Segmented Chlorine Dioxide Packaging for Shelf Life
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Solution Overview
Problem
Chlorine dioxide-based disinfectants and sanitizers face challenges with long-term stability, leading to limited shelf life and requiring on-site production or complex user-friendly mixing processes, which complicates manufacturing, inventory, and consumer use.
Innovation Solution
A method to produce stabilized chlorine dioxide by controlling the pH and using a combination of Hydrochloric acid, Sodium chlorite, and DOWFAX 3B2, with Sodium Hydroxide adjustments to achieve a stable chlorine dioxide solution, allowing for a ready-to-use product with improved shelf life and conventional packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chlorine dioxide is used as a biocidal agent, then disinfection efficacy is improved, but long-term stability deteriorates
Solution Approach 1:
The product is divided into two separate chambers: Chamber A contains the chlorine dioxide-generating ingredients (sodium chlorite and acid), while Chamber B contains the surfactant and water. This segmentation prevents premature reaction and maintains stability during storage, while enabling effective disinfection when the chambers are mixed at the point of use.
Solution Approach 2:
The precursors (sodium chlorite and acid) are prepared and sealed in advance in separate chambers, ready for reaction. This preliminary preparation allows the product to be stored stably while maintaining the capability to generate active chlorine dioxide when needed, resolving the contradiction between stability and efficacy.
2Duration of action of stationary object
If on-site production of chlorine dioxide is implemented, then shelf life is improved, but device complexity increases
Solution Approach 1:
The generator is divided into two chambers that can be stored separately and simply mixed at the point of use. This segmentation maintains shelf life by preventing premature reaction while keeping the packaging relatively simple and easy to manufacture compared to more complex dispensing systems.
Solution Approach 2:
The consumer performs a simple mixing action by combining the two chambers, and the chemical reaction occurs automatically without requiring external power, complex mechanisms, or specialized equipment. This self-service approach extends shelf life while minimizing device complexity.
3Stability of the object's composition
If 2-Part product system is used, then stability is improved, but ease of operation deteriorates
Solution Approach 1:
The product is segmented into two chambers contained within a single bottle, which are easily mixed by the consumer through simple inversion or shaking. This segmentation provides stability during storage while maintaining ease of operation during use, as the mixing process is simplified to a single mechanical action.
Solution Approach 2:
The two-part system is merged into a single container with integrated chambers, combining the stability benefits of separate storage with the ease of use of a single product. The consumer handles one bottle rather than multiple separate components, improving ease of operation while maintaining stability.
4Ease of manufacture
If conventional packaging is used, then ease of manufacture is improved, but stability deteriorates
Solution Approach 1:
The conventional bottle is segmented into two chambers, allowing the use of standard manufacturing processes for glass or plastic containers while achieving stability through physical separation of reactants. This segmentation maintains ease of manufacture using existing packaging infrastructure while resolving stability issues.
Solution Approach 2:
The physical state and arrangement of the product is changed by dividing it into two chambers, transforming a single homogeneous liquid into separated components. This parameter change (from mixed to separated) maintains compatibility with conventional packaging manufacturing while achieving the required stability.
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 method significantly enhances the stability and shelf life of chlorine dioxide solutions, enabling them to be used in various applications without the need for on-site production or complex mixing, providing a stable and effective disinfectant for household, commercial, and healthcare settings.
Implementation Method 1
The device includes a delivery device configured to deliver a solution to a target application and a stabilized chlorine dioxide (ClO2) product that is configured to be delivered using the delivery device. The chlorine dioxide is produced using a method that includes adding a first amount of Hydrochloric acid (HCl) to a second amount of Sodium chlorite (NaClO2) that is dissolved in water
Implementation Method 2
after the reaction to generate chlorine dioxide (ClO2) in solution has gone to completion, adding a fourth amount of Sodium Hydroxide (NaOH) to adjust the pH of the resulting ClO2 solution to a desired pH
Implementation Method 3
adding a third amount of DOWFAX 3B2 (i.e., sodium alkyl diphenyloxide disulfonate) to the solution and slowly agitate the HCl, NaClO2 and DOWFAX solution to distribute the DOWFAX
Data Source
AI summary
Disclosed are devices, systems, and methods for producing broad spectrum disinfectants, sanitizers, cleaner and deodorizers using chlorine dioxide compositions, and more particularly, to methods for producing chlorine dioxide compositions having improved long term stability by the proper choice of pH and through the careful choice of other product formula ingredients.