NON-AQUEOUS GEL DETERGENT COMPOSITIONS

Abstract

A method for manufacturing an automatic dishwashing composition in the form of a non-aqueous gel, the method comprising: (i) combining one or more non-ionic surfactants, a polar non-aqueous solvent and a rheology modifier to form a non-aqueous gel, the non-aqueous gel having a pH of less than 7 when measured as a dilution of 1 part in 100 parts of water by weight, wherein the rheology modifier is an alkali-swellable emulsion polymer or a hydrophobically-modified alkali-swellable emulsion polymer; and (ii) adding to the non-aqueous gel one or more active agents selected from the group consisting of builders, surfactants, polymers, enzymes, bleaching agents, bleach activators, bleach catalysts and corrosion inhibitors to form the automatic dishwashing composition.

Claims

1. A method for manufacturing an automatic dishwashing composition in the form of a non-aqueous gel, the method comprising: combining one or more non-ionic surfactants, a polar non-aqueous solvent and a rheology modifier to form a non-aqueous gel, the non-aqueous gel having a pH of less than 7 when measured as a dilution of 1 part in 100 parts of water by weight, wherein the rheology modifier is an alkali-swellable emulsion polymer or a hydrophobically-modified alkali-swellable emulsion polymer; and (ii) adding to the non-aqueous gel one or more active agents selected from the group consisting of builders, surfactants, polymers, enzymes, bleaching agents, bleach activators, bleach catalysts and corrosion inhibitors to form the automatic dishwashing composition.

2. The method according to claim 1, wherein the one or more non-ionic surfactants are selected from optionally endcapped alcohol alkoxylates.

3. The method according to claim 1, wherein the one or more non-ionic surfactants are liquid at 20° C.

4. The method according to claim 1, wherein the polar non-aqueous solvent is a polyalkylene glycol.

5. The method according to claim 1, wherein the rheology modifier is a copolymer comprising acrylic acid monomer units and alkyl acrylate monomer units.

6. The method according to claim 1, wherein the rheology modifier is a hydrophobically-modified alkali-swellable emulsion polymer, having the following structure: ##STR00004## wherein R, R.sub.1 and R.sub.3 are independently selected from H and alkyl groups, wherein R.sub.2 is an optionally alkoxylated alkyl group, and wherein w, x, y and z are integers.

7. The method according to claim 1, wherein the rheology modifier is an alkali-swellable emulsion polymer, having the following structure: ##STR00005## wherein R is selected from H and alkyl groups and R.sub.1 is an alkyl group, and wherein x and y are integers.

8. The method according to claim 1, wherein the composition comprises: from 20 to 35 wt % of the one or more non-ionic surfactants; from 55 to 75 wt % of the polar non-aqueous solvent; and/or from 2 to 6 wt % of the rheology modifier, based on the total weight of the one or more non-ionic surfactants, polar non-aqueous solvent and rheology modifier.

9. The method according to claim 1, wherein the composition comprises the one or more non-ionic surfactants, the polar non-aqueous solvent and the rheology modifier in a total amount of at least 50 wt % based on the weight of the composition, and wherein the composition comprises the one or more active agents in a total amount of up to 50 wt % based on the weight of the composition.

10. The method according to claim 1, wherein the composition is transparent or translucent.

11. The method according to claim 1, further comprising: incorporating the composition into an automatic dishwashing product, wherein the product is provided in a unit dosage form, and/or housed within a water-soluble or water-dispersible film or container, preferably a polyvinyl alcohol film or container.

12. An automatic dishwashing composition or an automatic dishwashing product obtainable by the method of claim 1.

13. An automatic dishwashing composition in the form of a non-aqueous gel comprising one or more non-ionic surfactants, a polar non-aqueous solvent and a rheology modifier, wherein the rheology modifier is an alkali-swellable emulsion polymer or a hydrophobically-modified alkali-swellable emulsion polymer, and wherein the composition comprises at most 1 wt % of an organic amine base based on the weight of the rheology modifier.

14. The automatic dishwashing composition according to claim 13, wherein the composition further comprises one or more active agents selected from the group consisting of builders, surfactants, polymers, enzymes, bleaching agents, bleach activators, bleach catalysts and corrosion inhibitors.

15. The automatic dishwashing product comprising the automatic dishwashing composition of claim 12.

16. The automatic dishwashing product according to claim 15, wherein the product is: in a unit dose form; and/or housed within a water soluble or water dispersible film or container.

17. A method of using automatic dishwashing composition according to claim 12 in an automatic dishwashing process.

18. A non-aqueous gel for use in the preparation of an automatic dishwashing composition, the non-aqueous gel comprising one or more non-ionic surfactants, a polar non-aqueous solvent and a rheology modifier, wherein the rheology modifier is an alkali-swellable emulsion polymer or a hydrophobically-modified alkali-swellable emulsion polymer, and wherein the non-aqueous gel has a pH of less than 7 when measured as a dilution of 1 part in 100 parts of water by weight.

19. The method according to claim 10, wherein the composition remains transparent or translucent upon storage for at least 3 months at 30° C. and 65% relative humidity.

20. The method according to claim 11, wherein the water soluble or water dispersible film or container is a polyvinyl alcohol film or container.

Description

EXAMPLE 1

[0155] The following non-aqueous gels were prepared, each comprising a polar non-aqueous solvent, a non-ionic surfactant and a HASE rheology modifier.

TABLE-US-00001 Component Amount (wt %) PEG 400 51.5 Fatty alcohol alkoxylate (Genapol ® EP 2584) 28 Acusol ® 805S 18 MIPA Dose response

[0156] (PEG=polyethylene glycol, MIPA=monoisopropanolamine)

[0157] The Acusol® 805S was provided as an emulsion containing 28-30 wt % solids.

[0158] The gels were prepared using the following method: [0159] 1. In a beaker, the PEG 400 was added; then Genapol® EP 2584 was added and the mixture was homogenized. [0160] 2. Acusol® 805S was added under agitation. [0161] 3. Optionally MIPA was added. The mixture was stirred under moderate agitation to avoid air bubbles.

[0162] The method was performed at room temperature.

[0163] The compositions were stored in a climate chamber for 1 week at 5° C. and 50% r.h. or 50° C. and 20% r.h. The compositions were stored (i) in a beaker/glass bottle with a lid and (ii) sealed in a multi-compartment PVOH pouch (with the pouch packed in a Doypack). The following colour changes were observed under both sets of conditions:

TABLE-US-00002 Basis w/o 0.5% 1% 1.5% 2.0% gel MIPA MIPA MIPA MIPA MIPA start colourless colourless colourless colourless colourless 5° C./ colourless slightly slightly slightly slightly 1 week yellow yellow yellow yellow 50° C./ colourless yellow yellow yellow Yellow 1 week

[0164] It was found that even low amounts of MIPA (e.g. 0.5%) led to yellowing, even upon storage at 5° C. The gels including MIPA were transparent, whereas the gel without MIPA was found to be translucent. Nevertheless, it was surprising that the HASE rheology modifier gave rise to significant thickening in the absence of MIPA.

EXAMPLE 2

[0165] Non-aqueous gel samples were prepared in accordance with the method of Example 1 containing 0% MIPA or 2.5% MIPA. In a final step, an automatic dishwashing active ingredient was blended into each gel sample by stirring with a spatula at room temperature.

[0166] The samples were stored for 1 week at 50° C. and 20% r.h under the conditions described in Example 1. The following colour changes were observed:

TABLE-US-00003 Maleic acid- Modified Fatty acrylic acid Alcohol copolymer, Polyglycolether sodium salt Sodium Sodium MGDA Trisodium (Dehypon GRA, (Sokalan CP7, Basis gel Carbonate Bicarbonate granules Citrate BASF) HEDP TAED fine BASF) % w/w of 30 30 30 30 10 5 5 5 gel with MIPA yellow Yellow yellow yellow yellow yellow yellow Yellow without slightly colourless yellow colourless dissolved, colourless colourless slightly MIPA yellow colourless yellow

[0167] While the active ingredients did not fully dissolve (other than Dehypon GRA), they were all well-dispersed and provided a homogeneous gel without phase separation. Again, it was surprisingly found that the HASE rheology modifier gave rise to significant thickening in the absence of MIPA. Advantageously, the omission of MIPA eliminated or at least significantly reduced yellowing.

EXAMPLE 3

[0168] Additional non-aqueous gels were prepared following the method of Example 1 to further investigate the effect of the HASE rheology modifier dosage on viscosity and transparency.

TABLE-US-00004 Polar solvent- 68.0% 66.0% 65.0% 62.0%   58% PEG 400E Surfactant- 20.0% 20.0% 20.0% 20.0% 20.0% Genapol EP 2584 Rheology 12.0% 14.0% 15.0% 18.0%   22% modifier- Acusol 805 S gel after transparent slightly translucent turbid mixing translucent gel stability transparent becomes translucent turbid at RT transparent when stirred, but turns again to slightly translucent

[0169] The turbidity was found to increase as the amount of rheology modifier increased. Nevertheless, at 12 wt % the viscosity of the gel was found to be lower. Accordingly, the gel containing 14 wt % rheology modifier was most preferred.

EXAMPLE 4

[0170] Additional non-aqueous gels were prepared to further investigate the effect of the HASE rheology modifier dosage on viscosity and transparency.

TABLE-US-00005 Polar solvent-PEG 400E 66.0% 57.7% 51.0% Surfactant-Genapol EP 2584 20.0% 28.3% 35.0% Rheology modifier-Acusol 805 S 14.0% 14.0% 14.0% gel after mixing transparent turbid gel stability at RT transparent turbid

[0171] It was found that the amount of surfactant can be varied within a relatively broad range without adversely affecting the transparency or viscosity of the gel. However, above a certain surfactant concentration, the gel becomes turbid.

EXAMPLE 5

[0172] A basis gel consisting of 66 wt % PEG 400E, 20 wt % Genapol EP 2584 and 14 wt % HASE/ASE polymer was prepared. The HASE/ASE polymer was varied and each gel was stored in the gel compartment of a thermoformed multi-compartment product for 1 week at 50° C. The gels were observed to have the following appearances:

TABLE-US-00006 Acusol Polymer Acusol 805S Acusol 801S Acusol 810 Acusol 830 Millennium Observation Transparent, Transparent, Transparent, Transparent, Transparent, colourless colourless colourless colourless colourless

[0173] Acusol 830 is an ASE polymer, whereas the remainder are HASE polymers. Accordingly, the HASE and ASE polymer can be varied without compromising the transparency observed under these storage conditions.

EXAMPLE 6

[0174] A three-compartment monodose automatic dishwashing product was prepared. In particular, a water-soluble, polyvinyl alcohol injection-moulded three-compartment container was prepared and filled with the following compositions, then sealed.

[0175] Gel Composition

TABLE-US-00007 Fatty alcohol alkoxylate (Genapol EP 2584) 19.43% PEG 400 36.27% Acusol 805S    9% Trisodium Citrate   22% Sodium Bicarbonate    8% HEDP 88, 5    2% Amylase granules    1% Modified Fatty Acohol  1.99% Polyglycolether (Dehypon GRA, BASF) Dye  0.01%

[0176] The gel was prepared by first mixing the gel base according to the method described in Example 1, then adding the solids in the order as listed above while stirring with a propeller stirrer at 200-300 rpm at room temperature.

[0177] The gel was a transparent solid, present in Compartment 2 in a dosage of 4 g/wash.

[0178] Powder Composition

TABLE-US-00008 Sodium Citrate 11% Sodium Percarbonate 21% Bleach Activators  6% (TAED, Catalyst) Sodium 58% carbonate/bicarbonate Polymers and  9% surfactants Enzymes  1%

[0179] The powder was present in Compartment 1 at a dosage of 9 g/wash.

[0180] Liquid Composition

TABLE-US-00009 Non-ionic 99.87% surfactant Dye  0.13%

[0181] The liquid composition was present in Compartment 3 at a dosage of 0.7 g/wash.

[0182] Reference ADW Composition:

[0183] A reference formula with the following composition was prepared.

TABLE-US-00010 Sodium Citrate 14% Percarbonate bleach, 13% activator and catalyst Bleach Activators  6% (TAED, Catalyst) Sodium 55% carbonate/bicarbonate Polymers and 11% surfactants Enzymes  1%

[0184] The reference formula was tested at a dosage of 14 g/wash.

[0185] Cleaning Performance

[0186] The cleaning performance of the automatic dishwashing product was tested according to the IKW method with reference to the control. The cleaning performance was found to be comparable.

[0187] Storage Stability

[0188] For the product in accordance with the invention:

[0189] No visual change was observed after 12 weeks at 25° C./50% r.h under the storage conditions of Example 1. A minor visual change was observed after 12 weeks at 40° C./75% r.h.—a minimal amount (3-4 drops) of liquid had separated from the gel.

[0190] The foregoing detailed description has been provided by way of explanation and illustration, and is not intended to limit the scope of the appended claims. Many variations in the presently preferred embodiments illustrated herein will be apparent to one of ordinary skill in the art, and remain within the scope of the appended claims and their equivalents.