Field of the invention
The invention relates to bleach catalysts, compositions
containing same and a method for using the catalysts for
cleaning substrates, especially fabrics.
Background of the invention an the Related Art
Many household and personal care products are formulated
with an active oxygen-releasing material to effect removal
of stain and soil. Oxygen-releasing materials have an
important limitation; their activity is extremely
temperature dependent. Temperatures in excess of 60°C are
normally required to achieve any bleach effectiveness in an
aqueous wash system. Especially for cleaning fabrics, high
temperature operation is both economically and practically
disadvantageous.
The art has partially solved the aforementioned problem
through the use of activators. These activators, also known
as bleach precursors, often appear in the form of carboxylic
acid esters. In an aqueous liquor, anions of hydrogen
peroxide react with the ester to generate the corresponding
peroxyacid which oxidizes the stained substrate. Commercial
application of this technology is found in certain fabric
bleaching detergent powders incorporating sodium
nonanoyloxybenzene sulfonate. This activator is typical of a
class that features a phenol sulfonate leaving group; see
US-A-4,412,934.
While carboxylic acid ester activators and the like are
often effective, they are not catalytic. Once the ester has
been perhydrolyzed it can no longer be recycled.
Therefore, relatively large amounts of activator are
necessary. Amounts as high as 8% may be necessary in a
detergent formulation for bleaching fabrics. Cost for these
relatively expensive activators is of major concern at such
levels.
DE-A-4 223 065 discloses heterocyclic imine compounds as
bleach activators in washing, disinfecting and cleaning
compositions comprising 10 to 30 weight percent of a
bleaching catalyst.
A significant advance in catalysis was reported utilizing
sulfonimines in US-A-5,041,232, US-A-5,047,163 and US-A-5,045,223.
Only a few of the reported compounds have been
studied in any detail. More investigation needs to be
conducted to identify catalysts of even greater activity.
Accordingly, it is an object of the present invention to
provide novel bleach catalysts that can operate over a wide
temperature range including that of under 60°C.
It is another object of the present invention to provide
bleach catalysts which are effective at relatively low
concentrations thereby achieving a cost effective stain
removal system.
A further object of the present invention is to provide a
method for bleaching stained substrates such as clothes,
household hard surfaces including sinks, toilets and the
like, and even dentures.
Other objects of the present invention will become apparent
through the following summary, detailed discussion and
examples.
SUMMARY OF THE INVENTION
A bleaching composition is provided including:
(i) between 1 and 10% by weight of a peroxygen compound; (ii) from 0.01 to 10% of an oxygen transfer agent whose
structure is:
R1R2C=NCOR3
wherein:
- R1 may be hydrogen or a C1-C40 substituted or
unsubstituted radical selected from the group
consisting of phenyl, aryl, acyl, heterocyclic ring,
alkyl and cycloalkyl radicals;
- R2 may be hydrogen, nitro, halo or a C1-C40 substituted
or unsubstituted radical selected from the group
consisting of phenyl, aryl, heterocyclic ring, alkyl,
cycloalkyl, R1C=NCOR3, cyano, alkoxy,
keto, carboxylic and carboalkoxy radicals;
- R3 may be nitro, halo or a C1-C40 substituted or
unsubstituted radical selected from the group
consisting of phenyl, aryl, heterocyclic ring, alkyl,
cycloalkyl, and cyano radicals;
- R1 with R2 and R2 with R3 may respectively together
independently form a cycloalkyl, heterocyclic, and
aromatic ring system; and
(iii) from about 0.5 to 50% of a surfactant.
Additionally, there is provided a method for bleaching a
stained substrate comprising the step of applying to the
stained substrate an aqueous solution comprising a peroxygen
compound and an oxygen transfer agent whose structure is
R1R2C=NCOR3, with radical groups as defined above, the mole
ratio of peroxygen compound to oxygen transfer agent being
from about 250:1 to about 1:2.
Certain compounds are also provided whose structure is
R1R2C=NCOR3 having radical groups as defined above, with the
proviso that at least one of R1, R2, R3 is substituted with a
water-solubilizing functional group. Typical water-solubilizing
groups include carboxylic acid, phosphoric
acid, phosphonic acid, sulfuric acid, sulfonic acid, and,
especially, their salt derivatives and quaternary ammonium
salts.
Detailed description of the invention
It has been found that N-acylimines operate even more
effectively than sulfonimines as catalysts for activating
peroxygen compounds to transfer active oxygen to stains.
Consumer and industrial articles can effectively be bleached
to remove stains present on such articles. N-acylimines
covered by the present invention are those whose structure
is:
R1R2C=NCOR3
wherein:
- R1 may be hydrogen or a C1-C40 substituted or
unsubstituted radical selected from the group the group
consisting of phenyl, aryl, acyl, heterocyclic ring,
alkyl and cycloalkyl radicals;
- R2 may be hydrogen nitro, halo, or a C1-C40 substituted
or unsubstituted radical selected from the group
consisting of phenyl, aryl, heterocyclic ring, alkyl,
cycloalkyl, R1C=NCOR3, cyano, alkoxy, keto, carboxylic
and carboalkoxy radicals;
- R3 may be a nitro, halo, or a C1-C40 substituted or
unsubstituted radical selected from the group
consisting of phenyl, aryl, heterocyclic ring, alkyl,
cycloalkyl, and cyano radicals; and
- R1 with R2 and R2 with R3 may respectively together
independently form a cycloalkyl, heterocyclic or
aromatic ring system.
Often advantageous are N-acylimines having at least one of
R1, R2, R3 substituted with a water-solubilizing functional
group. These functional groups may be selected from
carboxylates, phosphates, phosphonates, sulfates, sulfonates
in acid and salt form and quaternary ammonium salts.
Suitable salts include those whose counterions are selected
from alkali metal, ammonium, and C2-C6 alkanolammonium
cations.
Amine functional groups may also be incorporated into R1, R2
or R3 to provide water-solubilization of the N-acylimines.
An example combining the amine and heterocyclic structure is
that of pyridine.
A water-solubilizing functional group is one which renders
the N-acylimines soluble to the extent of at least 2 mg/l,
preferably at least 25 mg/l, optimally at least 250 mg/l by
weight in water at 25°C.
Heterocyclic rings according to this invention include
cycloaliphatic and cycloaromatic type radicals incorporating
an oxygen, sulfur and/or nitrogen atom within the ring
system. Representative nitrogen heterocycles include
pyridine, morpholine, pyrrole, imidazole, triazole,
tetrazole, pyrrolidine, piperidine and piperazine. Suitable
oxygen heterocycles include furan, tetrahydrofuran and
dioxane. Sulfur heterocycles may include thiophene and
tetrahydrothiophene. Among the various heterocycles, it has
been found that those incorporating nitrogen are the most
active.
The term "substituted" is defined in relation to R1, R2, R3
as a substituent which is a nitro, halo, cyano, C1-C20 alkyl,
acyl, amino, aminoalkyl, thioalkyl, sulfoxyalkyl,
carboxyester, hydroxy, C1-C20 alkoxy, polyalkoxy and C1-C40
quaternary di- or trialkylammonium function.
Novel N-acylimine compounds are described below wherein R
1 is
hydrogen, R
2 is phenyl with a Z substitutent, and R
3 is
phenyl with a Y substituent. Very often Z and Y groups are
water-solubilizing groups, most commonly being carboxylic
acid or salts thereof. Representative structures are as
follows:
Illustrative of cycloaromatic and of heterocyclic N-acylimines
are the Imine 11, Imine 12, Imine 13 and Imine 14
compounds whose structures are outlined below.
The following further compounds are illustrative of N-acylimines
of the present invention.
| R1 | R2 | 2H-imidazol-2-ones: |
| CH3 | CH3 | 2H-4,5-dimethylimidazol-2-one |
| Ph | CH3 | 2H-4-methyl-5-phenylimidazol-2-one |
| Ph | Ph | 2H-4,5-diphenylimidazol-2-one |
| R1 | R2 | R3 | 2(5H)-oxazalones: |
| CH3 | CH3 | CH3 | 4,5,5-trimethyl-2(5H)-oxazalone |
| CH3 | CH3 | Ph | 5,5-dimethyl-4-phenyl-2(5H)-oxazalone |
| R1 | R2 | R3 | R4 | 5H-2-pyrimidones: |
| CH3 | CH3 | CH3 | CH3 | 5H-4,5,5,6-tetramethyl-2-pyrimidone |
| Ph | CH3 | CH3 | Ph | 5H-5,5-dimethyl-4,6-diphenyl-2-pyrimidone |
| R1 | R2 | R3 | 2H-1,3-oxazin-2-ones: |
| CH3 | CH3 | CH3 | 4,5,6-tertamethyl-2H-1,3-oxazin-2-one |
| CH3 | CH3 | Ph | 5,6-dimethyl-4-phenyl-2H-1,3-oxazin-2-one |
| Ph | CH3 | CH3 | 4,5-dimethyl-5-phenyl-2H-1,3-oxazin-2-one |
| R1 | R2 | R3 | R4 | R5 | 5,6-dihydro-2H-1,3-oxazin-2-ones: |
| CH3 | CH3 | CH3 | CH3 | CH3 | 5,6-dihydro-4,5,5,6,6-pentamethyl-2H-1,3-oxazin-2-one |
| CH3 | CH3 | CH3 | CH3 | Ph | 5,6-dihydro-5,5,6,6-tetramethyl-4-phenyl-2H-1,3-oxazin-2-one |
Multi-heterocyclic ring compounds illustrative of N-acylimines
include:
wherein the R groups are independently selected from those
defined by R
2 described above.
The foregoing oxygen transfer agents may be incorporated
into detergent bleach compositions along with a further
essential component which is a peroxygen compound capable of
yielding peroxide anion or peroxyacid in an aqueous
solution.
Amounts of oxygen transfer agent suitable for the present
invention may range from 0.01 to 10%, preferably from 0.1 to
5%, optimally between 0.5 and 1.5% by weight of the
composition.
The peroxygen compound may be present between about 2 and
10% by weight.
The molar ratio of peroxygen compound to oxygen transfer
agent will range from about 250:1 to 1:2, preferably 100:1
to 1:1, optimally between about 25:1 to 2:1.
Peroxyacid and peroxide anion sources are well known in the
art. They include the alkali metal peroxides, organic
peroxides such as urea peroxide, and inorganic persalts,
such as the alkali metal perborates, percarbonates,
perphosphates, persilicates and persulfates (e.g. Oxone®).
Mixtures of two or more such compounds may also be suitable.
Particularly preferred are sodium percarbonate, Oxone® and
sodium perborate monohydrate.
Alkylhydroperoxides are another suitable class of peroxygen
compounds. Examples of these materials include cumene
hydroperoxide and t-butyl hydroperoxide.
Organic peroxy acids may also be suitable as the peroxygen
compound. Such materials have a general formula:
wherein X is oxygen or nitrogen, n=0 or 1, R is an alkylene
or substituted alkylene group containing from 1 to about 22
carbon atoms or a phenylene or substituted phenylene group,
and Y' is hydrogen, halogen, alkyl, aryl or
When the organic peroxy acid is aromatic, the unsubstituted
acid has the general formula:
wherein Y' is hydrogen, alkyl, alkylhalogen, halogen, COOH,
NHCOOOH or COOOH; R is phenylene or arylene; and X is oxygen
or nitrogen.
Typical monoperoxy acids useful herein include alkyl peroxy
acids and aryl peroxy acids such as:
(i) peroxybenzoic acid and ring-substituted peroxybenzoic
acids, e.g. peroxy-α-naphthoic acid; (ii) aliphatic, substituted aliphatic and arylalkyl
monoperoxy acids, e.g. peroxylauric acid, peroxystearic
acid, and N,N- phthaloylaminoperoxycaproic acid (PAP).
Typical diperoxy acids useful herein include alkyl diperoxy
acids and aryldiperoxy acids, such as: (iii) 1,12-diperoxydodecanedioic acid; (iv) 1,9-diperoxyazelaic acid; (v) diperoxybrassylic acid; diperoxysebacic acid and
diperoxyisophthalic acid; (vi) 2-decyldiperoxybutane-1,4-dioic acid; (vii) 4,4'-sulfonylbisperoxybenzoic acid; (viii)N,N'-terephthaloyl-di(6-aminoperoxycaproic acid).
Particularly preferred organic acids are N,N-phthaloylaminoperoxycaproic
acid, peracetic acid,
monoperoxyphthalic acid (magnesium salt hexahydrate), and
diperoxydodecanedioic acid. Under certain circumstances,
hydrogen peroxide itself may directly be employed as the
peroxygen compound.
Optionally, compositions of the present invention may
further include a pre-bleach precursor that reacts with
peroxide anion or peroxyacid and forms therewith a peracid,
percarbonic acid or perimidic acid.
The preferred precursors are N,N,N',N'-tetraacetylethylene
diamine (TAED), tetraacetyl-glycoluril (TAGU), glucose
pentaacetate, xylose tetraacetate, sodium acetyloxybenzene
sulfonate (SABS) and sodium nonanoyloxybenzene sulfonate
(SNOBS). Levels of precursor may range from 0.1 to 40%,
preferably from 1 to 10%, optimally from 2 to 8% by weight.
Bleach systems of the present invention may be employed for
a wide variety of purposes, but are especially useful in the
cleaning of laundry. When intended for such purpose, the
peroxygen compound and oxygen transfer agent of the present
invention will usually also be combined with surface-active
materials, detergency builders and other known ingredients
of laundry detergent formulations.
The surface-active material may be naturally derived, or
synthetic material selected from anionic, nonionic,
amphoteric, zwitterionic, cationic actives and mixtures
thereof. Many suitable actives are commercially available
and are fully described in the literature, for example in
"Surface Active Agents and Detergents", Volumes I and II, by
Schwartz, Perry and Berch. The total level of the surface-active
material may range up to 50% by weight, preferably
being from 0.5 to 40% by weight of the composition, most
preferably 4 to 25%.
Synthetic anionic surface-actives are usually water-soluble
alkali metal salts of organic sulphates and sulphonates
having alkyl radicals containing from about 8 to about 22
carbon atoms.
Examples of suitable synthetic anionic detergent compounds
are sodium and ammonium alkyl sulphates, especially those
obtained by sulphating higher (C8-C18) alcohols produced for
example from tallow or coconut oil; sodium and ammonium
alkyl (C9-C20) benzene sulphonates, sodium alkyl glyceryl
ether sulphates, especially those ethers of the higher
alcohols derived from tallow or coconut oil and synthetic
alcohols derived from petroleum; sodium coconut oil fatty
acid monoglyceride sulphates and sulphonates; sodium and
ammonium salts of sulphuric acid esters of higher (C9-C18)
fatty alcohol-alkylene oxide, particularly ethylene oxide,
reaction products; the reaction products of fatty acids such
as coconut fatty acids esterified with isethionic acid and
neutralized with sodium hydroxide; sodium and ammonium salts
of fatty acid amides of methyl taurine; alkane
monosulphonates such as those derived by reacting alpha-olefins
(C8-C20) with sodium bisulphite and those derived by
reacting paraffins with SO2 and Cl2 and then hydrolyzing with
a base to produce a random sulphonate; sodium and ammonium
C7-C12 dialkyl sulfosuccinates; and olefin sulphonates,
which term is used to describe the material made by reacting
olefins, particularly C10-C20 alpha-olefins, with SO3 and then
neutralizing and hydrolyzing the reaction product. The
preferred anionic detergent compounds are sodium (C11-C15)
alkylbenzene sulphonates, sodium (C16-C18) alkyl sulphates and
sodium (C16-C18) alkyl ether sulphates.
Examples of suitable nonionic surface-active compounds which
may be used, preferably together with the anionic surface-active
compounds, include in particular the reaction
products of alkylene oxides, usually ethylene oxide, with
alkyl (C6-C22) phenols, generally 5-25 EO, i.e. 5-25 units of
ethylene oxide per molecule; the condensation products of
aliphatic (C8-C18) primary or secondary linear or branched
alcohols with ethylene oxide, generally 2-30 EO, and
products made by condensation of ethylene oxide with the
reaction products of propylene oxide and ethylene diamine.
Other so-called nonionic surface-actives include alkyl
polyglucosides, long chain tertiary amine oxides, and fatty
amido polyols such as methyl glucamines.
Amphoteric or zwitterionic surface-active compounds such as
alkylamidopropyl betaines can also be used in the
compositions of the invention. If any amphoteric or
zwitterionic detergent compounds are used, it is generally
in small amounts in compositions based on the much more
commonly used synthetic anionic and nonionic actives.
Soaps may also be incorporated into the compositions of the
invention, preferably at a level of less than 30% by weight.
They are particularly useful at low levels in binary
(soap/anionic) or ternary mixtures together with nonionic or
mixed synthetic anionic and nonionic compounds. Soaps which
are used are preferably the sodium, or less desirably
potassium, salts of saturated or unsaturated C10-C24 fatty
acids or mixtures thereof.
The amount of such soaps can be varied between 0.5 and 25%
by weight, with lower amounts of 0.5 to 5% being generally
sufficient for lather control. Amounts of soap between 2
and 20%, especially between 5 and 15, are used to give a
beneficial effect on detergency. This is particularly
valuable in compositions used in hard water where the soap
acts as a supplementary builder.
The detergent compositions of the invention will normally
also contain a detergency builder. Builder materials may be
selected from (1) calcium sequestrant materials, (2)
precipitating materials, (3) calcium ion-exchange materials
and (4) mixtures thereof.
In particular, the compositions of the invention may contain
any one of the organic or inorganic builder materials, such
as sodium or potassium tripolyphosphate, sodium or potassium
pyrophosphate, sodium or potassium orthophosphate, sodium
carbonate, the sodium salt of nitrilotriacetic acid, sodium
citrate, carboxymethylmalonate, carboxymethyloxysuccinate,
tartrate mono- and di- succinate, oxydisuccinate,
crystalline or amorphous aluminosilicates and mixtures
thereof.
Polycarboxylic homo- and co-polymers may also be included as
builders and to function as powder structurants or
processing aids. Particularly preferred are polyacrylic
acid (available under the trademark Acrysol from the Rohm
and Haas Company) and acrylic-maleic acid copolymers
(available under the trademark Sokalan from the BASF
Corporation) and alkali metal or other salts thereof.
These builder materials may be present at a level of, for
example, from 1 to 80% by weight, preferably from 10 to 60%
by weight.
Upon dispersal in a wash water, the initial amount of
peroxygen compound should range anywhere from 0.05 to 250
ppm active oxygen per liter of water, preferably from 1 to
50 ppm. Within the wash media the amount of oxygen transfer
agent initially present should be from 0.01 to 300 ppm,
preferably from 5 to 100 ppm. Surfactant should be present
in the wash water from 0.05 to 1.0 grams per liter,
preferably from 0.15 to 0.20 grams per liter. When present,
the builder amount will range from 0.1 to 3.0 grams per
liter.
Apart from the components already mentioned, the detergent
compositions of the invention can contain any of the
conventional additives in the amounts in which such
materials are normally employed in detergent compositions.
Examples of these additives include dye transfer inhibition
agents (e.g. polymers based on N-vinylpyrrolidone and N-vinylimidazole),
lather boosters such as alkanolamides,
particularly the monoethanolamides derived from palmkernel
fatty acids and coconut fatty acids, lather-depressants such
as alkyl phosphates and silicones, anti-redeposition agents
such as sodium carboxymethylcellulose and alkyl or
substituted alkylcellulose ethers, stabilizers such as
ethylene diamine tetraacetic acid and phosphonic acid
derivatives (Dequest®), fabric softening agents, inorganic
salts such as sodium sulphate, and, usually present in very
small amounts, fluorescent agents, perfumes, enzymes such as
proteases, cellulases, lipases and amylases, germicides and
colorants.
The oxygen transfer agents in combination with a peroxygen
compound may be useful for removing stains both in consumer
type products and for industrial applications. Among
consumer products incorporating this invention are laundry
detergents, laundry bleaches, hard surface cleaners, toilet
bowl cleaners, automatic dishwashing compositions and even
denture cleaners.
Stained consumer products benefiting from treatment with
compositions of this invention may include clothes and other
fabrics; household fixtures and applicants such as sinks,
toilet bowls and oven ranges; tableware such as drinking
glasses, dishes, cookware and utensils; and even dentures.
Hair colorants may also be formulated with the bleach
composition of this invention. The bleaching system of this
invention may also be applied to industrial uses such as for
the bleaching of wood pulp.
The system of the present invention may be delivered in a
variety of product forms including powders, on sheets or
other substrates, in pouches, in tablets, in aqueous
liquids, or in nonaqueous liquids such as liquid nonionic
detergents.
The foregoing description and Examples illustrate selected
embodiments of the present invention. In light thereof,
various modifications will be suggested to one skilled in
the art all of which are within the spirit and purview of
this invention.