Cleaning compositions for solid surfaces – auxiliary compositions – Cleaning compositions or processes of preparing – Solid – shaped macroscopic article or structure
Reexamination Certificate
2000-06-01
2004-05-04
Douyon, Lorna M. (Department: 1751)
Cleaning compositions for solid surfaces, auxiliary compositions
Cleaning compositions or processes of preparing
Solid, shaped macroscopic article or structure
C510S445000
Reexamination Certificate
active
06730653
ABSTRACT:
FIELD OF THE INVENTION
The invention relates to molded detergent compositions and method for manufacturing and using a molded detergent composition.
BACKGROUND OF THE INVENTION
Solid detergent compositions are described in the prior art. See U.S. Pat. Nos. RE 32,763 to Fernholtz, et al., RE 32,818 to Femholtz, et al., 4,595,520 to Heile et al.; 4,680,134 to Heile et al.; 5,078,301 to Gladfelter et al.; and 5,080,819 to Morganson et al. The solid detergent compositions prepared according to these United States patents incorporate carbonate, caustic, silicate and other materials in combination with a variety of nonionic surfactants made using EO, PO, or EO and PO groups. In addition, see U.S. Pat. Nos. 4,753,755 to Gansser; 4,931,202 to Cotter et al.; 5,482,641 to Fleisher; and 5,670,467 to Fleisher disclose the use of nonionic surfactants in solid detergents. Many of the processes described in the prior art require the use of heat in the formation of solid detergent blocks.
Solid detergent blocks are desirable because they generally require less shelf space than liquid detergents, they are generally easier to handle than liquid detergents, and they reduce the splashing hazard common to the use of liquid detergents.
SUMMARY OF THE INVENTION
A method for manufacturing a molded detergent composition is provided by the invention. The method includes steps of mixing a hydrated component and a hydratable component to provide a mixture, and molding the mixture to provide a molded detergent composition having a melting point greater than about 30° C. The hydrated component has a melting point below about 100° C. and includes a transhydration product of an anhydrous material and water of hydration. The anhydrous material has a melting point greater than about 300° C. The hydratable component comprises water, if present at all, at a level of less than about 2 wt. % based on the weight of the hydratable component. The hydratable component will successfully compete with the hydrated component for at least a portion of the water of hydration.
The hydrated component can include any material having a melting point below about 100° C. which, when water is removed therefrom, has a melting point greater than about 300° C., and which surrenders water of hydration to the hydratable component. Preferably, the hydrated component is a material which surrenders water of hydration to the hydratable component under conditions of room temperature and atmosphere pressure to a sufficient extent to provide the molded detergent composition with a melting point greater than about 30° C. The hydrated component preferably includes a hydrated salt. Exemplary hydrated salts include sodium silicate, lithium silicate, potassium silicate, sodium metasilicate, sodium phosphate, calcium phosphate, magnesium phosphate, sodium pyrophosphate, sodium tripolyphosphate, sodium sulfate, sodium carbonate, sodium bicarbonate, sodium sesquicarbonate, sodium bisulfate, sodium thiosulfate, sodium perborate, and mixtures thereof.
The hydratable component can include any material having a water content of less than about 2 wt. % and which successfully competes with the hydrated component for at least a portion of the water of hydration. Preferably, the hydratable component successfully competes with the hydrated component for at least a portion of the water of hydration at room temperature and atmospheric pressure to an extent which provides the molded detergent composition with a melting point greater than about 30° C. The hydratable component is preferably a polar organic material. Preferred hydratable components include at least one of nonionic surfactants, anionic surfactants, glycol ethers, and mixture thereof.
The mixture can include additional components. Exemplary additional components include enzymes, solvents having high VOC content, dyes, fragrances, anti-redeposition agents, corrosion inhibitors, buffering agents, defoamers, anti-microbial agents, and preservatives.
The weight ratio of the hydrated component to the hydratable component is preferably between about 2:1 and about 20:1, and more preferably between about 3:1 and about 10:1. It should be understood that in determining this weight ratio, the weight of the hydrated component includes its water of hydration, and the weight of the hydratable component includes it water of hydration if it includes any water of hydration. The weight ratio of the hydrated component to the hydratable component can be expressed on an anhydrous weight basis for each component. On an anhydrous weight basis for each component, a preferred weight ratio of hydrated component to hydratable component is between about 5:1 and about 20:1, and more preferably between about 1:8 and about 5:1.
A molded detergent composition is provided according to the invention. The molded detergent composition includes as a result of mixing and molding a composition including a hydrated component and a hydratable component.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A molded detergent composition according to the invention can be used in conventional solid detergent dispensing equipment. It should be understood that the phrase “molded detergent composition” describes compositions which have been molded to provide a particular shape and which are solid under conditions of room temperature and atmospheric pressure. The molded detergent according to the invention is preferably provided in the form of blocks and/or pellets. Powder detergents and liquid detergents under conditions of room temperature and atmosphere pressure are not considered molded detergent compositions according to the invention. In contrast to blocks and pellets, powder detergents are generally available for use as detergents in a powdered state. That is, the powder detergents are generally provided as a mixture of granular dry material. Powder detergents are often prepared by mixing dry materials or by mixing a slurry and drying the slurry. Pellets and blocks are typically provided with a size that is determined by the shape or configuration of the mold or extruder through which the detergent composition is compressed. Pellets generally can be characterized as having an average diameter of about 0.5 cm to about 2 cm. Blocks generally can be characterized as having an average diameter of greater than about 2 cm. In general, blocks have an average diameter of between about 2 cm and about 2 ft, and, more preferably, between about 2 cm and about 1 ft.
The molded detergent composition according to the invention can be used in conventional solid detergent dispensing equipment. Commercially available solid detergent dispensing equipment which can be used to process the molded detergent composition according to the invention are available under the name Solid System® from Ecolab Inc. In general, a detergent use solution is generated in this type of equipment as a result of erosion of the molded detergent composition by a water stream.
The molded detergent composition can be prepared by mixing a hydrated component and a hydratable component, and molding the mixture to provide a molded detergent composition having a melting point greater than about 30° C. The hydrated component is preferably a component having a melting point below about 100° C. and can be characterized as a transhydration product of an anhydrous material and water of hydration. Preferably, the anhydrous material has a melting point greater than about 300° C. It should be understood that there is no requirement that the hydrated component is to be prepared from an anhydrous material. Furthermore, it should be understood that the anhydrous material characterizes the hydrated component under a condition where water has been removed to an extent reasonable under normal processing conditions for the removal of water. For example, if it is too difficult to remove all of the water, then the anhydrous material that characterizes the hydrated component can be considered as including water. When the anhydrous material is hydrated with water, the melting point decreases from greater than ab
Man Victor Fuk-Pong
Smith Kim R.
Stardig Richard
Wiseth Wendy
Douyon Lorna M.
Ecolab Inc.
Merchant & Gould P.C.
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