composite approach allows the formulation to withstand high alkalinity levels while maintaining emulsion stability, as the combined polymer system provides superior resistance to alkalinity-induced destabilization compared to single polymers.
2Reliability
If high levels of alkalinity source are used to achieve effective soil removal, then cleaning performance is improved, but viscosity control deteriorates causing the product to become too thick or too thin
Solution Approach 1:
The stabilizing system comprising acrylic acid crosslinked copolymer and polyacrylic acid acts as a mediator that buffers the effect of high alkalinity on viscosity. This polymer blend absorbs and manages the viscosity-changing effects of high pH, maintaining pourable consistency even with 40-95 wt.% alkalinity source present in the formulation.
Solution Approach 2:
The patent employs parameter changes in the polymer composition and ratios to control viscosity under varying alkalinity conditions. By adjusting the types and proportions of polymers in the stabilizing system, the formulation maintains optimal viscosity across the wide range of alkalinity levels (40-95 wt.%), ensuring the product remains pourable and easy to dispense.
3Stability of the object's composition
If polyacrylic acid or polymethacrylic acid stabilizers are used to maintain emulsion stability, then emulsion stability is improved, but manufacturing cost increases due to expensive pre-mix process
Solution Approach 1:
The patent replaces expensive, complex pre-mix stabilization methods with a simpler, more cost-effective direct addition approach using a synergistic polymer blend. This substitution eliminates the need for costly pre-mixing equipment and processes while maintaining emulsion stability, reducing manufacturing costs by using readily available polymer materials in a straightforward incorporation method.
Solution Approach 2:
The patent combines multiple polymer functions into a single stabilizing system blend that provides both thickening and stabilization functions. By merging the roles of acrylic acid crosslinked copolymer and polyacrylic acid into one integrated stabilizing system, the formulation eliminates the need for separate pre-mixing steps and multiple additives, simplifying manufacturing and reducing costs while maintaining emulsion stability.
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 composition achieves stable emulsions with ideal viscosity, maintaining performance for at least a year and reducing manufacturing costs by eliminating the need for a pre-mix process, while ensuring effective cleaning under high pH conditions.
Implementation Method 1
one or more nonionic surfactants
Implementation Method 2
a rheology modifier
Implementation Method 3
The liquid detergent compositions can be provided as a concentrate or as a use solution. The liquid detergent compositions in the form of the concentrate or the use solution are water-in-oil emulsions or oil-in-water emulsions
Data Source
AI summary
High active, high caustic liquid laundry detergent compositions which provide excellent stability are disclosed, including methods of making and using the same. The compositions generally comprise a source of alkalinity, a rheology modifier, one or more sequestering agents, one or more low mole ethoxylated nonionic surfactants, and an alkylpolysaccharide surfactant. The liquid detergent emulsions, provided as a concentrate, water-in-oil use solution emulsion, or oil-in-water use solution emulsion beneficially demonstrate improved stability even under high pH and high temperature conditions.