Solid Soil Release Polymer Composition for Polyester Stain Removal
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Solution Overview
Problem
Current laundry processes face challenges in removing residual alkalinity and oily stains from synthetic fabrics, particularly polyester, due to the instability of soil release polymers in alkaline and acidic environments, and the need for environmentally friendly and sustainable solutions.
Innovation Solution
A physically and chemically stable solid composition combining a soil release polymer and an acidulant is developed, which can be used in a post-wash step to neutralize alkalinity and remove oily stains, formulated to remain stable during aqueous dispensing and formed through processes like melting, casting, or pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If soil release polymer is used in liquid sour treatment, then oily stain removal is improved, but chemical stability deteriorates due to reaction with acid or oxidizer
Solution Approach 1:
The patent extracts the soil release polymer from the liquid sour treatment environment and places it in a solid detergent composition instead. This separation allows the polymer to remain stable during storage while still providing oily stain removal functionality when the detergent is used, resolving the contradiction between effectiveness and stability.
Solution Approach 2:
The patent changes the physical state parameter of the detergent composition from liquid to solid form. This parameter change creates a stable environment for the soil release polymer during storage, preventing chemical reactions with acid or oxidizer, while still allowing the polymer to function effectively for oily stain removal during the wash cycle.
2Ease of manufacture
If soil release polymer is used in final rinse step, then oily stain removal is improved, but polymer stability deteriorates in acidic environment
Solution Approach 1:
The patent extracts the soil release polymer from the acidic liquid sour environment and incorporates it into a solid detergent composition. This extraction protects the polymer from degradation during storage while maintaining its effectiveness for oily stain removal during the wash cycle.
Solution Approach 2:
The patent creates a composite solid detergent composition that combines the soil release polymer with other detergent ingredients in a stable matrix. This composite structure protects the polymer from chemical reactions during storage while allowing it to function effectively when the detergent is dissolved and applied to fabrics.
3Stability of the object's composition
If solid composition is formed through melting, casting, or pressing, then physical stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes phase transitions (melting and solidification) to form the solid detergent composition. By controlling the phase change of the composition during manufacturing, the patent achieves physical stability in the final product while using a relatively simple manufacturing process that doesn't require complex equipment or multiple steps.
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 solid composition effectively removes residual alkalinity and oily stains from synthetic fabrics, with the soil release polymer showing superior performance when used in the final rinse step, maintaining stability and increasing removal efficiency over multiple wash cycles.
Implementation Method 1
Synthetic fibers, (fabrics having synthetic fibers incorporated therein or made entirely of synthetic fibers), are hydrophobic and oleophilic. As such the oleophilic characteristics of the fiber permit oil and grime to be readily embedded in the fiber, and the hydrophobic properties of the fiber prevent water from entering the fiber to remove the contaminants from the fiber.
Implementation Method 2
The polymers work by having both hydrophobic and hydrophilic blocks that allow them to adhere to the polyester surface and make it more hydrophilic. By making the surface more hydrophilic the affinity of oily soils, like dirty motor oil, with polyester is reduced which makes the soil easier to remove.
Implementation Method 3
Sour materials contain acid components that neutralize alkaline residues on the fabric.
Data Source
AI summary
Applicants have developed a physically and chemically stable solid composition containing a soil release polymer and an acidulant. The sour step thus accomplishes both stain removal and residual alkalinity removal. A novel method of using a soil release polymer and an acidulant together in the same post wash step of a laundry wash process is also disclosed. The solid composition is physically stable, even during aqueous dispensing, i.e. non-slumping and non-weeping. The solid could be formed through a melt, cast, or pressed process.