Porous Dissolvable Solid Structure with Isethionate Surfactants
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Solution Overview
Problem
The removal of sulfate-based surfactants from dissolvable solid structures creates processing challenges such as poor tensile properties, making it difficult to process and commercialize non-sulfate formulations, which are prone to issues like peelability, rollability, and strength during roll unwinding and cutting.
Innovation Solution
A porous dissolvable solid structure comprising high levels of isethionate-based surfactants in combination with secondary anionic and amphoteric/zwitterionic surfactants, balancing crystallinity to enhance tensile strength and processability while maintaining fast dissolution properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If sulfate-based surfactants are removed from dissolvable solid structures, then the product becomes sulfate-free and meets consumer demands for gentler cleansers, but the tensile strength and processability deteriorate significantly
Solution Approach 1:
The patent applies composite materials by combining multiple non-sulfate surfactant types (anionic, amphoteric, and zwitterionic) with a water-soluble polymer matrix to create a dissolvable solid structure that achieves both sulfate-free formulation and adequate tensile strength. The synergistic interaction between different surfactant classes and the polymer carrier provides the necessary mechanical properties while maintaining the sulfate-free benefit.
Solution Approach 2:
The patent employs parameter changes by optimizing the concentration ranges of different surfactant components and the polymer carrier to achieve the desired balance between processability and tensile strength. Specific parameter ranges are defined for each ingredient to ensure the dissolvable solid structure has sufficient strength during processing while remaining sulfate-free.
2Object-affected harmful factors
If non-sulfate surfactant formulations are used, then consumer safety and gentleness are improved, but processing difficulties increase due to poor peelability and rollability
Solution Approach 1:
The patent uses composite materials by formulating a multi-component system comprising anionic surfactants, amphoteric surfactants, zwitterionic surfactants, and water-soluble polymers. This composite formulation provides both consumer safety (non-sulfate) and improved processability through the synergistic effects of the different components on the dissolvable solid structure's mechanical properties.
Solution Approach 2:
The patent applies parameter changes by defining specific concentration ranges for each surfactant type and polymer carrier that optimize both consumer safety and manufacturing ease. The parameter optimization ensures adequate peelability, rollability, and cutting properties while maintaining the non-sulfate formulation for consumer safety.
3Strength
If high levels of isethionate surfactants are used to improve tensile strength, then processability is enhanced, but the formulation complexity increases
Solution Approach 1:
The patent applies composite materials by using a balanced combination of multiple surfactant types at optimized concentration levels rather than relying on a single high-concentration component. This approach achieves the necessary tensile strength while distributing the formulation complexity across multiple functional ingredients that work synergistically.
Data Source
AI summary
A porous dissolvable solid can include an isethionate surfactant; an non-sulfate anionic surfactant; and an amphoteric surfactant, a zwitterionic surfactant, or a combination thereof.