Single-Chamber Detergent Pouch with Phase Separation
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Solution Overview
Problem
Existing unit dose detergent products face challenges such as increased manufacturing costs and operational failures due to multi-compartment systems, formulation compatibility issues with aqueous-based detergents, and aesthetic concerns, particularly when using water-soluble polymeric films.
Innovation Solution
Development of multi-phase unit dose detergent compositions within a single-chamber container, comprising a solid powder phase, a solid gel phase, and optionally a liquid phase, using a polyvinylalcohol (PVOH) film pouch, with specific ratios and formulations to minimize intermixing and enhance performance and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-compartment pouches are used to separate detergent compositions, then functional separation is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent merges multiple detergent compositions into a single-compartment pouch, eliminating the need for multiple sealed compartments while maintaining functional separation through strategic layering of powder and gel phases that dissolve at different rates during the wash cycle
Solution Approach 2:
The detergent composition is segmented into distinct phases (powder and gel) with different dissolution characteristics, allowing functional separation without physical compartment barriers, thereby simplifying manufacturing while maintaining versatility
2Adaptability or versatility
If multi-compartment pouches are used to separate detergent compositions, then functional separation is improved, but reliability decreases due to operational failure risks
Solution Approach 1:
By combining all detergent compositions into a single compartment without internal seals or barriers, the patent eliminates the reliability risks associated with multi-compartment systems (such as seal failures or incomplete dissolution of dividers) while maintaining functional separation through phase-based dissolution control
3Ease of manufacture
If water-soluble polymeric films are used for pouch production, then ease of manufacture is improved, but formulation compatibility issues arise
Solution Approach 1:
The patent adjusts formulation parameters by creating distinct powder and gel phases with different water affinity and dissolution rates, allowing compatibility with water-soluble polymeric films while maintaining composition stability throughout the wash cycle
4Productivity
If compacted formulation doses are used in unit dose compositions, then productivity is improved, but composition performance targets become difficult to achieve
Solution Approach 1:
The patent applies local quality by creating regions of different compaction densities within the single compartment - the gel phase provides a less compacted, more soluble region while the powder phase provides a compacted, slower-dissolving region, allowing both high productivity and performance target achievement in different local areas
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 provides a cost-effective, reliable, and aesthetically pleasing single-compartment detergent system that effectively removes soils from dishware and fabrics, with improved compatibility and performance compared to traditional multi-compartment systems.
Implementation Method 1
a water-soluble single-chamber container, such as a pouch
Implementation Method 2
a cleaning system comprising at least two different phases selected from the group consisting of a solid powder phase, a solid gel phase, and a liquid phase, wherein said at least two different phases demonstrate little or no visible intermixing at the interphase between said phases
Implementation Method 3
a cleaning system comprising at least one detersive surfactant
Data Source
Figure 1a
Figure 1b
Figure 2a~2b
AI summary
The present invention provides unit dose detergent products, such as those in the form of compositions comprising: a water-soluble single-chamber container, such as a pouch; and a cleaning system comprising at least one detersive surfactant, and optionally one or more additional components. The invention also provides methods of production of such compositions, and methods use of such compositions in processes for cleaning dishware and/or fabrics, including garments, by introducing one or more of the unit dose products of the invention into an automatic washing machine suitable for washing dishware or laundry, whereby the cleaning system is released such that it comes into contact with a soiled article (e.g., dishware or fabrics) under conditions favoring the removal of one or more soils from the article.