U.S. patent application number 12/636480 was filed with the patent office on 2010-04-08 for composition containing alpha-sulfofatty acid ester and hydrotrope and methods of making and using the same.
This patent application is currently assigned to THE SUN PRODUCTS CORPORATION. Invention is credited to PAUL DANTON HUISH, LAURIE A. JENSEN, PULE B. LIBE.
Application Number | 20100087355 12/636480 |
Document ID | / |
Family ID | 24312036 |
Filed Date | 2010-04-08 |
United States Patent
Application |
20100087355 |
Kind Code |
A1 |
HUISH; PAUL DANTON ; et
al. |
April 8, 2010 |
Composition Containing Alpha-Sulfofatty Acid Ester and Hydrotrope
and Methods of Making and Using The Same
Abstract
Compositions containing a .alpha.-sulfofatty acid ester and a
hydrotrope. The .alpha.-sulfofatty acid ester and the hydrotrope
reduce the pH drift in the composition and solubilize the
.alpha.-sulfofatty acid ester in solution. Methods are also
disclosed for making such compositions.
Inventors: |
HUISH; PAUL DANTON; (SALT
LAKE CITY, UT) ; JENSEN; LAURIE A.; (MIDVALE, UT)
; LIBE; PULE B.; (SALT LAKE CITY, UT) |
Correspondence
Address: |
STERNE, KESSLER, GOLDSTEIN & FOX P.L.L.C.
1100 NEW YORK AVENUE, N.W.
WASHINGTON
DC
20005
US
|
Assignee: |
THE SUN PRODUCTS
CORPORATION
WILTON
CT
|
Family ID: |
24312036 |
Appl. No.: |
12/636480 |
Filed: |
December 11, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11092191 |
Mar 28, 2005 |
7632798 |
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12636480 |
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10278161 |
Oct 21, 2002 |
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11092191 |
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09578248 |
May 24, 2000 |
6468956 |
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10278161 |
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Current U.S.
Class: |
510/340 ;
510/337 |
Current CPC
Class: |
C11D 1/523 20130101;
C11D 3/323 20130101; C11D 1/28 20130101; C11D 1/65 20130101 |
Class at
Publication: |
510/340 ;
510/337 |
International
Class: |
C11D 1/12 20060101
C11D001/12 |
Claims
1.-18. (canceled)
19. A method for making a composition, comprising: providing
.alpha.-sulfofatty acid ester; and combining the .alpha.-sulfofatty
acid ester with an effective amount of hydrotrope to solubilize the
.alpha.-sulfofatty acid ester in solution and to stabilize the pH
of the composition.
20. The method of claim 19, wherein the .alpha.-sulfofatty acid
ester is a methyl ester sulfonate.
21. The method of claim 20, further comprising: enriching the
C.sub.16 content of the methyl ester sulfonate.
22. The method of claim 19, further comprising: providing a
polyalkoxylated alkanolamide; and combining the polyalkoxylated
alkanolamide with the .alpha.-sulfofatty acid ester.
23. The method of claim 19, further comprising: providing another
detergent component; and combining the detergent component with the
.alpha.-sulfofatty acid ester.
24. The method of claim 19, wherein the hydrotrope is urea that is
substantially free of ammonium carbamate.
25.-39. (canceled)
40. The method of claim 19, wherein the composition has less than
about 1 wt % of a secondary anionic surfactant other than the
.alpha.-sulfofatty acid ester.
41. The method of claim 20, wherein the composition has less than
about 1 wt % of a secondary anionic surfactant other than the
.alpha.-sulfofatty acid ester.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to compositions
containing .alpha.-sulfofatty acid ester and methods for making and
using such compositions. More particularly, the present invention
relates to compositions containing .alpha.-sulfofatty acid ester
and hydrotrope, and methods for making and using the same.
[0002] Detergents have been used for many years to clean clothing
and other materials. Detergents originally contained soap derived
from animal fats. More recently, surfactants have been included in
detergents to enhance their cleaning performance. Typical
surfactants include anionics, nonionics, zwitterionics,
ampholytics, cationics and those described in Surface Active
Agents, Volumes I and II by Schwartz, Perry and Berch (New York,
Interscience Publishers), Nonionic Surfactants, ed. by M. J. Schick
(New York, M. Dekker, 1967), and in McCutcheon's Emulsifiers &
Detergents (1989 Annual, M. C. Publishing Co.), the disclosures of
which are incorporated herein by reference.
[0003] Anionic surfactants are a preferred type of surfactant for
laundry detergents due to their improved cleaning performance. The
cleaning performance of anionic surfactants can be limited,
however, by water hardness. Calcium and/or magnesium ions in hard
water interfere with some anionic surfactants, such as alkyl olefin
sulfonates, alkyl sulfates, linear alkyl sulfonates, and linear
alkyl benzene sulfonates. Recently, interest in .alpha.-sulfofatty
acid esters (also referred to hereafter as "sulfofatty acids") has
increased due to the improved cleaning properties of these
surfactants in hard water. While .alpha.-sulfofatty acid esters and
other anionic surfactants have similar detergency in soft water, as
water hardness increases .alpha.-sulfofatty acid esters exhibit
better cleaning performance as compared with other anionic
surfactants.
[0004] The use of .alpha.-sulfofatty acid esters has not been
widely accepted, however, due to several disadvantages of such
sulfofatty acids. In particular, .alpha.-sulfofatty acid esters
tend to degrade to form di-salts during their manufacture. While
mono-salts of .alpha.-sulfofatty acid esters have the desired
surface active agent properties, di-salts have several undesirable
properties that degrade the performance of the .alpha.-sulfofatty
acid ester. For example, the Kraft point of a C.sub.16 methyl ester
sulfonate ("MES") di-salt is 65.degree. C., as compared to
17.degree. C. for the mono-salt form of C.sub.16 MES. (The Kraft
point is the temperature at which the solubility of an ionic
surfactant becomes equal to its critical micelle concentration;
below the Kraft point, surfactants form precipitates instead of
micelles.) Thus, the higher the Kraft point, the more di-salt
precipitates in the composition. The resulting poor di-salt
solubility in cool and even slightly hard water is a disadvantage
in most applications. Thus, significant amounts of di-salt in
otherwise high quality .alpha.-sulfofatty acid ester degrade the
performance of that sulfofatty acid. The presence of large amounts
of di-salt in .alpha.-sulfofatty acid ester, therefore, results in
a poorer quality .alpha.-sulfofatty acid ester product,
characterized by degraded performance and reduced application
flexibility.
[0005] Di-salts also result from hydrolysis of .alpha.-sulfofatty
acid ester during storage and in detergent formulations. In
particular, mono-salts of .alpha.-sulfofatty acid ester hydrolyze
in the presence of moisture and alkali-containing detergent
components to form di-salts. For example, in formulations where MES
is well mixed with high pH components under aqueous conditions, the
MES will hydrolyze nearly completely to the di-salt form. High pH
components include builders, such as silicates or carbonates, and
bases, such as sodium hydroxide (NaOH). This chemical instability
discourages the use of .alpha.-sulfofatty acid esters in many
applications.
[0006] A related problem associated with .alpha.-sulfofatty acid
ester-containing detergent compositions is pH drift. In
concentrated solutions, the pH of the solution drifts towards the
acidic (lower) range. Such pH drift interferes with other detergent
components in the composition. To prevent pH drift, buffering or
alkalizing agents are added to detergents. Buffering or alkalizing
agents, such as caustic soda (NaOH), cause additional di-salt
formation, however, which decreases the performance of the
.alpha.-sulfofatty acid ester.
[0007] .alpha.-Sulfofatty acid esters also have limited solubility
in concentrated solutions. For example, phase separation occurs in
concentrated solutions of C.sub.16 or C.sub.18 .alpha.-sulfofatty
acid esters if the sulfofatty acid ester is not adequately
solubilized. To prevent phase separation, a hydrotrope is added to
the detergent composition. (A hydrotrope is a compound that is
soluble in aqueous solutions and that increases the aqueous
solubility of organic compounds.) Common hydrotropes include urea,
lower molecular weight alkanols, glycols, and ammonium, potassium
or sodium salts of toluene, xylene or cumene or ethyl benzene
sulfonates. The latter hydrotropes tend to be more expensive, so
less expensive hydrotropes, such as urea ((NH.sub.2).sub.2CO) or
urea-alkanol mixtures, are frequently used as cost-effective
substitutes. Greater quantities of these hydrotropes are required,
however, to achieve the stabilizing effects of the more expensive
hydrotropes.
[0008] A disadvantage of urea-based hydrotropes, however, is that
contaminants in urea release unpleasant odors. In particular, urea
often contains ammonium carbamate (NH.sub.4CO.sub.2NH.sub.2), which
hydrolyzes to release ammonia. If ammonia is released during
washing, it can offend the consumer, leading to decreased consumer
satisfaction with the product. Urea itself also slowly hydrolyzes
to release ammonia. If high levels of urea are present, such
hydrolysis tends to increase the pH of the composition. Such high
pH values are generally incompatible with some uses of
.alpha.-sulfofatty acid esters and with other detergent
components.
[0009] Thus, there is a need for a composition of
.alpha.-sulfofatty acid ester and hydrotrope that stabilizes the
.alpha.-sulfofatty acid ester and reduces additional di-salt
formation. There is a further need for a hydrotrope that reduces pH
drift and/or phase separation by .alpha.-sulfofatty acid esters.
Surprisingly, the present invention satisfies these needs.
SUMMARY OF THE INVENTION
[0010] The present invention provides compositions comprising a
.alpha.-sulfofatty acid ester and hydrotrope. Effective amounts of
.alpha.-sulfofatty acid ester and hydrotrope are combined to form a
stabilized composition. In one embodiment, the hydrotrope
solubilizes the .alpha.-sulfofatty acid ester in solution and
reduces phase separation. In a second embodiment, the effective
amounts of the hydrotrope and the .alpha.-sulfofatty acid ester
reduce pH drift in the composition, thereby reducing di-salt
formation. In another embodiment, the hydrotrope reduces di-salt
formation by sparing the need for alkalizing agents. In still
another embodiment, the hydrotrope provides multiple stabilizing
effects.
[0011] The composition can optionally include detergent components.
In one embodiment, suitable detergent components include, nonionic
surfactants, other anionic surfactants, cationic surfactants,
zwitterionic surfactants, polymer dispersants, builders, oxidizing
agents, biocidal agents, foam regulators, activators, catalysts,
thickeners, other stabilizers, fragrances, soil suspending agents,
brighteners, enzymes, UV protectors, salts, water, inert
ingredients, and the like. In another embodiment, the nonionic
surfactant is a polyalkoxylated alkanolamide.
[0012] In another embodiment, the hydrotrope is urea. Such urea is
preferably substantially free of ammonium carbamate. In still
another embodiment, the composition comprises
environmentally-friendly, biodegradable components, including
.alpha.-sulfofatty acid ester, urea, polyalkoxylated alkanolamide,
and other biodegradable detergent components.
[0013] Methods of making compositions comprising .alpha.-sulfofatty
acid ester and hydrotrope are also provided. Such methods generally
include providing the .alpha.-sulfofatty acid ester and the
hydrotrope, and mixing these components to form the composition. In
another embodiment, detergents components are included in the
composition. Such detergent components include, for example,
nonionic surfactants, other anionic surfactants, cationic
surfactants, zwitterionic surfactants, polymer dispersants,
builders, oxidizing agents, biocidal agents, foam regulators,
activators, catalysts, thickeners, other stabilizers, fragrances,
soil suspending agents, brighteners, enzymes, UV protectors, salts,
water, inert ingredients, and the like.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The following description provides specific details, such as
materials and dimensions, to provide a thorough understanding of
the present invention. The skilled artisan, however, will
appreciate that the present invention can be practiced without
employing these specific details. Indeed, the present invention can
be practiced in conjunction with processing, manufacturing or
fabricating techniques conventionally used in the detergent
industry. Moreover, the processes below describe only steps, rather
than a complete process flow, for manufacturing the compositions
and detergents containing the compositions according to the present
invention.
[0015] A preferred embodiment is directed to compositions
comprising .alpha.-sulfofatty acid ester and hydrotrope. The
.alpha.-sulfofatty acid ester and the hydrotrope are combined to
form a stabilized composition according to the present
invention.
The .alpha.-Sulfofatty Acid Ester
[0016] In a preferred embodiment, the composition comprises at
least one .alpha.-sulfofatty acid ester. Such a sulfofatty acid is
typically formed by esterifying a carboxylic acid with an alkanol
and then sulfonating the .alpha.-position of the resulting ester.
The .alpha.-sulfofatty acid ester is typically of the following
formula (I):
##STR00001##
where R.sub.1 is a linear or branched alkane, R.sub.2 is a linear
or branched alkane, and R.sub.3 is hydrogen, a halogen, a
mono-valent or di-valent cation, or an unsubstituted or substituted
ammonium cation. R.sub.1 can be a C.sub.4 to C.sub.24 alkane,
including a C.sub.10, C.sub.12, C.sub.14, C.sub.16 and/or C.sub.18
alkane. R.sub.2 can be a C.sub.1 to C.sub.8 alkane, including a
methyl group. R.sub.3 is typically a mono-valent or di-valent
cation, such as a cation that forms a water soluble salt with the
.alpha.-sulfofatty acid ester (e.g., an alkali metal salt such as
sodium, potassium or lithium). The .alpha.-sulfofatty acid ester of
formula (I) can be a methyl ester sulfonate, such as a C.sub.16
methyl ester sulfonate, a C.sub.18 methyl ester sulfonate, or a
mixture thereof.
[0017] More typically, the .alpha.-sulfofatty acid ester is a salt,
which is generally of the following formula (II):
##STR00002##
where R.sub.1 and R.sub.2 are alkanes and M is a monovalent metal.
For example, R.sub.1 can be an alkane containing 4 to 24 carbon
atoms, and is typically a C.sub.8, C.sub.10, C.sub.12, C.sub.14,
C.sub.16 and/or C.sub.18 alkane. R.sub.2 is typically an alkane
containing 1 to 8 carbon atoms, and more typically a methyl group.
M is typically an alkali metal, such as sodium or potassium. The
.alpha.-sulfofatty acid ester of formula (II) can be a sodium
methyl ester sulfonate, such as a sodium C.sub.8-C.sub.18 methyl
ester sulfonate.
[0018] In one embodiment, the composition comprises at least one
.alpha.-sulfofatty acid ester. For example, the .alpha.-sulfofatty
acid ester can be a C.sub.10, C.sub.12, C.sub.14, C.sub.16 or
C.sub.18 .alpha.-sulfofatty acid ester. In another embodiment, the
.alpha.-sulfofatty acid ester comprises a mixture of sulfofatty
acids. For example, the composition can comprise a mixture of
.alpha.-sulfofatty acid esters, such as C.sub.10, C.sub.12,
C.sub.14, C.sub.16 and C.sub.18 sulfofatty acids. The proportions
of different chain lengths in the mixture are selected according to
the properties of the .alpha.-sulfofatty acid esters. For example,
C.sub.16 and C.sub.18 sulfofatty acids (e.g., from tallow and/or
palm stearin MES) generally provide better surface active agent
properties, but are less soluble in aqueous solutions. C.sub.10,
C.sub.12 and C.sub.14 .alpha.-sulfofatty acid esters (e.g., from
palm kernel oil or coconut oil) are more soluble in water, but have
lesser surface active agent properties. Suitable mixtures include
C.sub.8, C.sub.10, C.sub.12 and/or C.sub.14 .alpha.-sulfofatty acid
esters with C.sub.16 and/or C.sub.18 .alpha.-sulfofatty acid
esters. For example, about 1 to about 99 percent of C.sub.8,
C.sub.10, C.sub.12 and/or C.sub.14 .alpha.-sulfofatty acid ester
can be combined with about 99 to about 1 weight percent of C.sub.16
and/or C.sub.18 .alpha.-sulfofatty acid ester. In another
embodiment, the mixture comprises about 1 to about 99 weight
percent of a C.sub.16 or C.sub.18 .alpha.-sulfofatty acid ester and
about 99 to about 1 weight percent of a C.sub.16 or C.sub.18
.alpha.-sulfofatty acid ester. In yet another embodiment, the
.alpha.-sulfofatty acid ester is a mixture of C.sub.18 methyl ester
sulfonate and a C.sub.16 methyl ester sulfonate and having a ratio
of about 2:1 to about 1:3.
[0019] The composition can also be enriched for certain
.alpha.-sulfofatty acid esters, as disclosed in co-pending U.S.
patent application Ser. No. 09/574,996 (Attorney Docket No.
04193.009/1335), filed May 19, 2000, to provide the desired
surfactant properties. The disclosure of that application is
incorporated by reference herein. For example, .alpha.-sulfofatty
acid esters prepared from natural sources, such as palm kernel
(stearin) oil, palm kernel (olein) oil, or beef tallow, are
enriched for C.sub.16 and/or C.sub.18 .alpha.-sulfofatty acid
esters by addition of the purified or semi-purified
.alpha.-sulfofatty acid esters to a mixture of .alpha.-sulfofatty
acid esters. Suitable ratios for enrichment range from greater than
0.5:1, about 1:1, about 1.5:1, to greater than 2:1, and up to about
5 to about 6:1, or more, of C.sub.16-C.sub.18 to other chain length
.alpha.-sulfofatty acid esters. An enriched mixture can also
comprise about 50 to about 60 weight percent C.sub.8-C.sub.18
.alpha.-sulfofatty acid esters and about 40 to about 50 weight
percent C.sub.16 .alpha.-sulfofatty acid ester.
[0020] Methods of preparing .alpha.-sulfofatty acid esters are
known to the skilled artisan. (See, e.g., U.S. Pat. Nos. 5,587,500;
5,384,422; 5,382,677; 5,329,030; 4,816,188; and 4,671,900; the
disclosures of which are incorporated herein by reference.)
.alpha.-Sulfofatty acid esters can be prepared from a variety of
sources, including beef tallow, palm kernel oil, palm kernel
(olein) oil, palm kernel (stearin) oil, coconut oil, soybean oil,
canola oil, cohune oil, coco butter, palm oil, white grease,
cottonseed oil, corn oil, rape seed oil, soybean oil, yellow
grease, mixtures thereof or fractions thereof. Other sources of
fatty acids to make .alpha.-sulfofatty acid esters include caprylic
(C.sub.8), capric (C.sub.10), lauric (C.sub.12), myristic
(C.sub.14), myristoleic (C.sub.14), pahnitic (C.sub.16),
palmitoleic (C.sub.16), stearic (C.sub.18), oleic (C.sub.18),
linoleic (C.sub.18), linolenic (C.sub.18), ricinoleic (C.sub.18),
arachidic (C.sub.20), gadolic (C.sub.20), behenic (C.sub.22) and
erucic (C.sub.22) fatty acids. .alpha.-Sulfofatty acid esters
prepared from one or more of these sources are within the scope of
the present invention.
[0021] The compositions according to the present invention comprise
an effective amount of .alpha.-sulfofatty acid ester (i.e., an
amount which exhibits the desired cleaning and surfactant
properties). In one embodiment, an effective amount is at least
about 5 weight percent .alpha.-sulfofatty acid ester. In another
embodiment, an effective amount is at least about 10 weight percent
.alpha.-sulfofatty acid ester. In still another embodiment, an
effective amount is at least about 25 weight percent, at least
about 30 weight percent, or at least about 35 weight percent. These
weight percentages are based on the total weight of the
composition.
Hydrotrope
[0022] The composition is stabilized by an effective amount of the
hydrotrope. The hydrotrope provides one or more stabilizing effects
to the .alpha.-sulfofatty acid ester-containing composition. In one
embodiment, the hydrotrope aids in a solubilizing the
.alpha.-sulfofatty acid ester in an aqueous solution. In another
embodiment, the hydrotrope reduces phase separation of the
.alpha.-sulfofatty acid ester from aqueous components in solution.
Effective amounts of hydrotrope to aid in solubilizing
.alpha.-sulfofatty acid in solution, or in reducing phase
separation, are determined by, for example, titrating a solution
containing the .alpha.-sulfofatty acid ester until the desires
quantity of .alpha.-sulfofatty acid ester(s) is solubilized.
[0023] In another embodiment, effective amounts of the
.alpha.-sulfofatty acid ester and the hydrotrope stabilize the
composition by reducing pH drift towards either more acidic or more
basic values. The .alpha.-sulfofatty acid ester(s) is combined with
an effective amount of the hydrotrope to stabilize the pH of the
composition within a desired range, as compared with a
non-stabilized composition. In another embodiment, the effective
amount of hydrotrope reduces pH drift outside the desired pH range
during storage. The effective amount of the hydrotrope is
determined, for example, according to the intended shelf life of
the composition, so that the pH of the composition remains within
the desired pH range during to storage.
[0024] In another embodiment, the hydrotrope is compatible with the
.alpha.-sulfofatty acid ester, so that no more than a minor amount
of additional di-salt forms in the composition. The hydrotrope can
stabilize the composition by reducing pH drift, thereby sparing the
requirement for alkalizing agents. As used herein, the term a
"minor amount" means no more than about 30 weight percent
additional di-salt. More typically, a minor amount is no more than
about 15 weight percent additional di-salt, or no more than about 7
weight percent additional di-salt. As will be appreciated by the
skilled artisan, the preceding ranges apply to additional di-salt
formation and exclude di-salt already present in the
.alpha.-sulfofatty acid ester as a result of the manufacturing
process. The method of George Battaglini et al., Analytical Methods
for Alpha Sulfo Methyl Tallowate, JOACS, Vol. 63, No. 8 (August,
1986), can be used to determine the amount of di-salt in an
.alpha.-sulfofatty acid ester sample, and any increase in such a
sample as compared with a control sample. The disclosure of this
publication is incorporated by reference herein.
[0025] In still another embodiment, the hydrotrope provides more
than one stabilizing effect. For example, the hydrotrope can aid in
solubilizing the .alpha.-sulfofatty acid ester and reduce pH drift,
thereby reducing di-salt formation.
[0026] In a preferred embodiment, the hydrotrope is urea.
Typically, .alpha.-sulfofatty acid ester is combined with an
effective amount of urea to aid in solubilizing the
.alpha.-sulfofatty acid ester in solution and to reduce pH drift.
For example, in some applications an effective amount of
.alpha.-sulfofatty acid ester ranges from about 5 to about 35
weight percent and an effective amount of urea ranges from about 1
to about 30 weight percent, where the weight percentages are based
on the total weight of the composition. In other applications, the
effective amount of urea ranges from about 4 to about 20 weight
percent. Other examples of effective amounts of .alpha.-sulfofatty
acid ester and hydrotrope are about 5.4 weight percent
.alpha.-sulfofatty acid ester (e.g., MES) and about 4 weight
percent urea; about 9.45 weight percent .alpha.-sulfofatty acid
ester and about 7 weight percent urea; about 13.5% weight percent
.alpha.-sulfofatty acid ester and about 10 weight percent urea; and
about 27 weight percent .alpha.-sulfofatty acid ester and about 20
weight percent urea. The effective amount of urea is also
determined by titrating a solution containing .alpha.-sulfofatty
acid ester(s) until the composition is stabilized.
[0027] In a more preferred embodiment, the urea contains little to
no ammonium carbamate. For example, such urea preferably contains
less than about 0.1 weight percent ammonium carbamate.
[0028] The composition can optionally further include a secondary
hydrotrope. Such a secondary hydrotrope can be a Kraft point
reducer that helps prevent precipitation of the .alpha.-sulfofatty
acid ester at lower temperatures. As will be appreciated by the
skilled artisan, precipitation is generally indicated by the
presence of white turbidity in the solution. Examples of suitable
Kraft point reducers include, but are not limited to, pyrrolidones,
such as, for example, N-octyl pyrrolidone (SURFADONE.RTM.,
International Specialty Products, UK), the pyridone salts disclosed
in U.S. Pat. No. 4,367,169, the disclosure of which is incorporated
by reference herein, and the like. In one embodiment, the
composition comprises about 1 to about 5 percent by weight of the
Kraft point reducer, although greater and lesser amounts can be
used.
Other Components
[0029] In another preferred embodiment, the composition includes
other detergent components, such as nonionic surfactants, other
(secondary) anionic surfactants, cationic surfactants, zwitterionic
surfactants, polymer dispersants, builders, oxidizing agents,
biocidal agents, foam regulators, activators, catalysts,
thickeners, other stabilizers, fragrances, soil suspending agents,
brighteners, enzymes, UV protectors, salts, water, inert
ingredients, and the like.
[0030] Suitable nonionic surfactants include polyalkoxylated
alkanolamides, which are generally of the following formula
(III):
##STR00003##
where R.sub.4 is an alkane or hydroalkane, R.sub.5 and R.sub.7 are
alkanes and n is a positive integer. R.sub.4 is typically an alkane
containing 6 to 22 carbon atoms. R.sub.5 is typically an alkane
containing 1-8 carbon atoms. R.sub.7 is typically an alkane
containing 1 to 4 carbon atoms, and more typically an ethyl group.
The degree of polyalkoxylation (the molar ratio of the oxyalkyl
groups per mole of alkanolamide) typically ranges from about 1 to
about 100, or from about 3 to about 8, or about 5 to about 6.
R.sub.6 can be hydrogen, an alkane, a hydroalkane group or a
polyalkoxylated alkane. The polyalkoxylated alkanolamide is
typically a polyalkoxylated mono- or di-alkanolamide, such as a
C.sub.16 and/or C.sub.18 ethoxylated monoalkanolamide, or an
ethoxylated monoalkanolamide prepared from palm kernel oil or
coconut oil.
[0031] Methods of manufacturing polyalkoxylated alkanolamides are
known to the skilled artisan. (See, e.g., U.S. Pat. Nos. 6,034,257
and 6,034,257, the disclosure of which are incorporated by
reference herein.) Sources of fatty acids for the preparation of
alkanolamides include beef tallow, palm kernel (stearin or olein)
oil, coconut oil, soybean oil, canola oil, cohune oil, palm oil,
white grease, cottonseed oil, mixtures thereof and fractions
thereof. Other sources include caprylic (C.sub.8), capric
(C.sub.10), lauric (C.sub.12), myristic (C.sub.14), myristoleic
(C.sub.14), palmitic (C.sub.16), palmitoleic (C.sub.16), stearic
(C.sub.18), oleic (C.sub.18), linoleic (C.sub.18), linolenic
(C.sub.18), ricinoleic (C.sub.18), arachidic (C.sub.20), gadolic
(C.sub.20), behenic (C.sub.22) and erucic (C.sub.22) fatty acids.
Polyalkoxylated alkanolamides from one or more of these sources are
within the scope of the present invention.
[0032] The composition typically comprises an effective amount of
polyalkoxylated alkanolamide (e.g., an amount which exhibits the
desired surfactant properties). In some applications, the
composition contains about 1 to about 10 weight percent of a
polyalkoxylated alkanolamide. Typically, the composition comprises
at least about one weight percent of polyalkoxylated
alkanolamide.
[0033] Other suitable nonionic surfactants include those containing
an organic hydrophobic group and a hydrophilic group that is a
reaction product of a solubilizing group (such as a carboxylate,
hydroxyl, amido or amino group) with an alkylating agent, such as
ethylene oxide, propylene oxide, or a polyhydration product thereof
(such as polyethylene glycol). Such nonionic surfactants include,
for example, polyoxyalkylene alkyl ethers, polyoxyalkylene
alkylphenyl ethers, polyoxyalkylene sorbitan fatty acid esters,
polyoxyalkylene sorbitol fatty acid esters, polyalkylene glycol
fatty acid esters, alkyl polyalkylene glycol fatty acid esters,
polyoxyethylene polyoxypropylene alkyl ethers, polyoxyalkylene
castor oils, polyoxyalkylene alkylamines, glycerol fatty acid
esters, alkylglucosamides, alkylglucosides, and alkylamine oxides.
Other suitable surfactants include those disclosed in U.S. Pat.
Nos. 5,945,394 and 6,046,149, the disclosures of which are
incorporated herein by reference. In another embodiment, the
composition is substantially free of nonylphenol nonionic
surfactants. In this context, the term "substantially free" means
less than about one weight percent.
[0034] Polymer dispersants, such as polymers and co-polymers of
acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic
acid, and water-soluble salts thereof, such as alkali metal,
ammonium, or substituted ammonium salts, can optionally be included
in the composition. Suitable polymer dispersants further include
those sold under the trade names ACUSOL.RTM. 445 (polyacrylic
acid), ACUSOL.RTM. 445N (polyacrylic acid sodium salt), ACUSOL.RTM.
460N (a maleic acid/olefin copolymer sodium salt), and ACUSOL.RTM.
820 (acrylic copolymer), sold by Rohm and Haas Company.
[0035] In an embodiment, a secondary anionic surfactant is included
in the composition. Suitable secondary anionic surfactants includes
those surfactants that contain a long chain hydrocarbon hydrophobic
group in their molecular structure and a hydrophilic group, i.e.,
water solubilizing group including salts such as carboxylate,
sulfonate, sulfate or phosphate groups. Suitable anionic surfactant
salts include sodium, potassium, calcium, magnesium, barium, iron,
ammonium and amine salts. Other suitable secondary anionic
surfactants include the alkali metal, ammonium and alkanol ammonium
salts of organic sulfuric reaction products having in their
molecular structure an alkyl, or alkaryl group containing from 8 to
22 carbon atoms and a sulfonic or sulfuric acid ester group.
Examples of such anionic surfactants include water soluble salts of
alkyl benzene sulfonates having between 8 and 22 carbon atoms in
the alkyl group, alkyl ether sulfates having between 8 and 22
carbon atoms in the alkyl group. Other anionic surfactants include
polyethoxylated alcohol sulfates, such as those sold under the
trade name CALFOAM.RTM. 303 (Pilot Chemical Company, California).
Examples of other anionic surfactants are disclosed in U.S. Pat.
No. 3,976,586, the disclosure of which is incorporated by reference
herein. In another embodiment, the composition is substantially
free of additional (secondary) anionic surfactants.
[0036] Suitable zwitterionic surfactants can be broadly described
as derivatives of secondary and tertiary amines, derivatives of
heterocyclic secondary and tertiary amines, or derivatives of
quaternary ammonium, quaternary phosphonium or tertiary sulfonium
compounds, such as those disclosed in U.S. Pat. No. 3,929,678,
which is incorporated by reference herein.
[0037] Other suitable components include organic or inorganic
detergency builders. Examples of water-soluble inorganic builders
that can be used, either alone or in combination with themselves or
with organic alkaline sequestrant builder salts, are glycine, alkyl
and alkenyl succinates, alkali metal carbonates, alkali metal
bicarbonates, phosphates, polyphosphates and silicates. Specific
examples of such salts are sodium tripolyphosphate, sodium
carbonate, potassium carbonate, sodium bicarbonate, potassium
bicarbonate, sodium pyrophosphate and potassium pyrophosphate.
Examples of organic builder salts that can be used alone, or in
combination with each other, or with the preceding inorganic
alkaline builder salts, are alkali metal polycarboxylates,
water-soluble citrates such as sodium and potassium citrate, sodium
and potassium tartrate, sodium and potassium
ethylenediaminetetracetate, sodium and potassium
N(2-hydroxyethyl)-nitrilo triacetates, sodium and potassium
N-(2-hydroxyethyl)-nitrilo diacetates, sodium and potassium
oxydisuccinates, and sodium and potassium tartrate mono- and
di-succinates, such as those described in U.S. Pat. No. 4,663,071,
the disclosure of which is incorporated herein by reference.
[0038] Suitable biocidal agents include triclosan
(5-chloro-2(2,4-dichloro-phenoxy)phenol)), and the like. Suitable
optical brighteners include stilbenes such as TINOPAL.RTM. AMS,
distyrylbiphenyl derivatives such as TINOPAL.RTM. CBS-X,
stilbene/naphthotriazole blends such as TINOPAL.RTM. RA-16, all
sold by Ciba Geigy, oxazole derivatives, and coumarin
brighteners.
[0039] Suitable enzymes include those known in the art, such as
amylolytic, proteolytic, cellulolytic or lipolytic type, and those
listed in U.S. Pat. No. 5,958,864, the disclosure of which is
incorporated herein by reference. One preferred protease, sold
under the trade name SAVINASE.RTM. by Novo Nordisk Industries A/S,
is a subtillase from Bacillus lentus. Other suitable enzymes
include proteases, amylases, lipases and cellulases, such as
ALCALASE.RTM. (bacterial protease), EVERLASE.RTM.
(protein-engineered variant of SAVINASE.RTM.), ESPERASE.RTM.
(bacterial protease), LIPOLASE.RTM. (fungal lipase), LIPOLASE ULTRA
(Protein-engineered variant of LIPOLASE), LIPOPRIME.TM.
(protein-engineered variant of LIPOLASE), TERMAMYL.RTM. (bacterial
amylase), BAN (Bacterial Amylase Novo), CELLUZYME.RTM. (fungal
enzyme), and CAREZYME.RTM. (monocomponent cellulase), sold by Novo
Nordisk Industries A/S.
[0040] Suitable foam stabilizing agents include a polyalkoxylated
alkanolamide, amide, amine oxide, betaine, sultaine,
C.sub.8-C.sub.18 fatty alcohols, and those disclosed in U.S. Pat.
No. 5,616,781, the disclosure of which is incorporated by reference
herein. Foam stabilizing agents are used, for example, in amounts
of about 1 to about 20, typically about 3 to about 5 percent by
weight. The composition can further include an auxiliary foam
stabilizing surfactant, such as a fatty acid amide surfactant.
Suitable fatty acid amides are C.sub.8-C.sub.20 alkanol amides,
monoethanolamides, diethanolamides, and isopropanolamides.
[0041] Suitable liquid carriers include water, a mixture of water
and a C.sub.1-C.sub.4 monohydric alcohol (e.g., ethanol, propanol,
isopropanol, butanol, and mixtures thereof), and the like. In one
embodiment, a liquid carrier comprises from about 90% to about 25%
by weight, typically about 80% to about 50% by weight, more
typically about 70% to about 60% by weight of the composition.
Other suitable components include diluents, dyes and perfumes.
Diluents can be inorganic salts, such as sodium and potassium
sulfate, ammonium chloride, sodium and potassium chloride, sodium
bicarbonate, and the like. Such diluents are typically present at
levels of from about 1% to about 10%, preferably from about 2% to
about 5% by weight.
[0042] Compositions according to the present invention are formed
by any suitable method known to the skilled artisan. Typically,
effective amounts of .alpha.-sulfofatty acid ester and hydrotrope
are combined to form the composition. In one embodiment, the urea
is solubilized in a liquid carrier (e.g., water) prior to the
addition of the .alpha.-sulfofatty acid ester. Other suitable
methods include those described in Perry's Chemical Engineers'
Handbook (6.sup.th Ed.), chapter 19 (1984), the disclosure of which
is incorporated by reference herein. In another embodiment,
effective amounts of .alpha.-sulfofatty acid ester, the hydrotrope,
and other detergent components are combined, according to the
desired properties of the final composition. For example, the
.alpha.-sulfofatty acid ester and hydrotrope are combined in a
mixer, other detergent components are added, then the components
are mixed to form a composition, according to the present
invention.
[0043] Other embodiments of the present invention are exemplified
in the following examples, which illustrate embodiments according
to the present invention, although the invention is not intended to
be limited by or to these examples.
Example 1
[0044] A base for a laundry detergent is formulated by combining
the following components:
TABLE-US-00001 .alpha.-sulfofatty acid ester 5-35 weight percent
urea 1-30 weight percent Other components and water Balance
Example 2
[0045] A liquid laundry detergent is formulated as follows:
TABLE-US-00002 .alpha.-sulfofatty acid ester 5-35 weight percent
(palm kernel oil .alpha.-sulfofatty acid ester, 50-60%) (C.sub.16
.alpha.-sulfofatty acid ester, 40-50%) Urea 1-30 weight percent
Polyethoxylated monoalkanolamide 1-10 weight percent
(C.sub.16-C.sub.18 with a degree of ethoxylation of about 4-6)
Other detergent components Balance
Example 3
[0046] A base for a biodegradable laundry detergent is formulated
as follows:
TABLE-US-00003 .alpha.-sulfofatty acid ester 25-30 weight percent
(50% palm kernel oil .alpha.-sulfofatty acid ester plus 50%
C.sub.16 .alpha.-sulfofatty acid ester) Urea 10 weight percent
Polyethoxylated monoalkanolamide 10 weight percent (C.sub.16-18
with a degree of ethoxylation of about 5) Liquid carrier
Balance
[0047] Other biodegradable components are added to the base,
according to the desired properties of the final composition.
Example 4
[0048] The stability of liquid laundry detergents containing
.alpha.-sulfofatty acid esters was tested. Compositions A-F were
prepared as follows, where the amounts of each component are listed
as weight percentages:
TABLE-US-00004 TABLE 1 Compositions Components A B C D E F Urea 4.0
7.0 10.0 0 0 0 C.sub.16 alpha sulfofatty acids 2.4 4.2 6.0 2.4 4.2
6.0 C.sub.8-18 alpha sulfofatty acid 3.0 5.3 7.5 3.0 5.3 7.5
Polyalkoxylated 2.0 3.5 5.0 2.0 3.5 5.0 amide (5.5 moles EO) TEA
0.8 1.4 2.0 0.8 1.4 2.0 Preservatives 0.3 0.2 0.1 0.3 0.2 0.1
Brightener 0.2 0.2 0.4 0.2 0.2 0.4 Sodium Gluconate 0.1 0.1 0.1 0.1
0.1 0.1 Fragrance 0.2 0.2 0.2 0.2 0.2 0.2 Enzymes 0 0 0.7 0 0 0.7
Water Balance Balance Balance Balance Balance Balance Total 100.0
100.0 100.0 100.0 100.0 100.0
Example 5
[0049] The pH of compositions A-F was measured at 0, 6 and 9 days.
The results are shown in the following Table 2:
TABLE-US-00005 TABLE 2 pH Profile Elapsed time, days A B C D E F 0
9.5 9.5 9.5 9.5 9.5 9.5 6 9.5 9.6 9.6 9.2 9.1 9.0 9 9.5 9.5 9.6 9.3
9.3 9.2
[0050] As shown in Table 2, stabilized compositions A-C (containing
.alpha.-sulfofatty acid ester and a hydrotrope, urea) exhibit
reduced pH drift, while unstabilized compositions D-F (without
hydrotrope) exhibit pH drift towards the acidic range after 9 days.
As will be appreciated by the skilled artisan, the pH of the
composition will continue to be more acidic over longer time
periods.
Example 6
[0051] The phase stability of compositions A-F was measured by
visually observing compositions A-F for a period of 9 days.
Composition instability was indicated by the formation of a
precipitate. Referring to Table 3, the results of the stability
testing are as follows:
TABLE-US-00006 TABLE 3 Phase Stability Elapsed time, days A B C D E
F 0 Stable Stable Stable Not stable Not stable Not stable 6 Stable
Stable Stable Not stable Not stable Not stable 9 Stable Stable
Stable Not stable Not stable Not stable
Example 7
[0052] A heavy duty liquid laundry detergent is formulated as
follows:
TABLE-US-00007 .alpha.-sulfofatty acid ester 25-35 weight percent
(sodium methyl ester sulfonate derived from palm kernel oil) Urea
5-10 weight percent Polyethoxylated monoalkanolamide 1-5 weight
percent (C.sub.16-18 with a degree of ethoxylation of about 4-6)
Protease enzyme 0.9 weight percent Amylase enzyme 0.2 weight
percent Perfume 0.5 weight percent Inorganic Salt 2.1 weight
percent Water Balance
[0053] Having thus described in detail the preferred embodiments of
the present invention, it is to be understood that the invention
defined by the appended claims is not to be limited by particular
details set forth in the above description, as many apparent
variations thereof are possible without departing from the spirit
or scope thereof.
* * * * *