Fabric cleaning composition containing zeolite

Cleaning compositions for solid surfaces – auxiliary compositions – Cleaning compositions or processes of preparing – Clay or inorganic aluminosilicate salt component

Reexamination Certificate

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Details

C510S320000, C510S323000, C510S349000, C510S351000, C510S356000, C510S357000, C510S361000, C510S511000

Reexamination Certificate

active

06204239

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a free flowing granular cleaning composition for use in fabric care, wherein the composition contains a nonionic surfactant and an A, or MAP type zeolite having a particle size of 2.0 to 4.2 microns, single crystal or an agglomeration of crystallites, pore diameter of 300 to 4000 nanometers, porosity of at least 1.1 cc/gram.
BACKGROUND OF THE INVENTION
In recent years the use of zeolite in fabric cleaning compositions as a replacement for phosphate as a detergent builder has increased because of the ability of the zeolite (crystalline alkali metal aluminosilicate) to sequester calcium ions from the aqueous wash solution.
More recently the use of the traditional Zeolite A has been replaced by the use of zeolite MAP (maximum aluminum zeolite P which has a silicon to aluminum ratio of less than 1.33).
Zeolite MAP has been previously disclosed in the literature. EP384070A discloses the use of zeolite MAP in a cleaning composition. EP0448297A, EP0502675A, EP0533392B1 and EP0695341B1 teaches the use of zeolite MAP in combination with a bleach system for use in cleaning compositions. PCT WO97/34979 also teaches the use of zeolite MAP in combination with a bleaching system. U.S. Pat. Nos. 5,238,594; 5,259,981; 5,259,982 and 5,498,342 are also directed to cleaning compositions containing Zeolite MAP.
PCT Wo94/28109, EP0714432B1 and U.S. Pat. Nos. 5,490,954 and 5,518,649 teach cleaning compositions using zeolite MAP in combination with high levels of anionic surfactant as well as salts of fatty acids.
The aforementioned patents fail to provide a bleach free cleaning composition which has a low foam profile of less than 4 inches such that the cleaning composition can be used in either a front or top load washing machine.
SUMMARY OF THE INVENTION
The present invention relates to a free flowing granular, low foaming fabric cleaning composition which comprises an A, or MAP type zeolite having a particle size of 2.0 to 4.2 microns as measured on a sedigraph, single crystal or an agglomeration of crystallites, pore diameter of 300 to 4000 nanometers, porosity of at least 1.1 cc/gram, a nonionic surfactant, less than 10.0 wt. % of an anionic surfactant, a polyacrylate polymer, at least one nonphosphate supplemental builder which is not a zeolite and enzymes.
An object of the instant invention is to provide a free flowing granular, low foaming fabric cleaning composition which has a foam height at the end of the wash cycle in a top load washing machine at a dose level of 92 ml of less than 4 inches.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a free flowing granular, low foaming fabric cleaning composition having a bulk density of 0.4 to 0.85, more preferably 0.60 to 0.65 grams/cc which comprises approximately by weight:
(a) 5% to 20%, more preferably 7% to 11% of an ethoxylated nonionic surfactant;
(b) 2.5% to 30%, more preferably 12% to 18% of a zeolite on active basis or express as anhydrosis zeolite having a silicon to aluminum weight ratio of less than 1.33 and having a particle size of 2.0 to 4.2 microns (sedigraph), single crystal or an agglomeration of crystallites, pore diameter of 300 to 4000 nanometers, porosity of at least 1.1 cc/gram;
(c) 20% to 40%, preferably 32% to 38% of a supplemental detergent builder salt such as an alkali metal carbonate such as sodium carbonate;
(d) 0 to 10%, more preferably 0.5% to 6% of a sulfate or sulfonate anionic surfactant;
(e) 0.5% to 5.0%, more preferably 1.0% to 3.0% of a polyacrylate type polymer which functions as an agglomerating aid as well as a chelating agent for calcium and/or magnesium ions as well as an antiredeposition agent;
(f) 0.5% to 35%, more preferably 15% to 25% of sodium sulfate;
(g) 0.5% to 7%, more preferably 1 % to 6% of an alkali metal silicate such as sodium silicate or potassium silicate; and
(h) 0 to 3%, more preferably 0.05% to 1.5% of at least one enzyme.
The present invention also relates to a composition particle having a size of 325 to 475 microns and having a bulk density of 0.75 to 0.85 grams/cc comprising approximately by weight:
(a) 5% to 60%, more preferably 10% to 45% of a zeolite having a silicon to aluminum ratio of less than 1.33 and having a particle size of 2.5 to 3.2 microns, a pore size of 350 to 600 nanometers and a porosity of at least 1.75 cc/grams;
(b) 0 to 55%, more preferably 5% to 50% of an alkali metal carbonate;
(c) 0 to 10%, more preferably 0.1% to 6% of a polyacrylate type polymer;
(d) 0 to 2%, more preferably 0.1% to 1% of an optical brightener;
(e) 0 to 10% of an anionic surfactant; and
(f) 10% to 40% of an ethoxylated nonionic surfactant, wherein said ethoxylated nonionic surfactant is adsorbed on said zeolite and said alkali metal carbonate and the agglomerate composition has a minimum of 60% relative flowability.
The formulas referenced in this application and examples were made by mixing the appropriate components with the defined agglomerate compositions. Components could be added singularly or in part of whole in another pre-made composition. One method of combining a part or whole of the non-agglomerated components is through preparation of a spray dried base. A spray dried base can be made and added to the agglomeration composition. Additional components such as fragrance, enzymes, etc. were then added to this new mixed formulation.
The spray dried base referenced above was made via conventional methods. Materials were mixed in proper proportions, conditional, then dried to appropriate physical form. Conditions were controlled to yield a powder of appropriate chemistry, color, size, density, flow, etc. Chemical compositions of the dried composition comprising approximately by weight:
(a) 1.0% to 50% sodium sulfate;
(b) 1.0% to 70% sodium carbonate;
(c) 0.2% to 20%, preferably 0.2 to 10% of a sulfate or sulfonate anionic surfactant;
(d) 1.0% to 20% sodium silicate;
(e) 0.1% to 20% of a brightener;
(f) 0.5% to 10%, more preferably 1.0 to 5.0% of a polyacrylate type polymer;
(g) 0.1% to 5.0% moisture.
Bulk density could range from 0.30 to 0.75, more preferably 0.35 to 0.60 grams/cc.
Suitable anionic surfactants used in the instant compositions at less than 10 wt. % include the water-soluble alkali metal salts having alkyl radicals containing from about 8 to about 22 carbon atoms, the term alkyl being used to include the alkyl portion of higher acyl radicals. Examples of suitable synthetic anionic detergent compounds are sodium and potassium alkyl sulphates, especially those obtained by sulphating higher (C
8
-C
18
) alcohols produced, for example, from tallow or coconut oil; sodium and potassium alkyl (C
9
-C
20
) benzene sulfonates, particularly sodium linear secondary alkyl (C
10
-C
15
) benzene sulfonates; sodium alkyl glycerol ether sulfates, especially those ethers of the higher alcohols derived from tallow or coconut oil and synthetic alcohols derived from petroleum; sodium coconut oil fatty monoglyceride sulfates and sulfonates; sodium and potassium salts of sulfuric acid esters of higher (C
8
-C
18
) fatty alcohol-alkylene oxide, sulfates of methyl esters (C
8
-C
20
) with SO
3
forming alpha sulfonate commonly known as alpha methyl sulfo esters of fatty acids and also particularly ethylene oxide reaction products; the reaction products of fatty acids such as coconut fatty acids esterified with isethionic acid and neutralized with sodium hydroxide; sodium and potassium salts of fatty acid amides of methyl taurine; alkane monosulfonates such as those derived from reacting alpha-olefins (C
8
-C
20
) with sodium bisulfite and those derived from reacting paraffins with SO
2
and Cl
2
and then hydrolyzing with a base to produce a random sulfonate; and olefin sulfonates which term is used to describe the material made by reacting olefins, particularly C
10
-C
20
alpha-olefins, with SO
3
and then neutralizing and hydrolyzing the reaction product. The preferred anionic surfactants are (C
10
-C
18
) alkyl polyethoxy (1-11 Eo) sulfates and mixtures thereof having differing water solubilities.
Suitab

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