Unit Dose Product with Segmented Liquid and Solid Compartments
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Solution Overview
Problem
Existing laundry detergent compositions often cause skin and eye irritation due to harsh surfactants and allergenic solvents, and packaging in unit dose products poses challenges in maintaining effectiveness and mildness.
Innovation Solution
A unit dose product with a water-soluble film material containing a first compartment with a liquid composition of non-aqueous solvents and surfactants, and a second compartment with a solid surfactant, designed to limit swelling to no more than 30% in 24 hours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If harsh surfactants like linear alkylbenzene sulfonates are used, then cleaning efficacy is improved, but skin and eye irritation increases
Solution Approach 1:
The patent changes the chemical parameters of the surfactant system by using alcohol ethoxylates with specific ethoxylate values (AEV 5-30) and combining them with alcohol ethoxysulfates in controlled ratios. This parameter optimization maintains cleaning efficacy while reducing the harshness associated with traditional LAS surfactants, thereby lowering skin and eye irritation potential.
Solution Approach 2:
The patent creates a composite surfactant system combining multiple mild surfactants including alcohol ethoxylates, alcohol ethoxysulfates, and optionally amino acid surfactants or betaines. This composite approach provides synergistic cleaning action while the combined mildness of individual components reduces overall skin and eye irritation compared to single harsh surfactant systems.
2Ease of operation
If unit dose products are packaged, then convenience and reduced skin contact are improved, but formulation challenges increase
Solution Approach 1:
The patent segments the detergent formulation into distinct functional components: mild surfactants for cleaning, specific solvent systems for mildness and performance, and controlled amounts of additives. This segmentation allows each component to be optimized independently while maintaining overall compatibility, thereby reducing formulation complexity despite the constraints of unit dose packaging.
Solution Approach 2:
The patent adjusts critical formulation parameters including solvent to surfactant ratio (maintaining surfactant at ≥5%), specific solvent selections (polyethylene glycol, glycerin, propylene glycol), and surfactant concentration ranges. These parameter optimizations ensure the formulation remains stable and effective in unit dose packaging while minimizing skin contact risks.
3Productivity
If solvents like propylene glycol are included, then detergent performance is improved, but allergenic potential increases
Solution Approach 1:
The patent changes the solvent system parameters by limiting propylene glycol to ≤10% and incorporating alternative mild solvents like polyethylene glycol and glycerin in balanced ratios. This parameter adjustment maintains detergent performance through adequate solvent content while reducing the overall allergenic potential by minimizing propylene glycol exposure and incorporating less allergenic alternatives.
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 unit dose product effectively cleans textiles while maintaining mildness and minimizing allergenic compounds, with a low Zein score indicating reduced skin irritation potential.
Implementation Method 1
a water-soluble film material comprising a first compartment and a second compartment
Implementation Method 2
the percent swelling of the unit dose product is not more than about 30% in a 24 hr test
Data Source
AI summary
The present disclosure provides a unit dose product comprising a water-soluble film material comprising a first compartment and a second compartment. The first compartment encloses a liquid composition comprising about 35 wt % to about 70 wt % non-aqueous solvent and at least one surfactant. The second compartment encloses a solid composition comprising at least one solid surfactant, such as a methyl ester sulfonate. The percent swelling of the unit dose product is not more than about 30% in a 24 hr test. The liquid composition and/or solid composition can comprise additional components, such as a base, a performance polymer, an anti-redeposition agent, an enzyme, a bleaching agent, a bleach activator, a chelating agent, an optical brightener, a bitterant, a corrosion inhibitor, or any combination thereof. The detergent composition has improved mildness and reduced allergic components while maintaining integrity of the unit dose product.