CA2070001A1 - Linear viscoelastic aqueous liquid automatic dishwasher detergent composition - Google Patents

Abstract

LINEAR VISCOELASTIC AQUEOUS LIQUID
AUTOMATIC DISHWASHER DETERGENT COMPOSITION
ABSTRACT OF THE DISCLOSURE

Automatic dishwasher detergent composition is formulated as a linear viscoelastic, pseudoplastic, gel-like aqueous product of exceptionally good physical stability, low bottle residue, low cup leakage, and improved cleaning performance as well as the composition not substantially adhering to or wetting the interior surface of a polyolefinic bottle. Linear viscoelasticity and pseudoplastic behavior is attributed by incorporation of at least one cross-linked high molecular weight polyacrylic acid type thickener. Potassium to sodium weight ratios of at least 1/1 minimize amount of undissolved solid particles further contribute to the stability and pourability or the composition. Control of incorporated air bubbles functions to provide the product with a bulk density of 1.32 to 1.40 g/cc which roughly corresponds to the density of the liquid phase. Stearic acid or other fatty acid or salt further improve physical stability.

Description

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LINEAR VISCOELASTIC AQUEOUS
~IQUID AUTOMATIC DISHWASHER
DETERGENT COMPOSITION

Backqround of the Invention Liquid automatic dishwasher detergent compositions, both aqueous and nonaqueous, ha~e recently received much attention, and the aqueous products have achieved commercial popularity.
The acceptance and popularity of the liquid formulations as compared to the more conventional powder products stems from the convenience and performance of the liquid products.
However, even the best of the currently available li~uid formulations still suffer from two major problems, product phase instability and bottle residue, and to some extent cup leakage from the dispenser cup of the automatic dishwashing machine.
Representative of the relevant patent art in this area, mention i9 made of Rek, U.S. Patent 4,556,504; Bush, et al., U.S. Patent 4,226,736; Ulrich, U.S. Patent 4,431,559;
Sabatelli, U.S. Patent 4,147,650; Paucot, U.S. Patent 4,07g,015; ~eikhem, U.S. Patent 4,116,849; Milora, U.S. Patent 4,521,332; ~ones, U.S. Patent 4,597,889; Heile, U.S. Patent 4,512,908; Laitem, U.S. Patent 4,753,748; Sabatelli, U.S.
Patent 3,579,455; Hynam, U.S. Patent 3,684,722: other patents relating to thickened detergent compositions include U.S.
Patent 3,9a5,668; U.K. Patent Applications GB 2,116,199A and GB 240,450A; U.S. Patent 4,511,487; U.S. Patent 4,752,409 (Drapier, et al.); U.S. Patent 4,801,395 (Drapier, et al.);

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U.S. Patent 4,801,395 (Drapier, et al.). Commonly assigned co-pending patents include, for example, Serial No. 204,476 filed ~une 9, 1988; Seriai No. 92~,385, filed October 29, 1986; Serial No. 323,138, filed March 13~ 1989; Serial No.
087,836, filed August 21, 1987; Serial No. 328,716, filed March 27, 1989; Serial No. 323,137, filed March 13, 1989;
Serial No. 323,134, filed March 13, 1989.
The present invention provides a solution to the above problems.
~rief_Description of the Drawings Figures 1-13 are rheograms, plotting elastic modules G' and viscous modulus G" as a function of applied strain, for the compositions of Example 1, Formulations A, C, D, G, ~, H, I and K, Example 2, A and B, Example 3, L and M and Comparative Example 1, respectively.

Summary of the Invention According to the present invention there is provided a novel aqueous liquid automatic dishwasher detergent composition. The composition is characterized by its linear viscoelastic behavior, substantially indefinite stability against phase separation or settling of dissolved or suspended particles, low levels of bottle residue, relatively high bulk density, substantial absence of unbound or free water, and that the composition will not adhere onto the interior surface of a polyolefinic bottle. This unique combination of properties is achieved by virtue of the incorporation into the ~rl~D~3~.
aqueous mixture of dishwashing detergent surfactant, alkali metal deteryent builder salt(s) and chlorine bleach compound, a small but effective amount of a polymeric thickening agent such aæ a high molecular weight cross-linked polyacrylic acid type thickening agent, a physical stabilizing amount of a long chain fatty acid or salt thereof, and a source of potassium ions to provide a potassium/sodium weight ratio in the range of from 1:1 to 45:1, such that substantially all of the detergent builder salts and other no~mally solid detergent additives present in the composition are present dissolved in the aqueous phase. The compositions are further characterized by a bulk density of at least 1.28 g/cc, such that the density of the polymeric phase and the density of the aqueous (continuous) phase are approximately the same.
Detailed Description of the Preferred Embodiments The compositions of this invention are aqueous liquids containing various cleansing active ingredients, detergent adjuvants, structuring and thickening agents and stabilizing components, although some ingredients may serve more than one of these functions.
The advantageous characteristics of the compositions of this invention, including physical stability, low bottle residue, high cleaning performance, e.g. low spotting and filming, dirt residue removal, and so on, and superior aesthetics, are believed to be attributed to several interrelated factors such as low solids, i.e. undissolved particulate content, product density and linear viscoelastic rheology as well as a means for preventing the composition from wetting and adhering to the interior surface of a polyolefinic bottle. These factors are, in turn, dependent on several critical compositional components of the formulations, namely, (1) the inclusion of a thickening effective amount of polymeric thickening agent having high water absorption capacity, exemplified by high molecular weight cross-linked polyacrylic acid, (2) inclusion of a physical stabilizing amount of a long chain fatty acid or salt thereof, (3) potassium ion to sodium ion weight ratio K/Na in the range oE
from 1:1 to ~5:1, especially from 1:1 to 3:1, and (4) a product bulk density of at least 1.28 g/cc, such that the bulk density and liquid phase density are the same.
The polymeric thickening agents contribute to the linear viscoelastic rheology of the invention compositions. As used herein, "linear viscoelastic "or" linear viscoelasticity"
means that the elastic (storage) moduli (G') and the viscous (109s) moduli (G") are both substantially independent of strain, at least in an applied strain range of from 0-50%, and preferably over an applied strain range of from 0-80~. More specifically, a composition is considered to be linear viscoelastic for purposes of this invention, if over the strain range of 0-50~ the elastic moduli G' has a minimum value of 100 dynes/sq.cm., preferably at least 250 dynes/sq.cm., and varies less than 500 dynes/sq.cm, preferably less than 300 dynes/sq.cm., especially preferably less than 100 dynes/sq.cm. Preferably, the minimum value of G' and maximum variation of G' applies over the strain range ~7~
o~ 0 to 80~. Typically, the variation ln loss moduli G" will be less than that of G'. As a further characteristic of the preferred linear viscoelastic compositions the ratio of G"/G
(tanS) is less than 1, preferably less than 0.8, hut more than 0.05, preferably more than 0.2, at least over the strain range of 0 to 50%, and preferably over the strain range of 0 to 80%.
It should be noted in this regard that ~ strain is shear strain xlO0.
By way of further explanation, the elastic (storage) modulus G' is a measure of the energy stored and retrieved when a strain is applied to the composition while viscous (loss) modulus G" is a measure to the amount of energy dissipated as heat when strain is applied~ Therefore, a value of tan ~
O.OSc tan S ~1, preferably 0.2 ~ tan ~ 0.8 means that the compositions will retain sufficient energy when a stress or strain is applied, at least over the extent expected to be encountered for products of this type, for example, when poured from or shaken in the bottle, or stored in the dishwasher detergent dispenser cup of an automatic dishwashing machine, to return to its previous condition when the stress or strain is removed. The compositions with tan values in these ranges, therefore, will also have a high cohesive property, namely, when a shear or strain is applied to a portion of the composition to cause it to flow, the surrounding portions will follow. As a result of this cohesiveness of the subject linear viscoelastic compositions, the compositions will readily flow uniformly and homogeneously from a bottle when the bottle is tilted, thereby contributing to the physical (phase) stability of the formulation and the low bottle residue (low product loss in the bottle) which characterizes the invention compositions. The linear viscoelastic property also contributes to improved physical stability against phase separation of any undissolved suspended particles by providing a resistance to movement of the particles due to the strain exerted by a particle on the surrounding fluid medium.
Also contributing to the physical stability and low bottle residue of the invention compositions is the high potassium to sodium ion ratios in the range of 1:1 to 45:1, preferably 1:1 to 4:1, especially preferably from 1.05:1 to 3:1, for example 1.1:1, 1.2:1, 1.5:1, 2:1, or 2.5:1. At these ratios the solubility of the solid salt components, such as detergent builder salts, bleach, alkali metal silicates, and the like, is substantially increased since the presence of the potassium (K~) ions requires less water of hydration than the sodium (Na+) ions, such that more water is available to dissolve these salt compounds. Therefore, all or nearly all of the normally solid components are present dissolved in the aqueous phase. Since there is none or only a very low percentage, i.e. less than 5~, preferably less than 3~ by weight, of ~uspended solids present in the formulation there is no or only reduced tendency for undissolved particles to settle out of the compositions causing, for example, formation 2 ~ g ~
of hard masses of particles, which could result in high bot~le residues (i.e. 105s oE product). Furthermore, any undissolved solids tend to be present in extremely small particle sizes, usually colloidal or sub-colloidal, such as 1 micron or less, thereby further reducing the tendency for the undissolved particles to settle.
A still further attribute of the lnvention compositions contributing to the overall product stability and low bottle residue is the high water absorption capacity of the cross-linked polyacrylic acid type thickening agent. As a result of this high water absorption capacity virtual].y all of the aqueous vehicle component is held tightly bound to the polymer matrix. Therefore, there is no or substantially no free water present in the invention compositions. This absence of free water (as well as the cohesiveness of the composition) i9 manifested by the observation that when the composition i9 poured from a bottle onto a piece of water absorbent filter paper virtually no water i9 absorbed onto the filter paper and, furthermore, the mass of the linear viscoelastic material poured onto the filter paper will retain its shape and structure until i~ i9 again subjected to a stress or strain.
As a result of the absence of unbound or free water, there is virtually no phase separation between the aqueous pha~e and the polymeric matrix or dissolved solid particles. This characteristic is maniEested by the fact that when the subject compositions are subjected to centrifugation, e.g. at 1000 rpm for 30 minutes, there is no phase separation and the composition remains homogeneous.

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However, it has also been discovered that linear viscoelasticity and K/Na ratios in the above-mentione~ range do not, by themselves, assure long term physical stability (as determined by phase separation). In order to ma~imize physical (phase) stability, the den~ity of the composition should be controlled such that the bulk density of the liquid phase is approximately the same as the bulk density of the entire composition, including the polymeric thickening agent.
This control and equalization of the densities is achieved, according to the invention, by providing the composition with a bulk density of at least 1.28 g/cc, preferably at least 1.32 g/cc, up to 1.42 g/cc, preferably up to 1.~0 g/cc.
Furthermore, to achieve these relatively high bulk densities, it i9 important to minimize the amount of air incorporated into the composition (a density of 1.42 g/cc is essentially equivalent to zero air content).
It has previously been found in connection with other types of thickened aqueous liquid, automatic dishwasher detergent compositions that incorporation of finely divided air bubbles in amounts up to 8 to 10~ by volume can function effectively to stabili~e the composition against phase separation, but that to prevent agglomeration of or escape of the air bubbles it was important to incorporate certain surface active ingredients, especially higher fatty acids and the salts thereof, such as stearic acid, behenic acid, palmitic acid, sodium stearate, aluminum stearate, and the like. These surface active agents apparently functioned by forming an interfacial film at the bubble surface while also forming hydrogen bonds or contributing to the electrostatic attraction with the suspended particles, such that the air bubbles and attracted particles formed agglomerates of approximately the same density as the density of the continuous liquid phase.
Therefore, in a preferred embodiment of the present invention, stabilization of air bubbles which may become incorporated into the compositions during normal processing, such as during various mixing steps, is avoided by post-adding the surface active ingredients, including Eatty acid or fatty acid salt stabilizer, to the remainder of the composition, under low shear condition~ using mixing devices designed to minimize cavitation and vortex formation.
As will be described in greater detail below the surface active ingredients present in the composition will include the main detergent surface active cleaning agent, and will also preferably include anti-foaming agent and higher fatty acid or salt thereof as a physical stabilizer.
Exemplary of the cross-linked polyacrylic acid-type thickening agents are the products sold by B.F. Goodrich under their Carbopol trademark, especially Carbopol 941, which is the most ion-insensitive of this class of polymers, and Carbopol 940 and Carbopol 934. The Carbopol resins, al90 known as "Carbomer", are hydrophilic high molecular weight, cross-linked acrylic acid polymers having an average equivalent weight of 76, and the general structure illustrated by the following formula:

2~7 f H

H0-'-' ~ 0 n.

Carbopol 941 has a molecular weight of 1,250,000; Carbopol 940 a molecular weight of approximately ~,000,000 and Carbopol 934 a molecular weight of approximately 3,000,000. The Carbopol resins are cross-linked with polyalkenyl polyether, e.~ of a polyallyl ether of sucrose having an average of 5.8 allyl groups for each molecule of sucrose. Further detailed information on the Carbopol resins is available from ~.F. Goodrich, see, for example, the ~.F. Goodrich catalog GC-67, Carbopol~ Water Soluble Resins.
While most favorable results have been achieved with Carbopol 941 polyacrylic resin, other lightly cross-linked polyacrylic acid-type thickening agents can also be used in the compositions of this invention. As used herein "polyacrylic acid-type" refers to water-soluble homopolymers of acrylic acid or methacrylic acid or water-dispersible or water-soluble salts, esters or amides thereof, or water-soluble copolymers of these acids of their salts, esters or ameides with each other or with one or more other etylenically unsaturated monomers, such as, for example, styrene, maleic acid, maleic anhydride, 2-hydroxyethylacrylate, acrylonitrile, vinyl acetate, ethylene, propylene, and the like.
The homopolymers or copolymers are characterized by their high molecular weight, in the range of from 500,000 to 10,000,000, preferably 500,000 to 5,000,000, especially from ' '' , .

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1,000,300 to ~,ooo,ooo, and by their water solubility, generally at least to an extent o~ up to 5~ by weight, or more, in water at 25C.
These thickeniny agents are used in their lightly cross-linked form wherein the cross-llnking may be accompli~hed by means known in the polymer arts, as by irradiation, or, preferably, by the incorporation into the monomer mixture to be polymeri~ed of known chemical cross-linking monomeric agents, typically polyunsaturated (e.g. diethylenically unsaturated) monomers, such as, for example, divinylbenzene, divinylether of diethylene glycol, N, N'-methylene-bisacrylamide, polyalkenylpolyethers (such as described above), and the like. Typically, amounts of cross-linking agent to be i.ncorporated in the final polymer ma~ range from 0.01 to 1.5 percent, preferably from 0.05 to 1.2 percent, and especially, pre~erably from 0.1 to 0.9 percent, by weight of cross-linking agent to weight of total polymer.
Generally, those skilled in the art will recognize that the degree of cross-linking should be sufficient to impart some coiling of the otherwise generally linear polymeric compound while maintaining the cross-linked polymer at least water dispersible and highly water-swellable in an ion.ic aqueous medium. It is also understood that the water-swelling of the polymer which provides the desired thickening and viscous properties generally depends on one or two mechanisms, namely, conversion of the acid group containing polymers to the corresponding salts, e.g. sodium, generating negative charges along the polymer backbone, thereby causing the coiled 2 ~ rll ;~

molecules to expand and thicken the aqueous solution; or by formation of hydrogen bonds, for example, between the carboxyl groups of the polymer and hydroxyl donor. The former mechanism is especially important in the present invention, S and therefore, the preferred polyacrylic acid-type thickening agents will contain free carboxylic acid (COOH) groups along the polymer backbone. Also, it will be understood that the degree of cross-linking should not be so high as to render the cross-linked polymer completely inso:Luble or non-dispersible in water or inhiblt or prevent the uncoiling of the polymer molecules in the presence of the ionic aqueous system.
The amount of at least one high molecular weight, cross-linked polyacrylic acid or other high molecular weight, hydrophilic cross-linked polyacrylic acid-type thickening agent used to impart the desired rheological property of linear viscoelasticity will generally be in the range of from 0.1 to 2~, preferably from 0.2 to 1.4~, by weight, based on the weight of the composition, although the amount will depend on the particular cross-linking a~ent, ionic strength of the composition, hydroxyl donors and the like.
The compositions of this invention must include sufricient amount of potassium ions and sodium ions to pro~ide a weight ratio of K/Na of at least 1:1, preferably from 1:1 to 45:1, especially from 1:1 to 3:1, more preferably from 1.05:1 to 3:1, such as 1.5:1, or 2:1. When the K/Na ratio is less than 1 there is insufficient solubility of the normally solid ingredients whereas when the K/Na ratio is more than 45, especially when it is gre~ter than 3, the product becomes too 2 ~

liquid and phase separation begins to occur. When the K/Na ratio is more than ~5, especially when it is greater than 3, the product becomes too liquid and phase separation begins to occur. When the K/Na ratios become much larger than 45, such as in all or mostly potassium formulation, the polymer thickener loses its absorption capacity and begins to salt out of the aqueous phase.
The potassium and sodium ions can be made present in the compositions as the alkali metal cation of the detergent builder salt(s), or alkali metal silicate or alkali metal hydroxide components of the compositions. The alkali metal cation may also be present in the compositions as a component of an ionic detergent, bleach or other ionizable salt compound additive, e.g. alkali metal carbonate. In determining the K/Na weight ratios all of these sources should be taken into consideration.
Speci~ic examples of detergent builder salt~ include the polyphosphates, such as alkali metal pyrophosphate, alkali metal tripolyphosphate, alkali metal metaphospha~e, and the like, for example, sodium or potassium tripolyphosphate (hydrated or anhydrous), tetrasodium or ~etrapotassium pyrophosphate, sodium or potas~ium hexa-metaphosphate, trisodium or tripotassium orthophosphate and the like, sodium or potassium carbonate, sodium or potassium citrate, sodium or potassium nitrilotriacetate, and the like. The phosphate builders, where not precluded due to local regulations, are preferred and mixtures of tetrapotassium pyrophosphate (TKPP) and sodium tripolyphosphate (NaTPP) (especially the 2 ~ L

hexahydrate) are especially preferred. Typical ratio~ of NaTPP to TKPP are fro~ 2:1 to 1:8, especially from 1:1.1 to 1:6. The total amount of detergent builder salts is preferably from 5 to 35~ by weight, more preferably from 15 to 35~, especially ~rom 18 to 30~ by weight of the composition.
In connection with the builder salts are optionally used a low molecular weight noncrosslinked polyacrylates having a molecular weight of 1,000 to 100,000, more preferably 2,000 to 80,000. A preferred low molecular weight polyacrylate is Norasol ~MW45ND manufactured by Norsoshaas and having a molecular weight of 4,500. These low molecular weight polyacrylates are employed at a concentration of 0.1 to 15 wt.%, more preferably 0.25 to 10 wt.~.
Other useful low molecular weight noncrosslinked polymers are Acusol~640D provided by Rohm & Haas; Norasol QR1014 from Norsohaas having a GPC molecular weight of 10,000.
The linear viscoelastic compositions of this invention may, and preferably will, contain a small, but stabilizing effective amount of a long chain fatty acid or monovalent or polyvalent salt thereof. Although the manner by which the fatty acid or salt contributes to the rheology and stability of the composition has not been fully elucidated it is hypothesi2ed that it may function as a hydrogen bonding agent or cross-linking agent for the polymeric thickener.
The preferred long chain fatty acids are the higher aliphatic fatty acids having from 8 to 22 carbon atoms, more preferably from 10 to 20 carbon atoms, and especially preEerably from 12 to 1~ carbon atoms, and especially preferably from 12 ~o 18 carbon atoms, :inclusive of the carbon atom of the carboxyl group of the fatty acid. The aliphatic radical may be saturated or unsaturated and may be straight or branched. Straight chain saturated fatty acids are preferred.
Mixtures of fatty acids may be used, such as those derived from natural sources, such as tallow fatty acid, coco fatty acid, soya Eatty acid, mixtures of these acids, etc. Stearic acid and mixed fatty acids, e.g. stearic acid/palmitic acid, are preferred.
The more preferred long chain fatty acids are the higher aliphatic fatty acids having from 10 to 50 carbon atoms, more preferably from 12 to ~0 carbon atoms, and especially preferably from 14 to 40 carbon atoms, and most preferably 20 to 40, inclusive o~ the carbon atom of the carboxyl group of the fatty acid. The aliphatic radical may be saturated or unsaturated and may be straight or branched. Straight chain saturated fatty acids are preferred. Mixtures of fatty acids may be used, such as those deri~ed from natural sources, such as tallow fatty acid, coco fatty acid, soya fatty acid, etc., or from synthetic sources available from industrial manufacturing processes.
Thus, examples of the fatty acids include, for example, decanoic acid, dodecanoic acid, palmitic acid, myristic acid, stearic acid, behenic acid, oleic acid, eicosanoic acid, tallow fatty acid, coco fatty acid, soya fatty acid, mixtures of these acids, etc. Stearic acid and mixed fatty acids, e.g.
stearic acid/palmitic acid, are preferred.

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It has, however, al50 recently been discovered by some of us and others that further improvements in phase stabilit~, particularly under elevated temperature storage conditions, and maintenance of product viscosity levels can be obtained by using longer chain length fatty acids in the range of from C~8 to C~0. Either individual or mixtures of these longer chain length fatty acids can be used, however, the average chain length should be in the range of from 20 to 32 carbon atoms, especially 2g to 30 carbon atoms and mixture of fatty acids encompassing this range are preferred. Suitable mixed fatty acids are commercially available, for instance those sold under the trade name Syncrowax by Croda.
When the free acid form of the fatty acid is used directly it will generally associate with the potassium and sodium ions in the aqueous phase to form the corresponding alkali metal fatty acid soap. However, the fatty acid salts may be directly added to the composition as sodium salt or potassium salt, or as a polyvalent metal salt, although the alkali metal salts of the fatty acids are preferred fatty acid salts.
The preferred polyvalent metals are the di- and tri-valent metals of Groups IIA, IIB and IIIB, such as magnesium, calcium, aluminum and zinc, although other polyvalent metals, including those of Groups IIIA, IVA, VA, IB, IVB, VB VIB, VIIB
and VIII of the Periodic Table of the Elements can also be used. Specific examples of such other polyvalent metals include Ti, Zr, V, Nb, Mn, Fe, Co, Ni, Cd, Sn, Sb, Bi, etc.
Generally, the metals may be present in the divalent to 2 ~

pentavalent state. Preferably the metal salts are u~ed in their higher oxidation states. Naturally, Eor use in automatic dishwashers, as well as any other application~ where the invention composition will or may come in contact with articles u~ed for the handling, storage or serving of food products or which otherwise may come into contact with or be consumed by people or animals, the metal salt should be selected by taking into consideration the toxicity of the metal. For this purpose, the alkali metal and calcium and magnesium salts are especially higher preferred as generally safe food additives.
The amount of the fatty acid or fatty acid salt stabilizer to achieve the desired enhancement of physical stability will depend on such factors as the nature of the fatty acid or its salt, the nature and amount of the thickening agent, detergent active compound, inorganic salts, other ingredients, as well as the anticipated storage and shipping conditions.
Generally, however, amounts of the fatty acid or fatty 2Q acid salt stabilizing agents in the range of from 0.02 to 2%, preferably 0.04 to 1%, more preferably from 0.0~ to 0.8~, especially preferably from 0.08 to 0.4~, provide a long term stability and absence of phase separation upon standing or during transport at both low and elevated temperatures as are required for a commercially acceptable product.
Depending on the amounts, proportions and types of fatty acid physical stabilizers and polyacrylic acid-type thickening agents, the addition of ~he fatty acid or salt not only increases physical stability but also provides a simultaneous increase in apparent viscosity. Amounts of fatty acid or salt to polymeric thickening agent in the range of from 0.08-0.4 weight percent fatty acid salt and from 0.~-1.5 weight percent polymeric thlckening ayent are usually sufficient to provide these simultaneous benefits and, therefore, the use of these ingredients in these amounts is most preferred.
In order to achieve the desirecl benefit ~rom the fatty acid or fatty acid salt ~tabilizer, without stabilization of excess incorporated air bubbles and consequent excessive loweriny of the product bulk density, the fatty acid or salt should be post-added to the formulation, pre~erably together with the other surface active ingredients, including detergent active compound and anti-foaming agent, when present. These surface active ingredients are preferably added as an emulsion in water wherein the emulsified oily or fatty materials are finely and homogeneously dispersed throughout the aqueous phase. To achieve the desired fine emul~ification of the fatty acid or fatty acid salt and other surface active ingredients, it is usually necessary to heat the emulsion (or preheat the water) to an elevated temperature near the melting temperature of the fatty acid or its salt. For e~ample, for stearic acid having a melting point of 68C-69C, a temperature in the range of between 50C and 70C will be used. For lauric acid (m.p.=47C) an elevated temperature o 35C to 50C can be used. Apparently, at these elevated temperatures the fatty acid or salt and other surface active ingredients can be more 2 ~

readily ancl uniformly dispersed (emulsified) in the ~orm o~
fine droplets throughout the composition.
In contrast, as will be shown in the examples which follow, if the fatty acid is .simply post-added at ambient temperature, the composition is not linear viscoelastic as defined above and the stability of the composition is clearly inferior.
Foam inhibition is important to increase dishwasher machine efficiency and minimize destabilizing effects which might occur due to the presence of e~cess foam within the washer during use. Foam may be reduce by suitable selection of the type and/or amount of detergent active material, the main foam-producing component. The degree of foam is also somewhat dependent on the hardness of the wash water in the machine whereby ~uitable adjustment of the proportions of the builder salts such as NaTPP which has a water softening effect, may aid in providing a degree of foam inhibition.
However, it i3 generally preferred to include a chlorine bleach stable foam depressant or inhibitor. Particularly effective are the alkyl phosphoric acid estexs of the formula HO-~-R
OR
and especially the alkyl acid phosphate esters of the formula ll HO-P-OR
OR

2 ~

In the above fo~nulas, one or both R groups in each type of ester may represent independently a Cl2-C20 a]kyl group. The ethoxylated derivatives of each type of ester, for example, the condensation products of one mole of ester with from 1 to 10 moles, preferably 2 to ~ moles, more preferably 3 or 4 moles, ethylene oxide can also be used. Some examples of the foregoing are commercially available, such as the product~ SAP
from Hooker and LPKN-158 from Knapsack. Mixtures of the two types, or any o~her chlorine bleach stable types, or mixtures of mono- and di-esters of the same t~pe, may be employed.
Especially preferred is a mixture of mono- and di-CI6-C~8 alkyl acid phosphate esters such as monostearyl/distearyl acid phosphates 1.2/1, and the 3 to 4 mole ethylene oxide condensates thereof. When employed, proportions of 0.0 to 1.5 weight percent, preferably 0.1 to 0.5 weight percent, of foam depressant in the composition is typical, the weight ratio of detergent active component (d) to foam depressant (e) generally ranging from 10:1 to 1:1 and preferably 5:1 to 1:1. Other defoamers which may be used include, for example, the known silicones, such as available from Dow Chemicals. In addition, it is an advantageous feature of this invention that many of the stabilizing salts, such as the stearate salts, for example, aluminum stearate, when included, are also effective as foam killers.
Although any chlorine bleach compound may be employed in the compositions of this invention, such as dichloro-isocyanurate, dichloro-dimethyl hydantoin, or chlorinated TSP, alkali metal or alkaline earth metal, e.g. potassium, lithium, ~ ~.Q~3~

magnesium and especially sodium, hypochlorite i.s preferred.
The composition should contain sufficient amount of chlorine bleach compound to provide 0.2 to ~.0% by weight oE available chlorine, as determined, for example by aciclification of 100 parts of the composition with excess hydrochloric acid. A
solution containing 0.2 to 4.0~ by weight of sodium hypochlorite contains or provides roughly the same percentage of available chlorine. 0.~ to 1.6~ by weight of available chlorine i9 especially preferred. For example, sodium hypochlorite (NaOCL) solution of Erom 11 to 13% available chlorine in amounts of 3 to 20~, preferably 7 to 12~, can be advantageously used.
Detergent active material useful herein should be stable in the presence of chlorine bleach, especially hypochlorite bleach, and for this purpose those of the organic anionic, amine oxide, phosphine oxide, sulphoxide or betaine water dispersible surfactant types are preferred, the first mentioned anionics being most preferred. Particularly preferred surfactants herein are the linear or branched alkali metal mono- and/or di-(C8-CI~) alkyl diphenyl oxide mono- and/or di-sulphates, commercially a~ailable for example as DOWFAX
(registered trademark) 3B-2 and DOWFAX 2A-l. ln addition, the surfactant should be compatible with the other ingredients of the composition. Other suitable organic anionic, non soap surfactants include the primary alkylsulphates, alkylsulphonates, alkylarylsulphonates and sec.-alkylsulphates. Examples include sodium Cl0-C~8 alkylsulphates such as sodium dodecylsulphate ancd sodium tallow ~"~ J~

alcoholsulphate; sodium C~0- C18 alkanesulphonates such as sodium hexadecyl-1-sulphonate and sodium Cl2-C~8 alkylbenzenesulphonates such as sodium dodecylbenzenesylphonates. The corresponding potassium salts may also be employed.
As other suitable surfactants or detergents, the amine oxide surfactants are typically of the structure R2RINO, in which each R represents a lower alkyl group, for instance, methyl, and Rl represents a long chain alkyl group having Erom 8 to 22 carbon atoms, for instance a lauryl, myristyl, palmityl or cetyl group. Instead of an amine oxide, a corresponding surfactant phosphine oxide R2RIPO or sulphoxide RR~SO can be employed. Betaine surfactants are typically of the structure R2RIN+R'7COO-, in which each R represents a lower alkylene group having from 1 to 5 carbon atoms. Specific examples of these surfactants include lauryl-dimethylamine oxide, myristyl-dimethylamine oxide, myristyl-dimethylamine oxide, the corresponding phosphine oxides and sulphoxides, and the corresponding betaines, including dodecyldimethylammonium acetate, tetradecyldiethylammonium pentanoate, hexadecyldimethylammonium hexanoate and the like. For biodegradability, the alkyl groups in-~hese surfactants should be linear, and such compounds are preferred.
Surfactants of the foregoing type, all well known in the art, are described, for example, in U.S. Pa~ents 3,985l668 and 4,271,030. If chlorine bleach i9 not used than any of the well known low-foaming nonionic surfactants such as alkoxylated fatty alcohols, e.g. mixed ethylene oxide-propylene oxide condensates of C8-C22 fatty alcohols can also be used.
The chlorine bleach stable, water dispersible organic detergent-active material (surfactant) will normally be present in the composition in minor amounts, generally 1% by weight oE the composition in minor amounts, generally 1% by weight of the composition, although smaller or larger amounts, such as up to 5%, such as from 0 to 5~, preferably form 0.1 or 0.~4 to 3~ by weight of the composition, may be used.
Alkali metal (e.g. potassium or sodium) silicate, which provides alkalinity and protection of hard surfaces, such as fine china glaze and pattern, is generally employed in an amount ranging from 5 to 20 weight percent, preferably 5 to 15 weight percent, more preferably 8 to 12~ in the composition. The sodium or potassium silicate is generally added in the form of an aqueous solution, preferably havin~
Na20:SiO2 or K20: SiO2 ratio of 1:1.3 to 1:2.8, especially preferably 1:2.0 to 1:2.6. At this point, i~ should be mentioned that many of the other components of this composition, especially alkali metal hydroxide and bleach, are also often added in the form of a preliminary prepared a~ueous dispersion or solution.
In addition to the detergent active surfactant, foam inhibitor, alkali metal silicate corrosion inhibitor, and detergent builder salts, which all contribute to the cleaning performance, it i9 also known that the effectiveness of the liquid automatic dishwasher detergent compositions is related to the alkalinity, and particularly to moderate to high , ' .

alkalinity levels. Accordingly, the compositions of this invention will have pH values of at least 9.5, preferably at least 11 to as high as 14, generally up to 13 or more, and, when added to the aqueous wash bath at a typical concentration level of 10 grams per liter, will provide a pH in the wash bath of at least 9, preferably at least 10, such as 10.5, 11, 11.5 or 12 or more.
The alkalinity will be achieved, in part by the alkali metal ions contributed by the alkali metal detergent builder salts, e.g. sodium tripolyphosphate, tetrapotassium pyrophosphate, and alkali metal silicate, however, it is usually necessary to inclu~e alkali metal hydroxide, e.g. NaOH
or KOH, to achieve the desired high alkalinity. Amounts of alkali metal hydroxide in the range of (on an active basis) of from 0.5 to 8%, preferably from 1 to 6~, more preferably from 1.2 to 4~, by weight of the composition will be sufficient to achieve the desired pH level and/or to adjust the K/Na weight ratio.
Other alkali metal salts, such as alkali metal carbonate may also be present in the compositions in minor amounts, for example from 0 to 4%, preferably 0 to 2~, by weight of the composition.
Other conventional ingredients may be included in these compositions in small amounts, generally less than 3 weight percent, such as perfume, hydrotropic agents such as the sodium benzene, toluene, xylene and cumene sulphonates, preservatives, dyestuffs and pigments and the like, all of course being stable to chlorine bleach compound and high 2 ~ J~

alkalinity. Especially preferred ~or coloring are the chlorinated phythalocyanines and polysuphides of aluminosilicate which provide, respectively, pleasing green and blue tints. TiO2 may be employed for whitening or neutralizing off-shades. Even more preferred colorants used at a concentration of 0.01 to 1.0 wt. ~ are CI Direct Yellow # 2~ and Grapthlol Green pigment both made by Sandoz Chemical Corp.
Although for the reasons previously discussed excessive air bubbles are not often desirable in the invention compositions, depending on the amounts of dissolved solids and liquid phase densities, incorporation of small arnounts of finely divided air bubbles, generally up to 10% by volume, preferably up to 4% by volume, more preferably up to 2~ by volume, can be incorporated to adjust the bulk density to approximate liquid phase density. The incorporated air bubbles should be finely divided, such as up to 100 microns in diameter, preferably from 20 to 40 microns in diameter, to assure maximum stability. ~lthough air is the preferred gaseous medium for adjusting densities to improve physical stability of the composition other inert gases can also be used, such as nitrogen, carbon dioxide, helium, oxygen, etc.
The amount of wa~er contained in these compositions should, of course, be neither 50 high as to produce unduly low viscosity and fluidity, nor so low as to produce unduly high viscosity and low flowability, linear viscoelastic properties in either case being dimini~hed or destroyed by increasing tan Such amount is readily determined by routine 2 ~ /7 ~

experimentation in any particular instance, generally ranginy from 30 to 75 weight percent, prefera~ly 35 to 65 weight percent. The water should also be preferably deionized or softened.
The manner of formulating the invention compositions is also important. ~s discussed above, the order of mixing the ingredients as well as the manner in which the mixing is performed will generally have a significant effect on the properties of tha compo~ition, and in particular on product density (by incorporation and stabilization of more or less air) and physical stability (e.g. phase separation). Thus, according to the preferred practice of this invention the compositions are prepared by first forming a dispersion of the polyacrylic acid-~ype thickener in water under moderate to high shear conditions, neutralizing the dissolved polymer to cause gelation, and then introducing, while continuing mixir,g, the detergent builder salts, alkali metal dilicates, chlorine bleach compound and remaining detergent additi~es, including any previously unused alkali metal hydroxide, if any, other than the surface-active compounds. All of the additional ingredients can be added simul~aneously or se~uentially.
Preferably, the ingredients are added sequentially, although it is not necessary to complete the addition of one ingredient before beginning to add the next ingredient. Furthermore, one or more of these ingredients can be divided into portions and added a~ different times. These mixing steps should also be performed under moderate to high shear rates to achieve complete and uniform mixing. These mixing steps may be 2 ~

carried out at room temperature, although the polymer thickener neutralization (gelation) is usually exothermic.
The composition may be allowed to age, if necessary, to cause dissolved or dispersed air to dissipate out of the composition.
The remaining surface active ingredients, including the anti-foaming agent, organic detergent compound, and fatty acid or fatty acid salt stabilizer is post-added to the previously formed mixture in the form of an aqueous emulsion (using from 1 to 10~, preferably from 2 to 4~ of the total water added to the composition other than water added as carrier for other ingredients or water of hydration) which is pre-heated to a temperature in the range of from Tm~5 to Tm-20, preferably from Tm to TM-10, where 1~ is the melting point temperature of the fatty acid or fatty acid salt. For the preferred stearic acid stabilizer the heating temperature is in the range of 50C to 70C. However, if care is taken to avoid excessive air bubble incorporation during the gelatin step or duriny the mixing of the detergent builder salts and other additives, for example, by operating under vacuum, or using low shearing conditions, or special mixing operatatus, etc., the order of addition of the surface active ingredients should be less important.
In accordance with an especially preferred embodiment, the thickened linear viscoelastic aqueous automatic dishwasher detergent composition of this invention includes, on a weight basis:

2 ~

(a) 10 to 35~, preferably 15 to 30~, ~lkali metal polyphosphate detergent builder;
(b) 5 to 15~, preferably 8 to 12~, alkali metal silicate;
(c) 1 to 6~, preferably 1.2 to 4%, alkali metal hydroxide;
(d) 0 to 5~, preferably 0.1 to 3%, chlorine bleach stable, water-dispersible, low-foaming organic detergent active material, preferably non-soap anionic detergent;
(e) 0 to 1.5~, preferably 0.1 to 0.5~, chlorine bleach stable foam depressant;
(f) chlorine bleach compound in an amount to provide 0.2 to 4%, preEerably 0.8 to 1.6~, of available chlorine;
(g) at least one polymeric thickening agent such as a high molecular weight hydrophilic cross-linked polyacrylic acid thickening agent in an amount to pro~ide a linear viscoelasticity to the formulation, preferably from 0.1 to 2.0~, more preferably from 0.2 to 1.0%;
(h) a long chain fatty acid or a metal salt of a long chain fatty acid in an amount effective to increase the physical stability of the compositions, preferably from 0.02 to 2.0%, more preferably from 0.04 to 1.0%; and (i) balance water, preferably from 30 to 75~, more preferably from 35 to 65~; and wherein in (a) the alkali metal polyphosphate includes a mixture of from 5 to 30%, preferably from 12 to 22% of tetrapotassium pyrophosphate, and from 0 to 20~, preferably from 3 to 18~ of sodium tripolyphosphate, and wherein ln the entire composition the 2 ~
ratio, by weight, of potassium ions to sodium ions is from 1.05/1 to 3/1, preferabl~ from ~ to 2.5/l, the compositions having an amount of air incorporated therein such that the bulk density of the composition i9 from 1.28 to 1.42 g/cc, preferably from 1.32 to 1.40 g/cc. The improved gel-like viscoelastic automatic dishwashing composition are further describe~ as containing 10 to 60 weight percent of an alkali metal containing compound which is selected from the group consisting essentially of alkali metal hydroxides, alkali metal tripolyphosphates, alkali metal pyrophosphates, alkali metal carbonates and alkali metal silicates, wherein there is present in the composition both potassium ions and ~odium ions in a ratio o~ 1/1 to 45/1, 0 to 1.5 weight percent of a foam depressant, 0 to 5 weiyht percent oE a chlorine bleach stable, water-dispersible organic detergent active material, 0.02 to 2.0 weight percent of a long chain fatty acid or a metal salt thereof and a means for substantially preventing the composition from wetting and adhering to an interior vertical surface of a polyolefinic bottle; wherein the means comprises adding a polymeric thickening agent such as a high molecular weight polyacrylic thickening agent to the composition, wherein substantially all of the normally solid components of the composition are present dissolved in the aqueous phase, and substantially all of the water is tightly bound to the polymeric thickening agent and the composition has a bulk density of from 1.28 g/cm3 to 1.42 g/cm3 and the composition does not exhibit phase separation and remains homogenous, when the composition is s~

centrlfu~3ed at 1000 rpm for three mi~utes. The composition can further include 0.1 to 10.0 weight percent of a polyacrylate havlng a molecular weight of 1,000 to 100,000 and a chlorine containing compound to provide 0.2 to 4.0 weight percent of available chlorine.
Another especially preferred embodiment, the thickened linear viscoelastic aqueous automatic dishwasher detergent composition of this invention in~ludes, on a weight basis:
(a) (i) 8 ~o 25~, preferably 10 to 20%, potassium tripolyphosphate detergent builder;
(ii) 2 to 10%, preferably 4 to 8%, sodium tripolyphosphate detergent builder, at an (i)/(ii) weight ratio of from 1.4/1 to 10/1, preferably 2/1 to 6/1;
(b) 5 to 15, preferably 8 to 12%, alkali metal silicate;
(c) 1 to 6%, preferably 1.2 to 4~, alkali metal hydroxide;
(d) 0.1 to 3%, preferably 0.5 to 2~, chlorine bleach stable, water-dispersible, low-foaming organic detergent active material, preferably non-soap anionic detergent;
(e) 0 to 1.5~, preferably 0.1 to 0.5%, chlorine bleach stable foam depressant;
~f) chlorine bleach compound in an amount to provide 0.2 to 4~, preferably 0.8 to 1.6%, of available chlorine;
(g) at least one non-linear, water-dispersible polyacrylic acid thickening agent comprising at least one high molecular weight hydrophilic polycarboxylate having a molecular weight of from 750,000 to 4,000,000, preferably 800,000 to 3,000,000, in an amount to provide a linear ~ ~3 ~ ~ ~ Q 1 viscoelasticity to the formulation, preEerably from 0.2 to 2~, especially preferably from 0.~ to 1.5%, more preferably from 0.4 to 1.0~;
(h) a long chain fatty acid or a metal salt of a long chain fatty acid in an amount effective to increase the physical stability of the compositions, preferably from 0.02 to 0.4%, more pre~erably from 0.1 to 0.3%;
(i) 0 to 10~, preferably 1 to a%, especially 2 to 6% of non-cross-linked polyacrylic acid having a molecular weight in the range of from 800 to 200,000, p:referably 1000 to 150,000, especially 2,000 to 100,000; arld (j) balance water, preferably from 30 to 75%, more preferably from 35 to 65%; and wherein in the entire composition the ratio, by weight, of potassium ions to sodium ions is from 1.05/1 to 3/1 or 4/1, preferably from 1.1/1 to 2.5/1. The compositions may also have an amount of air incorporated therein such that the bulk density of the composition is from 1.28 to 1.42 g/cc, preferably from 1.32 to 1.42 g/cc, more preferably from 1.35 to 1.40 g/cc.
Another especially preferred embodiment, the thickened linear viscoelastic aqueous automatic dishwasher detergent composition of this invention includes, on a weight basis:
(a) 10 to 35%, preferably 15 to 30%, of at least one alkali metal detergent builder salt;
(b) 0 to 15, preferably 8 to 12%, alkali metal silicate;
(c) 1 to 6%, preferably 1.2 to ~, alkali metal hydroxide;

2 ~ ~ ~U

(d) 0 to 3~, preferably 0.1 to 2%, chlorine bleach stable, water-dispersible, low-foaming organic detergent active material, pre:Eerably non-soap anionic detergent;
(e) 0 to 1.5~, preferably 0.1 to 0.5~, chlorine bleach stable foam depressant;
(f) chlorine bleach compound in an amount to provide 0.2 to 4~, preferably 0. a to 1.6%, of available chlorine;
(g) high molecular weight hydrophilic cross-linked polyacrylic acid thickening agent in an amount to provide a linear viscoelasticity to the formulation, preferably from 0.1 to 2.0~, more preferably from 0.4 to 1.5~;
(h) a long chain fatty acid or a metal salt of a long chain fatty acid in an amount effective to increase the physical stability of the compositions, preferâbly from 0.08 to 2.0%, more preferably from 0.04 to 0.5~; and (i) balance water, preferably from 30 to 75%, more preferably from 35 ~o 65~; and wherein in (a) the alkali metal polyphosphate includes a mixture of from 5 to 30~, preferably from 12 to 22~ of tetrapotassium pyrophosphate, and from 0 to 20~, preferably from 3 to 18~ of sodium tripolyphosphate, and wherein in the entire composition the ratio, by weight, of potassium ions to sodium ions is from 1.05/1 to 3/1, preferably from 1.1/1 to 2.5/1, the compositions ha~ing an amount of air incorporated therein such that the bulk density of the composition is from 1.32 to 1.42 g/cc, preferably from 1.35 to 1.40 g/cc.
(j) 0.01 to 1.09~ of a chlorine stable dye or chlorine stable pigment.

The compositions will be supplied to the consumer in suitable dispenser containers preferably formed of molded plastic, e~pecially polyolefin plastic, and most preferably polyethylene, for which the invention compositions have particularly favorable 51ip characteristics. The slip characteristic of the composition i~: manifested by the fact that the in~tant compositions do not substantially adhere to the interior vertical surface of a polyolefinic bottle such as a blow molded high density polyethylene bottle or a polyethylene tetraphthatate bottle. This slip characteristic of the composition i9 directly attributable to the addition of the polymeric thickening agent to the composition which causes the composition to obtain its gel-like viscoelastic characteristic. In addition to their linear viscoelastic character, the compositions of this invention may also be characterized as pseudoplastic gels (non-thixotropic) which are typically near the borderline between liquid and solid viscoelastic gel, depending, for example, on the amount and type of the polymeric thickener. The invention compositions can be readily poured from their containers without any shaking or Rqueezing, although squeezable containers are often convenient and accepted by the consumer for gel-like products.
The liquid aqueous linear viscoelastic automatic dishwasher compositions of this invention are readily employed in known manner for washing dishes, other kitchen utensils and the like in an automatic dishwasher, provided with a suitable detergent dispenser, in an aqueous wash bath containing an effective amount of the composition, generally sufficient to 2 ~
fill or partlally fi].l the automatic dispenser cup of the particular machine being used.
The invention also provides a method for cleaning dishware in an automatic dishwashing machine with an aqueous wash bath containing an effective amount of the liquid linear viscoelastic automatic dishwasher detergent composition as described above. The composition can be readily poured from the polyethylene container with little or no squeezing or shaking into the dispensing cup of ~he automatic dishwashing machine and will be sufficiently viscous and cohesive to remain securely within the dispensing cup until shear forces are again applied thereto, such as by the water spray Erom the dishwashing machine.
The invention may be put into practice in various ways and a number of specific embodiments will be described to illustrate the invention with reference to the accompanying examples.
All the amounts and proportions referred to herein are by weight of the composition unless otherwise indicated.
Example 1 The following formulation~ A-K were prepared as described below:

_:~ ~ _~ __lli _ ~ ~ ~ _ I_ ~ ~ ~

K m O N , ~ 0 N ,l N ~1 O ~ V , ~
_ _ _ _ _ _ ___ _ _ _ _ ~ m ~ ~ ll N ~ N l ~ ~ O ~ N ~ ~
~! __ _ _ _ _ , __ _ u~ o __ H m _ N . ~ N _ __ _ _ . A _ _ m O 'l N 0 'l 'l r ~ ~ O ~ N ' ~r _ _ __ _ _ _ _ _ _ _ ~ m Nr~ ' N , N ,l N H O ~ N , ~r _ _ . _ _ _ _ ~ _ ~ m ~ ~ ll N ~ ~ ll ~ ~ ~ ~ A ~ ~
~! ; Ln - o 111 r~ __ _ _ ~ o _ o~ Ll~
~ ~ ,1 r~l l ~ t~ ~ l l ~1 l a~ Y l ,~
_ _ _ _ .. _ _ _ _ _ _ _ m O N ~ N ~ N ~ ~ ~ O ~ N ~ 0 _ _ _ _ _ _ _ _ _ _--O _ _ r~ ~ o ~ ll 'n ~ ~ ', ~ ~ ~1 ~ Y l O N _ In ~ N , N H O m V O N
. _ _ _ __ _ _ __ _ _ ~ m C Nr. ' m ~1 ' N ~1 O m v ' N
~ ~ _ ~i ~ __ e~_ ~ ~1115 11~1 ~_ ~11 ~11 _ ~ ~ ~r ~ _ N~ ~ o\

H ~ ~Z O In In ~ H 111 H ~ô In m H V o\~ H
H ~ H ~J m K K ~i ~ H ~ ~ 3 _ m rJ ~ ~ _ ~7~ f3~
~i ~ 9 t` 0 K . ~
~ ~ Ln .
~ .~ o o ~ O ~
~_~i_ O O R ~.
H lA A O ,q ~ _ _ O _ ~r~
. . . ~ U r~
P l,l i 4 N A X
. t~ ~r ~0 u .~ O' O 0~
I_ _ O O V h l O O ~

'~ _ _ A h O ~ (I) O O

~ A A
~ _ ._ -" o o ~1 U :~ O h o o ~ ~ U
~ L~ ~ ._._ . __ o ,~ .~ o o ,u~ ~
_~ _ . _ a) a~ o o r~ O o u~
. . . ~ ~ ~
m~ O O 4~ ~ ~, h a _ . _ ~ H h a h w ~ ,i ~ o o ,X l~
:b..,. _ ~ __ _ o 3 h h U . ~ K O ,1 a) aJ h ~a H O H ~i H o b~ O
~ ~3 ~ cn O ~ u~ o ~
E~ ~ O E~ P~ o 0\O
cn~o~0 cq~_ . . .
~1 . _ ~a __ ~

2~3S,~

Formulations A, B, C, D, E, G, J, and K are prepared by first forming a uniform dispersion of the Carbopol 9~1 or 940 thickener in 97~ of the water (balance). The Carbopol is slowly added to deionized water at room temperature using a mixer equipped with a premier blade, with ayitation set at a medium shear rate, as recommended by the manufacturer. The dispersion is then neutralized by addition, under mixing, of the caustic soda (50~ NaO~ or KOH) component to form a thickened product of gel-like consistency.
To the resulting gelled dispersion the silicate, tetrapotassium pyrophosphate (TKPP), sodium tripolyphosphate TP(TPP, Na) and bleach, are added sequentially, in the order stated, with the mixing continued at medium shear.
Separately, an emulsion of the phosphate anti-foaming agent (LPKN), ~tearic acid/palmitic acid mixture and detergent ~Dowfax 3B2) is prepared by adding these ingredients to the remaining 3~ of water (balance) and heating the resulting mixture to a temperature in the range of 50C to 70C.
This heated emulsion i9 then added to the previously prepared gelled dispersion under low shear conditions, such that a vortex is not formed.
The remaining formulations F, H and ~ are prepared in essentially the same manner as described above except that the heated emulsion of LPKN, stearic acid and Dowfax 3B2 is directly added to the neutralized Carbopol dispersion prior to the addition of the remaining ingredients. As a result, formulations F, H and I, have higher levels of incorporated air and densities below 1.30 g/cc.

2 ~3 1~

The rheograms for the formulations A, C, D, G and ~ are shown in figures 1-5, respectively, and rheograms for formulations H, I and K are shown in figures 6, 7 and 8 respectively.
These rheograms are obtained with the System 4 Rheometer Erom ~heometrics equipped with a Fluid Servo with a 100 grams-centimeter torque transducer and a 50 millimeter parallel plate geometry having an 0.8 millimeter gap between plates.
All measurements are made at room temperature (25C*1C) in a humidity chamber after a 5 minute or 10 minute holding period of the sample in the gap. The measurements are made by applying a frequency of 10 radians per second.
All of the co~position formulations A, B, C, D, G and J
according to the preferred embodiment of the invention which include Carbopol 941 and stearic acid exhibit linear viscoela~ticity as seen from the rheograms of figure 1-5.
Formulation E which includes Carbopol 941 but not stearic acid showed no phase separation at either room temperature or 100F
after 3 week~, but exhibited 10% phase separation after 8 weeks at room temperature and after only 6 weeks at 100F.
Formulation K, containing Carbopol 940 in place of Carbopol 941, as seen from the rheogram in figure 8, exhibits substantial linearity over the strain range of from 2~ to 50~
(G' at 1~ strain-G' at 50~ strain 500 dynes/~q.cm.) although tan ~ at a strain above 50~.

2 ~

Example 2 This example demonstrates the importance of the order of addition of the surface active component premix to the remainder of the composition on product density and stability.
The following formulations are prepared by methods A and B :
Ingr dlent Water, deionized Balance Carbopol 941 0.5 NaOH (50~) 2.4 Na Silicate (47.5~) 21 TPP, Na 13 Bleach (1%) 7.5 LPKN 0.16 Stearic Acid 0.1 Dowfax 3B2 Method A:
The Carbopol 941 i9 dispersed, under medium shear rate, using a premier blade mixer, in deionized water at ambient temperature. The NaOH is added, under mixing, to neutralize and gel the Carbopol 941 dispersion. To the thickened mixture the following ingredients are added sequentially while the stirring i9 continued: sodium silicate, TKPP, TPP, and bleach.
Separately, an emulsion i~ prepared by adding the Dowfax 3B2, stearic acid and LPKN to water while mixing at moderate shear and heating the mixture to o5C to finely disperse the emulsified surface active ingredients in the water phase.
This emulsion premix is then slowly added to the Carbopol dispersion while mixing under low shear conditions without forming a vortex. The results are shown below.

2 ~ ,r~ ~

Method B:
Method A i9 repeated except that the heated emulsion premix is added to the neutralized Carbopol 941 dispersion before the sodium stearate, TKPP, TPP, and bleach. The results are also shown below.

Method AMethod B
Density (g/cc) 1.38 1.30 Stability (RT-8 weeks) 0.00~ 7.00~
Rheogram Fig. 9Fig.10 From the rheograms of figures 9 and 10 it is seen that both products are linear viscoelastic although the ela.stic and viscous moduli G' and G~' are higher for Method A than for Method ~.
From the results it i9 seen that early addition of the surface active ingredients to the Carbopol gel significantly increases the degree of aeration and lowers the bulk density of the final product. Since the bulk density i9 lower than the density of the continuous liquid phase, the liquid phase undergoes i.nverse separation (a clear liquid phase forms on the bottom of the composition). This process of inverse separation appears to be kinetically controlled and will occur faster as the density of the product becomes lower.

Example 3 This example shows the importance of the temperature at which the premixed surfactant emulsion is prepared.
Two formulations, L and M, having the same composition as in Example 2 except that the amount of stearic acid was increased from 0.1~ to 0.~ are prepared as shown in Method A

~7~
for formulation L and by the following Method C Eor formulation M.
Method C
The procedure of Method A is repeated in all details except that elnulsion premix of the surEace active ingredients is prepared at room temperature and is not heated before being post-added to the thickened Carbopol dispersion containing silicate, builders and bleach. The rheograms for formulations L and M are shown in figures 11 and 12, respectively. From these rheograms it is seen that formulation L i9 linear viscoelastic in both G' and G" whereas formulation M is non-linear viscoelastic particularly for elastic modulus G' (G' at 1% strain-G~ at 30% strain > 500 dynes/cm2) and also for G" (G"
at 1% strain-G" at 30~ strain ~ 300 dynes/cm2).
Formulation L remains stable after storage at RT and 100F
for at least 6 weeks whereas formulation M undergoes phase separation.
Comparative Example 1 The following formulation is prepared without any potassium salts:
Weiqht %
Water Balance Carbopol 941 0.2 NaOH (50~) 2.4 TPP, Na (50%) 21.0 Na Silicate (47.5%) 17.24 Bleach ~1%) 7.13 Stearic Acid 0.1 LPKN (5%) 3.2 Dowfax 3B2 0.8 Soda Ash 5.0 Acrysol LMW 45-N 2.0 .7 ~ ~
The procedure used is analogous to Method A of Example 2 with the soda ash and Acrysol ~MW 45-N (low molecular weight polyacrylate polymer) being added before and after, respectively, the silicate, TPP and bleach, to the thickened Carbopol 941 dispersion, followed by addition to the heated surface active emulsion premix. The rheogram is shown in figure 13 and is non-linear with G~/G~ (tan~) ~ 1 over the range of strain of from 5~ to 80~.

Example 4 Formulations A, B, C, D and K according to this invention and comparative formulations F and a commercial liquid automatic dishwasher detergent product as shown in Table 1 above were subjected to a bottle residue test using a standard polyethylene 28 ounce bottle as used for current commercial liquid dishwasher detergent bottle.
Six bottles are filled with the respective samples and the product is dispensed, with a minimum of force, in 80 gram dosages, with a 2 minute rest period between dosages, until flow stops. At this point, the bottle was vigorously shaken to try to expel additional product.
The amount of product remaining in the bottle is measured as a percentage of the total product originally filled in the bottle. The results are shown below.

2~7~

Bottle R sidue Formulation Res~idue : D 5 F* 4 Commercial Product 20 *The sample separates upon aging Example 5 - The following formulations A-F were prepared as described below:

2a7~

r_c -, _ m o _ ul, ~:, _ _ ._ ~, _ 'o`7 =

~ O _ _ O _ 0 _ N _ O C O ~1 O O _ ¦ IYi 01 l l O ~ O l r~ ~1 0 r~ r~ rl O l N

a o _ _ O -- N ~D O O O O O _ _ r~l r ~ ~ w ~ ~
I ~ o~ u) o o ~ a~ ,~ rl O O
¦ U 01 l l O ~p N l N 11~ O O O r~ O l N
_ _ _ _ _ _ _ _~ _ ~1 0 r~ 1~ _ _ O _ O _ ql N r~ _ r~ O O O r1 O _ N

F~ a~ ~~1 Ll') r~l r1 O rl O
_ _ O _ _ N N _ _ _ _ O O _ O _ N

.1 0 ~ 1 ~ r z ~ ~ ,, ~ ~ l. ~ ~, 0~O a) ~ ~

~ S-l O r-l _ r _ N ri 1~ r~ ~ -rl r Cq O ~ R ~ R ~ ol X ~ Fj~l O ~ u ~ h H -rl ~H _ _ c ~-) z; _ E~ _ _ a _ ~ _ _ _ _ 2~7~?~

= ~ = = _ = = _ = _ Ul ~D 1~, ~ ~ ~ ~ O .
l O ,, ,, ~ ~ ~ ~ æ
_ _ ._ __ _ M _ M _ _ ~p Ul r~ 00 ~ ~ 'Y3 ~ 0 ,tn ~ o ,1 ~1 ,J a~ c~l ~`I ~ 1~
_ _ _ _ _ _ _ _ _ _ It) rl I~ 'Y3 ~ ~ ~
O ~O ~) . ~ ~ ~) _ O rl ~1 ~ N _ ~;

11~ ~ ~` 3 ~) _ O ,, ~ ~ _ _ l æ .~

Ot) t` M Ul _ _ t`~
O~ ~ ~ ~ Ul .~
_ _ O _ _ N _ __ _ _ ~O tO ~1 a~ I
a~ IY) 3 3 Q~ .
l l O ~i O~ ~ l l ~

u~ i~ o ~ 1~4 ~

~ I .,1 .,1 .,1 .,1 ~ ~
-,~ J ~ ~ ~1 ~1 1~ ~1 ~ w x a w w w w ~ w .~

2~70~

Formulations A, B, C, D, E and F are prepared by first forming a uniform dispersion of the Carbopol 614 or 940 thickener in 97% of the water of the total formula water.
The Carbopol is slowly added by sprinkling it into the vortex of previously colored deionized water preheated to a temperature of 105F using a mixer equipped with a premier blade, with agitation set at a medium shear rate, as recommended by the manufacturer. After mixing for 15 minutes, the dispersion is then neutralized by addition, under the same mixing, of the caustic soda (50% NaOH) component until a thickened product of gel-like consistency is formed ( 10 minutes).
To the resulting gelled dispersion the silicate, sodium tripolyphosphate (NaTPP), tetrapotassium pyrophosphate (TKPP), or potassium tripolyphosphate (KTPP), the surfactant emulsion (described below) and bleach and color, added sequentially, in the order stated, with the mixing continued at medium shear for several minutes before adding the next ingredient. After the addition of the surfactant emulsion (at 160F), the mixture is cooled to from 90-95F before the bleach i9 added.
Separately, the surfactant emulsion of the phosphate anti-foaming agent (LPKN), stearic acid or fatty acid mixture and detergent (Dowfax 3B2) is prepared by adding these ingredients to the remainin~ 3% of water and heating the resulting mixture to a temperature in ~he range of 160F
(71C). In formulation E, the Acrysol LMW 45-N may be added at this stage.

3 ~ s~ ~
The rheograms for the Eormulations A, ~3, C, D, E and F
are shown in figures 1-6, respectively.
These rheograms are obtained with the System 4 Rheometer from Rheometrics e~uipped with a Fluid Servo with a 100 grams-centimeter torque transducer and a 50 millimeter parallelplate geometry having an 0.8 millimeter gap between plates.
All measurements are made at room temperature (25~1C) in a humidity chamber after a 5 minute or 10 minute holding period of the sample in the gap. The measurements are made by applying a frequency of 10 radians per second.
All of the composition formulations C, D and F exhihit linear viscoelasticity as seen from the rheograms of figure 2-6. No phase separation at from ambient temperature to 140~F
were observed for any of the formulations for at least the minimum number of weeks re~lired to satisfy the criteria stability as shown in Table A above. Formulations E and F
were still being tested when this application was filed.
However, in the control formulations A and B maintained at 100F, the TKPP crystallized in the aqueous phase and eventually formed sufficiently large size crystals which separated to the bottom of the composition. Also, as seen in figures 1 and 2 formulations A and B are not linear viscoelastic, at least within the preferred criteria as previou~qly described. Formulations C, D, E and F, according to the invention did not undergo any crystal growth.
For the bottle residue test, each formulation is allowed to age for 1 week at ambient temperature in a standard 32 ounce small necked polyethylene bottle. An amount of product 2 ~
is poured from the bottle to fill a standard sized dispenser cup of an automatic dishwasher. The bottle is then replaced in an upright position and is retained in the upright position for at least 15 minutes. This procedure of filling the dispenser cup, placing the container in the upright position and waiting at least 15 minutes is repeated until no more product flows from the bottle. At this time, the weight of the bottle is measured. Bottle res:idue is calculated as Wf x 100 Wo Wo is the initial weight o~ the ~illed bottle and Wf is the final weight of the filled bottle. The bottle residue for each formulation A-F iY 4 to 5~. Formulations C-F have viscosities of from 10,000 to 20,000 measured with a Brookfield LVT viscometer, ~4 spindle at 20 rpm measured at 80F. All of these products are easily pourable from the polyethylene bottle.
Example 6 A Carbopol 614 slurry is formed as described in Example 1 except that the coloring agent is first added to the deionized water ( 92~ of the total added water) and the amounts of the ingredients are changed as shown below. The premix (surfactant emulsion) of the surface acti~e ingredients i9 also formed as in Example 1 using stearic acid as the fatty acid stabilizer and the remaining 8~ of the total added water.
The ingredients are then mixed together with the Carbopol 6i4 slurry in the following order: alkali metal silicate, NaTPP (powder), KTE'P (powder), surfactant emulsion, bleach and 2 ~ 7 ~ ~J ~
perfume. The resulting composition is obtained with the following ingredients in the following amounts:
Ingredient Amount (wt. ~) Deionized water q.s. 100.00 Carbopol 614 1.00 NaOH (38% Na2O) 6.38 Na silicate (1:24)(47.5~) 20.83 KTPP (anhydrous) powder 20.35 NaTPP (3~ H2O) 5.26 Dowfax 3B2 0.80 LPKN 0.16 Stearic acid 0.15 Bleach (Na hypochlorite-13~) 9.23 CI Pigment Green 7 (CI 74260) 0.0024 Highlights (fragrance) 0.05 The composition has a pH of 11.3 + 0.1 and density (9p .
gr.) of 1.39 -~ 0.03. The viscosity at 80F measured with a ~rookfield LVT viscometer at 20 rpm with a #4 spindle is 12,000 + 2,000.
All of the preferred criteria as set forth in Table A
above are satisfied.

~QrJ~O~
Example 7 The Eollowing formulas were prepared according to the procedure of Example 1 and tested.

. _ I 1 _ 2 _ 3 -4 ¦Water _ q.a. q.a. q.a. q.a ¦Carbopol 941 0.9 _ ~ _ ._ ¦Carbopol 940 0.9 ~ ~ ... _ ¦Carbopol 614 0.9 0.9 I _ _ ¦NaOH 4.5 4.5 4.5 4.5 Na-Silicate 21 21 21 21 .__~ . __ . _ ~_ Na-TPP Anhy. 13 13 13 13 .__ _ _ . _ _ . ._ ..
NaOC1 (1.0 Av. Chlorine) 7.5 11.1 11 11 . ._ . _ .

LPKN 158 0.16 0.16 0.16 0.16 Dowfax 3B-2 1 0.8 _ 0.8 0.8 l .__ _ . _ .. _ ~. __ l Sa (Emery 132) 0.2 _ __ , ... _ .... ___ Syncro Wax Acid (Cl836) - 0.2 -Syncro Wax Acid (C~36) 0.1 0.2 _ .~ .. , Air (~ v/v) c 2.0 c 2.0 ~ 2.0 c 2.0 __ .__ . .__ Vis. 0 wk. R.T. 8600 7020 8000 8000 _ ~ . . ,._ ._ , _ Vis. 6 wks~. R.T. 4200 _ 6000 7100 8000 Vis. 6 wk9. at 100F 3200 __ 5920 9100 9350 Phase separation RT Slight Sep. Stable Stable Stable , . .___ ._ _ Stability 100F Unstable Stable Stable Stable r~ ~ ~3 1 ~ ~ ~ ~ ~ ~ ~ ~_ _ _ ~_ _ ~a Ln o o C` ~ ~ ~ _ 1~ O ~ (~ r~ 00 r~l O O Ln Ln O O
H O _ _ _ O O . _ r` _ O O _ cL~n d~ (~l r~ cO ri O O In Ln Ln O
~ o ~ rl ~ 1~ o ~ ~1 c~ c~ ~ o o~
_ _ _ _ _ _ _ . ___ __ __ O

C!~ Ln r-l N r~ O r-l r l O C` C In r-l _ _ _ _ _ _ ____ _ _ _ O
Ln In ~ ~ rl O r-l Ln r-l Ln C Ln r l O

. _~ O ~ ~`l rl O N O r' ul In -- ~`i o ~
- - - - - - - - - #

Ln O ~ ~ r-l a~ O O O Ln Ln L~ O ~ Lrt) ~ Ot`l ~`1 ~ O O r l O t~ t~ Ln ~1 r-l _ Ln _ _ _ _ o o o _ Ln ~. _ _ O s~
_ C~O ~ ~ r~ r-l L j r-l Ln t~ r~ r-l CU

Ln _ _ _ _ _ OO O _ Ln _ _ O r~ O
tq O Lll ~ N r-l O ri r-l N Ln ~l r-l r~
_ _ _ _ _ _ _ _ _ __ _ _ _ O
cn ~ N rl a~ O O O Ln Ln ~1 ~OI
O O N ~1 O O r-l Ln rl ~ ~ r; r-l _~ ~ ~ ~ _ _ _ h _~ #: __ ~3 Z; li~ ~ g ~ 'O
r-l L o\~ H ~q H ~ ~C O E~ H

O O ~ Ln v ~ E~ Ln H O E~ O P~ H ~Zj H r-l ~ V O ~ h O H O ~ H 111 O r-t ~ V H W O
V ~ ~ ~ ~q ~ U~~ ~ P~ V~ ~ U~`~ ~ ~ ~ ~ _~
_~ ~ 3~_ ~ ~_ __ _ _ _~2 _ _ Example 8 The ,llowing formulars A-B were prepared accordinq to the procedure oE Example 1.

A B
~__ ____ I

_ I
NaOH (50~) 4 5 4 5 l _ STEARIC ACID 0.06 0 06 . _ DOWFAX 3B-2 0 8 0 8 l ._ _._ ._ SODIUM SILICATE (47.5~) _ 20.83 _ 20.83 __ POTASSIUM TRIPOLYPHOSPHATE 20.35 20.35 . _ _ . _ _ .,_ SODIUM 3% H20 TRIPLOYPYPHOSPH~TE 5.26 _ 5.26 SODIUM HYPOCHLORITE (13~) 10.13 _ 10.13 WATER 36.877 36 877 , . .. _ . __ -- -- I
CI DIRECT YELLOW 28 0.003 HIGHLIGHTS III PERFUME O.05 O.03 . . _ ~

._ . _ _ ~rookfield viscosity measured at room temperature at #4 spindle at 20 rpms.

Claims (9)

1. An improved gel-like viscoelastic automatic dishwashing composition comprising 10 to 60 weight percent of an alkali metal containing compound selected from the group consisting essentially of alkali metal hydroxides, alkali metal tripolyphosphates, alkali metal pyrophosphates, alkali metal carbonates and alkali metal silicates, wherein there is present in the composition both potassium ions and sodium ions in a ratio of 1/1 to 45/1, 0 to 1.5 weight percent of a foam depressant; 0 to 5 weight percent of a chlorine bleach stable, water-dispersible, organic detergent active material, 0.02 to 2.0 weight percent of a long chain fatty acid or a metal salt thereof, water, and a means for substantially preventing the composition from wetting and adhering to an interior vertical surface of a polyolefinic bottle.

2. The composition of Claim 1, wherein said means comprises adding to the composition 0.1 to 2.0 weight percent of at least one polyacrylic acid thickening agent being selected from the group consisting essentially of acrylic acid or methacrylic acid, water-dispersible or water-soluble salts, esters, or amides thereof, and water-soluble copolymers of these acids or their salts, ester, or amides with each other or with one or more other ethylenically unsaturated monomers, wherein substantially all of the normally solid components of the composition are present dissolved in the aqueous phase, and substantially all of the water in the composition is tightly bound to the cross-linked polyacrylic acid thickening agent, said composition having a bulk density of from 1.28 g/cm3 to 1.42 g/cm3 and said composition does not exhibit phase separation and remains homogenous, when said composition is centrifuged at 1000 rpm or 30 minutes.

3. The composition of Claim 2, further including a chlorine bleach compound in an amount to provide 0.2 to 4.0 weight percent of available chlorine.

4. The composition of Claim 3, further including 0.1 to 10.0 weight percent of a polyacrylate having a molecular weight of 1,000 to 100,000.

5. Linear viscoelastic aqueous liquid automatic dishwasher detergent composition comprising water, 0.01 to 2% by weight of a long chain fatty acid or salt thereof having 20 to 50 carbon atoms, from 0 to 5% by weight of a low-foaming chlorine bleach stable, water dispersible automatic dishwasher non-soap organic detergent, from 5 to 40% by weight of at least one alkali metal detergent builder salt, a sufficient amount of a chlorine bleach compound to provide 0.2 to 4% by weight of available chlorine, and 0.1 to 2% by weight of at least one cross-linked polycarboxylate-type thickening agent having a molecular weight of at least 800,000 wherein the aqueous phase includes both sodium and potassium ions at a K/Na weight ratio of from 1/1 to 45/1.

6. The composition of claim 5 wherein said polycarboxylate-type thickening agent is a cross-linked polyacrylic acid having a molecular weight in the range of from 1,000,000 to 4,000,000.

7. A linear viscoelastic aqueous liquid automatic dishwasher detergent composition comprising approximately by weight:
(a) 10 to 35% of at least one alkali metal detergent builder salt, said alkali metal detergent builder salt being selected from the group consisting essentially of alkali metal tripolyphosphate, alkali metal pyrophosphate, alkali metal metaphosphate, alkali metal carbonate, alkali metal citrate and alkali metal nitrilotriacetate and mixtures thereof;
(b) 5 to 15% alkali metal silicate;
(c) 1 to 6% alkali metal hydroxide;
(d) 0 to 3.0% chlorine bleach stable, water-dispersible, organic detergent active material;
(e) 0 to 1.5% chlorine bleach stable foam depressant;
(f) chlorine bleach compound in an amount to provide 0.2 to 4% of available chlorine;
(g) 0.1 to 2.0% of a cross-linked polyacrylic acid thickening agent having a molecular weight of from 1,000,000 to 4,000,000;
(h) 0.02 to 2% of a long chain fatty acid or a metal salt of a fatty acid;
(i) 0.01 to 1.0 wt. % of a pigment and/or dye;
(j) water, wherein said polyacrylic acid thickening agent being selected from the group consisting essentially of acrylic acid or methacrylic acid, water-dispersible or water-soluble salts, esters, or amides thereof, and water-soluble copolymers of these acids or their salts, ester, or amides with each other or with one or more other ethylenically unsaturated monomers, wherein the aqueous phase includes both sodium and potassium ions at a K/Na weight ratio of from 1/1 to 45/1, wherein substantially all of the normally solid components of the composition are present dissolved in the aqueous phase, and substantially all of the water in the composition is tightly bound to the cross-linked polyacrylic acid thickening agent, said composition having a bulk density of from 1.32 g/cm3 to 1.42 g/cm3 and said composition does not exhibit phase separation and remains homogenous, when said composition is centrifuged at 1000 rpm for 30 minutes.

8. The composition of Claim 7 which the chlorine bleach compound is sodium hypochlorite.

9. The composition of Claim 7 further including a fragrance.