Surfactant Concentrate Viscosity Control via Carboxylic Acid
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Detergent manufacturers face challenges in creating compact, low-water surfactant concentrates that maintain stability and pumpability, especially when formulating liquid compositions for unit doses in water-soluble pouches, as traditional methods often result in high viscosity and instability of anionic sulphated surfactants.
Innovation Solution
A surfactant concentrate comprising at least 75% completely neutralized anionic sulphated surfactant and 5-25% carboxylic acid, with 4-96% of the carboxylic acid in its free acid form, which stabilizes the surfactant and lowers viscosity, allowing for efficient processing and storage without water, and a continuous process for its production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If water is used to control the viscosity of the surfactant concentrate, then the concentrate becomes processable and pumpable, but the water content increases which contradicts the goal of creating compact, low-water formulae
Solution Approach 1:
The invention changes the chemical composition parameters by incorporating specific co-surfactants (nonionic surfactants with ethoxylate chains) and buffers (carbonate/bicarbonate systems) to modify the physical properties of the concentrate. This allows achieving pumpable viscosity (1-100 cP) without adding water, as the co-surfactants interact with the anionic surfactant to reduce intermolecular forces and lower viscosity.
Solution Approach 2:
The invention creates a composite surfactant system combining anionic surfactants (sulphated surfactants) with nonionic co-surfactants (alkoxylated alcohols or ethoxylated nonionic surfactants) and buffer salts. This composite formulation achieves synergistic effects where the nonionic components reduce viscosity and the buffers stabilize pH, enabling water-free processing while maintaining concentrate stability and pumpability.
2Reliability
If the concentrate is formulated with high anionic surfactant content for effectiveness, then cleaning performance improves, but viscosity increases making the concentrate difficult to process and pump
Solution Approach 1:
The invention modifies the molecular parameters by introducing co-surfactants with specific ethoxylate chain lengths (n=1-15) that interact with the anionic surfactant molecules. These co-surfactants reduce the hydrophobic interactions between anionic surfactant tails, thereby lowering viscosity while maintaining the high anionic surfactant content (60-90% w/w) needed for effective cleaning performance.
Solution Approach 2:
The composite formulation combines anionic surfactants with nonionic co-surfactants in specific ratios (co-surfactant 5-40% w/w) to create a synergistic system. The nonionic components act as spacing agents that prevent excessive aggregation of anionic surfactant molecules, reducing viscosity while preserving the high surfactant concentration required for cleaning effectiveness.
3Duration of action of stationary object
If the surfactant concentrate is stored for extended periods or exposed to varying temperatures, then distribution and shelf life requirements are met, but the anionic sulphated surfactant becomes unstable and disintegrates into degradation products
Solution Approach 1:
The invention creates a chemically stable environment by incorporating buffer systems (carbonate/bicarbonate salts) that maintain pH within 6.0-8.0, and by using nonionic co-surfactants that form steric barriers around the anionic surfactant molecules. This protective environment prevents hydrolysis and other degradation reactions, ensuring surfactant stability during extended storage and temperature variations.
Solution Approach 2:
The formulation includes buffer salts (sodium carbonate, potassium bicarbonate) and co-surfactants that preemptively protect the anionic surfactant from degradation. These components create a stable chemical environment that cushions against pH shifts and thermal stress before degradation can occur, preventing disintegration during storage and distribution.
4Quantity of substance
If the concentrate is highly concentrated to reduce packaging and shipping volume, then compact formula goals are achieved, but the viscosity becomes too high for effective processing and pumping
Solution Approach 1:
The invention changes the molecular interaction parameters by introducing co-surfactants with ethoxylate chains that reduce the cohesive forces between surfactant molecules. This allows achieving high concentrate concentrations (90-95% w/w active ingredients) while maintaining low viscosity (1-100 cP) through reduced intermolecular attraction, enabling both compact formulation and easy processing.
Solution Approach 2:
The composite system combines anionic surfactants with nonionic co-surfactants that act as molecular spacers. These co-surfactants prevent excessive molecular packing and aggregation at high concentrations, maintaining fluidity and pumpability even in highly concentrated formulations (90-95% w/w), thus achieving compact packaging without sacrificing processability.
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 provides a stable and pumpable surfactant concentrate that reduces water content, enhances formula flexibility, and minimizes environmental impact, while maintaining performance and stability over time and varying temperatures.
Implementation Method 1
5% to 25% carboxylic acid, of which 4% to 96% of the carboxylic acid is in its free acid form... stabilizes the surfactant and lowers viscosity
Data Source
AI summary
The present relates to a surfactant concentrate comprising at least 75% of an essentially completely neutralized anionic sulphated surfactant and 5% to 25% carboxylic acid, of which 4% to 96% of the carboxylic acid is in its free acid form, the process for making it and a detergent composition containing it.