Solid concentrated fabric softener composition
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Solution Overview
Problem
Developing a solid fabric softener composition that is environmentally friendly, stable, and has a high active content comparable to traditional liquid softeners, while maintaining an adequate dispense rate when sprayed with water during the rinse cycle, and not melting or separating during storage and transport temperatures.
Innovation Solution
A solid fabric softener composition is formulated using a combination of a cationic quaternary ammonium compound, medium to long chain carboxylic acid, and a water-soluble organic salt, with the carboxylic acid added to help solidify the formulation and reduce dispense rates, allowing for up to 70% quaternary ammonium compound content, and additional components like acidulants, salts, and silicones for stability and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If liquid fabric softener composition is used, then ease of dispensing and measurement is improved, but water content is high (90-95%) requiring large packaging and shipping weight
Solution Approach 1:
The patent transitions the fabric softener composition from liquid phase to solid phase by incorporating waxy esters and fatty alcohols. This phase transition reduces water content from 90-95% to approximately 72-80%, while maintaining dispensability through controlled melting at rinse cycle temperatures
Solution Approach 2:
The patent changes physical parameters of the composition by adjusting the ratio of waxy esters to fatty alcohols and controlling the melting point range. This allows the composition to remain solid at storage temperatures but become sufficiently fluid at rinse cycle temperatures for proper dispensing
2Quantity of substance
If concentrated fabric softener is produced to reduce water content, then environmental impact is improved and packaging is reduced, but the composition may become unstable and separate
Solution Approach 1:
The patent creates a composite material system combining waxy esters, fatty alcohols, and cationic fabric softening agents in specific ratios. This composite structure provides mutual stabilization where the waxy matrix prevents separation of the cationic active ingredients while maintaining concentration up to 20-40%
Solution Approach 2:
The patent uses fatty alcohols and waxy esters as intermediary substances that mediate between the cationic fabric softening agents and water. These intermediaries prevent direct interaction that would cause separation, while allowing controlled release during the rinse cycle
3Quantity of substance
If solid fabric softener composition is used, then packaging and shipping weight are reduced, but dispense rate may become inadequate
Solution Approach 1:
The patent creates a dynamic system where the physical state of the fabric softener changes from solid at storage to semi-fluid at use. The composition is formulated to melt within a specific temperature range (40-60°C) corresponding to rinse cycle temperatures, optimizing dispense rate at the moment of application
Solution Approach 2:
The patent performs preliminary heating of the composition during the rinse cycle before dispensing. The rinse water temperature pre-heats the solid composition, initiating melting and fluidization in advance of the actual dispensing operation, ensuring adequate flow rate
4Object-affected harmful factors
If biodegradable cationic quaternary ammonium compounds are used, then environmental friendliness is improved, but the composition requires stabilization to prevent melting and separation
Solution Approach 1:
The patent uses biodegradable cationic quaternary ammonium compounds with ester linkages that are designed to break down during washing and subsequent environmental processes. These compounds provide the necessary fabric softening function while being environmentally disposable, compensated for by the stabilizing waxy matrix
Solution Approach 2:
The patent employs waxy esters and fatty alcohols as intermediary stabilizing agents that protect the biodegradable cationic compounds from premature melting or separation. These intermediaries form a stable matrix that maintains structural integrity during storage while allowing controlled release during use
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 formulation provides fabric softening performance comparable to traditional liquid compositions, remains stable at typical storage temperatures, and ensures an adequate dispense rate during the rinse cycle, making it environmentally friendly and economically feasible.
Implementation Method 1
the carboxylic acid added to help solidify the formulation
Implementation Method 2
Fabric softener compositions are commonly used to deposit a fabric softening compound onto fabric
Data Source
AI summary
A solid fabric softening composition is disclosed which includes a quaternary ammonium fabric softening compound which is stabilized to form a solid with a mixture of a water soluble organic salt and a medium to long chain carboxylic acid. This stabilizing combination has been shown to effectively form a solid quaternary ammonium based fabric softening composition with up to as much as 70% by weight of quaternary ammonium compound. The formulations are stable at typical storage temperatures of up to 110° F. and provide fabric softening similar to and even superior to other traditional liquid formulations.