Particle Formation Process for Uniform Pore Distribution
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Solution Overview
Problem
Existing fabric care additives in the form of particles often have irregular pore distributions and surfaces, leading to incomplete dissolution and reduced durability, which limits their effectiveness and quality.
Innovation Solution
A process involving the entrainment of a gas mixture comprising 50-75% carbon dioxide and 25-50% other constituents into a precursor material, followed by passing it through a distributor with apertures and depositing it onto a moving conveyor for cooling, to form particles with a uniform pore distribution and improved surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If melt processing is used to form porous particles, then particles can be formed with pores, but bubbles coalesce and rise out of the molten material causing large pores at the surface, irregular rough outer surface, and eruptions of bubbles
Solution Approach 1:
The patent changes the physical parameters of the precursor material by controlling temperature and pressure conditions during processing. By maintaining the precursor material in a controlled state and adjusting processing parameters, the invention prevents bubble coalescence and surface eruptions while achieving uniform pore distribution throughout the particle interior without compromising outer surface regularity
Solution Approach 2:
The patent utilizes controlled phase transitions of the precursor material during processing. By carefully managing the phase state changes and timing, the invention allows pores to form uniformly within the particle structure while preventing bubble escape to the surface, thereby achieving both uniform pore distribution and smooth outer surface
2Manufacturing precision
If porous particles are formed via melt process, then particles have pores, but the outer surface becomes irregular and rough
Solution Approach 1:
The patent modifies processing parameters to control the formation and stabilization of pores within the particle structure. By adjusting temperature, pressure, and processing conditions, the invention creates uniform internal porosity while simultaneously ensuring the formation of a durable, smooth outer surface that resists dusting and degradation
Solution Approach 2:
The patent applies protective measures during the particle formation process by controlling the precursor material state and processing conditions to prevent surface defects before they occur. This beforehand cushioning approach ensures that the outer surface remains intact and durable while pores form uniformly in the particle interior
3Ease of operation
If particles sink in wash liquor, then they may be easier to handle, but they become trapped in folds and creases of laundry leading to incomplete dissolution
Solution Approach 1:
The patent creates particles with controlled porous structure that provides buoyancy, allowing particles to float on wash liquor. The porous structure is designed to maintain particle integrity while enabling complete dissolution during the wash cycle, preventing particles from becoming trapped in laundry folds and ensuring full delivery of fabric care benefits
Solution Approach 2:
The patent designs particles with specific physical properties (buoyancy, surface characteristics) that replicate the desired behavior of floating and complete dissolution. By copying the functional requirements into the particle design, the invention ensures particles float during handling and dissolution during washing, achieving both ease of operation and complete dissolution
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 particles that dissolve completely in wash liquor, providing consistent fabric care benefits and maintaining a pleasant scent, while being more durable and less prone to dustiness, thus enhancing user experience.
Implementation Method 1
entraining gas into said precursor material
Implementation Method 2
cooling said precursor material to form a plurality of particles
Data Source
AI summary
A process for forming particles. The process includes a step of entraining gas into a precursor material, wherein the gas includes from about 50 vol % to about 75 vol % carbon dioxide and from about 25 vol % to about 50 vol % other constituents. The precursor material is deposited onto a moving conveyor. The precursor material is cooled to form a plurality of particles.