Structured Detergent Particles Dry Neutralization Surfactant Content

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Solution Overview

Problem

Existing granular detergent compositions face challenges in achieving high surfactant activity and low moisture content while avoiding subsequent drying processes, often resulting in limited surfactant content and undesirable oversized particles.

Innovation Solution

The development of structured detergent particles comprising 35-50 wt% C10-C20 linear alkyl benzene sulphonate, 0.5-8 wt% hydrophilic silica, and 40-60 wt% water-soluble alkaline metal carbonate, formed through a dry neutralization process without subsequent drying, which allows for reduced moisture content and minimized oversized particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a liquid acid precursor (HLAS) is mixed with an aqueous solution of sodium hydroxide to form a neutralized LAS paste, then the surfactant content can be increased, but the water content becomes relatively high requiring subsequent drying

Engineering Contradiction:

Improvesurfactant contentVSAvoidwater content

Core Design Contradiction:

Quantity of substanceVSLoss of substance

Solution Approach 1:

The invention changes the physical state parameters of the reactants by using liquid HLAS and dry sodium carbonate particles instead of aqueous solutions, thereby eliminating the introduction of additional water into the system and avoiding the need for subsequent drying processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses dry powder ingredients as an intermediary medium to facilitate the neutralization reaction. The dry sodium carbonate particles provide a solid matrix for the reaction to occur, allowing the liquid HLAS to be neutralized without introducing excess water into the system

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of substance

If a dry neutralization process is used with sodium carbonate particles, then subsequent drying is eliminated, but the surfactant content is limited to no more than 30%

Engineering Contradiction:

Improvemoisture contentVSAvoidsurfactant content

Core Design Contradiction:

Loss of substanceVSQuantity of substance

Solution Approach 1:

The invention segments the neutralization process into two distinct stages: first, surface neutralization occurs on the outer surface of sodium carbonate particles during agglomeration; second, internal neutralization occurs within the particle structure after agglomeration is complete, allowing complete utilization of the sodium carbonate and achieving surfactant contents exceeding 30%

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention performs preliminary agglomeration with surface neutralization first, creating a structured particle framework, and then allows internal neutralization to occur subsequently, maximizing surfactant content without requiring additional drying steps

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If neutralization occurs only on the outer surface of sodium carbonate particles, then the dry neutralization process is simple, but a stoichiometrically excessive amount of sodium carbonate is required resulting in high sodium carbonate content and low surfactant activity

Engineering Contradiction:

Improveprocess simplicityVSAvoidsurfactant activity

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The invention divides the neutralization process into two phases: initial surface neutralization during agglomeration (maintaining process simplicity) and subsequent internal neutralization after agglomeration (maximizing surfactant content). This segmentation allows complete utilization of sodium carbonate particles while maintaining manufacturing simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention extends the neutralization action continuously from the outer surface into the interior of the particles after agglomeration, ensuring complete utilization of the sodium carbonate reactant and eliminating the need for stoichiometric excess, thereby maximizing surfactant activity

Inventive Principle:

Principle #20Continuity of useful action

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

This approach enables the creation of free-flowing detergent particles with enhanced surfactant activity and reduced moisture, eliminating the need for subsequent drying and minimizing oversized particles, thereby improving processing efficiency and product quality.

Implementation Method 1

a moisture content of from 0 wt% to about 3 wt%

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

Neutralization of HLAS occurs on the outer surface of the sodium carbonate particles, forming LAS and carbon dioxide gas with a small amount of water as by-products

Methodology Applied

Scientific EffectNeutralization reaction: Chemical Bonding

Data Source

PatentEP3194540B2Structured detergent particles and granular detergent compositions containing the same

Publication Date: 2023.01.25 PROCTER & GAMBLE CO

AI summary

A structured detergent particle with mid-level surfactant activity, which contains 35-50 wt% of a C 10-C 20 linear alkyl benzene sulphonate, 0.5-8 wt% of a hydrophilic silica, 40-60 wt% of a water-soluble alkaline metal carbonate, 0-5 wt% of a phosphate builder. Such structured detergent particles are free flowing with little or no moisture content, and are formed by a dry neutralization process without any subsequent drying.