Solid Fabric Softening Composition with Disintegrant System
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Solution Overview
Problem
Current solid fabric softening compositions, such as tablets, face challenges including undesirable interactions with laundry detergents during the washing step, poor mechanical stability, and residues left in the washing machine, which affect their effectiveness and user experience. Additionally, there is a need for more concentrated products with reduced environmental impact and improved dissolution behavior.
Innovation Solution
A solid fabric softening composition comprising 35-60% by weight of a disintegrant system and a quaternary ammonium compound with specific alkyl and alkenyl groups, along with an anionic counterion, which provides excellent softening benefits when applied during the washing step, maintaining mechanical stability and reducing residue issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fabric softener is applied during the washing step together with laundry detergent, then softening benefit can be achieved, but undesirable interactions occur between cationic softening active and anionic surfactants in the detergent
Solution Approach 1:
The patent extracts the cationic softening active from the washing step formulation, placing it only in the rinse step where no anionic surfactants are present. This eliminates the harmful chemical interactions while preserving the softening benefit, as the softening agent is applied after the washing cycle is complete.
Solution Approach 2:
The patent prepares the fabric surface during the washing step by removing oils and soils, creating a clean substrate. Then in the rinse step, the cationic softening active is applied to this pre-prepared surface, ensuring optimal adhesion and softening effect without interference from detergent components.
2Loss of substance
If solid fabric softening tablets are used, then packaging requirements and environmental impact are reduced, but mechanical stability and dissolution behavior become problematic
Solution Approach 1:
The patent modifies the physical and chemical parameters of the tablet formulation by incorporating specific disintegrants, binders, and surfactants in optimized ratios. These parameter changes enable the tablet to maintain mechanical integrity during storage and handling while ensuring complete dissolution and disintegration during the rinse cycle, releasing the softening active effectively.
Solution Approach 2:
The patent creates a composite tablet structure combining multiple functional materials: cationic softening actives, disintegrants (such as crosslinked polyacrylonitrile), binders, and surfactants. This composite formulation provides both the required mechanical stability for tablet handling and the necessary dissolution characteristics for effective softening performance.
3Productivity
If tablets dissolve completely during the wash sub-cycle, then fabric softening actives are released, but they may not survive until the rinsing step
Solution Approach 1:
The tablet is designed to remain intact during the washing sub-cycle, with its active ingredients protected within the matrix. The disintegrant system is triggered specifically during the rinse step, ensuring that the softening actives are released at the optimal time when they can effectively coat the fabric without being washed away or degraded during the vigorous washing phase.
Solution Approach 2:
The patent incorporates protective excipients and encapsulation strategies within the tablet matrix to cushion and protect the cationic softening actives during the harsh washing conditions. This preliminary protection ensures the actives survive the wash cycle intact and are only released when needed during the gentler rinse step.
4Loss of substance
If tablets are made more concentrated to reduce environmental impact, then packaging is reduced, but dissolution behavior and residue formation become more critical
Solution Approach 1:
The patent optimizes the concentration parameters of the active ingredients and excipients within the tablet. By carefully adjusting the ratio of cationic softening active to disintegrant and binder, the formulation achieves complete dissolution at higher concentrations without leaving residues. The improved solubility parameters ensure that even concentrated formulations dissolve fully during the rinse cycle.
Solution Approach 2:
The patent uses surfactants and solubilizing agents as intermediaries to facilitate the complete dissolution of concentrated softening actives. These intermediary substances help the highly concentrated active ingredients to dissolve uniformly and completely, preventing any undissolved residues from depositing on the fabric or in the washing machine.
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 composition effectively softens fabrics during the washing step, maintaining mechanical stability and reducing residue issues, while offering a more concentrated and environmentally friendly alternative to traditional liquid fabric softeners.
Implementation Method 1
a disintegrant system, wherein the disintegrant system comprises a combination of salt and acid
Implementation Method 2
Fabric softeners typically coat the surface of a fabric with substances that are electrically charged, causing threads to 'stand up' from the surface and thereby imparting a softer and fluffier texture
Data Source
AI summary
A solid fabric softening composition is disclosed comprising from 35 to 60% by weight of a disintegrant system and a quaternary ammonium compound having a structure represented by formula (I): (R1)(R2)N+(R3)(R4) A−, wherein each R1 and R2 is independently a C1 to C4 alkyl group or a C2 to C4 alkenyl group: each of R3 and R4 is independently a linear or branched C16 to C22 alkyl or alkenyl group: A− is an anionic counterion selected from a halide, alkyl sulfate and mixtures thereof; wherein the disintegrant system comprises a combination of salt and acid.