Liquid Anionic Surfactant Solidification Through Drying and Carriers
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Solution Overview
Problem
Existing methods struggle to convert liquid anionic surfactants like sulfates and sulfonates into solid form without compromising efficacy, leading to issues such as tackiness, caking, and reduced active concentration, making them unsuitable for solid formulations.
Innovation Solution
The use of a binder and/or carrier with a drying process, specifically through fluidized beds or spray drying, to solidify liquid anionic surfactants, resulting in compositions with high active concentrations and improved flow characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If liquid anionic surfactants are converted to solid form using traditional methods, then solid cleaning compositions can be made, but the surfactant efficacy is compromised and performance deteriorates
Solution Approach 1:
The patent changes the physical state parameter of the surfactant from liquid to solid through controlled drying processes (spray drying, fluidized bed drying) that remove water while preserving the surfactant's chemical structure and active properties. This allows the surfactant to transition phases without compromising its cleaning efficacy.
Solution Approach 2:
The patent uses binders and carriers as intermediary substances during the solidification process. These intermediaries facilitate the transition from liquid to solid form by providing a matrix that supports the surfactant molecules, preventing degradation and maintaining efficacy while enabling solid formulation.
2Shape
If liquid anionic surfactants are solidified, then solid formulations can be created, but the solidified surfactants become tacky and suffer from caking, compaction and agglomeration
Solution Approach 1:
The patent controls the drying parameters (temperature, humidity, drying time) to achieve optimal moisture content in the solidified surfactant. By precisely managing these parameters, the surfactant transitions to a free-flowing solid state without excessive tackiness, preventing caking and agglomeration while maintaining ease of handling.
Solution Approach 2:
The patent creates composite material systems by combining the surfactant with specific binders and carriers in optimized ratios. This composite structure provides the surfactant with free-flowing characteristics and prevents unwanted agglomeration, while the binder/carrier matrix maintains the surfactant's stability and performance.
3Shape
If traditional solidification methods are used, then liquid surfactants can be converted to solid form, but substantial amounts of binder and/or carrier are required thereby reducing the active concentration
Solution Approach 1:
The patent optimizes the drying process parameters to achieve maximum water removal with minimal binder/carrier addition. By controlling moisture content to specific levels and using efficient drying techniques, the patent reduces the quantity of inactive ingredients needed, thereby increasing the active surfactant concentration in the final solid formulation.
Solution Approach 2:
The patent extracts and removes excess water and unnecessary components during the drying process, concentrating the active surfactant. This extraction approach allows for higher active concentrations by eliminating the need for substantial amounts of binder and carrier that would otherwise be required to maintain structural integrity.
4Shape
If compounds with low water solubility are used for solidification, then solid form can be achieved, but formulation and end-use in water become problematic
Solution Approach 1:
The patent selects binders and carriers with optimized water solubility parameters that balance solid formulation requirements with aqueous end-use performance. By carefully controlling the solubility characteristics of the auxiliary materials, the patent ensures the solidified surfactant can be effectively formulated and dispersed in water-based cleaning applications.
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 solidified surfactants maintain performance in terms of foam and soil removal, enabling their use in higher concentrations within solid cleaning compositions and overcoming issues of tackiness and agglomeration.
Implementation Method 1
solidification of liquid sulfate and sulfonate surfactants with a binder, carrier, or both a binder and carrier... utilizing drying device(s)
Implementation Method 2
specifically through fluidized beds or spray drying
Data Source
AI summary
The invention relates to solidification of liquid anionic surfactants with a binder, carrier, or both binder and carrier to form a solidified surfactant composition. In particular, the invention relates to solidification of liquid surfactants utilizing drying device(s), wherein the feed composition contains at least one liquid surfactant and the binder, carrier, or binder and carrier to form a solidified surfactant composition. The solidified surfactant compositions can be useful in various cleaning compositions.