Shirasu Scrub Soap Manufacturing Homogeneous Mixing
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Solution Overview
Problem
Existing methods for manufacturing scrub soap with a large amount of volcanic glassy sediments as a scrub agent face challenges in achieving both long-lasting bubbling and good lathering without using fluidization auxiliary agents, and often result in separation issues and decreased productivity due to high viscosity and precipitation problems.
Innovation Solution
A manufacturing method involving a combination of shirasu and hollow shirasu with different average particle diameters, a specific fatty acid composition, and an alkali aqueous solution to create a soap basis material with at least 10% scrub agent by weight, ensuring homogeneous mixing and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of scrub agent is combined to improve cleaning effect, then the cleaning and scrubbing effect is enhanced, but the separation between scrub agent and liquid component occurs during manufacturing
Solution Approach 1:
The patent introduces a specific fatty acid composition (containing medium chain fatty acids like caprylic acid and capric acid) as an intermediary substance that mediates between the scrub agent particles and the liquid component. This fatty acid composition acts as a bonding agent that adheres to the surface of the scrub agent particles, preventing separation and precipitation while maintaining homogeneous mixing throughout the soap bar manufacturing process.
2Reliability
If a large amount of fine powder scrub agent is combined to improve cleaning effect, then the cleaning effect is enhanced, but mechanical mixing becomes impossible due to extremely high viscosity
Solution Approach 1:
The patent changes the physical and chemical parameters of the mixing system by introducing a specifically formulated fatty acid composition that modifies the rheological properties of the mixture. This composition reduces the viscosity and improves the fluidity of the mixture containing fine powder scrub agent, enabling mechanical mixing to proceed effectively while maintaining a high scrub agent content of 70% or more by weight.
3Duration of action of moving object
If shirasu balloon is used to achieve long-lasting bubbling, then bubbling duration is extended, but lathering is sacrificed
Solution Approach 1:
The patent merges two different scrub agent forms - shirasu balloon (for long-lasting bubbling) and shirasu with no hollow (for good lathering) - into a composite scrub agent system. By combining these two components in specific proportions, the patent achieves both long-lasting bubbling and good lathering simultaneously, resolving the trade-off between these two opposing requirements.
4Productivity
If medium chain fatty acid esters are added to increase fluidity, then the fluidity of materials is improved, but the number of materials and manufacturing steps increases
Solution Approach 1:
The patent makes the fatty acid composition multi-functional by designing it to simultaneously serve as a bonding agent (preventing separation), a fluidity improver (enabling mechanical mixing), and a lathering agent (providing foam). This consolidates multiple functions into a single material system, reducing the number of separate additives and manufacturing steps required compared to conventional approaches.
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 efficiently produces a scrub soap with long-lasting bubbling and improved lathering without using fluidization auxiliary agents, maintaining a suitable viscosity for effective mixing and dispersion of the scrub agent.
Implementation Method 1
a step of preparing a soap basis material by mixing the scrub agent, the alkali aqueous solution and the fatty acid composition
Implementation Method 2
the soap component of the soap formed inside of the hollow shirasu balloon is gradually eluted therefrom in use and accordingly bubbling is characteristically long-lasting
Implementation Method 3
The scrub agent can physically remove such as dirt on the skin or dead skin cell of the skin by rubbing and adsorbing
Data Source
AI summary
The present invention relates to provide a scrub soap and a method for manufacturing the same. A method for manufacturing a scrub soap includes preparing a scrub agent consisting of a shirasu and a hollow shirasu having a different average particle diameter each other, preparing a fatty acid composition consisting of at least one kind of fatty acid, preparing an alkali aqueous solution by dissolving at least one kind of alkali metal hydroxide of which molar ratio to at least one kind of fatty acid is not more than 1, and preparing a soap basis material by mixing the scrub agent, the alkali aqueous solution and the fatty acid composition.