Cleaning compositions for solid surfaces – auxiliary compositions – Cleaning compositions or processes of preparing – For cleaning a specific substrate or removing a specific...
Reexamination Certificate
2000-03-07
2001-04-17
Ogden, Necholus (Department: 1751)
Cleaning compositions for solid surfaces, auxiliary compositions
Cleaning compositions or processes of preparing
For cleaning a specific substrate or removing a specific...
C510S153000, C510S155000, C510S156000, C510S474000
Reexamination Certificate
active
06218347
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to a solid cleansing composition, of the general type and shape of a cleansing bar. A solid cleansing bar is provided with high filler loading, and simultaneously excellent lathering, texture, feel characteristics and aesthetics. The bar can be produced by conventional plodding technology, and yet exhibits superior properties when compared with related technology prepared according to tableting processes which are not nearly as productive.
2. Background of the Prior Art
U.S. patent application Ser. No. 08/621,965, filed Mar. 26, 1996, now U.S. Pat. No. 5,756,438, the entirety of which is incorporated herein by reference, discloses cleansing bars containing a high proportion of fillers, in particular fillers such as maltodextrin or dextrose. Other fillers, including other carbohydrates, starches and dextrins, as well as inorganic particulate fillers such as talc, kaolin, bentonite clay, carbonate or sulphate salts, sugars and crystalline polyols are noted. The filler is combined with a surfactant system which includes anionic surfactants, and/or non-ionic surfactants, which may be used together with zwitterionic and cationic surfactants. While this patent application describes the potential use of quaternary ammonium chlorides, use of the same is not exemplified. One problem with using such quaternary surfactants is the pH level generally encountered in solid cleansing products, even non-soap cleansing products of the type addressed herein and in the referenced pending application. Specifically, a neutral-alkaline pH may generate, through decomposition, free amines, and the associated unpleasant odor as well as product discoloration. Additionally, many commercially available quaternary surfactant compositions comprise residual free amines.
U.S. Pat. No. 5,756,438 describes a process for production that involves melting a waxy binder, mixing it with the remaining components and subsequently tableting the so processed mass. While the processing specified gives rise to a highly desirable product, it is specifically disclosed that the high production techniques generally used in bar products, referred to as “plodding”, cannot be used. This necessarily imparts significant costs to the process of manufacture.
Other highly filled bar products have been attempted, but are generally inadequate in one or more important product considerations. These include lathering, or foaming. In general, the presence of a high degree of filler complicates the ability to produce adequate foaming. Another essential aspect of the product is its feel or texture. The higher proportion of filler typically gives rise to a “dragging” or “rough” feeling in the bar itself. Similarly, the product must be aesthetically pleasing. Commercial products with a high filler loading provide an unattractive bar, that cracks or splinters quickly upon use, and/or presents a grainy, pebbled surface.
Japanese Kokai 56-84798, published Jul. 10, 1981, is directed to a soap composition which contains, by weight, 60-90% starch or cellulose. Unlike the non-soap product of U.S. Pat. No. 5,756,438, and the claimed invention, the Kokai is directed to a granular soap which is a compacted powder intended to achieve rapid disintegration, and through disintegration, washing. The product is intended for use as a tablet which disintegrates upon admixture with water. Thus, while other high-filler compositions are known, none provide a suitable combination of acceptable lathering performance, acceptable filler texture, aesthetic properties and ease of manufacturing. The provision of a personal, non-soap cleansing bar, meeting these goals, continues to be an object of those of skill in the art.
SUMMARY OF THE INVENTION
The above objects, and others explained in more detail below, are met by the provision of a non-soap solid cleansing bar which can be prepared on conventional plodding machines, which includes as essential components a surfactant including an anionic surfactant, and fillers. Fillers are present in amounts of about 45-80% by weight, anionic surfactants are present in an amount of about 15-45% by weight, quaternary surfactants are present in amounts of about 0-5% by weight and waxy binder materials are present in an amount of about 0-20% by weight. The resulting product exhibits superior lathering, is prepared by conventional plodding processing, and has excellent aesthetic and texture properties. The bar exhibits a pH below about 7.0, that is an acidic pH, generally about 4-6.5. This suppresses the generation of amine odors due to the presence of the quaternary surfactant. The cleansing bar further incorporates a minimum 5% by weight water. Water may be present in amounts up to about 20% by weight.
DETAILED DESCRIPTION OF THE INVENTION
This invention is described, in detail, below. All percentage values recited are active ingredient percentage by weight. Percentages, where recited, are approximate, unless indicated to the contrary. It is not the precise numerical value of the percentage recited, unless so indicated, but rather the balance of components selected so as to achieve the performance characteristics demonstrated, with ease of mechanical preparation, that characterize the claimed invention.
The invention is a personal non-soap cleansing bar. While shape and size is not unduly restricted, it is intended for, and must be acceptable for use by human hands or acceptable cleansing accessory (puffs, sponges, loofahs and the like), over an extended wear period with multiple uses. The product typically weighs between 1 and 10 ounces, and has physical dimensions in excess of several inches in at least one direction. The bar composition of this invention is of a shape and size generally known as “facial soap” or “bath soap” sizes. This invention is described in terms of the essential ingredients, discussed below, followed by exemplification and testing of the resulting product.
Surfactant
The surfactant system of this invention may include quaternary ammonium surfactants for their superior lathering ability and skin conditioning affect. Their inclusion is made possible by the low pH of 4-7 of the composition. The quaternary surfactant is typically of the formula:
In the general formula, R
1
, R
2
, R
3
and R4 are hydrogen or alkyl, and at least one of R
1
-R
4
are straight or branched alkyl of at least 8 carbon atoms. In general, the carbon count of R
1
-R
4
should be in excess of 12. These are generally referred to as “fatty quaternary compounds”. X is any suitable anion, typically chlorine. Bromine and methosulfate may also be used. These surfactants are present in an amount of 0.1% -5% by weight. Representative quaternary surfactants include behentrimonium chloride (BTAC), stearyl trimethyl ammonium chloride (STAC) and distearyldimonium chloride (DSDC).
In addition to the quaternary surfactant, the claimed invention employs anionic surfactants. The anionic surfactants are present in amounts of about 15-45% by weight, and are combined with the quaternary surfactant to give a total surfactant content of not more than 50% by weight. Preferred total surfactant content includes a combination of quaternary and anionic surfactants in the amount of 20-45% by weight.
A particularly preferred surfactant system includes sodium cocoyl isethionate (SCI) in combination with sodium dodecylbenzene sulfonate (LAS). These materials are advantageously used in about a 4:1 to 6:1 ratio (SCI:LAS). Other combinations of anionic surfactants perform acceptably.
Alternate anionic materials include:
alkyl (C8-18) sulfates (e.g., sodium lauryl sulfate, sodium ceteryl sulfate, sodium lauryl amide methylene sulfate),
alkyl (C8-18) ether sulfates (e.g., sodium laureth-x sulfate, x=1 to 12)
fatty acid soaps (e.g., sodium stearate, sodium laurate),
sulfated fatty acids (sulfated coconut acid, sulfated stearic acid, sulfated acid palmitic
sulfated lower alkyl fatty acid esters (sulfated methyl stearate, sulfated ethyl palmitate, sulfated propyl stearate), sulfonated fatty
Fischer Vincent J.
Freeman Gregory A.
Rau Allen H.
Schwartz Mary A.
Kelber Steven B.
Ogden Necholus
Piper Marbury Rudnick & Wolfe LLP
The Andrew Jergens Company
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