AU661826B2 - Laundry detergent compositions containing crystalling/layeredsilicates - Google Patents

Abstract

Particulate laundry detergent compositions are disclosed incorporating 5 % to 50 % of a surfactant, from 10 % to 95 % of a three-component non-phosphorus builder system comprising a mixture of a sodium aluminosilicate zeolite, a water-soluble monomeric or oligomeric carboxylate chelating agent and a crystalline layered sodium silicate, and from 0 % to 40 % of non-surfactant, non-builder detergent ingredients. The crystalline layered silicate is of composition NaMSixO2x+1.yH2O where M is sodium or hydrogen, x is a number from 1.9 to 4 and y is a number from 0 to 20. Preferably M is sodium, x is 2 and y is O.

Description

:t

L-;

;i I OPI DATE 17/03/92 AOJP DATE 30/04/92

INTERNATIC.

APPLN. ID 84970 91 PCT NUMBER PCT/US91/05533

EATY(PCT)

(51) International Patent Classification 5 (11) International Publication Number: WO 92/03525 C11D 1/08, 3/12, 3/395 Al C11D 7/54, 9/18 (43)

I

lternational Publication Date: 5 March 1992 (05.03.92) (21) International Application Number: PCT/US91/05533 (74) Agent: REED, David; The Procter Gamble Company, Ivorydale Technical Ctr., 5299 Spring Grove Ave., (22) International Filing Date: 5 August 1991 (05.08.91) Cincinnati, OH 45217-1087 (US).

Priority data: (81) Designated States: AT, AT (European patent), AU, BB, BE 9018157.9 17 August 1990 (17.08.90) GB (European patent), BF (OAPI patent), BG, BJ (OAPI patent), BR, CA, CF (OAPI patent), CG (OAPI patent), (71)Applicant: THE PROCTER GAMBLE COMPANY CH, CH (European patent), CI (OAPI patent), CM [US/US]; One Procter Gamble Plaza, Cincinnati, OH (OAPI patent), CS, DE, DE (European patent), DK, 45202 DK (European patent), ES, ES (European patent), FI, FR (European patent), GA (OAPI patent), GB, GB (Eu- (72) Inventors: PRETTY, Alastair, John 4 Whinbank, Carras ropean patent), GN (OAPI patent), GR (European pa- Hall, Newcastle Upon Tyne NE20 9HX FRASER, tent), HU, IT (European patent), JP, KP, KR, LK, LU, Douglas, Gilbert I 63 Bayswater Road, Newcastle upon LU (European patent), MC, MG, ML (OAPI patent), Tyne NE2 3HR HARDY, Paul, Andrew Rozier- MR (OAPI patent), MW, NL, NL (European patent), ensesteenweg 97, B-1900 Overijse NO, PL, RO, SD, SE, SE (European patent), SN (OAPI patent), SU+,TD (OAPI patent), TG (OAPI patent).

Published With international search report.

(54)Title: DETERGENT COMPOSITIONS LUWAlPy b_'TE SEAJTr COI'.POS7TTO S CoATT-4W A)jCr CAYSTLLNt-Cr/_AYFED- b ZL.LZC4TES (57) Abstract Particulate laundry detergent compositions are disclosed incorporating 5 to 50 of a surfactant, from 10 to 95 of a three-component nonophosphorus builder system comprising a mixture of a sodium aluiinosilicate zeoli'(e, a water-soluble monomeric or oligomeric carboxylate chelating agent and a crystalline layered sodium silicate, and from 0 to 40 of non-surfactant, non-builder detergent ingredients. The crystalline layered silicate is of composition NaMSixO2x+ 1 .yF20 where M is sodium or hydrogen, x is a number from 1.9 to 4 and y is a number from 0 to 20. Preferably M is sodium, x is 2 and y is O.

/0 Oe P I L v ~ZSl~i~jig cn *i WO 92/03525 PCT/US91/05533 -1- U-A/IDPWY ET'E r ET CoMPOSITOA)S CoATIrAG/C CAySTLLN7G-/LAyE SrLzCA-vTE This invention relates to laundry detergent compositions and more especially to laundry detergent compositions that incorporate little or no phosphorus containing materials.

Laundry detergent compositions of this type have become widely available as a result of public concern over, and/or legislative action to control, the environmental impact of aqueous effluent from untreated or partially treated domestic sewage containing dissolved phosphates.

The commercial introduction of zero-phosphate detergent products, whilst meeting the primary objective of reducing the phosphate load on the environment arising from detergent products, has added to formulation complexity and has also increased the load on the environment of organic materials. Zero phosphate compositions employ a combination of materials to replace the phosphate builder, the principal component usually being a water insoluble sodium aluminosilicate zeolite supplemented by a mixture of water soluble inorganic and polymeric organic salts.

Much effort has been expended by those working in the field in developing such multi-component builder systems, the need for which arises from the difficulty of finding a single material that will carry out all of the functions previously performed by the phosphate builder. Although not completely characterised, these functions include chelation of both Ca++ and Mg++ ion hardness together with peptisation and suspension of the soils removed from fabrics during the washing process.

It has now been found that the use of crystalline or so-called layered silicates (known per s) in particular combinations of detergent builder, components provides enhanced performance and permits certain other materials /y "VKI 2 to be reduced in level or omitted altogether from the resultant particulate detergent products. In preferred embodiments of the invention, cleaning performance equivalent to that of existing products can be obtained at a significantly lower level of usage of the detergent builder components thereby reducing the load on the environment. Other disadvantages include enhanced dispensing characteristics, i.e. dispersion and/or dissolution of the particulate product at the start of the wash cycle in an automatic domestic washing machine, a reduction in insoluble precipitates on fabrics (ash) and a reduction in fabric damage.

According to the present invention there is provided a particulate detergent composition including: from 5% to 50% by weight of one or more anionic, nonionic, ampholytic, zwitterionic or cationic surfactants or a mixture of any thereof; from 10% to 95% of a detergent builder system including a mixture of from 20% to 60% by weight of the mixture of a sodium a luminosilicate zeolite; (ii) from 10% to 30% by weight of the mixture of a water soluble monomeric or oligomeric organic carboxylate chelating agent; and (iii) from 10% to 65% by weight of the mixture of a crystalline layered sodium silicate having the composition NaMSixO 2 x+ 1 .yH 2 O, wherein M is sodium or hydrogen, x is a number from 1.9 to 4 and y is a number from 0 to 20; and from 0 to 40% of non-surfactant, non-builder detergent ingredients.

Preferably component (iii) of the builder system is a, 3, 0 or 8-Na 2 Si20 5 and component is a synthetic hydrated zeolite of unit cell formula Naz[(AIO 2 )z(SiO 2 )y].xH 2 0 wherein z and y are at least 6, the ratio of z to y is from 1.0 to 0.5 and x is at least 5, preferably from 7.5 to 276.

2A The present invention also provides a particulate detergent composition including from 5% to 50% by weight of an organic surfactant selected from the group consisting of anionic, nonionic, ampholytic and cationic surfactants and mixtures of any thereof: from 10% to 95% of a detergent builder system including a mixture of from 20% to 60% by weight of the mixture of a synthetic sodium aluminosilicate zeolite having the unit cell formula Naz[A1 0 2 )(SiO 2 )y].XH 2 0 wherein z y are at least 6, the ratio of z to y is from 1.0 to 0.5 and x is at least 5, preferably from 7.5 to 276.

(ii) from 10% to 30% by weight of the mixture of a water soluble aliphatic monomeric polycarboxylate chelating agent containing from 2 to 4 carboxyl groups and having a pkl of from 4 to 7.5; and (iii) from 10% to 65% by weight of the mixture of a crystalline layered sodium silicate having the formula 5 -Na 2 SisO 5 and from 0 to 40% of non-surfactant, non-builder detergent ingredients.

4 The present invention also provides a method of preparing a particulate detergent composition including from 5% to 50% by weight of an organic surfactant selected from the group Sconsists of anionic, nonionic, ampholytic and cationic surfactants and mixtures of any thereof; Io 2B i( from 10% to 95% of a detergent builder system including a mixture of from 20% to 60% by weight of the mixture of a synthetic sodium aluminosilicate zeolite having the unit cell formula Naz[(A1 0 2 )z(SiO 2 )y].XH 2 0 wherein z y are at least 6, the ratio of z to y is from 1.0 to 0.5 and x is at least 5, preferably from 7.5 to 276.

(ii) from 10% to 30% by weight of the mixture of a water soluble aliphatic monomeric poly carboxylate chelating agent containing from 2 to 4 carboxyl groups and having a pkl of from 4 to 7.5; and (iii) from 10% to 65% by weight of the mixture of a crystalline layered sodium silicate having the formula 8 -Na 2 Si 2 0 5 and from 0 to 40% of non-surfactant, non-builder detergent ingredients wherein the crystalline layered sodium silicate (iii) is added as a finely divided particulate solid to one or more granular solids including component component (ii) and, if present, component at least one of said granular solids comprising a multicomponent mixture, present in an amount of at least 20% by weight of the composition.

o I: I WO 92/03525 PCT/US91/05533 3 yn thctic hydrated zeelite of unit cell forniula Naz [(A10 2) (Sio wherein z and at least o, the ratio of z to y is from L, o 0.5 and x is at least 5, preferably from to 276.

Preferably also the monomeric or oligomeric organic carboxylate chelating agent has a first carboxyl logarithmic acidity constant (pK 1 of less than 9, preferably of from 2 to The present invention concerns a particulate detergent composition incorporating one or more surfactants and a detergent builder system composed of three principal components viz. a sodium aluminosilicate zeolite, a water soluble monomeric or oligomeric organic carboxylate chelating agent and a crystalline layered sodium silicate. Preferred compositions in accordance with the invention, also contain other, non surfactant, non-builder detergent ingredients.

A wide range of surfactants can be used in the detergent compositions. A typical listing of anionic, nonionic, ampholytic and zwitterionic classes, and species of these surfactants, is given in U.S.P. 3,664,961 issued to Norris on May 23, 1972.

Mixtures of anionic surfactants are particularly suitable herein, especially mixtures of sulphonate and sulphate surfactants in a weight ratio of from 5:1 to 1:2, preferably from 3:1 to 2t3, more preferably from, 3:1 to i 1:1. Preferred sulphonates include alkyl benzene ,T k \4 WO 92/03525 PCT/US91/05533 4 sulphonates having from 9 to 15, especially 11 to 13 carbon atoms in the alkyl radical, and alpha-sulphonated methyl fatty acid esters in which the fatty acid is derived from a C-C8 fatty source, preferably from a

C

16

-C

18 fatty source. In each instance the cation is an alkali metal, preferably sodium. Preferred sulphate surfactants are alkyl sulphates having from 12 to 22, preferably 14 to 18 carbon atoms in the alkyl radical, optionally in admixture with ethoxy sulphates having from to 20, preferably 10 to 16 carbon atoms in the alkyl radical and an average degree of ethoxylation of 1 to 6.

The cation in each instance is again an alkali metal cation, preferably sodium.

One class of nonionic surfactants useful in the present invention are condensates of ethylene oxide with a hydrophobic moiety to provide a surfactant having an average hydrophilic-lipophilic balance (HLB) in the range from 8 to 17, preferably from 9.5 to 13.5, more preferably from 10 to 12.5. The hydrophobic (lipophilic) moiety may be aliphatic or aromatic in nature and the length of the polyoxyethylene group which is condensed with any particular hydrophobic group can be readily adjusted to yield a water-soluble compound having the desired degree of balance between hydrophilic and hydrophobic elements.

Especially preferred nonionic surfactants of this type are the C 9

-C

15 primary alcohol ethoxylates containing 3-8 moles of ethylene oxide per mole of alcohol, particularly the C 14

-C

15 primary alcohols containing 6-8 moles of ethylene oxide per mole of alcohol and the C 12-C1 primary alcohols containing 3-5 moles of ethylene oxi(e per mole of alcohol.

WO 92/03525 PCT/US91/05533 Another class of nonionic surfactants comprises alkyl polyglucoside compounds of general formula RO (CnH 2 nO)tZx wherein Z is a moiety derived from glucose; R is a saturated hydrophobic alkyl group that contains from 12 to 18 carbon atoms; t is from 0 to 10 and n is 2 or 3; x i's from 1.3 to 4, the compounds including less than unreacted fatty alcohol and less than 50% short chain alkyl polyglucosides. Compounds of this type and their use in detergent compositions are disclosed in EP-B 0070074, 0070077, 0075996 and 0094118.

A further class of surfactants are the semi-polar surfactants such as amine oxides. Suitable amine oxides are selected from mono C -C 20 preferably C 10

-C

14 N-alkyl or alkenyl amine oxides and propyl;ne-l,3-diamine dioxides wherein the remaining N positions are substituted by methyl, hydroxyethyl or hydroxypropyl groups.

Cationic surfactants can also be used in the detergent compositions herein and suitable quaternary ammonium surfactants are selected from mono C 8

-C

16 preferably

C

10

-C

14 N-alkyl or alkenyl ammonium surfactants wherein remaining N positions are substituted by methyl, hydroxyethyl or hydroxypropyl groups.

The detergent compositions can comprise fro; 5% to 50% by weight of surfactant but usually comprises from 5% to more preferably from 5% to 15% by weight. Combinations of surfactant types are preferred, more especially anionic-nonionic and also anionic-nonionic-caticnic blends. Particularly preferred combinations are described

I

WO 92/03525 PCTi/'S91/65533 6 in GB--A-2040987 and EP-A-0087914. Although the surfactants can be incorporated into the compositions as mixtures, it is preferable to control the point of addition of each surfactant in order to optimise the physical characteristics of the composition and avoid processing problems. Preferred modes and orders of surfactant addition are described hereinafter.

The second essential component of compositions in accordance with the invention is a detergent builder system comprising a mixture of sodium aluminosilicate zeolite, a water soluble monomeric or oligomeric carboxylate chelating agent and a crystalline layered sodium silicate in defined amounts.

Whilst a range of aluminosilicate ion exchange materials can be used, preferred sodium aluminosilicate zeolites have the unit cell formula Naz [(AlO 2 )z (SiO 2 wherein z and y are at least 6; the molar ratio of z to y is from 1.0 to 0.5 and x is at least 5, preferably from to 276, more preferably from 10 to 264. The aluminosilicate materials are in hydrated form and are preferably crystalline, containing from 10% to 28%, more preferably from 18% to 22% water.

The above aluminosilicate ion exchange materials are further characterised by a particle size diameter of from 0.1 to 10 micrometers, preferably from 0.2 to 4 micrometers. The term "particle size diameter" herein represents the average particle size diameter of a given r, WO 92/03525 PCT/US91/05533 7ion exchange material as determined by conventional analytical techniques such as, for example, microscopic determination utilizing a scanning election microscope.

The aluminosilicate ion exchange materials are further characterised by their calcium ion exchange capacity, which is at least 200 mg equivalent of CaCO.

3 water hardness/g of aluminosilicate, calculated on an anhydrous basis, and which generally is in the range of from 300 mg eq./g to 352 mg eq./g. The aluminosilicate ion exchange materials herein are still further characterised by their calcium ion exchange rate which is at least 130 mg equivalent of CaCO 3 /litre/minute/(g/litre) [2 grains Ca /gallon/minute/(gram/gallon)] of aluminosilicate (anhydrous basis), and which generally lies within the range of from 130 mg equivalent of CaCO 3 /litre/minute/(gram/litre) [2 grains/gallon/minute/ (gram/gallon)] to 390 mg equivalent ofCaCO 3 /litre/minute/ (gram/litre) [6 grains/gallon/minute/(gram/gallon)], based on calcium ion hardness. Optimum aluminosilicates for builder purposes exhibit a calcium ion exchange rate of at least 260 mg equivalent of CaCO 3 /litre/minute/(gram/litre) [4 grains/gallon/minute/(gram/gallon)].

Aluminosilicate ion exchange materials useful in the practice of this invention are commercially available and can be naturally occurring materials, but are preferably synthetically derived. A method for producing aluminosilicate ion exchange materials is discussed in US Patent: No. 3,985,669. Preferred synthetic crystalline aluminosilicate ion exchange materials useful herein are available under the designations Zeolite A, Zeolite B, Zeolite X, Zeolite HS and mixtures thereof. In an especially preferred embodiment, the crystalline r WO 92/03525 PCT/US91/05533 8 aluminosilicate ion exchange material is Zeolite A and has the formula Na 1 2[(A10 2 1 2 (SiO 2 1 2 wherein x is from 20 to 30, especially 27. Zeolite X of formula Na 86 [(A10 2 86 (SiO 2 106 276 H 2 0 is also suitable, as well as Zeolite HS of formula Na 6 [(ilO 2 6 (SiO 2 6 7.5 H 2 0).

The water-soluble monomeric or oligomeric organic carboxylate chelating agent can be selected from a wide range of compounds but preferably has a first carboxyl logarithmic acidity/constant of less than 9, preferably of between 2 and 8.5, more preferably of between 4 and The lo;:irithmic acidity constant is defined by reference to the equilibrium A HA where A is the fully ionized carboxylate anion of the builder salt.

The equilibrium constant is therefore (H (A) and pK 1 log l0

K.

For the purposes of this specification, acidity constants are defined at 25°C and at zero ionic strength. Literature WO 92/03525 PCT/US91/05533 9 values are taken where possible (see Stability Constants of Metal-Ion Complexes, Special Publication No. 25, The Chemical Society, London): where doubt arises they are Aetermined by potentiometrir titration using a glass electrode.

Preferred carboxylates can also be defined in terms of their calcium ion stability constant (PKCa++) defined, analogously to pK 1 by the equations KCa++ loglKCa++ where KCa++ A)

(A)

Preferably, the polycarboxylate has a pKCa++ in the range from about 2 to about 7 especially from about 3 to about 6. Once again literature values of stability constants are taken where possible. The stability constant is defined at 25 0 C and at zero ionic strength using a glass electrode method of measurement as described in Complexation in Analytical Chemistry by Anders Ringbom (1963).

The carboxylate or polycarboxylate builder can be momomeric or oligomeric in type although monomeric polycarbozylates are generally preferred for reasons of cost and performance.

Monomeric and oligomeric builders can be selected from acyclic, alicyclic, heterocyclic and aromatic carboxylates having the general formulae *.1 WO 92/03525 PCT/US91/05533 10

Y

R X C R 2 Z m

Y

X C z n or Y z q wherein R 1 represents H,C1- 30 alkyl or alkenyl optionally substituted by hydroxy, carboxy, sulfo or phosphono groups or attached to a polyethylenoxy moiety containing up to 20 ethyleneoxy groups; R 2 represents

H,C

1 4 alkyl, alkenyl or hydroxy alkyl, or alkaryl, sulfo, or phosphono groups; X represents a single bond; 0; S; SO; SO 2 or NR Y represents H; carboxy;hydroxy; carboxymethyloxy; or C1- 30 alkyl or alkenyl optionally substituted by hydroxy or carboxy groups; Z represents H; or carboxy; m is an integer from 1 tO n is an integer from 3 to 6; p, q are integers from 0 to 6, p q being from 1 to 6; and wherein, X, Y, and Z each have the same or different representations when repeated in a given molecular formula, and wherein at least one Y or Z in a molecule contain a carboxyl group.

Suitable carboxylates containing one carboxy group include lactic acid, glycollic acid and ether derivatives thereof L 77 WO 92/03525 PCT/US91/05533 11 as disclosed in Belgian Patent Nos. 831,368, 821, 369 and 821,370. Polycarboxylates containing two carboxy groups include the water-soluble salts of succinic acid, malonic acid, (ethylenedioxy) diacetic acid, maleic acid, diglycollic acid, tartaric acid, tartronic acid and fumaric acid, as well as the ether carboxylates described in German Offenlegenschrift 2,446,686, and 2,446,687 6nd U.S. Patent No. 3,935,257 and the sulfinyl carboxylates described in Belgian Patent No. 840,623. Polycarboxylates containing three carboxy groups include, in particular, water-soluble citrates, aconitrates and citraconates as well as succinate derivatives such as the carboxymethyloxysuccinates described in British Patent No.

1,379,241, lactoxysuccinates described in British Patent No. 1,389,732, and aminosuccinates described in Netherlands Application 7205873, and the oxypo- -:arboxylate materials such as 2-oxa-1,1,3-propane trica.boxylates described in British Patent No. 1,387,447.

Polycarboxylates containing four carboxy groups include oxydisuccinates disclosed in British Patent No. 1,261,829, 1,1,2,2-ethane tetracarboxylates, 1,1,3,3-propane tetracarboxylates and 1,1,2,3-propane tetracarboxylates.

Polycarboxylates containing sulfo substituents include the sulfosuccinate derivatives disclosed in British Patent Nos. 1,398,421 and 1,398,422 and in U.S. Patent No.

3,936,448, and the sulfonated pyrolysed citrater described in British Patent No. 1,082,179, w;hile polycarboxylates containing phosphone substituents are disclosed in British Patent No. 1,439,000.

Alicyclic and heterocyclic polycarboxylates include cyclopentane-cis,cis,cis-tetracarboxylates, cyclopentadienide pentacarboxylates, 4 WO 92/03525 PCT/US91/05533 12 2,3,4,5-tetrahydrofuran cis, cis, cis-tetracarboxylates, -cis dicarboxylates, 2,2,5,5-tetrahydrofuran tetracarboxylates, 1,2,3,4,5,6-hexane -hexacarboxylates and carboxymethyl derivatives of polyhydric alcohols such as sorbitol, mannitol and xylitol. Aromatic polycarboxylates include mellitic acid, pyromellitic acid and the phthalic acid derivatives disclosed in British Patent No. 1,425,343.

Of the above, the preferred polycarboxylates are hydroxycarboxylates containing up to three carboxy groups per molecule, more particularly citrates.

The parent acids of the monomeric or oligomeric polycarboxylate chelating agents or mixtures thereof with their salts, eg. citric acid or citrate/citric acid mixtures are also contemplated as components of builder systems useful in the present invention.

The third element of the builder system is a crystalline layered sodium silicate having the general formula NaMSixO2x+l. wherein M is sodium or hydrogen, x is a number from 1.9 to 4 and y is a number from 0 to 20. Crystalline layered sodium silicates of this type are disclosed in EP-A-0164514 and methods for their preparation are disclosed in DE-A-3417649 and DE-A-3742043. For the purposes of the present invention x, in the general formula above has a value of 2, 3 or 4 and is preferably 2. More preferably M is sodium and y is 0 and preferred examples of this formula comprise the and 6 -forms of Na 2 Si20 5 These materials are available from Hoechst AG FRG as respectively NaSKS-5, NaSKS-7, .i i 1 WO 92/03525 PCI/US91/05533 13 NaSKS-11 and NaSKS-6. The most preferred material is S-Na 2 Si20 5 NaSKS-6.

Other detergent builder materials can also form part of the builder system but are not essential elements Sthereof. Such materials can be organic or inorganic in nature.

Inorganic builder materials that can form optional elements of the builder system for the purposes of the invention include alkali metal carbonates, bicarbonates and silicates. Suitable organic materials include the organic phosphonates and amino polyalkylene phosphonates although these materials are less preferred where the minimisation of phosphorus compounds in the compositions is desired.

Other suitable water soluble organic salts are the homoor co-polymeric polycarboxylic acids or their salts in which the polycarboxylic acid comprises at least two carboxyl radicals separateL -rom each other by not more than two carbon atoms. Polymers of the latter type are disclosed in GB-A-1,596,756. Examples of such salts are polyacrylates of MWt 2000-5000 and their copolymers with maleic anhydride, such copolymers having a molecular weight of from 20,000 to 70,000, especially about 40,000. These materials are normally used at levels of from 0.5% to 10% by weight more preferably from 0.75% to most preferably from 1% to 6% by weight of the composition.

The optional buijer materials, if present, will total no more than 25% by weight of the composition normally less than 20% and most usually less than 15% by weight.

WO 92/03525 PCT/US91/05533 14 14 For the purposes of compositions in accordance with the invention, the builder system will comprise from 10% to by weight of the compositions, more preferably from to 60% by weight. Within the builder system, the sodium aluminosilicate zeolite will comprise from 20% to by weight of the mixture, the monomeric or oligomeric carboxylate will comprise from 10% to 30% by weight of the mixture and the crystalline layered silicate will comprise from 10% to 65% by weight of the mixture. More preferably the zeolite is present in an amount of from 25% to the monomeric or oligomeric carboxylate comprises from to 25% and the layered silicate from 20% to 50% by weight of the builder system. Preferably also the builder system incorporates a combination of auxiliary inorganic and organic builders such as sodium carbonate and maleic anhydride/acrylic acid copolvmers in amounts of up to Compositions in accordance with the invention can also contain up to 40% of non-surfactant non detergent builder components as optional ingredients. Anti-redeposition and soil-suspension agents, optical brighteners, soil release agents, dyes and pigments are examples of such optional ingredients and can be added in varying amounts as desired.

Anti-redeposition and soil-suspension agents suitable herein include cellulose derivatives such as methylcellulose, carboxymethylcellulose and hydroxyethylcellulose, and homo- or co-polymeric

I

rj-: WO 92/03525 PCT/US91/05533 15 polycarboxylic acids or their salts. Polymers of this type include copolymers of maleic anhydride with ethylene, methylvinyl ether, acrylic or metnacrylic acid, the maleic anhydride constituting at least 20 mole percent of the copolymer. These materials are normally used at levels of from 0.5% to 10% by weight, more preferably from 0.75% to most preferably from 1% to 6% by weight of the composition.

Other useful polymeric materials are the polyethylene glycols, particularly those of molecular weight 1060-10000, more particularly 2000 to 8000 and most preferably about 4000. These are used at levels of from 0.20% to 5% more'preferably from 0.25% to 2.5% by weight.

These polymers and the previously mentioned homo- or co-polymeric polycarboxylate salts are valuable for improving whiteness maintenance, fabric ash deposition, and cleaning performance on clay, proteinaceous and oxidizable soils in the presence of transition metal impurities.

However one advantage of compositions in accordance with the present invention is their ability to maintain the suspension of insoluble particulate solids (ash) with reduced levels of polymeric polycarboxylate builder/anti redeposition agents or even, in preferred compositions of the invention, with no polymeric iycarboxylate present.

Thus a level of polymeric polycarboxylate of 5% in conventional products can be halved, i.e. to 2.5% with no increase in fabric ash level in compositions according to the present invention. If the polymeric polycarboxylate is removed entirely only a slight increase in fabric ash takes place in contrast to a virtual doubling of the ash level if the polymer is removed from a conventional formulation.

1 a j WO 92/03525 PC/US91/05533 16 Compositions in accordance with the invention also show robustness in hardness control in under built situations, i.e. where insufficient detergent builder is available to control all of the mineral hardness present. This benefit is believed to arise because of the ability of the ternary builder system components to redistribute the calcium and magnesium hardness ions amongst themselves in underbuilt situations, taking advantage of the enhanced affinity of the crystalline layered silicate component for magnesium ion.

t A further benefit provided by compositions in accordance with the present inventicrn s a reduction in damje to fabrics arising from the washing process. This loss is believed to arise from the interaction of heavy metal ions deposited on fabrics during the washing process with oxygen bleaches. Fabrics washed in compositions of the present invention show a level of deposition of heavy metal ions and a reduced tensile strength loss, relative to compositions in which the crystalline layered silicate component is replaced by a conventional amorphous silicate Preferred optical brighteners are anionic in character, examples of which are disodium 4 4 1 -bis-(2-diethanolamino-4-anilino triazin-6ylamino)stilbene-2:2 1 disulphonate, disodium 4, 41-bia-(2-morpholin-4-anilino-s-triazin-6 -y1aminostilbene-22 1 disulphonate, diso4ium 4, 41 bis-(2,4-dianiino-s-triazin-6-ylamino)stilben-2:2 1 disuiphonate, monosodium 41,411 -biu-(2,4-dianilinos-triazin-6-ylamino)stilbene-2-ulphonate, disodium 4,41 -bis-( 2-anilino-4-(N-methyl-N-2-hydromyethylamino)-s-triazin -6-ylamino) stailbene-2,2 1 disulphonate disodium 4,4 -bis-(4-phenyl-2,11,3-triazol-2-yl)-stilbone-2,2 disulphonate, disodium 4,4 1 bia(2-anliino-4-(1-methyl-

HI

r__ WO 92/03525 PCT/US91/05533 17 2-hydroxyethylamino)-s-triazin-6-ylamino)stilbene- 2,21disulphonate and sodium 2(stilbyl-411- (naphtho- 1 21:4,5)-1,2,3 triazole-2 11-sulphonate, Soil-release agents useful in compositions of the present invention are conventionally cogolymers or terpolymers of terephthalic acid with ethylene glycol and/or propylene glycol units in various arrangements. Examples of such polymers are disclosed in the commonly assigned US Patent Nos. 4116885 and 4711730 and European Published Patent Application No. 0272033. A particular preferred polymer in accordance with EP-A-0272033 has the formula

(CH

3

(PEG)

43 )07 (POH)0. [T-PO)2 (T-PEG) 0 4 ]T(PO-8)0.

2

((PEG)

43

CH

3 )0.75 where PEG is -(OC2H 4 0)0-PO is (OC H 0) and T is (pcOC H CO).

2.R4 3 66 4 Certain polymeric materials such as polyvinyl pyrrolidones typically of MWt 5000-20000, preferably 10000-15000, also form useful agents in preventing the transfer of labile dyestuffs between fabrics during the washing process.

Another optional but highly preferred ingredient is a particulate inorganic perhydrate bleach. Any particulate inorganic perhydrate bleach can be used, in an amount of from 3% to 40% by weight, more preferably from 8% to by weight and moat preferably from 12% to 20% by weight of the compositions, Preferred examples of such bleaches are sodium perborate monohydrate and tetrahydrate and mixtures thereof.

Another preferred ingredient is a peroxy carboxylic acid bleach precursor, commonly referred to as a bleach activator, which is preferably added in a prilled or agglomerated form. Examples of suitable compounds of this type are disclosed in British Patent is, 1586769 and 2143231 and a method for their formation into a prilled form is described in European Published Patent Application No. 0062523. Preferred examples of such compounds are tetracetyl ethylene diamine and sodium 3, 5, 5 trimethyl hexanoyloxybenzene sulphonate.

-18 Bleach activators are normally employed at levels of from to 10% by weight l more frequently from 1% to 8% and preferably from 2% to 6% by weight of the composition.

Another optional ingredient is a suds suppressor, exemplified by silicones, and silica-silicone mixtures.

Silicones can be generally represented by alkylated polysiloxane materials while silica is normally used in finely divided forms, exemplified by silica aerogels and xerogels and hydrophobic silicas of various types. These materials can be incorporated as particulates in which the suds suppressor is advantageously releasably incorporated in a water-soluble or water-dispersible, substantially non-surface-active detergent-impermeable carrier.

Alternatively the suds suppressor can be dissolved or dispersed in a liquid carrier and applied by spraying on to one or more of the other components.

As mentioned above, useful silicono suds controlling agents can comprise a mixture of an alkylated siloxane, of the type referred to hereinbefore, and solid silica. Such mixtures are prepared by affixing the silicone to the surface of the solid silica. A preferred silicone suds controlling agent is represented by a hydrophobic silanated (most preferably trimethyl-silanated) silica having a particle size in the range from 10 nanometers to nanometers and a specific surface area above 50 m"/g, intimately admixed with dimethyl silicone fluid having a molecular weight in the range from about 500 to about 200,000 at a weight ratio of silicone to silanated silica of from about 1:1 to about 1:2.

A preferred silicone suds controlling agent is disclosed in Bartollota et al. U.S. Patent 3,933, 672. Other particularly useful suds suppressors are the self-emulsifying silicone suds suppressors, described in t' F WO 92/03525 PCIUS91/05533 19 German Patent Application DTOS 2,646,126 published April 28, 1977. An example of such a compound is DC-544, commercially availably from row Corning, which is a siloxane/glycol copolymer.

The suds suppressors described above are normally employed at levels of from 0.001% to 0.5% by weight of the composition, preferably from 0.01% to 0.1% by weight.

The preferred methods of incorporation comprise either application of the suds suppressors in liquid form by spray-on to one or more of the major components of the composition or alternatively the formation of the suds suppressors into separate particulates that can then be mixed with the other solid components of the composition.

The incorporation of the suds modifiers as separate particulates also permits the inclusion therein of other suds controlling materials such as C 20

-C

24 fatty acids, microcrystalline waxes and high MWt copolymers of ethylee oxide and prCpylene oxide which would otherwise adversely affect the dispersibility of the matrix. Techniques for forming such suds modifying particulates are disclosed in the previously mentioned Bartolotta et al U.S. Patent No.

3,933,672, Another optional ingredient useful in the present invention is one or more enzymes.

Preferred enzymatic materials include the commercially availably amylases, neutral and alkaline proteases, lipases, esterases and cellulases conventionally incorporated into detergent compositions. Suitable enzymes are discussed in U.S. Patents 3,519,570 and 3,533,139.

Fabric softening agents can also be incorporated into detergent compositions in accordaince with the present invention. These agents may be inorganic or organic in type. Inorganic softening agents are exemplified by the WO 92/03525 PCT/US91/05533 20 smectite clays disclosed in GB-A-1,400,898. Organic fabric softening agents include the water insoluble tertiary amines as disclosed in GB-A-1514276 and EP-B-0011340.

Their combination with mono C 12

-C

14 quaternary ammonium salts is disclosed in EP-B-0026E27 528. Other useful organic fabric softening agents are the dilona chain amides as disclosed in EP-B-0242919. Additional organic ingredients of fabric softening systems include high molecular weight polyethylene oxide materials as disclosed in EP-A-0299575 and 0313146.

Levels of smectite clay are normally in the range from to 15%, more preferably from 8% to 12% by weight, with the material being added as a dry mixed component to the remainder of the formulation. Organic fabric softening agents such as the water-insoluble tertiary amines or dilong chain amide materials are incorporated at levels of from 0.5% to 5% by weight, normally from 1% to 3% by weight, whilst the high molecular weight polyethylene oxide materials and the water soluble cationic materials are added at levels of from 0.1% to normally from 0.15% to by weight. Where a portion of the composition is spray dried, these materials can be added to the aqueous slurry fed to the spray drying tower, although in some instances it may be more convenient to add them as a dry mixed particulate, or spray them as a molten liquid on to o -er solid components of the composition.

SThe compositions of the invention can be made via a variety of methods including dry mixing, spray drying, agglomeration and granulation and preferred methods involve combinations of these techniques. A preferred method of makinrg the compositions involves a combination of spray drying, agglomeration in a high speed mixer and dry mixing.

Preferred detergent compositions in accordance with the invention also comprise at least two particulate multiingredient components. The first component comprises at "i 1 i WO 92/03525 PCT/US91/05533 21 least 20%, conventionally from 30% to 70%, but more preferably no more than 40% by weight of the composition and the second component from 1% to 50%, more preferably to 40% by weight of the composition.

The first component comprises a particulate incorporating an anionic surf,' tant in an amount of from 0.75% to 35% by weight of the powder and one or more inorganic and/or organic salts in an amount of from 99.25% to 65% by weight of the powder. The particulate can have any suitable form such as granules, flakes, prills, marumes or noodles but is preferably granular. The granules themselves may be agglomerates formed by pan or drum agglomeration or by inline mixers but are preferably spray dried particles produced by atomising an aqueous slurry of the ingredients in a hot air stream which removes most of the water. In certain processes, the spray dried granules forming the first component may themselves be subjected to densification steps, eg. by high speed cutter mixers, to increase density before being reagglomerated. For illustrative purposes, the first component is described hereinafter as a spray dried powder as this constitutes a preferred embodiment of the invention.

An important characteristic of the principal anionic surfaetant in the first component is that it should have a low rate of solubility in aqueous media at the water temperatures th'a prevail during the fill step of the wash cycle in an automatic washing machine. With respect to European wash habits the water temperature during the fill step is predominantly in the range from 5*C to 20*C, more usually from 70C to 12*C.

Suitable anionic surfactants for the purposes of the first component have been found to be linear alkyl sulfate salts io which the alkyl group has an average of from 16 to 22 carbon atoms, and linear alkyl carboxylate salts in which the alkyl group has an average of from 16 to 24 csCbon atoms.

I

J'

WO 92/03525 PCT/US91/05533 2 I The alkyl groups for both types of surfactant are preferably derived from natural fats such as tallow.

Shorter chain alkyl sulfates or carboxylates, in which the alkyl group is derived from sources comprising a mixture of alkyl moieties more than 40% of which contain 14 or less carbon atoms, are less suitable as they cause the first component to form a gel like mass during dissolution.

The level of anionic surfactant in the spray dried powder forming the first component is from 0.75% to 40% by weight, more usually 2.5% to 25% preferably from 3% to 20% and most preferably from 5% to 15% by weight. Water-soluble surfactants auch as linear alkyl benzene sulphonates can be included or alterdatively may be applied subsequently to the spray diied powder by spray on.

The other major ingredient of the spray dried powder is one or'more inorganic or organic salts that provide the crystalline structure for,the granules. The inorganic and/or organic silts may be water-soluble or waterinsoluble, the latter type being comprised by the, or the major part of the, water-insoluble builders where these form part of the builder system. Suitable water soluble inorganic salts include the alkali metal carbonates, bicarbonates, sulphates and borates. Alkali metal silicates can also be present in the spray dried granule provided that aluminosilicate does not form part of the spray dried component.

It is preferred that at least part of the aluminosilicate builder be incorporated into the spray dried granule and, as indicated above, where this takes place, any silicate present should not form part of the spray dried component.

in these circumstances incorporation of the silicate can be achieved in several ways, e.g. by producing a separate WO 92103525 PCT/US91/05533 23 silicate containing spray dried particulate, by incorporating the silicate into an agglomerate of other ingredients, or more preferably by adding the silicate as a dry mixed solid ingredient.

Any of the previously mentioned optional builder salts can also be incorporated in the spray dried powder forming the first component. The spray dried powder can also include some or even all of the water soluble monomeric or oligomeric carboxylate chelating agent but this is less preferred as it tends to inhibit the rapid solution of this ingredient. The organic and/or inorganic salts comprise from 60% to 90% by weight of the first component, more preferably from 70% to 90% and most preferably from 75% to 854 by weight.

The spray dried powder also normally contains up to 15% by weight of miscellaneous ingredients.

In preferred compositions where the first component is a spray dried powder, optional ingredients included in the first component should be heat stable to the extent necessary to withstand the temperatures encountered in the spray drying process. Where the first component is a spray dried powder it will normally be dried to a moistUre content of from 7% to 11% by weight, more preferably from 8% to 10% by weight of the spray dried powder. Moisture contents of powders produced by other processes such as I agglomeration may be lower and can be in the range 1-10% by weight.

i w WO 92/03525 PCT/US91/05533 .4 The particle size of the first component is conventional and preferably not more than 5% by weight should be above 1.4 mm, while not more than 10% by weight should be less than 0.15 mm in maximum dimension. Preferably at least and most preferably at least 80% by weight of the powder lies between 0.7 mm and 0.25 mm in size. For spray dried powders, the bulk density of the particles should lie in the range from 350 g/litre to 650g/litre but is conventionally in the range from 540 to 600 g/litre. Bulk densities in the upper part of the range from 600-650 g/litre are particularly useful where production of so called concentrated products is desired. Bulk densities above this range may be produced if the spray dried powder is subjected to further processing steps such as size reduction in a high speed cutter/mixer followed by compaction. Alternatively, processes other than spray drying may be used to form the powder.

A second component of a preferred composition in accordance with the invention is a particulate containing a water soluble surfactant.

This may be anionic, nonionic, cationic or semipolar in type or a mixture of any of these. Suitable surfactants are listed hereinbefore but preferred surfactants are linear C 11

-C

15 alkyl benzene sulfonates and fatty

C

14

-C

18 methyl ester sulponates.

The second component may have any suitable physical form i.e. it may take the fovm of flakes, prills, marumes, noodles, ribbons, or grinules which may be spray-dried or non spray-dried agglomerates. Although the second component could in theory comprise the water soluble surtactant on its own, in practice at least one organic or inorganic salt is included to facilitate processing. This L. WO 92/03525 PCT/US91/05533 25 provides a degree of crystallinity, and hence acceptable flow characteristics, to the particulate and may be any one or more of the organic or inorganic salts present in the first component.

The particle size range of the second component is not critical but should be such as to obviate segregation from the particles of the spray dried first component when blended therewith. Thus not more than 5% by weight should be above 1.4 mm while not more than 10% should be less than 0.15 mm in maximum dimension.

The bulk .nsity of the second component will be a function of its mode of preparation. Thus, in spray dried granular form the second component may have a density of from 350 g/litre to 650 g/litre but more preferably will be in the range from 500 g/litre to 630 g/litre. The preferred form of the second component however is a mechanically mixed agglomerate which may be made by adding the ingredients dry or with an agglomerating agent to a pan agglomerator, Z blade mixer or more preferably an in-line mixer such as those manufactured by Schugi (Holland) BV, 29 Chroomstraat 8211 AS, Lelystad, Netherlands and Gebruder Lodige Maschinenban GmbH, D-4790 Paderborn 1, Elsenerstrasse 7-9, Postfach 2050 F.R.G. By this means the second component can be given a bulk density in the range from 650 g/litre to 1190 g/litre more preferably from 750 g/litre to 850 g/litre. This is particularly useful in formulating the so called 'concentrated' products.

WO 92/03525 PCT/US91/05533 -26 Preferred compositions include a level of alkali metal carbonate in the second component corresponding to an amount of from 3% to 15% by weight of the composition, more preferably from 5% to 12% by weight. This will provide a level of carbonate in the second component of from 20% to by weight.

A highly preferred ingredient of the second component is also a hydrated water insoluble aluminosilicate ion exchange material of the synthetic zeolite type, described hereinbefore, present at from 10% to 35% by weight of the second component. The amount of water insoluble aluminosilicate material incorporated in this way is from 1% to 10% by weight of the composition, more preferably 7rom 2% to 8% by weight. If the second component is spray dried, it is important that it does not contain both silicate and aluminosilicate ingredients for the reasons stated hereinbefore. In such circumstances, the silicate may be incorporated in the first component or, if that also contains aluminosilicate, may be added as a solid, together with other dry mixed materials, to the first and second components.

In one process for preparing the second component, the surfactant salt is formed in situ in an inline mixer. The liquid acid form /of the surfactant is added to a mixture of particulate anhydrous sodium carbonate and hydrated sodium aluminosilicate in a continuous high speed blender such as i a Lodige KM mixer and neutralised to form the surfactant salt whilst maintaining the particulate nature of the mixture. The resultant agglomerated mixture forms the second component which is then added to other components of the product. In a variant of this process, the surfactant salt is pte-neutralised and added as a viscous paste to the mixture of the other ingredients. In this variant, the mixer serves merely to agglomerate the ingredients to form the second component.

WO 92/03525 PCT/US91/05533 27 In a particularly preferred process for making compositions in accordance with the invention, part of the spray dried product comprising the first granular component is diverted and subjected to a low level of nonionic surfactant spray on before being reblended with the remainder. The second granular component is made using the preferred process described above. The first and second components together with other dry mix ingredients such as the carboxylate chelating agent, inorganic perocygen bleach, bleach activator, soil-release polymer, silicate and enzyme are then fed to a conveyor belt, from which they are transferred to a horizontally rotating drum in which perfume and silicone suds suppressor are sprayed on to the product. In highly preferred compositions, a further drum mixing step is employed in which a low (approx. 2% by weight) level of finely divided crystalline aluminosilicate is introduced to increase density and improve granular flow characteristics.

Compositions in accordance with the invention can also benefit from delivery systems that provide transient localised high concentrations of product in the drum of an automatic washing machine at the start of the wash cycle, i thereby also avoiding problems associated with loss of product in the pipework or sump of the machine.

Delivery to the drum can most easily be achieved by incorporation of the composition in a bag or container from which it is rapidly releasable at the start of the wash cycle in response to agitation, a rise in temperature or immersion in the wash water in the drum. Alternatively the washing machine itself may be adapted to permit direct addition of the compostion to the drum e.g. by a dispensing arrangement in the access door.

ii It/ WO 92/03525 PCT/US91/05533 28 Products comprising a detergent composition enclosed in a bag or container are usually designed in such a way that container integrity is maintained in the dry state to prevent egress of the contents when dry, but are adapted for release of the container contents on exposure to a washing environment, normally on immersion in an aqueous solution.

Usually the container will be flexible, such as a bag or pouch. The bag may be of fibrous construction coated with a water impermeable protective material so as to retain the contents, such as is disclosed in European published Patent Application No. 0018 4 678. Alternatively it may be formed of a water-insoluble synthetic polymeric material provided with an edge seal or closure designed to rupture in aqueous media as disclosed in European published Patent Application Nos. 0011500, 0011501, 0011502, and 0011968. A convenient form of water frangible closure comprises a water soluble adhesive disposed along and sealing one edge of a pouch formed of a water impermeable polymeric film such as polyethylene or polypropylene.

In a variant of the bag or container product form, laminated sheet products can be employed in which a central flexible layer is impregnated and/or coated with a composition and then one or more outer layers are applied

I

to produce a fabric-like aesthetic effect. The layers may be sealed together so as to remain attached during use or may separate on contact with water to facilitate the release of the coated or impregnated material.

An alternative laminate form comprises one layer embossed or deformed to provide a series of pouch-like containers into each of which the detergent component, are deposited 4, WO 92/03525 PCT/US91/05533 -29in measured amounts, with a second layer overlying the first layer and sealed thereto in those areas between the pouch-like containers where the two layers are in contact. The components may be deposited in particulate, paste or molten form and the laminate layers should prevent egress of the contents of the pouch-like containers prior to their addition to water. The layers may separate or may remain attached together on contact with water, the only requirement being that the structure should permit rapid release of the contents of the pouch-like containers into solution. The number of pouch-like containers per unit area of substrate is a matter of choice but will normally vary between 500 and 25,000 per square metre.

Suitable materials which can be used for the flexible laminate layers in this aspect of the invention include, among others, sponges, paper and woven and non-woven fabrics.

However the preferred means of carrying out the process of the invention is to introduce the composition into the liquid surrounding the fabrics that are in the drum via a reusable dispensing device having walls that are permeable to liquid but impermeable to the solid composition. j Devices of this kind are disclosed in European Patent Application Publication Nos. 0343069 0343070. Th latter Application discloses a device comprising a flexible sheath in the form of a bag extending from a support ring defining an orifice, the orifice being adapted to admit to the bag sufficient product for one washing cycle in a washing cycle. A portion of the washing medium flows through the orifice into the bag, dissolves the product, and the solution then passes outwardly through the orifice into the WO 92/03525 PCT/US9I/0533 30 washing medium. The support ring is provided with a masking arrangement to prevent egress of wetted, undissolved, product, this arrangement typically comprising radially extending walls extending from a central boss in a spoked wheel configuration, or a similar structure in which the walls have a helical form.

WO 92/03525 PCT/US91/05533 31 The invention is illustrated in the followi g non limiting Examples, in which all percentages are on a weight basis unless otherwise stated.

In the detergent compositions, the abbreviated component identifications have the following meanings:.

C

12 LAS Sodium linear C12 alkyl benzene sulphonate TAS Sodium tallow alcohol sulphate

C

1 4/ 1 5 AS Sodium C 14

-C

15 alkyl sulphate TAEn Tallow alcohol ethoxylated with n moles of ethylene oxide per mole of alcohol 45E7 A C 4

-C

15 predominantly linear primary alcohol condensed with an average of 7 moles of ethylene oxide CnAEE 6 .5 A C 12

-C

13 primary alcohol condensed with 6.5 moles of ethylene oxide.

PEG Polyethylene glycol (MWt normally follows) TAED Tetraacetyl ethylene Diamine Silicate Amorphous Sodium silicate (SiO 2 :Na20 ratio normally follows) NaSKS-6 Crystalline layered silicate of formula S -Na2Si 2 0 Carbonate Anhydrous sodium carbonate CMC Sodium carboxymethyl cellulose Zeolite A Hydrated Sodium Aluminosilicate of formula Na 1 2 (A10 2 Si0 2 1 2 27H 2 0 having a primary particle size the range from 1 to 10 micrometers Polyacrylate Homopolymer of acrylic acid of MWt 4000 Citrate Sodium citrate trihydrate WO 92/03525 Photoactivated Bleach

MA/AA

MVEMA

Perbor ate Perborate ionohydrate Enzyme Brightener PCT/US91/05533 -32- Tetra suiphonated Zinc phtha locyanine Copolymer of 1:4 rnaleic/acrylic acid, average molecular weight about 80,000.

Maleic anhydride/vinyl methyl ether copolymer, believed to have an average molecular weight of 240,000.

This material was prehydrolysed with NaQH before addition.

Sodium perborate tetrahydrate of nominal formula NaBO V 3H 2 .H 2 0 2 Anhydrous sodium perborate bleach empirical formula NaBO 2 'H 2 0 2 M4,xed proteolytic and amylolytic enzyme sold by Novo Industrie AS.

Disodium 4#4'-bis(2-mrorpholino-4anilino-,s-triazin-6-ylamino) stilbenet,2 :21-disulphonate.

Diethylene triamine peinta (methylene phosphornic acid), marketed by M4onsanto under the Trade name Dequest 2060 25% paraffin wax Mpt 50 0 C, 17% hydrophobic silica, 58% paraffin oil.

DETPMP

Mixed Suds Suppressor

V

WO 92/03525 PL-T/US91/05533 33 EXAMPLE I The granular deterg9ent products were prepared having compositions as shown below in parts by weight.

C 1 2

LAS

TAS

4 5E7 TA1 Zeolite A Na-SKIS-6 Citrate

MA/AA

TAED

Perborate Perborate rnonohydrate

DETPMP

Enzyme Silicate (2.0 ratio) Carbonate Suds suppressor

C?'C

Photo.activated bleach Perfume Brightener Moisture Misc.

4.4 4.0 3.7 1. 1 18.2 9 .25 4.9 5.0 10.0 6.0 0 .19 1.40 4 0 15 .5 0 .55 0.8 20 ppm 0.43 0.4 10.34 4.4 3.7 1.1.

111O 4.9 10.0 0.19 1.40 0.55 0.8 20 ppm 0.43 0.24 6.29 Both prod% cts were made by a combination of spray dryings agglomeration and dry mixing techniques. A spray dried powdar was made incorporating all of the TAS, app.-oximately one quarter of th6j LAS, all of the Maleic anhydride/acrylic acid copolymier# DETPMP, CMC and !j 1 1 l I WO 92/03525 PCT/US91/05533 Sbrightener and part of the carbonate and eolite builders. For Product A approximately 82% of the zeolite and 65% of the carbonate were included in the spray dried portion, while for Product B approximately 60% of the Izeolite and 45% of the carbonate were added in this way.

The spray dried product was passed through a Lodige KM high speed mixer/cutter and the 45E7 nonionic was sprayed on to the granules. The treated granules were then transferred to a conveyor belt. The remainder of the LAS, carbonate and zeolite were processed in a Lodige KM high speed mixer to form agglomerated particles which were fed to the conveyor belt. The other dry solid ingredients viz, the :'itrat., silicate, perborate and bleach activator were also added to the belt at the same time. Firnally the mixei particulates were subjected to a low intensity blending step in a I t drum, during which step the perfum and suds suppressor were sprayed on to the particulates to form the finished product, These products were then compared in a split bundle wavh testing programme to enable the assessment of cleaning and stain removal performance. The test programme was designed, and contained sufficient replicates, to permit statistical treatment of the results. Product A was used in an amount of 95g per load whereas Product B was used in an amount of 79g per load. The difference reflected the hihe concentration Lxf ingredients per 100 parts of Product B and thus the need to use less weight in order to provide the same levels of non builder ingredients. The test programme used AEG Lavamat 980 automatic washing machines set to the No. 2 cycle. The machines were Scharged with water of 250 German Hardness having a 3:1 Ca:Mg ratio Testio. e ng was carried out at three IpSK' WO 92/03525 PCT/US91/05533 35 temperatures, viz. 40°C, 60°C and 95°C, for which respectively, fabric loads of 1.81 kg 2.25 kg, and 2.72 kg were employed. Each load comprised a mixture of naturally soiled white cotton fabric articles together with swatches soiled with a variety of stains viz. greasy, clay soil, enzymatic and bleachable, to permit the assessment of whiteness and stain removal performance.

Each swatch comprised half of a pair, the other half being washed in the same machine using the comparison product.

Aft'er washing, the fabrics were dried at ambient temperature and were then subjected to panelling by expert judges using a 1-5 Scheffe scale to characterise differences in whiteness and stain removal performance between Products A and B at the selected temperatures.

The panelling showed significant advantages for Product B over Product A on greasy and clay stains at 40 0 C and on clay stains at 95°C, the overall stain removal performance of the products being otherwise statistically indistinguishable. Useful performance advantages therefore exist for a composition incorporating a builder system in accordance with the present invention over a pricl art composition. Moreover, such advantages can be obtained with a significant reduction (13.0 parts) in the level of builder ingredients.

i h I.- WO 92/03525 PCT/US91/05533 36- EXAMPLE II A comparison of the amount of deposited inorganic material on fabrics subjected to multiple washes r s made between Product B in Example I and a non-phosphate laundry detergent (UK Ariel Ultra manufactured in UK by Procter Gamble Limited).

The washing conditions comprised the mainwash cycle of a Miele Hydromatic W698 (Ca:Mg 3:1) and a wash temperature of 95 0 C. Each product was used to wash a load comprising 2.72 kg of new cotton terry towelling fabric and the respective washed loads were then subjected to a further 14 complete wash cycles.

A sample of the fabric from each load was then Weighed, I incinerated and the residue weighed to provide a value for the inorganic material deposited during the wash cycles.

Results were as follows: Product Dosage/wash Ash (wt%) Ariel Ultra 125g 0.698% Product B 102g 0.483% The results indicate that compositions in accordance with the invention produce lower levels of inorganic salt deposition than those obtained with con~ercially available non-phosphate detergent products.

WO 92/03525 PCT/US91/05533 -37 EXAMPLE III The following composition is in accordance with the invention and is made in the same manner as product B of Example I.

C LAS 6.80 12 TAS 2.20 45E7 3.27

TAE

1 3 1.00 Zeolite A 13.00 NaSKS 6 11.00 Citrate 6.00 MA/AA 4.25 Carbonate 9.00 TAED 5.00 Perborate Monohydrate 12.50 DETPMP 0.19 Enzyme 1.20 CMC 0.48 Photactivated Bleach 20 ppm Brightener 0.24 Suds Suppressor 0.49 Perfume 0.43 Moisture Misc. 8.70 j1 7- i WO 92/03525 PCT/US91/0S533 EXAMPLE IV Three detergent products C,D E were prepared in the manner of, and having compositions identical to, Composition B of Example I other than the builder system differences shown below (values are in parts by weight in the composition).

Zeolite A Citrate NaSKS6 Silicate (2.0 Ratio)*

MA/AA

C

13.0 6.0 11.0

D

13.0 6.0 11.0

E

13.0 13.75 4.25 2.0 *supplied as 80% active, providing 11.0 parts on an anhydrous basis The products were used to conduct full scale washing machine tests in which terry towelling cotton swatches were included with 4 Kg of clean fabric ballast loads and subjected to multiple wash cycles to determine the levels of heavy metal ions (Fe Mn) and total ash (inorganic salts) building up on the fabrics after repeated washing. A heavy metal ion 'spike' of 2.5 ppm Fe as FeCI3 and 0.2 ppm Mn as MnCl2 was added to the water fed to the machines.

The wash conditions were Machine Type Machine Cycle Water Hardness Artificial Soil Miele Hydromatic W698 95 0 C Cotton Newcastle upon Tyne (UK) City Water adjusted to give 250 German Hardness with Ca:Mg ratio of 3:1. (This water source typically contains 0-3ppm Cu).

20g/load of a mixture made up of Palmitic Acid 250g Stearic Acid 250g Garden Clay 200g Dirty Motor Oil 150g Glyceryl trioleate 150g Iron Oxide (Fe203) 5.36g WO 92/03525 PCT/US91/05533 -39- The swatches are subjected to 25 wash cycles and then analysed for heavy metal ion content (ppm) and total inorganic salt content (ash).

The latter required the burning of a weighed terry towelling fabric swatch in a flame for 3 minutes followed by calcination at 800 0 C for 2 1/2 hours. The ash was then analysed for the elements below and reported as a fraction of the original sample weight.

Results were as follows: C D E Fe ppm 8.8 9.9 27.2 Mn ppm 1.9 3.5 12.4 Cu ppm 1.4 2.3 Ca+Mg% 0.42 0.46 1.05 Si Al% 0.18 0.27 0.49 It can be seen that cotton fabrics washed in Products C D, comprising compositions in accordance with the invention, display similar ash and heavy metal ion contents. However Composition D contains a level of polymeric polycarboxylate auxiliary builder which is 50% of that used conventionally, showing that the use of the ternary builder system of the invention provides enhanced robustness to detergent compositions.

The results for Products C D, when compared with those of Comparative Product E, also show the reduction in the level of deposited inorganic salts (ash) arising from the use of the ternary builder system relative to prior art builder systems. More particularly, the comparision of Products C D with Product E shows the significant reduction in heavy metal ion levels on fabrics resulting from use of the compositions of the invention. Fabric heavy metal ion content can be directly correlated with Tensile Strength Loss in fabrics which is believed to arise from catalytic decomposition of inorganic perhydrate bleaches on the surface of the fabrics.

Claims (14)

1. A particulate detergent composition including: from 5% to 50% by weight of an organic surfactant selected from the group consisting of anionic, nonionic, ampholytic and cationic surfactants and mixtures of any thereof; from 10% to 95% of a detergent builder system including a mixture of from 20% to 60% by weight of the mixture of a sodium aluminosilicate zeolite; (ii) from 10% to 30% by weight of the mixture of a water soluble chelating agent selected from the group consisting of monomeric and oligomeric organic carboxylates and mixtures thereof; and (iii) from 10% to 65% by weight of the mixture of a crystalline layered sodium silicate having the composition NaMSixO2x+l.yH 2 0, wherein M is sodium or hydrogen, x is a number from 1.9 to 4 and y is a number from 0 to and -li 20 from 0 to 40% of non-surfactant, non-builder detergent ingredients.

2. A particulate detergent composition according to claim 1 wherein, in component (iii), x has a value of 2. S 25 3. A detergent composition according to either claim 1 or claim 2 wherein, in component (iii), M is sodium.

4. A detergent composition according to anyone of claims 1 to 3 wherein the component (iii) is a, P3, or 8 -Na 2 Si 2 Os. 41 A detergent composition according to any one of claims 1 to 4 wherein the sodium aluminosilicate zeolite is a hydrated synthetic zeolite having a Calcium ion exchange capacity of at least about 200 mg eq CaCO 3 water hardness per g of zeolite calculated on an anhydrous basis.

6. A detergent composition according to claim 5 wherein the synthetic hydrated zeolite has a unit cell formula Naz[AlO 2 )z(SiO 2 wherein z y are at least 6, the ratio of z to y is from 1.0 to 0.5 and x is at least preferably from 7.5 to 276.

7. A detergent composition according to any one of claims 1 to 6 wherein the sodium aluminosilicate zeolite is hydrated Zeolite A, X, B or HS.

8. A detergent composition according to any one of claims 1 to 7 wherein the organic carboxylate chelating agent has a first carboxyl logarithmic acidity constant (pkl) of less than about 9.

9. A detergent composition according to any one of claims 1 to 8 wherein the organic carboxylate chelating agent has a pkl of from about 2 to about S 10. A detergent composition according to any one of claims 1 to 9 wherein the organic carboxylate chelating agent includes a monomeric polycarboxylate having a pkl of from about 4 to about S 11 A detergent composition according to claim 10 wherein the monomeric polycarboxylate includes an aliphatic monomeric polycarboxylate containing from i 30 2 to 4 carboxyl groups.

12. A particulate detergent composition including Eft. 1 -wnbw 42 from 5% to 50% by weight of an organic surfactant selected from the group consisting of anionic, nonionic, ampholytic and cationic surfactants and mixtures of any thereof: from 10% to 95% of a detergent builder system including a mixture of from 20% to 60% by weight of the mixture of a synthetic sodium aluminosilicate zeolite having the unit cell formula Naz[AIO 2 )z(SiO 2 wherein z y are at least 6, the ratio of z to y is from 1.0 to 0.5 and x is at least 5, preferably from 7.5 to 276. (ii) from 10% to 30% by weight of the mixture of a water soluble aliphatic monomeric polycarboxylate chelating agent containing from 2 to 4 carboxyl groups and having a pkl of from 4 to 7.5; and (iii) from 10% to 65% by weight of the mixture of a crystalline layered sodium silicate having the formula 6 -Na 2 SisOs; and from 0 to 40% of non-surfactant, non-builder detergent ingredients. S 13. A detergent composition according to claim 12 including from about 5% to about 30% of component from about 20% to about 60% of component b) and from about 20% to about 40% of other detergent ingredients.

14. A detergent composition according to either claim 12 or claim 13 wherein the water soluble aliphatic monomeric polycarboxylate chelating agent is selected 30 from citric acid, a water soluble citrate salt and mixtures thereof. A detergent composition according to any one of claims 12 to 14 wherein S component also includes an auxiliary builder. 43 'I

16. A detergent composition according to claim 15 wherein the auxiliary builder is selected from the group consisting of water soluble amino poly alkylene phosphonates, alkali metal carbonates and bicarbonates, homo-/or copolymeric polycarboxylic acids and their salts in which the polycarboxylic acid comprises at least two carboxyl radicals separated from each other by not more than two carbon atoms, and mixtures of any thereof.

17. A detergent composition according to any one of claims 12 to 16 wherein component incudes an oxygen bleach.

18. A detergent composition according to claim 17 wherein the oxygen bleach is an inorganic perhydrate.

19. A detergent composition according to either claim 17 or claim 18 wherein the oxygen bleach includes an organic peroxy acid precursor. A detergent composition according to any one of claims 12 to 19 wherein component includes a detergent enzyme. "21. A method of p, eparing a particulate detergent composition including i i i from 5% to 50% by weight of an organic surfactant selected from the group consists of anionic, nonionic, ampholytic and cationic surfactants and mixtures of r'y thereof; from 10% to 95% of a detergent builder system including a mixture of from 20% to 60% by weight of the mixture of a synthetic sodium I 30 aluminosilicate zeolite having the unit cell formula i Naz[(A!O 2 )Z(SiO 2 )V].xH 2 O 1 44 wherein z y are at least 6, the ratio of z to y is from 1.0 to 0.5 and x is at least 5, preferaoly from 7.5 to 276. (ii) from 10% to 30% by weight of the mixture of a water soluble aliphatic monomeric poly carboxylate chelating agent containing from 2 to 4 carboxyl groups and having a pkl of from 4 to 7.5; and (iii) from 10% to 65% by weight of the mixture of a crystalline layered sodium silical having the formula 8 -Na 2 Si 2 Os; and from 0 to 40% of non-surfactant, non-builder detergent ingredients wherein the crystalline layered sodium silicate (iii) is added as a finely divided particulate solid to one or more granular solids including component component (ii) and, if present, component at least one of said granular solids comprising a multicomponent mixture, present in an amount of at least 20% by weight of the composition.

22. A method of preparing a particulate detergent composition according to claim 21 20 including the steps of I spray drying a first granular solid, comprising from about 30% to about of the composition said component consisting essentially of from about 0.75% to about 35% by weight of an anionic surfactant and from about 65% to about 99.25% of a salt selected from the group consisting of the synthetic aluminosilicate zeolite and other inorganic and organic detergent builder salts; (ii) preparing a second granular solid, including from about 1% to about by weight of the composition and consisting essentially of an agglomerated mixture of anionic surfactant, synthetic aluminosilicate _zeolite and other inorganic detergent builder salts; (iii) forming and admixture of said first and second granular solids; and (iv) adding thereto said water soluble aliphatic monomeric carboxylate chelating agent and said crystalline layered sodium silicate as seps;ate particulates, 23, A particulate detergent composition according to either claim 1 or claim 12 substantially as hereinbefore described with reference to any one of the examples. DATED 13 June, 1995 PHILLIPS ORMONDE FITZPATRICK Attorneys for: THE PROCTER AND GAMBLE COMPANY N- p S e INTERNATIONAL SEARCH REPORT International Application No, PCT/iUS9l/05533 I. CLASSIFICATION OF SUBJECT MATTER (it several classification symbols apply, Indicate all) Accoruin to International Patent Classification (IPC) or to both National Classification and IPC IPC( C)11iD 1/08; 3/12; 3/395, 7/54; 9/18 US 252/95; 135; 140; 174.12 174.24; 174.25 Dig. 12 11, FIELDS SEARCHED Minimum Documentation Searched 7 Classification System Classification Symbols Us 522/95; 135; 140; 174.12; 174.24; 174.125; Dig 12 Documentation Searched other than minimum Oocum_,iaion to the Extent that such Documents are Included In the Fields Searched aI COMPUTE SEARCH APS. CAS 1l1, DOCUMENTS CONSIDERED TO ME RELEVANTI Category Citation of Document, it with indication, where appropriate, of the relevant passages 12 Relevant to Claim No, 13 A DD 234878 AL (BERGK et 16 APRIL 1986 1-20 (see abstract) Y JSIA, 4737306 (WICHELHAUS et 12 APRIL 1988 12 (see col. 11, line 65 col, 12, line Y US,A, 4820439 (RIF17) 11 APRIL 1989; 1-20 (see abstract; col.3, lines 36-55; col. 4, lines 10-14 Col. 6, lines 5-11; and claims 1 2 and Y J01-153800 (LION CORP); 15 JUNE 1989; (see abstarct) 1-20 *Special categories of cited docUmentaltO 10'T' later document published alter the International filing date docUment dlefinrip the goniral state of the art which Is o or, priority date and not in fconflict with the application but Coniee t I be ofpricireeac cited to understand the princIple or theory underlying the E"ealiro omn buto piublshe r hethe ntnal InvetioIn V ealig docmn u ulthdovtatrth nentoa "VI document of paricular rlevancel the claimed Invention Oil ngdaticannot be considered novel or cannot be considered to "ILI document which may throw doubts on priority claim(s) or involve an inventive step which is cited to establish the publication date ot another IT document of particular relevance? the claimed Invention cittio ootespcarason (as specified) cannot be considered to Involve an Inventive stop when the document referring to an oral disclosure, ukio, exhibition or document is combined with one or more other such docu. other means Monts, such Combination being obvious to a parson skilled docume~nt Published prior to the International fi'ling date but In the art, later than the priority date Claimed document member of the same paent family IV. CERTIFICATION Dotei of the Actual Completion of the Inteirnar'cnal Search Date of MallIng of this Inteffstiofl Search Report International Sea rg A uthorijty o uthorlited afficer ISA/US ERIN M. HIGGINS ForrillCTdtl0t ooM (OV.1 147) I