NON-CAUSTIC SOLID POWDER CLEANER COMPOSITIONS AND METHODS FOR THE USE AND MANUFACTURE THEREOF

Abstract

A non-caustic solid powder cleaner composition is disclosed herein, as well as a method of making and using the same. A benefit of the powder cleaner composition can be providing a compact, lightweight powder composition that can be easily and efficiently transported, stored, dispensed, and used for safely cleaning grill and oven surfaces.

Claims

1. A non-caustic solid powder cleaner composition comprising: at least one chelator comprising sodium metasilicate, Ethylenediaminetetraacetic acid (EDTA), ethylene glycol-bis((-aminoethyl ether)-N,N,N,N-tetraacetic acid (EGTA), sodium citrate, a carboxylic acid chelator, or a combination thereof; sodium chloride; at least one solid carbonate base comprising sodium carbonate, sodium bicarbonate, a carbonic acid salt, or a combination thereof; at least one thickening agent comprising hydroxyethylcellulose, agar, or a combination thereof; at least one stabilizer comprising ethylene glycol, ethylene glycol monobutyl ether, propylene glycol monoether, polyethylene glycol, or a combination thereof; and at least one surfactant.

2. The composition of claim 1, wherein the composition comprises: from about 7.0% to about 19.0% by weight of sodium chloride; from about 48.25% to about 68.25% by weight of the at least one chelator; from about 10.2% to about 20.2% by weight of the at least one solid carbonate base; from about 0.2% to about 3.8% by weight of the at least one thickening agent; from about 0.2% to about 3.75% by weight of the at least one stabilizer; and from about 6.0% to about 16.0% by weight of the at least one surfactant, based on a total weight of the non-caustic solid powder cleaner composition.

3. The composition of claim 1, wherein the at least one surfactant comprises at least one ionic surfactant and at least one non-ionic surfactant, said at least one non-ionic surfactant comprising one or more alkoxylated alcohols.

4. The composition of claim 3, wherein the at least one surfactant comprises: sodium lauryl sulfate having a weight percent from about 2.0% by weight to about 12.0% by weight, based on a total weight of the non-caustic solid powder cleaner composition, and ethoxylated alcohol having a weight percent from about 2.0% to about 6.0% by weight in the solid powder cleaner composition, based on a total weight of the non-caustic solid powder cleaner composition.

5. The composition of claim 4, wherein: a weight percent ratio of ethoxylated alcohol to sodium lauryl sulfate ranges from about 1:1.4 to about 1:2.2; a weight percent ratio of the ethoxylated alcohol to the at least one chelator ranges from about 1:13 to about 1:16; a weight percent ratio of the ethoxylated alcohol to the at least one solid carbonate base ranges from about 1:3.0 to about 1:4.5; or a weight percent ratio of the ethoxylated alcohol to sodium chloride ranges from about 1:2.5 to about 1:3.5, based on the total weight of the non-caustic solid powder cleaner composition.

6. The composition of claim 4, wherein: a weight percent ratio of the combined weight percent of ethyoxylated alcohol and sodium lauryl sulfate to the at least one chelator ranges from about 1:5.0 to 1:5.5; or a weight percent ratio of the combined weight percent of ethyoxylated alcohol and sodium lauryl sulfate to the combined weight percent of sodium chloride, the at least one solid carbonate base, the at least one thickening agent and the at least one stabilizer ranges from about 1:2.5 to about 1:3.5, based on the total weight of the non-caustic solid powder cleaner composition.

7. A non-caustic solid powder cleaner composition comprising: from about 7.0% to about 19.0% by weight of sodium chloride; from about 48.25% to about 68.25% by weight of sodium metasilicate; from about 10.2% to about 20.2% by weight of sodium carbonate; from about 0.2% to about 3.8% by weight of hydroxy ethyl cellulose; from about 0.2% to about 3.75% by weight of ethylene glycol monobutyl ether; from about 2.0% to about 12.0% by weight of sodium lauryl sulfate; and from about 2.0% to about 6.0% by weight of ethoxylated alcohol, based on a total weight of the non-caustic solid powder cleaner composition.

8. The composition of claim 7, wherein: a weight percent ratio of the ethoxylated alcohol to sodium lauryl sulfate ranges from about 1:1.4 to about 1:2.2; a weight percent ratio of the ethoxylated alcohol to sodium metasilicate ranges from about 1:13 to about 1:16; a weight percent ratio of the ethoxylated alcohol to sodium carbonate ranges from about 1:3.0 to about 1:4.5; or a weight percent ratio of the ethoxylated alcohol to sodium chloride ranges from about 1:2.5 to about 1:3.5, based on the total weight of the non-caustic solid powder cleaner composition.

9. The composition of claim 7, wherein: a weight percent ratio of the combined weight percent of ethyoxylated alcohol and sodium lauryl sulfate to sodium metasilicate ranges from about 1:5.0 to 1:5.5; or a weight percent ratio of the combined weight percent of ethyoxylated alcohol and sodium lauryl sulfate to the combined weight percent of sodium chloride, sodium carbonate, hydroxy ethyl cellulose and ethylene glycol monobutyl ether ranges from about 1:2.5 to about 1:3.5, based on the total weight of the non-caustic solid powder cleaner composition.

10. The composition of claim 7, wherein composition consists of: from about 10.0% to about 14.0% by weight of sodium chloride; from about 53.25% to about 63.25% by weight of sodium metasilicate; from about 13.2% to about 17.2% by weight of sodium carbonate; from about 0.25% to about 3.0% by weight of hydroxy ethyl cellulose; from about 0.25% to about 3.0% by weight of ethylene glycol monobutyl ether; from about 5.0% to about 9.0% by weight of sodium lauryl sulfate; and from about 2.0% to about 6.0% by weight of ethoxylated alcohol, based on a total weight of the non-caustic solid powder cleaner composition.

11. A method for manufacturing a non-caustic solid powder cleaner composition comprising: forming a solid mixture by combining sodium chloride, at least one chelator, at least one solid carbonate base, and at least one thickening agent; forming a surfactant mixture by combining an amount of an ethoxylated alcohol and an amount of sodium lauryl sulfate; adding at least one stabilizer to the solid mixture for a first time duration; and forming the non-caustic solid powder cleaner composition by adding the surfactant mixture to the solid mixture for a second time duration and mixing without grinding.

12. The method of claim 11, wherein the method further comprises monitoring homogeneity of the non-caustic solid powder cleaner composition by measuring density.

13. The method of claim 11, wherein: the first time duration is from about 3 minutes to about 8 minutes, or the second time duration is from about 3 minutes to about 8 minutes, or the first time duration and the second time duration are non-simultaneous.

14. The method of claim 11, wherein at least one chelator comprises sodium metasilicate, Ethylenediaminetetraacetic acid (EDTA), ethylene glycol-bis((-aminoethyl ether)-N,N,N,N-tetraacetic acid (EGTA), sodium citrate, a carboxylic acid chelator, or a combination thereof, and wherein the at least one surfactant comprises at least one ionic surfactant and at least one non-ionic surfactant, said at least one non-ionic surfactant comprising one or more alkoxylated alcohols and said at least one ionic surfactant comprising sodium lauryl sulfate.

15. The method of claim 11, wherein the at least one solid carbonate base comprises sodium carbonate, sodium bicarbonate, a carbonic acid salt, or a combination thereof, and wherein the at least one thickening agent comprises hydroxyethylcellulose, agar, or a combination thereof, further wherein the at least one stabilizer comprises ethylene glycol, ethylene glycol monobutyl ether, propylene glycol monoether, polyethylene glycol, or a combination thereof.

16. The method of claim 11, wherein the non-caustic solid powder cleaner composition comprises: from about 7.0% to about 19.0% by weight of sodium chloride; from about 48.25% to about 68.25% by weight of sodium metasilicate; from about 10.2% to about 20.2% by weight of sodium carbonate; from about 0.2% to about 3.8% by weight of hydroxy ethyl cellulose; from about 0.2% to about 3.75% by weight of ethylene glycol monobutyl ether; from about 2.0% to about 12.0% by weight of sodium lauryl sulfate; and from about 2.0% to about 6.0% by weight of ethoxylated alcohol, based on a total weight of the non-caustic solid powder cleaner composition.

Description

EXAMPLES

[0046] Ingredients

TABLE-US-00001 TABLE 1 CAS Weight % of Ingredient Number Purity Appearance composition Sodium Chloride (NaCl) 7647-14-5 >99% White powder 12.00 Sodium Metasilicate Anhydrous 6834-92-0 50-60%.sup. Off white 58.25 (Na.sub.2SiO.sub.3) crystalline powder Sodium Carbonate 497-19-8 99.5 White powder 15.2 Hydroxy Ethyl Cellulose QP- 9004-62-0 Industrial White to off- 1.8 52000-H (CELLOSIZE) grade (86- white .sup.100%) Powder Ethylene Glycol Monobutyl 111-76-2 99.0 Clear liquid 1.75 ether sodium lauryl sulfate 151-21-3 Solid 7 (NaC.sub.12H.sub.25SO.sub.4) Ethoxylated Alcohol NA NA NA 4

[0047] Formulation [0048] 1. Thoroughly mix all the solid ingredients from the Table above: Namely, sodium chloride, Na.sub.2SiO.sub.3, Na.sub.2CO.sub.3, and CELLOSIZE to form a SOLID MIXTURE, without grinding. [0049] 2. Separately from the SOLID MIXTURE, mix ethoxylated alcohol and sodium lauryl sulfate to form a SURFACTANT MIXTURE. [0050] 3. Sequentially, add to the SOLID MIXTURE: [0051] a. Ethylene Glycol Monobutyl ether over the course of 3-8 minutes of mixing without grinding [0052] b. The SURFACTANT MIXTURE over the course of 3-8 minutes of mixing without grinding [0053] c. To obtain a dry solid powder detergent. [0054] 4. Check homogeneity of the dry solid powder detergent by measuring apparent density against the expected density.

Use of Formulation

[0055] 5. Prepare a liquid cleaning solution by diluting 100 g of the dry solid powder detergent in 3.26 L of water.