EP2941478B1 - Nettoyant pour four en dose unitaire en comprimé solide - Google Patents

Nettoyant pour four en dose unitaire en comprimé solide Download PDF

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Publication number
EP2941478B1
EP2941478B1 EP13870378.0A EP13870378A EP2941478B1 EP 2941478 B1 EP2941478 B1 EP 2941478B1 EP 13870378 A EP13870378 A EP 13870378A EP 2941478 B1 EP2941478 B1 EP 2941478B1
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Prior art keywords
composition
weight
solid
approximately
detergent composition
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EP13870378.0A
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German (de)
English (en)
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EP2941478A4 (fr
EP2941478A1 (fr
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Brenda L. Tjelta
Lisa M. Sanders
Michael E. Besse
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Ecolab USA Inc
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Ecolab USA Inc
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Priority claimed from US13/734,204 external-priority patent/US8951956B2/en
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Publication of EP2941478A4 publication Critical patent/EP2941478A4/fr
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    • 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
    • C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
    • C11D7/02—Inorganic compounds
    • C11D7/04—Water-soluble compounds
    • C11D7/06—Hydroxides
    • 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
    • C11D3/0005—Other compounding ingredients characterised by their effect
    • C11D3/0057—Oven-cleaning 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
    • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
    • C11D3/02—Inorganic compounds ; Elemental compounds
    • C11D3/04—Water-soluble compounds
    • C11D3/044—Hydroxides or bases
    • 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
    • C11D3/02—Inorganic compounds ; Elemental compounds
    • C11D3/04—Water-soluble compounds
    • C11D3/08—Silicates
    • 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
    • C11D3/02—Inorganic compounds ; Elemental compounds
    • C11D3/04—Water-soluble compounds
    • C11D3/10—Carbonates ; Bicarbonates
    • 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
    • C11D3/37—Polymers
    • C11D3/3746—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C11D3/3757—(Co)polymerised carboxylic acids, -anhydrides, -esters in solid and liquid compositions
    • C11D3/3761—(Co)polymerised carboxylic acids, -anhydrides, -esters in solid and liquid compositions in solid 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
    • C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
    • C11D7/02—Inorganic compounds
    • C11D7/04—Water-soluble compounds
    • C11D7/10—Salts
    • C11D7/12—Carbonates bicarbonates
    • 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
    • C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
    • C11D7/02—Inorganic compounds
    • C11D7/04—Water-soluble compounds
    • C11D7/10—Salts
    • C11D7/14—Silicates
    • 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
    • C11D2111/00—Cleaning compositions characterised by the objects to be cleaned; Cleaning compositions characterised by non-standard cleaning or washing processes
    • C11D2111/10—Objects to be cleaned
    • C11D2111/14—Hard surfaces
    • C11D2111/20—Industrial or commercial equipment, e.g. reactors, tubes or engines

Definitions

  • the present invention relates generally to the field of solidification and solidification matrices.
  • the present invention relates to solidification of a phosphate-free alkaline detergent composition.
  • the present invention relates to a phosphate-free alkaline detergent composition including sodium hydroxide, sodium carbonate and/or potassium carbonate, anhydrous sodium metasilicate and preferably a polycarboxylic acid polymer as part of the solidification matrix.
  • phosphates typically serve multiple purposes in the compositions, for example, to control the rate of solidification, to remove and suspend soils, and as an effective hardness sequestrant. It was found, disclosed, and claimed in U.S. Pat. Nos. 6,258,765 , 6,156,715 , 6,150,324 , and 6,177,392 , that a solid block functional material could be made using a binding agent that includes a carbonate salt, an organic acetate, such as an aminocarboxylate, or phosphonate component and water. Due to ecological concerns, further work has recently been directed to replacing phosphorous-containing compounds in detergents.
  • NTA nitrilotriacetic acid
  • US 2010/311634 A1 discloses a solidification matrix including a straight chain saturated carboxylic acid salt, sodium carbonate, and water.
  • the straight chain saturated carboxylic acid salt is selected from a salt of a mono-, di-, or tri-carboxylic acid.
  • the solidification matrix may be used, for example, in a solid detergent composition.
  • solidification matrices for solid, alkaline detergents has required numerous modifications, including removal of phosphorus and/or NTA. Additional modifications include the formulation of solidification matrices incorporating caustic material (sodium hydroxide) in combination with the less caustic materials, such as soda ash (e.g. sodium carbonate), continue to present difficulty in establishing solid, physically stable tablet compositions. It has been shown that highly caustic powders for solidification fail to consistently form stable compositions, such as tablets. Therefore, there is a need for using lower levels of sodium hydroxide in combination with other less caustic materials in order to formulate dimensionally-stable solid compositions. These and other aspects of forming physically stable detergent compositions provide the background against which the present invention is provided.
  • caustic material sodium hydroxide
  • soda ash e.g. sodium carbonate
  • a physically stable phosphate-free alkaline detergent tablet composition for combination ovens is provided.
  • methods for employing ash- and/or hydroxide-hydration to form a physically stable, phosphate-free alkaline detergent tablet containing sodium carbonate, sodium hydroxide and sodium metasilicate are provided.
  • compositions and methods of the invention provide physically stable compositions having durable cleaning performance, including for example in cleaning combination ovens.
  • One embodiment of the present invention is a solid detergent composition that comprises 10 to 50 wt.-% of an alkali metal hydroxide alkalinity source, 20 to 90 wt.-% of sodium carbonate and/or potassium carbonate, 5 to 50 wt.-% of an anhydrous silicate secondary alkalinity source, 1 to 10 wt.-% water, at least one functional ingredient, wherein if the solid detergent composition heated at a temperature of 48.88 °C (120 degrees Fahrenheit), the composition remains dimensionally stable and has a growth exponent of less than 3%, and wherein the solid detergent composition is free of phosphorous.
  • Yet a further embodiment is a method of forming a solid a detergent composition by combining 30 to 70 wt.-% sodium carbonate, 5 to 50 wt.-% an anhydrous silicate secondary alkalinity source and at least one additional functional component to form a powder pre-mix; and mixing the powder pre-mix with a water source to form a solid hydrate; and combining the solid hydrate with a source of sodium hydroxide and optionally a polycarboxylic acid polymer or salt thereof, wherein the produced solid detergent composition is phosphorous free, and if heated at a temperature of 48.88 °C (120 degrees Fahrenheit), the solid detergent composition is dimensionally stable and has a growth exponent of less than 3%.
  • dimensional stability and “dimensionally stable” as used herein, refer to a solid product having a growth exponent of less than about 3%, preferably less than about 2%.
  • weight percent refers to the concentration of a substance as the weight of that substance divided by the total weight of the composition and multiplied by 100. It is understood that, as used here, “percent,” “%,” and the like are intended to be synonymous with “weight percent,” “wt-%,” etc.
  • the solid compositions overcome a need in the prior art by providing a dimensionally stable solid composition for use in any pressed, extruded or cast solid composition containing a hydratable salt, an alkalinity active (e.g. alkali metal hydroxide) and water.
  • a hydratable salt e.g. alkali metal hydroxide
  • the dimensionally stable solid compositions are not used in cast solid compositions.
  • the composition would be useful for preparing a solid detergent composition that may be employed in any of a wide variety of situations where a dimensionally-stable, caustic-containing alkaline detergent that is substantially phosphorous-free and nitrilotriacetic acid (NTA)-free solid product is desired.
  • NTA nitrilotriacetic acid
  • Substantially phosphorus-free means a solidification matrix having less than approximately 0.5 wt-%, more particularly, less than approximately 0.1 wt-%, and even more particularly less than approximately 0.01 wt-% phosphorous based on the total weight of the solidification matrix.
  • NTA-free means a solidification matrix having less than approximately 0.5 wt-%, less than approximately 0.1 wt-%, and often less than approximately 0.01 wt-% NTA based on the total weight of the solidification matrix. Accordingly, the embodiments of the present invention are particularly useful in cleaning applications where it is desired to use an environmentally friendly solid detergent.
  • the solidification matrix of the present invention may be employed in any of a wide variety of situations in which a dimensionally stable solid product is desired.
  • the solidification matrix is dimensionally stable and has an appropriate rate of solidification.
  • the solidification matrix may be free of phosphorous and NTA, making the solidification matrix particularly useful in cleaning applications where it is desired to use an environmentally friendly, solid alkaline detergent.
  • Such applications include, but are not limited to: phosphate-free alkaline detergent use in combination ovens, such as those used in various food service industries.
  • Additional applications may include, for example, machine and manual warewashing employing a ware wash detergent, presoaks, fryer boil outs, power soak sinks and related applications, soak tanks, instrument reprocessing, laundry and textile cleaning and destaining, carpet cleaning and destaining, vehicle cleaning and care applications, surface cleaning and destaining, kitchen and bath cleaning and destaining, floor cleaning and destaining, cleaning in place operations, general purpose cleaning and destaining, and/or industrial or household cleaners.
  • Methods suitable for preparing a solid detergent composition using the solidification matrix are also provided.
  • the solidification matrix generally includes an alkali metal hydroxide alkalinity source, a hydratable salt, such as sodium carbonate (soda ash) and/or potassium carbonate, a functional ingredient, an anhydrous silicate secondary alkalinity source, and a water charge for forming solid compositions.
  • a hydratable salt such as sodium carbonate (soda ash) and/or potassium carbonate
  • a functional ingredient such as sodium carbonate (soda ash) and/or potassium carbonate
  • an anhydrous silicate secondary alkalinity source such as sodium carbonate (soda ash) and/or potassium carbonate
  • the solidification matrices may further include chelants, corrosion inhibitors, and/or additional water conditioning agents.
  • the solidification matrices may comprise, consist of and/or consist essentially of an alkali metal hydroxide, a hydratable salt, such as sodium carbonate (soda ash) and/or potassium carbonate, a functional ingredient, an anhydrous silicate secondary alkalinity source, a chelantand/or corrosion inhibitor source and a water charge.
  • a hydratable salt such as sodium carbonate (soda ash) and/or potassium carbonate
  • a functional ingredient such as sodium carbonate (soda ash) and/or potassium carbonate
  • an anhydrous silicate secondary alkalinity source such as sodium carbonate (soda ash) and/or potassium carbonate
  • an anhydrous silicate secondary alkalinity source such as sodium carbonate (soda ash) and/or potassium carbonate
  • an anhydrous silicate secondary alkalinity source such as sodium carbonate (soda ash) and/or potassium carbonate
  • Component concentrations for the solidification matrix range from between approximately 10% and 50% by weight alkali metal hydroxide alkalinity, 5% and approximately 50% by weight anhydrous silicate secondary alkalinity source, between approximately 1% and approximately 10% by weight water, and between approximately 20% and approximately 90% by weight sodium carbonate and/or potassium carbonate.
  • the component concentrations for the solidification matrix further include the following ranges from between approximately 0.1% and 50% by weight chelant, such as sodium gluconate, and 0.1% and 50% by weight corrosion inhibitor.
  • Particularly suitable component concentrations for the solidification matrix range from between approximately 1% and 50% by weight chelant, and 1% and 50% by weight corrosion inhibitor. More particularly suitable component concentrations for the solidification matrix range from between approximately 5% and 25% by weight chelant, and 1% and 20% by weight corrosion inhibitor.
  • chelant such as sodium gluconate
  • Particularly suitable component concentrations for the solidification matrix range from between approximately 1% and 50% by weight chelant, and 1% and 50% by weight corrosion inhibitor. More particularly suitable component concentrations for the solidification matrix range from between approximately 5% and 25% by weight chelant, and 1% and 20% by weight corrosion inhibitor.
  • all numeric ranges recited herein are inclusive of the numbers defining the range and include each integer within the defined range.
  • the solid detergent composition includes an effective amount of one or more alkalinity sources to provide effective cleaning of a substrate and improve soil removal performance of the solid detergent compositions.
  • the alkalinity source is an alkali metal hydroxide and is provided in an effective amount to improve substrate cleaning and soil removal.
  • the compositions of the invention include the alkalinity source in an amount of between about 10% and about 50% by weight, and most preferably between about 20% and about 40% by weight of the total weight of the solid detergent composition.
  • An effective amount of the alkalinity sources should be considered as an amount that provides a use composition having a pH of at least about 8, preferably at least about 10, and more preferably at least about 12.
  • a use composition having a pH of at least about 8, preferably at least about 10, and more preferably at least about 12.
  • the use composition has a pH of between about 8 and about 10, it can be considered mildly alkaline, and when the pH is greater than about 12, the use composition can be considered caustic.
  • alkali metal hydroxides that can be used include, but are not limited to sodium, lithium, or potassium hydroxide.
  • the alkali metal hydroxide may be added to the composition in any form known in the art, including as solid beads, dissolved in an aqueous solution, or a combination thereof.
  • Alkali metal hydroxides are commercially available as a solid in the form of prilled solids or beads having a mix of particle sizes ranging from about 12-100 U.S. mesh, or as an aqueous solution, as for example, as a 45% and a 50% by weight solution. It is preferred that the alkali metal hydroxide according to the invention is added in the form of prilled solids or beads.
  • the solid detergent compositions according to the invention comprise at least one hydratable salt selected from sodium carbonate (aka soda ash or ash) and/or potassium carbonate (aka potash).
  • the hydratable salt is sodium carbonate and excludes potassium carbonate.
  • the hydratable salt is provided in the ranges from between approximately 20% and approximately 90% by weight, preferably between approximately 25% and approximately 90% by weight, and more preferably between approximately 30% and approximately 70% by weight hydratable salt, such as sodium carbonate.
  • the hydratable salt may be combined with other solidification agents.
  • the hydratable salt may be used with additional solidification agents that are inorganic in nature and may also act optionally as a source of alkalinity.
  • the secondary solidification agent may include, but are not limited to: additional alkali metal hydroxides, anhydrous sodium carbonate, anhydrous sodium sulfate, anhydrous sodium acetate, and other known hydratable compounds or combinations thereof.
  • the secondary hydratable salt comprises sodium metasilicate and/or anhydrous sodium metasilicate.
  • the amount of secondary solidifying agent necessary to achieve solidification depends upon several factors, including the exact solidifying agent employed, the amount of water in the composition, and the hydration capacity of the other detergent components.
  • the secondary solidifying agent may also serve as an additional alkaline source.
  • the solid alkaline detergent compositions according to the invention may include as functional ingredient a polycarboxylic acid polymer or salt thereof.
  • a polycarboxylic acid polymer or salt thereof As referred to herein, the reference to any polycarboxylic acid polymer shall further encompass the salt thereof as also being a suitable polymer for use in the solid alkaline detergent compositions according to the invention.
  • particularly suitable polycarboxylic acid polymers include, but are not limited to: polyacrylic acid polymers, polyacrylic acid polymers modified by a fatty acid end group ("modified polyacrylic acid polymers"), polymaleic acid polymers and combinations of these polymer materials. Salts of each of the polycarboxylic acid polymers may further be employed for the solid alkaline detergent compositions.
  • Non-limiting examples of polycarboxylic acid polymer salts include polyacrylic acid salts and derivatives, such as water soluble acrylic polymers.
  • Such polymers include, but are not limited to, polyacrylic acid, polymethacrylic acid, acrylic acid, acrylic acid-methacrylic acid copolymers, polymaleic acid, hydrolyzed polyacrylamide, hydrolyzed methacrylamide, hydrolyzed acrylamide-methacrylamide copolymers, hydrolyzed polyacrylonitrile, hydrolyzed polymethacrylonitrile, hydrolyzed acrylonitrile methacrylonitrile copolymers, and the like, or combinations thereof or copolymers thereof.
  • Water soluble salts or partial salts of these polymers such as their respective alkali metal (e.g., sodium, potassium, or combinations thereof) or ammonium salts can also be used according to the invention.
  • Examples of particularly suitable polyacrylic acid polymers and modified polyacrylic acid polymers and salts and derivatives thereof include those having a molecular weight of between about 1,000 and about 100,000.
  • Examples of more particularly suitable polymaleic acid polymers and salts and derivatives thereof include those having a molecular weight of between about 500 and about 5,000.
  • An example of particularly suitable commercially available polyacrylic acid polymer and salts and derivatives thereof includes, but is not limited to, Acusol 445ND, available from Rohm & Haas LLC, Philadelphia, PA.
  • An example of particularly suitable commercially available modified polyacrylic acid polymer includes, but is not limited to, Alcosperse 325, available from Alco Chemical, Chattanooga, TN.
  • Examples of particularly suitable commercially available polymaleic acid polymers include, but are not limited to: Belclene 200, available from Houghton Chemical Corporation, Boston, MA and Aquatreat AR-801, available from Alco Chemical, Chattanooga, TN.
  • the solidification matrix of the present invention includes at least one polyacrylic acid polymer or salt thereof.
  • the solidification matrix may include between about 0.1% and 15% by weight, more particularly, between about 0.5% and 15% by weight polyacrylic acid polymer, between about 0.1% and 10% by weight, between about 1% and 10% by weight, more particularly, between about 2.5% and 10% by weight.
  • all numeric ranges recited herein are inclusive of the numbers defining the range.
  • the solidification matrix may include a polymaleic acid polymer and at least two polyacrylic acid polymers having different molecular weights.
  • the solidification matrix includes at least one carboxylic acid salt in addition to the at least one polycarboxylic acid polymer. Suitable carboxylic acid salts include straight chain saturated carboxylic acid salts such as acetic acid, gluconic acid, malic acid, succinic acid, glutaric acid, adipic acid, tartaric acid, citric acid or combinations thereof.
  • the solidification includes between about 0.1% and 10% by weight carboxylic acid salt, for example citric acid salt.
  • Water may be both independently added to the solidification matrix and/or may be provided in the solidification matrix as a result of its presence in an aqueous material that is added to the detergent composition.
  • the secondary alkalinity source e.g. silicate or metasilicate
  • the remaining components added to the detergent composition may include water or may be prepared in an aqueous premix available for reaction with the solidification matrix component(s).
  • Water is introduced into the solidification matrix to provide the solidification matrix with desired cohesive strength or compressibility and to provide a desired rate of solidification (e.g. hydroxide and/or ash hydration according to the aspects of the invention).
  • the aqueous medium may help in the solidification process when is desired to form the concentrate as a solid.
  • the water may also be provided as deionized water or as softened water.
  • the amount of water in the resulting solid detergent composition will depend on the methods of forming employed for the solid detergent composition (e.g. processing forming techniques). As the methods and compositions of the present invention are not preferred for use in casting (solidification occurring within a container), a lower amount of water is employed.
  • the use of forming techniques includes a relatively smaller amount of water for solidification compared with the casting techniques.
  • water is present in ranges of between about 1% and about 10% by weight. Without being limited to the scope of the invention, all numeric ranges recited herein are inclusive of the numbers defining the range.
  • the solidification matrix is phosphorus-free and may be nitrilotriacetic acid (NTA)-free to make the solid detergent composition more environmentally beneficial.
  • Phosphorus-free means a solidification matrix having less than approximately 0.5 wt-%, more particularly, less than approximately 0.1 wt-%, and even more particularly less than approximately 0.01 wt-% phosphorous based on the total weight of the solidification matrix.
  • NTA-free means a solidification matrix having less than approximately 0.5 wt-%, less than approximately 0.1 wt-%, and often less than approximately 0.01 wt-% NTA based on the total weight of the solidification matrix.
  • the solidification matrix and resulting solid detergent composition is also compatible with chlorine, which functions as an anti-redeposition and stain-removal agent.
  • the components of the solidification matrix can be combined with various functional components used to form a solid detergent composition.
  • the solidification matrix including the alkali metal hydroxide, secondary alkalinity source, water, and sodium carbonate and/or potassium carbonate make up a large amount, or even substantially all of the total weight of the detergent composition, for example, in embodiments having few or no additional functional materials disposed therein.
  • the component concentrations ranges provided above for the solidification matrix are representative of the ranges of those same components in the detergent composition.
  • compositions may include between about 10% and 50% alkali metal hydroxide, between about 1% and about 10% by weight water, between about 20% and 90% by weight sodium carbonate and/or potassium carbonate, between about 5% and 50% by weight secondary alkalinity source, with the balance of the composition comprising the additional functional components.
  • alkali metal hydroxide between about 1% and about 10% by weight water, between about 20% and 90% by weight sodium carbonate and/or potassium carbonate, between about 5% and 50% by weight secondary alkalinity source, with the balance of the composition comprising the additional functional components.
  • the functional materials provide desired properties and functionalities to the solid detergent composition.
  • the term "functional materials” includes a material that when dispersed or dissolved in a use and/or concentrate solution, such as an aqueous solution, provides a beneficial property in a particular use.
  • the solid detergent composition includes an effective amount of one or more secondary alkaline sources to provide alkalinity and/or enhance cleaning of a substrate and/or improve soil removal performance of the solid detergent composition.
  • the secondary alkaline source may be provided in concentrate form.
  • Such secondary alkalinity agents are commonly available in either aqueous or powdered form, either of which is useful in formulating the present solid detergent compositions. According to preferred embodiments of the invention, the secondary alkalinity agent is provided in a solid form.
  • silicates are used as secondary alkalinity sources.
  • Silicates are known for conventional benefits of corrosion inhibition and/or anti-redeposition efficacy in addition to providing alkalinity.
  • the silicate secondary alkalinity source is not provided in amounts sufficient for metal protection (i.e. corrosion inhibition) as a result of the solidification composition containing the alkali metal hydroxide component.
  • Exemplary silicates include, but are not limited to: sodium silicate and potassium silicate.
  • silicates may further include metasilicates (e.g. potassium or sodium metasilicates).
  • Silicates and/or metasilicates can be provided as powdered, particulate or granular silicates and/or metasilicates.
  • the silicates and/or metasilicates can be either anhydrous or contain water of hydration. According to the invention, the silicates and/or metasilicates are anhydrous.
  • the secondary alkaline source is provided in an amount of between about 5% and about 50% by weight of the total weight of the solid detergent composition. Without being limited to the scope of the invention, all numeric ranges recited herein are inclusive of the numbers defining the range.
  • the solid detergent composition can include at least one cleaning agent comprising a surfactant or surfactant system.
  • a cleaning agent comprising a surfactant or surfactant system.
  • surfactants can be used in a solid detergent composition, including, but not limited to: anionic, nonionic, cationic, and zwitterionic surfactants.
  • Surfactants are an optional component of the solid detergent composition and can be excluded from the concentrate.
  • Exemplary surfactants that can be used are commercially available from a number of sources. For a discussion of surfactants, see Kirk-Othmer, Encyclopedia of Chemical Technology, Third Edition, volume 8, pages 900-912 .
  • the cleaning agent is provided in an amount effective to provide a desired level of cleaning.
  • the solid detergent composition when provided as a concentrate, can include the cleaning agent in a range of about 0.05% to about 20% by weight, about 0.5% to about 15% by weight, about 1% to about 15% by weight, about 1.5% to about 10% by weight, and about 2% to about 8% by weight. Additional exemplary ranges of surfactant in a concentrate include about 0.5% to about 8% by weight, and about 1% to about 5% by weight. Without being limited to the scope of the invention, all numeric ranges recited herein are inclusive of the numbers defining the range.
  • anionic surfactants useful in the solid detergent composition include, but are not limited to: carboxylates such as alkylcarboxylates and polyalkoxycarboxylates, alcohol ethoxylate carboxylates, nonylphenol ethoxylate carboxylates; sulfonates such as alkylsulfonates, alkylbenzenesulfonates, alkylarylsulfonates, sulfonated fatty acid esters; sulfates such as sulfated alcohols, sulfated alcohol ethoxylates, sulfated alkylphenols, alkylsulfates, sulfosuccinates, and alkylether sulfates.
  • Exemplary anionic surfactants include, but are not limited to: sodium alkylarylsulfonate, alpha-olefinsulfonate, and fatty alcohol sulfates.
  • nonionic surfactants useful in the solid detergent composition include, but are not limited to, those having a polyalkylene oxide polymer as a portion of the surfactant molecule.
  • Such nonionic surfactants include, but are not limited to: chlorine-, benzyl-, methyl-, ethyl-, propyl-, butyl- and other like alkyl-capped polyethylene glycol ethers of fatty alcohols; polyalkylene oxide free nonionics such as alkyl polyglycosides; sorbitan and sucrose esters and their ethoxylates; alkoxylated amines such as alkoxylated ethylene diamine; alcohol alkoxylates such as alcohol ethoxylate propoxylates, alcohol propoxylates, alcohol propoxylate ethoxylate propoxylates, alcohol ethoxylate butoxylates; nonylphenol ethoxylate, polyoxyethylene glycol ether; carboxylic acid esters such as glycerol esters,
  • An example of a commercially available ethylene oxidc/propylene oxide block copolymer includes, but is not limited to, PLURONIC®, available from BASF Corporation, Florham Park, NJ.
  • An example of a commercially available silicone surfactant includes, but is not limited to, ABIL® B8852, available from Goldschmidt Chemical Corporation, Hopewell, VA.
  • the surfactants selected, if any surfactant is used can be those that provide an acceptable level of foaming when used inside a dishwashing or warewashing machine or a combination oven.
  • Solid detergent compositions for use in automatic dishwashing or warewashing machines are generally considered to be low-foaming compositions.
  • Low foaming surfactants that provide the desired level of detersive activity are advantageous in an environment such as a dishwashing machine where the presence of large amounts of foaming can be problematic.
  • defoaming agents can also be utilized to reduce the generation of foam. Accordingly, surfactants that are considered low foaming surfactants can be used.
  • other surfactants can be used in conjunction with a defoaming agent to control the level of foaming.
  • the solid detergent composition can include one or more building agents, also called chelating or sequestering agents (e.g., builders), including, but not limited to: an aminocarboxylic acid, or a polyacrylate.
  • a chelating agent is a molecule capable of coordinating (i.e., binding) the metal ions commonly found in natural water to prevent the metal ions from interfering with the action of the other detersive ingredients of a cleaning composition.
  • Preferable levels of addition for builders that can also be chelating or sequestering agents are between about 0.1% to about 70% by weight, about 1% to about 60% by weight, or about 1.5% to about 50% by weight.
  • the concentrate can include between approximately 1% to approximately 60% by weight, between approximately 3% to approximately 50% by weight, and between approximately 6% to approximately 45% by weight of the builders. Additional ranges of the builders include between approximately 3% to approximately 20% by weight, between approximately 6% to approximately 15% by weight, between approximately 25% to approximately 50% by weight, and between approximately 35% to approximately 45% by weight. Without being limited to the scope of the invention, all numeric ranges recited herein are inclusive of the numbers defining the range.
  • a chelant e.g. sodium gluconate
  • a chelant is provided in an amount of between about 0.1% and about 50% by weight, between about 0.5% and about 50% by weight, between about 1% and about 50% by weight, between about 1% and about 25% by weight, and between about 5% and about 25% by weight of the total weight of the solid detergent composition.
  • all numeric ranges recited herein are inclusive of the numbers defining the range.
  • chelants for use in the non-phosphate alkaline detergent compositions include carboxylates such as citrate, tartrate or gluconate are suitable.
  • carboxylates such as citrate, tartrate or gluconate are suitable.
  • sodium gluconate is employed as a chelant for the solid alkaline detergent compositions.
  • the solid detergent compositions can contain a non-phosphorus based builder. Although various components may include trace amounts of phosphorous, a composition that is considered free of phosphorous generally does not include phosphate or phosphonate builder or chelating components as an intentionally added component. Carboxylates such as citrate, tartrate or gluconate are suitable.
  • Useful aminocarboxylic acid materials containing little or no NTA include, but are not limited to: N-hydroxyethylaminodiacetic acid, ethylenediaminetetraacetic acid (EDTA), hydroxyethylenediaminetetraacetic acid, diethylenetriaminepentaacetic acid, N-hydroxyethyl-ethylenediaminetriacetic acid (HEDTA), diethylenetriaminepentaacetic acid (DTPA), and other similar acids having an amino group with a carboxylic acid substituent.
  • EDTA ethylenediaminetetraacetic acid
  • HEDTA N-hydroxyethyl-ethylenediaminetriacetic acid
  • DTPA diethylenetriaminepentaacetic acid
  • Water conditioning polymers can be used as non-phosphorus containing builders.
  • Exemplary water conditioning polymers include, but are not limited to: polycarboxylates.
  • Exemplary polycarboxylates that can be used as builders and/or water conditioning polymers include, but are not limited to: those having pendant carboxylate (-CO 2 - ) groups such as polyacrylic acid, maleic acid, maleic/olefin copolymer, sulfonated copolymer or terpolymer, acrylic/maleic copolymer, polymethacrylic acid, acrylic acid-methacrylic acid copolymers, hydrolyzed polyacrylamide, hydrolyzed polymethacrylamide, hydrolyzed polyamide-methacrylamide copolymers, hydrolyzed polyacrylonitrile, hydrolyzed polymethacrylonitrile, and hydrolyzed acrylonitrile-methacrylonitrile copolymers.
  • the solid detergent compositions can also include a hardening agent in addition to, or in the form of, the builder.
  • a hardening agent is a compound or system of compounds, organic or inorganic, which significantly contributes to the uniform solidification of the composition.
  • the hardening agents are compatible with the cleaning agents, including the sodium hydroxide active alkalinity, and other active ingredients of the composition and are capable of providing an effective amount of hardness and/or aqueous solubility to the processed composition.
  • the hardening agents should also be capable of forming a homogeneous matrix with the cleaning agent and other ingredients when mixed and solidified to provide a uniform dissolution of the cleaning agent from the solid detergent composition during use.
  • the amount of hardening agent included in the solid detergent composition will vary according to factors including, but not limited to: the type of solid detergent composition being prepared, the ingredients of the solid detergent composition, the intended use of the composition, the quantity of dispensing solution applied to the solid composition over time during use, the temperature of the dispensing solution, the hardness of the dispensing solution, the physical size of the solid detergent composition, the concentration of the other ingredients, and the concentration of the cleaning agent in the composition. It is preferred that the amount of the hardening agent included in the solid detergent composition is effective to combine with the cleaning agent and other ingredients of the composition to form a homogeneous mixture under continuous mixing conditions and a temperature at or below the melting temperature of the hardening agent.
  • the hardening agent form a matrix with the cleaning agent and other ingredients which will harden to a solid form under ambient temperatures of approximately 30° C to approximately 50° C, particularly approximately 35° C to approximately 45° C, after mixing ceases and the mixture is dispensed from the mixing system, within approximately less than 1 minute, or from about 1 minute to approximately 3 hours, particularly approximately less than 2 minutes to approximately 2 hours, and particularly approximately less than 5 minutes to approximately 1 hour.
  • a minimal amount of heat from an external source may be applied to the mixture to facilitate processing of the mixture.
  • the amount of the hardening agent included in the solid detergent composition is effective to provide a desired hardness and desired rate of controlled solubility of the processed composition when placed in an aqueous medium to achieve a desired rate of dispensing the cleaning agent from the solidified composition during use.
  • the hardening agent may be an organic or an inorganic hardening agent.
  • the organic hardening agent is not a polyethylene glycol (PEG) compound, such as shown in Examples 10-23 according to the invention.
  • PEG polyethylene glycol
  • examples of polyethylene glycols include, but are not limited to: solid polyethylene glycols of the general formula H(OCH 2 CH 2 ) n OH, where n is greater than 15, particularly approximately 30 to approximately 1700 having a variety of molecular weights. It is further preferred that the hardening agent is not urea and/or urea particles.
  • Preferred inorganic hardening agents are hydratable inorganic salts, including, but not limited to: sulfates and bicarbonates.
  • the inorganic hardening agents are present at concentrations of up to approximately 50% by weight, particularly approximately 1% to approximately 25% by weight, and more particularly approximately 5% to approximately 15% by weight.
  • all numeric ranges recited herein are inclusive of the numbers defining the range.
  • Bleaching agents suitable for use in the solid detergent composition for lightening or whitening a substrate include bleaching compounds capable of liberating an active halogen species, such as Cl 2 , Br 2 , -OCl - and/or -OBr - , under conditions typically encountered during the cleansing process.
  • Suitable bleaching agents for use in the solid detergent compositions include, but are not limited to: chlorine-containing compounds such as chlorines, hypochlorites, or chloramines.
  • Exemplary halogen-releasing compounds include, but are not limited to: the alkali metal dichloroisocyanurates, chlorinated trisodium phosphate, the alkali metal hypochlorites, monochloramine, and dichloramine.
  • Encapsulated chlorine sources may also be used to enhance the stability of the chlorine source in the composition (see, for example, U.S. Patent Nos. 4,618,914 and 4,830,773 ).
  • a bleaching agent may also be a peroxygen or active oxygen source such as hydrogen peroxide, perborates, sodium carbonate peroxyhydrate, potassium permonosulfate, and sodium perborate mono and tetrahydrate, with and without activators such as tetraacetylethylene diamine.
  • the concentrate when the concentrate includes a bleaching agent, it can be included in an amount of between approximately 0.1% and approximately 60% by weight, between approximately 1% and approximately 20% by weight, between approximately 3% and approximately 8% by weight, and between approximately 3% and approximately 6% by weight.
  • all numeric ranges recited herein are inclusive of the numbers defining the range.
  • the solid detergent composition can include an effective amount of detergent fillers which do not perform as a cleaning agent per se, but cooperates with the cleaning agent to enhance the overall cleaning capacity of the composition.
  • detergent fillers suitable for use in the present cleaning compositions include, but are not limited to: sodium sulfate and sodium chloride.
  • the concentrate includes detergent filler, it can be included in an amount up to approximately 50% by weight, between approximately 1% and approximately 30% by weight, or between approximately 1.5% and approximately 25% by weight.
  • all numeric ranges recited herein are inclusive of the numbers defining the.
  • a defoaming agent for reducing the stability of foam may also be included in the warewashing composition.
  • defoaming agents include, but are not limited to: ethylene oxide/propylene block copolymers such as those available under the name Pluronic N-3; silicone compounds such as silica dispersed in polydimethylsiloxane, polydimethylsiloxane, and functionalized polydimethylsiloxane such as those available under the name Abil B9952; fatty amides, hydrocarbon waxes, fatty acids, fatty esters, fatty alcohols, fatty acid soaps, ethoxylates, mineral oils, polyethylene glycol esters, and alkyl phosphate esters such as monostearyl phosphate.
  • defoaming agents may be found, for example, in U.S. Patent No. 3,048,548 to Martin et al. , U.S. Patent No. 3,334,147 to Brunelle et al. , and U.S. Patent No. 3,442,242 to Rue et al.
  • the defoaming agent can be provided in an amount of between approximately 0.0001% and approximately 10% by weight, between approximately 0.001% and approximately 5% by weight, or between approximately 0.01% and approximately 1.0% by weight.
  • all numeric ranges recited herein are inclusive of the numbers defining the range.
  • the solid detergent composition can include an anti-redeposition agent for facilitating sustained suspension of soils in a cleaning solution and preventing the removed soils from being redeposited onto the substrate being cleaned.
  • suitable anti-redeposition agents include, but are not limited to: polyacrylates, styrene maleic anhydride copolymers, cellulosic derivatives such as hydroxyethyl cellulose, hydroxypropyl cellulose and carboxymethyl cellulose.
  • the anti-redeposition agent can be included in an amount of between approximately 0.5% and approximately 10% by weight, and between approximately 1% and approximately 5% by weight.
  • all numeric ranges recited herein are inclusive of the numbers defining the range.
  • the solid detergent composition may also include stabilizing agents.
  • suitable stabilizing agents include, but are not limited to: borate, calcium/magnesium ions, propylene glycol, and mixtures thereof.
  • the concentrate need not include a stabilizing agent, but when the concentrate includes a stabilizing agent, it can be included in an amount that provides the desired level of stability of the concentrate.
  • Exemplary ranges of the stabilizing agent include up to approximately 20% by weight, between approximately 0.5% and approximately 15% by weight, and between approximately 2% and approximately 10% by weight. Without being limited to the scope of the invention, all numeric ranges recited herein are inclusive of the numbers defining the range.
  • the solid detergent composition may also include dispersants.
  • suitable dispersants that can be used in the solid detergent composition include, but are not limited to: maleic acid/olefin copolymers, polyacrylic acid, and mixtures thereof.
  • the concentrate need not include a dispersant, but when a dispersant is included it can be included in an amount that provides the desired dispersant properties. Exemplary ranges of the dispersant in the concentrate can be up to approximately 20% by weight, between approximately 0.5% and approximately 15% by weight, and between approximately 2% and approximately 9% by weight. Without being limited to the scope of the invention, all numeric ranges recited herein are inclusive of the numbers defining the.
  • Enzymes that can be included in the solid detergent composition include those enzymes that aid in the removal of starch and/or protein stains.
  • Exemplary types of enzymes include, but are not limited to: proteases, alpha-amylases, and mixtures thereof.
  • Exemplary proteases that can be used include, but are not limited to: those derived from Bacillus licheniformix, Bacillus lenus, Bacillus alcalophilus, and Bacillus amyloliquefacins.
  • Exemplary alpha-amylases include Bacillus subtilis, Bacillus amyloliquefaceins and Bacillus licheniformis.
  • the concentrate need not include an enzyme, but when the concentrate includes an enzyme, it can be included in an amount that provides the desired enzymatic activity when the solid detergent composition is provided as a use composition.
  • Exemplary ranges of the enzyme in the concentrate include up to approximately 15% by weight, between approximately 0.5% to approximately 10% by weight, and between approximately 1% to approximately 5% by weight. Without being limited to the scope of the invention, all numeric ranges recited herein are inclusive of the numbers defining the range.
  • the solid detergent composition can include a metal corrosion inhibitor in an amount up to approximately 50% by weight, between approximately 1% and approximately 40% by weight, or between approximately 3% and approximately 30% by weight.
  • a metal corrosion inhibitor in an amount up to approximately 50% by weight, between approximately 1% and approximately 40% by weight, or between approximately 3% and approximately 30% by weight.
  • the corrosion inhibitor is included in the solid detergent composition in an amount sufficient to provide a use solution that exhibits a rate of corrosion and/or etching of glass that is less than the rate of corrosion and/or etching of glass for an otherwise identical use solution except for the absence of the corrosion inhibitor. It is expected that the use solution will include at least approximately 6 parts per million (ppm) of the corrosion inhibitor to provide desired corrosion inhibition properties. It is expected that larger amounts of corrosion inhibitor can be used in the use solution without deleterious effects. It is expected that at a certain point, the additive effect of increased corrosion and/or etching resistance with increasing corrosion inhibitor concentration will be lost, and additional corrosion inhibitor will simply increase the cost of using the solid detergent composition.
  • ppm parts per million
  • the use solution can include between approximately 6 ppm and approximately 300 ppm of the corrosion inhibitor, and between approximately 20 ppm and approximately 200 ppm of the corrosion inhibitor.
  • suitable corrosion inhibitors include, but are not limited to: a combination of a source of aluminum ion and a source of zinc ion, as well as an alkaline metal silicate or hydrate thereof.
  • the corrosion inhibitor can refer to the combination of a source of aluminum ion and a source of zinc ion.
  • the source of aluminum ion and the source of zinc ion provide aluminum ion and zinc ion, respectively, when the solid detergent composition is provided in the form of a use solution.
  • the amount of the corrosion inhibitor is calculated based upon the combined amount of the source of aluminum ion and the source of zinc ion. Anything that provides an aluminum ion in a use solution can be referred to as a source of aluminum ion, and anything that provides a zinc ion when provided in a use solution can be referred to as a source of zinc ion.
  • Aluminum ions can be considered a source of aluminum ion, and zinc ions can be considered a source of zinc ion.
  • the source of aluminum ion and the source of zinc ion can be provided as organic salts, inorganic salts, and mixtures thereof.
  • Exemplary sources of aluminum ion include, but are not limited to: aluminum salts such as sodium aluminate, aluminum bromide, aluminum chlorate, aluminum chloride, aluminum iodide, aluminum nitrate, aluminum sulfate, aluminum acetate, aluminum formate, aluminum tartrate, aluminum lactate, aluminum oleate, aluminum bromate, aluminum borate, aluminum potassium sulfate, aluminum zinc sulfate, and aluminum phosphate.
  • aluminum salts such as sodium aluminate, aluminum bromide, aluminum chlorate, aluminum chloride, aluminum iodide, aluminum nitrate, aluminum sulfate, aluminum acetate, aluminum formate, aluminum tartrate, aluminum lactate, aluminum oleate, aluminum bromate, aluminum borate, aluminum potassium sulfate, aluminum zinc sulfate, and aluminum phosphate.
  • Exemplary sources of zinc ion include, but are not limited to: zinc salts such as zinc chloride, zinc sulfate, zinc nitrate, zinc iodide, zinc thiocyanate, zinc fluorosilicate, zinc dichromate, zinc chlorate, sodium zincate, zinc gluconate, zinc acetate, zinc benzoate, zinc citrate, zinc lactate, zinc formate, zinc bromate, zinc bromide, zinc fluoride, zinc fluorosilicate, and zinc salicylate.
  • zinc salts such as zinc chloride, zinc sulfate, zinc nitrate, zinc iodide, zinc thiocyanate, zinc fluorosilicate, zinc dichromate, zinc chlorate, sodium zincate, zinc gluconate, zinc acetate, zinc benzoate, zinc citrate, zinc lactate, zinc formate, zinc bromate, zinc bromide, zinc fluoride, zinc fluorosilicate, and zinc salicylate.
  • the ratio of the source of aluminum ion to the source of zinc ion can be controlled to provide a synergistic effect.
  • the weight ratio of aluminum ion to zinc ion in the use solution can be between at least approximately 6:1, can be less than approximately 1:20, and can be between approximately 2:1 and approximately 1:15.
  • an effective amount of an alkaline metal silicate or hydrate thereof can be employed in the compositions and processes of the invention to form a stable solid detergent composition having metal protecting capacity.
  • the silicates employed in the compositions of the invention are those that have conventionally been used in solid detergent formulations.
  • typical alkali metal silicates are those powdered, particulate or granular silicates which are either anhydrous or preferably which contain water of hydration (approximately 5% to approximately 25% by weight, particularly approximately 15% to approximately 20% by weight water of hydration).
  • These silicates are preferably sodium silicates and have a Na 2 O:SiO 2 ratio of approximately 1:1 to approximately 1:5, respectively, and typically contain available water in the amount of from approximately 5% to approximately 25% by weight.
  • the silicates have a Na 2 O:SiO 2 ratio of approximately 1:1 to approximately 1:3.75, particularly approximately 1:1.5 to approximately 1:3.75 and most particularly approximately 1:1.5 to approximately 1:2.5.
  • a silicate with a Na 2 O:SiO 2 ratio of approximately 1:2 and approximately 16% to approximately 22% by weight water of hydration is most preferred.
  • such silicates are available in powder form as GD Silicate and in granular form as Britesil H-20, available from PQ Corporation, Valley Forge, PA. These ratios may be obtained with single silicate compositions or combinations of silicates which upon combination result in the preferred ratio.
  • the hydrated silicates at preferred ratios, a Na 2 O:SiO 2 ratio of approximately 1:1.5 to approximately 1:2.5, have been found to provide the optimum metal protection and rapidly form a solid detergent. Hydrated silicates are preferred.
  • Silicates can be included in the solid detergent composition to provide for metal protection but are additionally known to provide alkalinity and additionally function as anti-redeposition agents.
  • Exemplary silicates include, but are not limited to: sodium silicate and potassium silicate.
  • the solid detergent composition can be provided without silicates, but when silicates are included, they can be included in amounts that provide for desired metal protection.
  • the concentrate can include silicates in amounts of at least approximately 1% by weight, at least approximately 5% by weight, at least approximately 10% by weight, and at least approximately 15% by weight.
  • the silicate component can be provided at a level of less than approximately 35% by weight, less than approximately 25% by weight, less than approximately 20% by weight, and less than approximately 15% by weight.
  • all numeric ranges recited herein are inclusive of the numbers defining the range and include each integer within the defined range.
  • Suitable dyes that may be included to alter the appearance of the composition, include, but are not limited to: Direct Blue 86, available from Mac Dye-Chem Industries, Ahmedabad, India; Fastusol Blue, available from Mobay Chemical Corporation, Pittsburgh, PA; Acid Orange 7, available from American Cyanamid Company, Wayne, NJ; Basic Violet 10 and Sandolan Blue/Acid Blue 182, available from Sandoz, Princeton, NJ; Acid Yellow 23, available from Chemos GmbH, Regenstauf, Germany; Acid Yellow 17, available from Sigma Chemical, St.
  • Fragrances or perfumes that may be included in the compositions include, but are not limited to: terpenoids such as citronellol, aldehydes such as amyl cinnamaldehyde, a jasmine such as C1S-jasmine or jasmal, and vanillin.
  • Flow aids may further be referred to as carriers and/or glidants and are generally known for improving the processing of compositions, such as the solid detergent compositions according to the invention.
  • Suitable components for improving the flowability of the homogenous powder components according to the invention may include for example, inorganic or organic agents.
  • inorganic agents are preferred, including for example silicas, borates, acetate salts, sulfate salts and the like.
  • Silicas including for example the precipitated or fumed forms (e.g., Sipernat®, Aerosil®, CAB-O-SIL®) can be employed and are commercially available, for example from Evonik Industries.
  • the actual solidification mechanism may occur through hydroxide hydration, e.g. the interaction of the sodium hydroxide (or other alkali metal hydroxide) with water. It is believed that the combination of the sodium hydroxide and secondary alkalinity source (e.g. sodium metasilicate) along with a polycarboxylic acid polymer functions to control the kinetics and thermodynamics of the solidification process and provides a solidification matrix in which additional functional materials may be bound to form a functional solid composition.
  • a polycarboxylic acid polymer and other functional ingredients may have efficacy in stabilizing the hydroxide by acting as donor and/or acceptor of free water.
  • aspects of solidification as a result of ash hydration e.g. the interaction of the hydratable salt with water.
  • the carbonate hydrates by acting as a donor and/or acceptor of free water.
  • the rate of solidification of the detergent compositions may be controlled to provide process and dimensional stability to the resulting solid detergent composition product.
  • the rate of solidification is significant because if the solidification matrix solidifies too quickly, the composition may solidify during mixing and stop processing. If the solidification matrix solidifies too slowly, valuable process time is lost.
  • a polycarboxylic acid polymer may assist in providing dimensional stability to the end product by ensuring that the solid product containing the sodium hydroxide and secondary alkalinity source (e.g. sodium metasilicate) does not swell. If the solid product swells after solidification, various problems may occur, including but not limited to: decreased density, integrity, and appearance; and inability to dispense or package the solid product.
  • a solid product is considered to have dimensional stability if the solid product has a growth exponent of less than about 3% and particularly less than about 2%. Growth exponent refers to the percent growth or swelling of a product over a period of time after solidification under normal transport/storage conditions.
  • the growth exponent of a solid detergent product may be determined by measuring one or more dimensions of the product prior to and after heating at 48.8 °C (120 °F). The measured dimension or dimensions depends on the shape of the solid product and the manner in which it swells. For tablets, the change in both diameter and height is generally measured and added together to determine the growth exponent. For capsules, just the diameter is normally measured.
  • a solid detergent composition using the solidification matrix of the present invention can be created by combining the alkali metal hydroxide alkalinity source (e.g. sodium hydroxide), secondary alkalinity source (e.g. anhydrous sodium metasilicate), sodium carbonate and/or potassium carbonate, water, and any additional functional components and allowing the components to interact and solidify.
  • alkali metal hydroxide alkalinity source e.g. sodium hydroxide
  • secondary alkalinity source e.g. anhydrous sodium metasilicate
  • the solid detergent composition includes 10 to 50 wt.-% sodium hydroxide, 5 to 50 wt.-% anhydrous sodium metasilicate, 1 to 10 wt.-% water, 20 to 90 wt.-% sodium carbonate, and functional ingredients.
  • 10 to 50 wt.-% sodium hydroxide 5 to 50 wt.-% anhydrous sodium metasilicate
  • 1 to 10 wt.-% water 20 to 90 wt.-% sodium carbonate
  • functional ingredients included in a first embodiment, the solid detergent composition includes 10 to 50 wt.-% sodium hydroxide, 5 to 50 wt.-% anhydrous sodium metasilicate, 1 to 10 wt.-% water, 20 to 90 wt.-% sodium carbonate, and functional ingredients.
  • all numeric ranges recited herein are inclusive of the numbers defining the range.
  • the relative amounts of sodium hydroxide, water and polycarboxylic acid polymer are controlled within a composition.
  • the solidification matrix and additional functional components harden into solid form due to the chemical reaction of the sodium hydroxide and water (hydroxide hydration), and/or the sodium carbonate (ash hydration) with the water.
  • a binder composition can form to bind and solidify the components. At least a portion of the ingredients associate to form the binder while the balance of the ingredients forms the remainder of the solid composition.
  • the solidification process may last from a few minutes to about six hours, depending on factors including, but not limited to: the size of the formed composition, the ingredients of the composition, and the temperature of the composition.
  • the hydratable salt e.g. sodium carbonate
  • secondary alkalinity source e.g. anhydrous sodium metasilicate
  • at least one additional functional ingredient are combined into a homogenous powder mixture.
  • a water source is added to the homogenous powder mixture prior to incorporation into the detergent composition, and can be provided as a solid hydrate.
  • the addition of water to the homogenous powder mixture is referred to herein as a water "charge.”
  • a water charge is included in the solidification matrix for subsequent combination with the sodium hydroxide (and optionally the polycarboxylic acid polymer).
  • the water charge is from about 1% to about 10%, or from about 2% to about 10%.
  • an effective amount of the sodium hydroxide and sodium carbonate refer to amounts that effectively control the kinetics and thermodynamics of the solidification system by controlling the rate and movement of water into the hydroxide hydration process and/or ash hydration process.
  • Solid detergent compositions formed using the solidification matrix are produced using a batch or continuous mixing system.
  • a processing method of a tablet press is used to form tablets from the homogeneous mixtures according to the methods of the invention.
  • the processing temperature is at or below the melting temperature of the components.
  • the processed mixture may be dispensed from the mixer by forming, or other suitable means, whereupon the detergent composition hardens to a solid form.
  • the structure of the matrix may be characterized according to its hardness, melting point, material distribution, crystal structure, and other like properties according to known methods in the art.
  • a solid detergent composition processed according to the method of the invention is substantially homogeneous with regard to the distribution of ingredients throughout its mass and is dimensionally stable.
  • the liquid and solid components are introduced into the final mixing system and are continuously mixed until the components form a substantially homogeneous semi-solid mixture in which the components are distributed throughout its mass.
  • the components are mixed in the mixing system for at least approximately 5 seconds.
  • the mixture is then discharged from the mixing system into, or through, a die or other shaping means.
  • the product is then packaged.
  • the formed composition begins to harden to a solid form in less than 1 minute, or between approximately 1 minute and approximately 3 hours.
  • the formed composition begins to harden to a solid form in between a few seconds to about 1 minute. More particularly, the formed composition begins to harden to a solid form in between approximately a few seconds to about 2 minutes.
  • solid form it is meant that the hardened composition will not flow and will substantially retain its shape under moderate stress or pressure or mere gravity.
  • the degree of hardness of the solid composition may range from that of a fused solid product which is relatively dense and hard, for example, like concrete, to a consistency characterized as being a hardened paste.
  • solid refers to the state of the detergent composition under the expected conditions of storage and use of the solid detergent composition. According to the invention, the detergent composition will remain in solid form when exposed to temperatures of up to approximately 48.88 °C (120 °F).
  • the resulting solid detergent composition may take forms including, but not limited to: an extruded, molded or formed solid pellet, block, tablet, powder, granule, flake; or the formed solid can thereafter be ground or formed into a powder, granule, or flake.
  • the solid detergent compositions are not cast solid products.
  • extruded pellet materials formed by the solidification matrix have a weight of between approximately 50 grams and approximately 250 grams
  • extruded solids formed by the solidification matrix have a weight of approximately 100 grams or greater
  • solid block detergents formed by the solidification matrix have a mass of between approximately 0.25 and approximately 10 kilograms.
  • the solid compositions provide for a stabilized source of functional materials.
  • the solid composition may be dissolved, for example, in an aqueous or other medium, to create a concentrated and/or use solution.
  • the solution may be directed to a storage reservoir for later use and/or dilution, or may be applied directly to a point of use.
  • the solid detergent composition is provided in the form of a unit dose.
  • a unit dose refers to a solid detergent composition unit sized so that the entire unit is used during a single washing cycle. According to aspects of the invention, when the solid detergent composition is provided as a unit dose, it is typically provided as an extruded pellet, or a tablet having a size of between approximately 1 gram and approximately 250 grams.
  • the solid detergent composition is provided in the form of a multiple-use solid, such as a block or a plurality of pellets, and can be repeatedly used to generate aqueous detergent compositions for multiple washing cycles.
  • the solid detergent composition is provided as an extruded block, or a tablet having a mass of between approximately 5 grams and approximately 10 kilograms.
  • a multiple-use form of the solid detergent composition has a mass between approximately 1 kilogram and approximately 10 kilograms.
  • a multiple-use form of the solid detergent composition has a mass of between approximately 5 kilograms and about approximately 8 kilograms.
  • a multiple-use form of the solid detergent composition has a mass of between about approximately 5 grams and approximately 1 kilogram, or between approximately 5 grams and approximately 500 grams.
  • the detergent composition may also be provided in the form of a paste.
  • the concentrate is provided in the form of a paste, enough water is added to the detergent composition such that complete solidification of the detergent composition is precluded.
  • dispersants and other components may be incorporated into the detergent composition in order to maintain a desired distribution of components.
  • the various solidification matrices of the present invention may be employed in a wide variety of cleaning applications.
  • the solid detergent compositions of the invention are suitable for use in any applications requiring an environmentally friendly, solid alkaline detergent.
  • Such applications include, but are not limited to: phosphate-free alkaline detergent use in combination ovens, such as those used in various food service industries.
  • Additional applications may include, for example, machine warewashing employing a ware wash detergent, presoaks, fryer boil outs, power soak sinks and related applications, soak tanks, instrument reprocessing, laundry and textile cleaning and destaining, carpet cleaning and destaining, vehicle cleaning and care applications, surface cleaning and destaining, kitchen and bath cleaning and destaining, floor cleaning and destaining, cleaning in place operations, general purpose cleaning and destaining, and/or industrial or household cleaners.
  • machine warewashing employing a ware wash detergent, presoaks, fryer boil outs, power soak sinks and related applications, soak tanks, instrument reprocessing, laundry and textile cleaning and destaining, carpet cleaning and destaining, vehicle cleaning and care applications, surface cleaning and destaining, kitchen and bath cleaning and destaining, floor cleaning and destaining, cleaning in place operations, general purpose cleaning and destaining, and/or industrial or household cleaners.
  • the solid detergent compositions are particularly suited for cleaning combination ovens.
  • combination ovens are disclosed, for example, in U.S. Pat. Nos. 5,368,008 , 5,640,946 , and 6,410,890 , EP 0652405 and DE 2842771 .
  • combination ovens may refer to apparatuses having a double oven-steamer, a double oven-boiler, or having at least one oven chamber and a steam generator and/or boiler.
  • the solid detergent compositions according to the invention can be provided for cleaning of the combination oven apparatuses known in the art.
  • the solid detergent compositions may be added directly to a combination oven apparatus, for example through a funnel or other member, as described and depicted for example in U.S. Pat. No. 5,640,946 , instead of having to access the steamer and/or boiler components of the combination ovens.
  • a combination oven apparatus for example through a funnel or other member, as described and depicted for example in U.S. Pat. No. 5,640,946 , instead of having to access the steamer and/or boiler components of the combination ovens.
  • the solid detergent compositions according to the invention may be initially used to generate an aqueous solution or suspension for delivery to a combination over for cleaning according to the invention. Thereafter, the liquid compositions are applied to the internal surfaces of the apparatus, such as for example, through the use of spray nozzles and/or spray jets or the like.
  • the methods of cleaning using the solid detergent compositions according to the invention may further include one or more rinse steps, decalcification steps, a prewash step, and/or a soak step.
  • Approximately 50 grams batch of the product using a polycarboxylic acid polymer as part of the solidification matrix was first pressed in a die at approximately 6894 kPa (1000 pounds per square inch (psi)) for approximately 20 seconds to form tablets. The diameter and height of the tablets were measured and recorded. The tablets were maintained at room temperature for one day and then placed in an oven at a temperature of approximately 48.8 °C (120 °F). After the tablets were removed from the oven, the diameters and heights of the tablets were again measured and recorded. The growth exponent was determined for the tablets by measuring growth based on the cumulative change in the diameter and height of the tablet after heating.
  • Comparative Examples 1, 2, and 3 are compositions of the present invention using a polycarboxylic acid polymer as part of a solidification matrix.
  • the compositions of Comparative Examples 1, 2, and 3 used a polyacrylic acid polymer, a modified polyacrylic acid polymer, and a polymaleic acid polymer, respectively, as part of the solidification matrix.
  • the compositions of Comparative Examples 1, 2, and 3 also included component concentrations (in weight percent) of sodium carbonate (soda ash or dense ash), sodium bicarbonate, sodium metasilicate, a builder, surfactant, defoamers, sodium hydroxide, and water as provided in Table 1.
  • the sodium carbonate, sodium bicarbonate, sodium metasilicate, builder, surfactant, and defoamers were premixed to form a powder premix and the polycarboxylic acid polymer, sodium hydroxide, and water were premixed to form a liquid premix.
  • the powder premix and the liquid premix were then mixed together to form the composition.
  • Approximately 50 grams of the composition were pressed into a tablet at approximately 6894 kPa (1000 psi) for approximately 20 seconds.
  • Comparative Example A was prepared as in Comparative Examples 1, 2, and 3, except that the composition of Comparative Example A did not include a polycarboxylic acid polymer.
  • Comparative Example B was prepared as in Comparative Example 1 except for the addition of Trilon M Powder, which is a methylglycinediacetic acid (MGDA) powder.
  • Table 1 provides the component concentrations for the compositions of Comparative Example 1, 2, and 3 and Comparative Example A.
  • Table 2 provides the component concentrations of Comparative Example B.
  • Table 1 Component Comp. Example 1 Comp. Example 2 Comp.
  • Example 3 Comp.
  • Example A Sodium carbonate, wt.% 55.76 56.76 57.33 58.19 Sodium bicarbonate, wt.% 2.88 2.88 2.88 2.88 Sodium metasilicate, wt.% 3 3 3 3 3 3 Builder, wt.% 20 20 20 20 20 Nonionic surfactant, wt.% 3.53 3.53 3.53 3.53 Defoamer, wt.% 1.06 1.06 1.06 1.06 Polyacrylic acid, wt.% 7.34 0 0 0 0 Modified polyacrylic acid, wt.% 0 9 0 0 Polymaleic acid, wt.% 0 0 7.05 0 Sodium hydroxide (50%), wt.% 2.66 0 2.37 0 Water, wt.% 3.77 3.77 2.78 11.34 Table 2 Component Comp.
  • Example B Sodium carbonate, wt.% 43.52 Trilon M Powder, wt.% 13.24 Sodium bicarbonate, wt.% 2.88 Anhydrous metasilicate, wt.% 3.00 Builder, wt.% 20.00 Nonionic surfactant, wt.% 3.53 Defoamer, wt.% 1.06 Modified polyacrylic acid, wt.% 9.00 Water, wt. % 3.77
  • the formed products of the compositions of Comparative Examples 1, 2, and 3 exhibited considerably less swelling than the formed product of the composition of Comparative Example A.
  • the product of the composition of Comparative Example 1 had only a 0,6% growth in diameter and a 1.1% growth in height resulting in a growth exponent of 1.7%.
  • the product of the composition of Comparative Example 2 had a 0% growth in diameter and a -0.6% growth in height resulting in no positive growth exponent.
  • the product of the composition of Comparative Example 3 only had a 0.9% growth in diameter and a 1.2% growth in height resulting in a growth exponent of 2.1%.
  • the product of the composition of Comparative Example A had a 2.7% growth in diameter and an 8.2% growth in height resulting in a growth exponent of 10.9%.
  • compositions of Comparative Examples 1, 2, and 3 and Comparative Example A were the same in the compositions of Comparative Examples 1, 2, and 3 and Comparative Example A. It is thus believed that the polycarboxylic acid polymer aided in the dimensional stability of the products of the compositions of Comparative Example 1, Comparative Example 2, and Comparative Example 3. Because the composition of Comparative Example A did not contain a polycarboxylic acid polymer, the composition did not include a mechanism for controlling the movement of water within the solid product.
  • Comparative Examples 4, 5, and 6 are compositions using a polycarboxylic acid polymer as a part of the solidification matrix.
  • the composition of Comparative Example 4 used a polyacrylic acid polymer as part of the solidification matrix
  • the composition of Comparative Example 5 used a modified polyacrylic acid polymer as part of the solidification matrix
  • the composition of Comparative Example 6 used polymaleic acid polymer as part of the solidification matrix.
  • Each of the compositions of Comparative Examples 4, 5, and 6 also included component concentrations (in weight percent) of softened water, builder, water conditioner, sodium hydroxide 50%, sodium carbonate (dense ash), anionic surfactant, and nonionic surfactant, as provided in Table 3.
  • the liquids softened water, builder, water conditioner, polycarboxylic acid polymer, and sodium hydroxide 50%
  • the liquids were premixed in order to form a liquid premix and the powders (sodium carbonate, anionic surfactant, and nonionic surfactant) were premixed in order to form a powder premix.
  • the liquid premix and the powder premix were then mixed to form the composition, which was subsequently poured into capsules.
  • Comparative Example C was prepared as in Comparative Examples 4, 5, and 6 except that the composition of Comparative Example C did not contain a polycarboxylic acid polymer but did contain the same quantity of available water.
  • Table 5 provides the component concentrations for the compositions of Comparative Examples 4-6 and Comparative Example C.
  • Example 5 Comp.
  • Example 6 Comp.
  • Example C Water, softened, wt.% 22.49 22.5 20.49 24 Builder, wt.% 4 4 0 4 Water conditioner wt.% 3 3 3 3 3 Polyacrylic acid, wt.% 0 10 0 0 Modified polyacrylic acid, wt.% 10 0 0 0 Polymaleic Acid, wt.% 0 0 10 0 NaOH, 50%, wt.% 0 0 3.4 0 Sodium carbonate, wt.% 55.51 55.5 58.12 63.64 Anionic surfactant, wt.% 1 1 1 1 1 Nonionic surfactant, wt.% 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
  • the cast products of the compositions of Comparative Examples 4, 5, and 6 exhibited considerably less swelling than the cast product of the composition of Comparative Example C.
  • the product of the composition of Comparative Example 4 experienced only a 0.6% growth in diameter resulting in a 0.6% growth exponent
  • the product of Comparative Example 5 experienced only a 1.3% growth in diameter resulting in a 1.3% growth exponent
  • the product of the composition of Comparative Example 6 experienced only a 1.9% growth in diameter resulting in a 1.9% growth exponent.
  • the product of the composition of Comparative Example C had a 4.9% growth in diameter resulting in a 4.9% growth exponent.
  • Comparative Example C The only difference in the compositions of Comparative Examples 4, 5, and 6 and Comparative Example C was the presence of a polycarboxylic acid polymer. It is thus believed that the polycarboxylic acid polymer aided in the dimensional stability of the products of the compositions of Comparative Examples 4, 5, and 6. By contrast, because the composition of Comparative Example C did not contain a polycarboxylic acid polymer, the composition did not contain a mechanism for controlling the movement of water within the solid product.
  • Comparative Examples 7, 8 and 9 compare cleaning performance when various combinations of polymaleic acid and polyacrylic acid were utilized.
  • the composition of each Comparative Example is set forth in Table 7.
  • the sodium carbonate, builder, surfactant, and disaccharide were premixed to form a powder premix and the polycarboxylic acid polymer, potassium hydroxide, phosphonate and water were premixed to form a liquid premix.
  • the powder premix and the liquid premix were then mixed together to form the composition.
  • Approximately 1000 grams of the composition was pressed into a tablet at approximately 6894 kPa (1000 psi) for approximately 20 seconds and allowed to solidify.
  • the resulting tablets were employed in an AM-14 automatic dishwasher machine dispensing 17 grain water. Glassware was then subjected to 100 wash and rinse cycles and tested for cleanliness. Cleanliness was measured in two ways. First, a luminosity value was determined by acquiring a digital optical image of the glassware, and then analyzing a luminosity value via computer analysis. The luminosity test indicates the degree of film present on the glass surface, with a lower value indicating less film and a cleaner glass. Second, a visual rating was measured on a 1 to 5 rating scale, with a lower visual rating indicating a cleaner glass. The results of these tests are set forth in Table 8.
  • Example 9 Glass visual rating luminosity value visual rating luminosity value visual rating luminosity value visual rating luminosity value 1 2.50 15610 3.00 17720 3.00 19653 2 2.00 14250 3.00 16752 3.00 19539 3 2.00 14664 3.00 16955 3.50 24913 4 2.00 15005 3.50 21742 3.50 20485 5 2.50 14949 3.00 16615 3.00 18191 6 2.50 15389 3.50 18392 3.00 18759 Plastic 2.5 N/A 2.5 N/A 4 N/A 6 Glass Average: 2.29 14978 3.07 18029 3.29 20257 6 Glass Std. Dev.: 0.27 490 0.35 1939 0.39 2413 4 Glass Average: 2.13 14717 3.13 18016 3.25 20782 4 Glass Std. Dev.: 0.25 345 0.25 2488 0.29 2910
  • Table 10 shows the components evaluated including: potassium carbonate / potash (alkaline builder); sodium carbonate / ash (alkaline builder); sodium citrate (chelant, binder); sodium hydroxide (active cleaner, caustic, hydration (50%)); water (hydration); disodium metasilicate (alkalinity source, corrosion inhibitor); and sodium sulfate (filler).
  • the potassium carbonate, sodium carbonate and sodium citrate were added to the ribbon blender and mixed.
  • the sodium hydroxide (50%) and water were added and mixed until the powder appeared dry.
  • the disodium metasilicate, sodium sulfate and sodium hydroxide were added and mixed until the powder appeared uniform. Comparative Examples 24-29 did not provide adequate mixing; powders were wet, clumpy, and hard to get out of the ribbon blender. Because of poor mixing the powders were not pressed into tablets and the experiment was terminated.
  • Table 11 shows the components evaluated including: sodium carbonate (alkaline builder); sodium citrate (chelant, binder); citrate solution (33%); sodium hydroxide (active cleaner, caustic, hydration (50%)); water (hydration); disodium metasilicate (alkalinity source, corrosion inhibitor); and sodium sulfate (filler).
  • the sodium carbonate and sodium citrate was added to the ribbon blender and mixed.
  • the water and disodium metasilicate were added and mixed until the powder was uniform.
  • the 60 gram tablets were pressed at 4000 pounds (approximately 11032 kPa (1600 psi)) and at 2500 pounds, holding for 3 seconds using the 1.75" diameter tablet die and the Carver press.
  • the force required to break a tablet was measured (higher force/pressure required translates to a more durable tablet).
  • the tablets were then placed on dimensional stability testing for one week at room temperature and 50 °C (122 °F).
  • Comparative Example 33 showed improved compression strength and dimensional stability compared to the other examples, however the formulation required additional improvements to the solidification and dimensional stability.
  • Table 12 Component Comparative Examples 39 40 potassium carbonate, wt.% 25% 150 g 48% 288 g sodium citrate, wt.% 10% 60 g 10% 60 g water, wt.% 1% 6 g 2% 12 g disodium metasilicate, wt.% 15% 90 g 15% 90 g sodium sulfate, wt.% 24% 144 g 0 0 Sodium hydroxide, wt.% 25% 150 g 25% 150 g Total 100 600 g 100 600 g Component Examples 41 42 sodium carbonate, wt.% 25% 150 g 46.5% 279 g sodium citrate, wt.% 10% 60 g 10% 60 g anhydrous metasilicate, wt.% 35.5% 213 g 15% 90 g water, wt.% 405% 27 g 3.5% 21 g sodium hydroxide, wt.% 25% 150 g 25% 150 g Total 100 600 g 100 600 g
  • the sodium carbonate, sodium citrate and anhydrous metasilicate were added to the ribbon blender and mixed. The water was slowly added. Then the sodium hydroxide was mixed until the powder was uniform. Thereafter, 25 gram tablets were pressed at 2000 pounds, holding for 3 seconds using the 1.25" diameter tablet die and the Carver press. Then the force required to break a tablet was measured (higher force/pressure required translates to a more durable tablet). The tablets were then placed on dimensional stability testing for one week at room temperature and 50 °C (122 °F).
  • the formulation of the table compositions with anhydrous sodium metasilicate generated stronger tablets with less swelling than the prior Examples using disodium metasilicate penta-hydrate.
  • the Example shows that the use of potassium carbonate is capable of yielding dimensionally-stable solid compositions when the water charge employed during mixing is less than about 1%.
  • the additional benefits of using sodium carbonate namely improved cleaning performance, result in its preferred use over the potassium carbonate.
  • Table 13 shows the components evaluated in the Example compositions.
  • Table 13 Component Comparative Examples 43-44; Examples 45-46 43 44 45 46 sodium carbonate, wt.% 40 37 37 42 d-gluconic acid, monosodium salt, wt.% 15 15 15 0 sodium citrate, wt.% 0 0 0 10 disodium metasilicate penta-hydrate, wt.% 10 10 0 0 anhydrous metasilicate, wt.% 0 0 10 10 water, wt.% 0 3 3 3 3 sodium polyacrylate, wt.% 5 5 5 5 5 sodium hydroxide, wt.% 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30
  • Example formulations that were mixed with a liquid water charge had higher compression strengths than the Example formulations that did not have a free water charge.
  • Example 45 yielded the hardest tablets with the least amount of swelling (indicating greatest dimensional stability).

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Claims (10)

  1. Composition solide de détergent comprenant :
    10 à 50 % en poids d'une source d'alcalinité par hydroxyde de métal alcalin ;
    20 à 90 % en poids de carbonate de sodium et/ou de carbonate de potassium ;
    5 à 50 % en poids d'une source d'alcalinité secondaire par silicate anhydre ;
    1 à 10 % en poids en eau ;
    au moins un ingrédient fonctionnel ;
    dans lequel ia composition solide de détergent est exempte de phosphore et est un solide hydraté aux dimensions stables en ce que, lorsqu'il est chauffé à une température de 48,88 °C (120 °F), la composition solide de détergent présente un taux de croissance inférieur à 3 %.
  2. Composition selon la revendication 1, dans laquelle l'au moins un ingrédient fonctionnel est choisi parmi le groupe comprenant un constituant de détersif, un tensioactif, un inhibiteur de corrosion, un agent de conditionnement de l'eau, un agent de chélation, un agent auxiliaire d'écoulement et une combinaison de ces derniers.
  3. Composition selon la revendication 1, dans laquelle l'ingrédient fonctionnel est un polymère d'acide polycarboxylique, un polymère d'acide polyacrylique ou un polymère de polyacrylate, et représente entre 0,1 % et 15 % du poids de la composition.
  4. Composition selon la revendication 1, dans laquelle le carbonate de potassium et/ou de sodium représente entre 30 % et 70 % du poids de la composition.
  5. Composition selon la revendication 1, dans laquelle la composition n'inclut pas un/des polyéthylène(s) glycol(s) et/ou d'urée.
  6. Composition selon la revendication 1, dans laquelle la composition solide de détergent est un comprimé solide hydraté.
  7. Composition solide de détergent selon la revendication 1, composée essentiellement de :
    entre 10 % et 50 % d'hydroxyde de sodium, rapportés au poids de la composition solide de détergent,
    entre 20 % et 90 % de carbonate de sodium, rapportés au poids de la composition solide de détergent ; entre 0,1 % et 15 % de polymère d'acide polycarboxyiique ou de sel de ce dernier, rapportés au poids de la composition solide de détergent ;
    entre 1 % et 10 % d'eau, rapporté au poids de la composition solide de détergent,
    entre 5 % et 50 % de source secondaire d'alcalinité, rapportés au poids de la composition solide de détergent, dans laquelle ladite source d'alcalinité est un métasilicate anhydre ;
    entre environ 1 % et environ 50 % d'agent de chélation, rapportés au poids de la composition solide de détergent ;
    dans laquelle la composition solide de détergent est un solide hydraté exempt de phosphore,
    dans laquelle ledit solide, lorsque chauffé à une température de 48,88 °C (120 °F) présente des dimensions stables et présente un taux de croissance inférieur à 3 %.
  8. Composition selon la revendication 7, dans laquelle l'hydroxyde de sodium représente entre 10 % et 50 % du poids de la composition, le carbonate de sodium représente entre 30 % et 70 % du poids de la composition, le polymère d'acide polycarboxylique ou sel de ce dernier est un polymère de polyacrylate et représente entre 2,5 % et 10 % du poids de la composition, l'eau représente entre 1 % et 5 % du poids de la composition, la source secondaire d'alcalinité représente entre 5 % et 15 % du poids de la composition, et l'agent de chélation représente entre 5 % et 25 % du poids de la composition.
  9. Composition selon la revendication 6, dans laquelle la composition est un comprimé de solide hydraté qui ne contient pas de polyéthylène(s) glycol(s), d'urée et/ou de carbonate de potassium.
  10. Procédé de formation d'une composition solide de détergent, le procédé comprenant :
    la combinaison de 30 à 70 % en poids de carbonate de sodium, de 5 à 50 % en poids de source secondaire d'alcalinité par silicate anhydre et au moins
    un composant fonctionnel supplémentaire afin de former un mélange préliminaire de poudres ;
    le mélange du mélange préliminaire de poudres avec une source d'eau afin de former un solide hydraté ; et
    la combinaison du solide hydraté avec une source d'hydroxyde de sodium et facultativement un polymère d'acide polycarboxylique ou sel de ce dernier ;
    dans laquelle la composition solide de détergent est exempte de phosphore, et
    dans laquelle, lorsque chauffée à une température de 48,88 °C (120 °F), la composition solide de détergent présente des dimensions stables et présente un taux de croissance inférieur à 3 %.
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KR101958382B1 (ko) 2019-03-14
JP6374398B2 (ja) 2018-08-15
ES2686602T3 (es) 2018-10-18
CN103911225A (zh) 2014-07-09
EP2941478A1 (fr) 2015-11-11
CA2895835A1 (fr) 2014-07-10
CA2895835C (fr) 2019-11-12
AU2013371371B2 (en) 2017-02-09
AU2013371371A1 (en) 2015-07-02

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