KR20150105379A - Solid tablet unit dose oven cleaner - Google Patents

Abstract

The solidification matrix comprises sodium hydroxide, sodium carbonate, water fillers, anhydrous metasilicates, salts or derivatives of the polycarboxylic acid polymers, and additional functional ingredients. The sodium hydroxide, sodium carbonate, water filler, anhydrous metasilicate, polycarboxylic acid polymer, and additional functional ingredients interact to form a solid of hydrate. The solidification matrix may be used, for example, in a solid detergent composition. A method of making a solid detergent composition is disclosed.

Description

SOLID TABLET UNIT DOSE OVEN CLEANER [0002]

The present invention relates generally to the field of solidification and solidification matrices. The present invention relates to the solidification of phosphate-free alkaline detergent compositions. In particular, the present invention relates to a phosphate-free alkaline detergent composition comprising sodium hydroxide, sodium carbonate, anhydrous sodium metasilicate, preferably a polycarboxylic acid polymer as part of a solidification matrix.

Solidified in institutional and industrial operations technology and solid block detergents (solid block detergent) may, for example, used in the claims the SOLID POWER ^® brand described in US Reissue Patent No. 32 762 and No. 32 818, such as call Fernholz. In addition, sodium carbonate hydrate cast solid products using substantially hydrated sodium carbonate material are disclosed in Heile et al., US Pat. Nos. 4,595,520 and 4,680,134, the entirety of which are incorporated herein by reference.

More recently, it has been noticed that highly effective detergent materials are produced from less-caustic materials such as soda ash, also known as sodium carbonate. In previous work in developing sodium carbonate-based detergents, sodium carbonate hydrate-based materials have often been found to expand (i.e., become dimensionally unstable) after solidification. Such swelling can interfere with packaging, distribution, and use. Dimensional destabilization of solidified materials is associated with the unstable nature of the various hydrate forms produced when making sodium carbonate solid materials. Conventional products made from hydrated sodium carbonate typically include anhydrides, 1 molar hydrate, 7 molar hydrate, 10 molar hydrate or a mixture thereof. However, after the product is made and stored at ambient temperature, the hydration state of the initial product has been found to be converted, for example, in the hydration form of 1, 7, and 10 molar hydrates, resulting in dimensional destabilization of the block chemicals. In such conventional solid form compositions, changes in water content and temperature result in structural and dimensional changes which can lead to problems such as the destruction of solid forms and the inability to match solid materials to the machine for use.

In addition, conventional solid alkaline detergents, especially those intended for institutional and commercial use, generally require phosphate in their composition. Such phosphates typically serve multiple uses in the composition, for example, to control the rate of solidification, to remove and suspend soil, and as an effective hardness sequestering agent. This may be achieved by using a binding agent comprising a carbonate salt, an organic acetate such as an aminocarboxylate, or a phosphonate component and water to produce a solid block functional material. Patent No. 6,258,765, No. 6,156,715, No. 6,150,324, and No. 6,177,392. Due to ecological concerns, more recent work is directed towards replacing phosphorus-containing compounds in detergents. Also, nitrilotriacetic acid (NTA) -containing aminocarboxylate components used in place of phosphorus-containing compounds as binders and hard metal ion sequestrants in some cases are believed to be carcinogenic. As a result, its use is also diminishing.

Requirements for solidifying matrices for solid alkaline detergents require a number of modifications, including removal of phosphorus and / or NTA. Further reforming involves the formation of a solidified matrix incorporating a pseudo material (sodium hydroxide) in combination with a less viscous material such as soda ash (e. G., Sodium carbonate), continuing to establish a solid physically stable tablet composition This shows difficulties. Highly caustic powders for solidification appeared to fail to consistently form stable compositions such as tablets. Thus, there is a need to use lower levels of sodium hydroxide in combination with other less fugitive materials to formulate a dimensionally-stable solid composition. These and other aspects of forming a physically stable detergent composition provide the background in which the present invention is provided.

In an embodiment of the present invention, a physically stable phosphate-free alkaline detergent tablet composition is provided for a combination oven.

In an embodiment of the invention, a method is provided for forming physically stable phosphate-free alkaline detergent tablets containing sodium carbonate, sodium hydroxide and sodium metasilicate using ash and / or hydroxide-hydration.

In a further aspect of the invention, the compositions and methods of the present invention provide a physically stable composition having durable cleaning performance, including, for example, cleaning the combination oven.

One embodiment of the present invention is a solid detergent composition comprising an alkali metal hydroxide, a polycarboxylic acid polymer, sodium carbonate, water and one or more functional ingredients. According to one embodiment, when the solid detergent composition is heated at a temperature of 120 degrees Fahrenheit, the composition remains dimensionally stable and has a growth index of less than 3%. The composition preferably does not contain phosphorus.

Another embodiment is a solid detergent composition wherein the solid detergent composition comprises from about 5% to about 70% by weight of the solid detergent composition of sodium hydroxide; From about 20% to about 90% by weight of the solid detergent composition of sodium carbonate; From about 0.1% to about 15% by weight of the solid detergent composition of a polycarboxylic acid polymer; From about 0.1% to about 10% water by weight of the solid detergent composition; From about 1% to about 50% by weight of the secondary alkalinity source of the solid detergent composition; And from about 1% to about 50% by weight of the solid detergent composition of a chelant, wherein the detergent composition does not contain phosphorus. The solid detergent composition is dimensionally stable when heated to a temperature of 120 degrees Fahrenheit and has a growth index of less than 3%.

Another further embodiment is to form a powder pre-mixture by combining sodium carbonate, an anhydrous silicate secondary alkalinity source and at least one additional functional ingredient; Mixing the powder premix with a water source to form a solid hydrate; A solid detergent composition is formed by combining a solid hydrate with a source of sodium hydroxide and optionally a polycarboxylic acid polymer. In the present invention, the solid detergent composition produced does not contain phosphorus; When heated to a temperature of 120 degrees Fahrenheit, the solid detergent composition is dimensionally stable and has a growth index of less than 3%.

While multiple embodiments are disclosed, still other embodiments of the present invention will be apparent to those skilled in the art from the following detailed description that illustrates and describes exemplary embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.

Figure 1 is a graph showing the dimensional stability of various exemplary formulations according to embodiments of the methods and compositions of the present invention.
Figure 2 is a graph showing the compressive strengths of various exemplary formulations according to embodiments of the methods and compositions of the present invention.
Figure 3 is a graph showing the dimensional stability of various exemplary formulations according to embodiments of the methods and compositions of the present invention.
Figure 4 is a graph showing the compressive strengths of various exemplary formulations according to embodiments of the methods and compositions of the present invention.
Various embodiments of the present invention will be described in detail with reference to the drawings, wherein like reference numerals designate like parts throughout the several views. Reference to various embodiments does not limit the scope of the invention. The drawings presented herein are not intended to limit the various embodiments in accordance with the invention, but are presented for an exemplary scheme of the invention.

details

Embodiments of the present invention are not limited to any particular solid detergent composition, and may vary as will be understood by those skilled in the art. In addition, it should be understood that all terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting in any way or for any range. For example, the singular forms used in this specification and the appended claims may include multiple objects, unless the context clearly dictates otherwise. In addition, all units, prefixes, and symbols may be denoted in their SI-allowed form. Numerous ranges recited in the specification are intended to encompass a number specifying the range and include each integer within the specified range.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Many methods and materials similar, variations, or equivalents to those described herein can be used to practice embodiments of the present invention without undue experimentation, and preferred materials and methods are described herein. In describing and claiming embodiments of the present invention, the following terms will be used in accordance with the definitions set forth below.

As used herein, the term " about "means, by way of example, the typical measurement and liquid manipulation procedures used to prepare the concentrate or use solution in practice; By unintended mistakes in these procedures; Refers to variations in numerical quantities that can occur due to differences in fabrication, source, or purity of the components used to make the composition or perform the method. Whether or not modified by the term " about, " the claims include equivalents to that amount and refer to variations in numerical amounts that may occur.

As used herein, the terms "dimensional stability" and "dimensionally stable" refer to a solid product having a growth index of less than about 3%, preferably less than about 2%.

As used herein, the terms "weight percent", "wt-%", "percent weight", "% weight" and variations thereof refer to the concentration of a substance divided by the total weight of the composition and multiplied by 100 . As used herein, "percent" and "%" and the like are meant to indicate such things as "weight percent,"

According to embodiments of the present invention, the solid composition is a dimensionally stable solid composition for use in any pressed, extruded, cast solid composition containing hydratable salts, alkaline activators (e.g., alkali metal hydroxides) Thereby solving the need in the prior art. In a preferred embodiment, the dimensionally stable solid composition is not used in the cast solid composition. In particular, such compositions comprise a solid detergent composition which can be used in a wide variety of situations in which a substantially non-containing, finely divided, pseudo-stable, alkali-containing detergent and a nitrile lactic acid (NTA) . Substantially phosphorus-free is a solidifying matrix having a phosphorus content of less than about 0.5 wt-%, more particularly less than about 0.1 wt-%, even more particularly less than about 0.01 wt-% phosphorus, based on the total weight of the solidification matrix it means. NTA-free means a solidification matrix having less than about 0.5 wt-%, less than about 0.1 wt-%, and often less than about 0.01 wt-% NTA, based on the total weight of the solidified matrix. Accordingly, embodiments of the present invention are particularly useful for cleaning applications where it is desired to use environmentally friendly solid detergents.

The solidification matrix of the present invention can be used in any of a wide variety of situations where a dimensionally stable solid product is desired. The solidification matrix is dimensionally stable and has an appropriate solidification rate. In addition, the solidification matrix does not contain phosphorus and NTA, so that the solidification matrix can be particularly useful for cleaning applications where it is desired to use environmentally friendly solid alkaline detergents. Such applications include, but are not limited to, the use of phosphate-free alkaline detergents in combination ovens such as those used in a variety of food service industries. Additional applications include, for example, ware wash detergent, presoak, fryer boil out, power soak sink and related applications, soak tanks, Cleaning and decolorization, carpet cleaning and decoloration, vehicle cleaning and care application, surface cleaning and decolorization, kitchen and bathroom cleaning and decoloration, floor cleaning and decolorization, cleaning in place operation, general purpose cleaning and bleaching, and / or industrial or household cleaning agents. Methods suitable for preparing solid detergent compositions using solidifying matrices are also provided.

Solidification matrix and solid detergent composition

The solidified matrix generally comprises an alkali metal hydroxide alkalinity source to form a solid composition, a hydratable salt such as sodium carbonate (soda ash), a polycarboxylic acid polymer, and a water filler. The solidification matrix may further comprise a chelating agent, a corrosion inhibitor, an additional water conditioning agent and / or an additional alkalinity source. The solidification matrix may comprise and / or consist essentially of, and / or consist of, alkali metal hydroxides, hydratable salts, polycarboxylic acid polymers, chelating agents, additional alkalinity and / or corrosion inhibitor sources and / .

Suitable component concentrations for the solidification matrix are from about 1% to about 90% alkali metal hydroxide alkali, from about 0.1% to about 15% polycarboxylic acid polymer, from about 0.1% to about 25% water, and from about 20% To about 90% by weight of sodium carbonate. Particularly suitable component concentrations for the solidification matrix are from about 5% to 70% by weight of an alkali metal hydroxide alkali agent, from 1% by weight to about 10% by weight of polycarboxylic acid polymer, from about 0.1% by weight to about 10% To about 90% by weight of sodium carbonate. A more particularly suitable concentration for the solidification matrix is about 10% to 50% alkali metal hydroxide alkali, 2.5% to about 10% polycarboxylic acid polymer, about 1% to about 5% water, and about 30% By weight to about 70% by weight of sodium carbonate. Unexpectedly, the dimensionally stable solid compositions according to the present invention have a maximum of at least 30% or more, preferably at least 40% or more, or at most 50% or more, (E. G., Sodium hydroxide). ≪ / RTI >

In a further embodiment of the present invention, the component concentration for the solidified matrix further comprises from about 0.1% to 50% by weight of a chelating agent such as sodium gluconate, and from 0.1% to 50% by weight of a secondary alkalinity source and / Inhibitor < / RTI > Particularly suitable component concentrations for the solidification matrix are from about 1% to 50% by weight of the chelating agent, and from 1% to 50% by weight of the secondary alkalinity source and / or corrosion inhibitor. More particularly suitable component concentrations for the solidification matrix are from about 5% to 25% by weight of the chelating agent, and from 1% to 20% by weight of the secondary alkalinity source and / or corrosion inhibitor. Those skilled in the art will know other suitable concentrations of ingredients suitable for obtaining similar properties of the solidification matrix. Although not limited in scope, all numerical ranges referred to herein encompass numbers that specify a range and include each integer within a specified range.

Alkalinity source

The solid detergent composition comprises an effective amount of one or more alkalinity sources to provide effective cleaning of the substrate and improve soil removal performance of the solid detergent composition. Preferably the alkalinity source is an alkali metal hydroxide and is provided in an effective amount to improve substrate cleaning and soil removal. The compositions of the present invention comprise an alkalinity source in an amount of at least about 1 weight percent, at least about 5 weight percent, or at least about 10 weight percent. In a preferred embodiment, the alkalinity source comprises from about 1 wt% to about 90 wt%, from about 5 wt% to about 70 wt%, from about 10 wt% to about 50 wt%, and most preferably from about 1 wt% to about 20 wt% of the total weight of the solid detergent composition By weight to about 40% by weight.

An effective amount of an alkalinity source should be regarded as an amount that provides a use composition having a pH of at least about 8, preferably at least about 10, more preferably at least about 12. If the composition used has a pH of from about 8 to about 10, it may be considered slightly alkaline, and if the pH is greater than about 12, the composition used may be regarded as caustic.

Examples of suitable alkaline sources of solid detergent compositions include, but are not limited to, alkali metal hydroxides. Exemplary alkali metal hydroxides that may be used include, but are not limited to, sodium, lithium, or potassium hydroxide. Alkali metal hydroxides, including solid beads, are known in the art, may be dissolved in an aqueous solution, or may be added to the composition in any form of combination thereof. The alkali metal hydroxide may be in the range of about 12-100 U.S. Prilled solid or bead-like solids having a mixture of particle sizes in the mesh range, or commercially available as aqueous solutions, for example, 45 wt% and 50 wt% solutions. The alkali metal hydroxides according to the invention are preferably added in the form of prilled solids or beads.

Hydratable salt

A solid detergent composition according to the present invention comprises at least one hydratable salt. In one embodiment, the hydratable salts are sodium carbonate (alkaline soda ash or ash) and / or potassium carbonate (alkaline potassium). In a preferred embodiment, the hydratable salt is sodium carbonate and excludes potassium carbonate. The hydratable salt may be in the range of from about 20% to about 90% by weight, preferably from about 25% to about 90% by weight, more preferably from about 30% to about 70% by weight of hydratable salts such as sodium carbonate . Those skilled in the art will know other suitable concentrations of ingredients suitable for obtaining similar properties of the solidification matrix.

In another embodiment, the hydratable salts can be combined with other solidifying agents. For example, hydratable salts can be used with additional solidifying agents which are essentially inorganic, and may also optionally serve as an alkalinity source. In certain embodiments, the secondary solidifying agent may include, but is not limited to, additional alkali metal hydroxides, anhydrous sodium carbonate, anhydrous sodium sulfate, anhydrous sodium acetate, and other known hydratable compounds or combinations thereof. According to a preferred embodiment, the second hydratable salt comprises sodium metasilicate and / or anhydrous sodium metasilicate. The amount of secondary solidifying agent needed to achieve solidification depends on a number of factors including the exact solidifying agent used, the amount of water in the composition, and the hydration power of the other detergent ingredients. In certain embodiments, the secondary solidifying agent may also serve as an additional alkaline source.

The polycarboxylic acid polymer

The solid alkaline detergent composition according to the present invention comprises a polycarboxylic acid polymer or a salt or derivative thereof. As mentioned herein, reference to any polycarboxylic acid polymer will additionally include a salt or derivative thereof, which is also a polymer suitable for use in the solid alkaline detergent compositions according to the present invention. Examples of particularly suitable polycarboxylic acid polymers include, but are not limited to, polyacrylic acid polymers, polyacrylic acid polymers modified by fatty acid terminal groups ("modified polyacrylic acid polymers"), polymaleic acid polymers, and combinations of such polymeric materials Do not. Salts of each of the polycarboxylic acid polymers may additionally be used in solid alkaline detergent compositions.

Non-limiting examples of polycarboxylic acid polymer salts include polyacrylic acid salts and derivatives, such as water soluble acrylic polymers. Such polymers may be selected from the group consisting of polyacrylic acid, polymethacrylic acid, acrylic acid, acrylic acid-methacrylic acid copolymer, polymaleic acid, hydrolyzed polyacrylamide, hydrolyzed methacrylamide, hydrolyzed acrylamide-methacrylamide copolymer , Hydrolyzed polyacrylonitrile, hydrolyzed polymethacrylonitrile, and hydrolyzed acrylonitrile methacrylonitrile copolymer, and the like, or combinations thereof, or copolymers thereof, but are not limited thereto Do not. Water soluble or partial salts of such polymers, such as their respective alkali metals (e.g., sodium, potassium, or combinations thereof) or ammonium salts, may also be used in accordance with the present invention.

Particularly suitable examples of polyacrylic acid polymers and modified polyacrylic acid polymers and their salts and derivatives include those having a molecular weight of from about 1,000 to about 100,000. More particularly suitable examples of polymaleic acid polymers and salts and derivatives thereof include those having a molecular weight of from about 500 to about 5,000. Particularly suitable examples of commercially available polyacrylic acid polymers and their salts and derivatives include, but are not limited to, Acusol 445ND available from Rohm & Haas LLC (Philadelphia, Pa.). Particularly suitable examples of commercially available modified polyacrylic acid polymers include, but are not limited to, Alcosperse 325 available from Alco Chemical (Chattanooga, TN). Examples of particularly suitable commercially available polymaleic acid polymers include, but are not limited to, Belclene 200 available from Houghton Chemical Corporation (Boston, Mass.) And Aquatreat AR-801 available from Alco Chemical (Chattanooga, TN).

In one embodiment, the solidification matrix of the present invention comprises at least one polyacrylic acid polymer or salt or derivative thereof. For example, the solidification matrix may comprise from about 0.1% to 15% by weight, more particularly from about 0.5% to 15%, from about 0.1% to 10%, from about 1% to 10% And from 2.5% to 10% by weight of the polyacrylic acid polymer. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

In alternative embodiments, the solidification matrix may comprise a polymaleic acid polymer and two or more polyacrylic acid polymers having different molecular weights. In a further embodiment, the solidification matrix comprises at least one carboxylic acid salt in addition to at least one polycarboxylic acid polymer. Suitable carboxylic acid salts include straight chain saturated carboxylic acid salts such as acetic acid, gluconic acid, malic acid, succinic acid, glutaric acid, adipic acid, tartaric acid, citric acid, or combinations thereof. In one example, the solidification matrix comprises from about 0.1% to 10% by weight of a carboxylic acid salt, for example, a citric acid salt.

water

According to an embodiment of the invention, water can be added independently to the solidification matrix and / or can be provided to the solidification matrix by its presence in the aqueous material added to the detergent composition. Preferably, the secondary alkalinity source (e.g., silicate or metasilicate) is provided as anhydrous silicate and accordingly does not introduce water into the solidification matrix. However, the remainder of the components added to the detergent composition may comprise water or may be prepared in an aqueous premix that is available for reaction with the solidified matrix component (s). Water is introduced into the solidification matrix to provide the desired cohesive strength or compressive force to the solidification matrix and to provide the desired rate of solidification (e.g., hydroxide and / or ash hydration according to aspects of the present invention). It is also expected that the aqueous medium can assist the solidification process when it is desired to form the concentrate as a solid. Water may also be provided as deionized water or soft water.

The amount of water in the resulting solid detergent composition will depend on the foaming method used for the solid detergent composition (e. G., Process foaming technology). Because the method and process of the present invention is not desirable for use in casting (solidification occurs in the vessel), a smaller amount of water is used. The use of foaming technology involves a relatively small amount of water compared to casting techniques. When preparing solid detergent compositions by foaming techniques, water may be present in the range of from about 1% to about 25% by weight, especially from about 1% to about 20% by weight, more particularly from about 2% to about 10% have. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

The solidification matrix may be phosphorus-free and / or nitrilotriacetic acid (NTA) -free to make the solid detergent composition more environmentally beneficial. Phosphorus-free means a solidification matrix having less than about 0.5 wt-%, more particularly less than about 0.1 wt-%, even more particularly less than about 0.01 wt-% phosphorus based on the total weight of the solidification matrix. NTA-free means a solidification matrix having an NTA of less than about 0.5 wt-%, less than about 0.1 wt-%, often less than about 0.01 wt-%, based on the total weight of the solidified matrix. When the solidification matrix is NTA-free, the solidification matrix and the resulting solid detergent composition are also compatible with chlorine, which functions as a redeposition agent and a dye-removal agent.

Additional functional materials

The components of the solidification matrix may be combined with the various functional ingredients used to form the solidifying detergent composition. In some embodiments, the solidification matrix comprising an alkali metal hydroxide, a secondary alkalinity source, a chelating agent, a polycarboxylic acid polymer, water, and sodium carbonate can be used, for example, as a sphere with or without additional functional materials disposed thereon In the examples, it constitutes a large amount of detergent composition, or even substantially all of the total weight. In such embodiments, the component concentration ranges provided above for the solidification matrix represent the range of such identical components in the detergent composition. For example, such compositions may contain from about 5% to 70% by weight of an alkali metal hydroxide, from 0.1% to 15% by weight of a polycarboxylic acid polymer, from about 0.1% to about 10% From about 1% to about 50% by weight of a secondary alkalinity source, and from about 1% to about 50% by weight of a chelating agent, with the remainder of the composition including additional functional ingredients. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

Functional materials provide the properties and functions desired for solid detergent compositions. For purposes of this application, the term "functional material" includes materials that provide properties advantageous for a particular application when dispersed or dissolved in a use and / or concentration solution such as an aqueous solution. Some specific examples of functional materials are discussed in more detail below, but the particular materials discussed are given by way of example only and a wide variety of other functional materials may be used. For example, a number of functional materials discussed below relate to materials used in cleaning and / or decolorizing applications. However, other embodiments may include functional materials for use in other applications.

Secondary alkaline source

The solid detergent composition may comprise an effective amount of one or more alkaline sources to provide alkalinity and / or improve cleaning of the substrate and / or improve soil removal performance of the solid detergent composition. Depending on the source of alkali metal hydroxide alkalinity, a secondary alkaline source may be provided in the form of a concentrate.

Examples of suitable secondary alkaline sources of solid detergent compositions include alkali metal carbonates such as sodium or potassium carbonate, bicarbonate, sesquicarbonate, and mixtures thereof; Metal silicates such as sodium or potassium silicates or metasilicates, and mixtures thereof; Metal borates, such as sodium or potassium borate, and mixtures thereof; And ethanol amines and amines, and mixtures thereof. Such secondary alkaline formulations are commercially available in aqueous or powder form useful for formulating the solid detergent compositions of the present invention. According to a preferred embodiment of the present invention, the secondary alkaline agent is provided in solid form.

In one embodiment, the silicate is preferred for use as a secondary alkaline source. In addition to providing alkalinity, silicates are commonly known to be advantageous in inhibiting corrosion and / or preventing recoil. In an embodiment of the invention, the silicate secondary alkalinity source is not provided in an amount sufficient to protect the metal (i.e., corrosion inhibition) as a result of the solidifying composition containing the alkali metal hydroxide component. Exemplary silicates include, but are not limited to, sodium silicate and potassium silicate. As mentioned herein, the silicate may further comprise a meta silicate (e.g., potassium or sodium meta silicate). The silicates and / or the meta-silicates may be provided as powdery, particulate or granular silicates and / or meta-silicates. In addition, the silicate and / or the meta-silicate may be anhydrous or contain hydrated water. In a preferred embodiment of the present invention, the silicate and / or the meta silicate is anhydrous.

In some embodiments, the secondary alkaline source comprises from about 0.1% to about 50%, from about 0.5% to about 50%, from about 1% to about 50%, from about 1% to about 50% About 25 wt%, and about 5 wt% to about 15 wt%. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

Surfactants

The solid detergent composition may comprise at least one detergent comprising a surfactant or surfactant system. A wide variety of surfactants can be used in the solid detergent compositions, including but not limited to anionic, nonionic, cationic, and amphoteric surfactants. The surfactant is an optional component of the solid detergent composition and can not be excluded from the concentrate. Exemplary surfactants that may be used are commercially available from a number of suppliers. For a discussion of surfactants, see Kirk-Othmer, Encyclopedia of Chemical Technology, Third Edition, volume 8, pages 900-912, the entirety of which is incorporated herein by reference. When the solid detergent composition comprises a detergent, the detergent is provided in an amount effective to provide the desired level of cleaning. When provided as a concentrate, the solid detergent composition may comprise from about 0.05% to about 20%, from about 0.5% to about 15%, from about 1% to about 15%, from about 1.5% to about 10% , And from about 2% to about 8% by weight of detergent. A further exemplary range for the surfactant of the concentrate includes from about 0.5 wt% to about 8 wt%, and from about 1 wt% to about 5 wt%. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

Examples of anionic surfactants useful in solid detergent compositions include carboxylates such as alkyl carboxylates and polyalkoxycarboxylates, alcohol ethoxylate carboxylates, nonylphenol ethoxylate carboxylates; Sulfonates such as alkyl sulphonates, alkyl benzene sulphonates, alkyl aryl sulphonates, sulfonated fatty acid esters; But are not limited to, sulfates such as sulfated alcohols, sulfated alcohol ethoxylates, sulfated alkylphenols, alkyl sulfates, sulfosuccinates, and alkyl ether sulfates. Exemplary anionic surfactants include, but are not limited to, sodium alkyl aryl sulfonates, alpha-olefin sulfonates, and fatty alcohol sulfates.

Examples of nonionic surfactants useful in solid detergent compositions include, but are not limited to those having a polyalkylene oxide polymer as part of a surfactant molecule. Such non-ionic surfactants include chlorine-, benzyl-, methyl-, ethyl-, propyl-, butyl- and other similar alkyl-capped polyethylene glycol ethers of fatty alcohols; Polyalkylene oxide-free nonionic surfactants such as alkyl polyglycosides; Sorbitan and sucrose esters and ethoxylates thereof; Alkoxylated amines such as alkoxylated ethylenediamine; Alcohol alkoxylates such as alcohol ethoxylate propoxylate, alcohol propoxylate, alcohol propoxylate ethoxylate propoxylate, alcohol ethoxylate butoxylate; Nonylphenol ethoxylate, polyoxyethylene glycol ether; Carboxylic acid esters such as glycerol esters, polyoxyethylene esters, ethoxylation of fatty acids and glycol esters; Carboxylic acid amides such as diethanolamine condensates, monoalkanolamine condensates, polyoxyethylene fatty acid amides; And polyalkylene oxide block copolymers. Examples of commercially available ethylene oxide / propylene oxide block copolymer commercially available comprises a commercially available PLURONIC ^® from BASF Corporation (Florham Park, NJ), but is not limited thereto. Examples of the silicone surfactant commercially available include ABIL ^® B8852 can obtained from Goldschmidt Chemical Corporation (Hopewell, VA), but is not limited thereto.

Examples of cationic surfactants that can be used in solid detergent compositions include primary, secondary and tertiary monoamines having amines such as _C18 alkyl or alkenyl chains, ethoxylated alkylamines, alkoxylates of ethylenediamine, , For example, 1- (2-hydroxyethyl) -2-imidazoline, and 2-alkyl-1- (2-hydroxyethyl) -2-imidazoline; And quaternary ammonium salts such as alkyl quaternary ammonium chloride surfactants such as n-alkyl (C ₁₂ -C ₁₈ ) dimethylbenzylammonium chloride, n-tetradecyldimethylbenzylammonium chloride monohydrate, and naphthylene-substituted But are not limited to, quaternary ammonium chlorides, such as dimethyl-1-naphthylmethylammonium chloride. Cationic surfactants can be used to provide germicidal properties.

Examples of amphoteric surfactants that can be used in solid detergent compositions include, but are not limited to, betaines, imidazoles, and propionates.

When a solid detergent composition is intended to be used in an automatic dishwashing or article cleaning machine or combination oven, if any surfactant is used, the selected surfactant may be used when used in a dishwashing or article cleaning machine or in a combination oven To provide a possible foam level. Solid detergent compositions for use in automatic dishwashing or article cleaning machines are generally considered to be low-foaming compositions. Low foaming surfactants that provide the level of detergent activity desired are advantageous in environments such as dishwashing machines where the presence of large amounts of foaming can be a problem. In addition to selecting a low foaming surfactant, defoamer may also be used to reduce the generation of foam. Accordingly, a surfactant which is regarded as a low foaming surfactant can be used. In addition, other surfactants may be used with the defoamer to control the level of foam.

Chelating agents, builders and / or water conditioners

The solid detergent composition may include one or more building agents, also referred to as chelating or sequestering agents (e.g., builders), including, but not limited to, aminocarboxylic acids, or polyacrylates. Generally, a chelating agent is a substance that can coordinate (i.e., bind) metal ions that are commonly found in natural water to prevent metal ions from interfering with the activity of other detergent components of the cleaning composition. Also preferred levels of addition for builders that can be chelating or sequestering agents are from about 0.1 wt% to about 70 wt%, from about 1 wt% to about 60 wt%, or from about 1.5 wt% to about 50 wt%. When the solid detergent is provided as a concentrate, the concentrate may comprise from about 1 wt% to about 60 wt%, from about 3 wt% to about 50 wt%, and from about 6 wt% to about 45 wt% builder . An additional range of builders includes about 3 wt% to about 20 wt%, about 6 wt% to about 15 wt%, about 25 wt% to about 50 wt%, and about 35 wt% to about 45 wt%. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

In a preferred embodiment, the chelating agent (e.g., sodium gluconate) comprises from about 0.1% to about 50%, from about 0.5% to about 50%, from about 1% to about 50% , From about 1 wt% to about 25 wt%, and from about 5 wt% to about 25 wt%. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

Examples of preferred chelating agents for non-phosphate alkaline detergent compositions include carboxylates, such as citrates, tartrates or gluconates. In a preferred embodiment, sodium gluconate is used as a chelating agent for solid alkaline detergent compositions.

Solid detergent compositions may contain non-phosphorous based builders. While the various components may contain trace amounts of phosphorus, the compositions considered free of phosphorus generally do not contain a phosphate or phosphonate builder or a chelate component as a deliberately added ingredient. Carboxylates such as citrate, tartrate or gluconate are suitable. Useful aminocarboxylic acid materials that contain no or little NTA include N-hydroxyethylaminodiacetic acid, ethylenediaminetetraacetic acid (EDTA), hydroxyethylenediaminetetraacetic acid, diethylenetriaminepentaacetic acid, N-hydroxyethyl -Ethylenediaminetriacetic acid (HEDTA), diethylenetriaminepentaacetic acid (DTPA), and other similar acids having an amino group with a carboxylic acid substituent.

The water conditioning polymer can be used as a non-phosphorus containing builder. Exemplary water-conditioning polymers include, but are not limited to, polycarboxylates. Exemplary polycarboxylates that can be used as builders and / or water conditioning polymers include those having pendant carboxylate (-CO ₂ ^- ) groups such as polyacrylic acid, maleic acid, maleic acid / olefin copolymers, sulfonated copolymers Or a mixture of terpolymers, acrylic acid / maleic acid copolymers, polymethacrylic acid, acrylic acid-methacrylic acid copolymers, hydrolyzed polyacrylamides, hydrolyzed polymethacrylamides, hydrolyzed polyamide-methacrylamide copolymers , Hydrolyzed polyacrylonitrile, hydrolyzed polymethacrylonitrile, and hydrolyzed acrylonitrile-methacrylonitrile copolymers. ≪ RTI ID = 0.0 > For further discussion of chelating agents / sequestering agents, see Kirk-Othmer, Encyclopedia of Chemical Technology, Third Edition, volume 5, pages 339-366 and volume 23, pages 319 -320]. These materials can also be used at sub-stoichiometric levels to function as a crystal modifier.

Hardener

The solid detergent composition may also comprise a curing agent in addition to or in the form of a builder. The curing agent is a system, organic or inorganic material of the compound or compound that contributes significantly to the uniform solidification of the composition. Preferably, the curing agent is compatible with the detergent, including the sodium hydroxide active alkali agent, and other components of the composition, and can provide an effective amount of hardness and / or water solubility to the processed composition. The curing agent should also be able to form a homogeneous matrix with the detergent and other ingredients when mixed and solidified to provide uniform degradation of the detergent from the solid detergent composition during use.

The amount of curing agent included in the solid detergent composition will depend on the type of solid detergent composition being prepared, the composition of the solid detergent composition, the intended use of the composition, the amount of the diving solution applied over time to the solid composition during use, The hardness of the solution, the physical size of the solid detergent composition, the concentration of the other components, and the concentration of the cleaning agent in the composition. The amount of curing agent included in the solid detergent composition is preferably effective to form a homogeneous mixture at a temperature below the melting and melting temperature of the curing agent and under continuous mixing conditions in combination with the detergent and other components of the composition.

The curing agent also forms a matrix with a detergent and other ingredients to be cured in solid form at ambient temperatures of from about 30 DEG C to about 50 DEG C, especially from about 35 DEG C to about 45 DEG C after mixing has ceased, , Or from about 1 minute to about 3 hours, especially from about 2 minutes to about 2 hours, especially from about 5 minutes to less than about 1 hour. A minimum amount of heat from an external source can be applied to the mixture to facilitate processing of the mixture. The amount of curing agent included in the solid detergent composition is effective to provide the desired solubility control rate and desired hardness of the processed composition when it is put into the aqueous medium to achieve the desired speed of the machine of the detergent from the solidified composition during use desirable.

The curing agent may be an organic or inorganic curing agent. According to one aspect of the present invention, it is preferred that the organic hardener is not a polyethylene glycol (PEG) compound as shown in Examples 10-23 according to the present invention. Examples of polyethylene glycols include, but are not limited to, solid polyethylene glycols having the formula H (OCH ₂ CH ₂ ) _n OH of about 30 to about 1700, having various molecular weights; In the above formula, n is more than 15. In addition, it is preferred that the curing agent is not urea and / or urea particles.

Preferred inorganic curing agents are hydratable inorganic salts including, but not limited to, sulfate and bicarbonate. The inorganic curing agent is present in a concentration of up to about 50 wt.%, Especially about 1 wt.% To about 25 wt.%, More particularly about 5 wt.% To about 15 wt.%. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

bleach

Bleaching agents suitable for use in solid detergent compositions for lightening or whitening of the substrate under conditions typically encountered during the cleaning process include active halogen species such as Cl ₂ , Br ₂ , -OC 1 ^- and / or -OBr ^- to include bleaching compounds capable of liberating. Bleaching agents suitable for use in solid detergent compositions include, but are not limited to, chlorine-containing compounds such as chlorine, hypochlorite, or chloramine. Exemplary halogen-releasing compounds include, but are not limited to, alkali metal dichloroisocyanurate, chlorinated trisodium phosphate, alkali metal hypochlorite, monochloramine, and dichloramine. The encapsulated chlorine source can also be used to enhance the stability of the chlorine source in the composition (see, for example, U.S. Patent Nos. 4,618,914 and 4,830,773, the disclosure of which is incorporated herein by reference). Bleaches may also be peroxides or active oxygen sources such as hydrogen peroxide, perborate, sodium carbonate peroxyhydrate, potassium permonosulphate, and sodium perborate mono and tetrahydrate in the presence or absence of an activator such as tetraacetyl ethylenediamine .

When the concentrate comprises a bleach, it comprises from about 0.1 wt% to about 60 wt%, from about 1 wt% to about 20 wt%, from about 3 wt% to about 8 wt%, and from about 3 wt% to about 6 wt% As shown in FIG. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

Filler

The solid detergent composition does not itself function as a detergent, but may contain an effective amount of a detergent filler that works with the detergent to improve the overall detergency of the composition. Examples of suitable detergent fillers for use in the cleaning compositions of the present invention include, but are not limited to, sodium sulfate and sodium chloride. When the concentrate comprises a detergent filler, it may be included in an amount of up to about 50 wt%, from about 1 wt% to about 30 wt%, or from about 1.5 wt% to about 25 wt%. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

Defoamer

Defoaming agents to reduce the stability of the foam may be included in the article cleaning composition. Examples of antifoaming agents are ethylene oxide / propylene block copolymers, such as those available under the name Pluronic N-3; Silicon compounds, such as polydimethylsiloxane, polydimethylsiloxane, and silicas dispersed in functionalized polydimethylsiloxanes, such as those available under the name Abil B9952; But are not limited to, fatty amides, fatty amides, hydrocarbon waxes, fatty acids, fatty esters, fatty alcohols, fatty acid soaps, ethoxylates, mineral oils, polyethylene glycol esters, and alkyl phosphate esters such as monostearyl phosphate.

A discussion of antifoaming agents is provided, for example, by Martin et al., U.S. Pat. No. 3,048,548, Brunelle et al., U.S. Pat. U.S. Patent No. 3,334,147, and Rue et al. It can be found in patent No. 3,442,242. When the concentrate comprises a defoamer, the defoamer may be provided in an amount from about 0.0001 wt% to about 10 wt%, from about 0.001 wt% to about 5 wt%, or from about 0.01 wt% to about 1.0 wt%. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

Re-immersion inhibitor

The solid detergent composition may include a redeposition agent to facilitate suspension retention of the soil in the cleaning liquid and to prevent the removed soil from re-depositing on the cleaned substrate. Examples of suitable anti-redeposition agents include, but are not limited to, polyacrylates, styrene maleic anhydride copolymers, cellulose derivatives such as hydroxyethylcellulose, hydroxypropylcellulose and carboxymethylcellulose. When the concentrate comprises a redeposition inhibitor, the redeposition inhibitor may be included in an amount of from about 0.5% to about 10% by weight, and from about 1% to about 5% by weight. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

Stabilizer

The solid detergent composition may also comprise a stabilizer. Examples of suitable stabilizers include, but are not limited to, borates, calcium / magnesium ions, propylene glycol, and mixtures thereof. If the concentrate does not need to contain a stabilizer, but the concentrate comprises a stabilizer, it can be included in an amount that provides stabilization at the desired level of concentrate. Exemplary ranges of stabilizers include up to about 20 weight percent, from about 0.5 weight percent to about 15 weight percent, and from about 2 weight percent to about 10 weight percent. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

Dispersant

The solid detergent composition may also include a dispersant. Examples of suitable dispersants that may be used in the solid detergent compositions include, but are not limited to, maleic acid / olefin copolymers, polyacrylic acids, and mixtures thereof. While the concentrate need not include a dispersant, if a dispersant is included, the dispersant may be included in an amount that provides the desired dispersant properties. An exemplary range of dispersants in the concentrate may be up to about 20 wt%, from about 0.5 wt% to about 15 wt%, and from about 2 wt% to about 9 wt%. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

enzyme

Enzymes that may be included in the solid detergent composition include enzymes that aid in the removal of starch and / or protein stains. Exemplary types of enzymes include, but are not limited to, proteases, alpha-amylases, and mixtures thereof. Exemplary proteases that may be used include, but are not limited to, those derived from Bacillus licheniformix, Bacillus lenus, Bacillus alcalophilus, and Bacillus amyloliquefacins. Exemplary alpha-amylases include Bacillus subtilis, Bacillus amyloliquefaceins, and Bacillus licheniformis. If the concentrate does not need to contain the enzyme, but the concentrate comprises the enzyme, the enzyme may be included in an amount that provides the desired enzyme activity when the solid detergent composition is provided as a composition for use. Exemplary ranges of enzymes in the concentrate include up to about 15 wt%, about 0.5 wt% to about 10 wt%, and about 1 wt% to about 5 wt%. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

Glass and metal corrosion inhibitor

The solid detergent composition may comprise a metal corrosion inhibitor in an amount of up to about 50 wt%, from about 1 wt% to about 40 wt%, or from about 3 wt% to about 30 wt%. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

The corrosion inhibitor is included in the solid detergent composition in an amount sufficient to provide a use solution that exhibits corrosion and / or etch rates of glass less than the corrosion and / or etch rate of the glass for other ideal use solutions, do. The use solution is expected to contain at least about six million parts per million (ppm) corrosion inhibitor to provide the desired corrosion inhibiting properties. It is anticipated that large amounts of corrosion inhibitors may be used in the use solutions without deleterious effects. It is expected that the added effect of increased corrosion and / or etch resistance, while increasing the concentration of corrosion inhibitor at a particular point in time, will simply increase the cost of using a solid detergent composition. The use solution may comprise from about 6 ppm to about 300 ppm corrosion inhibitor, and from about 20 ppm to about 200 ppm corrosion inhibitor. Examples of suitable corrosion inhibitors include, but are not limited to, a source of aluminum ions and a source of zinc ions, as well as combinations of alkaline metal silicates or hydrates thereof.

The corrosion inhibitor may refer to a combination of a source of aluminum ions and a source of zinc ions. When a solid detergent composition is provided in the form of a solution for use, the source of aluminum ions and the source of zinc ions each provide aluminum ions and zinc ions. The amount of corrosion inhibitor is calculated based on the combined amount of the source of aluminum ions and the source of zinc ions. Any material that provides aluminum ions in the use solution may be referred to as a source of aluminum ions and any material that provides zinc ions as provided in the use solution may be referred to as a source of zinc ions. The source of aluminum ions and / or the source of zinc ions need not react to form aluminum ions and / or zinc ions. Aluminum ions can be regarded as a source of aluminum ions, and zinc ions can be regarded as a source of zinc ions. The source of aluminum ions and the source of zinc ions may be provided as organic salts, inorganic salts, and mixtures thereof. Exemplary sources of aluminum ions include aluminum salts such as sodium aluminate, aluminum bromide, aluminum chlorate, aluminum chloride, aluminum iodide, aluminum nitrate, aluminum sulfate, aluminum acetate, aluminum formate, aluminum tartrate, aluminum But are not limited to, lactate, aluminum oleate, aluminum bromate, aluminum borate, aluminum potassium sulfate, aluminum zinc sulfate, and aluminum phosphate. Exemplary sources of zinc ions include zinc salts such as zinc chloride, zinc sulfate, zinc nitrate, zinc iodide, zinc thiocyanate, zinc fluorosilicate, zinc dichlormate, zinc chloate, sodium zincate, But are not limited to, zinc gluconate, zinc acetate, zinc benzoate, zinc citrate, zinc lactate, zinc formate, zinc bromate, zinc bromide, zinc fluoride, zinc fluorosilicate, It does not.

Applicants have discovered that by controlling the ratio of aluminum ions to zinc ions in the working solution, they can provide reduced corrosion and / or etching of the glass and ceramic compared to the use of either component alone. That is, the combination of aluminum ions and zinc ions can provide a synergistic effect in reducing corrosion and / or etching. The ratio of the source of aluminum ions to the source of zinc ions can be controlled to provide a synergistic effect. Generally, the weight ratio of aluminum ion to zinc ion in the working solution may be at least about 6: 1, less than about 1: 20, and may be from about 2: 1 to about 1:15.

An effective amount of an alkaline metal silicate or hydrate thereof can be used in the compositions and processes of the present invention to form stable solid detergent compositions having metal protection performance. The silicates used in the compositions of the present invention are those conventionally used in solid detergent formulations. For example, a typical alkali metal silicate may be a powdery, particulate or water-insoluble material containing anhydrous or, preferably, hydrated water (from about 5 wt% to about 25 wt%, especially from about 15 wt% to about 20 wt% Granular silicate. Such silicates are preferably sodium silicates, each having a Na ₂ O: SiO ₂ ratio of from about 1: 1 to about 1: 5, and typically containing from about 5 wt% to about 25 wt% do. Generally, silicates have a Na ₂ O: SiO ₂ ratio of about 1: 1 to about 1: 3.75, especially about 1: 1.5 to about 1: 3.75, most especially about 1: 1.5 to about 1: 2.5. Most preferred is a silicate having a Na ₂ O: SiO ₂ ratio of about 1: 2 and a water content of about 16 wt% to about 22 wt%. For example, such silicates can be purchased in powder form from GD Silicate available from PQ Corporation (Valley Forge, Pa.) And Britesil H-20 in granular form. These ratios can be obtained in the form of a single silicate composition or a combination of silicates that produce a desirable ratio in combination. It has been found that hydrated silicates in a preferred ratio, i.e., 1: 1.5 to about 1: 2.5 Na ₂ O: SiO ₂ ratios, provide optimal metal protection and rapid formation of solid detergents. Hydrated silicates are preferred.

Silicates can be included in solid detergent compositions to provide metal protection, but are known to provide additional alkalinity and further function as an immersion inhibitor. Exemplary silicates include, but are not limited to, sodium silicate and potassium silicate. The solid detergent composition can be provided without a silicate, but if a silicate is included, it can be included in an amount that provides the desired metal protection. The concentrate may comprise a silicate in an amount of at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, and at least about 15 wt%. Also, in order to provide sufficient space for other components in the concentrate, the silicate component may be provided at a level of less than about 35 wt.%, Less than about 25 wt.%, Less than about 20 wt.%, And less than about 15 wt.% . Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

Spices and dyes

Various dyes, excipients including perfumes, and other aesthetic enhancers may also be included in the composition. Suitable dyes that may be included to modify the appearance of the composition include Direct Blue 86 available from Mac Dye-Chem Industries (Ahmedabad, India); Fastusol Blue available from Mobay Chemical Corporation (Pittsburgh, Pa.); Acid Orange 7 available from American Cyanamid Company (Wayne, NJ); Basic Violet 10 and Sandolan Blue / Acid Blue 182 available from Sandoz (Princeton, NJ); Acid Yellow 23 available from Chemos GmbH (Regenstauf, Germany); Acid Yellow 17 available from Sigma Chemical (St. Louis, MO); Sap Green and Metanil Yellow available from Keyston Analine and Chemical (Chicago, IL); Acid Blue 9 available from Emerald Hilton Davis, LLC (Cincinnati, OH); Hisol Fast Red and Fluorescein available from Capitol Color and Chemical Company (Newark, NJ); And Acid Green 25 available from Ciba Specialty Chemicals Corporation (Greenboro, NC).

Fragrances or perfumes that may be included in the composition include, but are not limited to, terpenoids such as citronellol, aldehydes such as amylcinnamaldehyde, jasmine such as CIS-jasmine or jasmin, and vanillin Do not.

Flow aid

A variety of flow adjuvants may also be included in the composition. Flow assistants can also be referred to as carriers and / or lubricants and are generally known to improve the processing of compositions, such as the solid detergent compositions according to the present invention. Suitable components for improving the fluidity of the homogeneous powder component according to the present invention may include, for example, inorganic or organic agents. According to one embodiment, inorganic agents are preferred, including, for example, silica, borates, acetate salts, and sulfate salts and the like. For example, silica (e.g., Sipernat (R), Aerosil (R), CAB-O-SIL (R)) in precipitated or fumed form may be used and is commercially available, for example, from Evonik Industries.

Manufacturing method and use

Without wishing to be bound by any particular theory of the present invention, the actual solidification mechanism may occur through hydroxide hydration, for example, the interaction of water with sodium hydroxide (or other alkali metal hydroxide). The combination of sodium hydroxide and a secondary alkalinity source (e.g., sodium metasilicate) together with the polycarboxylic acid polymer serves to control the kinetics and thermodynamics of the solidification process and the possibility that additional functional materials will form a functional solid composition It is believed that this provides a solidification matrix. For example, the polycarboxylic acid polymer and other functional components may have the effect of stabilizing the hydroxide by acting as a donor and / or acceptor of free water.

In another aspect of the invention, embodiments of ash may be present as a result of ash hydration, for example, the interaction of water with hydratable salts. For example, according to such an embodiment, the carbonate hydrates by acting as a free water donor and / or acceptor.

According to an aspect of the invention, the rate of solidification of the detergent composition can be controlled to provide process and dimensional stability to the resulting solid detergent composition product by controlling the rate of water transfer for hydration of the ash and / or hydroxide alkalinity source . The rate of solidification is important because if the solidification matrix is solidified too quickly, the composition will solidify during mixing and stop the process. If the solidification matrix solidifies too slowly, critical process times are lost.

Without wishing to be bound by any particular theory of the present invention, in one embodiment, the polycarboxylic acid polymer may be added to the final product by ensuring that the solid product containing the sodium hydroxide and the secondary alkalinity source (e.g., sodium metasilicate) And can help to provide dimensional stability. Density, integrity, and appearance degradation when the solid product is expanded after solidification; And a variety of problems including, but not limited to, the inability to distribute or package the solid product. Generally, a solid product is considered to have dimensional stability when the solid product has a growth index of less than about 3%, especially less than about 2%. The growth index refers to% growth and expansion of the product over time after solidification under normal transport / storage conditions. The growth index of the solid detergent product is determined by measuring one or more dimensions of the product before and after heating of 100 F to 120 F, since normal transport / storage conditions for detergent products often result in detergent compositions being given at elevated temperatures . The measured dimensions or dimensions depend on the shape of the solid product and the manner in which it is expanded. In the case of tablets, changes in both diameter and height are generally measured and added together to determine the growth index. In the case of capsules, only the diameter is generally measured.

In general, solid detergent compositions employing the solidification matrix of the present invention can be prepared by dissolving or dispersing an alkali metal hydroxide alkalinity source (e.g., sodium hydroxide), a secondary alkaline source (such as anhydrous sodium metasilicate), a polycarboxylic acid polymer, And any additional functional ingredients, and interacting and solidifying the ingredients.

For example, in a first embodiment, the solid detergent composition may comprise sodium hydroxide, anhydrous sodium metasilicate, a polycarboxylic acid polymer, a water filler, sodium carbonate, a chelating agent, and optional functional ingredients. In an exemplary embodiment, the solid detergent composition comprises from about 1% to 90% by weight of an alkali metal hydroxide alkali agent, from 0.1% to about 15% by weight of a polycarboxylic acid polymer, from about 0.1% to about 25% From about 20 wt% to about 90 wt% sodium carbonate, from about 0.1 wt% to about 50 wt% chelating agents such as sodium gluconate, and from 0.1 wt% to 50 wt% secondary alkalinity sources and / or corrosion inhibitors . In another exemplary embodiment, the solid detergent composition comprises about 5 wt% to 70 wt% alkali metal hydroxide alkali agent, 1 wt% to about 10 wt% polycarboxylic acid polymer, about 0.1 wt% to about 10 wt% water About 25 wt.% To about 90 wt.% Sodium carbonate, about 1 wt.% To 50 wt.% Chelating agent, and 1 wt.% To 50 wt.% Second alkalinity source and / or corrosion inhibitor. In yet another exemplary embodiment, the solid detergent composition comprises about 10% to 50% by weight alkali metal hydroxide alkali agent, 2.5% to about 10% by weight polycarboxylic acid polymer, about 1% to about 5% From about 30% to about 70% sodium carbonate, from about 1% to 50% chelating agent, and from 1% to 50% by weight secondary alkali source source and / or corrosion inhibitor. Without limiting the scope of the invention, all numerical ranges referred to herein are intended to encompass a number specifying the range and include each integer within the specified range.

In some embodiments, the relative amounts of sodium hydroxide, water, and polycarboxylic acid polymer are controlled within the composition. The solidification matrix and further functional components cure to a solid form due to the chemical reaction of water with sodium hydroxide and water (hydroxide hydration), and / or sodium carbonate (ash hydration). As the solidification matrix solidifies, a binder composition can be formed to bond and solidify the components. At least some of the components associate to form a bond while the remaining components form a residue of the solid composition. The solidification process may last from a few minutes to about 6 hours, depending on factors such as, but not limited to, the size of the formed composition, the composition's composition, and the temperature of the composition.

According to an aspect of the invention, a hydratable salt (e.g., sodium carbonate), a secondary alkalinity source (e.g., anhydrous sodium metasilicate) and at least one additional functional ingredient are combined into a homogeneous powder mixture. The water source may be added to the uniform powder mixture before incorporation into the detergent composition and provided as a solid hydrate. According to an aspect of the present invention, the addition of water to a uniform powder mixture is referred to herein as a water "fill ". The water filler is included in the solidification matrix for subsequent combination with sodium hydroxide (and optionally a polycarboxylic acid polymer). In one embodiment, a water fill of less than about 10%, from about 1% to about 10%, or from about 2% to about 10% is preferred.

Thereafter, the solid hydrate is then combined with sodium hydroxide (and optionally a polycarboxylic acid polymer). Sodium hydroxide is combined with water and a sodium carbonate matrix when the detergent composition is added to the detergent composition to effectively solidify according to the method of the present invention. In general, effective amounts of sodium hydroxide and sodium carbonate refer to amounts that effectively control the kinetics and thermodynamics of the solidification system by controlling the rate and movement of water to the hydroxidization process and / or the ash hydration process.

Solid detergent compositions formed using a solidified matrix are produced using a batch or continuous mixing system. In an exemplary embodiment, the processing method of tablet compression is used to form tablets from a homogeneous mixture according to the method of the present invention. In some embodiments, the processing temperature is the melting temperature of the component or less. The processed mixture is discharged from the mixer by molding, or other suitable means, once the detergent composition has solidified into a solid form. The structure of the matrix may be characterized according to its hardness, melting point, material distribution, crystal structure, and other similar properties according to methods known in the art. Generally, the solid detergent compositions processed according to the present method are substantially uniform and dimensionally stable with respect to the distribution of the components throughout their mass.

In particular, in the molding process, the liquid and solid components are introduced into the final mixing system and mixed homogeneously until the components form a substantially uniform semi-solid mixture in which the components are distributed throughout its mass. In an exemplary embodiment, the components are mixed for at least about 5 seconds in a mixing system. The mixture is then discharged from the mixing system to or through a die or other molding means. After that, the product is packaged. In an exemplary embodiment, the molded composition begins to cure in solid form within 1 minute, or from about 1 minute to about 3 hours. In particular, the molded composition begins to cure in solid form within a few seconds to about one minute. More particularly, the shaped composition begins to cure in solid form within from about a few seconds to about two minutes.

The term "solid form" means that the cured composition will not flow and will substantially retain its shape under moderate stress or pressure or merely gravity. The degree of cure of the solid composition may range from the degree of relatively dense and hardened fused solid product such as, for example, concrete to the consistency that is characterized as being a cured paste. The term "solid " refers to the condition of the detergent composition under the expected conditions of storage and use of the solid detergent composition. Generally, the detergent composition is exposed to temperatures of up to about 100 [deg.] F, It is expected to exist in solid form.

The resulting solid detergent composition may be in a form including but not limited to extruded, molded or molded solid pellets, blocks, tablets, powders, granules, flakes; The molded solid can then be pulverized or molded into powder, granules, or flakes. In embodiments of the present invention, the solid detergent composition is not a solid cast product. In an exemplary embodiment, the extruded pellet material formed by the solidification matrix has a weight of about 50 grams to about 250 grams, the extruded solid formed by the solidification matrix has a weight of about 100 grams or more, Lt; RTI ID = 0.0 > kg < / RTI > to about 10 kilograms. The solid composition provides a stabilized source of functional material. In some embodiments, the solid composition may be dissolved, for example, in an aqueous or other medium to produce a concentrated and / or use solution. The solution may be directed to a storage reservoir for further use and / or dilution, or it may be applied directly to the site of use.

In certain embodiments, the solid detergent composition is provided in unit dosage form. Unit capacity refers to a solid detergent composition unit that is sized such that the total unit is used for a single wash cycle. According to an embodiment of the invention, when a solid detergent composition is provided in unit dosage, it is provided in extruded pellets, or tablets, typically having a size of from about 1 gram to about 250 grams.

In other embodiments, the solid detergent composition is provided in the form of a multi-use solids, such as a block or a plurality of pellets, and can be used repeatedly to generate an aqueous detergent composition in multiple wash cycles. In certain embodiments, the solid detergent composition is provided in an extruded block, or tablet, having a mass of from about 5 grams to about 10 kilograms. In certain embodiments, the multi-use type of solid detergent composition has a mass of from about 1 kilogram to about 10 kilograms. In a further embodiment, the multi-use type of solid detergent composition has a mass of from about 5 kilograms to about 8 kilograms. In another embodiment, the multi-use type of solid detergent composition has a mass of from about 5 grams to about 1 kilogram, or from about 5 grams to about 500 grams.

Although it is discussed that the detergent composition is formed into a solid product, the detergent composition may also be provided in the form of a paste. When the concentrate is provided in the form of a paste, sufficient water is added to the detergent composition so that complete solidification of the detergent composition is not possible. In addition, dispersants and other ingredients may be incorporated into the detergent composition to maintain the desired ingredient distribution of the ingredients.

The various solidification matrices of the present invention can be used in a wide variety of cleaning applications. In some embodiments, the solid detergent compositions of the present invention are suitable for use in any application requiring an environmentally friendly solid alkaline detergent. Such applications include, but are not limited to, the use of phosphate-free alkaline detergents in combination ovens such as those used in various food service industries. Additional applications include, for example, product cleaning machines using article cleaning detergents, free soaks, fryer oil outs, power soak sinks and related applications, soak tanks, mechanical reprocessing, laundry and fabric cleaning and bleaching, carpet cleaning and bleaching , Vehicle cleaning and care applications, surface cleaning and decolorization, kitchen and bathroom cleaning and decoloration, floor cleaning and decolorization, cleaning in situ operations, general purpose cleaning and decolorization, and / or industrial or household cleaning.

In a preferred embodiment, the solid detergent composition is particularly suitable for cleaning a combination oven. Various descriptions of the combination oven are given in, for example, U. S. Pat. 5,368,008, 5,640,946, and 6,410,890, EP 0652405, and DE 2842771. For example, the combination oven may refer to a device having a dual oven-steamer, a double oven-boiler, or at least one oven chamber and a steam generator and / or a boiler. The solid detergent compositions according to the present invention may be provided for cleaning of the combination oven apparatus known in the art.

In some embodiments, the solid detergent compositions may be used in combination with other components such as, for example, U.S. Pat. May be added directly to the combination oven apparatus through, for example, a funnel or other member as described and illustrated in patent 5,640,946. These and other inflow locations for supplying the solid detergent compositions according to the present invention will be readily ascertainable by those skilled in the art. In some embodiments, the solid detergent composition according to the present invention may be used initially to generate an aqueous solution or suspension for delivery to a combination oven for cleaning according to the present invention. Thereafter, the liquid composition is applied to the inner surface of the device through the use of, for example, a spray nozzle and / or a spray jet.

The method of cleaning using the solid detergent composition according to the present invention may further comprise one or more rinsing steps, a demineralizing step, a pre-cleaning step, and / or a soaking step.

Example

The invention is further described in the following examples, which are intended as illustrations only, since many modifications and variations will become apparent to those skilled in the art, particularly within the scope of the present invention. Unless otherwise stated, all parts, percentages, and ratios reported in the following examples are by weight and all reagents used in the examples are available or available from the chemical suppliers described below , And can be synthesized by conventional techniques.

The following test methods were used to characterize the compositions produced in Examples 1, 2, and 3 and Comparative Examples A and B.

Dimensional stability test for formed products

Using a polycarboxylic acid polymer as part of the solidification matrix, a product of about 50 gram batches was first pressed on a die in pounds per square inch (psi) for about 20 seconds to form tablets. The diameter and height of the tablets were measured and recorded. The tablets were kept at room temperature for 1 day and then placed in an oven at a temperature of about 120 < 0 > F. After removing the tablets from the oven, the diameter and height of the tablets were again measured and recorded. The growth index for the tablet was determined by measuring the growth based on the cumulative change in diameter and height of the tablet after heating.

Examples 1, 2 and 3 and Comparative Examples A and B

Examples 1, 2, and 3 are compositions of the present invention using a polycarboxylic acid polymer as part of a solidification matrix. In particular, the compositions of Examples 1, 2, and 3 used polyacrylic acid polymer, modified polyacrylic acid polymer, and polymaleic acid polymer, respectively, as part of the solidification matrix. In addition, the compositions of Examples 1, 2, and 3 also contain sodium carbonate (soda ash or dense ash), sodium bicarbonate, sodium metasilicate, builder, Active agent, defoamer, sodium hydroxide, and water. Preliminary mixing of sodium carbonate, sodium bicarbonate, sodium metasilicate, builder, surfactant, and defoamer to form a powder premix and premix mixing the polycarboxylic acid polymer, sodium hydroxide, and water to form a liquid premix . The powder premix and the liquid premix were then mixed together to form a composition. About 50 grams of the composition was compressed into tablets at about 1000 psi for about 20 seconds.

The compositions of Comparative Example A were prepared as in Examples 1, 2, and 3, except that the composition of Comparative Example A did not include the polycarboxylic acid polymer.

The composition of Comparative Example B was prepared as in Example 1 except for the addition of Trilon M powder, a methyl glycinediacetic acid (MGDA) powder. Table 1 provides the component concentrations for the compositions of Examples 1, 2, and 3 and Comparative Example A. Table 2 provides the component concentrations of Comparative Example B. < tb > < TABLE >

Table 1

Table 2

The compositions of Examples 1, 2, and 3 and Comparative Example A were then subjected to a dimensional stability test for the formed product as discussed above to observe the dimensional stability of the composition after heating. The results are shown in Table 3 below.

Table 3

As illustrated in Table 3, the formed products of the compositions of Examples 1, 2, and 3 exhibited significantly less swelling than the formed products of the composition of Comparative Example A. In particular, the product of the composition of Example 1 exhibited a growth index of only 1.7% with 0.6% growth in diameter and 1.1% growth in height. The product of the composition of Example 2 exhibited 0% growth in diameter and -0.6% growth in height, indicating no growth index of amniotic fluid. The product of the composition of Example 3 exhibited a growth index of only 2.1% with 0.9% growth in diameter and 1.2% growth in height. In contrast, the product of the composition of Comparative Example A had a growth index of 10.9% with 2.7% growth in diameter and 8.2% growth in height.

The difference between the compositions of Examples 1, 2, and 3 and Comparative Example A was the presence of only the polycarboxylic acid polymer. Accordingly, it is believed that the polycarboxylic acid polymer helps the dimensional stability of the products of the compositions of Examples 1, 2, and 3. Since the composition of Comparative Example A contained no polycarboxylic acid polymer, the composition did not include a mechanism to control the movement of water in the solid product.

Six tablet samples of the composition of Comparative Example B were also tested for swelling. The diameter and height of each such tablet were measured and recorded. The tablets were kept at room temperature for 1 day and then placed in a heated oven at a temperature of about 120 < 0 > F. When the first tablet was taken out of the oven, the tablet broke, indicating that it was not a dimensionally stable product. The remaining samples were successfully removed from the oven and the diameter and height of each tablet were measured and recorded as described in Table 4 below.

Table 4

As can be seen from the results in Table 4, given a temperature of 120 degrees Fahrenheit, each of samples 1, 2, 3, 4, 5 and 6 containing MGDA is not stable and / .

Dimensional stability test for cast products

A batch of about 4000 grams of product using the polycarboxylic acid polymer as part of the solidification matrix was first poured into the capsules. The diameter of capsules was measured and recorded. The capsules were held at room temperature for 1 day, held in an oven at a temperature of about 104 < 0 > F for 2 days, and then returned to room temperature. After the capsules returned to room temperature, the diameter of the capsules was again measured and recorded. The growth index for capsules was determined by measuring the growth based on change in diameter after heating.

Examples 4, 5, and 6 and Comparative Example C

Examples 4, 5, and 6 are compositions of the present invention that specifically employ a small polycarboxylic acid polymer in the solidification matrix. In particular, the composition of Example 4 uses a polyacrylic acid polymer as part of the solidification matrix, the composition of Example 5 uses a modified polyacrylic acid polymer as part of the solidification matrix, A polymaleic acid polymer was used. The compositions of each of Examples 4, 5 and 6 were also prepared by mixing the ingredients (wt.%) Of softener, builder, water conditioner, sodium hydroxide 50%, sodium carbonate Active agents, and non-ionic surfactants. (Sodium carbonate, anionic surfactant, and nonionic surfactant) is preliminarily prepared by preliminarily mixing the liquid (softener, builder, water conditioner, polycarboxylic acid polymer, and sodium hydroxide 50% To form a powder premix. Thereafter, the liquid premix and the powder premix were mixed to form a composition which was subsequently poured into capsules.

The compositions of Comparative Example C were prepared as in Examples 4, 5, and 6, except that the composition of Comparative Example C did not contain the polycarboxylic acid polymer and did not contain an equivalent amount of available water.

Table 5 provides the component concentrations for the compositions of Examples 4-6 and Comparative Example C.

Table 5

After the compositions of Examples 4, 5, and 6 and Comparative Example C were formed, they were subjected to a dimensional stability test for the cast product as discussed above to observe the dimensional stability of the composition after heating. The results are shown in Table 6 below.

Table 6

As illustrated in Table 4, the cast products of the compositions of Examples 4, 5, and 6 exhibited significantly less swelling than the cast products of the Comparative Example C. In particular, the product of the composition of Example 4 exhibits a growth index of 0.6% only through 0.6% of its diameter, and the product of Example 5 exhibits a growth index of 1.3% after only 1.3% of its diameter growth, The product of the composition of Example 6 exhibited a growth index of 1.9% through growth of only 1.9% of its diameter. In contrast, the product of the composition of Comparative Example C had a growth index of 4.9% with a growth of 4.9% of the diameter.

The difference between Examples 4, 5, and 6 and Comparative Example C was the presence of only the polycarboxylic acid polymer. Therefore, it is believed that the polycarboxylic acid polymer helps the dimensional stability of the products of the compositions of Examples 4, 5, and 6. In contrast, since the composition of Comparative Example C did not contain a polycarboxylic acid polymer, the composition did not contain a mechanism to control the movement of water in the solid product.

Examples 7, 8 and 9

Examples 7, 8 and 9 compare the cleaning performance when various combinations of polymaleic acid and polyacrylic acid are used. The composition of each example is shown in Table 7. < tb > < TABLE > To form the composition, sodium carbonate, builders, surfactants and disaccharides are premixed to form a powder premix, and the polycarboxylic acid polymer, potassium hydroxide, phosphonate and water are pre-mixed to form a liquid premix / RTI > Thereafter, the powder premix and the liquid premix were mixed together to form a composition. About 1000 grams of the composition was pressed into tablets at about 1000 psi for about 20 seconds and allowed to solidify.

The resulting tablets were used in an AM-14 automatic dishwasher with 17 grains of water. Thereafter, the glass was subjected to 100 washing and rinsing cycles and tested for cleanliness. Three degrees were measured in two ways. First, we obtained the digital optical image of the glass and analyzed the brightness value by computer analysis. The lightness test indicates the degree of film present on the glass surface, the lower the value, the less film and the more cleaned glass. Secondly, the visual evaluation is measured with an evaluation rating of 1 to 5, and the lower the visual evaluation, the more clean the glass is. The results of these tests are shown in Table 8.

Table 7

Table 8

The results shown in Table 8 indicate that the combination of polymaleic acid and polyacrylic acid provides improved cleaning performance compared to polymaleic acid or polyacrylic acid alone.

Examples 10-23

A series of experiments with different concentrations and sources of water, chelating agents, and builders were used to evaluate the use of sodium hydroxide alkalinity to produce solid alkaline detergent compositions for the purposes of the present invention. Various formulas and mixing instructions for preparing solid phosphate-free alkaline detergent tablets were evaluated to provide a method for making physically stable and durable cleaning compositions in accordance with the present invention. Table 9 summarizes the results of a comparison of the potassium carbonate (alkaline builder); Sodium sulfate (filler); Sodium gluconate (chelating agent); Disodium metasilicate (alkalinity source, corrosion inhibitor); Sodium hydroxide (active detergent, caustic); And PEG (builder).

Table 9

Excellent batch mixing and powder migration was observed for Examples 10-23. Powder appearance was dependent on the batch, and particle size uniformity was dependent on the content of polyethylene glycol (PEG). The visual evaluation showed that the powder that did not contain PEG in the composition was the most uniform and the lump formation increased as the amount of PEG in the formula increased. A lump was formed when the molten PEG was added to the batch during mixing.

Dimensional stability test for extrusion and squeeze solids. Screening was performed at 2500, 3000, and 4000 lbs. Compression at 4000 lbs was found to produce the best tablets. Tablets made with this load had excellent stiffness, smooth surface and high compressive strength. The tablets made with the other two loads had a more porous surface and a weak edge. Tablets discharged from the crimp mold for all 14 jobs were poor. The compression head had to be cleaned so that there would be no residue after every 2-3 tablets were squeezed. For example, if the residue is not removed after the third purification, the fourth tablet may not be pulled from the compression head and may be removed with a weakened force or by dissolving the tablet with water.

Using PEG 8000 as a possible binder in high alkaline formulations browned the tablets over time. Color stability was dependent on how much PEG was included in the formula. Examples 12 and 19 did not contain PEG, but showed no discoloration over time. In all of the examples without PEG 8000, browning was observed in the chamber at 122 째 F before one day.

Dimensional stability, initial height, diameter, and visual appearance were recorded. The tablets were then sealed in plastic bags and placed in two different environmental chambers for one week. The two environmental chambers used were atmospheric (72 ℉, 50% relative humidity) and 122 ℉ (relative humidity NA). After one week, the tablets were again measured and visual appearance was recorded.

Procedures to determine the compressibility of extruded and pressed products. One tablet from each batch was tested within 3 hours of being made. After one week, the compressive strength was measured for both of the tablet sets, after completing the dimensional stability test and cooling the tablet at 122 ° F to atmospheric conditions. The formulations tested were not physically stable at 122 ° F. The tablets were expanded to 4% to 10%, and the tablets containing both PEG 8000 and sodium hydroxide turned brown. The results show that the composition according to the present invention does not contain PEG as a preferred binder for a stable, phosphate-free alkaline oven detergent cleaning composition.

Examples 24-29

Based on the results of Examples 10-23, an alternative solidification mechanism, i.e., carbonate hydration, was further evaluated. Potassium hydrate and sodium carbonate were evaluated to determine the effect on tablet stability using different chelating agents.

Table 10 summarizes the results of a comparison of the potassium carbonate / potassium (alkaline builder); Sodium carbonate / ash (alkaline builder); Sodium citrate (chelating agent, binder); Sodium hydroxide (active detergent, caustic, hydration (50%)); Water (hydration); Disodium metasilicate (alkalinity source, corrosion inhibitor); ≪ / RTI > and sodium sulfate (filler).

Table 10

Potassium carbonate, sodium carbonate and sodium citrate were added to a ribbon blender and mixed. Sodium hydroxide (50%) and water were added and mixed until the powder appeared dry. Disodium metasilicate, sodium sulfate and sodium hydroxide were added and mixed until the powder appeared uniform. Examples 24-29 did not provide adequate mixing; The powder was wet, wet, and hard to get from the ribbon blender. Due to poor mixing, the powder was not squeezed into tablets and the experiment was terminated.

Examples 30-38

Based on the results of Examples 24-29, the use of sodium carbonate instead of potassium carbonate was evaluated. The use of sodium carbonate (sulfur) in the composition was evaluated to obtain a more physically stable tablet formulation.

Table 11 summarizes the effects of sodium carbonate (alkaline builder); Sodium citrate (chelating agent, binder); Citrate solution (33%); Sodium hydroxide (active detergent, caustic, hydration (50%)); Water (hydration); Disodium metasilicate (alkalinity source, corrosion inhibitor); ≪ / RTI > and sodium sulfate (filler).

Table 11

For Examples 30-36, sodium carbonate was added to the ribbon blender and mixed. Sodium citrate was slowly added. The water / citrate solution and the disodium methanesilicate were then mixed until the powders were uniform. Thereafter, 60 grams of the tablet was compressed to 4000 pounds (about 1600 psi) and about 2500 pounds using a 1.75 "diameter tablet die and a Carver press to hold it for 3 seconds. Thereafter, the force required to fracture the tablet was measured (The need for higher forces / pressures means more durable tablets.) The tablets were then subjected to dimensional stability testing at room temperature and 122 일 for one week.

For Examples 37-38, sodium carbonate and sodium citrate were added to the ribbon blender and mixed. Water and disodium methasilicate were added and mixed until the powder became homogeneous. 60 grams of the tablet was then compressed at 4000 pounds (about 1600 psi) and about 2500 pounds by fixing the 60 gram tablet with a 1.75 "diameter purifying die and a Carver press for 3 seconds to force the tablet to break (The need for higher force / pressure means more durable tablets.) The tablets were then subjected to a dimensional stability test at room temperature and 122 일 for one week.

The formulations tested were physically stable at 72 ° F, but the formulations were not physically stable at 122 ° F. Tablets were bulged to 9% to 18% and compressive strength was weak in all Examples 30-38. Example 33 exhibited improved compressive strength and dimensional stability compared to the other examples, but formulation required further improvement in solidification and dimensional stability.

Examples 39-42

Based on the results of Examples 30-38, the use of different grades of sodium metasilicate was evaluated. Anhydrous sodium metasilicate was used in the formulation with potassium carbonate at lower water levels to assess improvement in solidification and dimensional stability. Table 12 shows the components evaluated in the example compositions.

Table 12

For Examples 39-40, potassium carbonate and sodium citrate were added to the ribbon blender and mixed. Water was slowly added. Thereafter, disodium methasilicate, sodium sulfate and sodium hydroxide were mixed until the powder was homogeneous. Thereafter, 25 grams of the tablet was squeezed to 2000 pounds using a 1.25 "diameter tablet die and a Carver press for 3 seconds, after which the force required to disrupt the tablet was measured (higher force / pressure required Later, the tablets were subjected to dimensional stability testing at room temperature and 122 일 for one week.

For Examples 41-42, sodium carbonate, sodium citrate and anhydrous metasilicate were added to the ribbon blender and mixed. Water was slowly added. Thereafter, sodium hydroxide was mixed until the powder became homogeneous. Thereafter, 25 grams of the tablet was squeezed to 2000 pounds using a 1.25 " diameter < / RTI > diameter die and a Carver press for 3 seconds to measure the force required to disrupt the tablet (a higher force / The tablets were then subjected to a dimensional stability test at room temperature and at 122 ° F for one week.

As shown in FIGS. 1-2, the formulation of a tablet composition having anhydrous sodium metasilicate produced less tablets and stronger tablets than the previous examples using disodium methanesilicate 5-hydrate. In addition, the examples show that the use of potassium carbonate can yield a dimensionally stable solid composition when less than about 1% of the water charge used during mixing. However, an additional advantage of using sodium carbonate, i.e., improved cleaning performance, has resulted in favorable use compared to potassium carbonate.

Examples 43-46

Based on the results of Examples 39-42, the use of different concentrations and sources of water in the production of durable and physically stable tablet compositions was evaluated. Table 13 shows the components evaluated in the example compositions.

Table 13

For Examples 43-46, sodium carbonate, d-gluconic acid, sodium citrate, sodium metasilicate and / or anhydrous metasilicate were added to the ribbon blender and mixed. Water was slowly added. Thereafter, the sodium polyacrylate polymer and sodium hydroxide were mixed until the powders were uniform. Thereafter, 60 grams of the tablet was pressed at 4000 pounds (about 1600 psi) and 2500 pounds using a 1.75 "diameter punch and a Carver press to hold it for 3 seconds. The force needed to break the tablet was then measured The need for higher forces / pressures meant more durable tablets.) The tablets were then subjected to dimensional stability testing at room temperature and 122 일 for one week.

As shown in FIGS. 3-4, the example formulation mixed with a liquid water filler had a higher compressive strength than the embodiment formulation without a free water impregnation. Example 45 yielded the most rigid tablets with minimal expansion (indicating the best dimensional stability).

While the present invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.

Various modifications and additions may be made to the exemplary embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above relate to particular features, the scope of the invention also encompasses embodiments that do not include both embodiments having different combinations of such features and features described above.

All publications and patent applications in this specification are indicative of the level of ordinary skill in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference.

Claims (20)

An alkaline metal hydroxide alkalinity source;
Sodium carbonate;
Anhydrous silicate secondary alkalinity source;
water; And
One or more functional ingredients
A solid detergent composition, comprising:
A solid detergent composition wherein the solid detergent composition is phosphorus-free and dimensionally stable when heated at a temperature of 120 degrees Fahrenheit, and wherein the solid detergent composition has a growth index of less than 3%. The composition of claim 1, wherein the at least one functional ingredient is selected from the group consisting of a secondary alkalinity source, a detergent builder, a surfactant, a corrosion inhibitor, a water conditioning agent, a chelant, a flow aid, ≪ / RTI > The composition of claim 1, wherein the functional ingredient is a polyacrylic acid polymer or a salt or derivative thereof. The composition of claim 1, wherein the functional ingredient is a polycarboxylic acid polymer, a polyacrylic acid polymer, or a polyacrylate polymer, and comprises from about 0.1% to about 15% by weight of the composition. The composition of claim 1, wherein the sodium carbonate comprises from about 20% to about 90% by weight of the composition. The composition of claim 1, wherein the water comprises from about 0.1% to about 10% by weight of the composition. The composition of claim 1 which does not comprise polyethylene glycol (s) and / or urea. The composition of claim 1, wherein the alkali metal hydroxide is sodium hydroxide and constitutes about 5% to 70% by weight of the composition. The composition of claim 1, wherein the at least one functional ingredient is a secondary alkalinity source and comprises from about 1% to 50% by weight of the composition. The composition of claim 1, wherein the at least one functional ingredient is a chelating agent and constitutes about 1% to 50% by weight of the composition. The composition of claim 1, wherein the composition is a hydrate solid tablet. As a solid detergent composition, a solid detergent composition
From about 5% to about 70% by weight of the solid detergent composition of sodium hydroxide;
From about 20% to about 90% by weight of the solid detergent composition of sodium carbonate;
From about 0.1% to about 15% by weight of the solid detergent composition of a polycarboxylic acid polymer or salt or derivative thereof;
From about 0.1% to about 10% water by weight of the solid detergent composition;
From about 1% to about 50% by weight of the secondary alkalinity source of the solid detergent composition; And
From about 1% to about 50% by weight of the solid detergent composition
≪ / RTI >
Wherein the alkalinity source is anhydrous metasilicate,
Wherein the solid detergent composition is a phosphorus-free hydrate solid,
Wherein said solid is dimensionally stable when heated at a temperature of 120 degrees Fahrenheit and has a growth index of less than 3%. 13. The composition of claim 12 wherein the sodium hydroxide comprises about 10% to 50% by weight of the composition, the sodium carbonate comprises about 30% to 70% by weight of the composition, and the polycarboxylic acid polymer or salt or derivative thereof Is a polyacrylate polymer and comprises from about 2.5% to 10% by weight of the composition, wherein the water comprises from about 1% to 5% by weight of the composition and the secondary alkalinity source comprises from about 1% to 20% And wherein the chelating agent comprises from about 5% to about 25% by weight of the composition. 14. The composition of claim 13, wherein the composition is a hydrate solid tablet that does not comprise polyethylene glycol (s), urea, and / or potassium carbonate. Combining a sodium carbonate, an anhydrous silicate secondary alkalinity source and at least one additional functional ingredient to form a powder pre-mixture;
Mixing the powder premix with a water source to form a solid hydrate;
A method of forming a solid detergent composition, comprising combining a solid hydrate with a source of sodium hydroxide and optionally a polycarboxylic acid polymer or salt or derivative thereof,
The solid detergent composition is phosphorus-free,
Wherein when heated to a temperature of 120 degrees Fahrenheit, the solid detergent composition is dimensionally stable and has a growth index of less than 3%. 16. The method of claim 15, wherein the solid detergent composition is a tablet. 16. The composition of claim 15, wherein the solid detergent composition comprises from about 5% to about 70% sodium hydroxide, from about 20% to about 90% sodium carbonate, from about 0.1% to about 15% % Of a polycarboxylic acid polymer or salt or derivative thereof, from about 0.1 wt% to about 10 wt% water, from about 1 wt% to about 50 wt% secondary alkalinity source, and from about 1 wt% to about 50 wt% ≪ / RTI > 16. The method of claim 15, further comprising solidifying the composition at ambient temperatures of from about 30 [deg.] C to about 50 [deg.] C. 16. The method of claim 15, wherein the dimensional stability of the solid detergent composition has a growth index of less than 2%. 16. The composition of claim 15, wherein the sodium hydroxide comprises about 10% to 50% by weight of the composition, the sodium carbonate comprises about 30% to 70% by weight of the composition, and the polycarboxylic acid polymer or salt or derivative thereof Is a polyacrylate polymer or salt or derivative thereof and comprises from about 2.5% to 10% by weight of the composition, wherein the water comprises from about 1% to 5% by weight of the composition and the secondary alkalinity source comprises from about 12% To 20% by weight of the composition, and wherein the chelating agent comprises from about 5% to 25% by weight of the composition.

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