US3725288A - Soap composition - Google Patents

Abstract

SOAP COMPOSITION AS AN IMPREGNANT FOR SCOURING PADS AND THE LIKE COMPRISES SODIUM NITRITE, POTASSIUM CARBONATE, POLYGLYCOL, SODIUM HIGH LAURIC ACID OIL SOAP, SODIUM TALLOW SOAP AND A FOAM BUILDER.

Description

United States Patent ABSTRACT OF THE DISCLOSURE Soap composition as an impregnant for scouring pads and the like comprises sodium nitrite, potassium carbonate, polyglycol, sodium high lauric acid oil soap, sodium tallow soap and a foam builder.

This invention relates to a soap composition for scouring pads and the like and methods for making same. In prior art compositions of such formulations considerable quantities of potassium soap have been necessary as an important constituent of the detergent composition. It will be appreciated that potassium soaps are much more expensive than the corresponding sodium soaps. The pres ent invention is predicated on the utilization of a potassium component other than soap, while all of the soap added to the composition is a sodium soap. The inclusion of a potassium component has been found to be efficacious to control fluidity when the soap is in a molten condition and is sprayed onto the fibers of scouring pads and the like.

The soap composition for scouring pads within the purview of the present invention may be composed of the following ingredients within the following ranges:

More preferably the above ingredients are employed in the following ranges:

Percent by weight Water 30-45 Sodium nitrite 1. 5-2. 5 Potassium carbonate. 5-8 Sodium carbonate 0-5 Sodium high lauric acid soap 5-30 30%,] Sodium tallow soap 15-40 Foam builder 2-4 Color and perfume 0-1 In carrying out the present invention, it is important that the components of the soap composition be employed at the amounts set forth herein in order to obtain the desired results.

It has been found in the course of certain tests to determine the effectiveness of detergent and soap impregnating compounds in connection with steel wool pads for use in cleansing purposes, that a soap made in accordance with the above formulation may advantageously be used to replace the soap compositions presently employed in commercial steel wool pads and to fulfill the needs and requirements of the practice. While reference hereinafter is primarily made to steel wool pads, it is to be understood that any other metal or plastic fiber may be substituted therefor.

In the novel impregnating agent, water is employed at 3,725,288 Patented Apr. 3, 1973 25-50% by Weight of the soap composition to provide a soap which may be applied to the scouring pad ribbon by any conventional means, e.g., dipping, spraying, etc. and which sets upon cooling.

Sodium nitrite when employed up to 5% by weight of the soap composition acts in combination with the other components to provide improved rust resistant properties in steel wool scouring pads. While sodium nitrite has been used in the past for such purposes, the soap composition of the present invention provides significantly superior rust inhibiting properties.

The potassium carbonate employed in the present invention at 25-10% by weight of the soap composition is selected for the source of the potassium element as opposed to prior art practices where potassium soap may be the source. It creates a more desirable fluidity in the soap composition, as opposed to sodium carbonate, to provide improved handling e.g. in spraying and dipping and better distribution of soap throughout the entire cross section of the scouring pad.

The sodium carbonate which is an optional ingredient, may be particularly desirable to control the viscosity of the composition, an important factor in obtaining proper impregnation of the wool pad, as well as reduce tackiness if and where it is a problem. As indicated above, up to 10% and preferably, up to 5% thereof may be employed.

One may, if desired, employ as a further adjuvant in the soap compositions in this invention polyglycols for reducing dust and possibly drying out during storage. Typical of the polyglycols which one may use are polyethylene glycol, sorbitol, maunitol, glycerine and the like in amounts from O to 6% The sodium high lauric acid soap employed in the present invention at 5-55 by weight of the soap composition may be made from a high lauric acid oil such as commercial coconut oil, palm kernel and babassu nut oil which has been saponified to provide the potassium soap. It is preferred to employ coconut oil soaps having lower moisture contents. Where commercially available sodium coconut oil soaps are employed, it may be necessary to reduce the moisture level of the soap composition after preparation in order to provide a water content of 25- 50% by weight.

The sodium tallow soap of the present invention is employed at 5-55 by weight of the soap composition. It is prepared by saponification of commercially available tallow or neutralization of fatty acids derived from tallow or other sources that give predominantly palmitic, stearic and oleic acids. It is essential that unsaturated oleic acid which is a normal component of many sodium tallow soaps be at a level of less than l8% by weight of the total soap composition. It has been found that levels of oleic acid in excess of 18% of the total soap composition cause noticeable foam deterioration.

In preparing the sodium salts of the high lauric acid source and the tallow or equivalent fatty acids, it has been found desirable to prepare the two soaps simultaneously in accordance with common soap making techniques employing the conventional kettle boiling process.

The foam builder employed in the present invention at less than 6% by weight of the soap composition may be a saturated fatty alcohol having a chain length of C to C In amounts greater than 6% by weight, it has been found that the foam builders frequently create handling problems and provide the soap composition with an undesirable physical appearance. While the lower chain length, e.g., C to C fatty alcohols provide acceptable results from the standpoint of foam characteristics, they may be less desirable for some uses due to their odor which may be objectionable. Where the higher chain length, e.g., C to C fatty alcohols are employed, it has been found preferable to use such fatty alcohols in combination to obtain optimum foaming effect. Typical of the fatty alcohols that may be employed in the present invention are octanol, decanol, tetradecanol, hexadecanol, octadecanol, dodecanol alcohols and the like. Of these fatty alcohols, the dodecanol is preferred in carrying out the present invention. Where the C to C saturated fatty alcohols have been employed, particularly satisfactory results have been obtained with mixtures of C C and C alcohols. It has also been found that the foam builders unexpectedly extend the use life of the scouring pads as compared to equivalent pads wherein no foam builder is added to the soa I t also was found in carrying out the present invention that in order to further reduce the rusting where steel wool is used in the scouring pad, that the chloride and sulfate ion concentration in the soap composition of the present invention must be less than 1% by weight of the total composition and preferably less than 0.2% by weight. Such ions are commonly a carry-over in salts formed in conventional soap making processes and exist in many commercial soap sources.

While, as hereinbefore stated, the soap compositions of the present invention may be applied to scouring pads by any common application means, it has been found that the soap composition is particularly suitable for use in a process utilizing a spray application. Heretofore, soap compositions of the prior art, due to their physical characteristics have been unsuitable for spray application on scouring pads. Such soaps, when spray application was attempted, generally provided pads having extremely poor appearance, uneven soap distribution and in addition thereto, the spraying resulted in high soap losses in the manufacturing operations.

A particularly satisfactory product may be prepared with the present soap composition or other suitable sprayable detergent which may be soap or synthetic detergent using a method wherein a fiat ribbon of suitable scouring pad wool or fibers having a thickness and width sufiicient to provide finished scouring pads of desired shape is sprayed with a detergent composition on at least one side. The detergent is supplied through a spray nozzle and pump connected to a suitable source of supply. The ribbon then has placed upon it, at spaced intervals, metered quantities of a detergent core in a semi-solid, plastic, paste-like form which is capable of maintaining its position and shape as a discrete body. The detergent may be the same detergent used in spraying or any other compatible detergent. The frequency of this charge of the semi-solid core composition and the linear speed of the ribbon are so correlated as to provide discrete bodies of the core composition on the ribbon. The ribbon may then be cut by cutting means at equally spaced intervals to provide each cut strip of ribbon with a unitary, discrete body of soap. In the alternative, if desired, the ribbon may be divided into desired lengths by tearing or cutting before applying the core. The cut ribbon is rolled into a cylinder with the discrete body of detergent in the center and compressed to form a finished scouring pad. As used herein the term cut refers to the cutting or tearing of steel wool or other ribbons to divide the ribbon into proper length.

In carrying out a preferred embodiment of the present invention, steel wool is the scouring pad fiber employed. It has been found that the type steel Wool employed may be varied considerably depending upon the abrasiveness and texture desired in the finished scouring pad. Preferably, commercial steel wools having the grades in the order of about 1 to are employed. It is preferred to employ long fibered steel wool capable of giving the finished pads desired elasticity and spring While at the same time reducing the number of short ends which can abrade the users hands.

In carrying out the spraying step in the method of the present invention, any spray system capable of handling soap may be employed.

When steel wool ribbon is employed, it is preferred to use a soap composition as the detergent to be applied. Typically, spray nozzles having orifice diameters of 0.005- 0.025 inch will provide satisfactory results with most soap compositions. The soap composition to be sprayed is maintained at a temperature above which the soap is fluid and may be atomized and below which the atomized soap dries too rapidly to permit satisfactory adhesion to the steel wool ribbon. At extremely high temperatures, the moisture in the soap flashes off instantaneously thereby partially drying the soap and reducing its adhesive properties. Typically, soap compositions at temperatures in the order of -210 F. will provide satisfactory results. Preferably, soap compositions having temperatures in the order of 150-190 F. are employed. The soap composition is sprayed onto the steel wool ribbon in an amount of 3-7 grams of soap solids per 6 gram of steel wool ribbon. While the soap may be sprayed onto either or both sides of the flattened steel wool ribbon, it is preferred in carrying out the present invention that the soap be sprayed onto one side of the steel wool ribbon.

The detergent employed in the core of the present invention may be any detergent composition which is compatible with the sprayed detergent composition employed and which can be extruded as a semi-solid, plastic, pastelike mass capable of substantially maintaining its position and shape as a discrete body after extrusion. It is preferred when soap is employed that 0-3 grams of soap solids are employed per 6 grams of steel wool ribbon.

The steel wool pads are formed from steel wool ribbons having a length of approximately 18 inches and weighing 6 grams. The ribbons may be cut or torn before or after the soap core is applied by use of conventional steel wool tearing or cutting equipment. The soap core is placed upon the steel wool and preferably located so that after formation of the pad the core is in the proximate center of the finished pad. The cut or torn steel wool ribbon, preferably with the soap core on the soap free side of the ribbon, is then rolled in the cylindrical form by conventional steel wool pad rolling equipment and then pressed in conventional steel wool pad presses to form the finished pad.

While the method of the present invention has been described with reference to the placing of a core portion on the ribbon, it has been found that it is possible with some scouring pad products to omit the core and yet obtain desirable results.

The soap composition may be prepared by the following examples:

EXAMPLE I A solution is prepared by dissolving 5 pounds of potassium carbonate and 2 /2 pounds of sodium nitrite in 26.8 pounds of water and the solution is heated to F. in a crutcher. 65.3 pounds of molten kettle soap (30% H O) containing 36.6 pounds of sodium tallow soap and 9.1 pounds of sodium coconut soap is added to the solution with agitation. Three pounds of dodecanol is added to the mixture. The resultant is agitated for 90 minutes while the temperature is maintained at F. The resultant soap mixture is then ready for application to scouring pads. In carrying out the present example, steel wool strips are dipped in the fluid soap mixture at F.il0 F. and fed through the nip between two rolls to express the excess soap solution. The soap impregnated steel wool is then cut and rolled to desired size and compressed. The finished scouring pads are dry and provide a creamy, long lasting lather when used.

EXAMPLE II The soap composition is prepared as in connection with Example I. To this composition a quantity of perfume and color are added and the mixture is agitated until uniformly distributed. 1

Steel wool is then sprayed with the thereby produced resulting soap composition at l60il0 F. The soap is sprayed on at a rate of grams of anhydrous soap per 18 inches of ribbon weighing 6 grams. One gram of anhydrous soap in a semi-solid, plastic, paste-like form is then extruded onto a ribbon being conveyed past an extrusion nozzle at 18-inch intervals. The ribbon is then cut at 18 inch intervals so as to provide each 18 inch length of ribbon with semi-solid, plastic, paste-like soap core on one end. The soap impregnated steel wool is then cut and rolled to desired size and compressed to form pads.

The soap composition is sprayed by means of a single fluid airless spray nozzle having an orifice of 0.02 inch in diameter. While a single fluid nozzle is employed in Example II, it is to be understood that any conventional spray equipment can be employed.

EXAMPLE III A solution is prepared by dissolving 8 pounds of potassium carbonate and 1.5 pounds of sodium nitrite in 26.9 pounds of Water and the solution is heated to 140 F. in a crutcher. 35.7 pounds of molten, kettle soap (70% soap-30% H O) containing 20 pounds sodium tallow soap and 5 pounds sodium coconut soap is added to the solution with agitation. Six pounds of dodecanol is added to the mixture and agitation continued for an additional 90 minutes while the temperature is maintained at 150 F. The resultant soap mixture is then ready for application to scouring pads. In carrying out the present example 'steel wool strips are dipped in the fluid soap mixture at 150:10" F. and fed through the nip between two rolls to express the excess soap solution. The soap impregnated steel wool is then cut and rolled to desired size and compressed. The scouring pads provide a creamy, long lasting lather.

EXAMPLE IV A solution is prepared by dissolving 5 pounds of potassium carbonate, 2.4 pounds of sodium nitrite in 32.56 pounds of water and the solution heated to 140 F. 60 pounds of molten, 70% solids kettle soap containing 52 pounds sodium tallow soap and 8 pounds sodium coconut soap is added to the solution with agitation. 3 pounds of dodecanol is added to the mixture and agitation is continued. The resultant is employed as in conjunction with Example 11.

EXAMPLE V The formulation of the soap composition is like Example IV except that the quantities of the sodium tallow soap and sodium coconut soap are reversed.

EXAMPLE VI A solution is prepared by dissolving 3.4 pounds of potassium carbonate, 2.7 pounds of sodium carbonate and 2.5 pounds sodium nitrite in 22.5 pounds in water and the solution is heated to 140 F. To this solution there is added with agitation 66.4 pounds of a molten kettle soap (70% soap solids) containing 27.9 pounds of sodium tallow soap and 18.6 pounds of sodium coconut soap. There is further added to this mixture with agitation 1.5 pounds of dodecanol. The resultant combination is used as in Example II with excellent results.

EXAMPLE VII Example VI is repeated except that in the initial solution preparation there is additionally added 1.4 pounds of glycerine.

EXAMPLE VIII Example VI is repeated except that the carbonate mixture comprises 5 pounds of the potassium salt and 1 pound of the sodium salt and the water content is 21 pounds; further there are used 69.5 pounds of a 70% solids kettle soap which contains a tallow to coconut soap ratio of 4: 1.

EXAMPLE D( Example VIII is repeated except that the dodecanol is replaced by a 1:1 mixture of dodecanol and tetradecanol.

6 EXAMPLE x Example VIII is further repeated with the provision of 3% polyethylene glycol (molecular weight equals 600) in the initial aqueous solution of salts.

EXAMPLE XI 7.9 pounds of potassium carbonate, 1.45 pounds of sodium carbonate, and 2.5 pounds of sodium nitrite are dissolved in 23.5 pounds of water, the temperature thereof is raised to F. To this solution, with constant agitation, there is added 61 pounds of a molten kettle soap (70% solids) with the ratio of coconut soap to tallow soap being 1.5:1 (i.e. -17.1 pounds of sodium tallow soap and 25.6 pounds of sodium coconut soap). There is then further added 3 pounds of dodecanol while agitation is continued. This composition is then employed as in Example II yielding an outstanding impregnated soap pad.

EXAMPLE XII Example XI is repeated with the additional adjuvant of 2.7 pounds of glycerine to the initial salt solution.

This solution is heated to 140 and while vigorously stirring there is added 61 pounds of a 70% solids kettle soap containing 17.1 pounds of sodium tallow soap and 25.6 sodium coconut soap.

EXAMPLE XIV Example VIII is repeated using 3.4 pounds potassium carbonate, 2.7 pounds sodium carbonate, 22.5 pounds Water, 2.5 pounds sodium nitrite and 1.42 pounds of glycerine in the initial solution. 66.4 pounds of kettle soap are further added containing 27.9 pounds of sodium tallow soap and 18.6 pounds of sodium coconut soap with the balance water.

EXAMPLE XV An aqueous solution is prepared by dissolving 2.5 pounds potassium carbonate and 1.5 pounds sodium carbonate in 34 pounds of water heated to 140 F. and while agitating vigorously there are added 40 pounds of sodium tallow soap, 20 pounds of sodium coconut soap followed by 2. pounds of dodecanol.

EXAMPLE XVI Example XV is repeated with the following changes: Only 1 pound of sodium carbonate is used; the dodecanol is omitted; the 60 pounds of mixed soap composition contains a tallow to coconut soap ratio of 7:5; and the water content is increased to 36.5 pounds.

EXAMPLE XVII 10 pounds of potassium carbonate and 2.5 pounds of sodium carbonate are dissolved in 25 pounds of water at 140 F. and while stirring vigorously, there are added 19 pounds of sodium tallow soap and 39 pounds of sodium coconut soap.

EXAMPLE XVIII Example XVII is repeated with the following changes:

The sodium carbonate level is raised to 3 pounds. The

mixed soap composition comprises 36 pounds of the tallow soap and 24 of the coconut soap and additionally there are added 2 pounds of dodecanol.

7 EXAMPLE XIX Each of the Examples I to IV is repeated except that the solution of carbonate and nitrite is added to the molten soap. Comparable results are obtained.

While the present invention has been described by means of specific examples, it is to be understood that the invention is not limited thereto, and not only may the compositions be varied in accordance with the general teachings herein but it is, of course, contemplated that many auxiliary materials, organic and inorganic be employed in the composition of this invention without affecting the nature thereof. These include whiteners, preservatives, perfumes, bacteriostatic agents, dyes, pigments, fillers, builders and the like.

What is claimed is:

1. A soap impregnating agent for scouring pads and the like consisting essentially of by weight the admixture of (a) 25-50 parts water (b) 2.510 parts potassium carbonate 0-10 parts sodium carbonate (d) -55 parts sodium high lauric acid soap (e) 5-55 parts sodium tallow soap (f) 0-6 parts of a C to C saturated fatty alcohol foam builder, and

(g) 0-6 parts of a dust-reducing polyglycol, there being present at least 25 parts of (d) and (e).

2. A composition as defined in claim 1 wherein there are present (a) 30-45 parts Water (b) 5-8 parts potassium carbonate (c) 5-30 parts sodium high lauric acid soap, and

(d) 1540 parts sodium tallow soap.

3. A composition as defined in claim 1 wherein there are present (a) 46.4 parts water (b) 5 parts potassium carbonate (d) 9.1 parts sodium coconut soap (e) 36.6 parts sodium tallow soap, and

(h) 2.5 parts sodium nitrite.

4. A composition as defined in claim 3 including (f) 3 parts dodecanol.

5. A composition as defined in claim 1 wherein there are present (a) 42.4 parts water (b) 3.4 parts potassium carbonate (c) 2.7 parts sodium carbonate (d) 18.6 parts sodium coconut soap (e) 27.9 parts sodium tallow soap, and

(f) 1.5 parts dodecanol.

6. A composition as defined in claim 1 containing (a) 41.8 parts water (b) 7.9 parts potassium carbonate (c) 1.45 parts sodium carbonate (d) 25.6 parts sodium coconut soap (e) 17.1 parts sodium tallow soap (f) 3 parts dodecanol, and

(h) 2.5 parts sodium nitrite.

7. In the preparation of a scouring pad impregnated with a soap composition, the improvement which comprises forming an admixture of the ingredients defined in claim 1 and thereafter impregnating said pad therewith.

8. The method as defined in claim 7 wherein the impregnation is effected by means of spraying the pad with the said admixture.

9. The method as defined in claim 8 wherein the said admixture is sprayed at a temperature of to 210 F.

10. The method as defined in claim 9 wherein the temperature of spraying is 15 0" to F.

References Cited UNITED STATES PATENTS 3,337,465 8/4967 'Lancz et al. 25291 3,293,684 12/1966 Tundermann 252-91 2,344,671 3/1944 Bertsch 252-123 LEON D. ROSDOL, Primary Examiner W. E. SCH'ULZ, Assistant Examiner U.S. Cl. X.R. 252l23