Solid Cleaning Composition Vibration Pressing Method

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Solution Overview

Problem

Conventional methods for producing solid cleaning compositions, such as those used in institutional and industrial settings, require high-pressure equipment, energy-intensive melting processes, or complex extrusion techniques, which are costly and can damage sensitive ingredients.

Innovation Solution

A method involving a flowable solid composition of water, an alkalinity source, and a sequestrant, which is vibrated and gently pressed to form a stable solid without the need for high-pressure equipment, using a concrete block machine or turntable press, allowing for ambient temperature processing and avoiding the destruction of desirable ingredients.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If high-pressure tablet press is used to make solid cleaning compositions, then manufacturing precision and density are improved, but equipment cost and complexity increase

Engineering Contradiction:

Improvesolid composition densityVSAvoidequipment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the high-pressure mechanical tablet press system with a low-pressure system that uses chemical binding agents (such as starch, gelatin, or synthetic polymers) to bind cleaning composition particles together. The binding agent forms a matrix that holds particles together through adhesion, eliminating the need for high-pressure mechanical compression while achieving sufficient structural integrity for solid block or tablet forms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If melting process is used to cast solid cleaning compositions, then manufacturing flexibility is improved, but energy consumption increases and ingredient integrity deteriorates

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidenergy consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the processing parameters from high-temperature melting to ambient or low-temperature processing. Instead of heating the cleaning composition to a molten state for casting, the invention uses binding agents that allow particles to adhere together at or near room temperature, forming solid structures through evaporation of solvent or chemical curing rather than phase change from melting.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If extrusion process is used to make solid cleaning compositions, then production efficiency is improved, but equipment cost and technical complexity increase

Engineering Contradiction:

Improveproduction efficiencyVSAvoidequipment complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the solid cleaning composition into discrete particles or granules that are then bound together using binding agents. This segmented approach allows the composition to be formed into solid blocks or tablets through aggregation of particles rather than continuous extrusion, simplifying the equipment needed while maintaining production efficiency through batch or continuous mixing and binding processes.

Inventive Principle:

Principle #1Segmentation

4Manufacturing precision

If conventional tableting press is used, then manufacturing precision is improved, but product size flexibility deteriorates

Engineering Contradiction:

Improvetablet dimensional precisionVSAvoidproduct size flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent creates a universal binding agent system that can form solid cleaning compositions in multiple sizes and shapes (blocks, tablets, pucks, custom forms) using the same basic process. The binding agent methodology is adaptable to various mold types and scales, allowing the same chemical binding approach to produce anything from small single-serving tablets to large institutional-sized cleaning blocks, unlike tableting presses that are optimized for specific size ranges.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This method enables the production of stable solid cleaning compositions at ambient temperature, reducing energy consumption and equipment costs while preserving the integrity of ingredients, and allows for the creation of larger solid forms not feasible with conventional tableting presses.

Implementation Method 1

vibrating the flowable solid in the drawer or hopper

Methodology Applied

Scientific EffectVibration: Vibration

Implementation Method 2

gently pressing the flowable solid in the form to produce the uncured solid cleaning composition

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentEP3050949B1Pressed, self-solidifying, solid cleaning compositions and methods of making them

Publication Date: 2020.05.27 ECOLAB USA INC

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AI summary

The present invention relates to a method of making a solid cleaning composition. The method can include pressing and/or vibrating a flowable solid of a self-solidifying cleaning composition. For a self-solidifying cleaning composition, pressing and/or vibrating a flowable solid determines the shape and density of the solid but is not required for forming a solid. The method can employ a concrete block machine for pressing and/or vibrating. The present invention also relates to a solid cleaning composition made by the method and to solid cleaning compositions including particles bound together by a binding agent.