Composition comprising fatty acyl isethionate and synthetic wax and method producing the same

Abstract

A method of preparing a component of a personal care bar, the method comprising: (a) providing a composition comprising an isethionate surfactant at a temperature of at least 20 C.; (b) combining the composition comprising the isethionate surfactant with a synthetic 5 wax and optional further components at a temperature of at least 120 C.; and (c) cooling the mixture obtained in step (b).

Claims

1. A method of preparing a component of a personal care bar, the method comprising: (a) providing a composition comprising an isethionate surfactant at a temperature of at least 120 C.; (b) combining the composition comprising the isethionate surfactant with a synthetic wax and optional further components at a temperature of at least 120 C.; and (c) cooling the mixture obtained in step (b); wherein the synthetic wax is an ethylene vinyl acetate copolymer.

2. A method of preparing a personal care bar, the method comprising preparing a component of a personal care bar according to claim 1 and combining the component with a soap component and optional further ingredients.

3. A method of preparing a personal care bar, the method comprising: (a) providing a composition comprising an isethionate surfactant at a temperature of at least 120 C.; (b) combining the composition comprising the isethionate surfactant with a synthetic wax and optional further components at a temperature of at least 120 C.; and (c) cooling the mixture obtained in step (b) forming into chips; and (d) combining the chips obtained in step (c) with chips of a soap component and optional further ingredients; wherein the synthetic wax is an ethylene vinyl acetate copolymer.

4. A personal cleansing bar comprising: (i) an isethionate surfactant; (ii) an ethylene vinyl acetate co-polymer; and (iii) a soap component, wherein the isethionate surfactant comprises at least 30 wt % based on the total amount of the isethionate surfactant and the ethylene vinyl acetate co-polymer.

5. A personal cleansing bar according to claim 4 which further comprises one or more components selected from: fatty acids; salts of fatty acids; polyalkylene glycols and derivatives; starches and dextrins, maltodextrin and other carbohydrates; inorganic particulate materials for example talc, kaolin, bentonite clay, aluminosilicate clays or other clays; carbonate or sulphate salts; glycerol esters or ethylene glycol esters; sugars and crystalline polyols; other waxes and fatty alcohols; fragrances or perfumes; germicides; antimicrobial agents; antioxidants; cationic polymers; sequestering agents for example sodium ethylenediaminetetraacetate (EDTA) and trisodium ethylenediamine disuccinate (EDDS); pigments, colorants and dyes; opacifiers and pearlizers for example titanium dioxide, zinc stearate or magnesium stearate; emollients for example benzoate esters; additional anionic, cationic or amphoteric surfactants for example, betaines, taurates, alkyl ether carboxylates, acyl glutamates, acyl sarcosinates, alkyl sulfates and alkyl ether sulfates; and additional water.

6. A personal cleansing bar according to claim 4 having a non-gritty feel.

7. A method of producing a soap free personal cleansing bar, the method comprising forming the synthetic detergent containing component obtained by the method of claim 1 into a bar.

8. A soap free personal cleansing bar comprising an isethionate surfactant and an ethylene vinyl acetate co-polymer, wherein the isethionate surfactant comprises at least 30 wt %.

9. A method of preparing a component of a personal care bar according to claim 1, wherein the ethylene vinyl acetate copolymer comprises 2 to 30% vinyl acetate.

10. A method of preparing a component of a personal care bar according to claim 3, wherein the ethylene vinyl acetate copolymer comprises 2 to 30% vinyl acetate.

11. A personal cleansing bar according to claim 4, wherein the ethylene vinyl acetate copolymer comprises 2 to 30% vinyl acetate.

12. A soap free personal cleansing bar according to claim 8, wherein the ethylene vinyl acetate copolymer comprises 2 to 30% vinyl acetate.

13. A method of preparing a component of a personal care bar according to claim 1, wherein the ethylene vinyl acetate copolymer has a drop melting point of greater than 70 C.

14. A method of preparing a component of a personal care bar according to claim 3, wherein the ethylene vinyl acetate copolymer has a drop melting point of greater than 70 C.

15. A personal cleansing bar according to claim 4, wherein the ethylene vinyl acetate copolymer has a drop melting point of greater than 70 C.

16. A soap free personal cleansing bar according to claim 8, wherein the ethylene vinyl acetate copolymer has a drop melting point of greater than 70 C.

17. A method of preparing a component of a personal care bar according to claim 1, wherein the ethylene vinyl acetate copolymer has a viscosity at 140 C. of from 250 to 750 mm.sup.2s.sup.1.

18. A method of preparing a component of a personal care bar according to claim 3, wherein the ethylene vinyl acetate copolymer has a viscosity at 140 C. of from 250 to 750 mm.sup.2s.sup.1.

19. A personal cleansing bar according to claim 4, wherein the ethylene vinyl acetate copolymer has a viscosity at 140 C. of from 250 to 750 mm.sup.2s.sup.1.

20. A soap free personal cleansing bar according to claim 8, wherein the ethylene vinyl acetate copolymer has a viscosity at 140 C. of from 250 to 750 mm.sup.2s.sup.1.

21. The personal cleansing bar according to claim 4, wherein the soap component comprises 5 to 90 wt %.

22. The personal cleansing bar according to claim 21, which further comprises one or more components selected from: fatty acids; salts of fatty acids; polyalkylene glycols and derivatives; starches and dextrins, maltodextrin and other carbohydrates; inorganic particulate materials for example talc, kaolin, bentonite clay, aluminosilicate clays or other clays; carbonate or sulphate salts; glycerol esters or ethylene glycol esters; sugars and crystalline polyols; other waxes and fatty alcohols; fragrances or perfumes; germicides; antimicrobial agents; antioxidants; cationic polymers; sequestering agents for example sodium ethylenediaminetetraacetate (EDTA) and trisodium ethylenediamine disuccinate (EDDS); pigments, colorants and dyes; opacifiers and pearlizers for example titanium dioxide, zinc stearate or magnesium stearate; emollients for example benzoate esters; additional anionic, cationic or amphoteric surfactants for example, betaines, taurates, alkyl ether carboxylates, acyl glutamates, acyl sarcosinates, alkyl sulfates and alkyl ether sulfates; and additional water.

23. The personal cleansing bar according to claim 21, having a non-gritty feel.

24. A personal cleansing bar comprising: (i) an isethionate surfactant; (ii) an ethylene vinyl acetate co-polymer; and (iii) a soap component, wherein the soap component comprises 5 to 90 wt %.

25. A personal cleansing bar according to claim 24, which further comprises one or more components selected from: fatty acids; salts of fatty acids; polyalkylene glycols and derivatives; starches and dextrins, maltodextrin and other carbohydrates; inorganic particulate materials for example talc, kaolin, bentonite clay, aluminosilicate clays or other clays; carbonate or sulphate salts; glycerol esters or ethylene glycol esters; sugars and crystalline polyols; other waxes and fatty alcohols; fragrances or perfumes; germicides; antimicrobial agents; antioxidants; cationic polymers; sequestering agents for example sodium ethylenediaminetetraacetate (EDTA) and trisodium ethylenediamine disuccinate (EDDS); pigments, colorants and dyes; opacifiers and pearlizers for example titanium dioxide, zinc stearate or magnesium stearate; emollients for example benzoate esters; additional anionic, cationic or amphoteric surfactants for example, betaines, taurates, alkyl ether carboxylates, acyl glutamates, acyl sarcosinates, alkyl sulfates and alkyl ether sulfates; and additional water.

26. A personal cleansing bar according to claim 24, having a non-gritty feel.

Description

Example 1A

(1) Composition A was prepared as follows: 51.6 Kg of sodium isethionate, 54.5 Kg of coconut fatty acids and 3.0 Kg of lauric acid were esterified at 240 C. using 0.1 Kg of zinc oxide catalyst and with removal of water to give a mixture comprising approximately 81% sodium cocoyl isethionate (SCI) and approximately 10% unreacted fatty acid. In a separate vessel, 22.9 Kg of stearic acid, 3.8 Kg of Sensymer E and 0.2 Kg titanium dioxide were mixed at 120 C. This mixture was added to the hot SCI mixture and mixed for 15 minutes at 225 C. The final mixture was then cooled to approximately 210 before pouring onto a stainless steel flaking sheet to harden and then flaked.

(2) Sensymer E is an ethylene vinyl acetate copolymer available from Innospec and having approximately 12% vinyl acetate content, a viscosity at 140 C. of 400 mPaS and a drop melting point of 99 C.

Example 1B

Comparative

(3) Composition B was prepared as follows: 51.6 Kg of sodium isethionate, 54.5 Kg of coconut fatty acids and 3.0 Kg of lauric acid were esterified at 240 C. using 0.1 Kg of zinc oxide catalyst and with removal of water to give a mixture comprising approximately 81% sodium cocoyl isethionate (SCI) and approximately 10% unreacted fatty acid. In a separate vessel, 22.9 Kg of stearic acid (vegetable based), 1.8 Kg of PEG-400 and 2.0 KG PEG-600 and 0.2 Kg titanium dioxide were mixed at 120 C. This mixture was added to the hot SCI mixture and mixed for 15 minutes at 225 C. The final mixture was then cooled to approximately 210 C. before pouring onto a stainless steel flaking sheet to harden and then flaked.

Example 1C

(4) Composition C was prepared as follows: 51.6 Kg of sodium isethionate, 54.5 Kg of coconut fatty acids and 3.0 Kg of lauric acid were esterified at 240 C. using 0.1 Kg of zinc oxide catalyst and with removal of water to give a mixture comprising approximately 81% sodium cocoyl isethionate (SCI) and approximately 10% unreacted fatty acid. In a separate vessel, 22.9 Kg of stearic acid (Tallow based), 3.8 Kg of Sensymer E and 0.2 Kg titanium dioxide were mixed at 120 C. This mixture was added to the hot SCI mixture and mixed for 15 minutes at 225 C. The final mixture was then cooled to approximately 210 C. before pouring onto a stainless steel flaking sheet to harden and then flaked.

Example 1D

(5) Composition D was prepared as follows: 51.6 Kg of sodium isethionate, 54.5 Kg of coconut fatty acids and 3.0 Kg of lauric acid were esterified at 240 C. using 0.1 Kg of zinc oxide catalyst and with removal of water to give a mixture comprising approximately 81% sodium cocoyl isethionate (SCI) and approximately 10% unreacted fatty acid. In a separate vessel, 25.8 Kg of stearic acid were melted at 120 C. and added to the hot SCI mixture and mixed for 15 minutes at 225 C. The final mixture was then cooled to approximately 210 before pouring onto a stainless steel flaking sheet to harden and then flaked.

Examples 1E to 1I

(6) Compositions E-G were prepared using a method analogous to that described in Example 1A. Each composition included the following base ingredients but included a different wax as detailed below:

(7) TABLE-US-00001 Sodium Isethionate 379.4 g Coconut fatty acid 400.6 g Lauric acid 21.7 g Zinc oxide 0.8 g Triple press stearic acid 168.4 g Titanium dioxide 1.3 g Waxes (natural) 27.8 g

(8) The waxes used were:

(9) ESynthetic polyethylene wax having a drop melting point of 104 C.;

(10) FBeeswaxa natural mixture of fatty acids, and fatty esters including hydroxy esters;

(11) GRoss waxa mineral oil wax, predominantly hydrocarbon having a melting point around 70 C. and available from Frank B.Ross Co;

(12) HCeresin waxa mineral wax available from Akrochem Corporation;

(13) ICastorwax MP-80a high melting point wax derived from hydrogenated castor oil and available from HallStar Co.

(14) TABLE-US-00002 TABLE 1 Wax Component Example No Composition used Colour Odour 1A A Sensymer E Good Good 1B B Mixture of PEG 400 Poor Poor and PEG 600 1C C Sensymer E Good Good 1D D None Good Good 1E E Synthetic Good Good polyethylene wax having a drop melting point of 104 C. 1F F Beeswax (1) Dark Bad 1G G Ross wax 160 (2) Dark Bad 1H H Cerasin wax (3) Dark Bad 1I I Castorwax MP-80 (4) Dark Bad

Example 2

(15) Compositions A to D of example 1 were used to prepare soap bars having the ingredients listed in table 2. All ingredients are given as percentages by weight.

(16) TABLE-US-00003 TABLE 2 Example Ingredient: 2A 2B 2C 2D 2E 2F 2G 2H 2I A 78.4 80 75 16.5 B 80 75 C 75 75 D 16 Soap, 80:20 13 12.7 13 18 18 74 81.96 18 palm:coconut Soap, 85:15 18 tallowate:cocoate Stearic Acid 1890 5 4.9 5 5 5 5 10 1.1 5 Mirataine BET C-30 1 1 1 1 1 1 0.22 1 (CAPB) Hostapon SI 1 1 1 1 1 1 0.22 1 (Sodium Isethionate) water 2 fragrance 100 100 100 100 100 100 100 100 100 Mirataine BET C-30 is an approx 30% aqueous solution of Cocamidopropyl betaine available from Rhodia Novecare. Hostapon SI approx 57% is an aqueous solution of Sodium Isethionate available from Clariant Stearic Acid 1890 is mixture of fatty acids comprising 90% stearic acid.

(17) Each of the soap bars 2A to 2H were assessed for bar feel, odour, foam, hardness and mush using the procedures outlined below.

(18) The results are shown in table 3:

(19) TABLE-US-00004 TABLE 3 Example Bar feel Odour Foam Hardness Mush 2A smooth poor 73 32 2B smooth good 163 25 2C smooth good 90 20 9.87 2D smooth good 95 19 7.58 2E smooth good 15 2F smooth good 80 25 14.25 2G gritty good 2H smooth good 30 60 7.94 2I smooth poor 26

(20) Bar hardness was measured using the ASTM Standard Test Method D1321-10. This method measures the extent of penetration of a standard needle into the test material, in this case a bar preparation. The method measures the depth to which a standard needle penetrates the bar surface. A penetrometer is an instrument that measures the depth to which a needle under a given force falls into the material. A standard penetrometer needle was used with a penetration force of 100 g which is the total mass of the needle, plunger and 50 g weight. Bars were equilibrated under controlled conditions of 25 C. and 50% RH. In the method a 50 g weight is placed above the penetrometer needle. The bar is positioned under the needle and the needle is lowered until the tip is touching the bar surface and is then locked into position. The indicator needle on the penetrometer is adjusted to read zero. When the above conditions are set, the needle shaft is then released and held free for 5 seconds. The indicator shaft is then depressed until it is stopped by the needle shaft. The penetration value is read from the indicator scale. Measurements were made on four points on a given bar surface and the results averaged to give the final penetration value in mm. A higher value indicates a softer material.

(21) Bar mush was measured as follows: a pre-weighed bar sample is immersed in 250 mL of water maintained at 25 C. for 4 hours. After this time, the bar is removed from the water and the mush, or soft hydrated layer, is scraped from the bar with a plastic spatula. The scraped bar is dried for 24 hours at room temperature and then weighed. The mush percentage is calculated as the weight change of the bar divided by the initial bar weight multiplied by 100.

(22) The foam volume was measured as follows: bars were pre-treated by washing with gloved hands in running tap water for 1 minute by twisting the bars between the hands about 20 times. The bar is held under running tap water and removed. The bar is rotated 15 times between the gloved hands and then placed to the side. The lather is generated in the next two steps. In step 1 the tips of the fingers of one hand are rubbed on the palm of the other 10 times. Then in step 2, one hand is used to grip the other to squeeze the foam off of the hand and into a 250-mL beaker. For smaller foal volumes use a 150-mL beaker. Repeat step 2 five times with each hand. Hold the bar again under running tap water, remove and repeat the whole procedure of lather generation twice more, combining all the lather in the beaker. Stir the collected foam gently to release large pockets of air. Record the foam volume in milliliters.