Classifications

• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D10/00—Compositions of detergents, not provided for by one single preceding group
  • C11D10/04—Compositions of detergents, not provided for by one single preceding group based on mixtures of surface-active non-soap compounds and soap
  • C11D10/042—Compositions of detergents, not provided for by one single preceding group based on mixtures of surface-active non-soap compounds and soap based on anionic surface-active compounds and soap
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/04—Carboxylic acids or salts thereof
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/04—Carboxylic acids or salts thereof
  • C11D1/08—Polycarboxylic acids containing no nitrogen or sulfur
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D10/00—Compositions of detergents, not provided for by one single preceding group
  • C11D10/04—Compositions of detergents, not provided for by one single preceding group based on mixtures of surface-active non-soap compounds and soap
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D10/00—Compositions of detergents, not provided for by one single preceding group
  • C11D10/04—Compositions of detergents, not provided for by one single preceding group based on mixtures of surface-active non-soap compounds and soap
  • C11D10/045—Compositions of detergents, not provided for by one single preceding group based on mixtures of surface-active non-soap compounds and soap based on non-ionic surface-active compounds and soap
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D17/00—Detergent materials or soaps characterised by their shape or physical properties
  • C11D17/0047—Detergents in the form of bars or tablets
  • C11D17/006—Detergents in the form of bars or tablets containing mainly surfactants, but no builders, e.g. syndet bar
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D17/00—Detergent materials or soaps characterised by their shape or physical properties
  • C11D17/0047—Detergents in the form of bars or tablets
  • C11D17/0065—Solid detergents containing builders
  • C11D17/0069—Laundry bars
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/04—Carboxylic acids or salts thereof
  • C11D1/10—Amino carboxylic acids; Imino carboxylic acids; Fatty acid condensates thereof
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
  • C11D1/123—Sulfonic acids or sulfuric acid esters; Salts thereof derived from carboxylic acids, e.g. sulfosuccinates
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
  • C11D1/126—Acylisethionates
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
  • C11D1/14—Sulfonic acids or sulfuric acid esters; Salts thereof derived from aliphatic hydrocarbons or mono-alcohols
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
  • C11D1/16—Sulfonic acids or sulfuric acid esters; Salts thereof derived from divalent or polyvalent alcohols
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
  • C11D1/22—Sulfonic acids or sulfuric acid esters; Salts thereof derived from aromatic compounds
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
  • C11D1/28—Sulfonation products derived from fatty acids or their derivatives, e.g. esters, amides
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
  • C11D1/29—Sulfates of polyoxyalkylene ethers
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/32—Protein hydrolysates; Fatty acid condensates thereof
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/02—Anionic compounds
  • C11D1/34—Derivatives of acids of phosphorus
  • C11D1/345—Phosphates or phosphites
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/66—Non-ionic compounds
  • C11D1/662—Carbohydrates or derivatives
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/66—Non-ionic compounds
  • C11D1/75—Amino oxides
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/88—Ampholytes; Electroneutral compounds
  • C11D1/90—Betaines
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/88—Ampholytes; Electroneutral compounds
  • C11D1/92—Sulfobetaines ; Sulfitobetaines

Definitions

• TECHNICAL FIELD This invention relates to neutralized carboxylic acid shaped solid compositions, particularly cleansing bars, cakes, soap bars, synbars and the like.
• Bar smear also referred to as bar sloth
• bar sloth is the soft solid or mush that forms at the surface of a bar when submerged in water and is regarded by consumers as messy, unattractive, and uneconomical
• Products made in the form of shaped solids, cakes and bars are numerous.
• E.g., certain high moisture and low smear personal cleansing bars are disclosed in U.S. Pat. No. 4,606,839 Harding, issued Aug. 19, 1986. Harding uses coconut and/or palm kernel oil soap.
• Japanese Pat. J5 7030-798 discloses trans ⁇ parent solid framed or molded soap bar in which fatty acids constituting the soap component are myristic, palmitic, and stearic acids.
• a transparent soap is described in which at least 90 wt.% of the fatty acids which constitute the soap component are myristic acid, palmitic acid, and stearic acid.
• the product is reported as a transparent, solid soap having good frothing and solidifying properties, good storage stability, and a low irritant effect on human skin.
• the process and transparent bar soap com ⁇ position exemplified in Jap. J5 7030-798 do not appear to contain synthetic surfactant.
• the invention provides a shaped, solid three-dimensional skeleton structure comprising: a relatively rigid, interlocking mesh of neutralized crystalline carboxylic acid.
• the present invention provides an improved cleansing bar which is comprised of said skeleton structure, i.e., the rigid, interlocking mesh of neutralized carboxylic acid, preferably sodium soap fibers.
• Some cleansing bars which comprise surpris ⁇ ingly large amounts of water and other liquids while maintaining their rigidity and excellent smear properties; even when allowed to soak overnight in water.
• Figures 1-8 show magnified views of bar samples of the present invention.
• Figures 9 and 10 show magnified views of two different conventional soap bars.
• the Scanning Electron Microscopy (SEM) sample preparation involves fracturing a shaped solid with simple pressure to obtain a fresh surface for examination.
• the fractured sample is reduced in size (razor blade) to approximately a 10 mm x 15 mm rectangle with a thickness of about 5 mm.
• the sample is mounted on an aluminum SEM stub using silver paint adhesive.
• the mounted sample is coated with approximately 300 angstroms of gold/palladium in a Pelco sputter coater. Prior to coating, the sample is subjected to vacuum for a period of time which is sufficient to allow sufficient loss of bar moisture assuring acceptable coating quality. After coating, the sample is transferred to the SEM chamber and examined under standard SEM operating conditions with an Hitachi Model S570 Scanning Electron Microscope in order to see the skeletal (core) frame.
• FIGS. 1 and 2 are copies of photographs of a highly enlarged skeleton core structure comprising a rigid, interlocking mesh of elongated neutralized carboxylic acid crystalline fibers. More specifically FIGS. 1 and 2 are elongated C ⁇ 2 sodium soap fibers, enlarged respectively at 5000X and 2500X magnifications.- The structure of FIGS. 1 and 2 are made with 5% soap; 94% water; and 1% sodium chloride. See Example 10 in Table 7 herein. Note that larger fibers in the interlocking mesh can be composed of smaller fibers. Also, note the "void" spaces. See FIG. 2.
• FIGS. 3, 4 and 5 are copies of photographs of a skeleton structure made with 25% sodium C12 soap; 74% water; and 1% sodium chloride.
• the crystalline fiber-like structure is shown respec ⁇ tively at 3000X, 5000X and 1000X magnifications.
• FIG. 6 is a copy of a photograph of a skeleton structure made with 20% disodium salt of 1,12-dodecanedioic acid.
• the crystal ⁇ line fiber-like structure is shown at 2000X magnification. See Example 26.
• FIG. 7 is a copy of a photograph of a skeleton (core) struc- ture comprising crystalline lithium neutralized C14 carboxylic acid mesh, shown at 1500X magnification. See Example 27.
• FIG. 8 is a copy of a photograph of a cleansing bar (Exam ⁇ ple I hereinbelow) comprising: coated C1 -16 sodium soap fibers. The fibers are coated and/or commingled with the other bar compo- nents. The magnification is 1500X.
• FIG. 9 shows a sample of a market IVORY ® freezer bar made with sodium/potassium coconut/tallow soap at 1000X on the scale. The air in the IVORY bar soap makes it float.
• FIG. 10 shows a sample of a market NEUTROGENA® transparent bar at 1500X.
• FIGS. 1 and 2 the samples are first melted on a hot plate and recooled on a glass slide.
• the other samples, FIGS. 3-10, are samples of original shaped solid structures or the conventional bar prepared as set out herein.
• the invention provides a shaped solid comprising two or more phases.
• One phase is a crystalline skeleton structure comprising a rigid interlocking, open, three-dimensional mesh of neutralized carboxylic acid elongated crystals.
• the other essential phase is an aqueous phase which is soft or flowable at 25 ⁇ C.
• the skeleton structure is a relatively rigid, interlocking, open, three-dimensional mesh of neutralized mono- and/or di-carboxylic acid elongated crystals.
• skeleton structure skeletal structure, core, and skeleton frame are often used interchangeably herein.
• shaped solid as used herein includes forms such as bars, cakes and the like.
• bar as used herein includes the same unless otherwise specified.
• the term "mesh” as used herein means an interlocking crystal ⁇ line skeleton network with voids or openings when viewed under magnification by scanning electron microscopy.
• the present invention provides an improved cleansing bar which is comprised of said skeleton struc ⁇ ture.
• Some shaped solids are in the form of cleansing bars which contain surprisingly high levels of said aqueous phase comprising water, other liquids and soft materials. Notwithstanding the presence of relatively large levels of an aqueous phase, the preferred bars of the present invention maintain their rigidity and excellent smear properties, even when allowed to soak over ⁇ night in water. While not being bound to any theory, the shaped solid comprising these phases is similar to a relatively rigid wet sponge.
• the crystalline phase comprises crystals in the form of either interlocking platelets and/or fibers, preferably fibers.
• said fibers are composed of sodium soap.
• the inter ⁇ locking mesh of said fibers and/or platelets imparts strength to the three-dimensional structure, even in the presence of rela ⁇ tively high levels of water or other soft materials; even when allowed to soak overnight in water.
• the strength of the skeleton structure can be measured indirectly by the hardness of the shaped solid, as determined by the resistance to penetration of the solid using a Standard Weighted Penetrometer Probe. See Bar Harness Test below for more details.
• the skeleton structure is of sufficient rigidity that a 20 mm thick or greater cleansing bar sample has a penetration of from about zero mm to about 12 mm, preferably from about 1 mm to about 10 mm, more preferably from about 3 mm to about 8 mm.
• the present bars are distinguished from conventional trans ⁇ parent bars based on crystal size, as well as other character ⁇ istics.
• the crystals or crystal bundles that make-up the inter ⁇ locking mesh structure of the present invention preferably are of a size that diffracts light and consequently are greater than 400 nm in either diameter or length.
• conventional transparent bars gain their transparency by having crystal diameters or length less than the wavelength of white light, which is greater than about 400 nm and consequently do not diffract light.
• a bar (shaped solid) comprising the rigid skeletal structure of the present invention loses its rigidity when subjected to fracturing mechanical forces, e.g., those used in a conventional plodded bar making process as disclosed in U.S. Pat. No. 4,812,253, Small et al . , or U.S. Pat. No. 4,820,447, Medcalf et al . This is because the fracturing mechanical forces shear and break up the rigid, skeletal structure into smaller pieces. Thus, when a bar of the present invention is sheared in a plodder, a much softer bar results.
• fracturing mechanical forces e.g., those used in a conventional plodded bar making process as disclosed in U.S. Pat. No. 4,812,253, Small et al . , or U.S. Pat. No. 4,820,447, Medcalf et al . This is because the fracturing mechanical forces shear and break up the rigid, skeletal
• phase materials that can be incorporated into the bar than the present invention.
• Such phases include most materials that are either flowable liquids or materials that are softer than the minimum hardness of an acceptable bar.
• These phases include aqueous solutions, liquid crystalline phases composed of water and surfactant, polymers; particularly sur ⁇ factant-containing crystalline phases, and especially hygroscopic surfactants, which tend to become soft and sticky when mixed with water or other liquid phases including water-soluble organics (e.g., propylene glycol and glycerine), hydrophobic materials (e.g., mineral oil, liquid triglycerides), or soft hydrophobic materials, e.g., petrolatum, low melting paraffin, and low melting triglycerides.
• water-soluble organics e.g., propylene glycol and glycerine
• hydrophobic materials e.g., mineral oil, liquid triglycerides
• soft hydrophobic materials e.g., petrolatum, low melting paraffin,
• the invention is a shaped solid comprising a skeleton struc ⁇ ture that is a relatively rigid interlocking, open three-dimen ⁇ sional mesh of neutralized mono- and/or di-carboxylic acid elon- gated crystals.
• the preferred embodiment is a cleansing bar comprising at least two phases: (1) an aqueous phase having a penetration value of about 12 mm for a 12 mm deep sample; said aqueous phase being soft or flowable; (2) a rigid crystalline phase comprising a rigid crystalline phase skeleton structure comprising an interlocking, open three-dimensional mesh of neutralized mono- and/or di-car ⁇ boxylic acid elongated crystals; wherein said cleansing bar comprising said rigid crystalline phase skeleton structure and said aqueous phase has a penetration value of of from zero to about 12 mm for a 25 mm deep sample; and wherein said penetration values are measured as 25 ⁇ C using a 247 gram Standard Weighted Penetrometer Probe having a conical needle attach to a 9 inch (22.9 cm) shaft weighing 47 grams, with 200 grams on top of said shaft for a total of said 247 grams, said conical needle having a 19/32 inch (1.51 cm) top and a 1/32 inch (0.08 cm) point.
• the above cleansing bar is preferred when said neutralized carboxylic acid is selected from the group consisting of: lithium and/or sodium neutralized: monocarboxylic acid (soap) and/or dicarboxylic acid; and mixtures thereof; wherein said monocar- boxylic acid has a fatty alkyl(ene) chain of from about 12 to about 24 carbon atoms; wherein said dicarboxylic acid has a fatty alkyl (ene) chain of from about 12 to about 18 carbon atoms; and wherein at least about 80% of said carboxylic acid has saturated alkyl (ene) chains; and wherein said rigid crystalline phase skeleton structure occupies from about above 3% to about 75% of said cleansing bar by volume; and wherein said neutralized car ⁇ boxylic acid comprises from about above 5% to about 75%; and wherein said cleansing bar contains from about 15% to about less than 94% water by weight of said cleansing bar.
• the above cleansing bar is preferred when at least 80%, preferably 90%, of the carboxylic acid has
• X H, OR, 0-C-R, R, or mixtures thereof
• R C1-C3 alkyl
• M Na, Li, or mixtures thereof.
• the above cleansing bar is highly preferred when said elon ⁇ gated crystals are composed of fiber-like sodium fatty acid soap of which at least about 25% of said saturated fatty alkyl chains is of a single chain length; and wherein said bar contains: from about 15% to about 75% of said sodium soap; wherein the ratio of said unneutralized (free) carboxylic acid to soap is from about 1:2 to about 0. In other words, the free fatty acid is no more than 50% by weight of the soap in the formulation.
• the above cleansing bar is preferred when said bar contains said sodium soap and water; and from about 2% to about 60% of a synthetic surfactant selected from the group consisting of: alkyl sulfates, paraffin sulfonates, alkylglycerylether sulfonates, acyl sarcosinates, methylacyl taurates, linear alkyl benzene sulfo ⁇ nates, N-acyl glutamates, alkyl glucosides, alpha sulfo fatty acid esters, acyl isethionates, alkyl sulfosuccinates, alkyl ether carboxylates, alkyl phosphate esters, ethoxylated alkyl phosphate esters, methyl glucose esters, protein condensates, alkyl amine oxides, alkyl betaines, alkyl sultatnes, the alkyl ether sulfates with 1 to 12 ethoxy groups,
• said synthetic sur ⁇ factant is hygroscopic; said hygroscopic surfactant being defined as a surfactant which absorbs at least 20% of its dry weight in water at 26"C and 80% Relative Humidity in three days and wherein said bar is relatively non-swelling.
• the above cleansing bar is preferred when said hygroscopic surfactant is selected from the group consisting of alpha sulfo fatty acid esters; alkyl sulfates; alkyl ether carboxylates; alkyl betaines; alkyl sultaines; alkyl amine oxides; alkyl ether sul- fates; and mixtures thereof.
• the above cleansing bar is preferred when the ratio of said water to said soap is from about 1:1 to about 5:1; said water is present at a level of from about 25% to about 60%; wherein said fatty alkyl chains are C1 to C22 and said soap level in said bar is from about 15% to about 35%; wherein at least about 85% of said alkyl chains are saturated; wherein the weight ratio of said unneutralized (free) carboxylic acid to said soap is from about 1:4 to 0; and wherein said synthetic surfactant level is from about 4% to about 25% by weight of the bar and said surfactant is selected from the group consisting of: sodium acyl isethionates, sodium acyl sarcosinates, sodium alpha sulfo fatty acid esters, sodium paraffin sulfonates, sodium alkyl ether sulfates, sodium alkyl sulfates, sodium linear alkyl benzene sulfonates, alkyl betaines, alkyl sultaine
• the above cleansing bar is preferred when the ratio of said water to soap ratio is from about 1.5:1 to about 2:1; the ratio of said unneutralized (free) carboxylic acid to said soap is from about 1:6 to 0; said water level is from about 30% to about 45%; said fatty alkyl chain is from about C 4 to about C - ', wherein at least about 95% of said alkyl chains are saturated; said soap level is from about 15% to about 30%; and said synthetic sur ⁇ factant level is from about 8% to about 16%.
• the above cleansing bar is preferred when said bar contains from about 0.1% to about 40% of a hydrophobic material selected from the group consisting of: microcrystalline wax, petrolatum, carnauba wax, palm wax, candelilla wax, sugarcane wax, vegetable derived triglycerides, beeswax, spemaceti, lanolin, wood wax, shellac wax, animal derived triglycerides, ontar, ozokerite, ceresin, and Fischer-Tropsch wax.
• a hydrophobic material selected from the group consisting of: microcrystalline wax, petrolatum, carnauba wax, palm wax, candelilla wax, sugarcane wax, vegetable derived triglycerides, beeswax, spemaceti, lanolin, wood wax, shellac wax, animal derived triglycerides, ontar, ozokerite, ceresin, and Fischer-Tropsch wax.
• the above cleansing bar is preferred when said bar contains from about 2% to about 35% of said hydrophobic material selected from the group consisting of petrolatum and wax, said petrolatum and wax, and mixtures thereof melting melting about 49 ⁇ C (120 ⁇ F) to about 85 ⁇ C (185 ⁇ F).
• said hydrophobic material selected from the group consisting of petrolatum and wax, said petrolatum and wax, and mixtures thereof melting melting about 49 ⁇ C (120 ⁇ F) to about 85 ⁇ C (185 ⁇ F).
• the above cleansing bar is preferred when said bar comprises from about 5% to about 25% by weight of the bar of paraffin wax.
• the above cleansing bar is preferred when said bar contains from about 1% to about 50% of a non-volatile, water-soluble, nonionic organic material having a solubility of at least 5 parts in 10 parts of water; and wherein said water-soluble nonionic organic material is selected from the group consisting of a polyol of the structure:
• the above cleansing bar is preferred when said bar contains from about 2% to about 40% of said non-volatile, water-soluble, nonionic organic material.
• the above cleansing bar is preferred when said non-volatile, water-soluble, nonionic organic material comprises from about 5% to about 20% by weight of the bar; and wherein said organic material is selected from the group consisting of: propylene glycol, glycerine, sucrose, and urea, and mixtures thereof.
• the above cleansing bar is preferred when said bar contains said sodium soap, said water, and said synthetic surfactant, and from about 0.1% to about 70% of other ingredients selected from the group consisting of: from about 1% to about 10% said potassium soap; from about 1% to about 35% said magnesium soap; from about 1% to about 35% said calcium soap; from about 1% to about 15% triethanolammonium soap; from about 1% to about 60% of impalpable water-insoluble materials selected from the group consisting of calcium carbonate and talc; from about 0.1% to about 20% of a polymeric skin feel aid; wherein said polymeric skin feel aid is selected from the group consisting of cationic polysaccharides, preferably cationic guar gum with molecular weights of 1,000 to 3,000,000; cationic polyalkylene i ines, ethoxypolyalkylene imines, and poly[N-[-3-(dimethyl- ammonio)propyl]-N'-[3-ethyleneoxyethylene dimethylammo- nio)propy
• the above cleansing bar is preferred when said elongated crystals are fiber-like and wherein said neutralized dicarboxylic acid is the disodium salt 1,12-dodecanedioic acid and wherein said neutralized dicarboxylic acid comprises from about 20% to about
• a Preferred Process for Making the Bar comprises the steps of:
• aqueous molten liquid comprising about 15% to about 94% water and from about 6% to about 75% by weight said neutralized carboxylic acid; II. pouring said molten liquid into a bar shaped mold; and III. crystallizing said molded molten liquid by cooling to provide said cleansing bar.
• the above process is preferred when the aqueous molten liquid is made by neutralizing an aqueous mixture of said carboxylic acid with sodium hydroxide or lithium hydroxide with stirring at a temperature of from about 50 ⁇ C (120 ⁇ F) to about 95 ⁇ C (205 ⁇ F).
• a "crystallization enhancing salt” selected from the group consisting of: sodium or lithium salt of sulfate, chloride, acetate and citrate, and mixtures thereof.
• aqueous molten liquid aqueous phase contains from about 2% to about 40% of a solubilizing aid selected from the group consisting of:
• non-volatile, water-soluble nonionic organic solvents selected from the group consisting of: a polyol of the structure:
• said aqueous phase contains from about 20% to about 100% water by weight of said aqueous phase.
• said rigid crystalline phase contains from about 75% to about 100% of said neutralized carboxylic acid by weight of said crystalline phase.
• a highly preferred embodiment of the present invention is: a personal cleansing bar composition comprising a rigid, crystalline interlocking mesh of elongated sodium soap crystals; said soap bar comprising: from about 15% to about 50% sodium fatty acid soap composed of at least about 50% saturated fatty alkylene chains having 12-24 carbon atoms of which at least about 25% of said saturated fatty alkyl chains is of a single chain length; from about 15% to about 60% water; and from about 2% to about 60% by weight of a hygroscopic synthetic surfactant wherein said hygro ⁇ scopic synthetic surfactant is selected from surfactants which absorb at least about 20% of their dry weight in water at 26 ⁇ C and 80% Relative Humidity in three days.
• the above highly preferred personal cleansing bar is more preferred when said hygroscopic synthetic surfactant is selected from the group consisting of alpha sulfo fatty acid esters; alkyl sulfates; alkyl ether carboxy!ates; alkyl betaines; alkyl sul- taines; alkyl amine oxides; alkyl ether sulfates; and mixtures thereof.
• This highly preferred personal cleansing bar is more pre ⁇ ferred when said bar contains from about 0.5% to about 40% of salts and/or salt hydrates selected from the group consisting of: sodium chloride, sodium sulfate, disodium hydrogen phosphate, sodium pyrophosphate, sodium tetraborate, sodium acetate, sodium citrate, and other compatible salts of inorganic acids and short chain organic acids.
• salts and/or salt hydrates selected from the group consisting of: sodium chloride, sodium sulfate, disodium hydrogen phosphate, sodium pyrophosphate, sodium tetraborate, sodium acetate, sodium citrate, and other compatible salts of inorganic acids and short chain organic acids.
• a highly preferred cleansing bar comprises: various combi- nations of the core structure of sodium soap fibers, water, mild synthetic surfactants, bar appearance stabilizers, skin mildness aides and other cleansing bar adjuvants.
• Such preferred bar can be formulated to have essentially no bar smear.
• Some preferred bars of the present invention comprise: a rigid, interlocking mesh of neutralized carboxylic acid fiber-like core consisting essentially of sodium fatty acid soap composed of at least 50% saturated fatty alkyl chains having 12 to 24 carbon atoms. Preferably at least about 25% of said saturated alkyl chains are of a single chain length.
• Some compositions of this invention comprise the above- defined rigid mesh with water and without water. These compo ⁇ sitions must be formed with water or another suitable solvent system. The compositions can be made with large amounts of water and the water level in the final composition can be reduced to as low as about 1% or 2%.
• More complex bars of the present invention comprise a skele ⁇ tal structure comprising other salts of fatty acids selected from potassium, magnesium, triethanolammonium and/or calcium soaps used in combination with the selected levels of sodium and/or lithium soaps. More complex cleansing bars can contain surprisingly large amounts of water, mild synthetic surfactants, bar appearance stabilizers, skin mildness aids and other cleansing bar adjuvants; yet are mild and have very good low smear.
• Tables 1-3 set out some preferred bars which are made with the sodium salts of the fatty carboxylic acid (FA) soap.
• the bars shown in Table 1 are made with the level of water indicated, but the water level of the final bars can be reduced to provide bars which contain reduced levels of water or even little or no water.
• a preferred level of water is from about 20% to about 80% by weight of the bar.
• Table 2 below shows some preferred levels of soaps of a single FA chain length.
• Table 3 shows some preferred levels of unsaturation in the FA's used in the compositions of the present invention.
• Some preferred compositions contain little or no short chain FA's of ten carbon atoms or less.
• the terms “soap”, “fatty acid (FA) salts” and “monocarboxylic acid salts” as used herein are sometimes interchangeable. "Soap” is used since it is easier to relate to and is the preferred embodiment.
• the highs and lows of some key preferred optional ingredients for complex soap bar compositions of this invention are set out in Table 4. None of these ingredients is essential for the basic, preferred bar core structure. Zero is the lowest level for each optional ingredient. Some preferred bars can contain a total of from about 0.1% up to about 70% of such ingredients. The idea here is that the core bars can contain large amounts of other ingredients besides soap and water.
• the levels set out in Table 4 are particularly illustrative for bars containing from more than 5% to about 75% selected sodium soap and other ingredients. it should be understood that solid shapes can be made with just lithium soap or just neutralized polycarboxylic acid, but would be expected to be somewhat different from the levels and ratios given for sodium soaps. TABLE 4
• the soaps useful in the present invention can be of the same alkyl chain lengths, i.e., which are selected from the 12 to 24 carbon atoms as set out in Table 2.
• the same chain lengths apply for the other non-sodium soaps used in the bars of the present invention.
• the sodium soap is preferably at least about 50% of the soap present in the bar.
• the levels of potassium soap and/or triethanolammonium soap should not exceed one-half, preferably one-third, more preferably less than one-fourth, that of the sodium soap and the level of magnesium soap should not exceed about one-third of the level of sodium soap, and is preferably less than about one-fourth that of the sodium soap.
• the total of other soaps, save lithium soap, should prefer ⁇ ably not exceed one-half, preferably one-third, of the sodium soap.
• the synthetic detergent constituent of the bar compositions of the invention can be designated as being a detergent from the class consisting of anionic, nonionic, amphoteric and zwitterionic synthetic detergents. Both low and high lathering and high and low water-soluble surfactants can be used in the bar compositions of the present invention.
• suitable synthetic detergents for use herein are those described in U.S. Pat. No. 3,351,558, Zimmerer, issued Nov. 7, 1967, at column 6, line 70 to column 7, line 74, incor ⁇ porated herein by reference.
• Examples include the water-soluble salts of organic, sulfonic acids and of aliphatic sulfuric acid esters, that is, water-sol ⁇ uble salts of organic sulfuric reaction products having in the molecular structure an alkyl radical of from 10 to 22 carbon atoms and a radical selected from the group consisting of sulfonic acid and sulfuric acid ester radicals.
• Synthetic sulfate detergents of special interest are the normally solid alkali metal salts of sulfuric acid esters of normal primary aliphatic alcohols having from 10 to 22 carbon atoms.
• the sodium and potassium salts of alkyl sulfuric acids obtained from the mixed higher alcohols derived by the reduction of tallow or by the reduction of coconut oil, palm oil, stearine, palm kernel oil, babassu kernel oil or other oils of the coconut group can be used herein.
• aliphatic sulfuric acid esters which can be suitably employed include the water-soluble salts of sulfuric acid esters of polyhydric alcohols incompletely esterified with high molecular weight soap-forming carboxylic acids.
• Such synthetic detergents include the water-soluble alkali metal salts of sulfuric acid esters of higher molecular weight fatty acid monoglycerides such as the sodium and potassium salts of the coconut oil fatty acid monoester of l,2-hydroxypropane-3-sulfuric acid ester, sodium and potassium monomyristoyl ethylene glycol sulfate, and sodium and potassium monolauroyl diglycerol sulfate.
• the synthetic surfactants and other optional materials useful in conventional cleaning products are also useful in the present invention.
• surfactant mildness can be measured by a skin barrier destruction test which is used to assess the irri- tancy potential of surfactants. In this test the milder the surfactant, the lesser the skin barrier is destroyed. Skin barrier destruction is measured by the relative amount of radio- labeled water ( 3 H-H2 ⁇ ) which passes from the test solution through the skin epidermis into the physiological buffer contained in the diffusate chamber. This test is described by T.J. Franz in the J. Invest. Dermatol., 1975, 64, pp. 190-195; and in U.S. Pat. No.
• Some examples of good lather enhancing detergent surfactants mild ones, are e.g., sodium lauroyl sarcosinate, alkyl glyceryl ether sulfonate, sulfonated fatty esters, paraffin sulfonates, and sulfonated fatty acids.
• surfactants include other alkyl sulfates, anionic acyl sarcosinates, methyl acyl taurates, N-acyl glutamates, acyl isethionates, alkyl sulfosuccinates, alkyl phosphate esters, ethoxylated alkyl phosphate esters, trideceth sulfates, protein condensates, mixtures of ethoxylated alkyl sulfates and alkyl amine oxides, betaines, sultaines, and mixtures thereof. Included in the surfactants are the alkyl ether sulfates with 1 to 12 ethoxy groups, especially ammonium and sodium lauryl ether sulfates.
• Alkyl chains for these other surfactants are C8-C 2- prefer ⁇ ably C10-C 8- Alkyl glycosides and methyl glucose esters are preferred mild nonionics which may be mixed with other mild anionic or amphoteric surfactants in the compositions of this invention.
• Alkyl polyglycoside detergents are useful lather enhancers.
• the alkyl group can vary from about 8 to about 22 and the glycoside units per molecule can vary from about 1.1 to about 5 to provide an appropriate balance between the hydrophilic and hydrophobic portions of the molecule.
• Sulfonated esters of fatty esters are preferred wherein the chain length of the carboxylic acid is C8-C22- preferably C12-C18; the chain length of the ester alcohol is C ⁇ -C6.
• These include sodium alpha sulfomethyl laurate, sodium alpha sulfomethyl coco- ate, and sodium alpha sulfomethyl tallowate.
• Amine oxide detergents are good lather enhancers.
• Some preferred amine oxides are Cs-Cis, preferably C10-C16, alkyl dimethyl amine oxides and Cs-Cis, preferably C1 -C16, fatty acyl amidopropyl dimethyl amine oxides and mixtures thereof.
• Fatty acid alkanolamides are good lather enhancers.
• Some preferred alkanolamides are Cs-Cis, preferably C12-C16, mono- ethanolamides, diethanolamides, and monoisopropanolamides and mixtures thereof.
• detergent surfactants are alkyl ethoxy carboxy!ates having the general formula
• R is a C3-22 alkyl group, k is an integer ranging from 0 to 10, and M is a cation; and polyhydroxy fatty acid amides having the general formula 0 Rl
• R2 - C - N - Z wherein Rl is H, a C1-4 alkyl group, 2-hydroxy ethyl, 2-hydroxy propyl, or mixtures thereof, R is a C5-31 hydrocarbyl, and Z is a polyhydroxyhydrocarbyl having a linear hydrocarbyl chain with at least 3 hydroxyl groups directly connected to the chain, or an alkoxylated derivative thereof.
• Betaines are good lather enhancers. Betaines such as Cs-C s, preferably C12-C16, alky! betaines, e.g., coco betaines or Cs-Cis, preferably C12-C16, acyl amido betaines, e.g., cocoamidopropyl betaine, and mixtures thereof, are preferred.
• Some of the preferred surfactants are hygroscopic synthetic surfactants which absorb at least about 20% of their dry weight at 26'C and 80% relative humidity in three days. Hygroscopic sur- factants help to improve bar lather. Some preferred hygroscopic synthetic surfactants are listed below. Note that all are not hygroscopic. Hygroscopicitv of Some Surfactants The hygroscopic surfactants are defined herein as having a minimum of 20% total moisture gain after 3 days at 26 ⁇ C and 80% Relative Humidity.
• the cationic synthetic polymers useful in the present invention are cationic polyalkylene imines, ethoxypolyalklene imines, and poly[N-[-3-(dimethylammonio)- propyl]-N'-[3-(ethyleneoxyethylene dimethylammonio)propyl]urea dichloride] the latter of which is available from Miranol Chemical Company, Inc. under the trademark of Miranol A-15, CAS Reg. No. 68555-36-2.
• Preferred cationic polymeric skin conditioning agents of the present invention are those cationic polysaccharides of the cationic guar gum class with molecular weights of 1,000 to 3,000,000. More preferred molecular weights are from 2,500 to 350,000. These polymers have a polysaccharide backbone comprised of galactomannan units and a degree of cationic substitution ranging from about 0.04 per anhydroglucose unit to about 0.80 per anhydroglucose unit with the substituent cationic group being the adduct of 2,3-epoxypropyltri ethyl ammonium chloride to the natural polysaccharide backbone. Examples are JAGUAR C-14-S, C-15 and C-17 sold by Celanese Corporation.
• a mild skin cleansing bar of the present invention can contain from about 0.5% to about 20% of a mixture of a silicone gum and a silicone fluid wherein the gum:fluid ratio is from about
• Silicone gum and fluid blends have been disclosed for use in shampoos and/or conditioners in U.S. Pat. Nos. 4,906,459, Cobb et al., issued March 6, 1990; 4,788,006, Bolich, Jr. et al., issued Nov. 29, 1988; 4,741,855, Grote et al., issued May 3, 1988; 4,728,457, Fieler et al ., issued March 1, 1988; 4,704,272, Oh et al., issued Nov. 3, 1987; and 2,826,551, Geen, issued March 11,
• the silicone component can be present in the bar at a level which is effective to deliver a skin mildness benefit, for exam- pie, from about 0.5% to about 20%, preferably from about 1.5% to about 16%, and most preferably from about 3% to about 12% of the composition.
• Silicone fluid denotes a silicone with viscosities ranging from about 5 to about 600,000 centistokes, most preferably from about 350 to about 100,000 centistokes, at 25°C.
• Silicone gum denotes a silicone with a mass molecular weight of from about 200,000 to about 1,000,000 and with a viscosity of greater than about 600,000 centistokes. The molecular weight and viscosity of the particular selected siloxanes will determine whether it is a gum or a fluid.
• the silicone gum and fluid are mixed together and incorporated into the compositions of the present invention.
• perfumes can be used in formu ⁇ lating the skin cleansing products, generally at a level of from about 0.1% to about 2.0% of the composition.
• Alcohols, hydro- tropes, colorants, and fillers such as talc, clay, water-insol ⁇ uble, impalpable calcium carbonate and dextrin can also be used.
• Cetearyl alcohol is a mixture of cetyl and stearyl alcohols.
• Preservatives e.g., sodium ethylenediaminetetraacetate (EDTA), generally at a level of less than 1% of the composition, can be incorporated in the cleansing products to prevent color and odor degradation.
• Antibacterials can also be incorporated, usually at levels up to 1.5%.
• the above patents disclose or refer to such ingredients and formulations which can be used in the bars of this invention, and are incorporated herein by reference.
• Some bars of this invention contain from about more than 5% to about 75% said sodium fatty acid soap fibers; from about 10% to about less than 94% water; and at least about 1% of another bar ingredient selected from: other soaps, moisturizers, colorants, solvents, fillers, synthetic detergent surfactants, polymeric skin feel and mildness aids, perfumes, preservatives, and mixtures thereof.
• Some bars of this invention comprise: more than 5% to 50% fibrous sodium fatty acid soap composed of at least about 50% saturated fatty alkyl chains having 12-24 carbon atoms of which at least about 25% of said saturated fatty alkyl chains is of a single chain length.
• Some bars of this invention comprise said fibers which occupy from about 3% to about 75%, preferably from about 15% to about 40%, of the volume of the bar structure.
• Some bars comprise a rigid, low smearing structure of: more than 5% to 75% sodium fatty acid soap composed of at least about 50% saturated fatty alkyl chains having 12-24 carbon atoms of which at least about 25% of said saturated fatty alkyl chains is of a single chain length; from about 10% to about 94% water; and about 0% to a total of about 70% of other selected soap bar ingredients selected from the group set out above in Table 4.
• Some personal cleansing soap bar compositions comprise a rigid interlocked mesh of sodium soap fibers; wherein the sodium fatty acid soap is composed of at least about 50% saturated fatty alkyl chains having 12-24 carbon atoms of which at least about 25% of said saturated fatty alkyl chains is of a single chain length; and from about 2% to about 40% by weight of a hygroscopic synthet ⁇ ic surfactant wherein said hygroscopic synthetic surfactant is selected from surfactants which absorb at least about 20% of its dry weight in water at 26 ⁇ C and 80% Relative Humidity in three days.
• Bar Appearance Aids are preferably selected from the group consisting of: compatible salt and salt hydrates; water-soluble organics such as polyols, urea; aluminu osilicates and clays; and mixtures thereof, as set out above in Table 4. Water-soluble organics are also used to stabilize the appear ⁇ ance of the bar soaps of the present invention. Some preferred water-soluble organics are propylene glycol, glycerine, ethylene glycol, sucrose, and urea, and other compatible polyols.
• a particularly suitable water-soluble organic is propylene glycol.
• Other compatible organics include polyols, such as ethylene glycol or 1,7-heptane-diol , respectively the mono- and polyethylene and propylene glycols of up to about 8,000 molecular weight, any mono-Ci-4 alkyl ethers thereof, sorbitol, glycerol, glycose, diglycerol, sucrose, lactose, dextrose, 2-pentanol, 1-butanol, mono- di- and triethanolammonium, 2-amino-l-butanol , and the like, especially the polyhydric alcohols.
• polyol as used herein includes non-reducing sugar, e.g., sucrose. Sucrose will not reduce Fehling's solution and therefore is classified as a "non-reducing" disaccharide. Unless otherwise specified, the term “sucrose” as used herein includes sucrose, its derivatives, and similar non-reducing sugars and similar polyols which are substantially stable at a soap pro ⁇ cessing temperature of up to about 210 ⁇ F (98"C), e.g., trialose, raffinose, and stachyose; and sorbitol, lactitol and maltitol.
• soap pro ⁇ cessing temperature up to about 210 ⁇ F (98"C)
• Compatible salt and salt hydrates are used to stabilize the bar soap appearance via the retention of water.
• Some preferred salts are sodium chloride, sodium sulfate, disodium hydrogen phosphate, sodium pyrophosphate, sodium tetraborate.
• compatible salts and salt hydrates include the sodium, potassium, magnesium, calcium, aluminum, lithium, and ammonium salts of inorganic acids and small (6 carbons or less) carboxylic or other organic acids, corresponding hydrates, and mixtures thereof, are applicable.
• the inorganic salts include chloride, bromide, sulfate, metasilicate, orthophosphate, pyro- phosphate, polyphosphate, metaborate, tetraborate, and carbonate.
• the organic salts include acetate, formate, methyl sulfate, and citrate.
• Water-soluble amine salts can also be used. Monoethanol- amine, diethanolamine, and triethanolammonium (TEA) chloride salts are preferred.
• Aluminosilicates and other clays are useful in the present invention. Some preferred clays are disclosed in U.S. Pat. Nos. 4,605,509 and 4,274,975, incorporated herein by reference. Other types of clays include zeolite, kaolinite, montmoril- lonite, attapulgite, illite, bentonite, and halloysite. Another preferred clay is kaolin.
• Waxes include petroleum based waxes (paraffin, microcrystal- line, and petrolatum), vegetable based waxes (carnauba, palm wax, candelilla, sugarcane wax, and vegetable derived triglycerides) animal waxes (beeswax, spemaceti, wool wax, shellac wax, and animal derived triglycerides), mineral waxes (montar, ozokerite, and ceresin) and synthetic waxes (Fischer-Tropsch) .
• a preferred wax is used in the Examples herein.
• a useful wax has a melting point (M.P.) of from about 120 ⁇ F to about 185 ⁇ F (49 ⁇ -85 ⁇ C), preferably from about 125 ⁇ F to about 175 ⁇ F (52 ⁇ -79°C).
• a preferred paraffin wax is a fully refined petroleum wax having a melting point ranging from about 130 ⁇ F to about 140°F (49 ⁇ -60 ⁇ C). This wax is odorless and tasteless and meets FDA requirements for use as coatings for food and food packages.
• paraffins are readily available commercially.
• a very suitable paraffin can be obtained, for example, from The Standard Oil Company of Ohio under the trade name Factowax R-133.
• the paraffin preferably is present in the bar in an amount ranging from about 5% to about 20% by weight.
• the paraffin ingredient is used in the product to impart skin mildness, plas- ticity, firmness, and processability. It also provides a glossy look and smooth feel to the bar.
• the paraffin ingredient is optionally supplemented by a microcrystalline wax.
• a suitable microcrystalline wax has a melting point ranging, for example, from about 140 ⁇ F (60 ⁇ C) to about 185 ⁇ F (85 ⁇ C), preferably from about 145 ⁇ F (62 ⁇ C) to about 175 ⁇ F (79 ⁇ C).
• the wax preferably should meet the FDA requirements for food grade microcrystalline waxes.
• a very suitable micro ⁇ crystalline wax is obtained from Witco Chemical Company under the trade name Multiwax X-145A.
• the microcrystalline wax preferably is present in the bar in an amount ranging from about 0.5% to about 5% by weight.
• the microcrystalline wax ingredient imparts pliability to the bar at room temperatures.
• Fatty acid precursor, propylene glycol, sodium chloride, and water are mixed and heated to 71 ⁇ C.
• aqueous molten liquid comprising from 15% to 94% water and from 5.5% to 75% soap (neutralized carboxylic acid).
• soap neutralized carboxylic acid
• the temperature during neutralization of the molten liquid increases to -95"C.
• Other ingredients are added preferably in the following order and the temperature is maintained at -88 ⁇ C: coco betaine; sodium lauroyl sarcosinate; or sodium alpha- sulfo methyl cocoate; kaolin clay; or hydrated zeolite (synthetic sodium aluminosilicate); and paraffin. Perfume is added last.
• the molten liquid mixture is poured into shaped molds. 5.
• the molten liquid crystallizes (solidifies) on cooling to room temperature and the resultant bars are removed from the molds.
• the bars of the examples are made using the above general procedure, unless otherwise specified.
• Example II is a very highly preferred overall bar.
• the hardness of a bar is determined by measuring at 25"C the depth of penetration (in mm) into the bar of a 247 gram Standard Weighted Penetrometer Probe having a conically shaped needle attached to a 22.9 cm (9 inch) shaft weighing 47 grams with 200 grams on top of said shaft.
• a hardness measurement of 5 mm or less indicates a very hard bar; 5-10 mm indicates a moderately hard bar; 10-12 mm indicates a somewhat soft bar of marginal acceptance; and greater than 12 mm indicates a very soft bar that is unacceptable for most uses. This defines "hardness" as used herein unless otherwise specified.
• Bar Smear Test 2 The smear grade is determined by a (1) placing a soap bar on a perch in a 1400 mm diameter circular dish; (2) adding 200 ml of room temperature water to the dish such that the bottom 3 mm of the bar is submerged in water; (3) letting the bar soak over ⁇ night (15 hours); (4) turn the bar over and grade qualitatively for the combined amount of smear, and characteristics of smear, depth of smear on a scale where 10 equals no smear, 8.0-9.5 equals low smear amount, 5.0-7.5 equals moderate smears similar to most marketed bars, and 4.5 or less equals very poor smear.
• soap bars 1-10 are set out to show bar hardness, smear and shrinkage for CJO .
• C12, C14, Ci ⁇ , and C g alkyl chain soaps as shown.
• the preferred alkyl chain soaps of the present invention are set out above in Tables 1 and 2.
• Ex. 1 has a very poor smear, notwithstanding a hardness of 8.9 as the smear methodology dissolves away the soluble C o soap.
• Example 10 has the rigid structure, but is not preferred as a cleaning bar because its hardness is 14.
• Examples 12-16 are excellent bars of the present invention.
• Examples 17-19 are made with more complex mixtures of soaps than the prior examples. They form very good bars of the present invention. They have little or no smear. Compare their hardness and smears with those made with conventional tallow and coconut soap shown in Table 11.
• Example 23 is a bar of the present invention which contains more synthetic surfactant than soap. It has low smear and good lather.
• Example 24 is a bar of the present invention which contains polymer and other bar soap ingredients.
• Examples 23 and 24 are similar to Example IV of Table 5.
• Example 24 is a mild bar formulation with polymeric skin mildness aid.
• Example 25 the formulation is prepared by heating the fatty acid precursor to 71"C, separately adding lithium hydroxide to water, and then adding the fatty acid and lithium hydroxide solution together, mixing together for 30 minutes maintaining the heat at least at 71°C, adding lithium chloride salt and stirring for an additional 5 minutes, then pouring into a mold and letting cool and solidify. A solid bar with excellent smear properties is formed.
• Example 26 the diacid is melted (150-180"C) and a hot (90"C) caustic solution (two equivalents of NaOH) is added. The mixture is stirred for -5 minutes.
• Example 27 the sodium lauroyl sarcosinate is predissolved in the caustic/water solution. The bar becomes solid on cooling, with further hardening occurring upon degradation, e.g., to about 35-40% water by weight of the bar.
• Example 25 demonstrates the ability to form high moisture, firm and non-smearing bars without the need for sodium soap.
• Examples 26 and 27 demonstrate the ability to form a totally soap-free product and still obtain the relatively rigid inter- meshed fiber structure.
• Example 28 below is made by a freezer bar process disclosed in commonly assigned, U.S. Pat. Application Ser. No. 07/731,163, Taneri et al., filed July 15, 1991.
• This process provides a personal cleansing freezer bar comprising a skeleton structure having a relatively rigid, interlocking, semi-continuous, open, three-dimensional, crystalline mesh of neutralized carboxylic acid soap made by the following steps:
• Step 1 - Mixing The soap specified in the formulation is made in situ by mixing the desired fatty acids, consisting essentially of C12-C2 chain lengths, with the appropriate base or mixture of bases, consisting essentially of sodium, lithium, magnesium, calcium, and potassium hydroxide and triethanolamine.
• the fatty acid, base, and water are mixed at from about 170 ⁇ F to about 200 ⁇ F (76"-93 0 C) to form the soap.
• 180 ⁇ F is used.
• Sufficient water is used such that the mixture is stirrable.
• the other ingredients are added, maintaining the temperature of from about 180'F to about 200 ⁇ F (82 ⁇ -93 ⁇ C) .
• Example 28 - 180 ⁇ F The optimal mixing temperatures can vary depending on the particular formulation.
• Step 2 Qptionals - Aeration, Minor Addition, and Flash Drying Optionals Aerate (optional) said mix and add perfume (only if drying) and other minors with positive displacement pump or other in-line mixer.
• Example 28 is not aerated or dried.
• the mixture of Step (1) is optionally dried to reduce the amount of said water to the desired level, preferably 20-40% water.
• the flash drying tem ⁇ perature is from about 225 ⁇ F to about 315"F (135 ⁇ -157°C) at pressure of from about 30 to abut 100 psi (115-517 mm Hg).
• Step 3 Freezer
• This final temperature also referred to herein as the Freezer Outlet Temperature (F0T) is typically the maximum temperature that will form a smooth plug that holds its shape once extruded onto a moving belt (Step 4).
• the F0T for Example 28 is 175 ⁇ F.
• Step 4 Extrusion
• the cooled mix of Step 3 is extruded out onto a moving belt as a soft plug which is then cooled and fully crystallized and then stamped and packaged.
• the plugs are preferably formed via an extrusion operation, as shown in U.S. Pat. No. 3,835,059, supra.
• Some of the composition crystallizes in the freezer (Step 3) in order to provide a semi-solid having a sufficient viscosity to stand up on the belt, while further crystallization occurs after extrusion, resulting in hardening of the bar.
• the final crystal ⁇ lization of the sodium soap forms the interlocking, semi -con ⁇ tinuous, open mesh structure in the freezer bar of the present
• the Plodding Stamped Bar Hardness Test can be used to differentiate the bars of this invention from other bars.
• Four trade bars are selected that represent various soap processes: SAFEGUARD ® , a soap milled bar; ZEST ® , a soap/synthetic milled bar; IVORY ® , a freezer bar; and LAVA ® , a framed bar. Samples of these market bars and formed bars of Example 28 and Example II are plodded using the procedure set out below.
• Formed bars (about 2.5 Kg or greater) are placed into a single stage plodder (4 inch/10.16 cm bonnet single stage plodder) without vacuum and are run through a noodle plate.
• the noodle plate contains nineteen 0.37 inch (0.93 cm) holes in a 3.1 inch (8 cm) plate.
• the barrel temperature is set at 120°F (49'C) and the nose temperature is set at 110'F (43.5'C).
• Step 1 is repeated with the noodles.
• Step 2 is repeated with the noodles.
• the noodles of Step 2 are placed into the single stage plodder (4 inch/10.16 cm bonnet single stage plodder) with vacuum applied and run through a brick-shaped orifice.
• a brick-shaped plug with approximate dimensions of 1.88 inches (4.6 cm) (height) by 1.16 inches (3 cm) (width) by 3 inches
• Example 28 (Formed Bar) 3.35 2
• Example 28 (Plodded/Stamped) 10.67 Delta (7.32)
• plodded bars with Delta's of 4 or greater is a strong indication that there is a skeletal structure in the original which is fractured or destroyed when plodded.
• the hard bars of the present invention will form soft, messy bars when plodded in a conventional bar process.
• Example 28 bars are first formed using the above freezer process.
• the bars of Example II are first formed using the above-described frame bar process.
• each bar is plodded and stamped.
• the market bars are made of tallow and coconut natural soaps.
• the hardness of plodded SAFEGUARD ® and ZEST ® bars are about the same as the original bars.
• the IVORY ® and LAVA ® plodded bars (2) are slightly softer than the original bars.
• the plodded Bar 2 of Example 28 is much softer than the original Bar 1 of Example 28. More dramatically, the plodded Bar 2 of Example II falls apart upon plodding and is too soft to stamp. Its hardness after plodding is that of a soft aqueous phase, indicating that the rigidity of the skeletal structure is essentially destroyed.

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• 1991
  • 1991-11-20 CA CA002095351A patent/CA2095351C/en not_active Expired - Fee Related
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  • 1991-11-20 ES ES92904074T patent/ES2079180T3/es not_active Expired - Lifetime
  • 1991-11-20 AT AT92904074T patent/ATE129522T1/de not_active IP Right Cessation
  • 1991-11-20 RU RU9193042103A patent/RU2080365C1/ru active
  • 1991-11-20 BR BR919107125A patent/BR9107125A/pt not_active IP Right Cessation
  • 1991-11-20 WO PCT/US1991/008733 patent/WO1992009679A1/en active IP Right Grant
  • 1991-11-20 CZ CS93987A patent/CZ283495B6/cs not_active IP Right Cessation
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  • 1991-11-20 DE DE69114143T patent/DE69114143T2/de not_active Expired - Fee Related
  • 1991-11-20 EP EP92904074A patent/EP0559837B1/en not_active Expired - Lifetime
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  • 1991-11-20 AU AU91763/91A patent/AU657295B2/en not_active Ceased
  • 1991-11-20 JP JP4504274A patent/JPH06503122A/ja active Pending
  • 1991-11-25 IE IE409491A patent/IE72087B1/en not_active IP Right Cessation
  • 1991-11-25 AR AR91321225A patent/AR247426A1/es active
  • 1991-11-25 NZ NZ240709A patent/NZ240709A/en unknown
  • 1991-11-26 PT PT99606A patent/PT99606A/pt not_active Application Discontinuation
  • 1991-11-26 MA MA22633A patent/MA22349A1/fr unknown
  • 1991-11-26 CN CN91111928A patent/CN1036529C/zh not_active Expired - Fee Related
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  • 1991-11-26 EG EG72291A patent/EG19580A/xx active
• 1993
  • 1993-05-21 NO NO93931848A patent/NO931848L/no unknown
  • 1993-05-25 FI FI932366A patent/FI932366A/fi not_active Application Discontinuation
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• 1995
  • 1995-10-26 GR GR950402864T patent/GR3017892T3/el unknown
• 1998
  • 1998-06-15 HK HK98105320A patent/HK1006179A1/xx not_active IP Right Cessation

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