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
  • C11D17/00—Detergent materials or soaps characterised by their shape or physical properties
  • C11D17/04—Detergent materials or soaps characterised by their shape or physical properties combined with or containing other objects
  • C11D17/041—Compositions releasably affixed on a substrate or incorporated into a dispensing means
  • C11D17/047—Arrangements specially adapted for dry cleaning or laundry dryer related applications
• • 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
  • C11D17/00—Detergent materials or soaps characterised by their shape or physical properties
  • C11D17/04—Detergent materials or soaps characterised by their shape or physical properties combined with or containing other objects
  • C11D17/041—Compositions releasably affixed on a substrate or incorporated into a dispensing means
  • C11D17/046—Insoluble free body dispenser
• • 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
  • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
  • C11D3/0005—Other compounding ingredients characterised by their effect
  • C11D3/001—Softening compositions
• • 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
  • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
  • C11D3/50—Perfumes
  • C11D3/502—Protected perfumes
  • C11D3/505—Protected perfumes encapsulated or adsorbed on a carrier, e.g. zeolite or clay

Definitions

• the present invention relates to substrates having prolonged fragrance. More particularly, the present invention provides compositions and methods for reducing the loss of perfume during manufacture.
• Fabric softener sheets typically include a substrate, a fabric conditioner base and a fragrance.
• the fabric conditioner base is used to impart a benefit to a fabric treated therewith. Such a benefit may include, for example, softness, reduced static of dried articles, easier ironing, etc.
• the fragrance is a used to impart a pleasant aroma to the dried fabric.
• these fabric softener sheets are typically placed in a conventional dryer together with fabric to be dried, e.g., wet laundry. During the drying process, fragrance and other benefits are transferred from the fabric softener sheet to the fabric being dried.
• a fabric softener sheet is manufactured by coating a mixture of fabric conditioner base and fragrance onto a substrate.
• fabric softener bases are solid mixtures that must be melted prior to use.
• fabric conditioner bases are melted in a holding tank at about 70°C to 90°C then fragrance is added.
• the conditioner base and fragrance may remain at these elevated temperatures for 4 to 8 hours.
• Fabric softener sheets are coated by continuously passing a substrate, e.g., a polyester sheet material, at high speed through a coating tank that is also held at 70°C to 90°C. The coated sheet material is then passed through a series of cooled rollers and a cooling tower to reduce the sheet temperature to about 30°C.
• Fragrance losses occur at various points during the conventional fabric sheet manufacturing process; these losses in total may be up to 30 percent to 45 percent.
• Encapsulates such as cyclodextrin compositions as outlined in U.S. Patent No. 5,348,667, have been used to reduce perfume loss during the manufacturing process. Such encapsulation technology, however, is expensive to make and use, and is therefore not cost effective in a large-scale commercial setting.
• Absorbents have been used to carry lipophilic materials such as fragrance in the manufacture of certain products.
• solids can adsorb oily materials, such as, perfume.
• Such adsorbent solids have been reportedly used as carpet cleaning powders (U.S. Patent No. 5,783,543 and U.S. Patent No. 5,286,400), in oil adsorbent products (U.S. Patent No. 4,537,877 and U.S. Patent No. 5,763,083), in detergent powders (U.S. Patent No. 5,656,584), in detergent liquids (U.S. Patent No. 4,983,422 and U.S. Patent No. 4,209,417), in detergent bars (EP 816484), and in liquid softeners (U.S. Patent No. 4,954,285).
• one object of the present invention is to provide a process for producing a fabric softener sheet which process significantly reduces the loss of the perfume in the fragrance matrix during the manufacture of such a sheet compared to conventional processes.
• Another object of the invention is to provide a substrate having prolonged fragrance compared to conventionally prepared substrates.
• Another object of the invention is to provide an efficient, cost-effective method for reducing the loss of perfume during the manufacture of fabric softener sheets.
• the present invention is directed to meeting these and other objects.
• the present invention provides a process for reducing fragrance loss during the manufacturing of fragranced substrates.
• This process includes providing a protected fragrance matrix that contains a perfume, a solid absorbent and optionally a fixative.
• a fabric conditioner base is further provided.
• a substrate is then combined with the fragrance matrix and the fabric conditioner base.
• a substrate treated in this manner retains more of the fragrance compared to conventionally prepared substrates.
• the present invention also provides a substrate impregnated with a fragrance matrix having prolonged organoleptic activity.
• This substrate is made by the process of forming a protected fragrance matrix that includes a perfume, an optional fixative and a solid absorbent.
• the fragrance matrix is then combined with a fabric conditioner base.
• the fragrance matrix and fabric conditioner base are then applied to the substrate either together as a mixture or sequentially. In this process, the fragrance matrix is combined with the fabric conditioner base immediately prior to application of the mixture to the substrate. Alternatively, the fragrance matrix is applied to the substrate immediately after the fabric conditioner base.
• the present invention provides a low cost method of reducing the loss of perfume during the manufacture of, e.g., a fabric softener sheet.
• This process includes the addition of a protected, i.e., an enrobed perfume contained within a fragrance matrix to a fabric conditioner base prior to application of the fabric conditioner base onto or into a substrate or during one of the rolling stages of a conventional fabric softener sheet manufacturing process.
• a protected, i.e., an enrobed perfume contained within a fragrance matrix to a fabric conditioner base prior to application of the fabric conditioner base onto or into a substrate or during one of the rolling stages of a conventional fabric softener sheet manufacturing process.
• the process of the present invention includes (1) preparing a fragrance matrix including an enrobed, i.e., a protected perfume, an optional fixative and a solid absorbent; and (2) combining the fragrance matrix with a fabric conditioner base and a substrate.
• the phrase, "fabric softener sheet” includes a substrate, a fabric softener base and a fragrance matrix.
• the term “substrate” is intended to mean any material that acts as a delivery vehicle for the fragrance matrix and fabric conditioner base.
• the substrate must be able to retain in its interior or on its surface a sufficient quantity of the fabric conditioner base and fragrance matrix required to deliver the desired performance (prolonged fragrance) to the fabric, e.g., a fabric softener sheet.
• the substrate is in the form of a sheet, although other forms may be used.
• the substrate may be a synthetic or natural fiber that is woven, knitted or extruded.
• Non-limiting examples of materials that may be used as a substrate in the present invention include cotton, Rayon, polyester, regenerated cellulose, and the like.
• fragment matrix or "protected fragrance matrix” mean that at least the most volatile parts of a perfume are protected or enrobed by a solid absorbent and optionally a fixative to reduce the amount of loss of fragrance during the manufacturing process of a substrate through evaporation of the perfume volatiles.
• the protected fragrance matrix is said to "enrobe” the perfume.
• enrobe refers to the sequestration of the perfume in the protected fragrance matrix to reduce the loss of fragrance during the manufacture of fragranced substrates, e.g., fabric softener sheets, and to prolong the effect of a fragrance on substrates coated with such an enrobed perfume.
• the protected fragrance matrix is preferably in the form of a flowable powder.
• the ratio of perfume, solid absorbents and fixative are carefully controlled to maintain the consistency of a flowable powder.
• the perfume-to-solid absorbent ratio is between about 1:20 to about 2:5, preferably about 1:5.
• the level of perfume will depend upon the final composition of the substrate.
• the fragrance may be present in the protected fragrance matrix in an amount of from about 10% to about 50% (wt/wt), preferably, in an amount of from or between about 20% to about 40% (wt/wt).
• the fragrance level will be about 1% to about 6% (wt/wt).
• the flowable powder may be dosed into, for example, a molten fabric conditioner base such as a softener or an antistatic system.
• a molten fabric conditioner base such as a softener or an antistatic system.
• the powder is mixed into the fabric conditioner base immediately prior to application of the mixture to the substrate.
• the powder is applied to a substrate previously coated with the fabric conditioner base at a subsequent processing step, such as at one of the rolling stations during the manufacture of a fabric softener sheet.
• the term "immediately" is intended to mean that the fragrance matrix is added to the fabric conditioner base just prior to application to the substrate.
• the fragrance matrix is added 1-20 minutes prior to application to the substrate, preferably 2-10 minutes prior to application to the substrate; most preferably the fragrance matrix is dosed at the rolling stage directly onto the substrate coated with the fabric conditioner base.
• the protected fragrance matrix may contain all or part of the perfume. If part of the perfume is protected, i.e., enrobed, then it is usual to select the most volatile components to be enrobed.
• the protected fragrance matrix is formed into a powder by mixing the perfume with an absorbent solid and an optional fixative.
• Absorbent solids that may be used in accordance with the present invention include, for example, clays, silicas, Celites® (ICN Biomedicals, Inc., Aurora, OH, USA.), zeolites, metal salts, including for example phosphates, cellulose, such as methyl cellulose, starches, carbonates, such as sodium bicarbonate, borates, such as sodium borate, sulfates, such as sodium sulfate, water-soluble polymers, borax and mixtures thereof.
• the term "perfume” is intended to mean a mixture of a single or complex mixture of aromatic chemicals which have been formulated to give an aesthetically pleasing smell to a substrate, such as for example, a fabric softener sheet.
• "aroma chemicals” are intended to mean chemicals that have an odor.
• the perfume may also contain small amounts of other additives, such as solvents, preservatives, antioxidants, UV screening agents and the like.
• the fragrance matrix may also include organoleptic components, such as for example, other well-known fragrance ingredients.
• a fixative is incorporated into the fragrance matrix of the present invention.
• the fixative preferably is a high molecular weight, low melting solid composition that may be mixed into a powder.
• suitable fixatives for use in the present invention include polyethylene glycol, Glycerox (Croda Inc., Parsippany, NJ, USA.), mineral oil and mixtures thereof.
• the molecular weight of the fixative may vary between about 400 to 20,000 daltons, preferably between about 2,000 to 10,000 daltons.
• Other fixatives having a similar viscosity and melting point to polyethylene glycol are also contemplated by the present invention.
• the level of fixative useful in accordance with the present invention is between about 1% and about 40% (wt).
• the solids and the liquids set forth above are combined by, for example mixing in a suitable mixer until the blend is flowable so that it is easy to apply (i.e., dose) to a substrate.
• the present invention also includes a fabric conditioner base.
• the fabric conditioner base includes a mixture of ingredients that impart a desired property to the fabric, such as for example, softness, no static cling, reduced creasing, easier ironing, and the like. These properties are achieved using, for example, cationic, zwitterionic, and non-ionic softeners, soaps and quaternary compounds, as well as other fatty materials alone or in combination.
• suitable fabric softener bases may be found in U.S. Patent No. 3,686,025.
• optional components may also be added to the fabric conditioner base to further impart various desired characteristics to the substrate, so long as these ingredients do not significantly interfere with the reduction of fragrance loss during manufacturing of substrates.
• Such optional components include, for example, antistatic agent(s), anti dye-transfer agent(s), soil release agent(s), and the like.
• the substrate may be coated at several carefully timed points and according to a specific sequence of events to achieve the desired fragrance effect.
• the substrate may be coated by combining the fragrance matrix with the fabric conditioner base to form a mixture immediately prior to applying the mixture to the substrate.
• the substrate is coated by applying the fabric conditioner base thereto to form a substrate-fabric conditioner base composition. Thereafter, the fragrance matrix is applied to the coated substrate.
• the fragrance matrix and/or fabric conditioner base is applied to the substrate using any conventional technique suited for the particular application, such as, for example, spraying, coating, dipping and the like. Using these and other techniques, the fragrance matrix and fabric conditioner base are applied to the substrate as a coating. Alternatively, the fragrance matrix and fabric conditioner are impregnated throughout the substrate, i.e., are dispersed within the interstitial matrix of the substrate as well as its surface.
• the fabric conditioner base and fragrance matrix are dispersed throughout the substrate to a uniform thickness of about 0.1 to about 2 mm to evenly distribute the fragrance throughout the entire substrate.
• Another embodiment of the present invention is a substrate impregnated with a fragrance matrix having prolonged organoleptic activity.
• This substrate is made by the process which includes (a) forming a protected fragrance matrix as set forth previously with a perfume, a fixative and a solid absorbent; and (b) mixing the fragrance matrix with the fabric conditioner base immediately prior to applying the mixture to the substrate or applying the fragrance matrix to the substrate immediately after the fabric conditioner base is applied to the substrate.
• a mixture of the fragrance matrix and fabric conditioner base is applied to the substrate.
• the fragrance matrix is added to the fabric conditioner immediately prior to application of the mixture to the substrate.
• the fabric conditioner base and fragrance matrix are applied to the substrate sequentially.
• the fabric conditioner is applied to the substrate first, immediately followed by the fragrance matrix.
• the fixative according to this embodiment is selected from high molecular weight, low melting point compositions such as for example, polyethylene glycol, Glycerox, mineral oil and mixtures thereof.
• An enrobed, i.e., protected fragrance matrix was made by combining the ingredients as set forth below: Component % Perfume Oil (Givaudan Roure) Fragrance PNF217FPN 20 Polyethylene Glycol 4000 (Union Carbide) 1 Bentonite H (Whitaker, Clark & Daniels) 10 Valfor® 100 Aluminosilicate Zeolite (PQ Corp.) 69
• a commercially available fragrance PNF217FPN (Givaudan Roure) was used to determine what effect prolonged heating would have on a conventionally prepared fabric conditioner base and a fabric conditioner base containing a protected fragrance matrix according to the present invention.
• the protected fragrance matrix does not evaporate as much as the neat oil and affords protection from the heated environment.
• Table 5 shows the amount of fragrance lost from the system. After 8 hours at 80°C, the enrobed fragrance matrix still contains twice as much fragrance as the conventional formulation. Fragrance Loss Summary Sample Time (Hours) 0hrs 2hrs 4hrs 6hrs 8hrs Conventional 10% 17.5% 20% 22.5% 27% Enrobed (Protected) 2.5% 2.5% 7.5% 7.5% 12.5%
• the use of the protected fragrance matrix does protect the fragrance to the extent that even after prolonged heating losses are less than those experienced under conventional production conditions.
• the enrobed composition of the present invention reduced the amount of fragrance loss by about 60% compared to the control.
• fragrance loss One of the highest levels of fragrance loss during the manufacture of fabric softener sheets occurs when the sheets are cooled. Adding fragrance near the end of the process or after coating should significantly reduce fragrance loss.
• a protected fragrance matrix according to the present invention was sprinkled uniformly onto the surface of warm sheets freshly coated with Varisoft fabric softener base. The sheets were then cooled, extracted, and analyzed.
• Table 7 compares the fragrance loss of conventionally prepared sheets to sheets prepared using the enrobed composition of Example 1 after coating. Fragrance Loss From Fabric Softener Sheets With and Without Protected Fragrance Matrixes Normal Coating Process Enrobed Fragrance % Fragrance % Loss % Fragrance % Loss 2.4 40% 3.88 3%
• Example 2 Three different samples were prepared as in Example 1 except that the following fixatives were substituted for the polyethylene glycol 4,000 recited therein: (a) polyethylene glycol with a molecular weight of 20,000 daltons; (b) Glycerox (a triglyceride mixture) with a molecular weight of about 2,000 daltons; and (c) mineral oil, with a molecular weight of approximately 400 daltons.
• fixatives were substituted for the polyethylene glycol 4,000 recited therein: (a) polyethylene glycol with a molecular weight of 20,000 daltons; (b) Glycerox (a triglyceride mixture) with a molecular weight of about 2,000 daltons; and (c) mineral oil, with a molecular weight of approximately 400 daltons.
• Varisoft 136-100 was used as the fabric conditioner base. It was heated to 80°C in a convection oven. For each of the three samples, 40g of Varisoft were placed into a pre-heated beaker. 10g of the enrobed composition as prepared in Example 1 was added with mixing. 1.5g of the molten mixture was evenly spread on a 1g blank woven polyester dryer sheet.
• Varisoft was heated to 80°C in a convection oven. 40g of the Varisoft was weighed into a pre-heated beaker and 10g of the enrobed fragrance matrix was added, mixed and held at 80°C for 4 hours and then applied onto a sheet using the same procedure as above.
• each of the three fixatives used with the protected fragrance matrix of the present invention reduce fragrance loss compared to a conventionally prepared dryer sheet.
• the higher molecular weight (PEG 20,000) sample provides the best effect of the three fixatives tested exhibiting a percent fragrance loss of only 1.5%.
• Enrobement or protection of the perfume in the fragrance matrix may be broken up into two parts: the fixative and the absorbent.
• the absorbent effects particularly the replacement of clay and zeolite absorbents with several other absorbents is shown.
• the fragrance absorption capacity of the dry blends was also tested and is presented below.
• Tables 9-11 indicate that several materials are suitable for use as absorbents in the present fragrance matrix either in place of or blended with zeolite and clay.
• the absorbent blends have a capacity of up to about 40% fragrance while remaining free flowing and homogeneous.
• Tables 9-11 demonstrate that various carriers and fragrances may be used in the present fragrance matrix by balancing each component to produce a free-flowing powder that is easily handled and applied to e.g., fabric softener sheets.
• any combination of a fragrance and a suitable carrier that results in a free flowing composition that is easily handled and dosed is encompassed by the present invention.
• Fabric softener sheets were prepared by adding the appropriate amounts of protected fragrance matrix, as set forth in Example 1, on to a blank polyester sheet dosed with the applicable amount of active as set forth in Example 1. This process simulates post dosing and was prepared at a fragrance level of 4%, and compared to a conventionally prepared sheet.
• Headspace GC-MS measurements were made from conventionally prepared fabric softener sheets, from fabric softener sheets prepared according to the present invention, and from towels that had been washed, then dried, with the respective fabric softener sheets.
• the results set forth in Table 12 indicate that the sheets containing the protected or enrobed fragrance, i.e., the fabric softener sheets made according to the present invention, retain far more fragrance and deposit much more fragrance on to towels in the dryer compared to commercially available alternatives.

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• Wood Science & Technology (AREA)
• Organic Chemistry (AREA)
• Dispersion Chemistry (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Chemical Or Physical Treatment Of Fibers (AREA)

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Citations (6)

• 2000
  • 2000-06-07 EP EP00112230A patent/EP1061124A1/fr not_active Withdrawn
  • 2000-06-14 JP JP2000178635A patent/JP2001032176A/ja active Pending

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