Compositions in the form of dissolvable solid structures

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Solution Overview

Problem

Existing dissolvable solid products face challenges in manufacturing cost, rate, and product variability, while liquid consumer products incur high packaging waste and costs, necessitating the development of effective dissolvable solid structures that perform well and are cost-efficient to produce.

Innovation Solution

The creation of porous dissolvable solid structures comprising surfactants and vinyl acetate-vinyl alcohol copolymers, with specific weight percentages and processing methods to form open-celled foams or fibrous structures, optimizing porosity and dissolution properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If dissolvable solid products are manufactured using conventional processes, then product performance is achieved, but manufacturing cost and production rate are suboptimal

Engineering Contradiction:

Improveproduction rateVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by optimizing the copolymer composition (specifically using 70% vinyl alcohol and 30% vinyl acetate units) and processing parameters (temperature, humidity, composition ratios) to achieve both high production rates and cost-effectiveness. This specific compositional parameter enables faster manufacturing while maintaining product performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite materials by combining surfactants with vinyl acetate-vinyl alcohol copolymers in specific ratios to create a dissolvable solid structure that optimizes both manufacturing efficiency and production rate, resolving the contradiction between ease of manufacture and productivity

Inventive Principle:

Principle #40Composite materials

2Reliability

If existing dissolvable solid products are used, then some performance benefits are achieved, but product variability and dissolution properties are insufficient

Engineering Contradiction:

Improveproduct performance consistencyVSAvoidproduct variability

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent reduces product variability by precisely controlling the copolymer composition parameters (70% vinyl alcohol, 30% vinyl acetate) and processing conditions (temperature, humidity, composition ratios), which ensures consistent dissolution properties and reliable product performance across batches

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention implements feedback control by monitoring and adjusting processing parameters such as temperature, humidity, and composition ratios during manufacturing to maintain consistent product quality and minimize variability, thereby improving both reliability and manufacturing precision

Inventive Principle:

Principle #23Feedback

3Ease of operation

If liquid consumer products are used, then convenience of use is achieved, but packaging waste and costs increase

Engineering Contradiction:

Improveconvenience of useVSAvoidpackaging waste

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The patent employs disposable dissolvable solid structures that eliminate the need for reusable packaging. These single-use dissolvable products provide convenience similar to liquid products while generating no packaging waste, as the entire product dissolves after use

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention uses porous dissolvable solid structures that allow for efficient dissolution and application, providing user convenience comparable to liquid products while being packaged in minimal or dissolvable containers, thereby reducing packaging waste

Inventive Principle:

Principle #31Porous materials

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 enables the production of dissolvable solid products with improved porosity, faster production rates, reduced water usage, and enhanced consumer satisfaction through efficient manufacturing processes, addressing the limitations of existing products.

Implementation Method 1

aerating the pre-mixture by introducing a gas into the pre-mixture to form a wet aerated mixture

Methodology Applied

Scientific EffectAeration: Aeration

Implementation Method 2

fibrillating the processing mixture into fibers by a fluid film fibrillation process comprising a first pressurized gas stream directed against a liquid film of the processing mixture to form the fibers

Methodology Applied

Scientific EffectFluid film fibrillation:

Implementation Method 3

at least partially drying the fibers of the processing mixture by a second pressurized gas stream

Methodology Applied

Scientific EffectPressurized gas drying:

Implementation Method 4

drying the wet aerated mixture by applying energy to heat the wet aerated mixture and evaporate water to provide a Structure

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS11352474B2Compositions in the form of dissolvable solid structures

Publication Date: 2022.06.07 PROCTER & GAMBLE CO

AI summary

Described are dissolvable, porous solid structures formed using certain vinyl acetate-vinyl alcohol copolymers. The copolymer and the porosity of the structure allow for liquid flow during use such that the structure readily dissolves to provide a desired consumer experience. Also described are processes for making open cell foam and fibrous dissolvable solid structures.