Solid Fabric Softener Composition With High-Load Storage Stability
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Solution Overview
Problem
Developing a solid fabric softener composition that maintains performance comparable to liquid softeners, is environmentally friendly, and has an adequate dispense rate when sprayed with water at typical temperatures, while remaining stable during storage and transport.
Innovation Solution
A solid fabric softener formulation stabilized with a combination of a water-soluble organic salt and a medium to long chain carboxylic acid, allowing for up to 70% quaternary ammonium compound content, which provides stability and effective fabric softening similar to traditional liquid formulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If liquid fabric softener compositions are concentrated to reduce water content, then the amount of packaging material and shipping weight are reduced, but the viscosity increases and the composition may become unstable during storage
Solution Approach 1:
The patent changes the physical state parameter from liquid to solid by incorporating waxes (beeswax, paraffin wax, microcrystalline wax) and fatty alcohols. This phase transition allows the composition to maintain high concentration (low water content) while achieving storage stability through the solid matrix structure that prevents ingredient separation.
Solution Approach 2:
The invention creates a composite solid composition combining multiple components: cationic fabric softening agents (quaternary ammonium compounds), waxes (beeswax, paraffin wax, microcrystalline wax), fatty alcohols, and optional co-solvents. This composite structure provides both the concentration benefit and storage stability by distributing ingredients within a solid wax-based matrix.
2Quantity of substance
If solid fabric softener compositions are formulated with high quaternary ammonium compound content, then the active ingredient concentration is improved, but the composition may become unstable and separate during storage
Solution Approach 1:
The patent uses waxes (beeswax, paraffin wax, microcrystalline wax) and fatty alcohols as intermediary substances that form a solid matrix to hold and stabilize the quaternary ammonium compounds. These intermediaries prevent direct contact and potential separation of the high-concentration active ingredients while maintaining their effectiveness.
Solution Approach 2:
The invention changes the physical state of the composition from liquid to solid through the addition of waxes and fatty alcohols. This parameter change allows the formulation to accommodate high quaternary ammonium compound content (up to 70% or more) while preventing separation and maintaining stability during storage and transport.
3Ease of operation
If liquid fabric softener compositions are used to ensure easy handling and dispensing, then the ease of operation is improved, but the packaging material requirements and shipping weight increase significantly
Solution Approach 1:
The patent changes the physical state from liquid to solid, which fundamentally alters the packaging requirements. Solid compositions can be dispensed through dissolution in water during the rinse cycle, eliminating the need for large-volume liquid containers and reducing shipping weight while maintaining ease of use through automated dispensing systems.
Solution Approach 2:
The invention utilizes phase transition from solid to dissolved state during use. The solid composition is introduced into the rinse cycle where it dissolves in water to form the active softening solution, providing both the packaging efficiency of solids and the operational benefits of liquid dispensing.
4Loss of substance
If the fabric softener composition is formulated as a solid to reduce packaging and shipping requirements, then the packaging material and shipping weight are reduced, but the dispense rate when sprayed with water may become inadequate
Solution Approach 1:
The patent optimizes the solid composition's solubility parameters by selecting specific waxes and fatty alcohols that dissolve rapidly in warm rinse water. This parameter optimization ensures that despite the solid form, the composition achieves adequate dispense rates when introduced to the rinse cycle, balancing packaging efficiency with operational effectiveness.
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 achieves stable non-weeping solid formulations with high quaternary ammonium content, ensuring adequate dispense rates and comparable softening performance to liquid compositions, while being environmentally friendly and economically feasible.
Implementation Method 1
a water soluble organic salt and a medium to long chain carboxylic acid, which stabilizes the composition
Implementation Method 2
contacting a cast solid with a sufficient amount of water to dissolve at least a portion of the solid fabric softener composition
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.