Solid-Layered Bleach Composition Resolving Residue and Malodor

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Solution Overview

Problem

Existing solid bleach compositions face issues such as residue formation, malodor generation, and stability problems due to the use of calcium hypochlorite and chlorinated hydantoins, and they often require coating or encapsulation to enhance stability, which increases costs and complexity.

Innovation Solution

A solid-layered bleach composition comprising two parts: the first part contains calcium hypochlorite and a builder, and the second part includes functional ingredients like surfactants and odor absorbents, without sodium hypochlorite or other oxidants, allowing for faster dissolution and improved performance without coatings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If calcium hypochlorite is used in solid bleach compositions, then cost and effectiveness are improved, but residue formation and malodor generation occur

Engineering Contradiction:
ImprovecostVSAvoidresidue formation
Core Design Contradiction:
Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The bleach composition is divided into multiple solid layers, with calcium hypochlorite confined to specific layers (e.g., first and third layers) separated from functional ingredients like surfactants and odor absorbents in intermediate layers. This segmentation prevents direct contact between calcium hypochlorite and ingredients that would otherwise react or interfere, eliminating residue formation while maintaining cost-effectiveness.

Inventive Principle:
Principle #1Segmentation

2Ease of manufacture

If calcium hypochlorite is used in solid bleach compositions, then cost and effectiveness are improved, but malodor generation occurs

Engineering Contradiction:
ImprovecostVSAvoidmalodor generation
Core Design Contradiction:
Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

An intermediate layer containing odor absorbent ingredients (such as activated carbon, zeolite, or clay) is positioned between the calcium hypochlorite-containing layers and other functional ingredients. This intermediary layer absorbs and traps malodors generated by calcium hypochlorite, preventing them from escaping while allowing the calcium hypochlorite to maintain its cost-effective cleaning performance.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Reliability

If functional ingredients are coated or encapsulated to improve stability, then shelf-life is improved, but cost and complexity increase

Engineering Contradiction:
Improveshelf-lifeVSAvoidcomplexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

Instead of coating or encapsulating individual ingredients, the composition uses a multi-layer solid structure where different ingredients are segregated into distinct layers. This segmentation provides inherent stability and shelf-life without requiring additional coating materials or encapsulation processes, thereby reducing complexity while maintaining reliability.

Inventive Principle:
Principle #1Segmentation

4Reliability

If functional ingredients are coated or encapsulated to improve stability, then shelf-life is improved, but dissolution time increases

Engineering Contradiction:
Improveshelf-lifeVSAvoiddissolution time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The solid-layered structure allows each layer to dissolve independently and rapidly when contacted with water or moisture. The segmented architecture eliminates the need for coating or encapsulation materials that would slow dissolution, enabling fast release of active ingredients while maintaining shelf-life through physical separation of unstable components.

Inventive Principle:
Principle #1Segmentation

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 overcomes residue and malodor issues, providing faster bleach release and improved stability without the need for coatings, enhancing its effectiveness and cost-efficiency.

Implementation Method 1

calcium hypochlorite...releases bleach faster than the typical use of halogenated hydantoins

Methodology Applied
Scientific EffectHydrolysis: Hydrolysis

Implementation Method 2

a water-soluble polymer selected from the group consisting of a polycarboxylate, sulfonated carboxylate, polysulfonate, polyvinylpyrrolidone, polyquaternary ammonium salts, copolymers and mixtures thereof

Methodology Applied
Scientific EffectSolvation: Solvation

Implementation Method 3

the second part includes functional ingredients like surfactants and odor absorbents

Methodology Applied
Scientific EffectAdsorption: Adsorption

Data Source

PatentUS8481471B2Method of using solid-layered bleach compositions
Publication Date: 2013.07.09 THE CLOROX CO

AI summary

The present invention provides a solid-layered composition having at least two parts. The first part comprises a) calcium hypochlorite, magnesium hypochlorite and mixtures thereof, b) a builder, c) a water-soluble polymer, d) an acid, and e) wherein the first part does not contain sodium hypochlorite, lithium hypochlorite, potassium hypochlorite and mixtures thereof. The second part comprises a) a functional ingredient, b) a builder or filler, and c) wherein the second part does not contain any oxidant.