Nonwoven Laundry Article With Enzyme Matrix for Stable Cleaning
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Solution Overview
Problem
Laundry tablets with disintegration aids are complex and costly, while liquid detergent pouches cannot formulate incompatible ingredients, and enzymes are sensitive to high temperatures and pH levels during manufacturing, affecting their stability and performance.
Innovation Solution
A laundry article comprising a water-insoluble nonwoven substrate coated with a detergent composition and an enzyme-containing composition, where the enzyme is embedded in a matrix of fatty acids, fatty acid soaps, polyols, and mixtures thereof, allowing for stable enzyme storage and quick release during washing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If enzymes are added to molten detergent composition during manufacturing, then cleaning performance is improved, but enzyme stability deteriorates due to high temperature and pH
Solution Approach 1:
The detergent article is divided into two distinct zones: a detergent composition zone and an enzyme-containing composition zone. This segmentation allows each zone to have optimized properties - the detergent zone provides cleaning power while the enzyme zone maintains enzyme stability through a protective matrix of hydrophilic polymers and buffering agents that create a stable microenvironment.
Solution Approach 2:
A matrix composed of hydrophilic polymers (such as polyvinyl alcohol, carboxymethyl cellulose, or starch) acts as an intermediary between the enzyme and the harsh detergent environment. This matrix protects the enzyme from high temperature and pH damage during manufacturing and storage, while still allowing the enzyme to become active and functional during the washing process.
2Ease of manufacture
If high temperature manufacturing process is used, then detergent composition is effectively applied, but enzyme activity is lost
Solution Approach 1:
The manufacturing process is segmented into two separate coating operations: first applying the detergent composition to the substrate, then applying the enzyme-containing composition in a separate zone. This allows the detergent to be applied under optimal high-temperature conditions while the enzyme is applied in a protected matrix that maintains enzyme activity throughout the manufacturing process.
Solution Approach 2:
The enzyme is pre-embedded in a protective matrix of hydrophilic polymers and buffering agents before being applied to the substrate. This preliminary protection allows the enzyme to withstand the subsequent high-temperature drying process without losing activity, enabling effective manufacturing while preserving enzyme function.
3Productivity
If water-soluble substrate is used, then quick dissolution is achieved, but ingredient compatibility is limited
Solution Approach 1:
The substrate material parameters are changed from water-soluble to water-insoluble (such as polyester or polypropylene). This parameter change allows the substrate to remain stable and maintain its structural integrity while holding both detergent and enzyme compositions in their respective zones, enabling the formulation of incompatible ingredients in the same product without premature dissolution or interaction.
4Device complexity
If polyvinyl alcohol wrapping is used for liquid detergent, then packaging is simplified, but incomplete dissolution occurs leaving residues
Solution Approach 1:
The patent uses a disposable water-insoluble substrate that is designed to remain intact throughout the washing process and be removed with the majority of the detergent residue in the wash water. The substrate itself does not need to dissolve completely, but rather serves its purpose by holding and releasing the detergent and enzyme compositions, then being discarded along with the wash water and lint filter contents.
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 solution provides effective cleaning properties, especially for enzyme-specific stains, with minimal water absorption and adjusted melting and pH points to protect enzymes during manufacturing, ensuring stable enzyme activity during storage and washing.
Implementation Method 1
coating said substrate with both the molten detergent composition and the molten enzyme-containing composition into at least one zone each and allowing the resulting detergent and enzyme-containing composition zones to cool and solidify on the substrate
Implementation Method 2
In order to manufacture such a laundry article preferably a heated molten mixture of the particular compositions is coated onto the water-insoluble substrate
Data Source
AI summary
A laundry article used for cleaning fabrics includes a water-insoluble nonwoven substrate and coated thereon into at least one zone each a detergent composition and an enzyme-containing composition. The enzyme-containing composition comprises an enzyme embedded in a matrix.