High Water Soap Bar Extrusion via Polyacrylate Structurant

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Solution Overview

Problem

Existing soap bar compositions with high water content face challenges in extrusion and stamping due to low TFM content, leading to stickiness and cracking issues, while attempts to address these problems with electrolytes result in undesirable cracking and efflorescence.

Innovation Solution

A soap bar composition incorporating a specific polymer with structural units of C1-4 alkyl acrylate, (meth)acrylic acid, and a specialized associative monomer, combined with controlled amounts of electrolytes, allows for high water content and easy extrusion without cracking or efflorescence.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If water content is increased to reduce TFM content, then sustainability and cleaning efficacy are improved, but extrusion becomes difficult and bars become sticky

Engineering Contradiction:

Improvewater contentVSAvoidextrusion difficulty

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

A polyacrylate polymer is introduced as an intermediary substance to mediate between the high water content and the extrusion process. The polymer acts as a structurant that enables the soap mass to be extruded at high rates while maintaining high water content (25-40%), resolving the contradiction between sustainability and manufacturability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention changes the physical-chemical parameters of the soap system by introducing a polyacrylate polymer with specific molecular weight and concentration ranges. This parameter change transforms the rheological properties of the soap mass, enabling easy extrusion despite high water content

Inventive Principle:

Principle #35Parameter changes

2Strength

If electrolytes are added to reduce stickiness, then bar hardness increases, but cracking and efflorescence occur

Engineering Contradiction:

Improvebar hardnessVSAvoidcracking and efflorescence

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The polyacrylate polymer serves as an intermediary that provides bar strength and hardness without the need for high electrolyte concentrations. It mediates between the desire for hard bars and the avoidance of cracking, offering an alternative mechanism for structure building

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention converts the potential harm of high water content (which causes stickiness and structural weakness) into a benefit by using the polyacrylate polymer to create a structured gel network. The high water content becomes advantageous for sustainability and skin benefits while the polymer prevents the associated drawbacks

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If extrusion speed is increased for high productivity, then output increases, but bar quality and integrity deteriorate

Engineering Contradiction:

Improveextrusion speedVSAvoidbar quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The polyacrylate polymer changes the rheological parameters of the soap mass, creating a viscoelastic structure that can be extruded at high speeds (up to 200 bars per minute) while maintaining bar integrity and quality. The polymer's molecular structure provides the necessary elasticity and strength

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4118175B1A soap bar with high water content

Publication Date: 2023.11.22 UNILEVER IP HLDG BV

AI summary

The present invention relates to a soap bar composition. It more particularly relates to a soap bar composition which comprises low amount of soap where high amount of water can be incorporated. This is achieved by including a selective polymer therein. The soap bars of the invention are easy to extrude and stamp.