Laundry Composition and Method of Making it

Abstract

A laundry composition comprises:- a) from 2 wt % to 10 wt % anionic soap surfactant, b) from 0.5 wt % to 2.5 wt % alkyl sulphate, c) from 0.1 wt % to 2 wt % nonionic surfactant, d) from 0.1 wt % to 2 wt % carboxy methyl cellulose, e) from 2 wt % to 12 wt % source of active oxygen.

Claims

1. A laundry composition comprising: a) about 0.1 wt % to about 20 wt % of an anionic soap surfactant, b) 0.5 wt % to 2.5 wt % of an alkyl sulphate surfactant, c) 0.1 wt % to 2 wt % of a nonionic surfactant, d) 0.1 wt % to 2 wt % of a dispersing or suspending agent, e) 2 wt % to 12 wt % to a source of active oxygen.

2. (canceled)

3. (canceled)

4. The laundry composition of claim 1, comprising: a) about 2 wt % to about 10 wt % of an anionic soap surfactant.

5. The laundry composition of claim 4, comprising: a) about 4 wt % to about 8 wt % of an anionic soap surfactant.

6. The laundry composition of claim 1, comprising: b) about 1.5 wt % of an alkyl sulphate surfactant.

7. The laundry composition of claim 1, comprising: c) about 1 wt % of a nonionic surfactant.

8. The laundry composition of claim 1, comprising: d) about 1 wt % of carboxy methyl cellulose.

9. The laundry composition of claim 1, comprising: e) about 7 wt % of active oxygen.

10. The laundry composition of claim 1, further comprising: f) 0.1 wt % to 40 wt % of a peracid precursor.

11. The laundry composition of claim 1, further comprising: g) 0.1 wt % to 80 wt % of a filler.

12. The laundry composition of claim 1, further comprising: h) 4 wt % to 30 wt % of a zeolite.

13. The laundry composition of claim 1, further comprising: i) 0.01 wt % to 90 wt % of a soil catcher.

14. The laundry composition of claim 1, further comprising: j) 0.01 wt % to 80 wt % of a builder.

15. The laundry composition of claim 1, further comprising: k) 0.01 wt % to 30 wt % of a solvent.

16. The laundry composition of claim 1, further comprising: l) 0.01 wt % to 10 wt % of an enzyme.

17. The laundry composition of claim 1, further comprising: m) 0.1 wt % to 50 wt % of a stain and/or dye catcher system.

18. The laundry composition of claim 17, wherein the dispersing or suspending agent is carboxy methyl cellulose, an acrylic polymer or an acrylic maleic copolymer.

19. The laundry composition of claim 1, further comprising: water; a filler; a zeolite; a copolymer.

20. A method of preparing the laundry composition of claim 19, the method comprising the steps of: I. forming a slurry of certain elements of the composition; II. feeding the slurry to a tower spray apparatus; and III. optionally (post) adding of elements of the composition; wherein the slurry formation comprises the following composition: a) water; b) an anionic soap surfactant; c) a filler; d) a zeolite; e) a copolymer; wherein during mixing of the slurry the pH during mixing is maintained below 8.5 and the working temperature is maintained between 50 C.-60 C.

21. The method of claim 20 wherein the slurry formation comprises the following composition: a) about 32 wt % of water; b) about 5.5 wt % of the anionic soap surfactant; c) about 45 wt % of the filler; d) about 20 wt % of the zeolite; e) about 5.5 wt % of the copolymer.

22. The method of claim 20, wherein components (a) to (e) are added to the slurry preparation vessel in the following sequential order: a) water; b) the anionic soap surfactant; c) the filler; d) the zeolite; e) the copolymer.

Description

[0065] The cleaning composition may also contain additives, such as builders, chelating agents, solvents, enzymes, fragrances, and anti-caking agents, as described in further detail below.

[0066] The cleaning composition is preferably in the form of a powder. By powder we mean any solid, flowable composition. Thus the powder may, for example, be in the form of granules or agglomerated particles. It may, however, be in the form of a loose agglomeration of particles. The d.sub.50 particle size of the particles may range from 0.001 mum to 10 mm, preferably from 0.01 mum to 2 mm, and more preferably from 0.1 mum to 2 mm, for example 1 mum to 1 mm.

[0067] Preferred anionic surfactants are frequently provided as alkali metal salts, ammonium salts, amine salts, aminoalcohol salts or magnesium salts. Contemplated as useful are one or more sulfate or sulfonate compounds including: alkyl benzene sulfates, alkyl sulfates, alkyl ether sulfates, al-kylamidoether sulfates, alkylaryl polyether sulfates, monoglyceride sulfates, alkylsulfonates, alkylamide sulfonates, alkylarylsulfonates, olefinsulfonates, paraffin sulfonates, alkyl sulfosuccinates, alkyl ether sulfosucci-nates, alkylamide sulfosuccinates, alkyl sulfosuccinamate, alkyl sulfoacetates, alkyl phosphates, alkyl ether phosphates, acyl sarconsinates, acyl isethionates, and N-acyl taurates. Generally, the alkyl or acyl radical in these various compounds comprise a carbon chain containing 12 to 20 carbon atoms.

[0068] Other surfactants which may be used are alkyl naphthalene sulfonates and oleoyl sarcosinates and mixtures thereof.

[0069] The composition of all aspects of the present invention may, for example, comprise at least one builder or a combination of them, for example in an amount of from 0.01 to 80 percent wt, preferably from 0.1 to 50 percent wt. Builders may be used as chelating agents for metals, as anti-redeposition agents and/or as alkalis.

[0070] Examples of builders are described below:

[0071] the parent acids of the monomeric or oligomeric polycar-boxylate chelating agents or mixtures thereof with their salts, e.g. citric acid or citrate/citric acid mixtures are also contemplated as useful builder components.

[0072] borate builders, as well as builders containing borate-forming materials than can produce borate under detergent storage or wash conditions can also be used.

[0073] iminosuccinic acid metal salts. -polyaspartic acid metal salts.

[0074] ethylene diamino tetra acetic acid and salt forms.

[0075] water-soluble phosphonate and phosphate builders are useful for this invention. Examples of phosphate builders are the alkali metal tripolyphosphates, sodium potassium and ammonium pyrophosphate, sodium and potassium and ammonium pyrophosphate, sodium and potassium orthophosphate sodium polymeta/phosphate in which the degree of polymerisation ranges from 6 to 21, and salts of phytic acid. Specific examples of water-soluble phosphate builders are the alkali metal tripolyphosphates, sodium, potassium and ammonium pyrophosphate, sodium, potassium and ammonium pyrophosphate, sodium and potassium orthophosphate, sodium polymeta/phosphate in which the degree of polymerization ranges from 6 to 21, and salts of phytic acid. Such polymers in-elude polycarboxylates containing two carboxy groups, water-soluble salts of succinic acid, malonic acid, (ethyl-enedioxy) diacetic acid, maleic acid, diglycolic acid, tartaric acid, tartronic acid and fumaric acid, as well as the ether carboxylates and the sulfinyl carboxylates.

[0076] Polycarboxylates containing three carboxy groups include, in particular, water-soluble citrates, aconitrates and citraconates as well as succinate derivates such as the carboxymethloxysuccinates described in GB-A-I, 379, 241, lac-toxysuccinates described in GB-A-1, 389, 732, and aminosucci-nates described in NL-A-7205873, and the oxypolycarboxylate materials such as 2-oxa-I, 1, 3-propane tricarboxylates de-scribed in GB-A-I, 387, 447.

[0077] Polycarboxylate containing four carboxy groups include oxy-disuccinates disclosed in GB-A-I, 261, 829, 1, 1, 2, 2-ethane tetracarboxylates, 1, 1, 3, 3-propane tetracarboxylates and 1, 1, 2, 3-propane tetracarobyxlates. Polycarboxylates containing sulfa substituents include the sulfosuccinate derivatives disclosed in GB-A-I, 398, 421, GB-A-I, 398, 422 and US-A-3, 936448, and the sulfonated pyrolysed citrates described in GB-A-I, 439, 000.

[0078] Alicylic and heterocyclic polycarboxylates include cyclopentane-cis, cis, cis-tetracarboxylates, cyclopentadi-enide pentacarboxylates, 2, 3, 4, 5, 6-hexane-hexacarboxy-lates and carboxymethyl derivates of polyhydric alcohols such as sorbitol, mannitol and xylitol. Aromatic polycarboxylates include mellitic acid, pyromellitic acid and the phthalic acid derivatives disclosed in GB-A-I, 425, 343.

[0079] Of the above, the preferred polycarboxylates are hydroxy-carboxylates containing up to three carboxy groups per molecule, more particularly citrates.

[0080] Suitable polymer water-soluble compounds include the water soluble monomeric polycarboxylates, or their acid forms, homo or copolymeric polycarboxylic acids or their salts in which the polycarboxylic acid comprises at least two car-boxylic radicals separated from each other by not more than two carbon atoms, carbonates, bicarbonates, borates, phosphates, and mixtures of any of the foregoing.

[0081] The carboxylate or polycarboxylate builder can be monomeric or oligomeric in type although monomeric polycarboxylates are generally preferred for reasons of cost and performance.

[0082] Suitable carboxylates containing one carboxy group include the water soluble salts of lactic acid, glycolic acid and ether derivatives thereof. Polycarboxylates containing two carboxy groups include the water-soluble salts of succinic acid, malonic acid, (ethylenedioxy) diacetic acid, maleic acid, diglycolic acid, tartaric acid, tartronic acid and fumaric acid, as well as the ether carboxylates and the sulfinyl carboxylates. Polycarboxylates containing three carboxy groups include, in particular, water-soluble citrates, aconitrates and citraconates as well as succinate derivates such as the carboxymethloxysuccinates described in GB-A-I, 379,241, lactoxysuccinates described in GB-A-1,389,732, and aminosuccinates described in NL-A-7205873, and the oxypolycarboxylate materials such as 2-oxa-I,I,3-propane tricarboxylates described in GB-A-I, 387, 447.

[0083] Polycarboxylate containing four carboxy groups include oxy-disuccinates disclosed in GB-A-I, 261, 829, 1, 1, 2, 2-ethane tetracarboxylates, 1, 1, 3, 3-propane tetracarboxylates and 1, 1, 2, 3-propane tetracarobyxlates. Polycarboxylates containing sulfa substituents include the sulfosuccinate de-rivatives disclosed in GB-A-1, 398, 421, GB-A-1, 398, 422 and US-A-3, 936448, and the sulfonated pyrolysed citrates described in GB-A-I, 439, 000.

[0084] Alicylic and heterocyclic polycarboxylates include cyclopentane-cis, cis, cis-tetracarboxylates, cyclopentadi-enide pentacarboxylates, 2, 3, 4, 5, 6-hexane-hexacarboxy-lates and carboxymethyl derivates of polyhydric alcohols such as sorbitol, mannitol and xylitol. Aromatic polycarboxylates include mellitic acid, pyromellitic acid and the phthalic acid derivatives disclosed in GB-A-I, 425, 343.

[0085] Of the above, the preferred polycarboxylates are hydroxy-carboxylates containing up to three carboxy groups per molecule, more particularly citrates.

[0086] More preferred polymers are homopolymers, copolymers and multiple polymers of acrylic, fluorinated acrylic, sul-fonated styrene, maleic anhydride, metacryl.ic, iso-butylene, styrene and ester monomers.

[0087] Examples of these polymers are Acusol supplied from Rohm AND Haas, Syntran supplied from Interpolymer and the Versa and Alcosperse series supplied from Alco Chemical, a National Starch AND Chemical Company.

[0088] The parent acids of the monomeric or oligomeric polycar-boxylate chelating agents or mixtures thereof with their salts, e.g. citric acid or citrate/citric acid mixtures are also contemplated as useful builder components.

[0089] Examples of bicarbonate and carbonate builders are the alkaline earth and the alkali metal carbonates, including so-dium and calcium carbonate and sesqui-carbonate and mixtures thereof. Other examples of carbonate type builders are the metal carboxy glycine and metal glycine carbonates.

[0090] In the context of the present application it will be appreciated that builders are compounds that sequester metal ions associated with the hardness of water, e.g. calcium and magnesium, whereas chelating agents are compounds that sequester transition metal ions capable of catalysing the degradation of oxygen bleach systems. However, certain compounds may have the ability to do perform both functions.

[0091] Suitable chelating agents to be used herein include chelating agents selected from the group of phosphonate chelating agents, amino carboxylate chelating agents, polyfunction-ally-substituted aromatic chelating agents, and further chelating agents like glycine, salicylic acid, aspartic acid, glutamic acid, malonic acid, or mixtures thereof. Chelating agents when used, are typically present herein in amounts ranging from 0.01 to 50 percent wt of the total composition and preferably from 0.05 to 10 percent wt.

[0092] Suitable phosphonate chelating agents to be used herein may include ethydronic acid as well as amino phosphonate compounds, including amino alkylene poly (alkylene phosphonate), alkali metal ethane 1-hydroxy diphosphonates, ni-trilo trimethylene phosphonates, ethylene diamine tetra me-thylene phosphonates, and diethylene triamine penta methylene phosphonates. The phosphonate compounds may be present either in their acid form or as salts of different cations on some or all of their acid functionalities. Preferred phosphonate chelating agents to be used herein are diethyl-ene triamine penta methylene phosphonates. Such phosphonate chelating agents are commercially available from Monsanto under the trade name DEQUEST .

[0093] Polyfunctionally-substituted aromatic chelating agents may also be useful in the compositions herein. See U.S. Pat. No. 3,812,044, issued May 21, 1974, to Connor et al. Preferred compounds of this type in acid form are dihydroxydisul-fobenzenes such as 1, 2-dihydroxy-3, 5-disulfobenzene.

[0094] A preferred biodegradable chelating agent for use herein is ethylene diamine N, N-disuccinic acid, or alkali metal, or alkaline earth, ammonium or substituted ammonium salts thereof or mixtures thereof. Ethylenediamine N, N.sup.1-disuccinic acids, especially the (S, S) isomer have been extensively described in U.S. Pat. No. 4,704,233, Nov. 3, 1987, to Hartman and Perkins. Ethylenediamine N,N-disuccinic acid is, for instance, commercially available under the tradename ssEDDS from Palmer Research Laboratories.

[0095] Suitable amino carboxylates to be used herein include ethylene diamine tetra acetates, diethylene triamine pentaace-tates, diethylene triamine pentaacetate (DTPA), N-hy-droxyethylethylenediamine triacetates, nitrilotri-acetates, ethylenediamine tetrapropionates, triethylenetetraamine-hexa-acetates, ethanol-diglycines, propylene diamine tet-racetic acid (PDTA) and methyl glycine diacetic acid (MGDA), both in their acid form, or in their alkali metal, ammonium, and substituted ammonium salt forms. Particularly suitable amino carboxylates to be used herein are diethylene triamine penta acetic acid, propylene diamine tet-racetic acid (PDTA) which is, for instance, commercially available from BASF under the trade name Trilon FS and methyl glycine di-acetic acid (MGDA).

[0096] The cleaning compositions of all aspects of the invention may also comprise fillers. Examples of fillers are sodium chloride, bentonite, zeolites, citrates, talc and metal sulfate salts such as sodium, calcium and aluminium sul-phates. They can be used at a level from 0.01 to 60 percent wt, preferably between 0.1 to 30 percent wt.

[0097] The cleaning compositions of all aspects of the invention may also comprise a solvent. Solvents can be used for pre-sent invention in amounts from 0.01 to 30 percent wt, preferably in amounts of 0.1 to 3 percent wt. The solvent constituent may include one or more alcohol, glycol, acetate, ether acetate, glycerol, polyethylene glycol with molecular weights ranging from 200 to 1000, silicones or glycol ethers. Ex-emplary alcohols useful in the compositions of the invention include C2-C8 primary and secondary alcohols which may be straight chained or branched, preferably pentanol and hexanol.

[0098] Preferred solvents for the invention are glycol ethers. Examples include those glycol ethers having the general structure R.sub.3O[CH.sub.2CH (R)(CH.sub.2)-0].sub.nH, wherein R.sub.a is Ci.sub.2o al-kyl or alkenyl, or a cyclic alkane group of at least 6 carbon atoms, which may be fully or partially unsaturated or aromatic; n is an integer from 1 to 10, preferably from 1 to 5; and each R is selected from H or CH.sub.3. Specific and preferred solvents are selected from propylene glycol methyl ether, dipropylene glycol methyl ether, tripropylene glycol methyl ether, propylene glycol n-propyl ether, eth-ylene glycol n-butyl ether, diethylene glycol n-butyl ether, diethylene glycol methyl ether, propylene glycol, ethylene glycol, isopropanol, ethanol, methanol, diethylene glycol monoethyl ether acetate, and, especially, propylene glycol phenyl ether, ethylene glycol hexyl ether and di-ethylene glycol hexyl ether.

[0099] The composition may, for example, comprise one enzyme or a combination of them, for example in an amount of from 0.01 to 10 percent wt, preferably from 0.1 to 2 percent wt. Enzymes in granular form are preferred. Examples of suitable enzymes are proteases, modified proteases stable in oxidisable conditions, amylases, lipases and cellulases.

[0100] Additional, optional, ingredients, selected from a list comprising fragrance, anticaking agent such as sodium xylene sulfonate and magnesium sulfate and dye, may be present, each at levels of up to 5 percent wt, preferably less then 1 percent wt.

[0101] Stain and/or dye catcher systems useful for the present invention may be mixed to the cleaning composition in an amount ranging from 0.1 to 50 percent wt, preferably from 1 to 30 percent wt. They can be optionally also added as filler to the enclosing wall in an amount ranging from 0.1 to 60 percent wt, more preferably from 1 to 30 percent wt.

[0102] The product of the present invention may also include dis-persing or suspending agents that may be released into the wash to aid the soil being bound to the soil catcher. Such agents may be deposited on the enclosing wall of the product, or contained in the enclosing wall with or as part of the cleaning composition. Examples of such agents include carboxy methyl cellulose and acrylic maleic copolymers or acrylic polymers. Such agents may be used in an amount of 0.01 to 30 percent wt, preferably 0.1 to 10 percent wt of the cleaning composition.

[0103] The present invention also provides a method of cleaning laundry in a laundry washing machine, which comprises adding a composition as defined above to the washing machine and conducting the wash.