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
  • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
  • C11D3/39—Organic or inorganic per-compounds
  • C11D3/3947—Liquid compositions
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/66—Non-ionic compounds
  • C11D1/83—Mixtures of non-ionic with anionic 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
  • C11D17/00—Detergent materials or soaps characterised by their shape or physical properties
  • C11D17/0004—Non aqueous liquid compositions comprising insoluble particles
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
  • C11D3/16—Organic compounds
  • C11D3/20—Organic compounds containing oxygen
  • C11D3/2068—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
  • C11D1/12—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
  • C11D1/66—Non-ionic compounds
  • C11D1/72—Ethers of polyoxyalkylene glycols

Definitions

• This invention relates to preparation of liquid laundry detergent products which are non-aqueous in nature and which are in the form of stable dispersions of particulate material such as bleaching agents and/or other detergent composition adjuvants.
• Liquid detergent products are often considered to be more convenient to use than are dry powdered or particulate detergent products. Liquid detergents have therefore found substantial favor with consumers. Such liquid detergent products are readily measurable, speedily dissolved in the wash water, capable of being easily applied in concentrated solutions or dispersions to soiled areas on garments to be laundered and are non-dusting. They also usually occupy less storage space than granular products. Additionally, liquid detergents may have incorporated in their formulations materials which could not withstand drying operations without deterioration, which operations are often employed in the manufacture of particulate or granular detergent products.
• liquid detergents have a number of advantages over granular detergent products, they also inherently possess several disadvantages.
• detergent composition components which may be compatible with each other in granular products may tend to interact or react with each other in a liquid, and especially in an aqueous liquid, environment.
• Such components as enzymes, surfactants, perfumes, brighteners, solvents and especially bleaches and bleach activators can be especially difficult to incorporate into liquid detergent products which have an acceptable degree of chemical stability.
• One approach for enhancing the chemical compatibility of detergent composition components in liquid detergent products has been to formulate non- aqueous (or anhydrous) liquid detergent compositions.
• Non-aqueous liquid detergent compositions including those which contain reactive materials such as peroxygen bleaching agents, have been disclosed for example, in Hep worth et al., U.S. Patent 4,615,820, Issued October 17, 1986; Schultz et al, U.S. Patent 4,929,380, Issued May 29, 1990; Schultz et al., U.S.
• non-aqueous liquid products that have a high degree of chemical, e.g., bleach and enzyme, stability along with commercially acceptable phase stability, pourability and detergent composition laundering, cleaning or bleaching performance. Accordingly, it is an object of the present invention to provide a process for preparing non-aqueous, particulate-containing liquid detergent products
• the present invention relates to a process for preparing non-aqueous liquid detergent compositions in the form of a stable suspension of solid, substantially insoluble particulate material dispersed throughout a non-aqueous liquid phase that 95 is preferably surfactant-containing and structured.
• Such a process comprises the steps of
• the particulate components which are dried in this manner are selected from 110 anionic surfactants, peroxygen bleaching agents, bleach activators, organic detergent builders and inorganic alkalinity sources
• the particulate components range in particle size from about 0 1 to 1500 microns
• non-aqueous liquid detergent compositions prepared in accordance with the process of this invention comprise a non-aqueous, liquid phase, that is preferably structured and surfactant-containing, in which solid substantially insoluble particulate material is suspended
• a non-aqueous, liquid phase that is preferably structured and surfactant-containing, in which solid substantially insoluble particulate material is suspended
• the components of the preferred structured liquid 120 phase and the solid dispersed materials of the preferred detergent compositions prepared herein, as well as composition form, preparation steps and composition use, are desc ⁇ bed in greater detail as follows- (All concentrations and ratios are on a weight basis unless otherwise specified )
• a surfactant-containing, structured liquid phase of the compositions prepared herein will generally comprise from about 45% to 95% by weight of the detergent compositions prepared herein More preferably, this liquid phase will comprise from about 50% to 95% by weight of the compositions. Most preferably, this liquid
• the structured liquid phase of the detergent compositions prepared herein is generally formed from one or more non-aqueous organic diluents into which is mixed a surfactant structu ⁇ ng agent which is preferably a specific type of anionic surfactant-containing powder
• the major component of the structured liquid phase of the preferred detergent compositions prepared herein comprises one or more non-aqueous organic diluents
• the non-aqueous organic diluents used in this invention may be either surface
• solvent 140 active i.e , surfactant, liquids or non-aqueous, non-surfactant liquids referred to herein as non-aqueous solvents
• solvent is used herein to connote the non-aqueous liquid portion of the compositions prepared herein While some of the essential and/or optional components of the compositions prepared herein may actually dissolve in the "solvent"-contairung liquid phase, other components will be
• solvent 145 present as particulate material dispersed within the "solvent" -containing liquid phase.
• solvent is not meant to require that the solvent material be capable of actually dissolving all of the detergent composition components added thereto.
• the non-aqueous liquid diluent component will generally comprise from about
• the liquid phase of the compositions prepared herein will comprise both non-aqueous, liquid surfactants and non-surfactant non-aqueous solvents.
• Suitable types of non-aqueous surfactant liquids which can be used to form the structured liquid phase of the compositions prepared herein include the alkoxylated alcohols, ethylene oxide (EO)-propylene oxide (PO) block polymers, polyhydroxy fatty acid amides, alkylpolysaccharides, and the like.
• EO ethylene oxide
• PO propylene oxide
• liquid surfactants are those having an HLB ranging from 10 to 16. Most preferred of the surfactant liquids are the alcohol alkoxylate nonionic surfactants.
• Alcohol alkoxylates are materials which correspond to the general formula:
• Rl(C m H 2m O) n OH wherein R is a Cg - C ⁇ alkyl group, m is from 2 to 4, and n ranges from about 2 to
• R' is an alkyl group, which may be primary or secondary, that contains from about 9 to 15 carbon atoms, more preferably from about 10 to 14 carbon atoms.
• the alkoxylated fatty alcohols will be ethoxylated materials that contain from about 2 to 12 ethylene oxide moieties per molecule, more preferably from about 3 to 10 ethylene oxide moieties per molecule.
• the alkoxylated fatty alcohol materials useful in the liquid phase will frequently have a hydrophilic-lipophilic balance (HLB) which ranges from about 3 to 17. More preferably, the HLB of this material will range from about 6 to 15, most preferably from about 8 to 15.
• HLB hydrophilic-lipophilic balance
• Neodol 175 phase of the compositions prepared herein will include those which are made from alcohols of 12 to 15 carbon atoms and which contain about 7 moles of ethylene oxide. Such materials have been commercially marketed under the trade names Neodol 25-7 and Neodol 23-6.5 by Shell Chemical Company. Other useful Neodols include Neodol 1-5, an ethoxylated fatty alcohol averaging 1 1 carbon atoms in its
• Neodol 23-9 an ethoxylated primary C ⁇ - C ⁇ 2 alcohol having about 9 moles of ethylene oxide
• Neodol 91 - 10 an ethoxylated C9-C1 1 primary alcohol having about 10 moles of ethylene oxide.
• Alcohol ethoxylates of this type have also been marketed by Shell Chemical Company under the Dobanol tradename.
• Dobanol 91-5 is an ethoxylated CQ-C U
• Dobanol 25-7 is an ethoxylated C]2-C j 5 fatty alcohol with an average of 7 moles of ethylene oxide per mole of fatty alcohol.
• Suitable ethoxylated alcohols include Tergitol 15-S-7 and Tergitol 15-S-9 both of which are linear secondary alcohol ethoxylates that have
• compositions are higher molecular weight nonionics, such as Neodol 45-1 1 , which are similar ethylene oxide condensation products of higher fatty alcohols, with the higher fatty alcohol being of 14-15 carbon atoms and the number of ethylene oxide groups per mole being about 11. Such products have also been commercially marketed by Shell Chemical Company.
• alcohol alkoxylate nonionic surfactant is utilized as part of the non- aqueous liquid phase in the detergent compositions prepared herein, it will preferably be present to the extent of from about 1 % to 60% of the composition structured liquid phase. More preferably, the alcohol alkoxylate component will comprise about 5% to 40% of the structured liquid phase. Most preferably, an
• alcohol alkoxylate component will comprise from about 5% to 35% of the detergent composition structured liquid phase. Utilization of alcohol alkoxylate in these concentrations in the liquid phase corresponds to an alcohol alkoxylate concentration in the total composition of from about 1% to 60% by weight, more preferably from about 2% to 40% by weight, and most preferably from about 10% to 25% by weight,
• non-aqueous surfactant liquid which may be utilized in this invention are the ethylene oxide (EO) - propylene oxide (PO) block polymers.
• EO ethylene oxide
• PO propylene oxide
• Materials of this type are well known nonionic surfactants which have been marketed under the tradename Pluronic. These materials are formed by adding
• 215 blocks of ethylene oxide moieties to the ends of polypropylene glycol chains to adjust the surface active properties of the resulting block polymers.
• EO-PO block polymer nonionics of this type are described in greater detail in Davidsohn and Milwidsky; Synthetic Detergents, 7th Ed.; Longman Scientific and Technical (1987) at pp. 34-36 and pp. 189-191 and in U.S. Patents 2,674,619 and 2,677,700. All of 220 these publications are incorporated herein by reference.
• Pluronic type nonionic surfactants are also believed to function as effective suspending agents for the particulate material which is dispersed in the liquid phase of the detergent compositions prepared herein.
• compositions prepared herein comprises polyhydroxy fatty acid amide surfactants.
• Materials of this type of nonionic surfactant are those which conform to the formula:
• R— C-N-Z wherein R is a C9.17 alkyl or alkenyl, p is from 1 to 6, and Z is glycityl derived from a reduced sugar or alkoxylated derivative thereof.
• Such materials include the
• N-methyl N-1-deoxyglucityl cocoamide N-methyl N-1-deoxyglucityl oleamide.
• Processes for making polyhydroxy fatty acid, amides are know and can be found, for example, in Wilson, U.S. Patent 2,965,576 and Schwartz, U.S. Patent 2,703,798, the disclosures of which are incorporated herein by reference. The materials themselves and their preparation
• the amount of total liquid surfactant in the preferred surfactant-structured, non-aqueous liquid phase herein will be determined by the type and amounts of other composition components and by the desired composition properties.
• the liquid surfactant can comprise from about 35% to 70% of the non- aqueous structured liquid phase of the compositions prepared herein. More preferably, the liquid surfactant will comprise from about 50% to 65% of the non- aqueous structured liquid phase. This corresponds to a non-aqueous liquid surfactant concentration in the total composition of from about 15% to 70% by
• the structured liquid phase of the detergent compositions prepared herein may also comprise one or more non-surfactant, non-aqueous organic solvents.
• non-surfactant non-aqueous liquids are preferably those of low polarity.
• low-polarity liquids are those which have little, if any, tendency to dissolve one of the preferred types of particulate material used in the compositions prepared herein, i.e., the peroxygen bleaching agents, sodium perborate or sodium percarbonate.
• relatively polar solvents such as ethanol are 255 preferably not utilized.
• Suitable types of low-polarity solvents useful in the non- aqueous liquid detergent compositions prepared herein do include non-vicinal C4- Cg alkylene glycols, alkylene glycol mono lower alkyl ethers, lower molecular weight polyethylene glycols, lower molecular weight methyl esters and amides, and the like.
• a preferred type of non-aqueous, low-polarity solvent for use in the compositions prepared herein comprises the non-vicinal C-j-Cg branched or straight chain alkylene glycols.
• Materials of this type include hexylene glycol (4-methyl- 2,4-pentanediol), 1 ,6-hexanediol, 1,3-butylene glycol and 1,4-butylene glycol. Hexylene glycol is the most preferred.
• non-aqueous, low-polarity solvent for use herein comprises the mono-, di-, tri-, or tetra- C2-C3 alkylene glycol mono C2-Cg alkyl ethers.
• the specific examples of such compounds include diethylene glycol monobutyl ether, tetraethylene glycol monobutyl ether, dipropoiyene glycol monoethyl ether, and dipropylene glycol monobutyl ether.
• 270 monobutyl ether, dipropylene glycol monobutyl ether and butoxy-propoxy-propanol (BPP) are especially preferred.
• Compounds of the type have been commercially marketed under the tradenames Dowanol, Carbitol, and Cellosolve.
• non-aqueous, low-polarity organic solvent useful herein comprises the lower molecular weight polyethylene glycols (PEGs).
• PEGs polyethylene glycols
• 275 materials are those having molecular weights of at least about 150. PEGs of molecular weight ranging from about 200 to 600 are most preferred.
• non-polar, non-aqueous solvent comprises lower molecular weight methyl esters.
• Such materials are those of the general formula: R! -C(O)-OCH3 wherein R-- ranges from 1 to about 18. Examples of suitable lower
• methyl esters include methyl acetate, methyl propionate, methyl octanoate, and methyl dodecanoate.
• non-aqueous, generally low-polarity, non-surfactant organic solvent(s) employed should, of course, be compatible and non-reactive with other composition components, e.g., bleach and/or activators, used in die liquid detergent compositions
• Such a solvent component is preferably utilized in an amount of from about 1% to 70% by weight of the structured liquid phase. More preferably, a non-aqueous, low-polarity, non-surfactant solvent will comprise from about 10% to 60% by weight of the structured liquid phase, most preferably from about 20% to 50% by weight, of the structured liquid phase of the composition. Utilization of
• non-surfactant solvent in these concentrations in the structured liquid phase corresponds to a non-surfactant solvent concentration in the total composition of from about 1% to 50% by weight, more preferably from about 5% to 40% by weight, and most preferably from about 10% to 30% by weight, of the composition.
• the ratio of surfactant to non-surfactant liquids e.g., the ratio of alcohol alkoxylate to low polarity solvent, within the preferred structured, surfactant-containing liquid phase can be used to vary the rheological properties of
• the detergent compositions eventually formed.
• the weight ratio of surfactant liquid to non-surfactant organic solvent will range about 50:1 to 1 :50. More preferably, this ratio will range from about 3:1 to 1 :3, most preferably from about 2: 1 to 1 :2.
• the surfactant-structured non-aqueous liquid phase of the preferred detergent compositions prepared in accordance with this invention is prepared by combining with the non-aqueous organic liquid diluents hereinbefore described a surfactant which is selected to add structure to the non-aqueous liquid phase of the detergent 310 compositions prepared herein.
• Structuring surfactants can be of the anionic, nonionic, cationic, and/or amphoteric types.
• Preferred structuring surfactants are the anionic surfactants such as the alkyl sulfates, the alkyl polyalkxylate sulfates and the linear alkyl benzene sulfonates.
• anionic surfactant material which may be optionally added 315 to the detergent compositions prepared herein as structurant comprises carboxy late- type anionics.
• Carboxylate-type anionics include the Cio-Cjg alkyl alkoxy carboxylates (especially the EO 1 to 5 ethoxycarboxylates) and the C ⁇ o-C ⁇ $ sarcosinates, especially oleoyl sarcosinate.
• Structuring anionic surfactants will generally comprise from about 1% to 30% by weight of the compositions prepared herein.
• one preferred type of structuring anionic surfactant comprises primary or secondary alkyl sulfate anionic surfactants.
• Such surfactants are those 325 produced by the sulfation of higher Cg-C20 fatty alcohols.
• R is typically a linear Cg - C20 hydrocarbyl group, which may be straight chain or branched chain, and M is a water-solubilizing cation.
• R is a C J Q
• R is about Cj2 and M is sodium.
• Secondary alkyl sulfate surfactants are those materials which have the sulfate moiety distributed randomly along the hydrocarbyl "backbone" of the
• alkyl sulfates will generally comprise from about 1% to 30% by
• Non-aqueous liquid detergent compositions containing alkyl sulfates, peroxygen bleaching agents, and bleach activators are described in greater detail in Kong-Chan et al.; WO 96/10073; Publiched April 4, 1996, which application is incorporated herein by reference.
• alkyl polyalkoxylate sulfates are also known as alkoxylated alkyl sulfates or alkyl ether sulfates. Such materials are those which correspond to the formula
• R ⁇ is a C10-C22 alkyl group
• m is from 2 to 4
• n is from about 1 to 15
• M is a salt-forming cation.
• R2 is a C ⁇ -Cjg alkyl
• m is 2
• n is from 2 to 4
• M is sodium, potassium, ammonium, alkylammonium or alkanolammonium.
• R ⁇ is a C12-C16
• m is 2
• n is from about 1 to 6
• M is sodium.
• Ammonium, alkylammonium and alkanolammonium counterions are preferably avoided when used in the compositions prepared herein because of incompatibility with peroxygen bleaching agents.
• alkyl polyalkoxylate sulfates can also generally comprise from about 1% to 30% by weight of the composition, more preferably from about 5% to 25% by weight of the composition.
• Non-aqueous liquid detergent compositions containing alkyl polyalkoxylate sulfates, in combination with polyhydroxy fatty acid amides, are described in greater detail in boutique et al; PCT Application No. PCT/US96/04223, which application is incorporated herein by reference.
• anionic surfactant for as a structurant use in the compositions prepared herein comprises the linear alkyl benzene sulfonate (LAS) surfactants.
• LAS surfactants can be formulated into a specific type of anionic surfactant-containing powder which is especially useful for incorporation into the preferred non-aqueous liquid detergent compositions of the present invention.
• Such a powder comprises two distinct phases. One of these phases is insoluble in the non-aqueous organic liquid diluents used in the compositions prepared herein; the other phase is soluble in the non-aqueous organic liquids.
• this preferred anionic surfactant-containing powder which can be dispersed in the non-aqueous liquid phase of the preferred compositions prepared herein and which forms a network of aggregated small particles that allows the final product to stably suspend other additional solid particulate materials in the composition.
• Such a preferred anionic surfactant-containing powder is formed by co-drying an aqueous slurry which essentially contains a) one of more alkali metal salts of C J O-16 linear alkyl benzene sulfonic acids; and b) one or more non-surfactant diluent salts.
• a slurry is dried to a solid material, generally in powder form, which comprises both the soluble and insoluble phases.
• the linear alkyl benzene sulfonate (LAS) materials used to form the preferred anionic surfactant-containing powder are well known materials. Such surfactants and their preparation are described for example in U.S. Patents 2,220,099 and 2,477,383, incorporated herein by reference. Especially preferred are the sodium and potassium linear straight chain alkylbenzene sulfonates in which the average number of carbon atoms in the alkyl group is from about 1 1 to 14. Sodium C] j - C14, e.g., Ci2, LAS is especially preferred.
• the alkyl benzene surfactant anionic surfactants are generally used in the powder-forming slurry in an amount from about 20 to 70% by weight of the slurry, more preferably from about 30% to 60% by weight of the slurry.
• the powder-forming slurry also contains a non-surfactant, organic or inorganic salt component that is co-dried with the LAS to form the two-phase anionic surfactant-containing powder.
• a non-surfactant, organic or inorganic salt component that is co-dried with the LAS to form the two-phase anionic surfactant-containing powder.
• Such salts can be any of the known sodium, potassium or magnesium halides, sulfates, citrates, carbonates, sulfates, borates, succinates, sulfo-succinates, xylene sulfonates, and the like.
• Sodium sulfate which is generally a bi-product of LAS production, is the preferred non-surfactant diluent salt for use herein. Salts which function as hydrotropes such as sodium sulfo- succinate may also usefully be included.
• the non-surfactant salts are generally used in the aqueous slurry, along with the LAS. in amounts ranging from about 1 to 12% by weight of the slurry, more preferably from about 2% to 10% by weight of the slurry. Salts that act as hydrotropes can preferably comprise up to about 3% by
• aqueous slurry containing the LAS and diluent salt components hereinbefore described can be dried to form the anionic surfactant-containing powder preferably added to the non-aqueous diluents in order to prepare a structured liquid phase within the compositions prepared herein. Any conventional drying
• 410 technique e.g., spray drying, drum drying, etc., or combination of drying techniques, may be employed. Drying should take place until the residual water content of the solid material which forms is within the range of from about 0.5% to 4% by weight, more preferably from about 1% to 3% by weight.
• the anionic surfactant-containing powder produced by the drying operation is the anionic surfactant-containing powder produced by the drying operation
• the insoluble phase in the anionic surfactant-containing powder generally comprises from about 10% to 60%, more preferably 10% to 25%, by weight of the powder, even more preferably from about 15% to 25% by weight of the powder.
• the anionic surfactant-containing powder that results after drying comprises from about 45% to 90%, more preferably from about 80% to 94%, by weight of the powder of alkylbenzene sulfonic acide salts. Such concentrations are generally sufficient to provide from about 0.5% to 60%, more preferably from about 15% to 60%, by weight of the total detergent composition of the alkyl benzene sulfonic acid
• the anionic surfactant-containing powder itself can comprise from about 0.45% to 45% by weight of the total composition. After drying, the anionic surfactant-containing powder will also contain from about 2% to 50%, more preferably from about 2% to 15%, by weight of the powder of the non-surfactant salts.
• the combined LAS/salt material can be converted to flakes or powder form by any known suitable milling or comminution process. Generally at the time such material is combined with the non-aqueous organic solvents to form the structured liquid phase of the compositions prepared herein, the particle size of this powder will range from 0.1 to 2000 microns, more
• a structured, surfactant-containing liquid phase of the preferred detergent compositions prepared herein can be prepared by combining the non-aqueous organic diluents hereinbefore described with the anionic surfactant-containing powder as hereinbefore described. Such combination results in the formation of a
• non-aqueous liquid phase and the solid phase anionic surfactant materials preferably used to structure the liquid phase, the non-aqueous
• compositions prepared herein also generally will comprise from about 5% to 55% by weight, more preferably from about 10% to 50% by weight, of additional solid phase particulate material which is dispersed and suspended within the liquid phase.
• additional solid phase particulate material is used in composition preparation in the form of hydrated or hydrable salts
• such particulate material will range in size from about 0.1 to 1500 microns, more preferably from about 0.1 to 900 microns. Most preferably, such material will range in size from about 5 to 200 microns.
• the additional particulate material utilized in the process herein can comprise one or more types of detergent composition components which in particulate form are substantially insoluble in the non-aqueous liquid phase of the composition.
• the types of particulate materials which can be utilized are described in detail as follows:
• the most preferred type of particulate material useful in the detergent compositions prepared herein comprises particles of a peroxygen bleaching agent.
• a peroxygen bleaching agent may be organic or inorganic in nature. Inorganic peroxygen bleaching agents are frequently utilized in combination with a bleach
• Useful organic peroxygen bleaching agents include percarboxylic acid bleaching agents and salts thereof. Suitable examples of this class of agents include magnesium monoperoxyphthalate hexahydrate, the magnesium salt of metachloro perbenzoic acid, 4-nonylamino-4-oxoperoxybutyric acid and diperoxydodecanedioic 475 acid.
• Such bleaching agents are disclosed in U.S. Patent 4,483,781 , Hartman, Issued November 20, 1984; European Patent Application EP-A-133,354, Banks et al.. Published February 20, 1985; and U.S. Patent 4,412.934, Chung et al., Issued November 1 , 1983.
• Highly preferred bleaching agents also include 6-nonylamino-6- oxoperoxycaproic acid (NAPAA) as described in U.S. Patent 4.634,551 , Issued
• Inorganic peroxygen bleaching agents may also be used in particulate form in the detergent compositions prepared herein. Inorganic bleaching agents are in fact preferred. Such inorganic peroxygen compounds include alkali metal perborate and percarbonate materials, most preferably the percarbonates. For example, sodium
• perborate e.g. mono- or tetra-hydrate
• Suitable inorganic bleaching agents can also include sodium or potassium carbonate peroxyhydrate and equivalent "percarbonate" bleaches, sodium pyrophosphate peroxyhydrate, urea peroxyhydrate, and sodium peroxide.
• Persulfate bleach e.g., OXONE, manufactured commercially by DuPont
• coated percarbonate particles are available from various commercial sources such as FMC, Solvay Interox, Tokai Denka and Degussa.
• Inorganic peroxygen bleaching agents e.g., the perborates, the percarbonates, etc.
• bleach activators which lead to the in situ
• TAED activators 500 tetraacetyl ethylene diamine (TAED) activators are typical. Mixtures thereof can also be used. See also the hereinbefore referenced U.S. 4,634,551 for other typical bleaches and activators useful herein.
• R s an alkyl group containing from about 6 to about 12 carbon atoms
• R 2 is an alkylene containing from 1 to about 6 carbon atoms
• R-5 is H or alkyl, aryl, or alkaryl containing from about 1 to about 10 carbon atoms
• L is any suitable
• a leaving group is any group that is displaced from the bleach activator as a consequence of the nucleophilic attack on the bleach activator by the perhydrolysis anion.
• a preferred leaving group is phenol sulfonate.
• bleach activators of the above formulae include (6- octanamido-caproyl)oxybenzenesulfonate, (6-nonanamidocaproyl)
• Another class of useful bleach activators comprises the benzoxazin-type 520 activators disclosed by Hodge et al. in U.S. Patent 4,966, 723, Issued October 30, 1990, incorporated herein by reference.
• a highly preferred activator of the benzoxazin-type is:
• Still another class of useful bleach activators includes the acyl lactam 525 activators, especially acyl caprolactams and acyl valerolactams of the formulae:
• R ⁇ is H or an alkyl, aryl, alkoxyaryl, or alkaryl group containing from 1 to about 12 carbon atoms.
• Highly preferred lactam activators include benzoyl caprolactam, octanoyl caprolactam, 3,5,5-trimethylhexanoyl caprolactam, nonanoyl
• peroxygen bleaching agents are used as all or part of the essentially present additional particulate material, they will generally comprise from about 1% to 30% by weight of the composition. More preferably, peroxygen bleaching agent will comprise from about 5% to 20% by weight of the composition. Most preferably,
• peroxygen bleaching agent will be present to the extent of from about 5% to 20% by weight of the composition.
• bleach activators can comprise from about 0.5% to 20%. more preferably from about 3% to 10%, by weight of the composition.
• activators are employed such that the molar ratio of bleaching agent to activator ranges from about 1 : 1 to 10: 1 , more preferably from about 1.5: 1 to 5: 1. 545
• bleach activators when agglomerated with certain acids such as citric acid, are more chemically stable.
• compositions prepared herein comprises an organic detergent builder material which serves to counteract the effects of calcium, or other ion, water hardness encountered during laundering bleaching use of the compositions prepared herein.
• organic detergent builder material which serves to counteract the effects of calcium, or other ion, water hardness encountered during laundering bleaching use of the compositions prepared herein.
• examples of such materials include the alkali metal, citrates, succinates, malonates, fatty acids,
• carboxymethyl succinates carboxylates, polycarboxylates and polyacetyl carboxylates.
• Specific examples include sodium, potassium and lithium salts of oxydisuccinic acid, mellitic acid, benzene polycarboxylic acids and citric acid.
• organic phosphonate type sequestering agents such as those which have been sold by Monsanto under the Dequest tradename and alkanehydroxy
• Citrate salts are highly preferred.
• suitable organic builders include the higher molecular weight polymers and copolymers known to have builder properties.
• such materials include appropriate polyacrylic acid, polymaleic acid, and polyacrylic/polymaleic acid copolymers and their salts, such as those sold by BASF under the Sokalan
• Another suitable type of organic builder comprises the water-soluble salts of higher fatty acids, i.e., "soaps".
• these include alkali metal soaps such as the sodium, potassium, ammonium, and alkylolammonium salts of higher fatty acids containing from about 8 to about 24 carbon atoms, and preferably from about 12 to about 18
• Soaps can be made by direct saponification of fats and oils or by the neutralization of free fatty acids. Particularly useful are the sodium and potassium salts of the mixtures of fatty acids derived from coconut oil and tallow, i.e., sodium or potassium tallow and coconut soap.
• 575 detergent builders can generally comprise from about 2% to 20% by weight of the compositions prepared herein. More preferably, such builder material can comprise from about 4% to 10% by weight of the composition.
• additional particulate material which can be suspended in the non-aqueous liquid detergent compositions prepared herein can comprise a material which serves to render aqueous washing solutions formed from such compositions generally alkaline in nature.
• Such materials may or may not also act as detergent builders, i.e., as materials which counteract the adverse effect of
• alkalinity sources examples include water-soluble alkali metal carbonates, bicarbonates, borates, silicates and metasilicates.
• water-soluble phosphate salts may also be utilized as alkalinity sources. These include alkali metal pyrophosphates, orthophosphates,
• alkali metal carbonates such as sodium carbonate are the most preferred.
• the alkalinity source if in the form of a hydratable salt, may also serve as a desiccant in the non-aqueous liquid detergent compositions prepared herein.
• the presence of an alkalinity source which is also a desiccant may provide benefits in
• composition components such as the peroxygen bleaching agent which may be susceptible to deactivation by water.
• the alkalinity source will generally comprise from about 1% to 25% by weight of the compositions prepared herein. More preferably, the alkalinity source can comprise
• Such materials while water- soluble, will generally be insoluble in the non-aqueous detergent compositions prepared herein. Thus such materials will generally be dispersed in the non-aqueous liquid phase in the form of discrete particles.
• the detergent compositions prepared herein can, and preferably will, contain various optional components.
• Such optional components may be in either liquid or solid form.
• the optional components may
• the detergent compositions prepared herein may also optionally contain one or more types of inorganic detergent builders beyond those listed hereinbefore that also function as alkalinity sources.
• optional inorganic builders can include, for example, aluminosilicates such as zeolites. Aluminosilicate zeolites, and their use as
• 620 detergent builders are more fully discussed in Corkill et al., U.S. Patent No. 4,605,509; Issued August 12, 1986, the disclosure of which is incorporated herein by reference. Also crystalline layered silicates, such as those discussed in this '509 U.S. patent, are also suitable for use in the detergent compositions prepared herein. If utilized, optional inorganic detergent builders can comprise from about 2% to
• the detergent compositions prepared herein may also optionally contain one or more types of detergent enzymes.
• Such enzymes can include proteases, amylases,
• cellulases and lipases Such materials are known in the art and are commercially available. They may be incorporated into the non-aqueous liquid detergent compositions prepared herein in the form of suspensions, "marumes" or "prills".
• Another suitable type of enzyme comprises those in the form of slurries of enzymes in nonionic surfactants, e.g., the enzymes marketed by Novo Nordisk under the
• Enzymes added to the compositions prepared herein in the form of conventional enzyme prills are especially preferred for use herein.
• Such prills will generally range in size from about 100 to 1 ,000 microns, more preferably from about
• compositions which utilize enzyme prills need not contain conventional enzyme
• enzymes will normally be incorporated into the non-aqueous liquid compositions prepared herein at levels sufficient to provide up to about 10 mg by weight, more typically from about 0.01 mg to about 5 mg, of active enzyme per
• non-aqueous liquid detergent compositions prepared herein will typically comprise from about 0.001% to 5%, preferably from about 0.01% to 1% by weight, of a commercial enzyme preparation.
• Protease enzymes for example, are usually present in such commercial preparations at levels sufficient to provide from 0.005 to 0.1 Anson units (AU) of activity per 655 gram of composition.
• the detergent compositions prepared herein may also optionally contain a chelating agent which serves to chelate metal ions, e.g., iron and/or manganese,
• Such chelating agents thus serve to form complexes with metal impurities in the composition which would otherwise tend to deactivate composition components such as the peroxygen bleaching agent.
• Useful chelating agents can include amino carboxylates, phosphonates, amino phosphonates, polyfunctionally-substituted aromatic chelating
• Amino carboxylates useful as optional chelating agents include ethylenediaminetetraacetates, N-hydroxyethyl-ethylenediaminetriacetates, nitrilotriacetates, ethylene-diamine tetrapropionates, triethylenetetraaminehexacetates, diethylenetriaminepentaacetates,
• Amino phosphonates are also suitable for use as chelating agents in the compositions of this invention when at least low levels of total phosphorus are permitted in detergent compositions, and include ethylenediaminetetrakis
• these amino phosphonates do not contain alkyl or alkenyl groups with more than about 6 carbon atoms.
• Preferred chelating agents include hydroxy-ethyldiphosphonic acid (HEDP), diethylene triamine penta acetic acid (DTPA), ethylenediamine disuccinic acid (EDDS) and dipicolinic acid (DPA) and salts thereof.
• HEDP hydroxy-ethyldiphosphonic acid
• DTPA diethylene triamine penta acetic acid
• EDDS ethylenediamine disuccinic acid
• DPA dipicolinic acid
• the chelating agent may, of
• the chelating agent can comprise from about 0.1% to 4% by weight of the compositions prepared herein. More preferably, the chelating agent will comprise from about 0.2% to 2% by weight of the detergent compositions prepared herein.
• the detergent compositions prepared herein may also optionally contain a polymeric material which serves to enhance the ability of the composition to maintain its solid particulate components in suspension.
• a polymeric material which serves to enhance the ability of the composition to maintain its solid particulate components in suspension.
• Such materials may thus act as thickeners, viscosity control agents and/or dispersing agents.
• polymeric polycarboxylates are frequently polymeric polycarboxylates but can include other polymeric materials such as polyvinylpyrrolidone (PVP) or polyamide resins.
• PVP polyvinylpyrrolidone
• Insoluble materials like fumed silica and titanium dioxide may also be used to enhance the elasticity of any structured liquid phase that is present.
• Polymeric polycarboxylate materials can be prepared by polymerizing or
• Unsaturated monomeric acids that can be polymerized to form suitable polymeric polycarboxylates include acrylic acid, maleic acid (or maleic anhydride), fumaric acid, itaconic acid, aconitic acid, mesaconic acid, citraconic acid and methylenemalonic acid.
• suitable polymeric polycarboxylates include acrylic acid, maleic acid (or maleic anhydride), fumaric acid, itaconic acid, aconitic acid, mesaconic acid, citraconic acid and methylenemalonic acid.
• Particularly suitable polymeric polycarboxylates can be derived from acrylic acid.
• acrylic acid-based polymers which are useful herein are the water-
• soluble salts of polymerized acrylic acid 710 soluble salts of polymerized acrylic acid.
• the average molecular weight of such polymers in the acid form preferably ranges from about 2,000 to 100,000, more preferably from about 2,000 to 10,000, even more preferably from about 4,000 to 7,000, and most preferably from about 4,000 to 5,000.
• Water-soluble salts of such acrylic acid polymers can include, for example, the alkali metal, salts. Soluble
• polymers of this type are known materials. Use of polyacrylates of this type in detergent compositions has been disclosed, for example, Diehl, U.S. Patent 3,308,067, issued March 7, 1967. Such materials may also perform a builder function.
• the optional thickening, viscosity control and/or dispersing agents are not utilized. If utilized, the optional thickening, viscosity control and/or dispersing agents
• compositions prepared herein should be present in the compositions prepared herein to the extent of from about 0.1% to 4% by weight. More preferably, such materials can comprise from about 0.5% to 2% by weight of the detergents compositions prepared herein.
• compositions prepared in accordance with the present invention can also optionally contain water-soluble ethoxylated amines having clay soil removal and anti-redeposition properties. If used, soil materials can contain from about 0.01% to
• compositions prepared herein 730 about 5% by weight of the compositions prepared herein.
• the most preferred soil release and anti-redeposition agent is ethoxylated tetraethylenepentamine. Exemplary ethoxylated amines are further described in U.S. Patent 4,597,898, VanderMeer, issued July 1, 1986.
• Another group of preferred clay soil removal-anti-redeposition agents are the cationic compounds disclosed in
• CMC carboxy methyl cellulose
• the detergent compositions prepared herein may also optionally contain bleach activators which are liquid in form at room temperature and which can be added as liquids to the non-aqueous liquid phase of the detergent compositions herein.
• bleach activators which are liquid in form at room temperature and which can be added as liquids to the non-aqueous liquid phase of the detergent compositions herein.
• One 750 such liquid bleach activator is acetyl triethyl citrate (ATC).
• ATC acetyl triethyl citrate
• Other examples include glycerol triacetate and nonanoyl valerolactam.
• Liquid bleach activators can be dissolved in the non-aqueous liquid phase of the compositions prepared herein.
• the detergent compositions prepared herein may also optionally contain conventional brighteners, suds suppressors, bleach catalysts, dyes and/or perfume materials.
• Such brighteners, suds suppressors, silicone oils, bleach catalysts, dyes and perfumes must, of course, be compatible and non-reactive with the other composition components in a non-aqueous environment. If present, brighteners suds
• Suitable bleach catalysts include the manganese based complexes disclosed in US 5,246,621, US 5,244,594, US 5, 1 14,606 and US 5, 1 14,61 1.
• non-aqueous liquid detergent compositions prepared herein are in the form of bleaching agent and/or other materials in particulate form as a solid phase suspended in and dispersed throughout a surfactant-containing, structured non-aqueous liquid phase.
• structured non-aqueous liquid Generally, the structured non-aqueous liquid
• phase will comprise from about 45% to 95%, more preferably from about 50% to 90%, by weight of the composition with the dispersed additional solid materials comprising from about 5% to 55%, more preferably from about 10% to 50%, by weight of the composition.
• the particulate-containing non-aqueous liquid detergent compositions prepared herein will be relatively viscous and phase stable under conditions of commercial marketing and use of such compositions. Frequently the viscosity of the compositions prepared herein will range from about 300 to 5,000 cps, more
• viscosity is measured with a Carrimed CSL2 Rheometer at a shear rate of 20 s ⁇ - .
• non-aqueous liquid detergent compositions prepared herein can be any non-aqueous liquid detergent compositions prepared herein.
• compositions prepared herein prepared by first forming the structured, surfactant-containing non-aqueous liquid phase and by thereafter adding to this structured phase the additional particulate components in any convenient order and by mixing, e.g., agitating, the resulting component combination to form the phase stable compositions prepared herein.
• additional particulate components in any convenient order and by mixing, e.g., agitating, the resulting component combination to form the phase stable compositions prepared herein.
• d e anionic surfactant- containing powder used to form the structured, surfactant-containing liquid phase is prepared.
• This pre-preparation step involves the formation of an aqueous slurry containing from about 30% to 60% of one or more alkali metal salts of linear C i Q.
• this slurry is dried to the extent necessary to form a solid material containing less than about 4% by weight of residual water.
• this material can be combined with one or more of the non-aqueous organic diluents to form the structured, surfactant-containing liquid phase of the detergent compositions prepared herein. This is done by reducing the anionic surfactant-containing material formed in the previously described pre-preparation step to powdered form and by combining such powdered material with an agitated liquid medium comprising one or more of the non-aqueous organic diluents, either surfactant or non-surfactant or both, as hereinbefore described.
• the non-aqueous liquid dispersion so prepared can then be subjected to milling or high shear agitation under conditions which are sufficient to provide the structured, surfactant-containing liquid phase of the detergent compositions prepared herein.
• Such milling or high shear agitation conditions will generally include maintenance of a temperature between about 10°C and 90°C, preferably between about 20°C and 60°C; and a processing time that is sufficient to form a network of aggregated small particles of the insoluble fraction of the anionic surfactant-containing powdered material.
• Suitable equipment for this purpose includes: stirred ball mills, co-ball mills (Fryma), colloid mills, high pressure homogenizers, high shear mixers, and the like.
• the colloid mill and high shear mixers are preferred for their high throughput and low capital and maintenance costs.
• the additional particulate material to be used in the detergent compositions prepared herein can be added.
• Such components which can be added under high shear agitation include the silica or titanium dioxide; particles of substantially all of an organic builder, e.g., citrate and/or fatty acid, and/or an alkalinity source, e.g., sodium carbonate, can be added while continuing to maintain this admixture of composition components under shear agitation. Agitation of the mixture is continued, and if necessary, can be increased at this point to form a
• the particles of the highly preferred peroxygen bleaching agent can be added to the composition, again while the mixture is maintained under shear agitation.
• enzyme prills are incorporated, they are preferably added to the non-aqueous liquid matrix last.
• compositions having the requisite viscosity, yield value and phase stability characteristics are continued for a period of time sufficient to form compositions having the requisite viscosity, yield value and phase stability characteristics. Frequently this will involve agitation for a period of from about 1 to 30 minutes.
• compositions of this invention can be used to form aqueous washing solutions for use in the laundering and bleaching of fabrics.
• an effective amount of such compositions is added to water, preferably in a conventional fabric laundering automatic washing machine, to form such aqueous laundering/bleaching solutions.
• An effective amount of the liquid detergent compositions prepared herein added to water to form aqueous laundering/bleaching solutions can comprise amounts sufficient to form from about 500 to 7,000 ppm of composition in aqueous
• NaLAS Sodium C12 linear alkyl benzene sulfonate
• NaLAS powder is produced by taking a slurry of NaLAS in water 890 (approximately 40-50% active) combined with dissolved sodium sulfate (3-15%) and a hydrotrope, sodium sulfosuccinate (1-3%). The hydrotrope and sulfate are used to improve the characteristics of the dry powder.
• a drum dryer is used to dry the slurry into a flake. When the NaLAS is dried with the sodium sulfate, two distinct phases are created within the flake. The insoluble phase creates a network 895 structure of aggregate small particles (0.4-2 um) which allows the finished non- aqueous detergent product to stably suspend solids.
• the NaLAS powder prepared according to this example has the following makeup shown in Table I.
• Butoxy-propoxy-propanol (BPP) and a Cn.j 5EO(5) ethoxylated alcohol nonionic surfactant (Neodol 1-5) are mixed for a short time (1-2 minutes) using a pitched blade turbine impeller in a mix tank into a single phase.
• NaLAS powder as prepared in Example I is added to the BPP/Neodol solution in the mix tank to partially dissolve the NaLAS. Mix time is approximately one hour. The tank is blanketed with nitrogen to prevent moisture pickup from the air. The soluble phase of NaLAS powder dissolves, while the insoluble NaLAS aggregates and forms a network structure within the BPP/Neodol
• Liquid base (LAS/BPP/NI) is pumped out into drums.
• Molecular sieves (type 3 A, 4-8 mesh) are added to each drum at 10% of the net weight of the liquid base.
• the molecular sieves are mixed into the liquid base using both single blade turbine mixers and drum rolling techniques. The mixing is done under
• Total mix time is 2 hours, after which 0.1-0.4% of the moisture in the liquid base is removed.
• Additional solid ingredients are prepared for addition to the composition.
• those ingredients in the form of hydrated or hydratable salts these ingredients are dried in a fluidized bed dryer to a free moisture content of less 0.5%.
• Such solid ingredients include the following:
• Titanium dioxide particles (1-5 microns)
• the batch is pumped once through a Fryma colloid mill, which is a simple 940 rotor-stator configuration in which a high-speed rotor spins inside a stator which creates a zone of high shear. This serves to disperse the insoluble NaLAS aggregates and partially reduce the particle size of all of the solids. This leads to an increase in yield value (i.e. structure).
• the batch is then recharged to the mix tank.
• Protease and amylase enzyme prills (100-1000 microns)
• Table II composition is a stable, anhydrous heavy-duty liquid 965 laundry detergent which provides excellent stain and soil removal performance when used in normal fabric laundering operations.
• test formulas as hereinbefore described are evaluated for percent of retained peracid in a 4-week aging test.
• Test formulas, moisture content of the maleic-acrylic copolymer and bleach stability results are shown in Table III.
• Table III data illustrate the beneficial effect on bleach stability which can be realized by pre-drying one of the solid components prior to its incorporation into non-aqueous liquid detergents in accordance with the process of this invention.

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