Laundry Product Stable Emulsion Process
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Solution Overview
Problem
Conventional fabric conditioners, particularly those with non-cationic actives, face stability issues such as phase separation and viscosity changes, which affect their pourability and dispensability, especially when produced using high aqueous media routes.
Innovation Solution
A process involving the preparation of a concentrated premix by co-melting alkylated sugars, fatty acids, and fatty acid esters, followed by dilution with water to create a stable emulsion with a specific viscosity range, which enhances the physical stability of the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fabric conditioner is produced using high aqueous media route, then production efficiency is improved, but storage stability deteriorates due to phase separation and viscosity changes
Solution Approach 1:
The patent applies preliminary action by first creating a stable concentrated premix of non-cationic actives (alkylated sugars, fatty acids, fatty acid esters, and fatty acid soaps) in a controlled environment, then subsequently diluting it with water to the desired concentration. This preliminary formation of a stable concentrated base ensures that the emulsion structure is established before water addition, preventing phase separation and viscosity changes that would occur if water were added during the formation process.
2Stability of the object's composition
If concentrated fabric conditioner is diluted to required concentration, then storage stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the manufacturing process into two distinct stages: first, producing a concentrated premix with specific ingredients in controlled proportions to form a stable emulsion structure; second, diluting this premix with water to achieve the desired final concentration. This segmentation allows each stage to be optimized independently, with the concentrated premix serving as a stable intermediate product that simplifies the overall manufacturing process despite the additional step.
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 process results in a stable and usable microstructure for the fabric conditioner, improving its storage stability and performance compared to traditional high aqueous synthesis methods.
Implementation Method 1
preparing a concentrated premix by co-melting alkylated sugars, fatty acids, and fatty acid esters
Implementation Method 2
diluting the isotropic premix with water to create a stable emulsion
Data Source
AI summary
A process for the preparation of liquid fabric treatment compositions comprising from 50 to 92% by weight of water, from 1 to 15% by weight of one or more alkylated sugars, from 1 to 15% by weight of one or more fatty acids, from 5 to 25% by weight of one or more fatty acid esters, and from 1 to 15% by weight of fatty acid soap, in the form of a stable emulsion, comprising the steps of :- a) preparing a concentrated premix, b) allowing the premix to form an isotropic premix, and c) diluting the isotropic premix with water; wherein the emulsion has a viscosity of from 800 to 6000 mPas-1 measured at 20°C using a spindle No. 2 at 10 r.p.m; gives unexpectedly high stability benefit.