Cleaning compositions for solid surfaces – auxiliary compositions – Cleaning compositions or processes of preparing – For cleaning a specific substrate or removing a specific...
Reexamination Certificate
2000-12-05
2001-10-30
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...
C510S141000, C510S153000, C510S155000
Reexamination Certificate
active
06310016
ABSTRACT:
The invention relates to a synergistic composition of soap/detergent bars for personal and/or fabric washing. It also relates to a process for the preparation of such soap/detergent bars for personal and/or fabric washing. The invention particularly relates to a low total fatty matter (TFM) detergent bar comprising high levels of water and other liquid benefit agents, and a process for its manufacture.
Conventional detergent bars based on soap for personal washing usually contain over about 70% by weight total fatty matter (TFM), the remainder being water (about 10-20%) and other ingredients such as colour, perfume, preservatives, etc. Structurants and fillers are also present in such compositions in small amounts, which replace some of the soap in the bar while retaining the desired hardness of the bar. A few known fillers include starch, kaolin and talc.
Hard non-milled soap bars containing moisture of less than 35% are also available. These bars have a TFM of about 30-65%. The reduction in TFM has usually been achieved by the use of insoluble particulate materials and/or soluble silicates. Milled bars generally have a water content about 8-15%, and the hard non-milled bars have a water content of about 20-35%.
It is important to deliver sensory properties such as lather and skin feel, preferably by incorporating benefit agents in the formulation without altering the processability and physical properties of the bar. It is often found that it is a problem to formulate detergent compositions that would perform well under hard water conditions. Incorporation of builders such as phosphates or others in soap systems create problems such as efflorescence, gritty feel, etc.
IN 176384 discloses a detergent composition with low TFM content having high ratio of water to TFM without affecting hardness, cleaning and lathering properties of the bar by the incorporation of up to 20% colloidal aluminium hydroxide (A-gel). The A-gel/TFM combination enables the preparation of bars with higher water content while using TFM at a lower level. In this patent, although the A-gel concentration disclosed is up to 20% by weight, the demonstration of the invention is restricted to the use of 7.5% by weight A-gel in combination with 40% TEM with an additional structurant such as 5% by weight of alkaline silicate. IN 177828 discloses a process wherein by providing a balanced combination of aluminium hydroxide and TFM it is possible to prepare a low TFM bar having high water content but with satisfactory hardness. The patent teaches the generation of colloidal alumina hydrate in-situ by a reaction of fatty acid/fat with an aluminium containing alkaline material such as sodium aluminate to form bars which are obtained by plodding. Our co-pending application 811/Bom/98 (corresponding to GB 9906834.8) discloses that use of A-gel from 9 to 16% by weight of the composition synergistically improves the processability, sensory and physical properties of low TFM bars.
In addition, our co-pending application 810/Bom/98 (corresponding to WO/EP99/09042) discloses a process of preparing a low TFM bar utilising a reaction of fatty acid with an aluminium containing alkaline material such as sodium aluminate solution that specifically has a solid content of 20 to 55%, wherein the alumina (Al
2
O
3
) to sodium oxide (Na
2
O) is in a ratio of 0.5 to 1.55 by weight that gives superior bar properties. These bars have improved hardness and smoother feel. This reaction can take place in a broader temperature range of 40 to 95° C.
In the process of the invention, it has now been found that in situ generation of aluminium hydroxide-phosphate complex by a reaction of fatty acid/fat in presence of phosphoric acid with an aluminium containing alkaline material such as sodium aluminate solution that preferably has a solid content of 20 to 55%, preferably wherein the alumina (Al
2
O
3
) to sodium oxide (Na
2
O) is in a ratio of 0.5 to 1.55 by weight gives superior bar properties. These bars will have significantly lower density and improved physical properties such as bar hardness without interfering with the sensory properties. By this process it is possible to formulate bars that are suitable for both soft and hard water situations.
It is an advantage of the invention to be able to formulate detergent compositions suitable for both soft and hard water situations where the density, processability and physical properties such as hardness of the bar are improved significantly by incorporation of colloidal aluminium hydroxide phosphate complex (Alphos).
It is another advantage of the invention to be able to manufacture extruded detergent bars using fatty acids mixtures having an Iodine Value (IV) in the range from.0 to 110. It is particularly significant that using fatty acid mixtures with an IV beyond 70 and the incorporation of Alphos as a structurant it is possible to produce detergent bars with good physical properties by an extrusion route, without the addition of processing aids such as silicates. It has also been possible to structure better and higher levels of liquid benefit agents other than water by the incorporation of colloidal aluminium hydroxide phosphate complex (Alphos).
According to a first aspect of the invention there is provided a low TFM detergent bar composition comprising
from 15 to 70% by weight of total fatty matter;
from 0.5 to 40% by weight of colloidal aluminium hydroxide-phosphate complex (e.g. Alphos);
from 10 to 55% by weight of water; and
optionally other benefit agents;
the balance being other and minor additives
According to a preferred aspect of this invention there is provided a low TFM detergent bar composition comprising
from 15 to 70% by weight of total fatty matter;
from 0.5 to 40% by weight of colloidal aluminium hydroxide-phosphate complex (e.g. Alphos);
from 10 to 55% by weight of water;
from 5-60% benefit agents;
the balance being other and minor additives.
According to a further aspect, there is provided process for preparing a low TFM detergent bar composition comprising:
from 15 to 70% by weight of total fatty matter;
from 0.5 to 40% by weight of colloidal aluminium hydroxide-phosphate complex (e.g. Alphos);
from 10 to 55% by weight of water; and
optionally other benefit agents;
the balance being other and minor additives as herein described, which process comprises the steps of:
a. reacting a mixture of one or more fatty acids/fat such as herein described and phosphoric acid with an aluminium containing alkaline material such as sodium aluminate with a solid content of e.g. 20 to 55% wherein the Al
2
O
3
to Na
2
O is e.g. in a ratio of 0.5 to 1.55 by weight to obtain a mixture of aluminium hydroxide-phosphate complex and soap at a temperature between 25° C. to 95° C.;
b. adding predetermined amount of water to the mixture of aluminium hydroxide-phosphate complex and soap;
c. adding if desired, other and minor additives such as herein described to the mixture of step (b)
d. converting the product of step (c) into bars by conventional method.
In the process of the invention, it is. especially preferable to maintain a weight ratio of Al
2
O
3
to phosphoric acid in the range 0.40 to 2.40:1. The phosphoric acid used in the reaction is preferably 26-85% pure. The particle size of aluminium hydroxide-phosphate complex may range from 0.1 to 25 &mgr;m.
The process of the invention is carried out in any mixer conventionally used in soap/detergent manufacture and is preferably a high shear kneading mixer. The preferred mixers include a ploughshare mixer, mixers with kneading members of Sigma type, multi-wiping overlap, single curve or double arm. The double arm kneading mixers can be of overlapping or the tangential design. Alternatively the invention can be carried out in a helical screw agitator vessel or multi-head dosing pump/high shear mixer and spray drier combinations as in conventional processing.
The term total fatty matter, usually abbreviated to TFM is used to denote the percentage by weight of fatty acid and triglyceride residues present without taking into account the accompanyi
Behal Vidur
Bhatia Atul
Kohli Gurpreet Singh
Lakshminarayanan Mahesh
Mital Vineet
Koatz Ronald A.
Ogden Necholus
Unilever Home & Personal Care USA , division of Conopco, Inc.
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