Classifications

• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
  • C11D1/14—Sulfonic acids or sulfuric acid esters; Salts thereof derived from aliphatic hydrocarbons or mono-alcohols
  • C11D1/146—Sulfuric acid esters
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/37—Mixtures of compounds all of which are anionic
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/38—Cationic compounds
  • C11D1/65—Mixtures of anionic with cationic compounds
  • C11D1/652—Mixtures of anionic compounds with carboxylic amides or alkylol amides
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/66—Non-ionic compounds
  • C11D1/83—Mixtures of non-ionic with anionic compounds
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
  • C11D1/29—Sulfates of polyoxyalkylene ethers
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/38—Cationic compounds
  • C11D1/52—Carboxylic amides, alkylolamides or imides or their condensation products with alkylene oxides
  • C11D1/523—Carboxylic alkylolamides, or dialkylolamides, or hydroxycarboxylic amides (R1-CO-NR2R3), where R1, R2 or R3 contain one hydroxy group per alkyl group
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/38—Cationic compounds
  • C11D1/52—Carboxylic amides, alkylolamides or imides or their condensation products with alkylene oxides
  • C11D1/525—Carboxylic amides (R1-CO-NR2R3), where R1, R2 or R3 contain two or more hydroxy groups per alkyl group, e.g. R3 being a reducing sugar rest
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/66—Non-ionic compounds
  • C11D1/662—Carbohydrates or derivatives
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/66—Non-ionic compounds
  • C11D1/72—Ethers of polyoxyalkylene glycols

Definitions

• the present invention relates to surfactant particles which comprise secondary (2,3) alkyl sulfate surfactants and one or more co-surfactants.
• the co-surfactants are believed to disrupt the crystallinity of the secondary (2,3) alkyl sulfates, and thereby
• the soluble particles are thus suitable for use in granular laundry compositions, even in cold water washing conditions.
• various detersive surfactants in order to remove a wide variety of soils and stains from surfaces.
• various anionic surfactants especially the alkyl benzene sulfon- ates, are useful for removing particulate soils
• various nonionic surfactants such as the alkyl ethoxylates and alkyl-
• ••-0 phenol ethoxylates are useful for removing greasy soils.
• One class of surfactants which has found limited use in various compositions where emulsification is desired comprises the secon ⁇ dary alkyl sulfates.
• the conventional secondary alkyl sulfates are available as generally pasty, random mixtures of sulfated
• condensed granular detergents are not without its difficulties.
• the so-called "inert" ingredients such as sodium sulfate are deleted.
• such ingredients do play a role in enhancing the solubility of detergent particles; hence, the condensed form will often suffer from solubility problems.
• conventional low-density detergent granules are usually prepared by spray-drying processes which result in porous detergent particles that are quite amenable to being solubilized in aqueous laundry liquors.
• condensed formulations will typically comprise substantially less porous, high density detergent particles which are less amenable to solubilization.
• the condensed form of granular detergents typically comprises particles which contain high levels of detersive ingredients with little room for solubilizing agents, and since such particles are intentionally manufactured at high bulk densities, the net result Is a substantial problem with regard to in-use solubility.
• the problems associated with "caking” or “clumping" of granular detergents can be accentuated in both spray-dried and condensed detergent products when mixtures of various surfactants and co-surfactants are used therein.
• the provision of crisp, free-flowing granular detergents remains a challenge to the formulator.
• secondary alkyl sulfates referred to herein as secondary (2,3) alkyl sulfates (“SAS”)
• SAS secondary alkyl sulfates
• the secondary alkyl (2,3) sulfates are available as dry, particulate solids which are more soluble in aqueous media than their counterpart primary alkyl sulfates of comparable chain lengths. Accordingly, they can be formulated as readily-soluble, high-surfactant (i.e., "high-active”) particles for use in granular laundry detergents.
• the solubility of the particulate secondary (2,3) alkyl sulfates allows them to be formulated in the concentrated, high density form now coming into vogue with granular laundry detergents. Since, with proper care in manufacturing, the secondary (2,3) alkyl sulfates are available in solid, particulate form, they can be dry-mixed into granular detergent compositions without the need for passage through spray drying towers. In addition to the foregoing advantages seen for the secondary (2,3) alkyl sulfates, it has now been determined that they are both aerobically and anaerobically degradable, which assists in their disposal in the environment. Moreover, they exhibit increased compatibility with detergent enzymes, especially in the presence of calcium ions.
• the particulate secondary (2,3) alkyl sulfates can be combined with various co-surfactants to yield high-active, mixed surfactant particles which are free-flowing and have a decreased tendency to cake or clump.
• SAS secondary (2,3) alkyl sulfates
• various co-surfactants especially polyhydroxy fatty acid amide surfactants (PFAS), alkyl ethoxylate surfactants (AE) and primary alkyl sulfate surfactants (AS) to provide mixed SAS/PFAS/AE/AS particles.
• the improved solubility is of substantial benefit under cold water conditions (e.g., at temperatures in the range of 5 * C to about 30'C) where the rate of solubility of granular detergents in an aqueous washing liquor can be problematic.
• the improved solubility achieved herein is also of substantial benefit when preparing the modern compact or dense detergent granules where solubility can be problematic.
• the mixed particles provided by this invention can be used to prepare fully-formulated granular laundry detergents, both of the low density and high density types.
• the present invention relates to the use of solid, secondary (2,3) alkyl sulfate surfactants to prepare "high-active", water- soluble surfactant particles containing, in one embodiment, at least about 80%, and in another embodiment at least about 35%, by weight of a mixture of detersive surfactants which comprises said secondary (2,3) alkyl sulfate surfactant in combination with one or more solubilizing co-surfactants.
• the invention thus encompasses surfactant particles which comprise at least about 80% by weight of total surfactants, said surfactants comprising a mixture of:
• Preferred particles of the foregoing type preferably comprise at least about 40%, more preferably at least about 75% by weight of C14-C18 secondary (2,3) alkyl sulfate surfactant, or mixtures thereof.
• the co-surfactant is a nonionic surfactant which preferably comprises no more than about 25% by weight of the surfactant mixture.
• Suitable nonionic co-surfactants are members selected from the group consisting of ethoxylated alcohols, ethoxylated alkyl phenols, polyhydroxy fatty acid amide amides, and alkyl polyglycosides, and fatty ethanol amides.
• co-surfactant component can comprise a mixture of polyhydroxy fatty acid amide, primary alkyl sulfate and alkyl ethoxy sulfate, typically at ratios of about 1:1:1.
• Preferred, non-tacky, free-flowing particles herein are those wherein the moisture content of the surfactants plus co-surfactants used to prepare the particles is less than about 20% by weight during the formulation process.
• the formulator may desire to include nonionic surfactants in amounts greater than 20% of the surfactant mixture. Inclusion in these larger proportions can be beneficial for solubility and performance, but is often difficult because of either the liquid nature of the nonionic surfactant, or the limited solubility of the solid nonionic surfactant.
• dry solid secondary (2,3) alkyl sulfate surfactant compositions of greater than 20% nonionics facilitates particle formation and solubility of both components, but usually requires the use of auxiliary dry ingredients to form a free-flowing particle. In such instances, dry ingredients may need to be included at proportions in excess of 20% of the particle, often in excess of 50% of the particle.
• the invention thus also encompasses a water-soluble agglomer ⁇ ated surfactant particle containing at least about 35% by weight of total surfactants comprising:
• agglomerated particle comprising conventional, powdered detergent ingredients and fillers.
• agglomerated particles are those wherein the co-surfactant is a member selected from the group consisting of nonionic ethoxylated alcohols, ethoxylated alkyl phenols, polyhydroxy fatty acid amides, alkyl polyglycosides, fatty ethanol amides, and mixtures thereof, or anionic primary alkyl sulfates, alkyl ethoxy sulfates, and mixtures thereof, or mixtures of said nonionic and anionic co-surfactants.
• Preferred agglomerates are those wherein the powdered ingredient (c) is selected from zeolite builders, layered silicate builders and mixtures thereof.
• Conventional solid fillers such as talc, or various nonhygroscopic silicates, sodium carbonate, sodium sulfate, and the like can also be used as the powdered ingredient (c).
• the surfactant particles herein will preferably comprise the surfactant:cosurfac ant (or mixture of co-surfactants) at a weight ratio of from about 10:1 to about 1:1, preferably about 7:1 to about 3:1.
• co-surfactants can be used as the "crystallinity-disrupting" material which enhances the solubility of the mixed particles herein.
• various ethoxylated C12-C18 alcohols such as C]4E0(5), C]6(E0)3 and the like can be used.
• such materials are generally liquids and may tend to cause the mixed particles to be undesirably tacky. If used, such liquid nonionics preferably comprise no more than 20% by weight of the particles.
• One class of especially suitable nonionic co-surfactants herein comprises the polyhydroxy fatty acid amide surfactant (PFAS) such as the C12-C18 NCj-C ⁇ alkyl glucamides disclosed more fully hereinafter.
• PFAS polyhydroxy fatty acid amide surfactant
• This class of nonionic surfactants has the advantage that they exist as slightly waxy solids at room temperature. Hence, when blended with the solid secondary (2,3) alkyl sulfates herein, the PFAS materials do not tend to increase the tackiness of the final mixed particles.
• co-surfactants useful herein for solubilizing purposes include Ci2" c 18 primary alkyl sulfates, but it will be appreciated by the formulator that a variety of acceptable co-surfactants may be chosen from standard formularies. Binary, ternary, quaternary, etc. mixtures of the secondary (2,3) alkyl sulfate/co-surfactants may also be used.
• the particles herein exhibit excellent free-flow properties. However, in one mode the particles can be additionally coated with a finely-divided particulate free-flow agent.
• Free-flow agents which are members selected from the group consisting of zeolites, layered silicates, silicates, particulate secondary (2,3) alkyl sulfate surfactants, and mixtures thereof, can be used for such coating, as can nonparticulate agents such as gelatin and polyvinylalcohol.
• Conventional primary alkyl sulfate surfactants have the general formula ROSO3-M+ wherein R is typically a linear C10-C20 hydrocarbyl group and M is a water-solubilizing cation.
• Branched-chain primary alkyl sulfate surfactants i.e., branched-chain "PAS" having 10-20 carbon atoms are also known; see, for example, European Patent Application 439,316, Smith et al, filed 21.01.91.
• водородани Conventional secondary alkyl sulfate surfactants are those materials which have the sulfate moiety distributed randomly along the hydrocarbyl "backbone" of the molecule. Such materials may be depicted by the structure CH3(CH 2 )n(CH0S03-M+)(CH2) m CH3 wherein m and n are integers of 2 or greater and the sum of m + n is typically about 9 to 17, and M is a water-solubilizing cation.
• the selected secondary (2,3) alkyl sulfate surfactants used herein comprise structures of formulas A and B
• Mixtures of the 2- and 3-sulfate can be used herein.
• x and (y+1) are, respectively, integers of at least about 6, and can range from about 7 to about 20, preferably about 10 to about 16.
• M is a cation, such as an alkali metal, ammonium, alkanolammonium, alkaline earth metal, or the like.
• Sodium is typical for use as M to prepare the water-soluble (2,3) alkyl sulfates, but ethanolam- monium, diethanolammonium, triethanolammonium, potassium, ammonium, and the like, can also be used.
• the C10-C20 secondary (2,3) alkyl sulfates can conveniently be employed herein.
• the C24- 18 compounds are preferred for laundry cleaning operations.
• the physical/chemical properties of the foregoing types of alkyl sulfate surfactants are unexpectedly different, one from another, in several aspects which are important to formulators of granular detergent compositions.
• the primary alkyl sulfates can disadvantageously interact with, and even be precipitated by, metal cations such as calcium and magnesium.
• metal cations such as calcium and magnesium.
• water hardness can negatively affect the primary alkyl sulfates to a greater extent than the secondary (2,3) alkyl sulfates.
• the secondary (2,3) alkyl sulfates have now been found to be preferred for use in the presence of calcium ions and under conditions of high water hardness, or in the so-called "under-built” situation which can occur when nonphosphate builders are employed.
• the solubility of the primary alkyl sulfates is not as great as the secondary (2,3) alkyl sulfates.
• the formulation of high-active, flowable, soluble surfactant particles and has now been found to be simpler and more effective with the secondary (2,3) alkyl sulfates than with the primary alkyl sulfates.
• the random secondary alkyl sulfates i.e., secondary alkyl sulfates with the sulfate group at positions such as the 4, 5, 6, 7, etc. secondary carbon atoms
• such materials tend to be tacky solids or, more generally, pastes.
• the random alkyl sulfates do not afford the processing advantages associated with the solid secondary (2,3) alkyl sulfates when formulating mixed detergent particles in the manner of this invention.
• the secondary (2,3) alkyl sulfates be substantially free (i.e., contain less than about 20%, preferably less than about 10%, most preferably less than about 5%) of such random secondary alkyl sulfates.
• the secondary (2,3) alkyl sulfates used herein are quite different in several important properties from the secondary olefin sulfonates (e.g., U.S. Patent 4,064,076, Klisch et al, 12/20/77); accordingly, the secondary sulfonates are not the focus of the present invention.
• the preparation of the secondary (2,3) alkyl sulfates of the type useful herein can be carried out by the addition of H2SO4 to olefins.
• a typical synthesis using ⁇ -olefins and sulfuric acid is disclosed in U.S. Patent 3,234,258, Morris, or in U.S. Patent 5,075,041, Lutz, granted December 24, 1991.
• the secondary (2,3) alkyl sulfates can be further purified to remove unwanted sodium sulfate.
• Various means can be used to lower the sodium sulfate content of the secondary (2,3) alkyl sulfates. For example, when the H2SO4 addition to the olefin is completed, care can be taken to remove unreacted H2SO4 before the acid form of the secondary (2,3) alkyl sulfate is neutralized.
• the sodium salt form of the secondary (2,3) alkyl sulfate which contains sodium sulfate can be rinsed with water at a temperature near or below the Krafft temperature of the sodium secondary (2,3) alkyl sulfate.
• Krafft temperature is a term of art which is well-known to workers in the field of surfactant sciences.
• Krafft temperature is described by K. Shinoda in the text “Principles of Solution and Solubility", translation in collaboration with Paul Becher, published by Marcel Dekker, Inc. 1978 at pages 160-161.
• the solubility of a surface active agent in water increases rather slowly with temperature up to that point, i.e., the Krafft temperature, at which the solubility evidences an extremely rapid rise.
• the Krafft temperature At a temperature approximately 4 * C above the Krafft temperature a solution of almost any composition becomes a homogeneous phase.
• the Krafft temperature of any given type of surfactant such as the secondary (2,3) alkyl sulfates herein which comprise an anionic hydrophilic sulfate group and a hydrophobic hydrocarbyl group, will vary with the chain length of the hydrocarbyl group. This is due to the change in water solubility with the variation in the hydrophobic portion of the surfactant molecule.
• the formulator may optionally wash the secondary (2,3) alkyl sulfate surfactant which is contaminated with sodium sulfate with water at a temperature that is no higher than the Krafft temperature, and which is preferably lower than the Krafft temperature, for the particular secondary (2,3) alkyl sulfate being washed. This allows the sodium sulfate to be dissolved and removed with the wash water, while keeping losses of the secondary (2,3) alkyl sulfate into the wash water to a minimum.
• the secondary (2,3) alkyl sulfate surfactant herein comprises a mixture of alkyl chain lengths
• the Krafft temperature will not be a single point but, rather, will be denoted as a "Krafft boundary”.
• the optional sodium sulfate removal operation it is preferred to conduct the optional sodium sulfate removal operation at a temperature which is below the Krafft boundary, and preferably below the Krafft temperature of the shortest chain-length surfactant present in such mixtures, since this avoids excessive losses of secondary (2,3) alkyl sulfate to the wash solution.
• Ci6 secondary sodium alkyl (2,3) sulfate surfactants it is preferred to conduct the washing operation at temperatures below about 30 * C, preferably below about 20 * C. It will be appreciated that as the cation is changed, the Krafft temperature of the secondary (2,3) alkyl sulfate will change; hence, the washing temperature should be adjusted appropriately.
• the washing process can be conducted batchwise by suspending wet or dry secondary (2,3) alkyl sulfates in sufficient water to provide 10-50% solids, typically for a mixing time of at least 10 minutes at about 22 * C (for a Ci6 secondary [2,3] alkyl sulfate), followed by pressure filtration.
• the slurry will comprise somewhat less than 35% solids, inasmuch as such slurries are free-flowing and amenable to agitation during the washing process.
• the washing process also reduces the levels of organic contaminants which comprise the random secondary alkyl sulfates noted above.
• Co-Surfactants contain various anionic, nonionic, zwitterionic, etc. co-surfactants. Such co-surfactants are typically present at levels of from about 5% to about 50% by weight of the particles.
• co-surfactants useful herein include the conventional Cn-Cjs alkyl benzene sulfonates and primary and random alkyl sulfates (having due regard for their solubility and tendency toward tackiness, as noted above), the Cjo-Ci ⁇ alkyl alkoxy sulfates (especially E0 1-5 ethoxy sulfates), the Cio-Cj ⁇ alkyl alkoxy carboxylates (especially E0 1-5 ethoxy carboxylates), the Cio-Ci ⁇ alkyl polyglycosides and their corresponding sulfated polyglycosides, C12-C18 alpha-sulfonated fatty acid esters, C12-C18 alkyl and al
• Preferred particles herein are substantially free of alkyl benzene sulfonates. Indeed, one advantage of the present invention is that it provides a replacement for such surfactants in laundry compositions.
• One particular class of nonionic co-surfactants especially useful herein comprises the polyhydroxy fatty acid amide surfactant materials (PFAS) of the formula:
• R 1 is H, Cj-C ⁇ hydrocarbyl, 2-hydroxyethyl, 2-hydroxy- propyl, or a mixture thereof, preferably C1-C4 alkyl, more prefer ⁇ ably Ci or C2 alkyl, most preferably Ci alkyl (i.e., methyl); and R2 is a C5-C32 hydrocarbyl moiety, preferably straight chain C7-C19 alkyl or alkenyl, more preferably straight chain C9-C17 alkyl or alkenyl, most preferably straight chain Cji-Cjg alkyl or alkenyl, or mixture thereof; and Z is a polyhydroxyhydrocarbyl moiety having a linear hydrocarbyl chain with at least 2 (in the case of glyceraldehyde) or at least 3 hydroxyls (in the case of other reducing sugars) directly connected to the chain, or an alkoxylated derivative (preferably e
• Z preferably will be derived from a reducing sugar in a reductive amination reaction; more preferably Z is a glycityl moiety.
• Suitable reducing sugars include glucose, fructose, maltose, lactose, galactose, mannose, and xylose, as well as glyceraldehyde.
• high dextrose corn syrup, high fructose corn syrup, and high maltose corn syrup can be utilized as well as the individual sugars listed above. These corn syrups may yield a mix of sugar components for Z. It should be understood that it is by no means intended to exclude other suitable raw materials.
• Z preferably will be selected from the group consisting of -CH2-(CHOH) n -CH2 ⁇ H, -CH(CH2 ⁇ H)-(CHOH) n -i- CH2OH, -CH2-(CHOH)2(CHOR')(CHOH)-CH2 ⁇ H, where n is an integer from 1 to 5, inclusive, and R' is H or a cyclic mono- or poly- saccharide, and alkoxylated derivatives thereof. Most preferred are glycityls wherein n is 4, particularly -CH2-(CHOH)4-CH2 ⁇ H.
• Rl can be, for example, N-methyl, N-ethyl, N-propyl, N-isopropyl, N-butyl, N-isobutyl, N-2-hydroxy ethyl, or N-2-hydroxy propyl.
• Rl is preferably methyl or hydroxyalkyl .
• Rl is preferably C2-C8 alkyl, especially n-propyl, iso-propyl, n-butyl, iso-butyl, pentyl, hexyl and 2-ethyl hexyl.
• R2-C0-N ⁇ can be, for example, cocamide, stearamide, oleamide, lauramide, myristamide, capricamide, palmitamide, tallowamide, etc.
• the methods comprise reacting N-alkylamino polyols with, preferably, fatty acid methyl esters in a solvent using an alkoxide catalyst at temperatures of about 85*C to provide high yields (90-98%) of polyhydroxy fatty acid amides having desirable low levels (typically, less than about 1.0%) of sub-optimally degradable cyclized by-products and also with improved color and improved color stability, e.g., Gardner Colors below about 4, preferably between 0 and 2.
• any unreacted N-alkylamino polyol remaining in the product can be acylated with an acid anhydride, e.g., acetic anhydride, maleic anhydride, or the like, to minimize the overall level of such residual amines in the product.
• Residual sources of classical fatty acids, which can suppress suds, can be depleted by reaction with, for example, triethanolamine.
• cyclized by-products herein is meant the undesirable reaction by-products of the primary reaction wherein it appears that the multiple hydroxyl groups in the polyhydroxy fatty acid amides can form ring structures which are, in the main, not readily biodegradable. It will be appreciated by those skilled in the chemical arts that the preparation of the polyhydroxy fatty acid amides herein using the di- and higher saccharides such as maltose will result in the formation of polyhydroxy fatty acid amides wherein linear substituent Z (which contains multiple hydroxy substituents) is naturally "capped” by a polyhydroxy ring structure. Such materials are not cyclized by-products, as defined herein.
• the foregoing polyhydroxy fatty acid amides can also be sulfated, e.g., by reaction with S03/pyridine, and the resulting sulfated material used as an anionic co-surfactant herein.
• High-active content detergent particles which comprise a mixture of the secondary (2,3) alkyl sulfates and one or more of the co-surfactants.
• high-active content particles can comprise 35% by weight of particles and greater, preferably 80% and greater, most preferably 90% and greater, of the mixture of secondary (2,3) alkyl sulfate surfactant plus co-surfactant.
• mixtures used in said particles will typically comprise at least about 40%, more preferably at least about 50%, by weight of the secondary (2,3) alkyl sulfate, the balance comprising the co-surfactant or mixtures of co-surfactants.
• the formulator may choose to coat the surfaces of the mixed particles with a free-flow promoter, such as finely- divided zeolite powder, or even, as now discovered, with a fine powder of the secondary (2,3) alkyl sulfate.
• a free-flow promoter such as finely- divided zeolite powder
• the formulator will also recognize that with certain co-surfactants the overall solubility of the mixed high-active particles may need additional boosting, especially in very cold water or with high density granules. Under such circumstances, various additional solubilizing agents can be incorporated into the particles, typically at levels in the range of 5%-20% by weight of particles. For example, any highly soluble material can be used for this purpose, and innocuous inorganic salts such as sodium sulfate, sodium bicarbonate, soluble builders as disclosed herein, and the like are typical.
• the mixed particles herein can comprise, for example: secondary (2,3) alkyl sulfates plus primary Cjo-Cie alkyl sul ⁇ fates; secondary (2,3) alkyl sulfates plus alkyl ethoxy carboxyl ⁇ ates; secondary (2,3) alkyl sulfates plus polyhydroxy fatty acid amide surfactants described more fully hereinafter; secondary (2,3) alkyl sulfates plus alkyl ethoxy sulfates; secondary (2,3) alkyl sulfates plus primary alkyl sulfates plus polyhydroxy fatty acid amides; secondary (2,3) alkyl sulfates plus alkyl ethoxy sulfates plus polyhydroxy fatty acid amides; secondary (2,3) alkyl sulfates plus primary alkyl sulfates plus alkyl ethoxy sulfates plus polyhydroxy fatty acid amides; secondary (2,3) alkyl sulfates plus primary alkyl
• Particles comprising the secondary (2,3) alkyl sulfates plus conventional Cio-Cj ⁇ soaps can also be prepared.
• the foregoing are intended to be nonlimiting examples of such mixed particles, others of which will readily come to mind with the skilled formulator.
• particles used herein comprising the secondary (2,3) alkyl sulfate surfactants can be prepared using a variety of well-known processes.
• particles can be formed by agglomeration, wherein solids (including the secondary (2,3) alkyl sulfates) are forced/hurled together by physical mixing and held together by a binder.
• Suitable apparatus for agglomeration includes dry powder mixers, fluid beds and turbilizers, available from manufacturers such as L ⁇ dige, Eric, Bepex and Aeromatic.
• particles can be formed by extrusion.
• solids such as the secondary (2,3) alkyl sulfates are forced together by pumping a damp powder at relatively high pressures and high energy inputs through small holes in a die plate.
• This process results in rod like particles which can be divided into any desired particle size.
• Apparatus includes axial or radial extruders such as those available from Fuji, Bepex and Teledyne/Readco.
• particles can be formed by prilling.
• a liquid mixture containing the desired ingredients i.e., one of them being secondary (2,3) alkyl sulfate particles
• the desired ingredients i.e., one of them being secondary (2,3) alkyl sulfate particles
• the liquid droplets cool they become more solid and thus the particles are formed.
• the solidification can occur due to the phase change of a molten binder to a solid or through hydration of free mois ⁇ ture into crystalline bound moisture by some hydratable material in the original liquid mixture.
• particles can be formed by compaction. This method is similar to tablet formation processes, wherein solids (I.e., secondary [2,3] alkyl sulfate particles) are forced together by compressing the powder feed into a die/mold on rollers or flat sheets.
• solids I.e., secondary [2,3] alkyl sulfate particles
• particles can be formed by melt/solidifica ⁇ tion.
• particles are formed by melting the second- ary (2,3) alkyl sulfate with any desired additional ingredient and allowing the melt to cool, e.g., in a mold or as droplets.
• Binders can optionally be used in the foregoing methods to enhance particle integrity and strength.
• Water alone, is an operative binder with secondary (2,3) alkyl sulfates, since it will dissolve some of the secondary (2,3) alkyl sulfate to provide a binding function.
• Other binders include, for example, starches, polyacrylates, carboxymethylcellulose and the like. Binders are well-known in the particle making literature. If used, binders are typically employed at levels of 0.1%-5% by weight of the finished particles.
• fillers such as hydratable and nonhydratable salts, crystalline and glassy solids, various detersive ingredients such as zeolites and the like, can be incorporated in the particles.
• Such fillers typically comprise up to about 40% by weight of the particles.
• Particles prepared in the manner disclosed herein can be subsequently dried or cooled to adjust their strength, physical properties and final moisture content, according to the desires of the formulator. Particle Formation
• the desired particle size can be achieved, for example, in blenders, such as that marketed under the trademark OSTER or in large-scale mills, such as that available under the trademark WILEY mill.
• the melt comprising the mixed surfactant plus co-surfactants can be sprayed through a nozzle to form droplets which, when cooled, provide particles of the desired size.
• a rotating disc can be used to form droplets of a melt comprising the secondary (2,3) alkyl sulfate and any desired co-surfactants.
• the droplets are then solidified by cooling and may be passed through appropriate sieves to secure particles of any desired size.
• tower prilling can be used to provide particles having a distribution of sizes around a given mean size range.
• a homogeneous melt of the secondary (2,3) alkyl sulfate plus co-surfactants is solidified and comminuted to provide particles.
• High energy comminution processes such as hammer, rod and ball mills can be used.
• low energy comminution processes such as grating through sieves of any desired pore size can be employed.
• the mixed surfactant/co-surfactants particles When used as the bulk surfactant ingredient in detergent compositions, the mixed surfactant/co-surfactants particles will typically range in size from about 400 to about 1,600 microns.
• the secondary (2,3) alkyl sulfate When used to coat larger particles comprising surfactant/co- surfactant mixtures herein, the secondary (2,3) alkyl sulfate will typically be in a substantially finer size range, typically from about 0.1 to about 5 microns. In any event, any desired size ranges herein can be achieved using standard sieves.
• Granulation Equipment Various means and equipment are available to prepare granular particles and detergent compositions according to the present invention. Current commercial practice in the field employs spray-drying towers to manufacture granular laundry detergents which have a density less than about 550 grams/liter. Accord ⁇ ingly, conventional spray drying can be used as the overall process herein. In the alternative, the formulator can eliminate spray-drying by using mixing, densifying and granulating equipment that is commercially available. The following is a nonlimiting description of such equipment suitable for use herein. High speed mixer/densifiers can optionally be used in the present process.
• the device marketed under the trademark "Lodige CB30" Recycler comprises a static cylindrical mixing drum having a central rotating shaft with mixing/cutting blades mounted thereon.
• the ingredients for the detergent composition are introduced into the drum and the shaft/blade assembly is rotated at speeds in the range of 100-2500 rpm to provide thorough mixing/densification.
• Other such apparatus includes the devices marketed under the trademark “Shugi Granulator” and under the trademark “Drais K-TTP 80).
• a processing step involving further densification can be conducted.
• Equipment such as that marketed under the trademark "L ⁇ dige KM300 Mixer", also known as the "Lodige Ploughshare" can be used. Such equipment is typically operated at 40-160 rpm.
• Other useful equipment includes the device which is available under the trademark "Drais K-T 160".
• the granulation process can be conducted using a fluidized bed mixer.
• the various ingredients of the finished composition are combined in an aqueous slurry and sprayed into a fluidized bed of particles comprising the secondary (2,3) alkyl sulfate plus co-surfactant to provide the finished detergent granules.
• the slurry can be sprayed into a fluidized bed of zeolite or layered silicate particles, or into a mixture of particles comprising secondary (2,3) alkyl sulfate/co-surfactant plus zeolite and/or layered silicate particles.
• the first step may optionally include mixing of the slurry using a "L ⁇ dige CB30" or “Flexomix 160", available from Shugi. Fluidized bed or moving beds of the type available under the trademark “Escher Wyss can be used in such processes.
• the compositions herein can be prepared by a combination of a spray-drying step, followed by an admixing/densi- fication step.
• a spray-drying step followed by an admixing/densi- fication step.
• an aqueous slurry of various heat-stable ingredients in the final detergent composition are formed into homogeneous granules by passage through a spray-dry tower, using conventional techniques.
• the resulting granules are then admixed with particles of the secondary (2,3) alkyl sulfate plus co-surfactant in a rotary or screw-type mixer/densifier, using a residence time of typically 1-5 minutes at an operating speed of 500-1500 rpm to provide the finished, densified product.
• heat-labile ingredients such as detersive enzymes and bleach activators are added to the composition in the mixer/densifier apparatus.
• the compositions are prepared and densified by passage through two mixer and densifier machines operating in sequence.
• the desired compositional ingredients can be admixed and passed through a L ⁇ dige mixer using residence times of 0.1 to 1.0 minutes then passed through a second L ⁇ dige mixer using residence times of 1 minute to 5 minutes.
• compositions can be prepared in densified granular form using any of the foregoing methods, followed by admixture with finely-powdered (typically 0.1-10 micrometer) particles comprising either pure secondary (2,3) alkyl sulfate, or mixtures thereof with the co-surfactant.
• finely-powdered particles typically 0.1-10 micrometer
• This provides a coating of particulate secondary (2,3) alkyl sulfate on the exterior surfaces of the densified granules, which enhances their flowability and reduces caking.
• an aqueous slurry (typically 80% solids content) comprising the desired formulation ingredients is sprayed into a fluidized bed of particulate secondary (2,3) alkyl sulfate plus co-surfactant (typically 400-1,200 micron size).
• the resulting particles can be further densified by passage through a L ⁇ dige apparatus, as noted above.
• Adjunct Ingredients In addition to the particles comprising secondary (2,3) alkyl sulfates plus co-surfactants, the detergent compositions herein will typically comprise various adjunct ingredients. Nonlimiting examples of such ingredients are as follows.
• Enzvmes - Enzymes can be included in the detergent formula ⁇ tions herein for a wide variety of fabric laundering purposes, including removal of protein-based, carbohydrate-based, or triglyceride-based stains, to prevent refugee dye transfer, and for fabric restoration.
• the enzymes to be incorporated include proteases, amylases, Upases, cellulases, and peroxidases, as well as mixtures thereof. Other types of enzymes may also be included. They may be of any suitable origin, such as vegetable, animal, bacterial, fungal and yeast origin. However, their choice is governed by several factors such as pH-activity and/or stability optima, thermostability, stability versus active detergents, builders and so on. In this respect bacterial or fungal enzymes are preferred, such as bacterial amylases and proteases, and fungal cellulases.
• Enzymes are normally incorporated at levels sufficient to provide up to about 5 mg by weight, more typically about 0.01 mg to about 3 mg, of active enzyme per gram of the composition. Stated otherwise, the compositions herein will typically comprise from about 0.001% to about 5%, preferably 0.01%-1%, by weight of a commercial enzyme preparation. Protease enzymes are usually present in such commercial preparations at levels sufficient to provide from 0.005 to 0.1 Anson units (AU) of activity per gram of composition. Suitable examples of proteases are the subtilisins which are obtained from particular strains of B.subtilis and B.licheniforms.
• protease is obtained from a strain of Bacillus, having maximum activity throughout the pH range of 8-12, developed and sold by Novo Industries A/S under the registered trade name ESPERASE. The preparation of this enzyme and analogous enzymes is described in British Patent Specification No. 1,243,784 of Novo.
• Proteolytic enzymes suitable for removing protein-based stains include those sold under the tradenames ALCALASE and SAVINASE by Novo Industries A/S (Denmark) and MAXATASE by International Bio-Synthetics, Inc. (The Netherlands).
• Other proteases include Protease A (see European Patent Application 130,756, published January 9, 1985) and Protease B (see European Patent Application Serial No. 87303761.8, filed April 28, 1987, and European Patent Application 130,756, Bott et al, published January 9, 1985).
• Amylases include, for example, ⁇ -amylases described in British Patent Specification No. 1,296,839 (Novo), RAPIDASE, International Bio-Synthetics, Inc. and TERMAMYL, Novo Industries.
• the cellulases usable in the present invention include both bacterial or fungal cellulase. Preferably, they will have a pH optimum of between 5 and 9.5. Suitable cellulases are disclosed in U.S. Patent 4,435,307, Barbesgoard et al, issued March 6, 1984, which discloses fungal cellulase produced from Humicola insolens and Humicola strain DSM1800 or a cellulase 212-producing fungus belonging to the genus Aeromonas, and cellulase extracted from the hepatopancreas of a marine mollusk (Dolabella Auricula Solander). Suitable cellulases are also • disclosed in GB-A-2.075.028; GB-A-2.095.275 and DE-OS-2.247.832.
• Suitable lipase enzymes for detergent usage include those produced by microorganisms of the Pseudomonas group, such as Pseudomonas stutzeri ATCC 19.154, as disclosed in British Patent 1,372,034. See also lipases in Japanese Patent Application 53-20487, laid open to public inspection on February 24, 1978. This lipase is available from Amano Pharmaceutical Co. Ltd., Nagoya, Japan, under the trade name Lipase P "Amano,” hereinafter referred to as "Amano-P.” Other commercial lipases include Amano-CES, lipases ex Chromobacter viscosum, e.g. Chromobacter viscosum var.
• Peroxidase enzymes are used in combination with oxygen sources, e.g., percarbonate, perborate, persulfate, hydrogen peroxide, etc. They are used for "solution bleaching," i.e. to prevent transfer of dyes or pigments removed from substrates during wash operations to other substrates in the wash solution.
• Peroxidase enzymes are known in the art, and include, for example, horseradish peroxidase, ligninase, and haloperoxidase such as chloro- and bro o-peroxidase.
• Peroxidase-containing detergent compositions are disclosed, for example, in PCT International Application WO 89/099813, published October 19, 1989, by 0. Kirk, assigned to Novo Industries A/S.
• Enzyme stabilization systems are also described, for example, in U.S. Patents 4,261,868, 3,600,319, and 3,519,570.
• Enzyme Stabilizers The enzymes employed herein are stabil ⁇ ized by the presence of water-soluble sources of calcium ions in the finished compositions which provide calcium ions to the enzymes. Additional stability can be provided by the presence of various other art-disclosed stabilizers, especially borate species: see Severson, U.S. 4,537,706, cited above.
• Typical detergents will comprise from about 1 to about 30, preferably from about 2 to about 20, more preferably from about 5 to about 15, and most preferably from about 8 to about 12, millimoles of calcium ion per liter of finished composition. This can vary somewhat, depending on the amount of enzyme present and its response to the calcium ions.
• the level of calcium ion should be selected so that there is always some minimum level available for the enzyme, after allowing for complexation with builders, fatty acids, etc., in the composition.
• Any water-soluble calcium salt can be used as the source of calcium ion, including, but not limited to, calcium chloride, calcium sulfate, calcium malate, calcium hydroxide, calcium formate, and calcium acetate.
• a small amount of calcium ion generally from about 0.05 to about 0.4 millimoles per liter, is often also present in the composition due to calcium in the enzyme slurry and formula water.
• Solid detergent compositions according to the present invention may include a sufficient quantity of a water-soluble calcium ion source to provide such amounts in the laundry liquor. In the alternative, natural water hardness may suffice.
• compositions herein may comprise from about 0.05% to about 2% by weight of a water-soluble source of calcium ions.
• the amount can vary, of course, with the amount and type of enzyme employed in the composition.
• compositions herein may also optionally, but preferably, contain various additional stabilizers, especially borate-type stabilizers.
• additional stabilizers especially borate-type stabilizers.
• such stabilizers will be used at levels in the compositions from about 0.25% to about 10%, preferably from about 0.5% to about 5%, more preferably from about 0.75% to about 3%, by weight of boric acid or other borate compound capable of forming boric acid in the composition (calculated on the basis of boric acid).
• Boric acid is preferred, although other compounds such as boric oxide, borax and other alkali metal borates (e.g., sodium ortho-, meta- and pyroborate, and sodium pentaborate) are suitable.
• compositions herein can option ⁇ ally include one or more other detergent adjunct materials or other materials for assisting or enhancing cleaning performance, treatment of the substrate to be cleaned, or to modify the aesthetics of the detergent composition (e.g., perfumes, colorants, dyes, etc.). The following are illustrative examples of such adjunct materials.
• Builders - Detergent builders can optionally be included in the compositions herein to assist in controlling mineral hardness. Inorganic as well as organic builders can be used. Builders are typically used in fabric laundering compositions to assist in the removal of particulate soils.
• the level of builder can vary widely depending upon the end use of the composition and its desired physical form. When present, the compositions will typically comprise at least about 1% builder. Granular formulations typically comprise from about 10% to about 80%, more typically from about 15% to about 50% by weight, of the detergent builder. Lower or higher levels of builder, however, are not meant to be excluded.
• Inorganic detergent builders include, but are not limited to, the alkali metal, ammonium and alkanolammonium salts of polyphos- phates (exemplified by the tripolyphosphates, pyrophosphates, and glassy polymeric meta-phosphates), phosphonates, phytic acid, silicates, carbonates (including bicarbonates and sesquicarbon- ates), sulphates, and aluminosilicates.
• non-phosphate builders are required in some locales.
• the composi ⁇ tions herein function surprisingly well even in the presence of the so-called “weak” builders (as compared with phosphates) such as citrate, or in the so-called “underbuilt” situation that may occur with zeolite or layered silicate builders.
• the secondary (2,3) alkyl sulfate plus enzyme components perform best in the presence of weak, nonphosphate builders which allow free calcium ions to be present.
• silicate builders are the alkali metal silicates, particularly those having a SiQ2:Na2 ⁇ ratio in the range 1.6:1 to 3.2:1 and layered silicates, such as the layered sodium silicates described in U.S. Patent 4,664,839, issued May 12, 1987 to H. P. Rieck.
• NaSKS-6 is the trademark for a crystalline layered silicate marketed by Hoechst (commonly abbreviated herein as "SKS-6").
• Hoechst commonly abbreviated herein as "SKS-6”
• the Na SKS-6 silicate builder does not contain aluminum.
• NaSKS-6 has the delta-Na2Si0s morphology form of layered silicate.
• SKS-6 is a highly preferred layered silicate for use herein, but other such layered silicates, such as those having the general formula NaMSi ⁇ 2 ⁇ +i*yH2 ⁇ wherein M is sodium or hydrogen, x is a number from 1.9 to 4, preferably 2, and y is a number from 0 to 20, preferably 0, can be used.
• Various other layered silicates from Hoechst include NaSKS-5, NaSKS-7 and NaSKS-11, as the alpha, beta and gamma forms.
• the delta-Na2S105 (NaSKS-6 form) 1s most preferred for use herein.
• Other silicates may also be useful such as for example magnesium silicate, which can serve as a crispening agent in granular formulations, as a stabilizing agent for oxygen bleaches, and as a component of suds control systems.
• carbonate builders are the alkaline earth and alkali metal carbonates as disclosed in German Patent Application No. 2,321,001 published on November 15, 1973.
• Aluminosilicate builders are especially useful in the present invention. Aluminosilicate builders are of great importance in most currently marketed heavy duty granular detergent composi ⁇ tions. Aluminosilicate builders include those having the empirical formula:
• Preferred aluminosilicates are zeolite builders which have the formula:
• aluminosilicate ion exchange materials are commer ⁇ cially available. These aluminosilicates can be crystalline or amorphous in structure and can be naturally-occurring aluminosili ⁇ cates or synthetically derived. A method for producing alumino ⁇ silicate ion exchange materials is disclosed in U.S. Patent 3,985,669, Krummel, et al , issued October 12, 1976. Preferred synthetic crystalline aluminosilicate ion exchange materials useful herein are available under the designations Zeolite A, Zeolite P (B), and Zeolite X.
• the crystalline aluminosilicate ion exchange material has the formula: Nai2[(A10 2 )l2(Si ⁇ 2)l2]-xH2 ⁇ wherein x is from about 20 to about 30, especially about 27.
• This material is known as Zeolite A.
• the aluminosilicate has a particle size of about 0.1-10 microns in diameter.
• Organic detergent builders suitable for the purposes of the present invention include, but are not restricted to, a wide variety of polycarboxylate compounds.
• polycar- boxylate refers to compounds having a plurality of carboxylate groups, preferably at least 3 carboxylates.
• Polycarboxylate builder can generally be added to the composition in acid form, but can also be added in the form of a neutralized salt. When utilized in salt form, alkali metals, such as sodium, potassium, and lithium, or alkanolammonium salts are preferred.
• polycarboxylate builders include a variety of categories of useful materials.
• One important category of poly- carboxylate builders encompasses the ether polycarboxylates, including oxydisuccinate, as disclosed in Berg, U.S. Patent 3,128,287, issued April 7, 1964, and Lamberti et al, U.S. Patent 3,635,830, issued January 18, 1972. See also "TMS/TDS" builders of U.S. Patent 4,663,071, issued to Bush et al, on May 5, 1987.
• Suitable ether polycarboxylates also include cyclic compounds, particularly alicyclic compounds, such as those described in U.S.
• ether hydroxy- polycarboxylates copolymers of maleic anhydride with ethylene or vinyl methyl ether, 1, 3, 5-trihydroxy benzene-2, 4, 6-trisul- phonic acid, and carboxymethyloxysuccinic acid
• various alkali metal, ammonium and substituted ammonium salts of polyacetic acids such as ethylenediamine tetraacetic acid and nitrilotriacetic acid
• polycarboxylates such as ellitic acid, succinic acid, oxydisuccinic acid, polymaleic acid, benzene 1,3,5-tricar- boxylic acid, carboxymethylox succinic acid, and soluble salts thereof.
• Citrate builders e.g., citric acid and soluble salts thereof (particularly sodium salt), are polycarboxylate builders of particular importance for heavy duty detergent formulations due to their availability from renewable resources and their biodegrad- ability. Citrates can also be used in granular compositions, especially in combination with zeolite and/or layered silicate builders. Oxydisuccinates are also especially useful in such compositions and combinations.
• succinic acid builders include the C5-C20 alkyl and alkenyl succinic acids and salts thereof.
• a particularly preferred compound of this type is dodecenylsuccinic acid.
• succinate builders include: laurylsuc- cinate, myristylsuccinate, palmitylsuccinate, 2-dodecenylsuccinate (preferred), 2-pentadecenylsuccinate, and the like.
• Laurylsuccin- ates are the preferred builders of this group, and are described in European Patent Application 86200690.5/0,200,263, published November 5, 1986.
• Other suitable polycarboxylates are disclosed in U.S. Patent 4,144,226, Crutchfield et al, issued March 13, 1979 and in U.S. Patent 3,308,067, Diehl, issued March 7, 1967. See also Diehl U.S. Patent 3,723,322.
• Fatty acids e.g., C12-C 8 monocarboxylic acids
• the aforesaid builders especially citrate and/or the succinate builders, to provide additional builder activity.
• Such use of fatty acids will generally result in a diminution of sudsing, which should be taken into account by the formulator.
• the various alkali metal phosphates such as the well-known sodium tripolyphosphates, sodium pyrophosphate and sodium orthophosphate can be used.
• Phosphonate builders such as ethane-1-hydroxy-1,1- diphosphonate and other known phosphonates (see, for example, U.S.
• Patents 3,159,581; 3,213,030; 3,422,021; 3,400,148 and 3,422,137) can also be used.
• the detergent compositions herein may optionally contain bleaching agents or bleaching compositions containing a bleaching agent and one or more bleach activators.
• bleaching agents will typically be at levels of from about 1% to about 30%, more typically from about 5% to about 20%, of the detergent composition, especially for fabric laundering.
• the amount of bleach activators will typically be from about 0.1% to about 60%, more typically from about 0.5% to about 40% of the bleaching composition comprising the bleaching agent-plus-bleach activator.
• the bleaching agents used herein can be any of the bleaching agents useful for detergent compositions in textile cleaning, hard surface cleaning, or other cleaning purposes that are now known or become known. These include oxygen bleaches as well as other bleaching agents.
• Perborate bleaches e.g., sodium perborate (e.g., mono- or tetra-hydrate) can be used herein.
• bleaching agent that can be used without restriction encompasses percarboxylic acid bleaching agents and salts thereof. Suitable examples of this class of agents include magnesium monoperoxyphthalate hexahydrate, the magnesium salt of meta-chloro perbenzoic acid, 4-nonylamino-4-oxoperoxybutyric acid and diperoxydodecanedioic acid.
• Such bleaching agents are dis ⁇ closed in U.S. Patent 4,483,781, Hartman, issued November 20, 1984, U.S. Patent Application 740,446, Burns et al, filed June 3, 1985, European Patent Application 0,133,354, Banks et al, pub ⁇ lished February 20, 1985, and U.S.
• Patent 4,412,934, Chung et al issued November 1, 1983.
• Highly preferred bleaching agents also include 6-nonylamino-6-oxoperoxycaproic acid as described in U.S. Patent 4,634,551, issued January 6, 1987 to Burns et al.
• Peroxygen bleaching agents can also be used. Suitable peroxygen bleaching compounds include sodium carbonate peroxy ⁇ hydrate and equivalent "percarbonate" bleaches, sodium pyrophosphate peroxyhydrate, urea peroxyhydrate, and sodium peroxide.
• Persulfate bleach e.g., OXONE, manufactured commer ⁇ cially by DuPont
• OXONE manufactured commer ⁇ cially by DuPont
• Mixtures of bleaching agents can also be used.
• Peroxygen bleaching agents, the perborates, the percarbon- ates, etc. are preferably combined with bleach activators, which lead to the in situ production in aqueous solution (i.e., during the washing process) of the peroxy acid corresponding to the bleach activator.
• bleach activators Various nonlimiting examples of activators are disclosed in U.S. Patent 4,915,854, issued April 10, 1990 to Mao et al, and U.S. Patent 4,412,934.
• the nonanoyloxybenzene sulfonate (NOBS) and tetraacetyl ethylene diamine (TAED) activators are typical, and mixtures thereof can also be used. See also U.S. 4,634,551 for other typical bleaches and activators useful herein.
• Bleaching agents other than oxygen bleaching agents are also known in the art and can be utilized herein.
• One type of non- oxygen bleaching agent of particular interest includes photo- activated bleaching agents such as the sulfonated zinc and/or aluminum phthalocyanines. See U.S. Patent 4,033,718, issued July 5, 1977 to Holcombe et al . If used, detergent compositions will typically contain about 0.025% to about 1.25%, by weight, of such bleaches, especially sulfonated zinc phthalocyanine.
• Polymeric Soil Release Agent Any polymeric soil release agent known to those skilled in the art can optionally be employed in the compositions and processes of this invention.
• Polymeric soil release agents are characterized by having both hydrophilic segments, to hydrophilize the surface of hydrophobic fibers, such as polyester and nylon, and hydrophobic segments, to deposit upon hydrophobic fibers and remain adhered thereto through completion of washing and rinsing cycles and, thus, serve as an anchor for the hydrophilic segments. This can enable stains occurring subsequent to treatment with the soil release agent to be more easily cleaned in later washing procedures.
• the polymeric soil release agents useful herein especially include those soil release agents having: (a) one or more nonionic hydrophile components consisting essentially of (i) polyoxyethylene segments with a degree of polymerization of at least 2, or (ii) oxypropylene or polyoxypropylene segments with a degree of polymerization of from 2 to 10, wherein said hydrophile segment does not encompass any oxypropylene unit unless it is bonded to adjacent moieties at each end by ether linkages, or (iii) a mixture of oxyalkylene units comprising oxyethylene and from 1 to about 30 oxypropylene units wherein said mixture con ⁇ tains a sufficient amount of oxyethylene units such that the hydrophile component has.
• hydrophilicity great enough to increase the hydrophilicity of conventional polyester synthetic fiber surfaces upon deposit of the soil release agent on such surface, said hydrophile segments preferably comprising at least about 25% oxyethylene units and more preferably, especially for such compon ⁇ ents having about 20 to 30 oxypropylene units, at least about 50% oxyethylene units; or (b) one or more hydrophobe components comprising (i) C3 oxyalkylene terephthalate segments, wherein, if said hydrophobe components also comprise oxyethylene terephthal ⁇ ate, the ratio of oxyethylene terephthalate:C3 oxyalkylene tere ⁇ phthalate units is about 2:1 or lower, (ii) C4-C6 alkylene or oxy C4-C6 alkylene segments, or mixtures therein, (iii) poly (vinyl ester) segments, preferably poly(vinyl acetate), having a degree of polymerization of at least 2, or (iv) C1-C4 alkyl ether or C
• the polyoxyethylene segments of (a)(i) will have a degree of polymerization of from 2 to about 200, although higher levels can be used, preferably from 3 to about 150, more prefer ⁇ ably from 6 to about 100.
• Suitable oxy C4-C6 alkylene hydrophobe segments include, but are not limited to, end-caps of polymeric soil release agents such as M ⁇ 3S(CH2)n CH2CH2 ⁇ -, where M is sodium and n is an integer from 4-6, as disclosed in U.S. Patent 4,721,580, issued January 26, 1988 to Gosselink.
• Polymeric soil release agents useful in the present invention also include cellulosic derivatives such as hydroxyether cellu- losic polymers, copolymeric blocks of ethylene terephthalate or propylene terephthalate with polyethylene oxide or polypropylene oxide terephthalate, and the like. Such agents are commercially available and include hydroxyethers of cellulose such as METHOCEL (Dow). Cellulosic soil release agents for use herein also include those selected from the group consisting of C1-C4 alkyl and C4 hydroxyalkyl cellulose; see U.S. Patent 4,000,093, issued December 28, 1976 to Nicol, et al.
• Soil release agents characterized by poly(vinyl ester) hydrophobe segments include graft copolymers of poly(vinyl ester), e.g., Ci-C ⁇ vinyl esters, preferably poly(vinyl acetate) grafted onto polyalkylene oxide backbones, such as polyethylene oxide backbones.
• poly(vinyl ester) e.g., Ci-C ⁇ vinyl esters
• poly(vinyl acetate) grafted onto polyalkylene oxide backbones such as polyethylene oxide backbones.
• Commercially available soil release agents of this kind include the S0KALAN type of material, e.g., S0KALAN HP-22, available from BASF (West Germany).
• One type of preferred soil release agent is a copolymer having random blocks of ethylene terephthalate and polyethylene oxide (PEO) terephthalate.
• the molecular weight of this polymeric soil release agent is in the range of from about 25,000 to about 55,000. See U.S. Patent 3,959,230 to Hays, issued May 25, 1976 and U.S. Patent 3,893,929 to Basadur issued July 8, 1975.
• Another preferred polymeric soil release agent is a polyester with repeat units of ethylene terephthalate units containing 10-15% by weight of ethylene terephthalate units together with 90-80% by weight of polyoxyethylene terephthalate units, derived from a polyoxyethylene glycol of average molecular weight 300-5,000. Examples of this polymer include the commercially available material ZELC0N 5126 (from Dupont) and MILEASE T (from ICI). See also U.S. Patent 4,702,857, issued October 27, 1987 to Gosselink.
• Another preferred polymeric soil release agent is a sulfonated product of a substantially linear ester oligomer comprised of an oligomeric ester backbone of terephthaloyl and oxyalkyleneoxy repeat units and terminal moieties covalently attached to the backbone.
• Suitable polymeric soil release agents include the terephthalate polyesters of U.S. Patent 4,711,730, issued December 8, 1987 to Gosselink et al, the anionic end-capped oligomeric esters of U.S. Patent 4,721,580, issued January 26, 1988 to Gosselink, and the block polyester oligomeric compounds of U.S. Patent 4,702,857, issued October 27, 1987 to Gosselink.
• Preferred polymeric soil release agents also include the soil release agents of U.S. Patent 4,877,896, issued October 31, 1989 to Maldonado et al, which discloses anionic, especially sulfo- aroyl, end-capped terephthalate esters.
• soil release agents will generally comprise from about 0.01% to about 10.0%, by weight, of the detergent composi- tions herein, typically from about 0.1% to about 5%, preferably from about 0.2% to about 3.0%.
• the detergent compositions herein may also optionally contain one or more iron and/or manganese chelating agents.
• chelating agents can be selected from the group consisting of amino carboxylates, amino phosphonates, polyfunctionally-substituted aromatic chelating agents and mixtures therein, all as hereinafter defined. Without intending to be bound by theory, it is believed that the benefit of these materials is due in part to their exceptional ability to remove iron and manganese ions from washing solutions by formation of soluble chelates.
• Amino carboxylates useful as optional chelating agents include ethylenediaminetetraacetates, N-hydroxyethylethylenedi- aminetriacetates, nitrilotriacetates, ethylenediamine tetrapropri- onates, triethylenetetraaminehexaacetates, diethylenetriamine- pentaacetates, and ethanoldiglycines, alkali metal, ammonium, and substituted ammonium salts therein and mixtures therein.
• Amino phosphonates are also suitable for use as chelating agents in the compositions of the invention when at least low levels of total phosphorus are permitted in detergent compositions, and include ethylenediaminetetrakis (methylenephos- phonates), nitrilotris (methylenephosphonates) and diethylenetri- aminepentakis (methylenephosphonates) as DEQUEST.
• these amino phosphonates do not contain alkyl or alkenyl groups with more than about 6 carbon atoms.
• Polyfunctionally-substituted aromatic chelating agents are also useful in the compositions herein. See U.S. Patent 3,812,044, issued May 21, 1974, to Connor et al .
• Preferred compounds of this type in acid form are dihydroxydisulfobenzenes such as 1,2-dihydroxy -3,5-disulfobenzene.
• a preferred biodegradable chelator for use herein is ethyl ⁇ enediamine disuccinate ("EDDS"), as described in U.S. Patent 4,704,233, November 3, 1987, to Hartman and Perkins.
• EDDS ethyl ⁇ enediamine disuccinate
• these chelating agents will generally comprise from about 0.1% to about 10% by weight of the detergent composi ⁇ tions herein. More preferably, if utilized, the chelating agents will comprise from about 0.1% to about 3.0% by weight of such compositions.
• compositions of the present invention can also optionally contain water-soluble ethoxylated amines having clay soil removal and anti-redeposition properties.
• Granular detergent compositions which contain these compounds typically contain from about 0.01% to about 10.0% by weight of the water-soluble ethoxylated amines.
• the most preferred soil release and anti-redeposition agent is ethoxylated tetraethylenepentamine. Exemplary ethoxylated amines are further described in U.S. Patent 4,597,898, VanderMeer, issued July 1, 1986.
• Another group of preferred clay soil removal/antiredeposition agents are the cationic compounds dis ⁇ closed in European Patent Application 111,965, Oh and Gosselink, published June 27, 1984.
• Other clay soil removal/antiredeposition agents which can be used include the ethoxylated amine polymers disclosed in European Patent Application 111,984, Gosselink, published June 27, 1984; the zwitterionic polymers disclosed in European Patent Application 112,592, Gosselink, published July 4, 1984; and the amine oxides disclosed in U.S.
• Other clay soil removal and/or anti redeposition agents known in the art can also be utilized in the compositions herein.
• Another type of preferred anti- redeposition agent includes the carboxy methyl cellulose (CMC) materials. These materials are well known in the art.
• CMC carboxy methyl cellulose
• Polymeric Dispersing Agents can advantageously be utilized at levels from about 0.1% to about 7%, by weight, in the compositions herein, especially in the presence of zeolite and/or layered silicate builders. Suitable polymeric dispersing agents include polymeric polycarboxylates and poly ⁇ ethylene glycols, although others known in the art can also be used.
• polymeric dispersing agents enhance overall detergent builder performance, when used in combination with other builders (including lower molecular weight polycarboxylates) by crystal growth inhibition, particulate soil release peptization, and anti-redeposition.
• Polymeric polycarboxylate materials can be prepared by polymerizing or copolymerizing suitable unsaturated monomers, preferably in their acid form.
• Unsaturated monomeric acids that can be polymerized to form suitable polymeric polycarboxylates include acrylic acid, maleic acid (or maleic anhydride), fumaric acid, itaconic acid, aconitic acid, mesaconic acid, citraconic acid and methylenemalonic acid.
• the presence in the polymeric polycarboxylates herein of monomeric segments, containing no carboxylate radicals such as vinylmethyl ether, styrene, ethylene, etc. is suitable provided that such segments do not constitute more than about 40% by weight.
• Particularly suitable polymeric polycarboxylates can be derived from acrylic acid.
• acrylic acid-based polymers which are useful herein are the water-soluble salts of polymerized acrylic acid.
• the average molecular weight of such polymers in the acid form preferably ranges from about 2,000 to 10,000, more preferably from about 4,000 to 7,000 and most preferably from about 4,000 to 5,000.
• Water-soluble salts of such acrylic acid polymers can include, for example, the alkali metal, ammonium and substituted ammonium salts. Soluble polymers of this type are known materials. Use of polyacrylates of this type in detergent compositions has been disclosed, for example, in Diehl, U.S. Patent 3,308,067, issued March 7., 1967.
• Acrylic/maleic-based copolymers may also be used as a preferred component of the dispersing/anti-redeposition agent.
• Such materials include the water-soluble salts of copolymers of acrylic acid and maleic acid.
• the average molecular weight of such copolymers in the acid form preferably ranges from about 2,000 to 100,000, more preferably from about 5,000 to 75,000, most preferably from about 7,000 to 65,000.
• the ratio of acrylate to maleate segments in such copolymers will generally range from about 30:1 to about 1:1, more preferably from about 10:1 to 2:1.
• Water-soluble salts of such acrylic acid/maleic acid copolymers can include, for example, the alkali metal, ammonium and substituted ammonium salts. Soluble acrylate/maleate copolymers of this type are known materials which are described in European Patent Application No. 66915, published December 15, 1982.
• PEG poly ⁇ ethylene glycol
• PEG can exhibit dispersing agent perform ⁇ ance as well as act as a clay soil removal/antiredeposition agent.
• Typical molecular weight ranges for these purposes range from about 500 to about 100,000, preferably from about 1,000 to about 50,000, more preferably from about 1,500 to about 10,000.
• Commercial optical brighteners which may be useful in the present invention can be classified into subgroups which include, but are not necessarily limited to, derivatives of stilbene, pyrazoline, coumarin, carboxylic acid, methinecyanines, dibenzothiphene-5,5-dioxide, azoles, 5- and 6-membered-ring heterocycles, and other miscellaneous agents. Examples of such brighteners are disclosed in "The Production and Application of Fluorescent Brightening Agents", M. Zahradnik, Published by John Wiley & Sons, New York (1982).
• optical brighteners which are useful in the present compositions are those identified in U.S. Patent 4,790,856, issued to Wixon on December 13, 1988. These brighten- ers include the PHORWHITE series of brighteners from Verona. Other brighteners disclosed in this reference include: Tinopal UNPA, Tinopal CBS and Tinopal 5BM; available from Ciba-Geigy; Arctic White CC and Artie White CWD, available from Hilton-Davis, located in Italy; the 2-(4-styryl-phenyl)-2H- naphthol[l,2-d]- triazoles; 4,4'-bis- (l,2,3-triazol-2-yl)-stil- benes; 4,4'-bis- (styryl)bisphenyls; and the aminocoumarins.
• these brighteners include 4-methyl-7-diethyl- amino coumarin; l,2-bis(-benzimidazol-2-yl)ethylene; 1,3-diphenylphrazolines; 2,5-bis(benzoxazol-2-yl)thiophene; 2-styryl-naphth-[l,2-d]oxazole; and 2-(stilbene-4-yl)-2H-naphtho- [l,2-d]triazole. See also U.S. Patent 3,646,015, issued February 29, 1972 to Hamilton.
• Suds Suppressors - Compounds for reducing or suppressing the formation of suds can be incorporated into the compositions of the present invention. Suds suppression can be of particular importance under conditions such as those found in European-style front loading laundry washing machines, or in the concentrated detergency process of U.S. Patents 4,489,455 and 4,489,574, or when the detergent compositions herein optionally include a relatively high sudsing adjunct surfactant.
• suds suppressors A wide variety of materials may be used as suds suppressors, and suds suppressors are well known to those skilled in the art. See, for example, Kirk Othmer Encyclopedia of Chemical Technology, Third Edition, Volume 7, pages 430-447 (John Wiley & Sons, Inc., 1979).
• One category of suds suppressor of particular interest encompasses monocarboxylic fatty acids and soluble salts therein. See U.S. Patent 2,954,347, issued September 27, 1960 to Wayne St. John.
• the monocarboxylic fatty acids and salts thereof used as suds suppressor typically have hydrocarbyl chains of 10 to about 24 carbon atoms, preferably 12 to 18 carbon atoms.
• Suitable salts include the alkali metal salts such as sodium, potassium, and lithium salts, and ammonium and alkanolammonium salts.
• the detergent compositions herein may also contain non- surfactant suds suppressors.
• non- surfactant suds suppressors include, for example: high molecular weight hydrocarbons such as paraffin, fatty acid esters (e.g., fatty acid triglycerides), fatty acid esters of monovalent alcohols, aliphatic C18-C40 ketones (e.g. stearone), etc.
• suds inhibitors include N-alkylated amino triazines such as tri- to hexa-alkylmelamines or di- to tetra-alkyldiamine chlortriazines formed as products of cyanuric chloride with two or three moles of a primary or secondary amine containing 1 to 24 carbon atoms, propylene oxide, and monostearyl phosphates such as monostearyl alcohol phosphate ester and monostearyl di-alkali metal (e.g. K, Na, and Li) phosphates and phosphate esters.
• the hydrocarbons such as paraffin and haloparaffin can be utilized in liquid form.
• the liquid hydrocarbons will be liquid at room temperature and atmospheric pressure, and will have a pour point in the range of about -40 * C and about 5 * C, and a minimum boiling point not less than about UO'C (atmospheric pressure). It is also known to utilize waxy hydrocarbons, preferrably having a melting point below about lOO'C.
• the hydrocarbons constitute a preferred category of suds suppressor for detergent compositions. Hydrocarbon suds suppressors are described, for example, in U.S. Patent 4,265,779, issued May 5, 1981 to Gandolfo et al.
• the hydrocarbons thus, include aliphatic, alicyclic, aromatic, and heterocyclic saturated or unsaturated hydrocarbons having from about 12 to about 70 carbon atoms.
• the term "paraffin,” as used in this suds suppressor discussion, is intended to include mixtures of true paraffins and cyclic hydrocarbons.
• Non-surfactant suds suppressors comprises silicone suds suppressors.
• This category includes the use of polyorganosiloxane oils, such as polydimethylsiloxane, dispersions or emulsions of polyorganosiloxane oils or resins, and combinations of polyorganosiloxane with silica particles wherein the polyorganosiloxane is chemisorbed of fused onto the silica.
• Silicone suds suppressors are well known in the art and are, for example, disclosed in U.S. Patent 4,265,779, issued May 5, 1981 to Gandolfo et al and European Patent Application No. 89307851.9, published February 7, 1990, by Starch, M. S.
• silicone and silanated silica are described, for instance, in German Patent Application DOS 2,124,526.
• Silicone defoamers and suds controlling agents in granular detergent compositions are disclosed in U.S. Patent 3,933,672, Bartolotta et al, and in U.S. Patent 4,652,392, Baginski et al, issued March 24, 1987.
• An exemplary silicone based suds suppressor for use herein is a suds suppressing amount of a suds controlling agent consisting essentially of:
• polydimethylsiloxane fluid having a viscosity of from about 20 cs. to about 1500 cs. at 25 * C;
• the solvent for a continuous phase is made up of certain polyethylene glycols or polyethylene-polypropylene glycol copolymers or mixtures thereof (preferred), and not polypropylene glycol.
• the primary silicone suds suppressor is branched/crosslinked and not linear.
• typical laundry detergent compositions with controlled suds will optionally comprise from about 0.001 to about 1, preferably from about 0.01 to about 0.7, most preferably from abut 0.05 to about 0.5, weight % of said silicone suds suppressor, which comprises (1) a nonaqueous emulsion of a primary antifoa agent which is a mixture of (a) a polyorganosiloxane, (b) a resinous siloxane or a silicone resin-producing silicone compound, (c) a finely divided filler material, and (d) a catalyst to promote the reaction of mixture components (a), (b) and (c), to form silanolates; (2) at least one nonionic silicone surfactant; and (3) polyethylene glycol or a copolymer of polyethylene-polypropylene glycol having a solubility in water at room temperature of more than about 2 weight %; and without polypropylene glycol. Similar amounts can be used in granular compositions, gels, etc. See also U
• the silicone suds suppressor herein preferably comprises polyethylene glycol and a copolymer of polyethylene glycol/poly- propylene glycol, all having an average molecular weight of less than about 1,000, preferably between about 100 and 800.
• the polyethylene glycol and polyethylene/polypropylene copolymers herein have a solubility in water at room temperature of more than about 2 weight %, preferably more than about 5 weight %.
• the preferred solvent herein is polyethylene glycol having an average molecular weight of less than about 1,000, more preferably between about 100 and 800, most preferably between 200 and 400, and a copolymer of polyethylene glycol/polypropylene glycol, preferably PPG 200/PEG 300.
• Preferred is a weight ratio of between about 1:1 and 1:10, most preferably between 1:3 and 1:6, of polyethylene glycol:copolymer of polyethylene-polypropylene glycol.
• the preferred silicone suds suppressors used herein do not contain polypropylene glycol, particularly of 4,000 molecular weight. They also preferably do not contain block copolymers of ethylene oxide and propylene oxide, like PLUR0NIC L101.
• Other suds suppressors useful herein comprise the secondary alcohols (e.g., 2-alkyl alkanols) and mixtures of such alcohols with silicone oils, such as the silicones disclosed in U.S. 4,798,679, 4,075,118 and EP 150,872.
• the secondary alcohols include the C6-Cj6 alkyl alcohols having a C1-C16 chain.
• a preferred alcohol is 2-butyl octanol, which is available from Condea under the trademark IS0F0L 12.
• Suds suppressors typically comprise mixtures of alcohol + silicone at a weight ratio of 1:5 to 5:1.
• suds should not form to the extent that they overflow the washing machine.
• Suds suppressors, when utilized, are preferably present in a "suds suppressing amount.”
• Suds suppressing amount is meant that the formulator of the composition can select an amount of this suds controlling agent that will sufficiently control the suds to result in a low-sudsing laundry detergent for use in automatic laundry washing machines.
• the compositions herein will generally comprise from 0% to about 5% of suds suppressor.
• monocarboxylic fatty acids, and salts therein When utilized as suds suppressors, monocarboxylic fatty acids, and salts therein, will be present typically in amounts up to about 5%, by weight, of the detergent composition. Preferably, from about 0.5% to about 3% of fatty monocarboxy ate suds suppressor is utilized. Silicone suds suppressors are typically utilized in amounts up to about 2.0%, by weight, of the detergent composition, although higher amounts may be used. This upper limit is practical in nature, due primarly to concern with keeping costs minimized and effectiveness of lower amounts for effectively controlling sudsing. Preferably from about 0.01% to about 1% of silicone suds suppressor is used, more preferably from about 0.25% to about 0.5%.
• these weight percentage values include any silica that may be utilized in combination with polyorganosiloxane, as well as any adjunct materials that may be utilized.
• Monostearyl phosphate suds suppressors are generally utilized in amounts ranging from about 0.1% to about 2%, by weight, of the composition.
• Hydrocarbon suds suppressors are typically utilized in amounts ranging from about 0.01% to about 5.0%, although higher levels can be used.
• the alcohol suds suppressors are typically used at 0.2%-3% by weight of the finished compositions.
• the surfactant compositions herein can also be used with a variety of other adjunct ingredients which provide still other benefits in various compositions within the scope of this invention.
• the following illustrates a variety of such adjunct ingredients, but is not intended to be limiting therein.
• Fabric Softeners Various through-the-wash fabric softeners, especially the impalpable smectite clays of U.S. Patent 4,062,647, Storm and Nirschl, issued December 13, 1977, as well as other softener clays known in the art, can optionally be used typically at levels of from about 0.5% to about 10% by weight in the present compositions to provide fabric softener benefits concurrently with fabric cleaning.
• Clay softeners can be used in combination with amine and cationic softeners, as disclosed, for example, in U.S. Patent 4,375,416, Crisp et al , March 1, 1983 and U.S. Patent 4,291,071, Harris et al , issued September 22, 1981.
• ingredients useful in detergent compositions can be included in the composi ⁇ tions herein, including other active ingredients, carriers, processing aids, dyes or pigments.
• suds boosters such as the C10-C16 alkanolamides can be incorpor ⁇ ated into the compositions, typically at 1%-10% levels.
• the C10-C14 monoethanol and diethanol amides illustrate a typical class of such suds boosters.
• Use of such suds boosters with high sudsing adjunct surfactants such as the amine oxides, betaines and sultaines noted above is also advantageous.
• soluble magnesium salts such as MgCl2, MgS ⁇ 4, and the like, can be added at levels of, typically, 0.1%-2%, to provide additional sudsing.
• Various detersive ingredients employed in the present compo ⁇ sitions optionally can be further stabilized by absorbing said ingredients onto a porous hydrophobic substrate, then coating said substrate with a hydrophobic coating.
• the detersive ingredient is admixed with a surfactant before being absorbed into the porous substrate.
• the detersive ingredient is released from the substrate into the aqueous washing liquor, where it performs its intended detersive function.
• a porous hydro- phobic silica (trademark SIPERNAT D10, DeGussa) is admixed with a proteolytic enzyme solution containing 3%-5% of C13-15 ethoxylated alcohol EO(7) nonionic surfactant.
• the enzyme/surfact- ant solution is 2.5 X the weight of silica.
• the resulting powder is dispersed with stirring in silicone oil (various silicone oil viscosities in the range of 500-12,500 can be used).
• silicone oil various silicone oil viscosities in the range of 500-12,500 can be used.
• the result ⁇ ing silicone oil dispersion is emulsified or otherwise added to the final detergent matrix.
• ingredients such as the aforementioned enzymes, bleaches, bleach activators, bleach catalysts, photoactivators, dyes, fluorescers, fabric conditioners and hydrolyzable surfactants can be "protected" for use in detergents.
• Water-soluble particles prepared in the manner of this invention include the following.
• EXAMPLE I High-active, highly water-soluble detergent particles are prepared by co-melting the following ingredients and comminuting the solidified melt. Ingredient % (wt)
• High-active, highly water-soluble detergent particles are prepared by agglomerating the following ingredients.
• the free moisture content is kept below about 10%.
• silica (1 micron) is dusted onto the outside of the particles as a free-flow aid.
• the fully-formulated detergent compositions herein will preferably be prepared using the mixed surfactant/co-surfactant particles and adjunct ingredients such that, during use in aqueous cleaning operations, the wash water will have a pH of between about 6.5 and about 11, preferably between about 7.5 and about 10.5.
• Techniques for controlling pH at recommended usage levels include the use of buffers, alkalis, acids, etc., and are well known to those skilled in the art.
• a preferred overall making process for particulate products herein involves three distinct Steps: (1) agglomeration of the ingredients to form the common base formula, followed by; (2) admixing various ingredients with the agglomerates formed in Step
• the base formula is agglomerated as opposed to spray dried in order to prevent degradation of some of the heat sensitive surfactants.
• the resulting product is a high density (ranging from 600 g/liter - 800 g/liter) free flowing detergent mix that can be used in place of current spray dried laundry detergents.
• Step 1 this procedure is comprised of four Steps: (A) preparing a surfactant paste using mixers such as the
• Step A Preparation of Surfactant Paste -
• the objective is to combine the surfactants and liquids in the compositions into a common mix in order to aid in surfactant solubilization and agglomeration.
• the surfactants are prepared as mixed particles.
• the other liquid components in the composition are mixed therewith in a Sigma Mixer at 140 * F (60*C) at about 40 rpm to about 75 rpm for a period of from 15 minutes to about 30 minutes to provide a paste having the general consistency of 20,000-40,000 centipoise.
• the paste is stored at 140 * F (60 * C) until agglomeration Step (B) is ready to be conducted.
• the ingredients used in this Step include the mixture of secondary (2,3) alkyl sulfate surfactant plus co-surfactant, acrylate/maleic polymer (m.w. 70,000) and polyethylene glycol "PEG" 4000-8000.
• Step B Agglomeration of Powders with Surfactant Paste -
• the purpose of this Step is to transform the base formula ingredients into flowable detergent particles having a medium particle size range of from about 300 microns to about 600 microns.
• the powders including materials such as zeolite, citrate, citric acid builder, layered silicate builder (as SKS-6), sodium carbonate, ethylenedia inedisuccinate, magnesium sulfate and optical brightener
• the Eirich Mixer R-Series
• mixed briefly ⁇ ca. 5 seconds - 10 seconds at about 1500 rpm to about 3000 rpm in order to mix the various dry powders fully.
• the surfactant paste from Step A is then charged into the mixer and the mixing is continued at about 1500 rpm to about 3000 rpm for a period from about 1 minute to about 10 minutes, preferably 1-3 minutes, at ambient temperature.
• the mixing is stopped when coarse agglomerates (average particle size 800-1600 microns) are formed.
• Step C The purpose of this Step is to reduce the agglomer- ates' stickiness by removing/drying moisture and to aid in particle size reduction to the target particle size (in the median particle size range from about 300 to about 600 microns, as measured by sieve analysis).
• the wet agglomerates are charged into a fluidized bed at an air stream temperature of from about 41 * C to about 60 * C and dried to a final moisture content of the particles from about 4% to about 10%.
• Step D Coat Agglomerates and Add Free-Flow Aids -
• the objective in this Step is to achieve the final target particle size range of from about 300 microns to about 600 microns, and to admix materials which coat the agglomerates, reduce the caking/ lumping tendency of the particles and help maintain acceptable flowability.
• the dried agglomerates from Step C are charged into the Eirich Mixer (R-Series) and mixed at a rate of about 1500 rpm to about 3000 rpm while adding 2-6% Zeolite A (median particle size Z-S ⁇ m) during the mixing.
• the mixing is continued until the desired median particle size of from about 1200 to about 400 microns is achieved (typically from about 5 seconds to about 45 seconds). At this point, from about 0.1% to about 1.5% by weight of precipitated silica (average particle size 1-3 microns) is added as a flow aid and the mixing is stopped.
• a granular detergent herein comprises the following. Ingredient % (wt . )
• Ci4-Ci5 alkyl ethoxylate E07
• Ci6-Ci8 AE11 alkyl ethoxylate Ell
• compositions can also optionally contain various adjunct cationic surfactants and mixtures of cationic and nonionic adjunct surfactants.
• useful cationics include the C 0- 18 alkyl trimethylammonium halides, the 10-C18 alkyl dimethyl (Cj-C ⁇ ) hydroxyalkylammonium halides,
• Such cationic surfactants can typically comprise from 1% to 15% by weight of the compositions herein.

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