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EP0551393A1 - Polyhydroxy fatty acid amides in polycarboxylate-built detergents. - Google Patents

Polyhydroxy fatty acid amides in polycarboxylate-built detergents.

Info

Publication number
EP0551393A1
EP0551393A1 EP19910918544 EP91918544A EP0551393A1 EP 0551393 A1 EP0551393 A1 EP 0551393A1 EP 19910918544 EP19910918544 EP 19910918544 EP 91918544 A EP91918544 A EP 91918544A EP 0551393 A1 EP0551393 A1 EP 0551393A1
Authority
EP
European Patent Office
Prior art keywords
fatty acid
alkyl
polyhydroxy fatty
acid amide
polycarboxylate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP19910918544
Other languages
German (de)
French (fr)
Other versions
EP0551393B1 (en
Inventor
Sandra Louise Honsa
Mark Hsiang-Kuen Mao
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Procter and Gamble Co
Original Assignee
Procter and Gamble Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Procter and Gamble Co filed Critical Procter and Gamble Co
Publication of EP0551393A1 publication Critical patent/EP0551393A1/en
Application granted granted Critical
Publication of EP0551393B1 publication Critical patent/EP0551393B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
    • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
    • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
    • C11D3/16—Organic compounds
    • C11D3/20—Organic compounds containing oxygen
    • C11D3/2075—Carboxylic acids-salts thereof
    • C11D3/2089—Ether acids-salts thereof
    • C—CHEMISTRY; METALLURGY
    • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
    • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
    • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
    • C11D1/38—Cationic compounds
    • C11D1/52—Carboxylic amides, alkylolamides or imides or their condensation products with alkylene oxides
    • C11D1/525—Carboxylic amides (R1-CO-NR2R3), where R1, R2 or R3 contain two or more hydroxy groups per alkyl group, e.g. R3 being a reducing sugar rest
    • C—CHEMISTRY; METALLURGY
    • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
    • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
    • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
    • C11D1/66—Non-ionic compounds
    • C11D1/662—Carbohydrates or derivatives
    • C—CHEMISTRY; METALLURGY
    • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
    • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
    • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
    • C11D3/16—Organic compounds
    • C11D3/20—Organic compounds containing oxygen
    • C11D3/2075—Carboxylic acids-salts thereof
    • C11D3/2082—Polycarboxylic acids-salts thereof
    • C—CHEMISTRY; METALLURGY
    • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
    • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
    • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
    • C11D3/16—Organic compounds
    • C11D3/20—Organic compounds containing oxygen
    • C11D3/2075—Carboxylic acids-salts thereof
    • C11D3/2086—Hydroxy carboxylic acids-salts thereof
    • C—CHEMISTRY; METALLURGY
    • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
    • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
    • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
    • C11D3/16—Organic compounds
    • C11D3/26—Organic compounds containing nitrogen
    • C11D3/32—Amides; Substituted amides

Definitions

  • sophis ⁇ ticated formulators have incorporated various detergency adjuncts therein.
  • Materials such as detersive enzymes, soil release poly ⁇ mers, and bleaches are commonly used to enhance the performance of carboxylate-built detergent compositions. This is especially true in liquid detergent formulations as high levels of builder can make various anionic surfactants, such as alkyl sulfates and alkyl ester sulfonates, insoluble in the formula.
  • the present invention employs an improved detersive surfactant system to help make up for the shortfall in cleaning performance occasioned by the use of polycarboxylate builders.
  • certain polyhydroxy fatty acid amides are used in polycarboxylate-built detergents to provide enhanced detergency performance.
  • these polyhydroxy fatty acid amides facilitate the formulation of granular and especially liquid detergents with high levels of builder and anionic surfactants.
  • N-acyl, N-methyl glucamides for example, are disclosed by J. W. Goodby, M. A. Marcus, E. Chin, and P. L. Finn in "The Thermotropic Liquid-Crystalline Properties of Some Straight Chain Carbohydrate A phiphiles," Liquid Crystals, 1988, Volume 3, No. 11, pp 1569-1581, and by A. Muller-Fahrnow, V. Zabel , M. Steifa, and R. Hilgenfeld in "Molecular and Crystal Structure of a Nonionic Detergent: Nonanoyl-N-methylglucamide," J. Chem. Soc. Chem.
  • N-alkyl polyhydroxya ide surfactants have been of substantial interest recently for use in biochemistry, for example in the dissociation of biological membranes. See, for— example, the journal article "N-D-Gluco-N-methyl-alkanamide Compounds, a New Class of Non-Ionic Detergents For Membrane Biochemistry," Biochem. J. (1982), Vol. 207, pp 363-366, by J. E. K. Hildreth.
  • the use of N-alkyl glucamides in detergent compositions has also been discussed.
  • Patent 809,060 published February 18, 1959, assigned to Thomas Hedley & Co., Ltd. relate to detergent compositions containing anionic surfactants and certain amide surfactants, which can include N-methyl glucamide, added as a low temperature suds enhancing agent. These compounds include an N-acyl radical of a higher straight chain fatty acid having 10-14 carbon atoms. These compositions may also contain auxiliary materials such as alkali metal phosphates, alkali metal silicates, sulfates, and carbonates. It is also generally indicated that additional constituents to impart desirable properties to the composition can also be included in the compositions, such as fluorescent dyes, bleaching agents, perfumes, etc.
  • U.S. Patent 2,703,798, issued March 8, 1955 to A. M. Schwartz relates to aqueous detergent compositions containing the condensa ⁇ tion reaction product of N-alkyl glucamine and an aliphatic ester of a fatty acid. The product of this reaction is said to be useable in aqueous detergent compositions without further purification. It is also known to prepare a sulfuric ester of acylated glucamine as disclosed in U.S. Patent 2,717,894, issued September 13, 1955, to A. M. Schwartz.
  • PCT International Application WO 83/04412, published December 22, 1983, by J. Hildreth relates to amphiphilic compounds contain ⁇ ing polyhydroxy!
  • aliphatic groups said to be useful for a variety of purposes including use as surfactants in cosmetics, drugs, shampoos, lotions, and eye ointments, as emulsifiers and dispensing agents for medicines, and in biochemistry for solubilizing membranes, whole cells, or other tissue samples, and for preparing liposomes.
  • R'C0N(R)CH2R" and R"C0N(R)R' wherein R is hydrogen or an organic grouping, R' is an aliphatic hydrocarbon group of at least three carbon atoms, and R" is the residue of an aldose.
  • N-polyhy roxy alkyl fatty acid amides as thickening agents in aqueous detergent systems. Included are amides of the formula R ⁇ C(0)N(X)R2 wherein Ri is a C1-C17 (preferably C7-C17) alkyl, R2 is hydrogen, a Ci-Cjs (preferably Ci-C ⁇ ) alkyl, or an alkylene oxide, and X is a polyhydroxy alkyl having four to seven carbon atoms, e.g., N-methyl, coconut fatty acid glucamide.
  • the thickening properties of the amides are indicated as being of particular use in liquid surfactant systems containing paraffin sulfonate, although the aqueous surfactant systems can contain other anionic surfactants, such as alkylaryl sulfonates, olefin sulfonate, sulfosuccinic acid half ester salts, and fatty alcohol ether sulfonates, and nonionic surfactants such as fatty alcohol polyglycol ether, alkylphenol polyglycol ether, fatty acid polyglycol ester, polypropylene oxide-polyethylene oxide mixed polymers, etc.
  • anionic surfactants such as alkylaryl sulfonates, olefin sulfonate, sulfosuccinic acid half ester salts, and fatty alcohol ether sulfonates
  • nonionic surfactants such as fatty alcohol polyglycol ether, alkylphenol polyglycol ether,
  • Paraffin sulfonate/N-methyl coconut fatty acid glucamide/nonionic surfactant shampoo formulations are exemplified.
  • the N-polyhydroxy alkyl fatty acid amides are said to have superior skin tolerance attributes.
  • U.S. Patent 2,982,737 issued May 2, 1961, to Boettner, et al., relates to detergent bars containing urea, sodium lauryl sulfate anionic surfactant, and an N-alkylglucamide nonionic surfactant which is selected from N-methyl ,N-sorbityl lauramide and N-methyl, N-sorbityl myristamide.
  • glucamide surfactants are disclosed, for example, in DT 2,226,872, published December 20, 1973, H. W. Eckert, et al . , which relates to washing compositions comprising one or more surfactants and builder salts selected from polymeric phosphates, sequestering agents, and washing alkalis, improved by the addition of an N-acylpolyhydroxyalkyl-amine of the formula R ⁇ C(0)N(R2)CH2(CH0H) n - CH2OH, wherein Rj is a C1-C3 alkyl, R2 is a C10-C22 alkyl, and n is 3 or 4.
  • the N-acylpolyhydroxyalkyl-amine is added as a soil sus ⁇ pending agent.
  • U.S. Patent 3,654,166, issued April 4, 1972, to H. W. Eckert, et al. relates to detergent compositions comprising at least one surfactant selected from the group of anionic, zwitterionic, and nonionic surfactants and, as a textile softener, an N-acyl, N-alkyl polyhydroxylalkyl compound of the formula R ⁇ N(Z)C(0)R2 wherein Ri is a C10-C22 alkyl, R2 is a C7-C21 alkyl, Ri and R2 total from 23 to 39 carbon atoms, and Z is a polyhydroxyalkyl which can be -CH2(CHOH) m CH2 ⁇ H where m is 3 or 4.
  • U.S. Patent 4,021,539 issued May 3, 1977, to H. M ⁇ ller, et al., relates to skin treating cosmetic compositions containing N-polyhydroxylalkyl-amines which include compounds of the formula RlN(R)CH(CH0H) m ⁇ 2 wherein Ri is H, lower alkyl, hydroxy-lower alkyl, or aminoalkyl, as well as heterocyclic aminoalkyl, R is the same as Rl but both cannot be H, and R2 is CH2OH or C00H.
  • French Patent 1,360,018, April 26, 1963, assigned to Commercial Solvents Corporation, relates to solutions of formaldehyde stabilized against polymerization with the addition of amides of the formula RC(0)N(R ⁇ )G wherein R is a carboxylic acid functionality having at least seven carbon atoms, Ri is hydrogen or a lower alkyl group, and G is a glycitol radical with at least 5 carbon atoms.
  • German Patent 1,261,861, February 29, 1968, A. Heins relates to glucamine derivatives useful as wetting and dispersing agents of the formula N(R)(R ⁇ )(R2) wherein R is a sugar residue of glucamine, Ri is a C10-C20 alk l radical, and R2 is a C1-C5 acyl radical.
  • G.B. Patent 745,036, published February 15, 1956, assigned to Atlas Powder Company, relates to heterocyclic amides and carboxylic estars thereof that are said to be useful as chemical intermediates, e ulsifiers, wetting and dispersing agents, detergents, textile softeners, etc.
  • the compounds are expressed by the formula N(R)(R ⁇ )C(0)R2 wherein R is the residue of an anhydrized hexane pentol or a carboxylic acid ester thereof, Ri is a monovalent hydrocarbon radical, and -C(0)R2 is the acyl radical of a carboxylic acid having from 2 to 25 carbon atoms.
  • Hooker discloses solid toilet bars that are substantially free of anionic detergents and alkaline builder materials, and which contain lithium soap of certain fatty acids, a nonionic surfactant selected from certain propylene oxide-ethylenediamine-ethylene oxide condensates, propylene oxide-propylene glycol-ethylene oxide condensates, and polymerized ethylene glycol, and also contain a nonionic lathering component which can include polyhydroxyamide of the formula RC(0)NRl(R2) wherein RC(0) contains from about 10 to about 14 carbon atoms, and R 1 and R 2 each are H or C1-C6 alkyl groups, said alkyl groups containing a total number of carbon atoms of from 2 to about 7 and a total number of substituent hydroxyl groups of from 2 to about 6.
  • RC(0)NRl(R2) wherein RC(0) contains from about 10 to about 14 carbon atoms, and R 1 and R 2 each are H or C1-C6 alkyl groups, said alkyl groups containing a total number
  • Improved detergent compositions containing polycarboxylate builder are provided by the inclusion of certain polyhydroxy fatty acid amide surfactants, and preferably one or more anionic, nonionic, or cationic detersive surfactants, or mixtures thereof.
  • compositions of the present invention comprise at least 1% by weight of polycarboxylate builder, and at least 1% by weight of a polyhydroxy fatty acid amide of the formula: 0 Rl
  • Rl is H, C1-C4 hydrocarbyl, 2-hydroxy ethyl, 2-hydroxy propyl, or a mixture thereof, preferably C1-C4 alkyl, more preferably Ci or C2 alkyl, most preferably Ci alkyl (i.e., methyl); and R 2 is a C5-C31 hydrocarbyl, preferably straight chain C7-C19 alkyl or alkenyl, more preferably straight chain C9-C17 alkyl or alkenyl, most preferably straight chain C11-C17 alkyl or alkenyl, or mixture thereof; and Z is a polyhydroxyhydrocarbyl having a linear hydrocarbyl chain with at least 3 hydroxyls directly connected to the chain, or an alkoxylated derivative (preferably ethoxylated or propoxylated) thereof.
  • Z preferably will be derived from a reducing sugar in a reductive amination reaction; more preferably Z is a glycityl.
  • Suitable reducing sugars include glucose, fructose, maltose, lactose, galactose, mannose, and xylose.
  • high dextrose corn syrup, high fructose corn syrup, and high maltose corn syrup can be utilized as well as the individual sugars listed above. These corn syrups may yield a mix of sugar components for Z. It should be understood that it is by no means intended to exclude other suitable raw materials.
  • Z preferably will be selected from the group consisting of -CH 2 -(CH0H) n -CH 2 0H, -CH(CH 2 0H) ⁇ (CH0H) n - ⁇ -CH 2 0H, -CH 2 -(CH0H)2(CH0R')(CH0H)-CH20H, where n is an integer from 3 to 5, inclusive, and R' is H or a cyclic or aliphatic monosaccharide, and alkoxylated derivatives thereof. Most preferred are glycityls wherein n is 4, particularly -CH2 ⁇ (CH0H)4-CH20H.
  • the weight ratio of polycarboxylate builder:polyhy- droxy fatty acid amide is within the range of about 1:10 to about 10:1, more preferably about 1:5 to about 7:1, most preferably about 1:1 to about 7:1.
  • This invention encompasses (but is not limited to) both liquid and granular detergent compositions.
  • This invention provides detergent composition built with polycarboxylate builders that have improved builder effectiveness and, consequently, can also have improved cleaning performance, especially in the area of grease/oil cleaning.
  • This invention further provides a method for improving the performance of detergents containing anionic, nonionic, and/or cationic surfactant and polycarboxylate builder by incorporating into such composition the polyhydroxy fatty acid amide surfactant described above, such that the weight ratio of polycarboxylate to the amide surfactant is from about 1:10 to about 10:1.
  • This invention further provides a method for cleaning substrates, such as fibers, fabrics, hard surfaces, skin, etc., by contacting said substrate with a detergent composition comprising one or more anionic, nonionic, or cationic surfactants, at least about 1% polycarboxylate builder, and at least 1% of the polyhydroxy fatty acid amide, wherein preferably the weight ratio of polycar- boxylate builder:polyhydroxy fatty acid amide surfactant is from about 1:10 to about 10:1, in the presence of a solvent such as water or water-miscible solvent (e.g., primary and secondary alcohols).
  • a solvent such as water or water-miscible solvent (e.g., primary and secondary alcohols).
  • Agitation is preferably provided for enhancing cleaning.
  • Suitable means for providing agitation include rubbing by hand or preferably with the aid of a brush, sponge, mop or other cleaning device, automatic laundry washing machines, automatic dishwashers, etc.
  • the more preferred polycarboxylate builder:polyhydroxy fatty acid amide weight ratios are from about
  • compositions hereof will comprise at least about 1%, typically from about 3% to about 50%, preferably from about 3% to about 30%, of the polyhydroxy fatty acid amide surfactant described below.
  • the polyhydroxy fatty acid amide surfactant component of the present invention comprises compounds of the structural formula: 0 R 1 (I) R2 - C - N - Z wherein: R 1 is H, C1-C4 hydrocarbyl, 2-hydroxy ethyl, 2-hydroxy propyl, or a mixture thereof, preferably C1-C4 alkyl, more preferably Ci or C2 alkyl, most preferably Ci alkyl (i.e., methyl); and R 2 is a C5-C31 hydrocarbyl, preferably straight chain C7-C19 alkyl or alkenyl, more preferably straight chain C9-C17 alkyl or alkenyl, most preferably straight chain C11-C17 alkyl or alkenyl, or mixture thereof; and Z is a polyhydroxyhydrocarbyl having a linear hydrocarbyl chain with at least 3 hydroxyls directly connected to the chain, or an alkoxylated derivative (preferably ethoxylated or propoxylated) thereof.
  • Z preferably will be derived from a reducing sugar in a reductive amination reaction; more preferably Z is a glycityl.
  • Suitable reducing sugars include glucose, fructose, maltose, lactose, galactose, mannose, and xylose.
  • high dextrose corn syrup, high fructose corn syrup, and high maltose corn syrup can be utilized as well as the individual sugars listed above. These corn syrups may yield a mix of sugar components for Z. It should be understood that it is by no means intended to exclude other suitable raw materials.
  • Z preferably will be selected from the group consisting of -CH 2 -(CH0H) n -CH 2 0H, -CHtCHzOHHCHOHJn-i- CH 2 0H, -CH 2 -(CH0H)2(CH0R')(CH0H)-CH20H, where n is an integer from 3 to 5, inclusive, and R' is H or a cyclic or aliphatic monosacchar ⁇ ide, and alkoxylated derivatives thereof. Most preferred are glycityls wherein n is 4, particularly -CH2-(CH0H)4-CH20H.
  • Rl can be, for example, N-methyl, N-ethyl , N-propyl, N-isopropyl, N-butyl, N-2-hydroxy ethyl, or N-2-hydroxy propyl .
  • R 2 -C0-N ⁇ can be, for example, cocamide, stearamide, oleamide, lauramide, myrista ide, capricamide, palmitamide, tallowamide, etc.
  • Z can be 1-deoxyglucityl , 2-deoxyfructityl , 1-deoxymaltityl , 1-deoxylactityl , 1-deoxygalactityl , 1-deoxymannityl , 1-deoxymalto- triotityl, etc.
  • polyhydroxy fatty acid amides are known in the art. In general, they can be made by reacting an alkyl amine with a reducing sugar in a reductive amination reaction to form a corresponding N-alkyl polyhydroxyamine, and then reacting the N-alkyl polyhydroxyamine with a fatty aliphatic ester or triglyceride in a condensation/amidation step to form the N-alkyl, N-polyhydroxy fatty acid amide product.
  • Processes for making compositions containing polyhydroxy fatty acid amides are disclosed, for example, in G.B. Patent Specification 809,060, published February 18, 1959, by Thomas Hedley & Co., Ltd., U.S.
  • N-deoxyglycityl fatty acid amides wherein the glycityl component is derived from glucose and the N-alkyl or N-hydroxyalkyl functionality is N-methyl, N-ethyl , N-propyl, N-butyl, N-hydroxyethyl , or N-hydroxypropyl
  • the product is made by reacting N-alkyl- or N-hydroxyalkyl-glucamine with a fatty ester selected from fatty methyl esters, fatty ethyl esters, and fatty triglycerides in the presence of a catalyst selected from the group consisting of trilithium phosphate, trisodium phosphate, tripotassium phosphate, tetrasodium pyrophosphate, pentapotassiu tripolyphosphate, lithium hydroxide, sodium hydroxide, potassium hydroxide, calcium hydroxide, lithium carbonate, sodium carbonate, potassium
  • the amount of catalyst is preferably from about 0.5 mole % to about 50 mole %, more preferably from about 2.0 mole % to about 10 mole %, on an N-alkyl or N-hydroxyalkyl-glucamine molar basis.
  • the reaction is preferably carried out at from about 138 ⁇ C to about 170 ⁇ C for typically from about 20 to about 90 minutes.
  • the reaction is also preferably carried out using from about 1 to about 10 weight % of a phase transfer agent, calculated on a weight percent basis of total reaction mixture, selected from saturated fatty alcohol polyethoxyl- ates, alkylpolyglycosides, linear glyca ide surfactant, and mixtures thereof.
  • a phase transfer agent calculated on a weight percent basis of total reaction mixture, selected from saturated fatty alcohol polyethoxyl- ates, alkylpolyglycosides, linear glyca ide surfactant, and mixtures thereof.
  • thi s process i s carried out as fol lows :
  • N-linear glucosyl fatty acid amide product is added to the reaction mixture, by weight of the reactants, as the phase transfer agent if the fatty ester is a triglyceride. This seeds the reaction, thereby increasing reaction rate.
  • a detailed experimental procedure is provided below in the Experimental.
  • polyhydroxy "fatty acid” amide materials used herein also offer the advantages to the detergent formulator that they can be prepared wholly or primarily from natural, renewable, non-petro- chemical feedstocks and are degradable. They also exhibit low toxicity to aquatic life.
  • the processes used to produce them will also typically produce quantities of nonvolatile by-product such as esteramides and cyclic polyhydroxy fatty acid amide.
  • the level of these by-products will vary depending upon the particular reactants and process conditions.
  • the polyhydroxy fatty acid amide incorporated into the detergent compositions hereof will be provided in a form such that the polyhydroxy fatty acid amide- containing composition added to the detergent contains less than- about 10%, preferably less than about 4%, of cyclic polyhydroxy fatty acid amide.
  • the preferred processes described above are advantageous in that they can yield rather low levels of by-products, including such cyclic amide by-product.
  • compositions hereof will comprise at least about 1% polycarboxylate builder.
  • the level of polycarboxylate builder can vary widely depending upon the end use of the composition and its desired physical form.
  • Liquid formulations typically comprise from about 5% to about 50%, more typically about 5% to about 30%, by weight, of detergent builder.
  • Granular formulations typically comprise from about 10% to about 80%, more typically from about 15% to about 50%, by weight, of the detergent builder.
  • Lower or higher levels of builder are not meant to be excluded.
  • the weight ratio of polyhydroxy fatty acid amide to polycarboxylate builder is from about 1:10 to about 10:1, more preferably from about 1:5 to about 7:1, most preferably from about 1:1 to about 7:1.
  • polycarboxylate refers to compounds having a plurality of carboxylate groups, preferably at least 3 carboxylates.
  • Polycarboxylate builder can generally be added to the composi ⁇ tion in acid form, but can also be added in the form of a neutral ⁇ ized salt.
  • alkali metals such as sodium, potassium, and lithium salts, especially sodium salts, or ammonium and substituted ammonium (e.g., al anolammonium) salts are preferred.
  • polycarboxylate builders include a variety of categories of useful materials.
  • One important category of polycarboxylate builders encompasses the ether polycarboxylates.
  • a number of ether polycarboxylates have been disclosed for use as detergent builders.
  • Examples of useful ether polycarboxylates include oxydisuccinate, as disclosed in Berg, U.S. Patent 3,128,287, issued April 7, 1964, and La berti et al., U.S. Patent 3,635,830, issued January 18, 1972, both of which are incorporated herein by reference.
  • ether polycarboxylates useful as builders in the present invention also include those having the-general formula:
  • A is H or OH; B is H or -0-CH(C00X)-CH2(C00X) ; and X is H or a salt-forming cation.
  • a and B are both H, then the compound is oxydissuccinic acid and its water-soluble salts. If A is OH and B is H, then the compound is tartrate monosuccinic acid (TMS) and its water-soluble salts.
  • TDS tartrate disuccinic acid
  • Suitable ether polycarboxylates also include cyclic compounds, particularly alicyclic compounds, such as those described in U.S. Patents 3,923,679; 3,835,163; 4,158,635; 4,120,874 and 4,102,903, all of which are incorporated herein by reference.
  • ether hydroxypoly- carboxylates represented by the structure: H0-[C(R)(C00M)-C(R)(C00M)-0] n -H wherein M is hydrogen or a cation wherein the resultant salt is water-soluble, preferably an alkali metal, ammonium or substituted ammonium cation, n is from about 2 to about 15 (preferably n is from about 2 to about 10, more preferably n averages from about 2 to about 4) and each R is the same or different and selected from hydrogen, C1-4 alkyl or C1-4 substituted alkyl (preferably R is hydrogen) .
  • Still other ether polycarboxylates include copolymers of maleic anhydride with ethylene or vinyl methyl ether, 1, 3, 5-trihydroxy benzene-2, 4, 6-trisulphonic acid, and carboxymethyloxysuccinic acid.
  • Organic polycarboxylate builders also include polyacetates such as the various alkali metal, ammonium and substituted ammonium salts of polyacetic acids.
  • polyacetic acid builder salts are the sodium, potassium, lithium, ammonium and substituted ammonium salts of ethylenediamine tetraacetic acid and nitrilotriacetic acid.
  • polycarboxylates such as mellitic acid, succinic acid, poly aleic acid, benzene 1,3,5-tricarboxylic acid, benezene pentacarboxylic acid, and carboxymethyloxysuccinic acid, and soluble salts thereof.
  • Citric builders e.g., citric acid and soluble salts thereof, is a polycarboxylate builder of particular importance for heavy duty liquid detergent formulations, but can also be used in granular compositions.
  • Suitable salts include the metal salts such as sodium, lithium, and potassium salts, as well as ammonium and substituted ammonium salts.
  • Other carboxylate builders include the carboxylated carbohy ⁇ drates disclosed in U.S. Patent 3,723,322, Diehl, issued March 28, 1973, incorporated herein by reference.
  • Also suitable in the detergent compositions of the present invention are the 3,3-dicarboxy-4-oxa-l,6-hexanedioates and the related compounds disclosed in U.S. Patent 4,566,984, Bush, issued January 28, 1986, incorporated herein by reference.
  • Useful succinic acid builders include the C5-C20 alkyl succinic acids and salts thereof.
  • a particularly preferred compound of this type is dodecenylsuccinic acid.
  • Alkyl succinic acids typically are of the general formula R-CH(C00H)CH2(C00H) i.e., derivatives of succinic acid, wherein R is hydrocarbon, e.g., C10-C20 alkyl or alkenyl, preferably C12-C16 or wherein R may be substituted with hydroxyl, sulfo, sulfoxy or sulfone substituents, all as described in the above-mentioned patents.
  • R is hydrocarbon, e.g., C10-C20 alkyl or alkenyl, preferably C12-C16 or wherein R may be substituted with hydroxyl, sulfo, sulfoxy or sulfone substituents, all as described in the above-mentioned patents.
  • the succinate builders are preferably used in the form of their water-soluble salts, including the sodium, potassium, ammonium and alkanolammonium salts.
  • succinate builders include: laurylsuccin- ate, myristylsuccinate, palmitylsuccinate, 2-dodecenylsuccinate (preferred), 2-pentadecenylsuccinate, and the like.
  • Laurylsuccin- ates are the preferred builders of this group, and are described in European Patent Application 86200690.5/0,200,263, published November 5, 1986.
  • useful builders also include sodium and potassium carboxymethyloxymalonate, carboxymethyloxysuccinate, cis-cyclohex- ane-hexacarboxylate, cis-cyclopentane-tetracarboxylate, water- soluble polyacrylates (these polyacrylates having molecular weights to above about 2,000 can also be effectively utilized as dispers- ants), and the copolymers of aleic anhydride with vinyl methyl ether or ethylene.
  • polyacetal carboxylates are the polyacetal carboxylates disclosed in U.S. Patent 4,144,226, Crutchfield et al., issued March 13, 1979, incorporated herein by reference. These polyacetal carboxylates can be prepared by bringing together, under polymeriza ⁇ tion conditions, an ester of glyoxylic acid and a polymerization initiator. The resulting polyacetal carboxylate ester is then attached to chemically stable end groups to stabilize the polyacetal carboxylate against rapid depolymerization in alkaline solution, converted to the corresponding salt, and added to a surfactant.
  • Polycarboxylate builders are also disclosed in U.S. Patent 3,308,067, Diehl, issued March 7, 1967, incorporated herein by reference. Such materials include the water-soluble salts of homo- and copolymers of aliphatic carboxylic acids such as maleic acid, itaconic acid, mesaconic acid, fumaric acid, aconitic acid, citraconic acid and methylenemalonic acid.
  • Other Builders include the water-soluble salts of homo- and copolymers of aliphatic carboxylic acids such as maleic acid, itaconic acid, mesaconic acid, fumaric acid, aconitic acid, citraconic acid and methylenemalonic acid.
  • compositions hereof can additionally contain auxiliary builders in addition to the polycarboxylate builders, including both organic and inorganic builders.
  • auxiliary builders are from about 5% to about 200% of the weight of the polycarboxylate builder.
  • Inorganic detergent builders include, but are not limited to, the alkali metal, ammonium and alkanolammonium salts of silicates, carbonates (including bicarbonates and sesquicarbonates), sulphates, and aluminosilicates.
  • Borate builders, as well as builders containing borate-forming materials that can produce borate under detergent storage or wash conditions can also be used.
  • non-borate builders are used in the compositions of the invention intended for use at wash temperatures less than about 50 * C, especially less than about 40 ⁇ C.
  • silicate builders are the alkali metal silicates, particularly those having a Si ⁇ :Na2 ⁇ ratio in the range 1.6:1 to 3.2:1 and layered silicates, such as the layered sodium silicates described in U.S. Patent 4,664,839, issued May 12, 1987 to H. P. Rieck, incorporated herein by reference.
  • layered silicates such as the layered sodium silicates described in U.S. Patent 4,664,839, issued May 12, 1987 to H. P. Rieck, incorporated herein by reference.
  • other silicates may also be useful such as for example magnesium silicate, which can serve as a crispening agent in granular formulations, as a stabilizing agent for oxygen bleaches, and as a component of suds control systems.
  • carbonate builders are the alkaline earth and alkali metal carbonates, including sodium carbonate and sesquicarbonate and mixtures thereof with ultra-fine calcium carbonate as disclosed in German Patent Application No. 2,321,001 published on November 15, 1973, the disclosure of which is incorporated herein by reference.
  • Aluminosilicate builders are especially useful for use in concentrates with polycarboxylate builders in the present invention.
  • Aluminosilicate builders are of great importance in most currently marketed heavy duty granular detergent compositions, and can also be a significant builder ingredient in liquid detergent formulations.
  • Aluminosilicate builders include those having the empirical formula: M z (zAl ⁇ 2-ySi ⁇ 2) wherein M is sodium, potassium, ammonium or substituted ammonium, z is from about 0.5 to about 2; and y is 1; this material having a magnesium ion exchange capacity of at least about 50 milligram equivalents of CaC ⁇ 3 hardness per gram of anhydrous aluminosilicate.
  • Preferred aluminosilicates have the formula:
  • aluminosilicate ion exchange materials are commercially available. These aluminosilicates can be crystalline or amorphous in structure and can be naturally-occurring aluminosilicates or synthetically derived. A method for producing aluminosilicate ion exchange materials is disclosed in U.S.
  • Preferred synthetic crystalline aluminosilicate ion exchange materials useful herein are known as zeolite and are available under the designations Zeolite A, Zeolite P (B), and Zeolite X.
  • the crystalline aluminosilicate ion exchange material has the formula:
  • the aluminosilicate has a particle size in the 0.1-10 micron range.
  • Phosphate and phosphonate builders can be added, although it is generally desired to replace these builders with polycarboxylate or other builders. Thus, if present they preferably are included only at low levels.
  • the phosphate builder comprises less than about 10%, by weight, more preferably less than about 5%, most preferably essentially zero percent, of total builder in the composition.
  • polyphosphates are the alkali metal tripolyphosphates, sodium, potassium and ammonium pyrophos ⁇ phate, sodium and potassium and ammonium pyrophosphate, sodium and potassium orthophosphate, sodium polymeta phosphate in which the degree of polymerization ranges from about 6 to about 21, and salts of phytic acid.
  • phosphonate builder salts are the water-soluble salts of ethane 1-hydroxy-l, 1-diphosphonate particularly the sodium and potassium salts, the water-soluble salts of methylene diphosphonic acid e.g.
  • Phosphonate builder salts of the aforementioned types are disclosed in U.S. Patent Nos. 3,159,581 and 3,213,030 issued December 1, 1964 and October 19, 1965, to Diehl; U.S. Patent No. 3,422,021 issued January 14, 1969, to Roy; and U.S. Patent Nos. 3,400,148 and 3,422,137 issued September 3, 1968, and January 14, 1969 to Quimby, said disclosures being incorporated herein by reference.
  • a preferred builder system for granular compositions comprises a mixture of from about 5% to about 50% of zeolite (preferably Zeolite A) and from about 5% to about 50% citrate (preferably sodium citrate), said percentages being based upon the total builder in the mixture, calculated on a weight basis.
  • zeolite preferably Zeolite A
  • citrate preferably sodium citrate
  • compositions hereof contain one or more additional surfactants which can be anionic, cationic or nonionic.
  • surfactant system will include one or more anionic and/or nonionic surfactants in addition to the polyhydroxy fatty acid amide.
  • the amount of additional detersive surfactant present is typically at least about 1%, by weight, preferably from about 3% to about 40%, by weight, of the detergent composition, more preferably from about 5% to about 30%.
  • anionic surfactants such as anionic sulfate or sulfonate surfactants, or mixtures thereof, is particularly contemplated. Suitable surfactants are described below. Alkyl Ester Sulfonate Surfactant
  • Alkyl ester sulfonate surfactants hereof include linear esters of C8-C20 carboxylic acids (i.e., fatty acids) which are sulfonated witn gaseous SO3 according to "The Journal of the American Oil Chemists Society," 52 (1975), pp. 323-329. Suitable starting materials would include natural fatty substances as derived from tallow, palm, and coconut oils, etc.
  • the preferred alkyl ester sulfonate surfactant especially for laundry applications, comprise alkyl ester sulfonate surfactants of the structural formula: 0
  • R3 - CH - C - 0R4 SO3M wherein R 3 is a C8-C20 hydrocarbyl, preferably an alkyl, or combination thereof, R 4 is a Ci-C ⁇ hydrocarbyl, preferably an alkyl, or combination thereof, and M is a cation which forms a water soluble salt with the alkyl ester sulfonate.
  • Suitable salt-forming cations include metals such as sodium, potassium, and lithium, and substituted or unsubstituted ammonium cations, such as methyl-, dimethyl, -trimethyl, and quaternary ammonium cations, e.g.
  • R3 is C10-C16 alkyl
  • R 4 is methyl, ethyl or isopropyl.
  • methyl ester sulfonates wherein R ⁇ is C14-C16 alkyl.
  • Alkyl sulfate surfactants hereof are water soluble salts or acids of the formula ROSO3M wherein R preferably is a C10-C24 hydrocarbyl, preferably an alkyl or hydroxyalkyl having a C10-C20 alkyl component, more preferably a C12-C18 alkyl or hydroxyalkyl , and M is H or a cation, e.g., an alkali metal cation (e.g., sodium, potassium, lithium), substituted or unsubstituted ammonium cations such as methyl-, dimethyl-, and tri ethyl ammonium, and quaternary ammonium cations, e.g., tetramethyl-ammonium and dimethyl piperdin ⁇ ium cations, and cations derived from alkanolamines such as ethanol- amine, diethanolamine, triethanolamine, and mixtures thereof, and the like.
  • R preferably is a C10-
  • alkyl chains of C12-C16 are preferred for lower wash temperatures (e.g., below about 50 ⁇ C) and C16-I8 alkyl chains are preferred for higher wash temperatures (e.g., above about 50 ⁇ C).
  • Alkyl Alkoxylated Sulfate Surfactant is preferred for lower wash temperatures (e.g., below about 50 ⁇ C) and C16-I8 alkyl chains are preferred for higher wash temperatures (e.g., above about 50 ⁇ C).
  • Alkyl alkoxylated sulfate surfactants hereof are water soluble salts or acids of the formula R0(A) m S03M wherein R is an unsubsti ⁇ tuted C10-C24 alkyl or hydroxyalkyl group having a C10-C24 alkyl component, preferably a C12-C20 alkyl or hydroxyalkyl, more prefer ⁇ ably C12-C18 alkyl or hydroxyalkyl , A is an ethoxy or propoxy unit, m is greater than zero, typically between about 0.5 and about 6, more preferably between about 0.5 and about 3, and M is H or a cation which can be, for example, a metal cation (e.g., sodium, potassium, lithium, calcium, magnesium, etc.), ammonium or substituted-ammonium cation.
  • R is an unsubsti ⁇ tuted C10-C24 alkyl or hydroxyalkyl group having a C10-C24 alkyl component, preferably
  • Alkyl ethoxylated sulfates as well as alkyl propoxylated sulfates are contemplated herein.
  • Specific examples of substituted ammonium cations include methyl-, dimethyl-,- trimethyl-ammonium and quaternary ammonium cations, such as tetramethyl-ammonium, dimethyl piperdinium, and cations derived from alkanolamines, e.g. monoethanolamine, diethanolamine, and trietha- nolamine, and mixtures thereof.
  • Exemplary surfactants are C12-C18 alkyl polyethoxylate (1.0) sulfate, C12-C18 alkyl polyethoxylate (2.25) sulfate, C12-C18 alkyl polyethoxylate (3.0) sulfate, and C 12 -C 18 alkyl polyethoxylate (4.0) sulfate wherein M is conveniently selected from sodium and potassium.
  • Other Anionic Surfactants Other anionic surfactants useful for detersive purposes can also be included in the compositions hereof.
  • salts including, for example, sodium, potassium, ammonium, and substituted ammonium salts such as mono-, di- and triethanolamine salts
  • soap C9-C20 linear alkylbenzenesulphonates, C8-C22 primary or secondary alkanesulphonates, C8-C24 olefinsulphonates, sulphonated polycarboxylic acids prepared by sulphonation of the pyrolyzed product of alkaline earth metal citrates, e.g., as described in British patent specification No.
  • alkyl glycerol sulfonates alkyl glycerol sulfonates, fatty acyl glycerol sulfonates, fatty oleyl glycerol sulfates, alkyl phenol ethylene oxide ether sulfates, paraffin sulfonates, alkyl phosphates, isethionates such as the acyl isethionates, N-acyl taurates, fatty acid amides of methyl tauride, alkyl succinamates and sulfosuccinates, onoesters of sulfosuccinate (especially saturated and unsaturated C12-C18 monoesters), diesters of sulfosuccinate (especially saturated and unsaturated Cg-Ci4 diesters), N-acyl sarcosinates, sulfates of alkylpolysaccharides such as the sulfates of alkylpolygluco
  • Resin acids and hydrogenated resin acids are also suitable, such as rosin, hydrogenated rosin, and resin acids and hydrogenated resin acids present in or derived from tall oil. Further examples are described in "Surface Active Agents and Detergents" (Vol. I and II by Schwartz, Perry and Berch). A variety of such surfactants are also generally disclosed in U.S. Patent 3,929,678, issued December 30, 1975 to Laughlin, et al . at Column 23, line 58 through Column 29, line 23 (herein incorporated by reference) .
  • Nonionic Detergent Surfactants are also generally disclosed in U.S. Patent 3,929,678, issued December 30, 1975 to Laughlin, et al . at Column 23, line 58 through Column 29, line 23 (herein incorporated by reference) .
  • Suitable nonionic detergent surfactants are generally disclosed in U.S. Patent 3,929,678, Laughlin et al., issued December 30, 1975, at column 13, line 14 through column 16, line 6, incorporated herein by reference. Exemplary, non-limiting classes of useful nonioni surfactants are listed below.
  • the polyethylene, polypropylene, and polybutylene oxide condensates of alkyl phenols are preferred. These compounds include the condensation products of alkyl phenols having an alkyl group containing from about 6 to about 12 carbon atoms in either a straight chain or branched chain configuration with the alkylene oxide.
  • the ethylene oxide is present in an amount equal to from about 5 to about 25 moles of ethylene oxide per mole of alkyl phenol.
  • nonionic surfactants of this type include IgepalTM C0-630, marketed by the GAF Corporation; and TritonTM ⁇ -45, X-114, X-100, and X-102, all marketed by the Rohm & Haas Company. These surfactants are commonly referred to as alkyl phenol alkoxylates, e.g., alkyl phenol ethoxy!ates.
  • the condensation products of aliphatic alcohols with from about 1 to about 25 moles of ethylene oxide can either be straight or branched, primary or secondary, and generally contains from about 8 to about 22 carbon atoms. Particularly preferred are the condensation products of alcohols having an alkyl group containing from about 10 to about 20 carbon atoms with from about 2 to about 18 moles of ethylene oxide per mole of alcohol.
  • nonionic surfactants of this type include TergitolTM 15-S-9 (the condensation product of C11-C15 linear secondary alcohol with 9 moles ethylene oxide), TergitolTM 24-L-6 NMW (the condensation product of C12-C 4 primary alcohol with 6 moles ethylene oxide with a narrow molecular weight distribution), both marketed by Union Carbide Corporation; Neodol 45.9 ( he condensation product of C14-C15 linear alcohol with 9 moles of ethylene oxide), NeodolTM 23-6.5 (the condensation product of C12-C13 linear alcohol with 6.5 moles of ethylene oxide), NeodolTM 45.7 ( he condensation product of C14-C15 linear alcohol with 7 moles of ethylene oxide), NeodolTM 45-4 (the condensation product of C14-C15 linear alcohol with 4 moles of ethylene oxide), marketed by Shell Chemical Company, and KyroTM EOB (the condensation product of C13-C15 alcohol with 9 moles ethylene oxide), marketed by The Procter & Gamble Company
  • the hydrophobic portion of these compounds preferably has a molecular weight of from about 1500 to about 1800 and exhibits water insolubility.
  • the addition of polyoxyethylene moieties to this hydrophobic portion tends to increase the water solubility of the molecule as a whole, and the liquid character of the product is retained up to the point where the polyoxyethylene content is about 50% of the total weight of the condensation product, which corresponds to condensation with up to about 40 moles of ethylene oxide.
  • Examples of compounds of this type include certain of the commercially-available PluronicTM surfactants, marketed by BASF.
  • the condensation products of ethylene oxide with the product resulting from the reaction of propylene oxide and ethylenediamine consist of the reaction product of ethylenediamine and excess propylene oxide, and generally has a molecular weight of from about 2500 to about 3000.
  • This hydrophobic moiety is condensed with ethylene oxide to the extent that the condensation product contains from about 40% to about 80% by weight of polyoxyethylene and has a molecular weight of from about 5,000 to about 11,000.
  • this type of nonionic surfactant include certain of the commercially available TetronicTM compounds, marketed by BASF.
  • Semi-polar nonionic surfactants are a special category of nonionic surfactants which include water-soluble amine oxides containing one alkyl moiety of from about 10 to about 18 carbon atoms and 2 moieties selected from the group consisting of alkyl groups and hydroxyalkyl groups containing from about 1 to about 3 carbon atoms; water-soluble phosphine oxides containing one alkyl moiety of from about 10 to about 18 carbon atoms and 2 moieties selected from the group consisting of alkyl groups and hydroxyalkyl groups containing from about 1 to about 3 carbon atoms; and water-soluble sulfoxides containing one alkyl moiety of from about 10 to about 18 carbon atoms and a moiety selected from the group consisting of alkyl and hydroxyalkyl moieties of from about 1 to about 3 carbon atoms.
  • Semi-polar nonionic detergent surfactants include the amine oxide surfactants having the formula 0 R3(0R4) X N(R5) 2 wherein R 3 is an alkyl, hydroxyalkyl, or alkyl phenyl group or mixtures thereof containing from about 8 to about 22 carbon atoms; R 4 is an alkylene or hydroxyalkylene group containing from about 2 to about 3 carbon atoms or mixtures thereof; x is from 0 to about 3; and each R 5 is an alkyl or hydroxyalkyl group containing from about 1 to about 3 carbon atoms or a polyethylene oxide group containing from about 1 to about 3 ethylene oxide groups.
  • the R 5 groups can be attached to each other, e.g., through an oxygen or nitrogen atom, to form a ring structure.
  • amine oxide surfactants in particular include Cio-Cis alkyl dimethyl amine oxides and C8-C12 alkoxy ethyl dihydroxy ethyl amine oxides.
  • Any reducing saccharide containing 5 or 6 carbon atoms can be used, e.g., glucose, galactose and galacto- syl moieties can be substituted for the glucosyl moieties.
  • the hydrophobic group is attached at the 2-, 3-, 4-, etc. positions thus giving a glucose or galactose as opposed to a gluco-- side or galactoside.
  • the intersaccharide bonds can be, e.g., between the one position of the additional saccharide units and the 2-, 3-, 4-, and/or 6- positions on the preceding saccharide units.
  • a polyalkylene- oxide chain joining the hydrophobic moiety and the polysaccharide moiety.
  • the preferred alkyleneoxide is ethylene oxide.
  • Typical hydrophobic groups include alkyl groups, either saturated or unsaturated, branched or unbranched containing from about 8 to about 18, preferably from about 10 to about 16, carbon atoms.
  • the alkyl group is a straight chain saturated alkyl group.
  • the alkyl group can contain up to about 3 hydroxy groups and/or the polyalkyleneoxide chain can contain up to about 10, preferably less than 5, alkyleneoxide moieties.
  • Suitable alkyl polysaccharides are octyl, nonyldecyl, undecyldodecyl , tridecyl, tetradecyl , pentadecyl , hexadecyl, heptadecyl , and octadecyl , di-, tri-, tetra-, penta-, and hexaglucosides, galactosides, lactosides, glucoses, fructosides, fructoses and/or galactoses.
  • Suitable mixtures include coconut alkyl, di-, tri-, tetra-, and pentaglucosides and tallow alkyl tetra-, penta-, and hexaglucosides.
  • the preferred alkylpolyglycosides have the formula
  • R 2 0(C n H2nO)t(glycosyl) x
  • R 2 is selected from the group consisting of alkyl, al yl- phenyl, hydroxyalkyl , hydroxyal ylphenyl , and mixtures thereof in which the alkyl groups contain from about 10 to about 18, preferably from about 12 to about 14, carbon atoms; n is 2 or 3, preferably 2; t is from 0 to about 10, preferably 0; and x is from about 1.3 to about 10, preferably from about 1.3 to about 3, most preferably from about 1.3 to about 2.7.
  • the glycosyl is preferably derived from glucose.
  • the alcohol or alkylpol ethoxy alcohol is formed first and then reacted with glucose, or a source of glucose, to form the glucoside (attachment at the 1-position).
  • the additional glycosyl units can then be attached between their 1-position and the preceding glycosyl units 2-, 3-, 4- and/or 6-position, preferably predominately the 2-position.
  • R 6 is an alkyl group containing from about 7 to about 21 (preferably from about 9 to about 17) carbon atoms and each R? is selected from the group consisting of hydrogen, C1-C4 alkyl, C1-C4 hydroxyalkyl , and -(C2H4 ⁇ ) x H where x varies from about 1 to about 3.
  • Preferred amides are C8-C20 ammonia amides, onoethanolamides, diethanolamides, and isopropanolamides.
  • nonionics for use in addition to the polyhydroxy fatty acid amides include alkyl ethoxylates, alkyl polyglycosides, and alkyl phenol ethoxylates. These can be included in addition to any anionic surfactant present in the composition.
  • Cationic Surfactants include alkyl ethoxylates, alkyl polyglycosides, and alkyl phenol ethoxylates.
  • Cationic detersive surfactants can also be included in deter ⁇ gent compositions of the present invention.
  • Cationic surfactants include the ammonium surfactants such as alkyldimethylammonium halogenides, and those surfactants having the formula:
  • R 2 is an alkyl or alkyl benzyl group having from about 8 to about 18 carbon atoms in the alkyl chain
  • each R 3 is selected from the group consisting of -CH2CH2-, -CH2CH(CH3)-, -CH2CH(CH20H)-, -CH2CH2CH2-, and mixtures thereof
  • each R 4 is selected from the group consisting of C1-C4 alkyl, C1-C4 hydroxyalkyl , benzyl, ring structures formed by joining the two R 4 groups, -CH2CHOH-CHOHCOR 6 - CHOHCH2OH wherein R ⁇ is any hexose or hexose polymer having a molecular weight less than about 1000, and hydrogen when y is not 0
  • R 5 is the same as R 4 or is an alkyl chain wherein the total number of carbon atoms of R 2 plus
  • Ampholytic surfactants can be incorporated into the detergent compositions hereof. These surfactants can be broadly described as aliphatic derivatives of secondary or tertiary amines, or aliphatic derivatives of heterocyclic secondary and tertiary amines in which the aliphatic radical can be straight chain or branched.
  • One of the aliphatic substituents contains at least about 8 carbon atoms, typically from about 8 to about 18 carbon atoms, and at least one contains an anionic water-solubilizing group, e.g., carboxy, sulfonate, sulfate. See U.S. Patent No. 3,929,678 to Laughlin et al . , issued December 30, 1975 at column 19, lines 18-35 (herein incorporated by reference) for examples of ampholytic surfactants.
  • Zwitterionic surfactants can also be incorporated into the detergent compositions hereof. These surfactants can be broadly described as derivatives of secondary and tertiary amines, derivatives of heterocyclic secondary and tertiary amines, or derivatives of quaternary ammonium, quaternary phosphonium or tertiary sulfoniu compounds. See U.S. Patent No. 3,929,678 to Laughlin et al., issued December 30, 1975 at column 19, line 38 through column 22, line 48 (herein incorporated by reference) for examples of zwitterionic surfactants. Ampholytic and zwitterionic surfactants are generally used in combination with one or more anionic and/or nonionic surfactants. Enzymes
  • Detersive enzymes can be included in the detergent formulations for a variety of purposes including removal of protein-based, carbohydrate-based, or triglyceride-based stains, for example, and prevention of refugee dye transfer.
  • the enzymes to be incorporated include proteases, amylases, lipases, cellulases, and peroxidases, as well as mixtures thereof.
  • Other enzymes may additionally be included. They may be of any suitable origin, such as vegetable, animal, bacterial, fungal and yeast origin. However, their choice is governed by several factors such as pH-activity and/or stability optima, thermostability, stability versus active detergents, builders and so on. In this respect bacterial or fungal enzymes are preferred, such as bacterial amylases and proteases, and fungal cellulases.
  • proteases are the subtilisins which are obtained from particular strains of B.subtilis and B.licheniforms. Another suitable protease is obtained from a strain of Bacillus, having maximum activity throughout the pH range of 8-12, developed and sold by Novo Industries A/S under the registered trade name Esperase ® . The preparation of this enzyme and analogous enzymes is described in British patent specification No. 1,243,784 of Novo.
  • protealytic enzymes suitable for removing protein-based stains that are commercially available include those sold under the tradenames ALCALASETM and SAVINASETM by Novo Industries A/S (Denmark) and MAXATASETM y International Bio-Synthetics, Inc. (The Netherlands).
  • Protease A and Protease B are enzymes referred to herein as Protease A and Protease B.
  • Protease A and methods for its preparation are described in European Patent Application 130,756, published January 9, 1985, incorporated herein by reference.
  • Protease B is a proteolytic enzyme which differs from Protease A in that it has a leucine substituted for tyrosine in position 217 in its amino acid sequence.
  • Protease B is described in European Patent Application Serial No. 87303761.8, filed April 28, 1987, incorpor ⁇ ated herein by reference.
  • Methods for preparation of Protease B are also disclosed in European Patent Application 130,756, Bott et al., published January 9, 1985, incorporated herein by reference.
  • Amylases include, for example, ⁇ -amylases obtained from a special strain of B.licheniforms, described in more detail in British patent specification No. 1,296,839 (Novo), previously incorporated herein by reference.
  • Amylolytic proteins include, for example, RAPIDASETM, International Bio-Synthetics, Inc. and TERMAMYLTM, NOVO Industries.
  • the cellulases usable in the present invention include both bacterial or fungal cellulase. Preferably, they will have a pH optimum of between 5 and 9.5. Suitable cellulases are disclosed in U.S. Patent 4,435,307, Barbesgoard et al . , issued March 6, 1984, incorporated herein by reference, which discloses fungal cellulase produced from Humicola insolens. Suitable cellulases are also disclosed in GB-A-2.075.028; GB-A-2.095.275 and DE-0S-2.247.832. Examples of such cellulases are cellulases produced by a strain of Humicola insolens (Humicola grisea var.
  • thermoidea particularly the Humicola strain DSM 1800, and cellulases produced by a fungus of Bacillus N or a cellulase 212-producing fungus belonging to the genus Aeromonas, and cellulase extracted from the hepatopancreas of a marine mollusc (Dolabella Auricula Solander).
  • Suitable lipase enzymes for detergent usage include those produced by microorganisms of the Pseudomonas group, such as
  • Suitable upases include those which show a positive immunoligical cross-reaction with the antibody of the lipase, produced by the microorganism Pseudomonas fluorescens IAM 1057.
  • This lipase and a method for its purification have been described in Japanese Patent Application No. 53-20487, laid open to public inspection on February 24, 1978. This lipase is available from Amano Pharmaceutical Co.
  • Amano-P Lipase P
  • Such Upases of the present invention should show a positive immunological cross reaction with the Amano-P antibody, using the standard and well-known immunodiffusion procedure accord ⁇ ing to Ouchterlony (Acta. Med. Scan., 133, pages 76-79 (1950)).
  • These upases, and a method for their immunological cross-reaction with Amano-P are also described in U.S. Patent 4,707,291, Thom et al., issued November 17, 1987, incorporated herein by reference.
  • Typical examples thereof are the Amano-P lipase, the lipase ex Pseudomonas fragi FERM P 1339 (available under the trade name Amano-B), lipase ex Psuedomonas nitroreducens var. l ipolyticum FERM P 1338 (available under the trade name A ano-CES), upases ex Chromobacter viscosum, e.g. Chromobacter viscosum var. l ipolyticum NRRLB 3673, commercially available from Toyo Jozo Co., Tagata, Japan; and further Chromobacter viscosum upases from U.S. Biochemical Corp., U.S.A. and Disoynth Co., The Netherlands, and upases ex Pseudomonas gladiol i .
  • Peroxidase enzymes are used in combination with oxygen sources, e.g., percarbonate, perborate, persulfate, hydrogen peroxide, etc. They are used for "solution bleaching," i.e. to prevent transfer of dyes or pigments removed from substrates during wash operations to other substrates in the wash solution.
  • Peroxidase enzymes are known in the art, and include, for example, horseradish peroxidase, ligninase, and haloperoxidases such as chloro- and bromo-peroxidase.
  • Peroxidase-containing detergent compositions are disclosed, for example, in PCT International Application WO 89/099813, published October 19, 1989, by 0. Kirk, assigned to Novo Industries A/S, incorporated herein by reference.
  • the enzymes are preferably coated or prilled with additives inert toward the enzymes to minimize dust formation and improve storage stability. Techniques for accomplish ⁇ ing this are well known in the art.
  • an enzyme stabilization system is preferably utilized. Enzyme stabilization techniques for aqueous detergent compositions are well known in the art.
  • one technique for enzyme stabilization in aqueous solutions involves the use of free calcium ions from sources such as calcium acetate, calcium formate, and calcium propionate. Calcium ions can be used in combination with short chain carboxylic acid salts, perferably formates. See, for example, U.S. Patent 4,318,818, Letton, et al., issued March 9, 1982, incorporated herein by reference.
  • the detergent compositions hereof may contain bleaching agents or bleaching compositions containing bleaching agent and one or more bleach activators.
  • bleaching compounds When present bleaching compounds will typically be present at levels of from about 1% to about 20%, more typically from about 1% to about 10%, of the detergent composition.
  • bleaching compounds are optional components in non-liquid formulations, e.g., granular detergents. If present, the amount of bleach activators will typically be from about 0.1% to about 60%, more typically from about 0.5% to about 40% of the bleaching composition.
  • the bleaching agents used herein can be any of the bleaching agents useful for detergent compositions in textile cleaning, hard surface cleaning, or other cleaning purposes that are now known or become known. These include oxygen bleaches as well as other bleaching agents.
  • the compositions hereof not contain borate or material which can form borate in situ (i.e. borate-forming material) under detergent storage or wash conditions.
  • borate-forming material i.e. borate-forming material
  • detergents to be used at these temperatures are substantially free of borate and borate-forming material of any type.
  • substantially free of borate and borate-forming material shall mean that the composition contains not more than about 2% by weight of borate-containing and borate-forming material, preferably, no more than 1%, more preferably 0%.
  • One category of bleaching agent that can be used encompasses percarboxylic acid bleaching agents and salts thereof. Suitable examples of this class of agents include magnesium monoperoxyphthal- ate hexahydrate, the magnesium salt of meta-chloro perbenzoic acid, 4-nonylamino-4-oxoperoxybutyric acid and diperoxydodecanedioic acid. Such bleaching agents are disclosed in U.S. Patent 4,483,781, Hartman, issued November 20, 1984, U.S.
  • Highly preferred bleach ⁇ ing agents also include 6-nonylamino-6-oxoperoxycaproic acid as described in U.S. Patent 4,634,551, issued January 6, 1987 to Burns, et al., incorporated herein by reference.
  • hypohalite bleach ⁇ ing agents include trichloro isocyanuric acid and the sodium and potassium dichloroisocyanurates and N-chloro and N-bromo alkane sulphonamides. Such materials are normally added at 0.5-10% by weight of the finished product, preferably 1-5% by weight.
  • Peroxygen bleaching agents other than per boron compounds, can also be used. Suitable peroxygen bleaching compounds include sodium carbonate peroxyhydrate, sodium pyrophosphate peroxyhydrate, urea peroxyhydrate, and sodium peroxide.
  • Peroxygen bleaching agents are preferably combined with bleach activators, which lead to the in situ production in aqueous solution (i.e., during the washing process) of the peroxy acid corresponding to the bleach activator.
  • Preferred bleach activators incorporated into compositions of the present invention have the general formula:
  • R - C - L wherein R is an alkyl group containing from about 1 to about 18 carbon atoms wherein the longest linear alkyl chain extending from and including the carbonyl carbon contains from about 6 to about 10 carbon atoms and L is a leaving group, the conjugate acid of which has a pK a in the range of from about 4 to about 13.
  • Bleaching agents other than oxygen bleaching agents are also known in the art and can be utilized herein.
  • One type of non-oxygen— bleaching agent of particular interest includes photoactivated bleaching agents such as sulfonated zinc and aluminum phthalocyanines. These materials can be deposited upon the substrate during the washing process. Upon irradiation with light, in the presence of oxygen, such as by hanging clothes out to dry in the daylight, the sulfonated zinc phthalocyanine is activated and, consequently, the substrate is bleached.
  • Preferred zinc phthalocyanine and a photoactivated bleaching process are described in U.S. Patent 4,033,718, issued July 5, 1977 to Holcombe et al., incorporated herein by reference.
  • detergent compositions will contain about 0.025% to about 1.25%, by weight, of sulfonated zinc phthalocyanine.
  • Polymeric soil release agents are characterized by having both hydrophilic segments, to hydrophilize the surface of hydrophobic fibers, such as polyester and nylon, and hydrophobic segments, to deposit upon hydrophobic fibers and remain adhered thereto through completion of washing and rinsing cycles and, thus, serve as an anchor for the hydrophilic segments. This can enable stains occurring subsequent to treatment with the soil release agent to be more easily cleaned in later washing procedures.
  • polymeric soil release agents in any of the detergent compositions hereof, especially those compositions utilized for laundry or other applications wherein removal of grease and oil from hydrophobic surfaces is needed
  • the presence of polyhydroxy fatty acid amide in detergent compositions also containing anionic surfactants can enhance performance of many of the more commonly utilized types of polymeric soil release agents.
  • Anionic surfactants interfere with the ability of certain soil release agents to deposit upon and adhere to hydrophobic surfaces.
  • These polymeric soil release agents have nonionic hydrophile segments or hydrophobe segments which are anionic surfactant-interactive.
  • compositions hereof for which improved polymeric soil release agent performance can be obtained through the use of polyhydroxy fatty acid amide are those which contain an anionic surfactant system, an anionic surfactant-interactive soil release agent and a soil release agent-enhancing amount of the polyhydroxy fatty acid amide (PFA), wherein: (I) anionic surfactant- interaction between the soil release agent and the anionic surfactant system of the detergent composition can be shown by a comparison of the level of soil release agent (SRA) deposition on hydrophobic fibers (e.g., polyester) in aqueous solution between (A) a "Control" run wherein deposition of the SRA of the detergent composition in aqueous solution, in the absence of the other detergent ingredients, is measured, and (B) an "SRA/Anionic surfact ⁇ ant" test run wherein the same type and amount of the anionic surfactant system utilized in detergent composition is combined in aqueous solution with the SRA, at the same weight ratio of SRA to the anionic surfactant system of
  • the tests hereof should be conducted at anionic surfactant concentrations in the aqueous solution that are above the critical micelle concentration (CMC) of the anionic surfactant and preferably above about 100 ppm.
  • CMC critical micelle concentration
  • the polymeric soil release agent concentration should be at least 15 ppm.
  • a swatch of polyester fabric should be used for the hydrophobic fiber source. Identical swatches are immersed and agitated in 35'C aqueous solu ⁇ tions for the respective test runs for a period of 12 minutes, then removed, and analyzed.
  • Polymeric soil release agent deposition level can be determined by radiotagging the soil release agent prior to treatment and subsequently conducting radiochemical analysis, according to techniques known in the art.
  • soil release agent deposition can alternately be determined in the above test runs (i.e., test runs A, B, and C) by determination of ultraviolet light (UV) absorbance of the test solutions, according to techniques well known in the art. Decreased UV absorbance in the test solution after removal of the hydrophobic fiber material corresponds to increased SRA deposition.
  • UV analysis should not be utilized for test solutions containing types and levels of materials which cause excessive UV absorbance interference, such as high levels of surfactants with aromatic groups (e.g., alkyl benzene sulfonates, etc.).
  • soil release agent-enhancing amount of polyhydroxy fatty acid amide is meant an amount of such surfactant that will enhance deposition of the soil release agent upon hydrophobic fibers, as described above, or an amount for which enhanced grease/oil cleaning performance can be obtained for fabrics washed in the detergent composition hereof in the next subsequent cleaning operation.
  • the amount of polyhydroxy fatty acid amide needed to enhance deposition will vary with the anionic surfactant selected, the amount of anionic surfactant, the particular soil release agent chosen, as well as the particular polyhydroxy fatty acid amide chosen.
  • compositions will comprise from about 0.01% to about 10%, by weight, of the polymeric soil release agent, typically from about 0.1% to about 5%, and from about 4% to about 50%, more typically from about 5% to about 30% of anionic surfactant.
  • Such compositions should generally contain at least about 1%, preferably at least about 3%, by weight, of the polyhydroxy fatty acid amide, though it is not intended to necessarily be limited thereto.
  • the polymeric soil release agents for which performance is enhanced by polyhydroxy fatty acid amide in the presence of anionic surfactant include those soil release agents having: (a) one or more nonionic hydrophile components consisting essentially of (i) polyoxyethylene segments with a degree of polymerization of at least 2, or (ii) oxypropylene or polyoxypropylene segments with a degree of polymerization of from 2 to 10, wherein said hydrophile segment does not encompass any oxypropylene unit unless it is bonded to adjacent moieties at each end by ether linkages, or (iii) a mixture of oxyalkylene units comprising oxyethylene and from 1 to about 30 oxypropylene units wherein said mixture contains a sufficient amount of oxyethylene units such that the hydrophile component has hydrophilicity great enough to increase the hydrophilicity of conventional polyester synthetic fiber surfaces upon deposit of the soil release agent on such surface, said hydrophile segments preferably comprising at least about 25% oxyethylene units and more preferably, especially for such components having about 20 to
  • the polyoxyethylene segments of (a)(i) will have a degree of polymerization of from 2 to about 200, although higher levels can be used, preferably from 3 to about 150, more preferably from 6 to about 100.
  • Suitable oxy C4-C6 alkylene hydrophobe seg ⁇ ments include, but are not limited to, end-caps of polymeric soil release agents such as M ⁇ 3S(CH2)n oc H2CH2 ⁇ -, where M is sodium and n is an integer from 4-6, as disclosed in U.S. Patent 4,721,580,- issued January 26, 1988 to Gosselink, incorporated herein by reference.
  • Polymeric soil release agents useful in the present invention include cellulosic derivatives such as hydroxyether cellulosic polymers, copolymeric blocks of ethylene terephthalate or propylene terephthalate with polyethylene oxide or polypropylene oxide terephthalate, and the like.
  • Cellulosic derivatives that are functional as soil release agents are commercially available and include hydroxyethers of cellulose such as Methocel ⁇ (Dow).
  • Cel l ul osic soil release agents for use herein al so incl ude those sel ected from the group consi sting of C1-C4 al kyl and C4 hydroxyalkyl cellulose such as methylcellulose, ethylcellulose, hydroxypropyl methylcellulose, and hydroxybutyl methylcellulose.
  • C1-C4 al kyl and C4 hydroxyalkyl cellulose such as methylcellulose, ethylcellulose, hydroxypropyl methylcellulose, and hydroxybutyl methylcellulose.
  • a variety of cellulose derivatives useful as soil release polymers are disclosed in U.S. Patent 4,000,093, issued December 28, 1976 to Nicol, et al . , incorporated herein by reference.
  • Soil release agents characterized by poly(vinyl ester) hydrophobe segments include graft copolymers of poly(vinyl ester), e.g., Ci-Ce vinyl esters, preferably poly(vinyl acetate) grafted onto polyalkylene oxide backbones, such as polyethylene oxide backbones.
  • poly(vinyl ester) e.g., Ci-Ce vinyl esters
  • poly(vinyl acetate) grafted onto polyalkylene oxide backbones such as polyethylene oxide backbones.
  • Such materials are known in the art and are described in European Patent Application 0 219 048, published April 22, 1987 by Kud, et al.
  • Suitable commercially available soil release agents of this kind include the SokalanTM type of material, e.g., SokalanTM HP-22, available from BASF (West Germany).
  • One type of preferred soil release agent is a copolymer having random blocks of ethylene terephthalate and polyethylene oxide (PE0) terephthalate. More specifically, these polymers are comprised of repeating units of ethylene terephthalate and PE0 terephthalate in a mole ratio of ethylene terephthalate units to PE0 terephthalate units of from about 25:75 to about 35:65, said PEO terephthalate units containing polyethylene oxide having molecular weights of from about 300 to about 2000.
  • the molecular weight of this polymeric soil release agent is in the range of from about 25,000 to about 55,000. See U.S. Patent 3,959,230 to Hays, issued May 25, 1976, which is incorporated by reference. See also U.S. Patent 3,893,929 to Basadur issued July 8, 1975 (incorporated by reference) which discloses similar copolymers.
  • Another preferred polymeric soil release agent is a polyester with repeat units of ethylene terephthalate units containing 10-15% by weight of ethylene terephthalate units together with 90-80% by weight of polyoxyethylene terephthalate units, derived from a polyoxyethylene glycol of average molecular weight 300-5,000, and the mole ratio of ethylene terephthalate units to polyoxyethylene terephthalate units in the polymeric compound is between 2:1 and 6:1.
  • this polymer include the commercially available material Zelcon R 5126 (from Dupont) and Milease R T (from ICI). These polymers and methods of their preparation are more fully described in U.S. Patent 4,702,857, issued October 27, 1987 to Gosselink, which is incorporated herein by reference.
  • Another preferred polymeric soil release agent is a sulfonated product of a substantially linear ester oligomer comprised of an oligomeric ester backbone of terephthaloyl and oxyalkyleneoxy repeat units and terminal moieties covalently attached to the backbone, said soil release agent being derived from ally! alcohol ethoxylate, dimethyl terephthalate, and 1,2 propylene diol, wherein after sulfonation, the terminal moieties of each oligomer have, on average, a total of from about 1 to about 4 sulfonate groups.
  • These soil release agents are described fully in U.S. Patent 4,968,451, issued November 6, 1990 to J. J. Scheibel and E. P.
  • Gosselink U.S. Serial No. 07/474,709, filed January 29, 1990, incorporated herein by reference.
  • Other suitable polymeric soil release agents include the ethyl- or methyl-capped 1,2-propylene terephthalate-polyoxyethylene terephthalate polyesters of U.S. Patent 4,711,730, issued December 8, 1987 to Gosselink et al . , the anionic end-capped oligomeric esters of U.S. Patent 4,721,580, issued January 26, 1988 to Gosselink, wherein the anionic end-caps comprise sulfo-polyethoxy groups derived from polyethylene glycol (PEG), the block polyester oligomeric compounds of U.S.
  • PEG polyethylene glycol
  • Patent 4,702,857 issued October 27, 1987 to Gosselink, having polyethoxy end-caps of the formula X-(0CH2CH2)n- wherein n is from 12 to about 43 and X is a C1-C4 alkyl, or preferably methyl, all of these patents being incorporated herein by reference.
  • Additional polymeric soil release agents include the soil release agents of U.S. Patent 4,877,896, issued October 31, 1989 to Maldonado et al., which discloses anionic, especially sulfoaroyl, end-capped terephthalate esters, said patent being incorporated herein by reference.
  • the terephthalate esters contain unsymmetrically substituted oxy-1,2-alkyleneoxy units.
  • Included among the soil release polymers of U.S. Patent 4,877,896 are materials with polyoxyethylene hydrophile components or C3 oxyalkylene terephthalate (propylene terephthalate) repeat units within the scope of the hydrophobe components of (b)(i) above. It is the polymeric soil release agents characterized by either, or both, of these criteria that particularly benefit from the inclusion of the polyhydroxy fatty acid amides hereof, in the presence of anionic surfactants.
  • soil release agents will generally comprise from about 0.01% to about 10.0%, by weight, of the detergent compositions herein, typically from about 0.1% to about 5%, preferably from about 0.2% to about 3.0%.
  • the detergent compositions herein may also optionally contain one or more iron and manganese chelating agents as a builder adjunct material.
  • chelating agents can be selected from the group consisting of amino carboxylates, amino phosphonates, polyfunctionally-substituted aromatic chelating agents and mixtures thereof, all as hereinafter defined. Without intending to be bound by theory, it is believed that the benefit of these materials is due in part to their exceptional ability to remove iron and manganese ions from washing solutions by formation of soluble chelates.
  • Amino carboxylates useful as optional chelating agents in compositions of the invention can have one or more, preferably at least two, units of the substructure
  • these amino carboxylates do not contain alkyl or alkenyl groups with more than about 6 carbon atoms.
  • Operable amine carboxylates include ethylenediaminetetraacetates, N-hydroxyethyl- ethylenediaminetriacetates, nitrilotriacetates, ethylenediamine tetraproprionates, triethylenetetraaminehexaacetates, diethylenetri- aminepentaacetates, and ethanoldiglycines, alkali metal, ammonium, and substituted ammonium salts thereof and mixtures thereof.
  • Amino phosphonates are also suitable for use as chelating agents in the compositions of the invention when at least low levels of total phosphorus are permitted in detergent compositions.
  • ⁇ N (CH 2 ) ⁇ PO3M2 wherein M is hydrogen, alkali metal, ammonium or substituted ammon ⁇ ium and x is from 1 to about 3, preferably 1, are useful and include ethylenediaminetetrakis (methylenephosphonates), nitrilotris (methylenephosphonates) and diethylenetriaminepentakis (methylene ⁇ phosphonates). Preferably, these amino phosphonates do not contain alkyl or alkenyl groups with more than about 6 carbon atoms. Alkylene groups can be shared by substructures. Polyfunctionally - substituted aromatic chelating agents are also useful in the compositions herein. These materials can com ⁇ prise compounds having the general formula
  • R is -SO3H or -COOH or soluble salts thereof and mixtures thereof.
  • Alkaline detergent compositions can contain these materials in the form of alkali metal, ammonium or substituted ammonium (e.g. ono- or triethanol-amine) salts.
  • these chelating agents will generally comprise from about 0.1% to about 10% by weight of the detergent compositions herein. More preferably chelating agents will comprise from about 0.1% to about 3.0% by weight of such compositions.
  • Clay Soil Removal/Anti-redeposition Agents will generally comprise from about 0.1% to about 10% by weight of the detergent compositions herein. More preferably chelating agents will comprise from about 0.1% to about 3.0% by weight of such compositions.
  • compositions of the present invention can also optionally contain water-soluble ethoxylated amines having clay soil removal and anti-redeposition properties.
  • Granular detergent compositions which contain these compounds typically contain from about 0.01% to about 10.0% by weight of the water-soluble ethoxylated amines; liquid detergent compositions, typically about 0.01% to about 5%.
  • These compounds are selected preferably from the group consisting of: (1) ethoxylated monoamines having the formula:
  • R is H or C1-C4 alkyl or hydroxyalkyl;
  • R is C2-C12 alkylene, hydroxyal kyl ene, alkenyl ene, aryl ene or alkarylene, or a C2-C3 oxyalkylene moiety having from 2 to about 20 oxyalkylene units provided that no 0-N bonds are formed;
  • each R 2 is C1-C4 or hydroxy ⁇ alkyl, the moiety -L-X, or two R 2 together form the moiety -(CH2)r » -A 2 -(CH2)s- > wherein A 2 is -0- or -CH2-, r is 1 or 2, s is 1 or 2, and r + s is 3 or 4;
  • X is a nonionic group, an anionic group or mixture thereof;
  • R 3 is a substituted C3-C12 alkyl, hydroxyalkyl, alkenyl, aryl, or alkaryl
  • the most preferred soil release and anti-redeposition agent is ethoxylated tetraethylenepentamine.
  • Exemplary ethoxylated amines are further described in U.S. Patent 4,597,898, VanderMeer, issued July 1, 1986, incorporated herein by reference.
  • Another group of preferred clay soil re oval/anti-redeposition agents are the cati ⁇ onic compounds disclosed in European Patent Application 111,965, Oh and Gosselink, published June 27, 1984, incorporated herein by reference.
  • clay soil removal/anti-redeposition agents which can be used include the ethoxylated amine polymers disclosed in European Patent Application 111,984, Gosselink, published June 27, 1984; the zwitterionic polymers disclosed in European Patent Appli ⁇ cation 112,592, Gosselink, published July 4, 1984; and the amine oxides disclosed in U.S. Patent 4,548,744, Connor, issued October 22, 1985, all of which are incorporated herein by reference.
  • CMC carboxy methyl cellulose
  • Polymeric dispersing agents can advantageously be utilized in the compositions hereof. These materials can aid in calcium and magnesium hardness control. Suitable polymeric dispersing agents include polymeric polycarboxylates and polyethylene glycols, although others known in the art can also be used. Polycarboxylate materials which can be employed as the polymeric dispersing agent herein are these polymers or copolymers which contain at least about 60% by weight of segments with the general
  • X, Y, and Z are each selected from the group consisting of hydrogen, methyl, carboxy, carboxymethyl , hydroxy and hydroxymethyl; a salt-forming cation and n is from about 30 to about 400.
  • X is hydrogen or hydroxy
  • Y is hydrogen or carboxy
  • Z is hydrogen
  • M is hydrogen, alkali metal, ammonia or substituted ammonium.
  • Polymeric polycarboxylate materials of this type can be prepared by polymerizing or copolymerizing suitable unsaturated monomers, preferably in their acid form.
  • Unsaturated monomeric acids that can be polymerized to form suitable polymeric polycar ⁇ boxylates include acrylic acid, maleic acid (or maleic anhydride), fumaric acid, itaconic acid, aconitic acid, mesaconic acid, citra- conic acid and methylenemalonic acid.
  • the presence in the polymeric polycarboxylates herein of monomeric segments, containing no car- boxylate radicals such as vinylmethyl ether, styrene, ethylene, etc. is suitable provided that such segments do not constitute more than about 40% by weight.
  • Particularly suitable polymeric polycarboxylates can be derived from acrylic acid.
  • acrylic acid-based polymers which are useful herein are the water-soluble salts of polymerized acrylic acid.
  • the average molecular weight of such polymers in the acid form preferably ranges from about 2,000 to 10,000, more preferably from about 4,000 to 7,000 and most preferably from about 4,000 to 5,000.
  • Water-soluble salts of such acrylic acid polymers can include, for example, the alkali metal, ammonium and substituted ammonium salts. Soluble polymers of this type are known materials. Use of polyacrylates of this type in detergent compositions has been disclosed, for example, in Diehl, U.S. Patent No. 3,308,067, issued March 7, 1967. This patent is incorporated herein by reference.
  • Acrylic/maleic-based copolymers may also be used as a preferred component of the dispersing agent.
  • Such materials include the water-soluble salts of copolymers of acrylic acid and maleic acid.
  • the average molecular weight of such copolymers in the acid form preferably ranges from about 2,000 to 100,000, more preferably from about 5,000 to 75,000, most preferably from about 7,000 to 65,000.
  • the ratio of acrylate to maleate segments in such copolymers will generally range from about 30:1 to about 1:1, more preferably from about 10:1 to 2:1.
  • Water-soluble salts of such acrylic acid/maleic acid copolymers can include, for example, the alkali metal, ammonium and substituted ammonium salts. Soluble acrylate/maleate copolymers of this type are known materials which are described in European Patent Application No. 66915, published December 15, 1982, which publication is incorporated herein by reference.
  • PEG polyethyl ⁇ ene glycol
  • PEG can exhibit dispersing agent performance as well as act as a clay soil removal/anti-redeposition agent.
  • Typical molecular weight ranges for these purposes range from about 500 to about 100,000, preferably from about 1,000 to about 50,000, more preferably from about 1,500 to about 10,000.
  • the choice of brightener for use in detergent compositions will depend upon a number of factors, such as the type of detergent, the nature of other components present in the detergent composition, the temperatures of wash water, the degree of agitation, and the ratio of the material washed to tub size.
  • the brightener selection is also dependent upon the type of material to be cleaned, e.g., cottons, synthetics, etc. Since most laundry detergent products are used to clean a variety of fabrics, the detergent compositions should contain a mixture of brighteners which will be effective for a variety of fabrics. It is of course necessary that the individual components of such a brightener mixture be compatible.
  • optical brighteners which may be useful in the present invention can be classified into subgroups which include, but are not necessarily limited to, derivatives of stilbene, pyrazoline, cou arin, carboxylic acid, methinecyanines, dibenzothiphene-5,5-dioxide, azoles, 5- and 6-membered-ring heterocycles, and other miscellaneous agents. Examples of such brighteners are disclosed in "The Production and Application of Fluorescent Brightening Agents", M. Zahradnik, Published by John Wiley & Sons, New York (1982), the disclosure of which is incorporated herein by reference.
  • Stilbene derivatives which may be useful in the present invention include, but are not necessarily limited to, derivatives of bis(triazinyl)amino-stilbene; bisacylamino derivatives " of stilbene; triazole derivatives of stilbene; oxadiazole derivatives of stilbene; oxazole derivatives of stilbene; and styryl derivatives of stilbene.
  • Certain derivatives of bis(triazinyl)aminostilbene which may be useful in the present invention may be prepared from 4,4'-diamine- stilbene-2,2'-disulfonic acid.
  • Coumarin derivatives which may be useful in the present invention include, but are not necessarily limited to, derivatives substituted in the 3-position, in the 7-position, and in the 3- and 7-positions.
  • Carboxylic acid derivatives which may be useful in the present invention include, but are not necessarily limited-to, fumaric acid derivatives; benzoic acid derivatives; p-phenylene-bis-acrylic acid derivatives; naphthalenedicarboxylic acid derivatives; heterocyclic acid derivatives; and cinnamic acid derivatives.
  • Cinnamic acid derivatives which may be useful in the present invention can be further subclassified into groups which include, but are not necessarily limited to, cinnamic acid derivatives, styrylazoles, styrylbenzofurans, styryloxadiazoles, styryltriazoles, and styrylpolyphenyls, as disclosed on page 77 of the Zahradnik reference.
  • the styrylazoles can be further subclassified into styryl- benzoxazoles, styrylimidazoles and styrylthiazoles, as disclosed on page 78 of the Zahradnik reference. It will be understood that these three identified subclasses may not necessarily reflect an exhaustive list of subgroups into which styrylazoles may be subclassified.
  • optical brighteners which may be useful in the present invention are the derivatives of dibenzothiophene-5,5- dioxide disclosed at page 741-749 of The Kirk-Othmer Encyclopedia of Chemical Technology. Volume 3, pages 737-750 (John Wiley & Son, Inc., 1962), the disclosure of which is incorporated herein by reference, and include 3,7-diaminodibenzothiophene-2,8-disulfonic acid 5,5 dioxide.
  • Another class of brighteners which may be useful in the present invention are the derivatives of 6-membered-ring hetero- cycles disclosed in the Kirk-Othmer reference. Examples of such compounds include brighteners derived from pyrazine and brighteners derived from 4-aminonaphthalamide.
  • miscellaneous agents may also be useful as brighteners.
  • miscellaneous agents are disclosed at pages 93-95 of the Zahradnik reference, and include l-hydroxy-3,6,8-pyrenetri- sulphonic acid; 2,4-dimethoxy-l,3,5-triazin-6-yl-pyrene; 4,5-di- phenylimidazolone- disulphonic acid; and derivatives of pyrazoline- quinoline.
  • Other specific examples of optical brighteners which may be useful in the present invention are those identified in U.S. Patent 4,790,856, issued to Wixon on December 13, 1988, the disclosure of which is incorporated herein by reference.
  • These brighteners include the PhorwhiteTM series of brighteners from Verona.
  • Other brighteners disclosed in this reference include: Tinopal UNPA, Tinopal CBS and Tinopal 5BM; available from Ciba-Geigy; Arctic White CC and Artie White CWD, available from Hilton-Davis, located in Italy; the 2-(4-styryl-phenyl )-2H- naphthol [l,2-d]triazoles; 4,4'-bis- (l,2,3-triazol-2-yl)-stil- benes; 4,4'-bis(styryl)bis- phenyls; and the y-aminocoumarins.
  • these brighteners include 4-methyl-7-diethyl- amino coumarin; 1,2-bis- (-benzimidazol-2-yl)ethylene; 1,3-diphenylphrazolines; 2,5-bis- (benzoxazol-2-yl)thiophene; 2-styryl-naphth-[l,2-d]oxazole; and 2-(stilbene-4-yl)-2H-naphtho- [l,2-d]triazole.
  • Suds suppressors can be desirable because the polyhydroxy fatty acid amide surfactants hereof can increase suds stability of the detergent compositions. Suds suppression can be of particular importance when the detergent compositions include a relatively high sudsing surfactant in combination with the poly ⁇ hydroxy fatty acid amide surfactant. Suds suppression is particu ⁇ larly desirable for compositions intended for use in front loading automatic washing machines. These machines are typically character ⁇ ized by having drums for containing the laundry and wash water, which have a horizontal axis and rotary action about the axis.
  • suds suppressors are well known to those skilled in the art. They are generally described, for example, in Kirk Othmer Encyclopedia of Chemical Technology, Third Edition, Volume 7, pages 430-447 (John Wil ⁇ y & Sons, Inc., 1979).
  • On ⁇ category of suds suppressor of particular interest encompasses monocarboxylic fatty acids and soluble salts thereof. These materials are discussed in U.S.
  • the onocarboxylic fatty acids, and salts thereof, for use as suds suppressor typically have hydrocarbyl chains of 10 to about 24 carbon atoms, preferably 12 to 18 carbon atoms.
  • Suitable salts include the alkali metal salts such as sodium, potassium, and lithium salts, and ammonium and alkanolammonium salts. These materials are a preferred category of suds suppressor for detergent compositions.
  • the detergent compositions may also contain non-surfactant suds suppressors.
  • non-surfactant suds suppressors include, for example, list: high molecular weight hydrocarbons such as paraffin, fatty acid esters (e.g., fatty acid triglycerides), fatty acid esters of monovalent alcohols, aliphatic C18-C40 ketones (e.g. stearone), etc.
  • suds inhibitors include N-alkylated amino triazines such as tri- to hexa-alkylmelamines or di- to tetra-alkyldiamine chlortriazines formed as products of cyanuric chloride with two or three moles of a primary or secondary amine containing 1 to 24 carbon atoms, propylene oxide, and monostearyl phosphates such as monostearyl alcohol phosphate ester and monostearyl di-alkali metal (e.g. Na, Li, K) phosphates.
  • the hydrocarbons such as paraffin and haloparaf- fin can be utilized in liquid form.
  • the liquid hydrocarbons will be liquid at room temperature and atmospheric pressure, and will have a pour point in the range of about -40'C and about 5 * C, and a minimum boiling point not less than about 110'C (atmospheric pressure). It is also known to utilize waxy hydrocarbons, preferrably having a- elting point below about lOO'C.
  • the hydrocarbons constitute a preferred category of suds suppressor for detergent compositions. Hydrocarbon suds suppressors are described, for example, in U.S. Patent 4,265,779, issued May 5, 1981 to Gandolfo, et al . , incorpor- ated herein by reference.
  • hydrocarbons thus, include ali ⁇ phatic, alicyclic, aromatic, and heterocyclic saturated or unsatur ⁇ ated hydrocarbons having from about 12 to about 70 carbon atoms.
  • paraffin as used in this suds suppressor discussion, is intended to include mixtures of true paraffins and cyclic hydrocarbons.
  • Non-surfactant suds comprises silicone suds suppressors.
  • This category includes the use of polyorganosiloxane oils, such as polydimethylsiloxane, dispersions or emulsions of polyorganosiloxane oils or resins, and combinations of polyorganosiloxane with silica particles wherein the polyorgano ⁇ siloxane is chemisorbed of fused onto the silica.
  • Silicone suds suppressors are well known in the art and are, for example, dis ⁇ closed in U.S. Patent 4,265,779, issued May 5, 1981 to Gandolfo et al . and European Patent Application No. 89307851.9, published February 7, 1990, by Starch, M.
  • silicone and silanated silica are described, for instance, in German Patent Application DOS 2,124,526.
  • Silicone defoamers and suds controlling agents in granular detergent compositions are disclosed in U.S. Patent 3,933,672, Bartolotta et al., and in U.S. Patent 4,652,392, Baginski et al . , issued March 24, 1987.
  • An exemplary silicone based suds suppressor for use herein is a suds suppressing amount of a suds controlling agent consisting essentially of:
  • polydimethylsiloxane fluid having a viscosity of from about 20 cs. to about 1500 cs. at 25 * C; (ii) from about 5 to about 50 parts per 100 parts by weight of (i) of siloxane resin composed of (CH3)3 Si0 ⁇ /2 units of Si ⁇ 2 units in a ratio of from (CH3)3 SiO ⁇ /2 units and to Si ⁇ 2 units of from about 0.6:1 to about 1.2:1; and (iii) from about 1 to about 20 parts per 100 parts by weight of (i) of a solid silica gel;
  • suds should not form to the extent that they overflow the washing machine.
  • Suds suppressors when utilized, are preferably present in a "suds suppressing amount.”
  • Suds suppressing amount is meant that the formulator of the composition can select an amount of this suds controlling agent that will sufficiently control the suds to result in a low-sudsing laundry detergent for use in automatic laundry washing machines.
  • the amount of suds control will vary with the detergent surfactants selected. For example, with high sudsing surfactants, relatively more of the suds controlling agent is used to achieve the desired suds control than with lesser foaming surfactants.
  • a sufficient amount of suds suppressor should be incorporated in low sudsing detergent compositions so that the suds that form during the wash cycle of the automatic washing machine (i.e., upon agitation of the detergent in aqueous solution under the intended wash temperature and concentration conditions) do not exceed about 75% of the void volume of washing machine's containment drum, preferably the suds do not exceed about 50% of said void volume, wherein the void volume is determined as the difference between total volume of the containment drum and the volume of the water plus the laundry.
  • the compositions hereof will generally comprise from 0% to about 5% of suds suppressor.
  • monocarboxylic fatty acids, and salts thereof When utilized as suds suppressors, monocarboxylic fatty acids, and salts thereof, will be present typically in amounts up to about 5%, by weight, of the detergent composition. Preferably, from about 0.5% to about 3% of fatty monocarboxylate suds suppressor is utilized. Silicone suds suppressors are typically utilized in amounts up to about 2.0%, by weight, of the detergent composition, although higher amounts may be used. This upper limit is practical in nature, due primarily to concern with keeping costs minimized and effectiveness of lower amounts for effectively controlling sudsing. Preferably from about .01% to about 1% of silicone suds suppressor is used, more preferably from about 0.25% to about 0.5%.
  • these weight percentage values include any silica that may be utilized in combination with polyorganosiloxane, as well as any adjunct materials that may be utilized.
  • the monostearyl phosphate suds suppressors are typically utilized in amounts ranging from about 0.1% to about 2%, by weight, of the composition.
  • Hydrocarbon suds suppressors are typically utilized in amounts ranging from about .01% to about 5.0%, although higher levels can be used.
  • Other Ingredients are typically utilized in amounts ranging from about .01% to about 5.0%, although higher levels can be used.
  • compositions hereof A wide variety of other ingredients useful in detergent compositions can be included in the compositions hereof, including other active ingredients, carriers, hydrotropes, processing aids, dyes or pigments, solvents for liquid formulations, etc.
  • liquid heavy duty detergent compositions can be more easily formulated with anionic surfactants and the polycarboxylate builders hereof, by the inclusion of the polyhydroxy fatty acid amides described above, in addition to the improved, built detergent compositions resulting from the combination of polycarboxylate builder and polyhydroxy fatty acid amide, in general.
  • this invention provides liquid detergent compositions comprising one or more anionic surfactants, polycarboxylate builder, polyhydroxy fatty acid amide, and a liquid carrier.
  • These liquid detergent compositions can have relatively high levels of anionic surfactant and polycarboxylate builder incorporated therein.
  • high levels of polycarboxylate builder means levels of excess of about 10%, especially in excess of about 15%, by weight, of the detergent composition.
  • Liquid detergent compositions can contain water and other solvents as carriers.
  • Low molecular weight primary or secondary alcohols exemplified by methanol, ethanol, propanol , and isopropanol are suitable.
  • Monohydric alcohols are preferred for solubilizing surfactant, but polyols such as those containing from 2 to about 6 carbon atoms and from 2 to about 6 hydroxy groups (e.g., propylene glycol, ethylene glycol, glycerine, and 1,2-propanediol ) can also be used.
  • the detergent compositions hereof will preferably be formulated such that during use in aqueous cleaning operations, the wash water will have a pH of between about 6.5 and about 11, preferably between about 7.5 and about 10.5.
  • Liquid product formulations (measured at standard 10% dilution level) preferably have a pH between about 7.5 and about 9.5, more preferably between about 7.5 and about 9.0.
  • pH can be higher, preferably about pH 8.5-10.5.
  • Techniques for controlling pH at recommended usage levels include the use of buffers, alkalis, acids, etc., and are well known to those skilled in the art.
  • This invention further provides a method for improving the performance of detergents containing anionic, nonionic, and/or cationic surfactant and polycarboxylate builder by incorporating into such composition the polyhydroxy fatty acid amide surfactant described above, such that the weight ratio of polycarboxylate to the amide surfactant is from about 1:10 to about 10:1.
  • This invention further provides a method for cleaning substrates, such as fibers, fabrics, hard surfaces, skin, etc., by contacting said substrate, with a detergent composition comprising one or more anionic, nonionic, or cationic surfactants, at least about 1% polycarboxylate builder, and at least 1% of the polyhydroxy fatty acid amide, wherein preferably of the weight ratio of polycarboxylate builder:the amide surfactant is from about 1:10 to about 10:1, in the presence of a solvent such as water or water-miscible solvent (e.g., primary and secondary alcohols). Agitation is preferably provided for enhancing cleaning.
  • a detergent composition comprising one or more anionic, nonionic, or cationic surfactants, at least about 1% polycarboxylate builder, and at least 1% of the polyhydroxy fatty acid amide, wherein preferably of the weight ratio of polycarboxylate builder:the amide surfactant is from about 1:10 to about 10:1, in the presence of a
  • Suitable means for providing agitation include rubbing by hand or preferably with the aid of a brush, or other cleaning device, automatic laundry washing machines, automatic dishwashers, etc.
  • the more preferred polycarboxylate builder:polyhydroxy fatty acid amide weight ratios are from about 1:5 to about 7:1, most preferably from about 1:1 to about 7:1, and the preferred amounts and types of polyhydroxy fatty acid amide and polycarboxylate are as described herein.
  • one suitable apparatus for use herein comprises a three-liter four-necked flask fitted with a motor-driven paddle stirrer and a thermometer of length sufficient to contact the reaction medium.
  • the other two necks of the flask are fitted with a nitrogen sweep and a wide-bore side-arm (caution: a wide-bore side-arm is important in case of very rapid methanol evolution) to which is connected an efficient collecting condenser and vacuum outlet.
  • the latter is connected to a nitrogen bleed and vacuum gauge, then to an aspirator and a trap.
  • a 500 watt heating mantle with a variable transformer temperature controller (“Variac”) used to heat the reaction is so placed on a lab-jack that it may be readily raised or lowered to further control temperature of the reaction.
  • Variac variable transformer temperature controller
  • N-methylglucamine (195 g., 1.0 mole, Aldrich, M4700-0) and methyl laurate (Procter & Gamble CE 1270, 220.9 g., 1.0 mole) are placed in a flask.
  • the solid/liquid mixture is heated with stirring under a nitrogen sweep to form a melt (approximately 25 minutes).
  • catalyst anhydrous powdered sodium carbonate, 10.5 g., 0.1 mole, J. T. Baker
  • the nitrogen sweep is shut off and the aspirator and nitrogen bleed are adjusted to give 5 inches (5/31 atm.) Hg. vacuum. From this point on, the reaction temperature is held at 150° C by adjusting the Variac and/or by raising or lowering the mantle.
  • Examples 1-3 are formulations for preferred use of about 1400 ppm, wash water weight basis, for temperatures below about 50 ⁇ C.
  • the above examples are made by combining the base granule ingredients as a slurry, and spray drying to about 4-8% residual moisture.
  • the remaining dry ingredients are admixed in granular or powder form with the spray dryed granule in a rotary mixing drum, and the liquid ingredients (nonionic surfactant and perfume) sprayed on.
  • Total 100.0 100.0 Examples 4 and 5 exemplify condensed granular detergent compositions, preferably utilized at about 1000 ppm, wash water basis, and intended for temperatures below about 50° C. These are prepared by spray drying the base granule components to about 5-8% moisture, admixing the powdered or granular dry ingredients, and spraying on the liquid admix components.
  • TMS/TDS tartrate monosuccinate/tartrate disuccinate.
  • **Suds Suppressor Flake is a silica/silicone oil dispersion encapsulated in a matrix of polyethylene glycol (8000 MW), about 5% active suds suppressor.
  • compositions of Examples 6 and 7 represent condensed granular formulations prepared by slurrying and spray drying the base granule ingredients to a moisture of about 5%, and admixing in the additional dry ingredients. The resulting mixture is dedusted by spraying on the liquid ingredients.
  • the product is intended for use at about 1000 ppm concentration, at wash temperatures less than about 30 ⁇ C.
  • compositions of Examples 8 and 9 are preferably utilized at concentrations of about 6000 ppm, wash water weight basis, at temperature of from about 30'C to 95 ⁇ C. These compositions can be made by slurrying the base granule ingredients and spray dried to about 9% moisture content. Remaining dry ingredients are added in a granular or powdered form and mixed in a rotary mix drum, followed by spray on addition of the final liquid ingredients.
  • EXAMPLES 10-20 The examples show heavy duty liquid detergent compositions containing polyhydroxy fatty acid amide and polycarboxylate builder.
  • 100.0 100.0 100.0 100.0 Examples 10-16 are preferably used at about 12000 ppm, wash water weight basis, at temperatures from 30-95°C. These are prepared by combining non-aqueous solvents, aqueous surfactant pastes or solutions, melted fatty acids, aqueous solutions of polycarboxylate builders and other salts, aqueous ethoxylated tetraethylenpentamine, buffering agents, caustic, and the remaining water. The pH is adjusted using either an aqueous citric acid solution or sodium hydroxide solution to about pH 8.5. After pH adjustment the final ingredients, such as soil release agents, enzymes, colorants, and perfume, are added and the mixture stirred until a single phase is achieved.
  • TMS/TDS tartrate monosuccinate/tartrate disuccinate
  • Examples 18-20 are preferably used at about 2000 ppm, wash water weight basis, for wash tempertures below about 50"C. These are prepared by combining non-aqueous solvents, aqueous surfactant pastes or solutions, melted fatty acids, aqueous solutions of polycarboxylate builders and other salts, aqueous ethoxylated tetraethylene pentamine, buffering agents, caustic, and the remaining water. The pH is adjusted using either an aqueous citric acid solution or sodium hydroxide solution to about pH 8.5; for Examples 18 and 19, which have high builder content, pH can optionally be adjusted up to about pH 10.5. After pH adjustment the final ingredients, such as soil release agents, enzymes, colorants, and perfume, are added and the mixture stirred until a single phase is achieved. EXAMPLE 21
  • An alternate method for preparing the polyhydroxy fatty acid amides used herein is as follows.
  • a reaction mixture consisting of 84.87g. fatty acid methyl ester (source: Procter & Gamble methyl ester CE1270), 75g. N-methyl-D-glucamine (source: Aldrich Chemical Company M4700-0), 1.04g. sodium methoxide (source: Aldrich Chemical Company 16,499-2), and 68.51g. methyl alcohol is used.
  • the reaction vessel comprises a standard reflux set-up fitted with a drying tube, condenser and stir bar. In this procedure, the N-methyl glucamine is combined with methanol with stirring under argon and heating is begun with good mixing (stir bar; reflux).
  • the ester and sodium methoxide catalyst are added. Samples are taken periodically to monitor the course of the reaction, but it is noted that the solution is completely clear by 63.5 minutes. It is judged that the reaction is, in fact, nearly complete at that point.
  • the reaction mixture is maintained at reflux for 4 hours. After removal of the methanol, the recovered crude product weighs 156.16 grams. After vacuum drying and purification, an overall yield of 106.92 grams purified product is recovered. However, percentage yields are not calculated on this basis, inasmuch as regular sampling throughout the course of the reaction makes an overall percentage yield value meaningless.
  • the reaction can be carried out at 80% and 90% reactant concentrations for periods up to 6 hours to yield products with extremely small by-product formation.
  • the polyhydroxy fatty acid amides are, by virtue of their amide bond, subject to some instability under highly basic or highly acidic conditions. While some decomposition can be tolerated, it is preferred that these materials not be subjected to pH's above about 11, preferably 10, nor below about 3 for unduly extended periods. Final product pH (liquids) is typically 7.0-9.0. During the manufacture of the polyhydroxy fatty acid amides it will typically be necessary to at least partially neutralize the base catalyst used to form the amide bond. While any acid can be used for this purpose, the detergent formulator will recognize that it is a simple and convenient matter to use an acid which provides an anion that is otherwise useful and desirable in the finished detergent composition.
  • citric acid can be used for purposes of neutralization and the resulting citrate ion (ca. 1%) be allowed to remain with a ca. 40% polyhydroxy fatty acid amide slurry and be pumped into the later manufacturing stages of the overall detergent-manufacturing process.
  • the acid forms of materials such- as oxydisuccinate, nitrilotriacetate, ethylenediaminetetraacetate, tartrate/succinate, and the like, can be used similarly.
  • the polyhydroxy fatty acid amides derived from coconut alkyl fatty acids are more soluble than their tallow alkyl (predominantly C 16 -C 18 ) counterparts. Accordingly, the C 12 -C 14 materials are somewhat easier to formulate in liquid compositions, and are more soluble in cool-water laundering baths. However, the C 16 -C 18 materials are also quite useful, especially under circumstances where warm-to-hot wash water is used. Indeed, the C 16 -C 18 materials may be better detersive surfactants than their C 12 -C 14 counterparts. Accordingly, the formulator may wish to balance ease-of-manufacture vs. performance when selecting a particular polyhydroxy fatty acid amide for use in a given formulation.
  • solubility of the polyhydroxy fatty acid amides can be increased by having points of unsaturation and/or chain branching in the fatty acid moiety.
  • materials such as the polyhydroxy fatty acid amides derived from oleic acid and iso-stearic acid are more soluble than their n-alkyl counterparts.
  • polyhydroxy fatty acid amides prepared from disaccharides, trisaccharides, etc. will ordinarily be greater than the solubility of their onosaccharide-derived counterpart materials. This higher solubility can be of particular assistance when formulating liquid compositions.
  • polyhydroxy fatty acid amides wherein the polyhydroxy group is derived from maltose appear to function especially well as detergents when used in combination with conventional alkylbenzene sulfonate ("LAS") surfactants.
  • LAS alkylbenzene sulfonate
  • the polyhydroxy fatty acid amides can be manufactured not only from the purified sugars, but also from hydrolyzed starches, e.g., corn starch, potato starch, or any other convenient plant-derived starch which contains the mono-, di-, etc. sacchari-de desired by the formulator. This is of particular importance from the economic standpoint. Thus, "high glucose” corn syrup, "high maltose” corn syrup, etc. can conveniently and economically be used. De-lignified, hydrolyzed cellulose pulp can also provide a raw material source for the polyhydroxy fatty acid amides.
  • polyhydroxy fatty acid amides derived from the higher saccharides such as maltose, lactose, etc.
  • the more soluble polyhydroxy fatty acid amides can help solubilize their less soluble counterparts, to varying degrees.
  • the formulator may elect to use a raw material comprising a high glucose corn syrup, for example, but to select a syrup which contains a modicum of maltose (e.g., 1% or more).
  • the resulting mixture of polyhydroxy fatty acids will, in general, exhibit more preferred solubility properties over a broader range of temperatures and concentrations than would a "pure" glucose-derived polyhydroxy fatty acid amide.
  • the polyhydroxy fatty acid amides prepared from mixed sugars can offer very substantial advantages with respect to performance and/or ease-of- formulation.
  • some loss of grease removal performance may be noted at fatty acid malt ⁇ amide levels above about 25% and some loss in sudsing above about 33% (said percentages being the percentage of maltamide-derived polyhydroxy fatty acid amide vs. glucose-derived polyhydroxy fatty acid amide in the mixture). This can vary somewhat, depending on the chain length of the fatty acid moiety.
  • the formulator electing to use such mixtures may find it advantageous to select polyhydroxy fatty acid amide mixtures which contain ratios of monosaccharides (e.g., glucose) to di- and higher saccharides (e.g., maltose) from about 4:1 to about 99:1.
  • monosaccharides e.g., glucose
  • di- and higher saccharides e.g., maltose
  • the manufacture of preferred, uncyclized polyhydroxy fatty acid amides from fatty esters and N-alkyl polyols can be carried out in alcohol solvents at temperatures from about 30 * C-90 ⁇ C, preferably about 50 ⁇ C-80'C. It has now been determined that it may be conven ⁇ ient for the formulator of, for example, liquid detergents to conduct such processes in 1,2-propylene glycol solvent, since the glycol solvent need not be completely removed from the reaction product prior to use in the finished detergent formulation.
  • the formulator of, for example, solid, typically granular, detergent compositions may find it convenient to run the process at 30"C-90 * C in solvents which comprise ethoxylated alcohols, such as the ethoxylated (EO 3-8) C 12 -C 14 alcohols, such as those available as NEODOL 23 E06.5 (Shell).
  • ethoxylated alcohols such as the ethoxylated (EO 3-8) C 12 -C 14 alcohols, such as those available as NEODOL 23 E06.5 (Shell).
  • the industrial scale reaction sequence for preparing the preferred acyclic polyhydroxy fatty acid amides will comprise: Step 1 - preparing the N-alkyl polyhydroxy amine derivative from the desired sugar or sugar mixture by formation of an adduct of the N-alkyl amine and the sugar, followed by reaction with hydrogen in the presence of a catalyst; followed by Step 2 - reacting the aforesaid polyhydroxy amine with, preferably, a fatty ester to form an amide bond.
  • N-alkyl polyhydroxy amines useful in Step 2 of the reaction sequence can be prepared by various art-disclosed processes, the following process is convenient and makes use of economical sugar syrup as the raw material. It is to be understood that, for best results when using such syrup raw materials, the manufacturer should select syrups that are quite light in color or, preferably, nearly colorless ("water-white").
  • Adduct Formation The following is a standard process in which about 420 g of about 55% glucose solution (corn syrup - about 231 g glucose - about 1.28 moles) having a Gardner Color of less than 1 is reacted with about 119 g of about 50% aqueous methylamine (59.5 g of methylamine - 1.92 moles) solution.
  • the methylamine (MMA) solution is purged and shielded with N 2 and cooled to about 10 ⁇ C, or less.
  • the corn syrup is purged and shielded with N 2 at a temperature of about 10 # -20'C.
  • the corn syrup is added slowly to the MMA solution at the indicated reaction temperature as shown.
  • the Gardner Color is measured at the indicated approximate times in minutes.
  • the Gardner Color for the adduct is much worse as the temperature is raised above about 30'C and at about 50'C, the time that the adduct has a Gardner Color below 7 is only about 30 minutes.
  • the temperature should be less than about 20'C.
  • the Gardner Color should be less than about 7, and preferably less than about 4 for good color glucamine.
  • the time to reach substantial equilibrium concentration of the adduct is shortened by the use of higher ratios of amine to sugar.
  • equilibrium is reached in about two hours at a reaction temperature of about 30'C.
  • the time is at least about three hours.
  • the combination of amine:sugar ratio; reaction temperature; and reaction time is selected to achieve substantially equilibrium conversion, e.g., more than about 90%, preferably more than about 95%, even more preferably more than about 99%, based upon the sugar, and a color that is less than about 7, preferably less than about 4, more preferably less than about 1, for the adduct.
  • the starting sugar materi al must be very near col orl ess in order to consi stently have adduct that i s acceptabl e.
  • the adduct i s sometimes acceptabl e and sometimes not acceptabl e.
  • the Gardner Col or i s above 1 the resul ting adduct i s unacceptabl e.
  • the above procedure is repeated with about 23.1 g of Raney Ni catalyst with the following changes.
  • the catalyst is washed three times and the reactor, with the catalyst in the reactor, is purged twice with 200 psig H 2 and the reactor is pressurized with H 2 at 1600 psig for two hours, the pressure is released at one hour and the reactor is repressurized to 1600 psig.
  • the adduct is then pumped into the reactor which is at 200 psig and 20 * C, and the reactor is purged with 200 psig H 2 , etc., as above.
  • the resulting product in each case is greater than about 95% N-methyl glucamine; has less than about 10 ppm Ni based upon the glucamine; and has a solution color of less than about Gardner 2.
  • the crude N-methyl glucamine is color stable to about 140 * C for a short exposure time.
  • adduct that has low sugar content (less than about 5%, preferably less than about 1%) and a good color (less than about 7, preferably less than about 4 Gardner, more preferably less than about 1).
  • adduct is prepared starting with about 159 g of about 50% methylamine in water, which is purged and shielded with N 2 at about 10-20'C. About 330 g of about 70% corn syrup (near water-white) is degassed with N 2 at about 50°C and is added slowly to the methylamine solution at a temperature of less than about 20'C. The solution is mixed for about 30 minutes to give about 95% adduct that is a very light yellow solution.
  • About 190 g of adduct in water and about 9 g of United Catalyst G49B Ni catalyst are added to a 200 ml autoclave and purged three times with H 2 at about 20'C.
  • the H 2 pressure is raised to about 200 psi and the temperature is raised to about 50'C.
  • the pressure is raised to 250 psi and the temperature is held at about 50-55'C for about three hours.
  • the product, which is about 95% hydrogenated at this point, is then raised to a temperature of about 85°C for about 30 minutes and the product, after removal of water and evaporation, is about 95% N-methyl glucamine, a white powder.
  • Ni content in the glucamine is about 100 ppm as compared to the less than 10 ppm in the previous reaction.
  • a 200 ml autoclave reactor is used following typical procedures similar to those set forth above to make adduct and to run the hydrogen reaction at various temperatures.
  • Adduct for use in making glucamine is prepared by combining about 420 g of about 55% glucose (corn syrup) solution (231 g glucose; 1.28 moles) (the solution is made using 99DE corn syrup from CarGill, the solution having a color less than Gardner 1) and about 119 g of 50% methylamine (59.5 g MMA; 1.92 moles) (from Air Products).
  • the glucamine adduct hydrogen reactions are as follows: 1. Add about 134 g adduct (color less than about Gardner 1) and about 5.8 g G49B Ni to a 200 ml autoclave.
  • the preparation of the tallow (hardened) fatty acid amide of N-methyl maltamine for use in detergent compositions according to this invention is as follows.
  • Step 1 - Reactants Maltose monohydrate (Aldrich, lot 01318KW); methylamine (40 wt% in water) (Aldrich, lot 03325TM); Raney nickel, 50% slurry (UAD 52-73D, Aldrich, lot 12921LW).
  • the reactants are added to glass liner (250 g maltose, 428 g methylamine solution, 100 g catalyst slurry - 50 g Raney Ni) and placed in 3 L rocking autoclave, which is purged with nitrogen (3X500 psig) and hydrogen (2X500 psig) and rocked under H 2 at room temperature over a weekend at temperatures ranging from 28'C to 50'C.
  • the crude reaction mixture is vacuum filtered 2X through a glass microfiber filter with a silica gel plug.
  • the filtrate is concentrated to a viscous material.
  • the final traces of water are azetroped off by dissolving the material in methanol and then removing the methanol/water on a rotary evaporator. Final drying is done under high vacuum.
  • the crude product is dissolved in refluxing methanol, filtered, cooled to recrystallize, filtered and the filter cake is dried under vacuum at 35 * C. This is cut #1.
  • the filtrate is concentrated until a precipitate begins to form and is stored in a refrigerator overnight.
  • the solid is filtered and dried under vacuum. This is cut #2.
  • the filtrate is again concentrated to half its volume and a recrystallization is performed. Very little precipitate forms.
  • a small quantity of ethanol is added and the solution is left in the freezer over a weekend.
  • the solid material is filtered and dried under vacuum.
  • the combined solids comprise
  • N-methyl maltamine which is used in Step 2 of the overall synthesis.
  • Step 2 Reactants: N-methyl maltamine (from Step 1); hardened tallow methyl esters; sodium methoxide (25% in methanol); absolute methanol (solvent); mole ratio 1:1 amine:ester; initial catalyst level 10 mole % (w/r maltamine), raised to 20 mole %; solvent level- 50% (wt.).
  • a silica gel slurry in 100% methanol is loaded into a funnel and washed several times with 100% methanol.
  • a concentrated sample of the product (20 g in 100 ml of 100% methanol) is loaded onto the silica gel and eluted several times using vacuum and several methanol washes.
  • the collected eluant is evaporated to dryness (rotary evaporator). Any remaining tallow ester is removed by trituration in ethyl acetate overnight, followed by filtration. The filter cake is vacuum dried overnight.
  • the product is the tallowalkyl N-methyl maltamide.
  • Step 1 of the foregoing reaction sequence can be conducted using commercial corn syrup comprising glucose or mixtures of glucose and, typically, 5%, or higher, maltose.
  • the resulting polyhydroxy fatty acid amides and mixtures can be used in any of the detergent compositions herein.
  • Step 2 of the foregoing reaction sequence can be carried out in 1,2-propylene glycol or NEODOL.
  • the propylene glycol or NEODOL need not be removed from the reaction product pri «r to its use to formulate detergent compositions.
  • the methoxide catalyst can be neutralized by citric acid to provide sodium citrate, which can remain in the polyhydroxy fatty acid amide.
  • the compositions herein can contain more or less of various suds control agents.
  • various suds control agents For dishwashing high sudsing is desirable so no suds control agent will be used.
  • a wide variety of suds control agents are known in the art and can be routinely selected for use herein. Indeed, the selection of suds control agent, or mixtures of suds control agents, for any specific detergent composition will depend not only on the presence and amount of polyhydroxy fatty acid amide used therein, but also on the other surfactants present in the formulation.
  • silicone-based suds control agents of various types are more efficient (i.e., lower levels can be used) than various other types of suds control agents.
  • the silicone suds control agents available as X2-3419 and Q2-3302 (Dow Corning) are particularly useful.
  • the formulator of fabric laundering compositions which can advantageously contain soil release agent has a wide variety of known materials to choose from (see, for example, U.S. Patents 3,962,152; 4,116,885; 4,238,531; 4,702,857; 4,721,580 and 4,877,896).
  • Additional soil release materials useful herein include the nonionic oligomeric esterification product of a reaction mixture comprising a source of C !
  • -C 4 alkoxy-terminated polyethoxy units e.g., CH 3 [0CH 2 CH 2 ] 16 0H
  • a source of terephthaloyl units e.g., dimethyl terephthalate
  • a source of poly(oxyethylene)oxy units e.g., polyethylene glycol 1500
  • a source of oxyiso-propyleneoxy units e.g., 1,2-propylene glycol
  • oxyethyleneoxy units e.g., ethylene glycol especially wherein the mole ratio of oxyethyleneoxy units:oxyiso-propyleneoxy units is at least about rmula
  • R 1 is lower (e.g., C ⁇ -C 4 ) alkyl, especially methyl; x and y are each integers from about 6 to about 100; m is an integer of from about 0.75 to about 30; n is an integer from about 0.25 to about 20; and R z is a mixture of both H and CH 3 to provide a mole ratio of oxyethyleneoxy:oxyisopropyleneoxy of at least about 0.5:1.
  • soil release agent useful herein is of the general anionic type described in U.S. Patent 4,877,896, but with the condition that such agents be substantially free of monomers of the HOROH type wherein R is propylene or higher alkyl.
  • the soil release agents of U.S. Patent 4,877,896 can comprise, for example, the reaction product of dimethyl terephthalate, ethylene glycol, 1,2-propylene glycol and 3-sodiosulfobenzoic acid
  • these additional soil release agents can comprise, for example, the reaction product of dimethyl terephthalate, ethylene glycol, 5-sodiosulfoisophthalate and 3-sodiosulfobenzoic acid.
  • compositions herein can contain a solid percarbonate bleach, normally in the form of the sodium salt, incorporated at a level of from 3% to 20% by weight, more preferably from 5% to 18% by weight and most preferably from 8% to 15% by weight of the composition.
  • Sodium percarbonate is an addition compound having a formula corresponding to 2Na 2 C0 3 . 3H 2 0 2 , and is available commercially as a crystalline solid. Most commercially available material includes a low level of a heavy metal sequestrant such as EDTA, 1-hydroxyethylidene 1,1-diphosphonic acid (HEDP) or an amino-phosphonate, that is incorporated during the manufacturing process.
  • a heavy metal sequestrant such as EDTA, 1-hydroxyethylidene 1,1-diphosphonic acid (HEDP) or an amino-phosphonate
  • the percarbonate can be incorporated into detergent compositions without additional protection, but preferred embodiments of the invention utilize a stable form of the material (FMC).
  • Magnesium silicate can also be used and a chelant such as one of those mentioned above can also be included in the coating.
  • the particle size range of the crystalline percarbonate is from 350 micrometers to 450 micrometers with a mean of approximately 400 micrometers. When coated, the crystals have a size in the range from 400 to 600 micrometers.
  • the percarbonate While heavy metals present in the sodium carbonate used to manufacture the percarbonate can be controlled by the inclusion of sequestrants in the reaction mixture, the percarbonate still requires protection from heavy metals present as impurities in other ingredients of the product. It has been found that the total level of iron, copper and manganese ions in the product should not exceed 25 ppm and preferably should be less than 20 ppm in order to avoid an unacceptably adverse effect on percarbonate stability.
  • a modern, condensed laundry detergent granule is as follows.
  • Layered silicate builders are known in the art. Preferred are the layered sodium silicates. See, for example, the layered sodium silicate builders of U.S. Patent 4,664,859, issued May 12, 1987 to H. P. Rieck, incorporated herein by reference.
  • a suitable layered silicate builder is available as SKS-6 from Hoechst. 2 Avail ble from Novo Nordisk A/S, Copenhagen.
  • Highly preferred granules of the foregoing types are those which comprise from about 0.0001% to about 2% by weight of active enzyme and at least about 1% by weight of said polyhydroxy fatty acid amide, and, most preferably, wherein the anionic surfactant is not an alkylbenzene sulfonate surfactant.
  • the following relates to the preparation of a preferred liquid heavy duty laundry detergent according to this invention.
  • the stability of enzymes in such compositions is considerably less than in granular detergents.
  • typical enzyme stabilizers such as formate and boric acid
  • lipase and cellulase enzymes can be protected from degradation by protease enzymes.
  • lipase stability is still relatively poor in the presence of alkylbenzene sulfonate (“LAS”) surfactants.
  • LAS alkylbenzene sulfonate
  • LAS alkylbenzene sulfonate
  • liquid detergent compositions containing lipase, protease and cellulase enzymes, together. It is particu ⁇ larly challenging to provide such tertiary enzyme systems in stable liquid detergents together with an effective blend of detersive surfactants. Additionally, it is difficult to incorporate peroxidase and/or amylase enzymes stably in such compositions.
  • liquid detergent compositions typically contain LAS or mixtures of LAS with surfactants of the RO(A) m S0 3 M type ("AES") noted hereinabove, i.e., LAS/AES mixtures.
  • the liquid detergents herein preferably comprise binary mixtures of the AES and polyhydroxy fatty acid amides of the type disclosed herein. While minimal amounts of LAS can be present, it will be appreciated that the stability of the enzymes will be lessened thereby. Accordingly, it is preferred that the liquid compositions be substantially free (i.e., contain less than about 10%, preferably less than about 5%, more preferably less than about 1%, most preferably 0%) of LAS.
  • the present invention provides a liquid detergent composition
  • a liquid detergent composition comprising: (a) from about 1% to about 50%, preferably from about 4% to about 40%, of anionic surfactant;
  • an enzyme performance-enhancing amount (preferably from about 0.5% to about 12%) of a polyhydroxy fatty acid amide material of the formula
  • R 2 - C - N - Z wherein R 1 is H 1 ⁇ C ⁇ -C 4 hydrocarbyl, 2-hydroxy ethyl, 2-hydroxy propyl, or a mixture thereof, R 2 is C 5 -C 31 hydrocarbyl, and Z is a polyhydroxylhydrocarbyl having a linear hydrocarbyl chain with at least 3 hydroxyls directly connected to said chain, or an alkoxylated derivative thereof; and wherein the composition is substantially free of alkylbenzene sulfonate.
  • the water-soluble anionic surfactant herein preferably comprises (“AES”):
  • R0(A) m S0 3 M wherein R is an unsubstituted C 10 -C 24 alkyl or hydroxyalkyl (C ⁇ 0 -C 24 ) group, A is an ethoxy or propoxy unit, m is an integer greater than 0 and M is hydrogen or a cation.
  • R is an unsubstituted C 12 -C 18 alkyl group, A is an ethoxy unit, m is from about 0.5 to about 6, and M is a cation.
  • the cation is preferably a metal cation (e.g., sodium-preferred, potassium, lithium, calcium, magnesium, etc.) or an ammonium or substituted ammonium cation.
  • the ratio of the above surfactant ("AES") to the polyhydroxy fatty acid amide herein be from about 1:2 to about 8:1, preferably about 1:1 to about 5:1, most preferably about 1:1 to about 4:1.
  • the liquid compositions herein may alternatively comprise polyhydroxy fatty acid amide, AES, and from about 0.5% to about 5% of the condensation product of C 8 -C 22 (preferably C 10 -C 20 ) linear alcohol with between about 1 and about 25, preferably between about 2 and about 18, moles of ethylene oxide per mole of alcohol.
  • the liquid compositions herein preferably have a pH in a 10% solution in water at 20'C of from about 6.5 to about 11.0, preferably from about 7.0 to about 8.5.
  • compositions preferably further comprise from about 0.1% to about 50% of detergency builder.
  • These compositions preferably comprise from about 0.1% to about 20% of citric acid, or water-soluble salt thereof, and from about 0.1% to about 20% of a water-soluble succinate tartrate, especially the sodium salt thereof, and mixtures thereof, or from about 0.1% to about 20% by weight of oxydisuccinate or mixtures thereof with the aforesaid builders.
  • 0.1%-50% alkenyl succinate can also be used.
  • the preferred liquid compositions herein comprise from about 0.0001% to about 2%, preferably about 0.0001% to about 1%, most preferably about 0.001% to about 0.5%, on an active basis, of detersive enzyme.
  • detersive enzymes are preferably selected from the group consisting of protease (preferred), lipase (preferred), amylase, cellulase, peroxidase, and mixtures thereof.
  • Preferred are compositions with two or more classes of enzymes, most preferably where one is a protease.
  • lipases of interest include Amano AKG and Bacillis Sp lipase (e.g., Solvay enzymes). Also, see the lipases described in EP A 0399 681, published November 28, 1990, EP A 0 218272, published April 15, 1987 and PCT/DK 88/00177, published May 18, 1989, all incorporated herein by reference.
  • Suitable fungal Upases include those producible by Humicola lanuginosa and Ther o yces lanuginosus.
  • lipase obtained by cloning the gene from Humicola lanuginosa and expressing the gene in Aspergi l lus oryzae, as described in European Patent Application 0 258068, incorporated herein by reference, commercially available under the trade name LIP0LASE.
  • lipase units of lipase per gram (LU/g) of product can be used in these compositions.
  • a lipase unit is that amount of lipase which produces 1 ⁇ mol of titratable butyric acid per minute in a pH stat, where pH is 7.0, temperature is 30'C, and substrate is an emulsion tributyrin and gum arabic, in the presence of Ca ++ and NaCl in phosphate buffer.
  • Example 1 illustrates a preferred heavy duty liquid detergent composition
  • a preferred heavy duty liquid detergent composition comprising:
  • a polyhydroxy fatty acid amine surfactant of the type disclosed herein typically comprising at least about 2% by weight of the composition, more typically from about 3% to about 15%, preferably from about 7% to about 14%;
  • liquid carrier especially water or water-alcohol mixtures
  • Silicone suds suppressor 0.0375 Boric acid 2.00
  • Protease B is a modified bacterial serine protease described in European Patent Application Serial No. 87 303761 filed April 28, 1987, particularly pages 17, 24 and 98.
  • Lipase used herein is the lipase obtained by cloning the gene from Humicola lanuginosa and expressing the gene in Aspergi l lus oryzae, as described in European Patent Application 0 258068, commercially available under the trade name LIPOLASE (ex Novo Nordisk A/S, Copenhagen Denmark).
  • the brightener is added to the composition as a separately prepared pre-mix of brightener (4.5%), monoethanolamine (60%) and water (35.5%).
  • the following illustrates a perborate bleach-plus-bleach activator detergent composition of the present invention which is prepared by admixing the listed ingredients in a mixing drum.
  • Zeolite A refers to hydrated crystalline Zeolite A containing about 20% water and having an average particle size of 1 to 10, preferably 2 to 5, microns;
  • LAS refers to sodium c i 2 . 3 linear alkylbenzene sulfonate; AS refers to sodium C 14 -C 15 alkyl sulfate;
  • nonionic refers to coconut alcohol condensed with about 6.5 moles of ethylene oxide per mole of alcohol and stripped of unethoxylated and monoethoxylated alcohol, also abbreviated as CnAE6.5T.; and
  • DTPA refers to sodium diethylenetriamine pentaacetate.
  • the base granules are produced by spray drying an aqueous crutcher mix of the listed ingredients.
  • NAPAA wet cake which typically consists of about 60% water, about 2% peroxyacid available oxygen
  • This wet cake is the crude reaction product of NAAA (monononyl imide of a.dipic icid), sulfuric acid, and hydrogen peroxide which is subsequently quenched by addition to water followed by filtration, washing with distilled water, phosphate buffer washing and final suction filtration to recover the wet cake.
  • a portion of the wet cake is air-dried at room temperature to obtain a dry sample which typically consists of about 5% AvO (corresponding to about 90% NAPAA) and about 10% unreacted starting material. When dry, the sample pH is about 4.5.
  • NAPAA granules are prepared by mixing about 51.7 parts of the dried NAPAA wet cake (containing about 10% unreacted), about 11.1 parts of sodium C 12 . 3 linear alkyl benzene sulfonate (LAS) paste (45% active), about 43.3 parts of sodium sulfate, and about 30 parts of water in a CUISINART mixer. After drying, the granules (which contain about 47% NAPAA) are sized by passing through a No. 14 Tyler mesh sieve and retaining all particles not passing through a No. 65 Tyler mesh. The average amide peroxyacid particle (agglomerate) size is about 5-40 microns and the median particle size is about 10-20 microns, as determined by Malvern particle size analysis.
  • LAS linear alkyl benzene sulfonate
  • NOBS nonanoyloxybenzene sulfonate
  • Zeolite granules having the following composition are made by mixing Zeolite A with PEG 8000 and CnAE6.5T in an Eirich R08 energy intensive mixer. Parts by Wei ht
  • the PEG 8000 is in an aqueous form containing 50% water and is at a temperature of approximately 55 * F (12.8'C).
  • the CnAE6.5T is in a liquid state and is held at approximately 90'F (32.2"C).
  • the two liquids are combined by pumping through a 12 element static mixer.
  • the resulting binder material has an outlet temperature of- approximately 75'F (23.9'C) and a viscosity of approximately 5000 cps.
  • the ratio of PEG 8000 and CnAE6.5T through the static mixer is 72:28 respectively.
  • the Eirich R08 energy intensive mixer is operated in a batch type mode. First, 34.1 kg of powdered Zeolite A is weighed into the pan of the mixer. The mixer is started by first rotating the pan in a counterclockwise direction at approximately 75 rotations per minute (rpm), and then rotating the rotor blade in a clockwise direction at 1800 rpm. The binder material is then pumped from the static mixer directly into the Eirich R08 energy intensive mixer which contains Zeolite A. The feed rate of the binder material is about 2 minutes. The mixer continues to mix for an additional 1 minute for a total batch time of approximately 3 minutes. The batch is then discharged and collected in a fiber drum.
  • the batch step is repeated until approximately 225 kg of wet product has been collected.
  • This discharged product is then dried in a fluid bed at 240-270'F (116-132'C).
  • the drying step removes most of the free water and changes the composition as described above.
  • the total energy input by the mixer to the product in a batch mode is approximately 1.31X10 12 erg/kg. at a rate of approximately 2.18X10 9 erg/kg-s.
  • the resulting free flowing agglomerates have a mean particle size of about 450-500 microns.
  • EXAMPLE 26 A liquid laundry detergent composition suitable for use at the relatively high concentrations common to front-loading automatic washing machines, especially in Europe, and over a wide range of temperatures is as follows.
  • Soil release polymer 10 0.2 Silicone (suds control) 11 0.4
  • Dispersant for silicone suds control agent available as DC-3225C from Dow Corning. *Preferred fatty acid is topped palm kernel, comprising 12% oleic acid and 2% each of stearic and linoleic.
  • EXAMPLE 27 A granular laundry detergent composition suitable for use at the relatively high concentrations common to front-loading automatic washing machines, especially in Europe, and over a wide range of temperatures is as follows.
  • Zeolite A (anhydrous 2-5 ⁇ ) 17.92
  • X2-3419 is a silicone suds suppressor available from Dow Corning.
  • the procedure for preparing the granules comprises various tower-drying, agglomerating, dry-additions, etc., as follows. The percentages are based on the finished composition.
  • a surfactant mixture of 20% DOBANOL C 12 . 15 E0(3) and 80% C 16 -C 18 N-methyl glucose amide is obtained and coagglomerated with 10% sodium carbonate.
  • the above particle is then coagglomerated with a high active paste (70%) of a sodium salt of C 14 -C 15 alkyl sulfate and C 12 . 15 E0(3) sulfate and Zeolite A and extra sodium carbonate. This particle evidences a good dispersibility in cold water of the- C 16 -C 18 N-methyl glucose amide.
  • the overall formulation of this particle (contribution to the detergent formulation after the drying of the agglomerate) is: C 16 -C 18 N-methyl glucose amide 4.1% DOBANOL C 12 . 15 E0(3) 0.94%
  • the silicone suds suppressor X2-3419 (95%-97% high molecular weight linear silicone; 3%-5% hydrophobic silica) ex Dow Corning is coagglomerated with Zeolite A (2-5 ⁇ size), starch and stearyl alcohol binder. This particle has the following formulation: Zeolite A 0.22%
  • the detergent preparation exhibits excellent solubility, superior performance and excellent suds control when used in European washing machine, e.g., using 85 g detergent in a AEG-brand washing machine in 30'C, 40'C, 60'C and 90"C cycles.
  • the fatty acid glucamide surfactant can be replaced by an equivalent amount of the maltamide surfactant, or mixtures of glucamide/maltamide surfactants derived from plant sugar sources.
  • the use of ethanol- amides appears to help cold temperature stability of the finished formulations.
  • the use of sulfobetaine (aka “sultaine”) surfactants provides superior sudsing.
  • the formulator of high sudsing compositions will desirably avoid the introduction of suds-suppressing amounts of such fatty acids into high sudsing compositions with the polyhydroxy fatty acid amides, and/or avoid the formation of C 14 and higher fatty acids on storage of the finished compositions.
  • One simple means is to use C 12 ester reactants to prepare the polyhydroxy fatty acid amides herein. Fortunately, the use of amine oxide or sulfobetaine surfactants can overcome some of the negative sudsing effects caused by the fatty acids.
  • anionic optical brighteners to liquid detergents containing relatively high concentrations (e.g., 10% and greater) of anionic or polyanionic substituents such as the polycarboxylate builders may find it useful to pre-mix the bright ⁇ ener with water and the polyhydroxy fatty acid amide, and then to add the pre-mix to the final composition.
  • Polyglutamic acid or polyaspartic acid dispersants can be usefully employed with zeolite-built detergents.
  • AE fluid or flake and DC-544 are other examples of useful suds control agents herein.

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Abstract

Disclosed are detergent compositions containing polycarboxylate builders and one or more anionic, nonionic, or cationic detersive surfactants, or mixtures thereof, improved by the inclusion of certain polyhydroxy fatty acid amide surfactants. The compositions comprise at least 1 % by weight of polycarboxylate builder, and at least 1 % by weight of a polyhydroxy fatty acid amide of formula (I) wherein R<1> is H, C1-C4 hydrocarbyl, 2-hydroxy ethyl, 2-hydroxy propyl, or a mixture thereof; and R<2> is a C5-C31 hydrocarbyl; and Z is a polyhydroxyhydrocarbyl having a linear hydrocarbyl chain with at least 3 hydroxyls directly connected to the chain, or an alkoxylated derivative (preferably ethoxylated or propoxylated) thereof.

Description

POLYHYDROXY FATTY ACID AMIDES IN POLYCARBOXYLATE-BUILT DETERGENTS
FIELD OF THE INVENTION The performance of detergent compositions built with polycar¬ boxylate builders is increased by means of polyhydroxy fatty acid amide surfactants.
CROSS REFERENCE TO RELATED APPLICATION This application is a continuation-in-part of co-pending application Serial No. 589,732 filed September 28, 1990.
BACKGROUND OF THE INVENTION Various builder materials have been suggested for use in detergent compositions. Such materials serve a variety of functions, including hardness sequestration, peptization, pH control, and the like. For many years, sodium tripolyphosphate was the builder of choice, but recent developments in the field include builder materials such as zeolites, various polycarboxylates, and the like. Currently, many fully-formulated detergent compositions contain a polycarboxylate builder, or contain builder mixtures containing various polycarboxylate builders.
The development of high performance laundry detergent compositions without phosphates has been a considerable challenge to the industry. From the performance standpoint, even the best polycarboxylate builders often result in an "under-built" situation in hard water. Furthermore, simply increasing the level of builder utilized can excessively increase cost and can lead to solubility problems for anionic detersive surfactants in use, particularly under conditions wherein water hardness is relatively high. Conven¬ tional nonionic surfactants, such as the alkyl ethoxylates, suffer from no solubility problems but, on the other hand, typically do not provide excellent overall cleaning at low to moderate wash tempera¬ tures. Conventional nonionic surfactants can also be difficult to formulate in granular and liquid detergent formulations.
Accordingly, the formulator of heavy duty detergents has been constrained to rely on other means to boost performance. In order to enhance the detergency performance of such compositions, sophis¬ ticated formulators have incorporated various detergency adjuncts therein. Materials such as detersive enzymes, soil release poly¬ mers, and bleaches are commonly used to enhance the performance of carboxylate-built detergent compositions. This is especially true in liquid detergent formulations as high levels of builder can make various anionic surfactants, such as alkyl sulfates and alkyl ester sulfonates, insoluble in the formula. Simply stated, the present invention employs an improved detersive surfactant system to help make up for the shortfall in cleaning performance occasioned by the use of polycarboxylate builders. By the practice of this invention, certain polyhydroxy fatty acid amides are used in polycarboxylate-built detergents to provide enhanced detergency performance. Furthermore, these polyhydroxy fatty acid amides facilitate the formulation of granular and especially liquid detergents with high levels of builder and anionic surfactants.
BACKGROUND ART A variety of polyhydroxy fatty acid amides have been described in the art. N-acyl, N-methyl glucamides, for example, are disclosed by J. W. Goodby, M. A. Marcus, E. Chin, and P. L. Finn in "The Thermotropic Liquid-Crystalline Properties of Some Straight Chain Carbohydrate A phiphiles," Liquid Crystals, 1988, Volume 3, No. 11, pp 1569-1581, and by A. Muller-Fahrnow, V. Zabel , M. Steifa, and R. Hilgenfeld in "Molecular and Crystal Structure of a Nonionic Detergent: Nonanoyl-N-methylglucamide," J. Chem. Soc. Chem. Commun., 1986, pp 1573-1574. The use of N-alkyl polyhydroxya ide surfactants has been of substantial interest recently for use in biochemistry, for example in the dissociation of biological membranes. See, for— example, the journal article "N-D-Gluco-N-methyl-alkanamide Compounds, a New Class of Non-Ionic Detergents For Membrane Biochemistry," Biochem. J. (1982), Vol. 207, pp 363-366, by J. E. K. Hildreth. The use of N-alkyl glucamides in detergent compositions has also been discussed. U.S. Patent 2,965,576, issued December 20, 1960 to E. R. Wilson, and G.B. Patent 809,060, published February 18, 1959, assigned to Thomas Hedley & Co., Ltd. relate to detergent compositions containing anionic surfactants and certain amide surfactants, which can include N-methyl glucamide, added as a low temperature suds enhancing agent. These compounds include an N-acyl radical of a higher straight chain fatty acid having 10-14 carbon atoms. These compositions may also contain auxiliary materials such as alkali metal phosphates, alkali metal silicates, sulfates, and carbonates. It is also generally indicated that additional constituents to impart desirable properties to the composition can also be included in the compositions, such as fluorescent dyes, bleaching agents, perfumes, etc.
U.S. Patent 2,703,798, issued March 8, 1955 to A. M. Schwartz, relates to aqueous detergent compositions containing the condensa¬ tion reaction product of N-alkyl glucamine and an aliphatic ester of a fatty acid. The product of this reaction is said to be useable in aqueous detergent compositions without further purification. It is also known to prepare a sulfuric ester of acylated glucamine as disclosed in U.S. Patent 2,717,894, issued September 13, 1955, to A. M. Schwartz. PCT International Application WO 83/04412, published December 22, 1983, by J. Hildreth, relates to amphiphilic compounds contain¬ ing polyhydroxy! aliphatic groups said to be useful for a variety of purposes including use as surfactants in cosmetics, drugs, shampoos, lotions, and eye ointments, as emulsifiers and dispensing agents for medicines, and in biochemistry for solubilizing membranes, whole cells, or other tissue samples, and for preparing liposomes. Included in this disclosure are compounds of the formula R'C0N(R)CH2R" and R"C0N(R)R' wherein R is hydrogen or an organic grouping, R' is an aliphatic hydrocarbon group of at least three carbon atoms, and R" is the residue of an aldose.
European Patent 0 285 768, published October 12, 1988, H. Kelkenberg, et al., relates to the use of N-polyhy roxy alkyl fatty acid amides as thickening agents in aqueous detergent systems. Included are amides of the formula RιC(0)N(X)R2 wherein Ri is a C1-C17 (preferably C7-C17) alkyl, R2 is hydrogen, a Ci-Cjs (preferably Ci-Cδ) alkyl, or an alkylene oxide, and X is a polyhydroxy alkyl having four to seven carbon atoms, e.g., N-methyl, coconut fatty acid glucamide. The thickening properties of the amides are indicated as being of particular use in liquid surfactant systems containing paraffin sulfonate, although the aqueous surfactant systems can contain other anionic surfactants, such as alkylaryl sulfonates, olefin sulfonate, sulfosuccinic acid half ester salts, and fatty alcohol ether sulfonates, and nonionic surfactants such as fatty alcohol polyglycol ether, alkylphenol polyglycol ether, fatty acid polyglycol ester, polypropylene oxide-polyethylene oxide mixed polymers, etc. Paraffin sulfonate/N-methyl coconut fatty acid glucamide/nonionic surfactant shampoo formulations are exemplified. In addition to thickening attributes, the N-polyhydroxy alkyl fatty acid amides are said to have superior skin tolerance attributes.
U.S. Patent 2,982,737, issued May 2, 1961, to Boettner, et al., relates to detergent bars containing urea, sodium lauryl sulfate anionic surfactant, and an N-alkylglucamide nonionic surfactant which is selected from N-methyl ,N-sorbityl lauramide and N-methyl, N-sorbityl myristamide.
Other glucamide surfactants are disclosed, for example, in DT 2,226,872, published December 20, 1973, H. W. Eckert, et al . , which relates to washing compositions comprising one or more surfactants and builder salts selected from polymeric phosphates, sequestering agents, and washing alkalis, improved by the addition of an N-acylpolyhydroxyalkyl-amine of the formula RιC(0)N(R2)CH2(CH0H)n- CH2OH, wherein Rj is a C1-C3 alkyl, R2 is a C10-C22 alkyl, and n is 3 or 4. The N-acylpolyhydroxyalkyl-amine is added as a soil sus¬ pending agent.
U.S. Patent 3,654,166, issued April 4, 1972, to H. W. Eckert, et al., relates to detergent compositions comprising at least one surfactant selected from the group of anionic, zwitterionic, and nonionic surfactants and, as a textile softener, an N-acyl, N-alkyl polyhydroxylalkyl compound of the formula RιN(Z)C(0)R2 wherein Ri is a C10-C22 alkyl, R2 is a C7-C21 alkyl, Ri and R2 total from 23 to 39 carbon atoms, and Z is a polyhydroxyalkyl which can be -CH2(CHOH)mCH2θH where m is 3 or 4.
U.S. Patent 4,021,539, issued May 3, 1977, to H. Mδller, et al., relates to skin treating cosmetic compositions containing N-polyhydroxylalkyl-amines which include compounds of the formula RlN(R)CH(CH0H)mκ2 wherein Ri is H, lower alkyl, hydroxy-lower alkyl, or aminoalkyl, as well as heterocyclic aminoalkyl, R is the same as Rl but both cannot be H, and R2 is CH2OH or C00H. French Patent 1,360,018, April 26, 1963, assigned to Commercial Solvents Corporation, relates to solutions of formaldehyde stabilized against polymerization with the addition of amides of the formula RC(0)N(Rι)G wherein R is a carboxylic acid functionality having at least seven carbon atoms, Ri is hydrogen or a lower alkyl group, and G is a glycitol radical with at least 5 carbon atoms.
German Patent 1,261,861, February 29, 1968, A. Heins, relates to glucamine derivatives useful as wetting and dispersing agents of the formula N(R)(Rι)(R2) wherein R is a sugar residue of glucamine, Ri is a C10-C20 alk l radical, and R2 is a C1-C5 acyl radical.
G.B. Patent 745,036, published February 15, 1956, assigned to Atlas Powder Company, relates to heterocyclic amides and carboxylic estars thereof that are said to be useful as chemical intermediates, e ulsifiers, wetting and dispersing agents, detergents, textile softeners, etc. The compounds are expressed by the formula N(R)(Rι)C(0)R2 wherein R is the residue of an anhydrized hexane pentol or a carboxylic acid ester thereof, Ri is a monovalent hydrocarbon radical, and -C(0)R2 is the acyl radical of a carboxylic acid having from 2 to 25 carbon atoms. U.S. Patent 3,312,627, issued April 4, 1967 to D. T. Hooker, discloses solid toilet bars that are substantially free of anionic detergents and alkaline builder materials, and which contain lithium soap of certain fatty acids, a nonionic surfactant selected from certain propylene oxide-ethylenediamine-ethylene oxide condensates, propylene oxide-propylene glycol-ethylene oxide condensates, and polymerized ethylene glycol, and also contain a nonionic lathering component which can include polyhydroxyamide of the formula RC(0)NRl(R2) wherein RC(0) contains from about 10 to about 14 carbon atoms, and R1 and R2 each are H or C1-C6 alkyl groups, said alkyl groups containing a total number of carbon atoms of from 2 to about 7 and a total number of substituent hydroxyl groups of from 2 to about 6. A substantially similar disclosure is found in U.S. Patent 3,312,626, also issued April 4, 1967 to D. T. Hooker.
SUMMARY OF THE INVENTION Improved detergent compositions containing polycarboxylate builder are provided by the inclusion of certain polyhydroxy fatty acid amide surfactants, and preferably one or more anionic, nonionic, or cationic detersive surfactants, or mixtures thereof.
Accordingly, the compositions of the present invention comprise at least 1% by weight of polycarboxylate builder, and at least 1% by weight of a polyhydroxy fatty acid amide of the formula: 0 Rl
'I • R2 - C - N - Z wherein: Rl is H, C1-C4 hydrocarbyl, 2-hydroxy ethyl, 2-hydroxy propyl, or a mixture thereof, preferably C1-C4 alkyl, more preferably Ci or C2 alkyl, most preferably Ci alkyl (i.e., methyl); and R2 is a C5-C31 hydrocarbyl, preferably straight chain C7-C19 alkyl or alkenyl, more preferably straight chain C9-C17 alkyl or alkenyl, most preferably straight chain C11-C17 alkyl or alkenyl, or mixture thereof; and Z is a polyhydroxyhydrocarbyl having a linear hydrocarbyl chain with at least 3 hydroxyls directly connected to the chain, or an alkoxylated derivative (preferably ethoxylated or propoxylated) thereof. Z preferably will be derived from a reducing sugar in a reductive amination reaction; more preferably Z is a glycityl. Suitable reducing sugars include glucose, fructose, maltose, lactose, galactose, mannose, and xylose. As raw materials, high dextrose corn syrup, high fructose corn syrup, and high maltose corn syrup can be utilized as well as the individual sugars listed above. These corn syrups may yield a mix of sugar components for Z. It should be understood that it is by no means intended to exclude other suitable raw materials. Thus, Z preferably will be selected from the group consisting of -CH2-(CH0H)n-CH20H, -CH(CH20H)~ (CH0H)n-ι-CH20H, -CH2-(CH0H)2(CH0R')(CH0H)-CH20H, where n is an integer from 3 to 5, inclusive, and R' is H or a cyclic or aliphatic monosaccharide, and alkoxylated derivatives thereof. Most preferred are glycityls wherein n is 4, particularly -CH2~(CH0H)4-CH20H. Preferably, the weight ratio of polycarboxylate builder:polyhy- droxy fatty acid amide is within the range of about 1:10 to about 10:1, more preferably about 1:5 to about 7:1, most preferably about 1:1 to about 7:1. This invention encompasses (but is not limited to) both liquid and granular detergent compositions. This invention provides detergent composition built with polycarboxylate builders that have improved builder effectiveness and, consequently, can also have improved cleaning performance, especially in the area of grease/oil cleaning.
This invention further provides a method for improving the performance of detergents containing anionic, nonionic, and/or cationic surfactant and polycarboxylate builder by incorporating into such composition the polyhydroxy fatty acid amide surfactant described above, such that the weight ratio of polycarboxylate to the amide surfactant is from about 1:10 to about 10:1.
This invention further provides a method for cleaning substrates, such as fibers, fabrics, hard surfaces, skin, etc., by contacting said substrate with a detergent composition comprising one or more anionic, nonionic, or cationic surfactants, at least about 1% polycarboxylate builder, and at least 1% of the polyhydroxy fatty acid amide, wherein preferably the weight ratio of polycar- boxylate builder:polyhydroxy fatty acid amide surfactant is from about 1:10 to about 10:1, in the presence of a solvent such as water or water-miscible solvent (e.g., primary and secondary alcohols).
Agitation is preferably provided for enhancing cleaning. Suitable means for providing agitation include rubbing by hand or preferably with the aid of a brush, sponge, mop or other cleaning device, automatic laundry washing machines, automatic dishwashers, etc.
In the above methods, the more preferred polycarboxylate builder:polyhydroxy fatty acid amide weight ratios are from about
1:5 to about 7:1, most preferably from about 1:1 to about 7:1, and the preferred amounts and types of polyhydroxy fatty acid amide and polycarboxylate are as described herein.
DETAILED DESCRIPTION OF THE INVENTION Polyhydroxy Fatty Acid Amide Surfactant
The compositions hereof will comprise at least about 1%, typically from about 3% to about 50%, preferably from about 3% to about 30%, of the polyhydroxy fatty acid amide surfactant described below.
The polyhydroxy fatty acid amide surfactant component of the present invention comprises compounds of the structural formula: 0 R1 (I) R2 - C - N - Z wherein: R1 is H, C1-C4 hydrocarbyl, 2-hydroxy ethyl, 2-hydroxy propyl, or a mixture thereof, preferably C1-C4 alkyl, more preferably Ci or C2 alkyl, most preferably Ci alkyl (i.e., methyl); and R2 is a C5-C31 hydrocarbyl, preferably straight chain C7-C19 alkyl or alkenyl, more preferably straight chain C9-C17 alkyl or alkenyl, most preferably straight chain C11-C17 alkyl or alkenyl, or mixture thereof; and Z is a polyhydroxyhydrocarbyl having a linear hydrocarbyl chain with at least 3 hydroxyls directly connected to the chain, or an alkoxylated derivative (preferably ethoxylated or propoxylated) thereof. Z preferably will be derived from a reducing sugar in a reductive amination reaction; more preferably Z is a glycityl. Suitable reducing sugars include glucose, fructose, maltose, lactose, galactose, mannose, and xylose. As raw materials, high dextrose corn syrup, high fructose corn syrup, and high maltose corn syrup can be utilized as well as the individual sugars listed above. These corn syrups may yield a mix of sugar components for Z. It should be understood that it is by no means intended to exclude other suitable raw materials. Z preferably will be selected from the group consisting of -CH2-(CH0H)n-CH20H, -CHtCHzOHHCHOHJn-i- CH20H, -CH2-(CH0H)2(CH0R')(CH0H)-CH20H, where n is an integer from 3 to 5, inclusive, and R' is H or a cyclic or aliphatic monosacchar¬ ide, and alkoxylated derivatives thereof. Most preferred are glycityls wherein n is 4, particularly -CH2-(CH0H)4-CH20H.
In Formula (I), Rl can be, for example, N-methyl, N-ethyl , N-propyl, N-isopropyl, N-butyl, N-2-hydroxy ethyl, or N-2-hydroxy propyl .
R2-C0-N< can be, for example, cocamide, stearamide, oleamide, lauramide, myrista ide, capricamide, palmitamide, tallowamide, etc. Z can be 1-deoxyglucityl , 2-deoxyfructityl , 1-deoxymaltityl , 1-deoxylactityl , 1-deoxygalactityl , 1-deoxymannityl , 1-deoxymalto- triotityl, etc.
Methods for making polyhydroxy fatty acid amides are known in the art. In general, they can be made by reacting an alkyl amine with a reducing sugar in a reductive amination reaction to form a corresponding N-alkyl polyhydroxyamine, and then reacting the N-alkyl polyhydroxyamine with a fatty aliphatic ester or triglyceride in a condensation/amidation step to form the N-alkyl, N-polyhydroxy fatty acid amide product. Processes for making compositions containing polyhydroxy fatty acid amides are disclosed, for example, in G.B. Patent Specification 809,060, published February 18, 1959, by Thomas Hedley & Co., Ltd., U.S. Patent 2,965,576, issued December 20, 1960 to E. R. Wilson, and U.S. Patent 2,703,798, Anthony M. Schwartz, issued March 8, 1955, and U.S. Patent 1,985,424, issued December 25, 1934 to Piggott, each of which is incorporated herein by reference.
In one process for producing N-alkyl or N-hydroxyalkyl, N-deoxyglycityl fatty acid amides wherein the glycityl component is derived from glucose and the N-alkyl or N-hydroxyalkyl functionality is N-methyl, N-ethyl , N-propyl, N-butyl, N-hydroxyethyl , or N-hydroxypropyl , the product is made by reacting N-alkyl- or N-hydroxyalkyl-glucamine with a fatty ester selected from fatty methyl esters, fatty ethyl esters, and fatty triglycerides in the presence of a catalyst selected from the group consisting of trilithium phosphate, trisodium phosphate, tripotassium phosphate, tetrasodium pyrophosphate, pentapotassiu tripolyphosphate, lithium hydroxide, sodium hydroxide, potassium hydroxide, calcium hydroxide, lithium carbonate, sodium carbonate, potassium carbonate, disodiu tartrate, dipotassium tartrate, sodium potassium tartrate, trisodium citrate, tripotassium citrate, sodium basic silicates, potassium basic silicates, sodium basic aluminosilicates, and potassium basic aluminosilicates, and mixtures thereof. The amount of catalyst is preferably from about 0.5 mole % to about 50 mole %, more preferably from about 2.0 mole % to about 10 mole %, on an N-alkyl or N-hydroxyalkyl-glucamine molar basis. The reaction is preferably carried out at from about 138βC to about 170βC for typically from about 20 to about 90 minutes. When triglycerides are utilized in the reaction mixture as the fatty ester source, the reaction is also preferably carried out using from about 1 to about 10 weight % of a phase transfer agent, calculated on a weight percent basis of total reaction mixture, selected from saturated fatty alcohol polyethoxyl- ates, alkylpolyglycosides, linear glyca ide surfactant, and mixtures thereof.
Preferably, thi s process i s carried out as fol lows :
(a) preheating the fatty ester to about 138βC to about 170βC; (b) adding the N-alkyl or N-hydroxyalkyl glucamine to the heated fatty acid ester and mixing to the extent needed to form a two-phase liquid/liquid mixture;
(c) mixing the catalyst into the reaction mixture; and (d) stirring for the specified reaction time.
Also preferably, from about 2% to about 20% of preformed linear N-alkyl/N-hydroxyalkyl, N-linear glucosyl fatty acid amide product is added to the reaction mixture, by weight of the reactants, as the phase transfer agent if the fatty ester is a triglyceride. This seeds the reaction, thereby increasing reaction rate. A detailed experimental procedure is provided below in the Experimental.
The polyhydroxy "fatty acid" amide materials used herein also offer the advantages to the detergent formulator that they can be prepared wholly or primarily from natural, renewable, non-petro- chemical feedstocks and are degradable. They also exhibit low toxicity to aquatic life.
It should be recognized that along with the polyhydroxy fatty acid amides of Formula (I), the processes used to produce them will also typically produce quantities of nonvolatile by-product such as esteramides and cyclic polyhydroxy fatty acid amide. The level of these by-products will vary depending upon the particular reactants and process conditions. Preferably, the polyhydroxy fatty acid amide incorporated into the detergent compositions hereof will be provided in a form such that the polyhydroxy fatty acid amide- containing composition added to the detergent contains less than- about 10%, preferably less than about 4%, of cyclic polyhydroxy fatty acid amide. The preferred processes described above are advantageous in that they can yield rather low levels of by-products, including such cyclic amide by-product. Polycarboxylate Builder
The compositions hereof will comprise at least about 1% polycarboxylate builder.
The level of polycarboxylate builder can vary widely depending upon the end use of the composition and its desired physical form. Liquid formulations typically comprise from about 5% to about 50%, more typically about 5% to about 30%, by weight, of detergent builder. Granular formulations typically comprise from about 10% to about 80%, more typically from about 15% to about 50%, by weight, of the detergent builder. Lower or higher levels of builder, however, are not meant to be excluded. Preferably, the weight ratio of polyhydroxy fatty acid amide to polycarboxylate builder is from about 1:10 to about 10:1, more preferably from about 1:5 to about 7:1, most preferably from about 1:1 to about 7:1.
A variety of polycarboxylate compounds can be utilized in the compositions hereof. As used herein, "polycarboxylate" refers to compounds having a plurality of carboxylate groups, preferably at least 3 carboxylates.
Polycarboxylate builder can generally be added to the composi¬ tion in acid form, but can also be added in the form of a neutral¬ ized salt. When utilized in salt form, alkali metals, such as sodium, potassium, and lithium salts, especially sodium salts, or ammonium and substituted ammonium (e.g., al anolammonium) salts are preferred.
Included among the polycarboxylate builders are a variety of categories of useful materials. One important category of polycarboxylate builders encompasses the ether polycarboxylates. A number of ether polycarboxylates have been disclosed for use as detergent builders. Examples of useful ether polycarboxylates include oxydisuccinate, as disclosed in Berg, U.S. Patent 3,128,287, issued April 7, 1964, and La berti et al., U.S. Patent 3,635,830, issued January 18, 1972, both of which are incorporated herein by reference.
A specific type of ether polycarboxylates useful as builders in the present invention also include those having the-general formula:
CH(A)(C0OX)-CH(CO0X)-O-CH(C00X)-CH(C00X)(B) wherein A is H or OH; B is H or -0-CH(C00X)-CH2(C00X) ; and X is H or a salt-forming cation. For example, if in the above general formula A and B are both H, then the compound is oxydissuccinic acid and its water-soluble salts. If A is OH and B is H, then the compound is tartrate monosuccinic acid (TMS) and its water-soluble salts. If A is H and B is -0-CH(C00X)-CH2(C00X), then the compound is tartrate disuccinic acid (TDS) and its water-soluble salts. Mixtures of these builders are especially preferred for use herein. Particu¬ larly preferred are mixtures of TMS and TDS in a weight ratio of TMS to TDS of from about 97:3 to about 20:8Q. These builders are disclosed in U.S. Patent 4,663,071, issued to Bush et al . t on May 5, 1987.
Suitable ether polycarboxylates also include cyclic compounds, particularly alicyclic compounds, such as those described in U.S. Patents 3,923,679; 3,835,163; 4,158,635; 4,120,874 and 4,102,903, all of which are incorporated herein by reference.
Other useful detergency builders include the ether hydroxypoly- carboxylates represented by the structure: H0-[C(R)(C00M)-C(R)(C00M)-0]n-H wherein M is hydrogen or a cation wherein the resultant salt is water-soluble, preferably an alkali metal, ammonium or substituted ammonium cation, n is from about 2 to about 15 (preferably n is from about 2 to about 10, more preferably n averages from about 2 to about 4) and each R is the same or different and selected from hydrogen, C1-4 alkyl or C1-4 substituted alkyl (preferably R is hydrogen) .
Still other ether polycarboxylates include copolymers of maleic anhydride with ethylene or vinyl methyl ether, 1, 3, 5-trihydroxy benzene-2, 4, 6-trisulphonic acid, and carboxymethyloxysuccinic acid.
Organic polycarboxylate builders also include polyacetates such as the various alkali metal, ammonium and substituted ammonium salts of polyacetic acids. Examples of polyacetic acid builder salts are the sodium, potassium, lithium, ammonium and substituted ammonium salts of ethylenediamine tetraacetic acid and nitrilotriacetic acid.
Also included are polycarboxylates such as mellitic acid, succinic acid, poly aleic acid, benzene 1,3,5-tricarboxylic acid, benezene pentacarboxylic acid, and carboxymethyloxysuccinic acid, and soluble salts thereof.
Citric builders, e.g., citric acid and soluble salts thereof, is a polycarboxylate builder of particular importance for heavy duty liquid detergent formulations, but can also be used in granular compositions. Suitable salts include the metal salts such as sodium, lithium, and potassium salts, as well as ammonium and substituted ammonium salts. Other carboxylate builders include the carboxylated carbohy¬ drates disclosed in U.S. Patent 3,723,322, Diehl, issued March 28, 1973, incorporated herein by reference.
Also suitable in the detergent compositions of the present invention are the 3,3-dicarboxy-4-oxa-l,6-hexanedioates and the related compounds disclosed in U.S. Patent 4,566,984, Bush, issued January 28, 1986, incorporated herein by reference. Useful succinic acid builders include the C5-C20 alkyl succinic acids and salts thereof. A particularly preferred compound of this type is dodecenylsuccinic acid. Alkyl succinic acids typically are of the general formula R-CH(C00H)CH2(C00H) i.e., derivatives of succinic acid, wherein R is hydrocarbon, e.g., C10-C20 alkyl or alkenyl, preferably C12-C16 or wherein R may be substituted with hydroxyl, sulfo, sulfoxy or sulfone substituents, all as described in the above-mentioned patents.
The succinate builders are preferably used in the form of their water-soluble salts, including the sodium, potassium, ammonium and alkanolammonium salts.
Specific examples of succinate builders include: laurylsuccin- ate, myristylsuccinate, palmitylsuccinate, 2-dodecenylsuccinate (preferred), 2-pentadecenylsuccinate, and the like. Laurylsuccin- ates are the preferred builders of this group, and are described in European Patent Application 86200690.5/0,200,263, published November 5, 1986. Examples of useful builders also include sodium and potassium carboxymethyloxymalonate, carboxymethyloxysuccinate, cis-cyclohex- ane-hexacarboxylate, cis-cyclopentane-tetracarboxylate, water- soluble polyacrylates (these polyacrylates having molecular weights to above about 2,000 can also be effectively utilized as dispers- ants), and the copolymers of aleic anhydride with vinyl methyl ether or ethylene.
Other suitable polycarboxylates are the polyacetal carboxylates disclosed in U.S. Patent 4,144,226, Crutchfield et al., issued March 13, 1979, incorporated herein by reference. These polyacetal carboxylates can be prepared by bringing together, under polymeriza¬ tion conditions, an ester of glyoxylic acid and a polymerization initiator. The resulting polyacetal carboxylate ester is then attached to chemically stable end groups to stabilize the polyacetal carboxylate against rapid depolymerization in alkaline solution, converted to the corresponding salt, and added to a surfactant.
Polycarboxylate builders are also disclosed in U.S. Patent 3,308,067, Diehl, issued March 7, 1967, incorporated herein by reference. Such materials include the water-soluble salts of homo- and copolymers of aliphatic carboxylic acids such as maleic acid, itaconic acid, mesaconic acid, fumaric acid, aconitic acid, citraconic acid and methylenemalonic acid. Other Builders
The compositions hereof can additionally contain auxiliary builders in addition to the polycarboxylate builders, including both organic and inorganic builders. Typical amounts of auxiliary builders are from about 5% to about 200% of the weight of the polycarboxylate builder.
Inorganic detergent builders include, but are not limited to, the alkali metal, ammonium and alkanolammonium salts of silicates, carbonates (including bicarbonates and sesquicarbonates), sulphates, and aluminosilicates. Borate builders, as well as builders containing borate-forming materials that can produce borate under detergent storage or wash conditions (hereinafter, collectively "borate builders"), can also be used. Preferably non-borate builders are used in the compositions of the invention intended for use at wash temperatures less than about 50*C, especially less than about 40βC.
Examples of silicate builders are the alkali metal silicates, particularly those having a Siθ :Na2θ ratio in the range 1.6:1 to 3.2:1 and layered silicates, such as the layered sodium silicates described in U.S. Patent 4,664,839, issued May 12, 1987 to H. P. Rieck, incorporated herein by reference. However, other silicates may also be useful such as for example magnesium silicate, which can serve as a crispening agent in granular formulations, as a stabilizing agent for oxygen bleaches, and as a component of suds control systems. Examples of carbonate builders are the alkaline earth and alkali metal carbonates, including sodium carbonate and sesquicarbonate and mixtures thereof with ultra-fine calcium carbonate as disclosed in German Patent Application No. 2,321,001 published on November 15, 1973, the disclosure of which is incorporated herein by reference.
Aluminosilicate builders are especially useful for use in concentrates with polycarboxylate builders in the present invention. Aluminosilicate builders are of great importance in most currently marketed heavy duty granular detergent compositions, and can also be a significant builder ingredient in liquid detergent formulations. Aluminosilicate builders include those having the empirical formula: Mz(zAlθ2-ySiθ2) wherein M is sodium, potassium, ammonium or substituted ammonium, z is from about 0.5 to about 2; and y is 1; this material having a magnesium ion exchange capacity of at least about 50 milligram equivalents of CaCθ3 hardness per gram of anhydrous aluminosilicate. Preferred aluminosilicates have the formula:
Naz[(A102)z (Si02)y]-xH20 wherein z and y are integers of at least 6, the molar ratio of z to y is in the range from 1.0 to about 0.5, and x is an integer from about 15 to about 264. Useful aluminosilicate ion exchange materials are commercially available. These aluminosilicates can be crystalline or amorphous in structure and can be naturally-occurring aluminosilicates or synthetically derived. A method for producing aluminosilicate ion exchange materials is disclosed in U.S. Patent 3,985,669, Krummel , et al., issued October 12, 1976, incorporated herein by reference. Preferred synthetic crystalline aluminosilicate ion exchange materials useful herein are known as zeolite and are available under the designations Zeolite A, Zeolite P (B), and Zeolite X. In an especially preferred embodiment, the crystalline aluminosilicate ion exchange material has the formula:
Nai2[(A102)i2(S102)i2]-xH20 wherein x is from about 20 to about 30, especially about 27. This zeolite is known as Zeolite A. Preferably, the aluminosilicate has a particle size in the 0.1-10 micron range. Phosphate and phosphonate builders can be added, although it is generally desired to replace these builders with polycarboxylate or other builders. Thus, if present they preferably are included only at low levels. Preferably, the phosphate builder comprises less than about 10%, by weight, more preferably less than about 5%, most preferably essentially zero percent, of total builder in the composition. Specific examples of polyphosphates are the alkali metal tripolyphosphates, sodium, potassium and ammonium pyrophos¬ phate, sodium and potassium and ammonium pyrophosphate, sodium and potassium orthophosphate, sodium polymeta phosphate in which the degree of polymerization ranges from about 6 to about 21, and salts of phytic acid. Examples of phosphonate builder salts are the water-soluble salts of ethane 1-hydroxy-l, 1-diphosphonate particularly the sodium and potassium salts, the water-soluble salts of methylene diphosphonic acid e.g. the trisodium and tripotassium salts and the water-soluble salts of substituted methylene diphosphonic acids, such as the trisodium and tripotassium ethylidene, isopyropylidene benzylmethylidene and halo methylidene phosphonates. Phosphonate builder salts of the aforementioned types are disclosed in U.S. Patent Nos. 3,159,581 and 3,213,030 issued December 1, 1964 and October 19, 1965, to Diehl; U.S. Patent No. 3,422,021 issued January 14, 1969, to Roy; and U.S. Patent Nos. 3,400,148 and 3,422,137 issued September 3, 1968, and January 14, 1969 to Quimby, said disclosures being incorporated herein by reference.
A preferred builder system for granular compositions comprises a mixture of from about 5% to about 50% of zeolite (preferably Zeolite A) and from about 5% to about 50% citrate (preferably sodium citrate), said percentages being based upon the total builder in the mixture, calculated on a weight basis.
Other organic builders known in the art can also be used. For example, onocarboxylic acids, and soluble salts thereof, having long chain hydrocarbyls can be utilized. These would include materials generally referred to as "soaps." Chain lengths of C10-C20 are typically utilized. The hydrocarbyls can be saturated or unsaturated. 16 61 a 1 ve ou r i a Lc oVs efll In addition to the polyhydroxy fatty acid amide and polycarboxylate builder, the compositions hereof contain one or more additional surfactants which can be anionic, cationic or nonionic. Typically the surfactant system will include one or more anionic and/or nonionic surfactants in addition to the polyhydroxy fatty acid amide. The amount of additional detersive surfactant present is typically at least about 1%, by weight, preferably from about 3% to about 40%, by weight, of the detergent composition, more preferably from about 5% to about 30%. The use of anionic surfactants, such as anionic sulfate or sulfonate surfactants, or mixtures thereof, is particularly contemplated. Suitable surfactants are described below. Alkyl Ester Sulfonate Surfactant
Alkyl ester sulfonate surfactants hereof include linear esters of C8-C20 carboxylic acids (i.e., fatty acids) which are sulfonated witn gaseous SO3 according to "The Journal of the American Oil Chemists Society," 52 (1975), pp. 323-329. Suitable starting materials would include natural fatty substances as derived from tallow, palm, and coconut oils, etc.
The preferred alkyl ester sulfonate surfactant, especially for laundry applications, comprise alkyl ester sulfonate surfactants of the structural formula: 0
R3 - CH - C - 0R4 SO3M wherein R3 is a C8-C20 hydrocarbyl, preferably an alkyl, or combination thereof, R4 is a Ci-Cδ hydrocarbyl, preferably an alkyl, or combination thereof, and M is a cation which forms a water soluble salt with the alkyl ester sulfonate. Suitable salt-forming cations include metals such as sodium, potassium, and lithium, and substituted or unsubstituted ammonium cations, such as methyl-, dimethyl, -trimethyl, and quaternary ammonium cations, e.g. tetramethyl -ammonium and dimethyl piperdinium, and cations derived from alkanolamines, e.g. monoethanolamine, diethanolamine, and triethanolamine. Preferably, R3 is C10-C16 alkyl, and R4 is methyl, ethyl or isopropyl. Especially preferred are the methyl ester sulfonates wherein R^ is C14-C16 alkyl. Alkyl Sulfate Surfactant
Alkyl sulfate surfactants hereof are water soluble salts or acids of the formula ROSO3M wherein R preferably is a C10-C24 hydrocarbyl, preferably an alkyl or hydroxyalkyl having a C10-C20 alkyl component, more preferably a C12-C18 alkyl or hydroxyalkyl , and M is H or a cation, e.g., an alkali metal cation (e.g., sodium, potassium, lithium), substituted or unsubstituted ammonium cations such as methyl-, dimethyl-, and tri ethyl ammonium, and quaternary ammonium cations, e.g., tetramethyl-ammonium and dimethyl piperdin¬ ium cations, and cations derived from alkanolamines such as ethanol- amine, diethanolamine, triethanolamine, and mixtures thereof, and the like. Typically, alkyl chains of C12-C16 are preferred for lower wash temperatures (e.g., below about 50βC) and C16-I8 alkyl chains are preferred for higher wash temperatures (e.g., above about 50βC). Alkyl Alkoxylated Sulfate Surfactant
Alkyl alkoxylated sulfate surfactants hereof are water soluble salts or acids of the formula R0(A)mS03M wherein R is an unsubsti¬ tuted C10-C24 alkyl or hydroxyalkyl group having a C10-C24 alkyl component, preferably a C12-C20 alkyl or hydroxyalkyl, more prefer¬ ably C12-C18 alkyl or hydroxyalkyl , A is an ethoxy or propoxy unit, m is greater than zero, typically between about 0.5 and about 6, more preferably between about 0.5 and about 3, and M is H or a cation which can be, for example, a metal cation (e.g., sodium, potassium, lithium, calcium, magnesium, etc.), ammonium or substituted-ammonium cation. Alkyl ethoxylated sulfates as well as alkyl propoxylated sulfates are contemplated herein. Specific examples of substituted ammonium cations include methyl-, dimethyl-,- trimethyl-ammonium and quaternary ammonium cations, such as tetramethyl-ammonium, dimethyl piperdinium, and cations derived from alkanolamines, e.g. monoethanolamine, diethanolamine, and trietha- nolamine, and mixtures thereof. Exemplary surfactants are C12-C18 alkyl polyethoxylate (1.0) sulfate, C12-C18 alkyl polyethoxylate (2.25) sulfate, C12-C18 alkyl polyethoxylate (3.0) sulfate, and C12-C18 alkyl polyethoxylate (4.0) sulfate wherein M is conveniently selected from sodium and potassium. Other Anionic Surfactants Other anionic surfactants useful for detersive purposes can also be included in the compositions hereof. These can include salts (including, for example, sodium, potassium, ammonium, and substituted ammonium salts such as mono-, di- and triethanolamine salts) of soap, C9-C20 linear alkylbenzenesulphonates, C8-C22 primary or secondary alkanesulphonates, C8-C24 olefinsulphonates, sulphonated polycarboxylic acids prepared by sulphonation of the pyrolyzed product of alkaline earth metal citrates, e.g., as described in British patent specification No. 1,082,179, alkyl glycerol sulfonates, fatty acyl glycerol sulfonates, fatty oleyl glycerol sulfates, alkyl phenol ethylene oxide ether sulfates, paraffin sulfonates, alkyl phosphates, isethionates such as the acyl isethionates, N-acyl taurates, fatty acid amides of methyl tauride, alkyl succinamates and sulfosuccinates, onoesters of sulfosuccinate (especially saturated and unsaturated C12-C18 monoesters), diesters of sulfosuccinate (especially saturated and unsaturated Cg-Ci4 diesters), N-acyl sarcosinates, sulfates of alkylpolysaccharides such as the sulfates of alkylpolyglucoside (the nonionic nonsulfated compounds being described below), branched primary alkyl sulfates, alkyl polyethoxy carboxylates such as those of the formula RO(CH2CH2θ)kCH2COO-M+ wherein R is a C8-C22 alkyl, k is an integer from 0 to 10, and M is a soluble salt-forming cation, and fatty acids esterified with isethionic acid and neutralized with sodium hydroxide. Resin acids and hydrogenated resin acids are also suitable, such as rosin, hydrogenated rosin, and resin acids and hydrogenated resin acids present in or derived from tall oil. Further examples are described in "Surface Active Agents and Detergents" (Vol. I and II by Schwartz, Perry and Berch). A variety of such surfactants are also generally disclosed in U.S. Patent 3,929,678, issued December 30, 1975 to Laughlin, et al . at Column 23, line 58 through Column 29, line 23 (herein incorporated by reference) . Nonionic Detergent Surfactants
Suitable nonionic detergent surfactants are generally disclosed in U.S. Patent 3,929,678, Laughlin et al., issued December 30, 1975, at column 13, line 14 through column 16, line 6, incorporated herein by reference. Exemplary, non-limiting classes of useful nonioni surfactants are listed below.
1. The polyethylene, polypropylene, and polybutylene oxide condensates of alkyl phenols. In general, the polyethylene oxide condensates are preferred. These compounds include the condensation products of alkyl phenols having an alkyl group containing from about 6 to about 12 carbon atoms in either a straight chain or branched chain configuration with the alkylene oxide. In a preferred embodiment, the ethylene oxide is present in an amount equal to from about 5 to about 25 moles of ethylene oxide per mole of alkyl phenol. Commercially available nonionic surfactants of this type include Igepal™ C0-630, marketed by the GAF Corporation; and TritonTM χ-45, X-114, X-100, and X-102, all marketed by the Rohm & Haas Company. These surfactants are commonly referred to as alkyl phenol alkoxylates, e.g., alkyl phenol ethoxy!ates.
2. The condensation products of aliphatic alcohols with from about 1 to about 25 moles of ethylene oxide. The alkyl chain of the aliphatic alcohol can either be straight or branched, primary or secondary, and generally contains from about 8 to about 22 carbon atoms. Particularly preferred are the condensation products of alcohols having an alkyl group containing from about 10 to about 20 carbon atoms with from about 2 to about 18 moles of ethylene oxide per mole of alcohol. Examples of commercially available nonionic surfactants of this type include TergitolTM 15-S-9 (the condensation product of C11-C15 linear secondary alcohol with 9 moles ethylene oxide), TergitolTM 24-L-6 NMW (the condensation product of C12-C 4 primary alcohol with 6 moles ethylene oxide with a narrow molecular weight distribution), both marketed by Union Carbide Corporation; Neodol 45.9 ( he condensation product of C14-C15 linear alcohol with 9 moles of ethylene oxide), NeodolTM 23-6.5 (the condensation product of C12-C13 linear alcohol with 6.5 moles of ethylene oxide), NeodolTM 45.7 ( he condensation product of C14-C15 linear alcohol with 7 moles of ethylene oxide), NeodolTM 45-4 (the condensation product of C14-C15 linear alcohol with 4 moles of ethylene oxide), marketed by Shell Chemical Company, and KyroTM EOB (the condensation product of C13-C15 alcohol with 9 moles ethylene oxide), marketed by The Procter & Gamble Company. These surfactants are often referred to as alkyl ethoxylates. 3. The condensation products of ethylene oxide with a hydrophobic base formed by the condensation of propylene oxide with propylene glycol. The hydrophobic portion of these compounds preferably has a molecular weight of from about 1500 to about 1800 and exhibits water insolubility. The addition of polyoxyethylene moieties to this hydrophobic portion tends to increase the water solubility of the molecule as a whole, and the liquid character of the product is retained up to the point where the polyoxyethylene content is about 50% of the total weight of the condensation product, which corresponds to condensation with up to about 40 moles of ethylene oxide. Examples of compounds of this type include certain of the commercially-available Pluronic™ surfactants, marketed by BASF.
4. The condensation products of ethylene oxide with the product resulting from the reaction of propylene oxide and ethylenediamine. The hydrophobic moiety of these products consists of the reaction product of ethylenediamine and excess propylene oxide, and generally has a molecular weight of from about 2500 to about 3000. This hydrophobic moiety is condensed with ethylene oxide to the extent that the condensation product contains from about 40% to about 80% by weight of polyoxyethylene and has a molecular weight of from about 5,000 to about 11,000. Examples of this type of nonionic surfactant include certain of the commercially available TetronicTM compounds, marketed by BASF.
5. Semi-polar nonionic surfactants are a special category of nonionic surfactants which include water-soluble amine oxides containing one alkyl moiety of from about 10 to about 18 carbon atoms and 2 moieties selected from the group consisting of alkyl groups and hydroxyalkyl groups containing from about 1 to about 3 carbon atoms; water-soluble phosphine oxides containing one alkyl moiety of from about 10 to about 18 carbon atoms and 2 moieties selected from the group consisting of alkyl groups and hydroxyalkyl groups containing from about 1 to about 3 carbon atoms; and water-soluble sulfoxides containing one alkyl moiety of from about 10 to about 18 carbon atoms and a moiety selected from the group consisting of alkyl and hydroxyalkyl moieties of from about 1 to about 3 carbon atoms. Semi-polar nonionic detergent surfactants include the amine oxide surfactants having the formula 0 R3(0R4)XN(R5)2 wherein R3 is an alkyl, hydroxyalkyl, or alkyl phenyl group or mixtures thereof containing from about 8 to about 22 carbon atoms; R4 is an alkylene or hydroxyalkylene group containing from about 2 to about 3 carbon atoms or mixtures thereof; x is from 0 to about 3; and each R5 is an alkyl or hydroxyalkyl group containing from about 1 to about 3 carbon atoms or a polyethylene oxide group containing from about 1 to about 3 ethylene oxide groups. The R5 groups can be attached to each other, e.g., through an oxygen or nitrogen atom, to form a ring structure.
These amine oxide surfactants in particular include Cio-Cis alkyl dimethyl amine oxides and C8-C12 alkoxy ethyl dihydroxy ethyl amine oxides. 6. Alkylpolysaccharides disclosed in U.S. Patent 4,565,647, Llenado, issued January 21, 1986, having a hydrophobic group con¬ taining from about 6 to about 30 carbon atoms, preferably from about 10 to about 16 carbon atoms and a polysaccharide, e.g., a polyglyco- side, hydrophilic group containing from about 1.3 to about 10, preferably from about 1.3 to about 3, most preferably from about 1.3 to about 2.7 saccharide units. Any reducing saccharide containing 5 or 6 carbon atoms can be used, e.g., glucose, galactose and galacto- syl moieties can be substituted for the glucosyl moieties. (Option¬ ally the hydrophobic group is attached at the 2-, 3-, 4-, etc. positions thus giving a glucose or galactose as opposed to a gluco-- side or galactoside.) The intersaccharide bonds can be, e.g., between the one position of the additional saccharide units and the 2-, 3-, 4-, and/or 6- positions on the preceding saccharide units. Optionally, and less desirably, there can be a polyalkylene- oxide chain joining the hydrophobic moiety and the polysaccharide moiety. The preferred alkyleneoxide is ethylene oxide. Typical hydrophobic groups include alkyl groups, either saturated or unsaturated, branched or unbranched containing from about 8 to about 18, preferably from about 10 to about 16, carbon atoms. Preferably, the alkyl group is a straight chain saturated alkyl group. The alkyl group can contain up to about 3 hydroxy groups and/or the polyalkyleneoxide chain can contain up to about 10, preferably less than 5, alkyleneoxide moieties. Suitable alkyl polysaccharides are octyl, nonyldecyl, undecyldodecyl , tridecyl, tetradecyl , pentadecyl , hexadecyl, heptadecyl , and octadecyl , di-, tri-, tetra-, penta-, and hexaglucosides, galactosides, lactosides, glucoses, fructosides, fructoses and/or galactoses. Suitable mixtures include coconut alkyl, di-, tri-, tetra-, and pentaglucosides and tallow alkyl tetra-, penta-, and hexaglucosides.
The preferred alkylpolyglycosides have the formula
R20(CnH2nO)t(glycosyl)x wherein R2 is selected from the group consisting of alkyl, al yl- phenyl, hydroxyalkyl , hydroxyal ylphenyl , and mixtures thereof in which the alkyl groups contain from about 10 to about 18, preferably from about 12 to about 14, carbon atoms; n is 2 or 3, preferably 2; t is from 0 to about 10, preferably 0; and x is from about 1.3 to about 10, preferably from about 1.3 to about 3, most preferably from about 1.3 to about 2.7. The glycosyl is preferably derived from glucose. To prepare these compounds, the alcohol or alkylpol ethoxy alcohol is formed first and then reacted with glucose, or a source of glucose, to form the glucoside (attachment at the 1-position). The additional glycosyl units can then be attached between their 1-position and the preceding glycosyl units 2-, 3-, 4- and/or 6-position, preferably predominately the 2-position.
7. Fatty acid amide surfactants having the formula:
wherein R6 is an alkyl group containing from about 7 to about 21 (preferably from about 9 to about 17) carbon atoms and each R? is selected from the group consisting of hydrogen, C1-C4 alkyl, C1-C4 hydroxyalkyl , and -(C2H4θ)xH where x varies from about 1 to about 3. Preferred amides are C8-C20 ammonia amides, onoethanolamides, diethanolamides, and isopropanolamides.
In general, preferred nonionics for use in addition to the polyhydroxy fatty acid amides, include alkyl ethoxylates, alkyl polyglycosides, and alkyl phenol ethoxylates. These can be included in addition to any anionic surfactant present in the composition. Cationic Surfactants
Cationic detersive surfactants can also be included in deter¬ gent compositions of the present invention. Cationic surfactants include the ammonium surfactants such as alkyldimethylammonium halogenides, and those surfactants having the formula:
[R (0R )y][R4(0R )y]2R5N+X- wherein R2 is an alkyl or alkyl benzyl group having from about 8 to about 18 carbon atoms in the alkyl chain, each R3 is selected from the group consisting of -CH2CH2-, -CH2CH(CH3)-, -CH2CH(CH20H)-, -CH2CH2CH2-, and mixtures thereof; each R4 is selected from the group consisting of C1-C4 alkyl, C1-C4 hydroxyalkyl , benzyl, ring structures formed by joining the two R4 groups, -CH2CHOH-CHOHCOR6- CHOHCH2OH wherein Rδ is any hexose or hexose polymer having a molecular weight less than about 1000, and hydrogen when y is not 0; R5 is the same as R4 or is an alkyl chain wherein the total number of carbon atoms of R2 plus ~ is not more than about 18; each y is from 0 to about 10 and the sum of the y values is from 0 to about 15; and X is any compatible anion.
Other cationic surfactants useful herein are also described in U.S. Patent 4,228,044, Cambre, issued October 14, 1980, incorporated herein by reference. Other Surfactants
Ampholytic surfactants can be incorporated into the detergent compositions hereof. These surfactants can be broadly described as aliphatic derivatives of secondary or tertiary amines, or aliphatic derivatives of heterocyclic secondary and tertiary amines in which the aliphatic radical can be straight chain or branched. One of the aliphatic substituents contains at least about 8 carbon atoms, typically from about 8 to about 18 carbon atoms, and at least one contains an anionic water-solubilizing group, e.g., carboxy, sulfonate, sulfate. See U.S. Patent No. 3,929,678 to Laughlin et al . , issued December 30, 1975 at column 19, lines 18-35 (herein incorporated by reference) for examples of ampholytic surfactants.
Zwitterionic surfactants can also be incorporated into the detergent compositions hereof. These surfactants can be broadly described as derivatives of secondary and tertiary amines, derivatives of heterocyclic secondary and tertiary amines, or derivatives of quaternary ammonium, quaternary phosphonium or tertiary sulfoniu compounds. See U.S. Patent No. 3,929,678 to Laughlin et al., issued December 30, 1975 at column 19, line 38 through column 22, line 48 (herein incorporated by reference) for examples of zwitterionic surfactants. Ampholytic and zwitterionic surfactants are generally used in combination with one or more anionic and/or nonionic surfactants. Enzymes
Detersive enzymes can be included in the detergent formulations for a variety of purposes including removal of protein-based, carbohydrate-based, or triglyceride-based stains, for example, and prevention of refugee dye transfer. The enzymes to be incorporated include proteases, amylases, lipases, cellulases, and peroxidases, as well as mixtures thereof. Other enzymes may additionally be included. They may be of any suitable origin, such as vegetable, animal, bacterial, fungal and yeast origin. However, their choice is governed by several factors such as pH-activity and/or stability optima, thermostability, stability versus active detergents, builders and so on. In this respect bacterial or fungal enzymes are preferred, such as bacterial amylases and proteases, and fungal cellulases.
Suitable examples of proteases are the subtilisins which are obtained from particular strains of B.subtilis and B.licheniforms. Another suitable protease is obtained from a strain of Bacillus, having maximum activity throughout the pH range of 8-12, developed and sold by Novo Industries A/S under the registered trade name Esperase®. The preparation of this enzyme and analogous enzymes is described in British patent specification No. 1,243,784 of Novo. Proteolytic enzymes suitable for removing protein-based stains that are commercially available include those sold under the tradenames ALCALASE™ and SAVINASE™ by Novo Industries A/S (Denmark) and MAXATASETM y International Bio-Synthetics, Inc. (The Netherlands).
Of interest in the category of proteolytic enzymes, especially for liquid detergent compositions, are enzymes referred to herein as Protease A and Protease B. Protease A and methods for its preparation are described in European Patent Application 130,756, published January 9, 1985, incorporated herein by reference. Protease B is a proteolytic enzyme which differs from Protease A in that it has a leucine substituted for tyrosine in position 217 in its amino acid sequence. Protease B is described in European Patent Application Serial No. 87303761.8, filed April 28, 1987, incorpor¬ ated herein by reference. Methods for preparation of Protease B are also disclosed in European Patent Application 130,756, Bott et al., published January 9, 1985, incorporated herein by reference.
Amylases include, for example, α-amylases obtained from a special strain of B.licheniforms, described in more detail in British patent specification No. 1,296,839 (Novo), previously incorporated herein by reference. Amylolytic proteins include, for example, RAPIDASE™, International Bio-Synthetics, Inc. and TERMAMYL™, NOVO Industries.
The cellulases usable in the present invention include both bacterial or fungal cellulase. Preferably, they will have a pH optimum of between 5 and 9.5. Suitable cellulases are disclosed in U.S. Patent 4,435,307, Barbesgoard et al . , issued March 6, 1984, incorporated herein by reference, which discloses fungal cellulase produced from Humicola insolens. Suitable cellulases are also disclosed in GB-A-2.075.028; GB-A-2.095.275 and DE-0S-2.247.832. Examples of such cellulases are cellulases produced by a strain of Humicola insolens (Humicola grisea var. thermoidea), particularly the Humicola strain DSM 1800, and cellulases produced by a fungus of Bacillus N or a cellulase 212-producing fungus belonging to the genus Aeromonas, and cellulase extracted from the hepatopancreas of a marine mollusc (Dolabella Auricula Solander). -
Suitable lipase enzymes for detergent usage include those produced by microorganisms of the Pseudomonas group, such as
Pseudomonas stutzeri ATCC 19.154, as disclosed in British Patent No.
1,372,034, incorporated herein by reference. Suitable upases include those which show a positive immunoligical cross-reaction with the antibody of the lipase, produced by the microorganism Pseudomonas fluorescens IAM 1057. This lipase and a method for its purification have been described in Japanese Patent Application No. 53-20487, laid open to public inspection on February 24, 1978. This lipase is available from Amano Pharmaceutical Co. Ltd., Nagoya, Japan, under the trade name Lipase P "Amano," hereinafter referred to as "Amano-P." Such Upases of the present invention should show a positive immunological cross reaction with the Amano-P antibody, using the standard and well-known immunodiffusion procedure accord¬ ing to Ouchterlony (Acta. Med. Scan., 133, pages 76-79 (1950)). These upases, and a method for their immunological cross-reaction with Amano-P, are also described in U.S. Patent 4,707,291, Thom et al., issued November 17, 1987, incorporated herein by reference. Typical examples thereof are the Amano-P lipase, the lipase ex Pseudomonas fragi FERM P 1339 (available under the trade name Amano-B), lipase ex Psuedomonas nitroreducens var. l ipolyticum FERM P 1338 (available under the trade name A ano-CES), upases ex Chromobacter viscosum, e.g. Chromobacter viscosum var. l ipolyticum NRRLB 3673, commercially available from Toyo Jozo Co., Tagata, Japan; and further Chromobacter viscosum upases from U.S. Biochemical Corp., U.S.A. and Disoynth Co., The Netherlands, and upases ex Pseudomonas gladiol i .
Peroxidase enzymes are used in combination with oxygen sources, e.g., percarbonate, perborate, persulfate, hydrogen peroxide, etc. They are used for "solution bleaching," i.e. to prevent transfer of dyes or pigments removed from substrates during wash operations to other substrates in the wash solution. Peroxidase enzymes are known in the art, and include, for example, horseradish peroxidase, ligninase, and haloperoxidases such as chloro- and bromo-peroxidase. Peroxidase-containing detergent compositions are disclosed, for example, in PCT International Application WO 89/099813, published October 19, 1989, by 0. Kirk, assigned to Novo Industries A/S, incorporated herein by reference.
A wide range of enzyme materials and means for-their incorpora¬ tion into synthetic detergent granules is also disclosed in U.S. Patent 3,553,139, issued January 5, 1971 to McCarty et al . (incorp- orated herein by reference). Enzymes are further disclosed in U.S. Patent No. 4,101,457, Place et al., issued July 18, 1978, and in U.S. Patent 4,507,219, Hughes, issued March 26, 1985, both incorpor¬ ated herein by reference. Enzyme materials useful for liquid detergent formulations, and their incorporation into such formula- tions, are disclosed in U.S. Patent 4,261,868, Hora et al . , issued April 14, 1981, also incorporated herein by reference. Enzymes are normally incorporated at levels sufficient to provide up to about 5 mg by weight, more typically about 0.05 mg to about 3 mg, of active enzyme per gram of the composition.
For granular detergents, the enzymes are preferably coated or prilled with additives inert toward the enzymes to minimize dust formation and improve storage stability. Techniques for accomplish¬ ing this are well known in the art. In liquid formulations, an enzyme stabilization system is preferably utilized. Enzyme stabilization techniques for aqueous detergent compositions are well known in the art. For example, one technique for enzyme stabilization in aqueous solutions involves the use of free calcium ions from sources such as calcium acetate, calcium formate, and calcium propionate. Calcium ions can be used in combination with short chain carboxylic acid salts, perferably formates. See, for example, U.S. Patent 4,318,818, Letton, et al., issued March 9, 1982, incorporated herein by reference. It has also been proposed to use polyols like glycerol and sorbitol. Alkoxy-alcohols, dial- kylglycoethers, mixtures of polyvalent alcohols with polyfunctional aliphatic amines (e.g. alkanolamines such as diethanolamine, tri- ethanolamine, di-isopropanolamine, etc.), and boric acid or alkali metal borate. Enzyme stabilization techniques are additionally disclosed and exemplified in U.S. Patent 4,261,868, issued April 14, 1981 to Horn, et al., U. S. Patent 3,600,319, issued August 17, 1971 to Gedge, et al., both incorporated herein by reference, and European Patent Application Publication No. 0 199 405, Application No. 86200586.5, published October 29, 1986, Venegas. Non-boric acid and borate stabilizers are preferred. Enzyme stabilization systems are also described, for example, in U.S. Patents 4,261,868, 3,600,319, and 3,519,570. Bleaching Compounds - Bleaching Agents and Bleach Activators
The detergent compositions hereof may contain bleaching agents or bleaching compositions containing bleaching agent and one or more bleach activators. When present bleaching compounds will typically be present at levels of from about 1% to about 20%, more typically from about 1% to about 10%, of the detergent composition. In general, bleaching compounds are optional components in non-liquid formulations, e.g., granular detergents. If present, the amount of bleach activators will typically be from about 0.1% to about 60%, more typically from about 0.5% to about 40% of the bleaching composition.
The bleaching agents used herein can be any of the bleaching agents useful for detergent compositions in textile cleaning, hard surface cleaning, or other cleaning purposes that are now known or become known. These include oxygen bleaches as well as other bleaching agents. For wash conditions below about 50'C, especially below about 40'C, it is preferred that the compositions hereof not contain borate or material which can form borate in situ (i.e. borate-forming material) under detergent storage or wash conditions. Thus it is preferred under these conditions that a non-borate, non-borate-forming bleaching agent is used. Preferably, detergents to be used at these temperatures are substantially free of borate and borate-forming material of any type. As used herein, "substantially free of borate and borate-forming material" shall mean that the composition contains not more than about 2% by weight of borate-containing and borate-forming material, preferably, no more than 1%, more preferably 0%. One category of bleaching agent that can be used encompasses percarboxylic acid bleaching agents and salts thereof. Suitable examples of this class of agents include magnesium monoperoxyphthal- ate hexahydrate, the magnesium salt of meta-chloro perbenzoic acid, 4-nonylamino-4-oxoperoxybutyric acid and diperoxydodecanedioic acid. Such bleaching agents are disclosed in U.S. Patent 4,483,781, Hartman, issued November 20, 1984, U.S. Patent Application 740,446, Burns et al., filed June 3, 1985, European Patent Application 0,133,354, Banks et al . , published February 20, 1985, and U.S. Patent 4,412,934, Chung et al ., issued November 1, 1983, all of which are incorporated by reference herein. Highly preferred bleach¬ ing agents also include 6-nonylamino-6-oxoperoxycaproic acid as described in U.S. Patent 4,634,551, issued January 6, 1987 to Burns, et al., incorporated herein by reference.
Another category of bleaching agents that can be used encom- passes the halogen bleaching agents. Examples of hypohalite bleach¬ ing agents, for example, include trichloro isocyanuric acid and the sodium and potassium dichloroisocyanurates and N-chloro and N-bromo alkane sulphonamides. Such materials are normally added at 0.5-10% by weight of the finished product, preferably 1-5% by weight.
Peroxygen bleaching agents, other than per boron compounds, can also be used. Suitable peroxygen bleaching compounds include sodium carbonate peroxyhydrate, sodium pyrophosphate peroxyhydrate, urea peroxyhydrate, and sodium peroxide.
Peroxygen bleaching agents are preferably combined with bleach activators, which lead to the in situ production in aqueous solution (i.e., during the washing process) of the peroxy acid corresponding to the bleach activator.
Preferred bleach activators incorporated into compositions of the present invention have the general formula:
0
II
R - C - L wherein R is an alkyl group containing from about 1 to about 18 carbon atoms wherein the longest linear alkyl chain extending from and including the carbonyl carbon contains from about 6 to about 10 carbon atoms and L is a leaving group, the conjugate acid of which has a pKa in the range of from about 4 to about 13. These bleach activators are described in U.S. Patent 4,915,854, issued April 10, 1990 to Mao, et al., incorporated herein by reference, and U.S. Patent 4,412,934, which was previously incorporated herein by reference.
Bleaching agents other than oxygen bleaching agents are also known in the art and can be utilized herein. One type of non-oxygen— bleaching agent of particular interest includes photoactivated bleaching agents such as sulfonated zinc and aluminum phthalocyanines. These materials can be deposited upon the substrate during the washing process. Upon irradiation with light, in the presence of oxygen, such as by hanging clothes out to dry in the daylight, the sulfonated zinc phthalocyanine is activated and, consequently, the substrate is bleached. Preferred zinc phthalocyanine and a photoactivated bleaching process are described in U.S. Patent 4,033,718, issued July 5, 1977 to Holcombe et al., incorporated herein by reference. Typically, detergent compositions will contain about 0.025% to about 1.25%, by weight, of sulfonated zinc phthalocyanine. Polymeric Soil Release Agent
Any polymeric soil release agents known to those skilled in the art can be employed in the practice of this invention. Polymeric soil release agents are characterized by having both hydrophilic segments, to hydrophilize the surface of hydrophobic fibers, such as polyester and nylon, and hydrophobic segments, to deposit upon hydrophobic fibers and remain adhered thereto through completion of washing and rinsing cycles and, thus, serve as an anchor for the hydrophilic segments. This can enable stains occurring subsequent to treatment with the soil release agent to be more easily cleaned in later washing procedures.
Whereas it can be beneficial to utilize polymeric soil release agents in any of the detergent compositions hereof, especially those compositions utilized for laundry or other applications wherein removal of grease and oil from hydrophobic surfaces is needed, the presence of polyhydroxy fatty acid amide in detergent compositions also containing anionic surfactants can enhance performance of many of the more commonly utilized types of polymeric soil release agents. Anionic surfactants interfere with the ability of certain soil release agents to deposit upon and adhere to hydrophobic surfaces. These polymeric soil release agents have nonionic hydrophile segments or hydrophobe segments which are anionic surfactant-interactive.
The compositions hereof for which improved polymeric soil release agent performance can be obtained through the use of polyhydroxy fatty acid amide are those which contain an anionic surfactant system, an anionic surfactant-interactive soil release agent and a soil release agent-enhancing amount of the polyhydroxy fatty acid amide (PFA), wherein: (I) anionic surfactant- interaction between the soil release agent and the anionic surfactant system of the detergent composition can be shown by a comparison of the level of soil release agent (SRA) deposition on hydrophobic fibers (e.g., polyester) in aqueous solution between (A) a "Control" run wherein deposition of the SRA of the detergent composition in aqueous solution, in the absence of the other detergent ingredients, is measured, and (B) an "SRA/Anionic surfact¬ ant" test run wherein the same type and amount of the anionic surfactant system utilized in detergent composition is combined in aqueous solution with the SRA, at the same weight ratio of SRA to the anionic surfactant system of the detergent composition, whereby reduced deposition in (B) relative to (A) indicates anionic- surfactant interaction; and (II) whether the detergent composition contains a soil release agent-enhancing amount of polyhydroxy fatty acid amide can be determined by a comparison of the SRA deposition of the SRA/Anionic surfactant test run of (B) with soil release agent deposition in (C) an "SRA/Anionic surfactant/PFA test run" wherein the same type and level of polyhydroxy fatty acid amide of the detergent composition is combined with the soil release agent and anionic surfactant system corresponding to said SRA/Anionic surfactant test run, whereby improved deposition of the soil release agent in test run (C) relative to test run (B) indicates that a soil release agent-enhancing amount of polyhydroxy fatty acid amide is present. For purposes hereof, the tests hereof should be conducted at anionic surfactant concentrations in the aqueous solution that are above the critical micelle concentration (CMC) of the anionic surfactant and preferably above about 100 ppm. The polymeric soil release agent concentration should be at least 15 ppm. A swatch of polyester fabric should be used for the hydrophobic fiber source. Identical swatches are immersed and agitated in 35'C aqueous solu¬ tions for the respective test runs for a period of 12 minutes, then removed, and analyzed. Polymeric soil release agent deposition level can be determined by radiotagging the soil release agent prior to treatment and subsequently conducting radiochemical analysis, according to techniques known in the art.
As an alternative to the radiochemical analytical methodology discussed above, soil release agent deposition can alternately be determined in the above test runs (i.e., test runs A, B, and C) by determination of ultraviolet light (UV) absorbance of the test solutions, according to techniques well known in the art. Decreased UV absorbance in the test solution after removal of the hydrophobic fiber material corresponds to increased SRA deposition. As will be understood by those skilled in the art, UV analysis should not be utilized for test solutions containing types and levels of materials which cause excessive UV absorbance interference, such as high levels of surfactants with aromatic groups (e.g., alkyl benzene sulfonates, etc.).
Thus by "soil release agent-enhancing amount" of polyhydroxy fatty acid amide is meant an amount of such surfactant that will enhance deposition of the soil release agent upon hydrophobic fibers, as described above, or an amount for which enhanced grease/oil cleaning performance can be obtained for fabrics washed in the detergent composition hereof in the next subsequent cleaning operation. The amount of polyhydroxy fatty acid amide needed to enhance deposition will vary with the anionic surfactant selected, the amount of anionic surfactant, the particular soil release agent chosen, as well as the particular polyhydroxy fatty acid amide chosen. Generally, compositions will comprise from about 0.01% to about 10%, by weight, of the polymeric soil release agent, typically from about 0.1% to about 5%, and from about 4% to about 50%, more typically from about 5% to about 30% of anionic surfactant. Such compositions should generally contain at least about 1%, preferably at least about 3%, by weight, of the polyhydroxy fatty acid amide, though it is not intended to necessarily be limited thereto.
The polymeric soil release agents for which performance is enhanced by polyhydroxy fatty acid amide in the presence of anionic surfactant include those soil release agents having: (a) one or more nonionic hydrophile components consisting essentially of (i) polyoxyethylene segments with a degree of polymerization of at least 2, or (ii) oxypropylene or polyoxypropylene segments with a degree of polymerization of from 2 to 10, wherein said hydrophile segment does not encompass any oxypropylene unit unless it is bonded to adjacent moieties at each end by ether linkages, or (iii) a mixture of oxyalkylene units comprising oxyethylene and from 1 to about 30 oxypropylene units wherein said mixture contains a sufficient amount of oxyethylene units such that the hydrophile component has hydrophilicity great enough to increase the hydrophilicity of conventional polyester synthetic fiber surfaces upon deposit of the soil release agent on such surface, said hydrophile segments preferably comprising at least about 25% oxyethylene units and more preferably, especially for such components having about 20 to 30 oxypropylene units, at least about 50% oxyethylene units; or (b) one or more hydrophobe components comprising (i) C3 oxyalkylene terephthalate segments, wherein, if said hydrophobe components also comprise oxyethylene terephthalate, the ratio of oxyethylene terephthalate:C3 oxyalkylene terephthalate units is about 2:1 or lower, (ii) C4-C5 alkylene or oxy C4-C6 alkylene segments, or mixtures thereof, (iii) poly (vinyl ester) segments, preferably poly(vinyl acetate), having a degree of polymerization of at least 2, or (iv) C1-C4 alkyl ether or C4 hydroxyalkyl ether substituents, or mixtures thereof, wherein said substituents are present in the form of C1-C4 alkyl ether or C4 hydroxyalkyl ether cellulose derivatives, or mixtures thereof, and such cellulose derivatives are amphiphilic, whereby they have a sufficient level of C1-C4 alkyl ether and/or C4 hydroxyalkyl ether units to deposit upon conven- tional polyester synthetic fiber surfaces and retain a sufficient level of hydroxyls, once adhered to such conventional synthetic fiber surface, to increase fiber surface hydrophilicity, or a combination of (a) and (b).
Typically, the polyoxyethylene segments of (a)(i) will have a degree of polymerization of from 2 to about 200, although higher levels can be used, preferably from 3 to about 150, more preferably from 6 to about 100. Suitable oxy C4-C6 alkylene hydrophobe seg¬ ments include, but are not limited to, end-caps of polymeric soil release agents such as Mθ3S(CH2)nocH2CH2θ-, where M is sodium and n is an integer from 4-6, as disclosed in U.S. Patent 4,721,580,- issued January 26, 1988 to Gosselink, incorporated herein by reference.
Polymeric soil release agents useful in the present invention include cellulosic derivatives such as hydroxyether cellulosic polymers, copolymeric blocks of ethylene terephthalate or propylene terephthalate with polyethylene oxide or polypropylene oxide terephthalate, and the like.
Cellulosic derivatives that are functional as soil release agents are commercially available and include hydroxyethers of cellulose such as Methocel^ (Dow).
Cel l ul osic soil release agents for use herein al so incl ude those sel ected from the group consi sting of C1-C4 al kyl and C4 hydroxyalkyl cellulose such as methylcellulose, ethylcellulose, hydroxypropyl methylcellulose, and hydroxybutyl methylcellulose. A variety of cellulose derivatives useful as soil release polymers are disclosed in U.S. Patent 4,000,093, issued December 28, 1976 to Nicol, et al . , incorporated herein by reference.
Soil release agents characterized by poly(vinyl ester) hydrophobe segments include graft copolymers of poly(vinyl ester), e.g., Ci-Ce vinyl esters, preferably poly(vinyl acetate) grafted onto polyalkylene oxide backbones, such as polyethylene oxide backbones. Such materials are known in the art and are described in European Patent Application 0 219 048, published April 22, 1987 by Kud, et al. Suitable commercially available soil release agents of this kind include the Sokalan™ type of material, e.g., Sokalan™ HP-22, available from BASF (West Germany). One type of preferred soil release agent is a copolymer having random blocks of ethylene terephthalate and polyethylene oxide (PE0) terephthalate. More specifically, these polymers are comprised of repeating units of ethylene terephthalate and PE0 terephthalate in a mole ratio of ethylene terephthalate units to PE0 terephthalate units of from about 25:75 to about 35:65, said PEO terephthalate units containing polyethylene oxide having molecular weights of from about 300 to about 2000. The molecular weight of this polymeric soil release agent is in the range of from about 25,000 to about 55,000. See U.S. Patent 3,959,230 to Hays, issued May 25, 1976, which is incorporated by reference. See also U.S. Patent 3,893,929 to Basadur issued July 8, 1975 (incorporated by reference) which discloses similar copolymers.
Another preferred polymeric soil release agent is a polyester with repeat units of ethylene terephthalate units containing 10-15% by weight of ethylene terephthalate units together with 90-80% by weight of polyoxyethylene terephthalate units, derived from a polyoxyethylene glycol of average molecular weight 300-5,000, and the mole ratio of ethylene terephthalate units to polyoxyethylene terephthalate units in the polymeric compound is between 2:1 and 6:1. Examples of this polymer include the commercially available material ZelconR 5126 (from Dupont) and MileaseR T (from ICI). These polymers and methods of their preparation are more fully described in U.S. Patent 4,702,857, issued October 27, 1987 to Gosselink, which is incorporated herein by reference.
Another preferred polymeric soil release agent is a sulfonated product of a substantially linear ester oligomer comprised of an oligomeric ester backbone of terephthaloyl and oxyalkyleneoxy repeat units and terminal moieties covalently attached to the backbone, said soil release agent being derived from ally! alcohol ethoxylate, dimethyl terephthalate, and 1,2 propylene diol, wherein after sulfonation, the terminal moieties of each oligomer have, on average, a total of from about 1 to about 4 sulfonate groups. These soil release agents are described fully in U.S. Patent 4,968,451, issued November 6, 1990 to J. J. Scheibel and E. P. Gosselink, U.S. Serial No. 07/474,709, filed January 29, 1990, incorporated herein by reference. Other suitable polymeric soil release agents include the ethyl- or methyl-capped 1,2-propylene terephthalate-polyoxyethylene terephthalate polyesters of U.S. Patent 4,711,730, issued December 8, 1987 to Gosselink et al . , the anionic end-capped oligomeric esters of U.S. Patent 4,721,580, issued January 26, 1988 to Gosselink, wherein the anionic end-caps comprise sulfo-polyethoxy groups derived from polyethylene glycol (PEG), the block polyester oligomeric compounds of U.S. Patent 4,702,857, issued October 27, 1987 to Gosselink, having polyethoxy end-caps of the formula X-(0CH2CH2)n- wherein n is from 12 to about 43 and X is a C1-C4 alkyl, or preferably methyl, all of these patents being incorporated herein by reference.
Additional polymeric soil release agents include the soil release agents of U.S. Patent 4,877,896, issued October 31, 1989 to Maldonado et al., which discloses anionic, especially sulfoaroyl, end-capped terephthalate esters, said patent being incorporated herein by reference. The terephthalate esters contain unsymmetrically substituted oxy-1,2-alkyleneoxy units. Included among the soil release polymers of U.S. Patent 4,877,896 are materials with polyoxyethylene hydrophile components or C3 oxyalkylene terephthalate (propylene terephthalate) repeat units within the scope of the hydrophobe components of (b)(i) above. It is the polymeric soil release agents characterized by either, or both, of these criteria that particularly benefit from the inclusion of the polyhydroxy fatty acid amides hereof, in the presence of anionic surfactants.
If utilized, soil release agents will generally comprise from about 0.01% to about 10.0%, by weight, of the detergent compositions herein, typically from about 0.1% to about 5%, preferably from about 0.2% to about 3.0%. Chelating Agents
The detergent compositions herein may also optionally contain one or more iron and manganese chelating agents as a builder adjunct material. Such chelating agents can be selected from the group consisting of amino carboxylates, amino phosphonates, polyfunctionally-substituted aromatic chelating agents and mixtures thereof, all as hereinafter defined. Without intending to be bound by theory, it is believed that the benefit of these materials is due in part to their exceptional ability to remove iron and manganese ions from washing solutions by formation of soluble chelates.
Amino carboxylates useful as optional chelating agents in compositions of the invention can have one or more, preferably at least two, units of the substructure
CH2
^ N - (CH2)χ - C00M, wherein M is hydrogen, alkali metal, ammonium or substituted ammonium (e.g. ethanolamine) and x is from 1 to about 3, preferably 1. Preferably, these amino carboxylates do not contain alkyl or alkenyl groups with more than about 6 carbon atoms. Operable amine carboxylates include ethylenediaminetetraacetates, N-hydroxyethyl- ethylenediaminetriacetates, nitrilotriacetates, ethylenediamine tetraproprionates, triethylenetetraaminehexaacetates, diethylenetri- aminepentaacetates, and ethanoldiglycines, alkali metal, ammonium, and substituted ammonium salts thereof and mixtures thereof.
Amino phosphonates are also suitable for use as chelating agents in the compositions of the invention when at least low levels of total phosphorus are permitted in detergent compositions. Compounds with one or more, preferably at least two, units of the substructure CH;
\
^ N (CH2)χ PO3M2, wherein M is hydrogen, alkali metal, ammonium or substituted ammon¬ ium and x is from 1 to about 3, preferably 1, are useful and include ethylenediaminetetrakis (methylenephosphonates), nitrilotris (methylenephosphonates) and diethylenetriaminepentakis (methylene¬ phosphonates). Preferably, these amino phosphonates do not contain alkyl or alkenyl groups with more than about 6 carbon atoms. Alkylene groups can be shared by substructures. Polyfunctionally - substituted aromatic chelating agents are also useful in the compositions herein. These materials can com¬ prise compounds having the general formula
wherein at least one R is -SO3H or -COOH or soluble salts thereof and mixtures thereof. U.S. Patent 3,812,044, issued May 21, 1974, to Connor et al., incorporated herein by reference, discloses polyfunctionally-substituted aromatic chelating and sequestering agents. Preferred compounds of this type in acid form are dihy¬ droxydisulfobenzenes such as 1,2-dihydroxy -3,5-disulfobenzene. Alkaline detergent compositions can contain these materials in the form of alkali metal, ammonium or substituted ammonium (e.g. ono- or triethanol-amine) salts.
If utilized, these chelating agents will generally comprise from about 0.1% to about 10% by weight of the detergent compositions herein. More preferably chelating agents will comprise from about 0.1% to about 3.0% by weight of such compositions. Clay Soil Removal/Anti-redeposition Agents
The compositions of the present invention can also optionally contain water-soluble ethoxylated amines having clay soil removal and anti-redeposition properties. Granular detergent compositions which contain these compounds typically contain from about 0.01% to about 10.0% by weight of the water-soluble ethoxylated amines; liquid detergent compositions, typically about 0.01% to about 5%. These compounds are selected preferably from the group consisting of: (1) ethoxylated monoamines having the formula:
(2) ethoxylated diamines having the formula:
R2-N I-Rl-NI-R2 (R2)2-N-RIl-N-(R2)2 L L L i i I
X X X or
(3) ethoxylated polyamines having the formula: f
R3-[(Al)q-(R )t-N-L-X]p
(4) ethoxylated amine polymers having the general formula:
[(R2)2-N3wER1-N3χER1-N}yfRl-N-L-X)z
X and
(5) mixtures thereof; wherein Al is 0 ~ 0 II 0 It 0 II 0 I, -NC-, -NC0-, -NCN-, -CN-, -0CN-,
R R R R R R
0 0 0 00 ι: ;/ n a u
-CO-, -0C0-, -0C-, -CNC-,
R or -0-; R is H or C1-C4 alkyl or hydroxyalkyl; R is C2-C12 alkylene, hydroxyal kyl ene, alkenyl ene, aryl ene or alkarylene, or a C2-C3 oxyalkylene moiety having from 2 to about 20 oxyalkylene units provided that no 0-N bonds are formed; each R2 is C1-C4 or hydroxy¬ alkyl, the moiety -L-X, or two R2 together form the moiety -(CH2)r» -A2-(CH2)s-> wherein A2 is -0- or -CH2-, r is 1 or 2, s is 1 or 2, and r + s is 3 or 4; X is a nonionic group, an anionic group or mixture thereof; R3 is a substituted C3-C12 alkyl, hydroxyalkyl, alkenyl, aryl, or alkaryl group having substitution sites; R4 is C1-C12 alkylene, hydroxyal kyl ene, alkenylene, arylene or alkarylene, or a C2-C3 oxyalkylene moiety having from 2 to about 20 oxyalkylene units provided that no 0-0 or 0-N bonds are formed; L is a hydro¬ philic chain which contains the polyoxyalkylene moiety -[(R50)m(CH2CH2θ)n]-> wherein R- is C3-C4 alkylene or hydroxyal¬ kylene and m and n are numbers such that the moiety -(CH2CH2θ)n- comprises at least about 50% by weight of said polyoxyalkylene moiety; for said monoamines, m is from 0 to about 4, and n is at least about 12; for said diamines, m is from 0 to about 3, and n is at least about 6 when Rl is C2-C3 alkylene, hydroxyalkylene, or alkenylene, and at least about 3 when Rl is other than C2-C3 alkyl¬ ene, hydroxyalkylene or alkenylene; for said polyamines and amine polymers, m is from 0 to about 10 and n is at least about 3; p is from 3 to 8; q is 1 or 0; t is 1 or 0, provided that t is 1 when q is 1; w is 1 or 0; x + y + z is at least 2; and y + z is at least 2. The most preferred soil release and anti-redeposition agent is ethoxylated tetraethylenepentamine. Exemplary ethoxylated amines are further described in U.S. Patent 4,597,898, VanderMeer, issued July 1, 1986, incorporated herein by reference. Another group of preferred clay soil re oval/anti-redeposition agents are the cati¬ onic compounds disclosed in European Patent Application 111,965, Oh and Gosselink, published June 27, 1984, incorporated herein by reference. Other clay soil removal/anti-redeposition agents which can be used include the ethoxylated amine polymers disclosed in European Patent Application 111,984, Gosselink, published June 27, 1984; the zwitterionic polymers disclosed in European Patent Appli¬ cation 112,592, Gosselink, published July 4, 1984; and the amine oxides disclosed in U.S. Patent 4,548,744, Connor, issued October 22, 1985, all of which are incorporated herein by reference.
Other clay soil removal and/or anti redeposition agents known in the art can also be utilized in the compositions hereof. Another type of preferred anti-redeposition agent includes the carboxy methyl cellulose (CMC) materials. These materials are well known in the art.
Polymeric Dispersing Agents
Polymeric dispersing agents can advantageously be utilized in the compositions hereof. These materials can aid in calcium and magnesium hardness control. Suitable polymeric dispersing agents include polymeric polycarboxylates and polyethylene glycols, although others known in the art can also be used. Polycarboxylate materials which can be employed as the polymeric dispersing agent herein are these polymers or copolymers which contain at least about 60% by weight of segments with the general
wherein X, Y, and Z are each selected from the group consisting of hydrogen, methyl, carboxy, carboxymethyl , hydroxy and hydroxymethyl; a salt-forming cation and n is from about 30 to about 400. Prefer¬ ably, X is hydrogen or hydroxy, Y is hydrogen or carboxy, Z is hydrogen and M is hydrogen, alkali metal, ammonia or substituted ammonium.
Polymeric polycarboxylate materials of this type can be prepared by polymerizing or copolymerizing suitable unsaturated monomers, preferably in their acid form. Unsaturated monomeric acids that can be polymerized to form suitable polymeric polycar¬ boxylates include acrylic acid, maleic acid (or maleic anhydride), fumaric acid, itaconic acid, aconitic acid, mesaconic acid, citra- conic acid and methylenemalonic acid. The presence in the polymeric polycarboxylates herein of monomeric segments, containing no car- boxylate radicals such as vinylmethyl ether, styrene, ethylene, etc. is suitable provided that such segments do not constitute more than about 40% by weight.
Particularly suitable polymeric polycarboxylates can be derived from acrylic acid. Such acrylic acid-based polymers which are useful herein are the water-soluble salts of polymerized acrylic acid. The average molecular weight of such polymers in the acid form preferably ranges from about 2,000 to 10,000, more preferably from about 4,000 to 7,000 and most preferably from about 4,000 to 5,000. Water-soluble salts of such acrylic acid polymers can include, for example, the alkali metal, ammonium and substituted ammonium salts. Soluble polymers of this type are known materials. Use of polyacrylates of this type in detergent compositions has been disclosed, for example, in Diehl, U.S. Patent No. 3,308,067, issued March 7, 1967. This patent is incorporated herein by reference.
Acrylic/maleic-based copolymers may also be used as a preferred component of the dispersing agent. Such materials include the water-soluble salts of copolymers of acrylic acid and maleic acid. The average molecular weight of such copolymers in the acid form preferably ranges from about 2,000 to 100,000, more preferably from about 5,000 to 75,000, most preferably from about 7,000 to 65,000. The ratio of acrylate to maleate segments in such copolymers will generally range from about 30:1 to about 1:1, more preferably from about 10:1 to 2:1. Water-soluble salts of such acrylic acid/maleic acid copolymers can include, for example, the alkali metal, ammonium and substituted ammonium salts. Soluble acrylate/maleate copolymers of this type are known materials which are described in European Patent Application No. 66915, published December 15, 1982, which publication is incorporated herein by reference.
Another polymeric material which can be included is polyethyl¬ ene glycol (PEG). PEG can exhibit dispersing agent performance as well as act as a clay soil removal/anti-redeposition agent. Typical molecular weight ranges for these purposes range from about 500 to about 100,000, preferably from about 1,000 to about 50,000, more preferably from about 1,500 to about 10,000. Brightener
Any optical brighteners or other brightening or whitening agents known in the art can be incorporated into the detergent- compositions hereof.
The choice of brightener for use in detergent compositions will depend upon a number of factors, such as the type of detergent, the nature of other components present in the detergent composition, the temperatures of wash water, the degree of agitation, and the ratio of the material washed to tub size.
The brightener selection is also dependent upon the type of material to be cleaned, e.g., cottons, synthetics, etc. Since most laundry detergent products are used to clean a variety of fabrics, the detergent compositions should contain a mixture of brighteners which will be effective for a variety of fabrics. It is of course necessary that the individual components of such a brightener mixture be compatible.
Commercial optical brighteners which may be useful in the present invention can be classified into subgroups which include, but are not necessarily limited to, derivatives of stilbene, pyrazoline, cou arin, carboxylic acid, methinecyanines, dibenzothiphene-5,5-dioxide, azoles, 5- and 6-membered-ring heterocycles, and other miscellaneous agents. Examples of such brighteners are disclosed in "The Production and Application of Fluorescent Brightening Agents", M. Zahradnik, Published by John Wiley & Sons, New York (1982), the disclosure of which is incorporated herein by reference.
Stilbene derivatives which may be useful in the present invention include, but are not necessarily limited to, derivatives of bis(triazinyl)amino-stilbene; bisacylamino derivatives "of stilbene; triazole derivatives of stilbene; oxadiazole derivatives of stilbene; oxazole derivatives of stilbene; and styryl derivatives of stilbene.
Certain derivatives of bis(triazinyl)aminostilbene which may be useful in the present invention may be prepared from 4,4'-diamine- stilbene-2,2'-disulfonic acid.
Coumarin derivatives which may be useful in the present invention include, but are not necessarily limited to, derivatives substituted in the 3-position, in the 7-position, and in the 3- and 7-positions.
Carboxylic acid derivatives which may be useful in the present invention include, but are not necessarily limited-to, fumaric acid derivatives; benzoic acid derivatives; p-phenylene-bis-acrylic acid derivatives; naphthalenedicarboxylic acid derivatives; heterocyclic acid derivatives; and cinnamic acid derivatives.
Cinnamic acid derivatives which may be useful in the present invention can be further subclassified into groups which include, but are not necessarily limited to, cinnamic acid derivatives, styrylazoles, styrylbenzofurans, styryloxadiazoles, styryltriazoles, and styrylpolyphenyls, as disclosed on page 77 of the Zahradnik reference. The styrylazoles can be further subclassified into styryl- benzoxazoles, styrylimidazoles and styrylthiazoles, as disclosed on page 78 of the Zahradnik reference. It will be understood that these three identified subclasses may not necessarily reflect an exhaustive list of subgroups into which styrylazoles may be subclassified.
Another class of optical brighteners which may be useful in the present invention are the derivatives of dibenzothiophene-5,5- dioxide disclosed at page 741-749 of The Kirk-Othmer Encyclopedia of Chemical Technology. Volume 3, pages 737-750 (John Wiley & Son, Inc., 1962), the disclosure of which is incorporated herein by reference, and include 3,7-diaminodibenzothiophene-2,8-disulfonic acid 5,5 dioxide.
Another class of optical brighteners which may be useful in the present invention include azoles, which are derivatives of 5-membered ring heterocycles. These can be further subcategorized into monoazoles and bisazoles. Examples of monoazoles and bisazoles are disclosed in the Kirk-Othmer reference.
Another class of brighteners which may be useful in the present invention are the derivatives of 6-membered-ring hetero- cycles disclosed in the Kirk-Othmer reference. Examples of such compounds include brighteners derived from pyrazine and brighteners derived from 4-aminonaphthalamide.
In addition to the brighteners already described, miscellaneous agents may also be useful as brighteners. Examples of such miscellaneous agents are disclosed at pages 93-95 of the Zahradnik reference, and include l-hydroxy-3,6,8-pyrenetri- sulphonic acid; 2,4-dimethoxy-l,3,5-triazin-6-yl-pyrene; 4,5-di- phenylimidazolone- disulphonic acid; and derivatives of pyrazoline- quinoline. Other specific examples of optical brighteners which may be useful in the present invention are those identified in U.S. Patent 4,790,856, issued to Wixon on December 13, 1988, the disclosure of which is incorporated herein by reference. These brighteners include the PhorwhiteTM series of brighteners from Verona. Other brighteners disclosed in this reference include: Tinopal UNPA, Tinopal CBS and Tinopal 5BM; available from Ciba-Geigy; Arctic White CC and Artie White CWD, available from Hilton-Davis, located in Italy; the 2-(4-styryl-phenyl )-2H- naphthol [l,2-d]triazoles; 4,4'-bis- (l,2,3-triazol-2-yl)-stil- benes; 4,4'-bis(styryl)bis- phenyls; and the y-aminocoumarins. Specific examples of these brighteners include 4-methyl-7-diethyl- amino coumarin; 1,2-bis- (-benzimidazol-2-yl)ethylene; 1,3-diphenylphrazolines; 2,5-bis- (benzoxazol-2-yl)thiophene; 2-styryl-naphth-[l,2-d]oxazole; and 2-(stilbene-4-yl)-2H-naphtho- [l,2-d]triazole.
Other optical brighteners which may be useful in the present invention include those disclosed in U.S. Patent 3,646,015, issued February 29, 1972 to Hamilton, the disclosure of which is incorpor¬ ated herein by reference. Suds Suppressors
Compounds known, or which become known, for reducing or sup¬ pressing the formation of suds can be incorporated into the composi- tions of the present invention. The incorporation of such materials, hereinafter "suds suppressors," can be desirable because the polyhydroxy fatty acid amide surfactants hereof can increase suds stability of the detergent compositions. Suds suppression can be of particular importance when the detergent compositions include a relatively high sudsing surfactant in combination with the poly¬ hydroxy fatty acid amide surfactant. Suds suppression is particu¬ larly desirable for compositions intended for use in front loading automatic washing machines. These machines are typically character¬ ized by having drums for containing the laundry and wash water, which have a horizontal axis and rotary action about the axis. This type of agitation can result in high suds formation and, conse¬ quently, in reduced cleaning performance. The use of suds suppres¬ sors can also be of particular importance under hot water washing conditions and under high surfactant concentration conditions. A wide variety of materials may be used as suds suppressors in the compositions hereof. Suds suppressors are well known to those skilled in the art. They are generally described, for example, in Kirk Othmer Encyclopedia of Chemical Technology, Third Edition, Volume 7, pages 430-447 (John Wilεy & Sons, Inc., 1979). Onε category of suds suppressor of particular interest encompasses monocarboxylic fatty acids and soluble salts thereof. These materials are discussed in U.S. Patent 2,954,347, issued September 27, I960 to Wayne St. John, said patent being incorporated herein by reference. The onocarboxylic fatty acids, and salts thereof, for use as suds suppressor typically have hydrocarbyl chains of 10 to about 24 carbon atoms, preferably 12 to 18 carbon atoms. Suitable salts include the alkali metal salts such as sodium, potassium, and lithium salts, and ammonium and alkanolammonium salts. These materials are a preferred category of suds suppressor for detergent compositions.
The detergent compositions may also contain non-surfactant suds suppressors. These include, for example, list: high molecular weight hydrocarbons such as paraffin, fatty acid esters (e.g., fatty acid triglycerides), fatty acid esters of monovalent alcohols, aliphatic C18-C40 ketones (e.g. stearone), etc. Other suds inhibitors include N-alkylated amino triazines such as tri- to hexa-alkylmelamines or di- to tetra-alkyldiamine chlortriazines formed as products of cyanuric chloride with two or three moles of a primary or secondary amine containing 1 to 24 carbon atoms, propylene oxide, and monostearyl phosphates such as monostearyl alcohol phosphate ester and monostearyl di-alkali metal (e.g. Na, Li, K) phosphates. The hydrocarbons such as paraffin and haloparaf- fin can be utilized in liquid form. The liquid hydrocarbons will be liquid at room temperature and atmospheric pressure, and will have a pour point in the range of about -40'C and about 5*C, and a minimum boiling point not less than about 110'C (atmospheric pressure). It is also known to utilize waxy hydrocarbons, preferrably having a- elting point below about lOO'C. The hydrocarbons constitute a preferred category of suds suppressor for detergent compositions. Hydrocarbon suds suppressors are described, for example, in U.S. Patent 4,265,779, issued May 5, 1981 to Gandolfo, et al . , incorpor- ated herein by reference. The hydrocarbons, thus, include ali¬ phatic, alicyclic, aromatic, and heterocyclic saturated or unsatur¬ ated hydrocarbons having from about 12 to about 70 carbon atoms. The term "paraffin," as used in this suds suppressor discussion, is intended to include mixtures of true paraffins and cyclic hydrocarbons.
Another preferred category of non-surfactant suds comprises silicone suds suppressors. This category includes the use of polyorganosiloxane oils, such as polydimethylsiloxane, dispersions or emulsions of polyorganosiloxane oils or resins, and combinations of polyorganosiloxane with silica particles wherein the polyorgano¬ siloxane is chemisorbed of fused onto the silica. Silicone suds suppressors are well known in the art and are, for example, dis¬ closed in U.S. Patent 4,265,779, issued May 5, 1981 to Gandolfo et al . and European Patent Application No. 89307851.9, published February 7, 1990, by Starch, M. S., both incorporated herein by reference. Other silicone suds suppressors are disclosed in U.S. Patent 3,455,839 which relates to compositions and processes for defoaming aqueous solutions by incorporating therein small amounts of polydi¬ methylsiloxane fluids.
Mixtures of silicone and silanated silica are described, for instance, in German Patent Application DOS 2,124,526. Silicone defoamers and suds controlling agents in granular detergent compositions are disclosed in U.S. Patent 3,933,672, Bartolotta et al., and in U.S. Patent 4,652,392, Baginski et al . , issued March 24, 1987. An exemplary silicone based suds suppressor for use herein is a suds suppressing amount of a suds controlling agent consisting essentially of:
(i) polydimethylsiloxane fluid having a viscosity of from about 20 cs. to about 1500 cs. at 25*C; (ii) from about 5 to about 50 parts per 100 parts by weight of (i) of siloxane resin composed of (CH3)3 Si0ι/2 units of Siθ2 units in a ratio of from (CH3)3 SiOχ/2 units and to Siθ2 units of from about 0.6:1 to about 1.2:1; and (iii) from about 1 to about 20 parts per 100 parts by weight of (i) of a solid silica gel;
For any detergent compositions to be used in automatic laundry washing machines, suds should not form to the extent that they overflow the washing machine. Suds suppressors, when utilized, are preferably present in a "suds suppressing amount." By "suds suppressing amount" is meant that the formulator of the composition can select an amount of this suds controlling agent that will sufficiently control the suds to result in a low-sudsing laundry detergent for use in automatic laundry washing machines. The amount of suds control will vary with the detergent surfactants selected. For example, with high sudsing surfactants, relatively more of the suds controlling agent is used to achieve the desired suds control than with lesser foaming surfactants. In general, a sufficient amount of suds suppressor should be incorporated in low sudsing detergent compositions so that the suds that form during the wash cycle of the automatic washing machine (i.e., upon agitation of the detergent in aqueous solution under the intended wash temperature and concentration conditions) do not exceed about 75% of the void volume of washing machine's containment drum, preferably the suds do not exceed about 50% of said void volume, wherein the void volume is determined as the difference between total volume of the containment drum and the volume of the water plus the laundry. The compositions hereof will generally comprise from 0% to about 5% of suds suppressor. When utilized as suds suppressors, monocarboxylic fatty acids, and salts thereof, will be present typically in amounts up to about 5%, by weight, of the detergent composition. Preferably, from about 0.5% to about 3% of fatty monocarboxylate suds suppressor is utilized. Silicone suds suppressors are typically utilized in amounts up to about 2.0%, by weight, of the detergent composition, although higher amounts may be used. This upper limit is practical in nature, due primarily to concern with keeping costs minimized and effectiveness of lower amounts for effectively controlling sudsing. Preferably from about .01% to about 1% of silicone suds suppressor is used, more preferably from about 0.25% to about 0.5%. As used herein, these weight percentage values include any silica that may be utilized in combination with polyorganosiloxane, as well as any adjunct materials that may be utilized. The monostearyl phosphate suds suppressors are typically utilized in amounts ranging from about 0.1% to about 2%, by weight, of the composition.
Hydrocarbon suds suppressors are typically utilized in amounts ranging from about .01% to about 5.0%, although higher levels can be used. Other Ingredients
A wide variety of other ingredients useful in detergent compositions can be included in the compositions hereof, including other active ingredients, carriers, hydrotropes, processing aids, dyes or pigments, solvents for liquid formulations, etc.
It is an especially important benefit of this invention that liquid heavy duty detergent compositions can be more easily formulated with anionic surfactants and the polycarboxylate builders hereof, by the inclusion of the polyhydroxy fatty acid amides described above, in addition to the improved, built detergent compositions resulting from the combination of polycarboxylate builder and polyhydroxy fatty acid amide, in general. Thus, this invention provides liquid detergent compositions comprising one or more anionic surfactants, polycarboxylate builder, polyhydroxy fatty acid amide, and a liquid carrier. These liquid detergent compositions can have relatively high levels of anionic surfactant and polycarboxylate builder incorporated therein. As used herein, high levels of polycarboxylate builder means levels of excess of about 10%, especially in excess of about 15%, by weight, of the detergent composition.
Liquid detergent compositions can contain water and other solvents as carriers. Low molecular weight primary or secondary alcohols exemplified by methanol, ethanol, propanol , and isopropanol are suitable. Monohydric alcohols are preferred for solubilizing surfactant, but polyols such as those containing from 2 to about 6 carbon atoms and from 2 to about 6 hydroxy groups (e.g., propylene glycol, ethylene glycol, glycerine, and 1,2-propanediol ) can also be used.
The detergent compositions hereof will preferably be formulated such that during use in aqueous cleaning operations, the wash water will have a pH of between about 6.5 and about 11, preferably between about 7.5 and about 10.5. Liquid product formulations (measured at standard 10% dilution level) preferably have a pH between about 7.5 and about 9.5, more preferably between about 7.5 and about 9.0. For high builder content liquids, pH can be higher, preferably about pH 8.5-10.5. Techniques for controlling pH at recommended usage levels include the use of buffers, alkalis, acids, etc., and are well known to those skilled in the art. This invention further provides a method for improving the performance of detergents containing anionic, nonionic, and/or cationic surfactant and polycarboxylate builder by incorporating into such composition the polyhydroxy fatty acid amide surfactant described above, such that the weight ratio of polycarboxylate to the amide surfactant is from about 1:10 to about 10:1.
This invention further provides a method for cleaning substrates, such as fibers, fabrics, hard surfaces, skin, etc., by contacting said substrate, with a detergent composition comprising one or more anionic, nonionic, or cationic surfactants, at least about 1% polycarboxylate builder, and at least 1% of the polyhydroxy fatty acid amide, wherein preferably of the weight ratio of polycarboxylate builder:the amide surfactant is from about 1:10 to about 10:1, in the presence of a solvent such as water or water-miscible solvent (e.g., primary and secondary alcohols). Agitation is preferably provided for enhancing cleaning. Suitable means for providing agitation include rubbing by hand or preferably with the aid of a brush, or other cleaning device, automatic laundry washing machines, automatic dishwashers, etc. In the above methods, the more preferred polycarboxylate builder:polyhydroxy fatty acid amide weight ratios are from about 1:5 to about 7:1, most preferably from about 1:1 to about 7:1, and the preferred amounts and types of polyhydroxy fatty acid amide and polycarboxylate are as described herein. EXPERIMENTAL
This exemplifies a process for making a N-methyl, 1-deoxyglucityl laura ide surfactant for use herein. Although a skilled chemist can vary apparatus configuration, one suitable apparatus for use herein comprises a three-liter four-necked flask fitted with a motor-driven paddle stirrer and a thermometer of length sufficient to contact the reaction medium. The other two necks of the flask are fitted with a nitrogen sweep and a wide-bore side-arm (caution: a wide-bore side-arm is important in case of very rapid methanol evolution) to which is connected an efficient collecting condenser and vacuum outlet. The latter is connected to a nitrogen bleed and vacuum gauge, then to an aspirator and a trap. A 500 watt heating mantle with a variable transformer temperature controller ("Variac") used to heat the reaction is so placed on a lab-jack that it may be readily raised or lowered to further control temperature of the reaction.
N-methylglucamine (195 g., 1.0 mole, Aldrich, M4700-0) and methyl laurate (Procter & Gamble CE 1270, 220.9 g., 1.0 mole) are placed in a flask. The solid/liquid mixture is heated with stirring under a nitrogen sweep to form a melt (approximately 25 minutes). When the melt temperature reaches 145" C, catalyst (anhydrous powdered sodium carbonate, 10.5 g., 0.1 mole, J. T. Baker) is added. The nitrogen sweep is shut off and the aspirator and nitrogen bleed are adjusted to give 5 inches (5/31 atm.) Hg. vacuum. From this point on, the reaction temperature is held at 150° C by adjusting the Variac and/or by raising or lowering the mantle.
Within 7 minutes, first methanol bubbles are sighted at the meniscus of the reaction mixture. A vigorous reaction soon follows. Methanol is distilled over until its rate subsides. The vacuum is adjusted to give about 10 inches Hg. (10/31 atm.) vacuum. The vacuum is increased approximately as follows (in inches Hg. at minutes): 10 at 3, 20 at 7, 25 at 10. 11 minutes from the onset of methanol evolution, heating and stirring are discontinued co-incident with some foaming. The product is cooled and solidifies.
The following examples are meant to exemplify compositions of the present invention, but are not necessarily meant to limit or otherwise define the scope of the invention, said scope being determined according to claims which follow.
EXAMPLES 1-12 These examples show heavy duty granular detergent compositions containing polyhydroxy fatty acid amide and polycarboxylate builders.
Sodium Carbonate
Sodium Silicate
Sodium Sulfate
Sodium Polyacrylate (4500 MW) Polyethylene Glycol (8000 MW)
Tallow Fatty Acid
Brightener
Admix and Sorav-On
C16-18 Methyl Ester Sulfonate Protease (1.4% active enzyme)
Perfume
C12-13 Alkyl Ethoxylate (6.5 mole)
Water and Miscellaneous 100.0 100.0 100.0
Examples 1-3 are formulations for preferred use of about 1400 ppm, wash water weight basis, for temperatures below about 50βC.
The above examples are made by combining the base granule ingredients as a slurry, and spray drying to about 4-8% residual moisture. The remaining dry ingredients are admixed in granular or powder form with the spray dryed granule in a rotary mixing drum, and the liquid ingredients (nonionic surfactant and perfume) sprayed on.
Base Granul e Linear C12 Al kyl benzene Sul fonate
C14-15 Al kyl Sul fate
N-Methyl N-1-Deoxygl ucityl Cocoamide
Zeol i te A
Polyacrylate 4500 MW Citric Acid
Silicate (Si02/Na2θ = 1.6)
Brightener
Polyethylene Glycol (8000 MW)
Sodium Sul fate Water
Si l i cone Oi l Mi scel l aneous Admix and sprav-on
N-Methyl N-1-Deoxyglucityl Cocoamide
C14-15 Alkyl Sulfate
Citric Acid Sodium Citrate
Protease (1.4% active enzyme)
C12-13 Alkyl Ethoxylate (6.5 mole)
Miscellaneous
Total 100.0 100.0 Examples 4 and 5 exemplify condensed granular detergent compositions, preferably utilized at about 1000 ppm, wash water basis, and intended for temperatures below about 50° C. These are prepared by spray drying the base granule components to about 5-8% moisture, admixing the powdered or granular dry ingredients, and spraying on the liquid admix components.
Base Granule
C16-18 Fatty Acid
TMS/TDS (80:20) *
Polyacrylate (4500 MW) Polyethylene Glycol (8000 MW)
Sodium Carbonate
Sodium Sulfate
Sodium Silicate (Siθ2/Na2θ=2)
Sodium Diethylenetriamine Pentaacetate Brightener
Admix
Zeolite
Suds Suppressor flake **
Sodium Percarbonate Nonanoyloxybenzenesulfonate
N-Methyl N-1-Deoxyglucityl Cocoamide
C16-18 Methyl Ester Sulfonate
C12-I8 Alkyl Sulfate 19.1
Spray-on C12-13 Alkyl Ethoxylate (6.5 mole) 2.0 2.0
Perfume 0.5 0.5 Water and Miscellaneous 8.2 8.2
Totals 100.0 100.0
*TMS/TDS is tartrate monosuccinate/tartrate disuccinate. **Suds Suppressor Flake is a silica/silicone oil dispersion encapsulated in a matrix of polyethylene glycol (8000 MW), about 5% active suds suppressor.
The compositions of Examples 6 and 7 represent condensed granular formulations prepared by slurrying and spray drying the base granule ingredients to a moisture of about 5%, and admixing in the additional dry ingredients. The resulting mixture is dedusted by spraying on the liquid ingredients. The product is intended for use at about 1000 ppm concentration, at wash temperatures less than about 30βC.
Base Granule i4-i5 Al kyl Sul fate
C16-18 Al kyl Sul fate
C16-18 Al kyl Ethoxyl ate (11 mol e)
Zeol ite
Acrylate/maleate copolymer (60000 MW) Diethylenetriamine
Penta ethylenephosphonate
Brightener
Zinc Phthalocyanine Sulfonate
Water and Miscellaneous Admix
N-Methyl N-1-Deoxyglucityl Cocoamide 7.0
N-Methyl N-1-Deoxyglucityl Tallow Fatty Amide 4.0
C16-18 Methyl Ester Sulfonate 4.6
Sodium Citrate 8.0 8.0 Sodium Carbonate 17.5 17.5
Sodium Silicate (1.6r) 3.5 3.5
Sodium Perborate.H20 12.5 12.5
Carboxymethyl Cellulose 0.5 0.5
Tetraacetylethylenediamine 5.0 5.0 Protease (2.1% active enzyme) 1.4 1.4
Sorav-on
Perfume 0.4 0.4 Silicone Fluid 0.5 0.5
100.0 100.0 *1.5 AU/gm at 72 AU/gm active enzyme
The compositions of Examples 8 and 9 are preferably utilized at concentrations of about 6000 ppm, wash water weight basis, at temperature of from about 30'C to 95βC. These compositions can be made by slurrying the base granule ingredients and spray dried to about 9% moisture content. Remaining dry ingredients are added in a granular or powdered form and mixed in a rotary mix drum, followed by spray on addition of the final liquid ingredients.
EXAMPLES 10-20 The examples show heavy duty liquid detergent compositions containing polyhydroxy fatty acid amide and polycarboxylate builder.
Linear C12 Alkylbenzene Sulfonate C12-14 Alkyl Sulfate C12-14 Alkyl Ethoxylate (7 mole) N-Methyl N-1-Deoxyglucityl Cocoam N-Methyl N-1-Deoxyglucityl Oleami Oleic acid Citric acid
Dodecenyl succinic acid Miscellaneous (solvents, enzymes, brightener, stabilizers, buffer) Water
Linear C12 Alkylbenzene Sulfonate 10.0 C12-14 Alkyl Sulfate C12-14 Alkyl Ethoxylate (7 mole)
N-Methyl N-1-Deoxyglucityl Cocoamide N-Methyl N-1-Deoxyglucityl Oleamide Oleic Acid
Dodecenyl succinic acid
Miscellaneous (solvents, enzymes, brightener stabilizers, buffer, etc) 15.8 15.2 16.3 Water 48.1 48.3 48.3
100.0 100.0 100.0 Examples 10-16 are preferably used at about 12000 ppm, wash water weight basis, at temperatures from 30-95°C. These are prepared by combining non-aqueous solvents, aqueous surfactant pastes or solutions, melted fatty acids, aqueous solutions of polycarboxylate builders and other salts, aqueous ethoxylated tetraethylenpentamine, buffering agents, caustic, and the remaining water. The pH is adjusted using either an aqueous citric acid solution or sodium hydroxide solution to about pH 8.5. After pH adjustment the final ingredients, such as soil release agents, enzymes, colorants, and perfume, are added and the mixture stirred until a single phase is achieved.
100.0 100.0 100.0 100.0 * TMS/TDS is tartrate monosuccinate/tartrate disuccinate
Examples 18-20 are preferably used at about 2000 ppm, wash water weight basis, for wash tempertures below about 50"C. These are prepared by combining non-aqueous solvents, aqueous surfactant pastes or solutions, melted fatty acids, aqueous solutions of polycarboxylate builders and other salts, aqueous ethoxylated tetraethylene pentamine, buffering agents, caustic, and the remaining water. The pH is adjusted using either an aqueous citric acid solution or sodium hydroxide solution to about pH 8.5; for Examples 18 and 19, which have high builder content, pH can optionally be adjusted up to about pH 10.5. After pH adjustment the final ingredients, such as soil release agents, enzymes, colorants, and perfume, are added and the mixture stirred until a single phase is achieved. EXAMPLE 21
An alternate method for preparing the polyhydroxy fatty acid amides used herein is as follows. A reaction mixture consisting of 84.87g. fatty acid methyl ester (source: Procter & Gamble methyl ester CE1270), 75g. N-methyl-D-glucamine (source: Aldrich Chemical Company M4700-0), 1.04g. sodium methoxide (source: Aldrich Chemical Company 16,499-2), and 68.51g. methyl alcohol is used. The reaction vessel comprises a standard reflux set-up fitted with a drying tube, condenser and stir bar. In this procedure, the N-methyl glucamine is combined with methanol with stirring under argon and heating is begun with good mixing (stir bar; reflux). After 15-20 minutes, when the solution has reached the desired temperature, the ester and sodium methoxide catalyst are added. Samples are taken periodically to monitor the course of the reaction, but it is noted that the solution is completely clear by 63.5 minutes. It is judged that the reaction is, in fact, nearly complete at that point. The reaction mixture is maintained at reflux for 4 hours. After removal of the methanol, the recovered crude product weighs 156.16 grams. After vacuum drying and purification, an overall yield of 106.92 grams purified product is recovered. However, percentage yields are not calculated on this basis, inasmuch as regular sampling throughout the course of the reaction makes an overall percentage yield value meaningless. The reaction can be carried out at 80% and 90% reactant concentrations for periods up to 6 hours to yield products with extremely small by-product formation.
The following is not intended to limit the invention herein, but is simply to further illustrate additional aspects of the technology which may be considered by the formulator in the manufacture of a wide variety of detergent compositions using the polyhydroxy fatty acid amides.
It will be readily appreciated that the polyhydroxy fatty acid amides are, by virtue of their amide bond, subject to some instability under highly basic or highly acidic conditions. While some decomposition can be tolerated, it is preferred that these materials not be subjected to pH's above about 11, preferably 10, nor below about 3 for unduly extended periods. Final product pH (liquids) is typically 7.0-9.0. During the manufacture of the polyhydroxy fatty acid amides it will typically be necessary to at least partially neutralize the base catalyst used to form the amide bond. While any acid can be used for this purpose, the detergent formulator will recognize that it is a simple and convenient matter to use an acid which provides an anion that is otherwise useful and desirable in the finished detergent composition. For example, citric acid can be used for purposes of neutralization and the resulting citrate ion (ca. 1%) be allowed to remain with a ca. 40% polyhydroxy fatty acid amide slurry and be pumped into the later manufacturing stages of the overall detergent-manufacturing process. The acid forms of materials such- as oxydisuccinate, nitrilotriacetate, ethylenediaminetetraacetate, tartrate/succinate, and the like, can be used similarly.
The polyhydroxy fatty acid amides derived from coconut alkyl fatty acids (predominantly C12-C14) are more soluble than their tallow alkyl (predominantly C16-C18) counterparts. Accordingly, the C12-C14 materials are somewhat easier to formulate in liquid compositions, and are more soluble in cool-water laundering baths. However, the C16-C18 materials are also quite useful, especially under circumstances where warm-to-hot wash water is used. Indeed, the C16-C18 materials may be better detersive surfactants than their C12-C14 counterparts. Accordingly, the formulator may wish to balance ease-of-manufacture vs. performance when selecting a particular polyhydroxy fatty acid amide for use in a given formulation.
It will also be appreciated that the solubility of the polyhydroxy fatty acid amides can be increased by having points of unsaturation and/or chain branching in the fatty acid moiety. Thus, materials such as the polyhydroxy fatty acid amides derived from oleic acid and iso-stearic acid are more soluble than their n-alkyl counterparts.
Likewise, the solubility of polyhydroxy fatty acid amides prepared from disaccharides, trisaccharides, etc., will ordinarily be greater than the solubility of their onosaccharide-derived counterpart materials. This higher solubility can be of particular assistance when formulating liquid compositions. Moreover, the polyhydroxy fatty acid amides wherein the polyhydroxy group is derived from maltose appear to function especially well as detergents when used in combination with conventional alkylbenzene sulfonate ("LAS") surfactants. While not intending to be limited by theory, it appears that the combination of LAS with the polyhydroxy fatty acid amides derived from the higher saccharides such as maltose causes a substantial and unexpected lowering of interfacial tension in aqueous media, thereby enhancing net detergency performance. (The manufacture of a polyhydroxy fatty acid amide derived from maltose is described hereinafter.)
The polyhydroxy fatty acid amides can be manufactured not only from the purified sugars, but also from hydrolyzed starches, e.g., corn starch, potato starch, or any other convenient plant-derived starch which contains the mono-, di-, etc. sacchari-de desired by the formulator. This is of particular importance from the economic standpoint. Thus, "high glucose" corn syrup, "high maltose" corn syrup, etc. can conveniently and economically be used. De-lignified, hydrolyzed cellulose pulp can also provide a raw material source for the polyhydroxy fatty acid amides.
As noted above, polyhydroxy fatty acid amides derived from the higher saccharides, such as maltose, lactose, etc., are more soluble than their glucose counterparts. Moreover, it appears that the more soluble polyhydroxy fatty acid amides can help solubilize their less soluble counterparts, to varying degrees. Accordingly, the formulator may elect to use a raw material comprising a high glucose corn syrup, for example, but to select a syrup which contains a modicum of maltose (e.g., 1% or more). The resulting mixture of polyhydroxy fatty acids will, in general, exhibit more preferred solubility properties over a broader range of temperatures and concentrations than would a "pure" glucose-derived polyhydroxy fatty acid amide. Thus, in addition to any economic advantages for using sugar mixtures rather than pure sugar reactants, the polyhydroxy fatty acid amides prepared from mixed sugars can offer very substantial advantages with respect to performance and/or ease-of- formulation. In some instances, however, some loss of grease removal performance (dishwashing) may be noted at fatty acid malt¬ amide levels above about 25% and some loss in sudsing above about 33% (said percentages being the percentage of maltamide-derived polyhydroxy fatty acid amide vs. glucose-derived polyhydroxy fatty acid amide in the mixture). This can vary somewhat, depending on the chain length of the fatty acid moiety. Typically, then, the formulator electing to use such mixtures may find it advantageous to select polyhydroxy fatty acid amide mixtures which contain ratios of monosaccharides (e.g., glucose) to di- and higher saccharides (e.g., maltose) from about 4:1 to about 99:1.
The manufacture of preferred, uncyclized polyhydroxy fatty acid amides from fatty esters and N-alkyl polyols can be carried out in alcohol solvents at temperatures from about 30*C-90βC, preferably about 50βC-80'C. It has now been determined that it may be conven¬ ient for the formulator of, for example, liquid detergents to conduct such processes in 1,2-propylene glycol solvent, since the glycol solvent need not be completely removed from the reaction product prior to use in the finished detergent formulation. Like- wise, the formulator of, for example, solid, typically granular, detergent compositions may find it convenient to run the process at 30"C-90*C in solvents which comprise ethoxylated alcohols, such as the ethoxylated (EO 3-8) C12-C14 alcohols, such as those available as NEODOL 23 E06.5 (Shell). When such ethoxylates are used, it is preferred that they not contain substantial amounts of unethoxylated alcohol and, most preferably, not contain substantial amounts of mono-ethoxylated alcohol. ("T" designation.) While methods for making polyhydroxy fatty acid amides per se form no part of the invention herein, the formulator can also note other syntheses of polyhydroxy fatty acid amides as described hereinafter. Typically, the industrial scale reaction sequence for preparing the preferred acyclic polyhydroxy fatty acid amides will comprise: Step 1 - preparing the N-alkyl polyhydroxy amine derivative from the desired sugar or sugar mixture by formation of an adduct of the N-alkyl amine and the sugar, followed by reaction with hydrogen in the presence of a catalyst; followed by Step 2 - reacting the aforesaid polyhydroxy amine with, preferably, a fatty ester to form an amide bond. While a variety of N-alkyl polyhydroxy amines useful in Step 2 of the reaction sequence can be prepared by various art-disclosed processes, the following process is convenient and makes use of economical sugar syrup as the raw material. It is to be understood that, for best results when using such syrup raw materials, the manufacturer should select syrups that are quite light in color or, preferably, nearly colorless ("water-white"). Preparation of N-Alkyl Polyhydroxy Amine From Plant-Derived Sugar Syrup
I. Adduct Formation - The following is a standard process in which about 420 g of about 55% glucose solution (corn syrup - about 231 g glucose - about 1.28 moles) having a Gardner Color of less than 1 is reacted with about 119 g of about 50% aqueous methylamine (59.5 g of methylamine - 1.92 moles) solution. The methylamine (MMA) solution is purged and shielded with N2 and cooled to about 10βC, or less. The corn syrup is purged and shielded with N2 at a temperature of about 10#-20'C. The corn syrup is added slowly to the MMA solution at the indicated reaction temperature as shown. The Gardner Color is measured at the indicated approximate times in minutes.
TABLE 1
As can be seen from the above data, the Gardner Color for the adduct is much worse as the temperature is raised above about 30'C and at about 50'C, the time that the adduct has a Gardner Color below 7 is only about 30 minutes. For longer reaction, and/or holding times, the temperature should be less than about 20'C. The Gardner Color should be less than about 7, and preferably less than about 4 for good color glucamine.
When one uses lower temperatures for forming the adduct, the time to reach substantial equilibrium concentration of the adduct is shortened by the use of higher ratios of amine to sugar. With the 1.5:1 mole ratio of amine to sugar noted, equilibrium is reached in about two hours at a reaction temperature of about 30'C. At a 1.2:1 mole ratio, under the same conditions, the time is at least about three hours. For good color, the combination of amine:sugar ratio; reaction temperature; and reaction time is selected to achieve substantially equilibrium conversion, e.g., more than about 90%, preferably more than about 95%, even more preferably more than about 99%, based upon the sugar, and a color that is less than about 7, preferably less than about 4, more preferably less than about 1, for the adduct.
Using the above process at a reaction temperature of less than about 20'C and corn syrups with different Gardner Colors as indicated, the MMA adduct color (after substantial equilibrium is reached in at least about two hours) is as indicated. TABLE 2 Gardner Col or (Approximate)
Corn syrup 1 1 1 1+ 0 0 0+
Adduct 3 4/5 7/8 7/8 1 2 1
As can be seen from the above, the starting sugar materi al must be very near col orl ess in order to consi stently have adduct that i s acceptabl e. When the sugar has a Gardner Col or of about 1 , the adduct i s sometimes acceptabl e and sometimes not acceptabl e. When the Gardner Col or i s above 1 the resul ting adduct i s unacceptabl e. The better the initi al col or of the sugar, the better i s the col or of the adduct . II. Hydrogen Reaction - Adduct from the above having a Gardner Color of 1 or less is hydrogenated according to the following procedure.
About 539 g of adduct in water and about 23.1 g of United Catalyst G49B Ni catalyst are added to a one liter autoclave and purged two times with 200 psig H2 at about 20'C. The H2 pressure is raised to about 1400 psi and the temperature is raised to about 50'C. The pressure is then raised to about 1600 psig and the temperature is held at about 50-55'C for about three hours. The product is about 95% hydrogenated at this point. The temperature is then raised to about 85"C for about 30 minutes and the reaction mixture is decanted and the catalyst is filtered out. The product, after removal of water and MMA by evaporation, is about 95% N-methyl glucamine, a white powder. The above procedure is repeated with about 23.1 g of Raney Ni catalyst with the following changes. The catalyst is washed three times and the reactor, with the catalyst in the reactor, is purged twice with 200 psig H2 and the reactor is pressurized with H2 at 1600 psig for two hours, the pressure is released at one hour and the reactor is repressurized to 1600 psig. The adduct is then pumped into the reactor which is at 200 psig and 20*C, and the reactor is purged with 200 psig H2, etc., as above.
The resulting product in each case is greater than about 95% N-methyl glucamine; has less than about 10 ppm Ni based upon the glucamine; and has a solution color of less than about Gardner 2.
The crude N-methyl glucamine is color stable to about 140*C for a short exposure time.
It is important to have good adduct that has low sugar content (less than about 5%, preferably less than about 1%) and a good color (less than about 7, preferably less than about 4 Gardner, more preferably less than about 1).
In another reaction, adduct is prepared starting with about 159 g of about 50% methylamine in water, which is purged and shielded with N2 at about 10-20'C. About 330 g of about 70% corn syrup (near water-white) is degassed with N2 at about 50°C and is added slowly to the methylamine solution at a temperature of less than about 20'C. The solution is mixed for about 30 minutes to give about 95% adduct that is a very light yellow solution.
About 190 g of adduct in water and about 9 g of United Catalyst G49B Ni catalyst are added to a 200 ml autoclave and purged three times with H2 at about 20'C. The H2 pressure is raised to about 200 psi and the temperature is raised to about 50'C. The pressure is raised to 250 psi and the temperature is held at about 50-55'C for about three hours. The product, which is about 95% hydrogenated at this point, is then raised to a temperature of about 85°C for about 30 minutes and the product, after removal of water and evaporation, is about 95% N-methyl glucamine, a white powder.
It is also important to minimize contact between adduct and catalyst when the H2 pressure is less than about 1000 psig to minimize Ni content in the glucamine. The nickel content in the N-methyl glucamine in this reaction is about 100 ppm as compared to the less than 10 ppm in the previous reaction.
The following reactions with H2 are run for direct comparison of reaction temperature effects.
A 200 ml autoclave reactor is used following typical procedures similar to those set forth above to make adduct and to run the hydrogen reaction at various temperatures.
Adduct for use in making glucamine is prepared by combining about 420 g of about 55% glucose (corn syrup) solution (231 g glucose; 1.28 moles) (the solution is made using 99DE corn syrup from CarGill, the solution having a color less than Gardner 1) and about 119 g of 50% methylamine (59.5 g MMA; 1.92 moles) (from Air Products).
The reaction procedure is as follows:
1. Add about 119 g of the 50% methylamine solution to a N2 purged reactor, shield with N2 and cool down to less than about lO'C.
2. Degas and/or purge the 55% corn syrup solution at 10-20'C with N2 to remove oxygen in the solution.
3. Slowly add the corn syrup solution to the methylamine solution and keep the temperature less than about 20'C. 4. Once all corn syrup solution is added in, agitate for about 1-2 hours. The adduct is used for the hydrogen reaction right after making, or is stored at low temperature to prevent further degradation.
The glucamine adduct hydrogen reactions are as follows: 1. Add about 134 g adduct (color less than about Gardner 1) and about 5.8 g G49B Ni to a 200 ml autoclave.
2. Purge the reaction mix with about 200 psi H2 twice at about 20-30'C.
3. Pressure with H2 to about 400 psi and raise the temperature to about 50'C.
4. Raise pressure to about 500 psi, react for about 3 hours. Keep temperature at about 50-55'C. Take Sample 1.
5. Raise temperature to about 85'C for about 30 minutes.
6. Decant and filter out the Ni catalyst. Take Sample 2. Conditions for constant temperature reactions:
1. Add about 134 g adduct and about 5.8 g G49B Ni to a 200 ml autoclave.
2. Purge with about 200 psi H2 twice at low temperature.
3. Pressure with H2 to about 400 psi and raise temperature to about 50'C.
4. Raise pressure to about 500 psi, react for about 3.5 hours. Keep temperature at indicated temperature.
5. Decant and filter out the Ni catalyst. Sample 3 is for about 50-55'C; Sample 4 is for about 75'C; and Sample 5 is for about 85'C. (The reaction time for about 85'C is about 45 minutes.) All runs give similar purity of N-methyl glucamine (about 94%); the Gardner Colors of the runs are similar right after reaction, but only the two-stage heat treatment gives good color stability; and the 85*C run gives marginal color immediately after reaction. EXAMPLE 22
The preparation of the tallow (hardened) fatty acid amide of N-methyl maltamine for use in detergent compositions according to this invention is as follows.
Step 1 - Reactants: Maltose monohydrate (Aldrich, lot 01318KW); methylamine (40 wt% in water) (Aldrich, lot 03325TM); Raney nickel, 50% slurry (UAD 52-73D, Aldrich, lot 12921LW). The reactants are added to glass liner (250 g maltose, 428 g methylamine solution, 100 g catalyst slurry - 50 g Raney Ni) and placed in 3 L rocking autoclave, which is purged with nitrogen (3X500 psig) and hydrogen (2X500 psig) and rocked under H2 at room temperature over a weekend at temperatures ranging from 28'C to 50'C. The crude reaction mixture is vacuum filtered 2X through a glass microfiber filter with a silica gel plug. The filtrate is concentrated to a viscous material. The final traces of water are azetroped off by dissolving the material in methanol and then removing the methanol/water on a rotary evaporator. Final drying is done under high vacuum. The crude product is dissolved in refluxing methanol, filtered, cooled to recrystallize, filtered and the filter cake is dried under vacuum at 35*C. This is cut #1. The filtrate is concentrated until a precipitate begins to form and is stored in a refrigerator overnight. The solid is filtered and dried under vacuum. This is cut #2. The filtrate is again concentrated to half its volume and a recrystallization is performed. Very little precipitate forms. A small quantity of ethanol is added and the solution is left in the freezer over a weekend. The solid material is filtered and dried under vacuum. The combined solids comprise
N-methyl maltamine which is used in Step 2 of the overall synthesis.
Step 2 - Reactants: N-methyl maltamine (from Step 1); hardened tallow methyl esters; sodium methoxide (25% in methanol); absolute methanol (solvent); mole ratio 1:1 amine:ester; initial catalyst level 10 mole % (w/r maltamine), raised to 20 mole %; solvent level- 50% (wt.).
In a sealed bottle, 20.36 g of the tallow methyl ester is heated to its melting point (water bath) and loaded into a 250 ml 3-neck round-bottom flask with mechanical stirring. The flask is heated to ca . 70'C to prevent the ester from solidifying. Separ¬ ately, 25.0 g of N-methyl maltamine is combined with 45.36 g of methanol, and the resulting slurry is added to the tallow ester with good mixing. 1.51 g of 25% sodium methoxide in methanol is added. After four hours the reaction mixture has not clarified, so an additional 10 mole % of catalyst (to a total of 20 mole %) is added and the reaction is allowed to continue overnight (ca . 68'C) after which time the mixture is clear. The reaction flask is then modified for distillation. The temperature is increased to llO'C. Distillation at atmospheric pressure is continued for 60 minutes. High vacuum distillation is then begun and continued for 14 minutes, at which time the product is very thick. The product is allowed to remain in the reaction flask at 110'C (external temperature) for 60 minutes. The product is scraped from the flask and triturated in ethyl ether over a weekend. Ether is removed on a rotary evaporator and the product is stored in an oven overnight, and ground to a powder. Any remaining N-methyl maltamine is removed from the product using silica gel. A silica gel slurry in 100% methanol is loaded into a funnel and washed several times with 100% methanol. A concentrated sample of the product (20 g in 100 ml of 100% methanol) is loaded onto the silica gel and eluted several times using vacuum and several methanol washes. The collected eluant is evaporated to dryness (rotary evaporator). Any remaining tallow ester is removed by trituration in ethyl acetate overnight, followed by filtration. The filter cake is vacuum dried overnight. The product is the tallowalkyl N-methyl maltamide.
In an alternate mode, Step 1 of the foregoing reaction sequence can be conducted using commercial corn syrup comprising glucose or mixtures of glucose and, typically, 5%, or higher, maltose. The resulting polyhydroxy fatty acid amides and mixtures can be used in any of the detergent compositions herein.
In still another mode, Step 2 of the foregoing reaction sequence can be carried out in 1,2-propylene glycol or NEODOL. At the discretion of the formulator, the propylene glycol or NEODOL need not be removed from the reaction product pri«r to its use to formulate detergent compositions. Again, according to the desires of the formulator, the methoxide catalyst can be neutralized by citric acid to provide sodium citrate, which can remain in the polyhydroxy fatty acid amide.
Depending on the desires of the formulator, the compositions herein can contain more or less of various suds control agents. Typically, for dishwashing high sudsing is desirable so no suds control agent will be used. For fabric laundering in top-loading washing machines some control of suds may be desirable, and for front-loaders some considerable degree of suds control may be preferred. A wide variety of suds control agents are known in the art and can be routinely selected for use herein. Indeed, the selection of suds control agent, or mixtures of suds control agents, for any specific detergent composition will depend not only on the presence and amount of polyhydroxy fatty acid amide used therein, but also on the other surfactants present in the formulation. However, it appears that, for use with polyhydroxy fatty acid amides, silicone-based suds control agents of various types are more efficient (i.e., lower levels can be used) than various other types of suds control agents. The silicone suds control agents available as X2-3419 and Q2-3302 (Dow Corning) are particularly useful.
The formulator of fabric laundering compositions which can advantageously contain soil release agent has a wide variety of known materials to choose from (see, for example, U.S. Patents 3,962,152; 4,116,885; 4,238,531; 4,702,857; 4,721,580 and 4,877,896). Additional soil release materials useful herein include the nonionic oligomeric esterification product of a reaction mixture comprising a source of C!-C4 alkoxy-terminated polyethoxy units (e.g., CH3[0CH2CH2]160H), a source of terephthaloyl units (e.g., dimethyl terephthalate); a source of poly(oxyethylene)oxy units (e.g., polyethylene glycol 1500); a source of oxyiso-propyleneoxy units (e.g., 1,2-propylene glycol); and a source of oxyethyleneoxy units (e.g., ethylene glycol) especially wherein the mole ratio of oxyethyleneoxy units:oxyiso-propyleneoxy units is at least about rmula
wherein R1 is lower (e.g., Cχ-C4) alkyl, especially methyl; x and y are each integers from about 6 to about 100; m is an integer of from about 0.75 to about 30; n is an integer from about 0.25 to about 20; and Rz is a mixture of both H and CH3 to provide a mole ratio of oxyethyleneoxy:oxyisopropyleneoxy of at least about 0.5:1.
Another preferred type of soil release agent useful herein is of the general anionic type described in U.S. Patent 4,877,896, but with the condition that such agents be substantially free of monomers of the HOROH type wherein R is propylene or higher alkyl. Thus, the soil release agents of U.S. Patent 4,877,896 can comprise, for example, the reaction product of dimethyl terephthalate, ethylene glycol, 1,2-propylene glycol and 3-sodiosulfobenzoic acid, whereas these additional soil release agents can comprise, for example, the reaction product of dimethyl terephthalate, ethylene glycol, 5-sodiosulfoisophthalate and 3-sodiosulfobenzoic acid. Such agents are preferred for use in granular laundry detergents. The formulator may also determine that it is advantageous to include a non-perborate bleach, especially in heavy-duty granular laundry detergents. A variety of peroxygen bleaches are available, commercially, and can be used herein, but, of these, percarbonate is convenient and economical. Thus, the compositions herein can contain a solid percarbonate bleach, normally in the form of the sodium salt, incorporated at a level of from 3% to 20% by weight, more preferably from 5% to 18% by weight and most preferably from 8% to 15% by weight of the composition.
Sodium percarbonate is an addition compound having a formula corresponding to 2Na2C03. 3H202, and is available commercially as a crystalline solid. Most commercially available material includes a low level of a heavy metal sequestrant such as EDTA, 1-hydroxyethylidene 1,1-diphosphonic acid (HEDP) or an amino-phosphonate, that is incorporated during the manufacturing process. For use herein, the percarbonate can be incorporated into detergent compositions without additional protection, but preferred embodiments of the invention utilize a stable form of the material (FMC). Although a variety of coatings can be used, the most economical is sodium silicate of Si02:Na20 ratio from 1.6:1 to 2.8:1, preferably 2.0:1, applied as an aqueous solution and dried to give a level of from 2% to 10% (normally from 3% to 5%), of silicate solids by weight of the percarbonate. Magnesium silicate can also be used and a chelant such as one of those mentioned above can also be included in the coating. The particle size range of the crystalline percarbonate is from 350 micrometers to 450 micrometers with a mean of approximately 400 micrometers. When coated, the crystals have a size in the range from 400 to 600 micrometers.
While heavy metals present in the sodium carbonate used to manufacture the percarbonate can be controlled by the inclusion of sequestrants in the reaction mixture, the percarbonate still requires protection from heavy metals present as impurities in other ingredients of the product. It has been found that the total level of iron, copper and manganese ions in the product should not exceed 25 ppm and preferably should be less than 20 ppm in order to avoid an unacceptably adverse effect on percarbonate stability.
A modern, condensed laundry detergent granule is as follows.
EXAMPLE 23 Ingredient Wt.%
C14.15 alkyl alcohol sulfonic acid 13 C14.15 alkyl polyethoxy (2.25) sulfonic acid 5.60 C12_13 alkyl polyethoxylate (6.5) 1.45 ci2-i4 fatty acid N-methyl glucamide 2.50
Sodium aluminosilicate (as hydrated Zeolite A) 25.2 Crystalline layered silicate builder1 23.3 Citric acid 10.0
Sodium carbonate To get wash pH = 9.90
Sodium polyacrylate ( .w. 2000-4500) 3.2
Diethylenetriamine pentaacetic acid 0.45
Savinase2 0.70 6-Nonanoylamino-6-oxo-peroxycaproic acid 7.40
Sodium perborate monohydrate 2.10
Nonanoyloxybenzene sulfonic acid 5.00
Brightener 0.10
1Layered silicate builders are known in the art. Preferred are the layered sodium silicates. See, for example, the layered sodium silicate builders of U.S. Patent 4,664,859, issued May 12, 1987 to H. P. Rieck, incorporated herein by reference. A suitable layered silicate builder is available as SKS-6 from Hoechst. 2Avail ble from Novo Nordisk A/S, Copenhagen. Highly preferred granules of the foregoing types are those which comprise from about 0.0001% to about 2% by weight of active enzyme and at least about 1% by weight of said polyhydroxy fatty acid amide, and, most preferably, wherein the anionic surfactant is not an alkylbenzene sulfonate surfactant.
The following relates to the preparation of a preferred liquid heavy duty laundry detergent according to this invention. It will be appreciated that the stability of enzymes in such compositions is considerably less than in granular detergents. However, by using typical enzyme stabilizers such as formate and boric acid, lipase and cellulase enzymes can be protected from degradation by protease enzymes. However, lipase stability is still relatively poor in the presence of alkylbenzene sulfonate ("LAS") surfactants. Apparently, LAS partially denatures lipase, and, further, it seems that denatured lipase is more vulnerable to attack by protease.
In view of the foregoing considerations, which, as noted, can be particularly troublesome in liquid compositions, it is a challenge to provide liquid detergent compositions containing lipase, protease and cellulase enzymes, together. It is particu¬ larly challenging to provide such tertiary enzyme systems in stable liquid detergents together with an effective blend of detersive surfactants. Additionally, it is difficult to incorporate peroxidase and/or amylase enzymes stably in such compositions.
It has now been determined that various mixtures of upases, proteases, cellulases, amylases and peroxidases are adequately stable in the presence of certain non-alkylbenzene sulfonate surfactant systems, such that effective, heavy-duty solid and even liquid detergents can be formulated. Indeed, the formulation of stable, liquid, enzyme-containing detergent compositions constitutes a highly advantageous and preferred embodiment -afforded by the technology of the present invention.
In particular, prior art liquid detergent compositions typically contain LAS or mixtures of LAS with surfactants of the RO(A)mS03M type ("AES") noted hereinabove, i.e., LAS/AES mixtures. By contrast, the liquid detergents herein preferably comprise binary mixtures of the AES and polyhydroxy fatty acid amides of the type disclosed herein. While minimal amounts of LAS can be present, it will be appreciated that the stability of the enzymes will be lessened thereby. Accordingly, it is preferred that the liquid compositions be substantially free (i.e., contain less than about 10%, preferably less than about 5%, more preferably less than about 1%, most preferably 0%) of LAS.
The present invention provides a liquid detergent composition comprising: (a) from about 1% to about 50%, preferably from about 4% to about 40%, of anionic surfactant;
(b) from about 0.0001% to about 2% of active detersive enzyme;
(c) an enzyme performance-enhancing amount (preferably from about 0.5% to about 12%) of a polyhydroxy fatty acid amide material of the formula
0 R1
II I
R2 - C - N - Z wherein R1 is H1} Cχ-C4 hydrocarbyl, 2-hydroxy ethyl, 2-hydroxy propyl, or a mixture thereof, R2 is C5-C31 hydrocarbyl, and Z is a polyhydroxylhydrocarbyl having a linear hydrocarbyl chain with at least 3 hydroxyls directly connected to said chain, or an alkoxylated derivative thereof; and wherein the composition is substantially free of alkylbenzene sulfonate.
The water-soluble anionic surfactant herein preferably comprises ("AES"):
R0(A)m S03 M wherein R is an unsubstituted C10-C24 alkyl or hydroxyalkyl (Cι0-C24) group, A is an ethoxy or propoxy unit, m is an integer greater than 0 and M is hydrogen or a cation. Preferably, R is an unsubstituted C12-C18 alkyl group, A is an ethoxy unit, m is from about 0.5 to about 6, and M is a cation. The cation is preferably a metal cation (e.g., sodium-preferred, potassium, lithium, calcium, magnesium, etc.) or an ammonium or substituted ammonium cation.
It is preferred that the ratio of the above surfactant ("AES") to the polyhydroxy fatty acid amide herein be from about 1:2 to about 8:1, preferably about 1:1 to about 5:1, most preferably about 1:1 to about 4:1. The liquid compositions herein may alternatively comprise polyhydroxy fatty acid amide, AES, and from about 0.5% to about 5% of the condensation product of C8-C22 (preferably C10-C20) linear alcohol with between about 1 and about 25, preferably between about 2 and about 18, moles of ethylene oxide per mole of alcohol.
As described above, the liquid compositions herein preferably have a pH in a 10% solution in water at 20'C of from about 6.5 to about 11.0, preferably from about 7.0 to about 8.5.
The instant compositions preferably further comprise from about 0.1% to about 50% of detergency builder. These compositions preferably comprise from about 0.1% to about 20% of citric acid, or water-soluble salt thereof, and from about 0.1% to about 20% of a water-soluble succinate tartrate, especially the sodium salt thereof, and mixtures thereof, or from about 0.1% to about 20% by weight of oxydisuccinate or mixtures thereof with the aforesaid builders. 0.1%-50% alkenyl succinate can also be used.
The preferred liquid compositions herein comprise from about 0.0001% to about 2%, preferably about 0.0001% to about 1%, most preferably about 0.001% to about 0.5%, on an active basis, of detersive enzyme. These enzymes are preferably selected from the group consisting of protease (preferred), lipase (preferred), amylase, cellulase, peroxidase, and mixtures thereof. Preferred are compositions with two or more classes of enzymes, most preferably where one is a protease.
While various descriptions of detergent proteases, cellulases, etc., are available in the literature, detergent upases may be somewhat less familiar. Accordingly, to assist the formulator, lipases of interest include Amano AKG and Bacillis Sp lipase (e.g., Solvay enzymes). Also, see the lipases described in EP A 0399 681, published November 28, 1990, EP A 0 218272, published April 15, 1987 and PCT/DK 88/00177, published May 18, 1989, all incorporated herein by reference. Suitable fungal Upases include those producible by Humicola lanuginosa and Ther o yces lanuginosus. Most preferred is the lipase obtained by cloning the gene from Humicola lanuginosa and expressing the gene in Aspergi l lus oryzae, as described in European Patent Application 0 258068, incorporated herein by reference, commercially available under the trade name LIP0LASE.
From about 2 to about 20,000, preferably about 10 to about 6,000, lipase units of lipase per gram (LU/g) of product can be used in these compositions. A lipase unit is that amount of lipase which produces 1 μmol of titratable butyric acid per minute in a pH stat, where pH is 7.0, temperature is 30'C, and substrate is an emulsion tributyrin and gum arabic, in the presence of Ca++ and NaCl in phosphate buffer.
The following Example illustrates a preferred heavy duty liquid detergent composition comprising:
(a) an enzyme selected from proteases, cellulases and upases, or, preferably, a mixture thereof, typically comprising from about 0.01% to about 2% by weight of the total composition, although the amounts used can be adjusted according to the desires of the formulator to provide an "effective" amount (i.e., soil -removing amount) of said enzyme or enzyme mixture; (b) a polyhydroxy fatty acid amine surfactant of the type disclosed herein, typically comprising at least about 2% by weight of the composition, more typically from about 3% to about 15%, preferably from about 7% to about 14%; (c) a surfactant of the R0(A)mS03M type, as disclosed herein, preferably R0(CH2CH20)mS03M, wherein R is C14-C15 (avg.) and is 2-3 (avg.), wherein M is H or a water-soluble salt-forming cation, e.g., Na+, said surfactant typically comprising from about 5% to about 25% by weight of the composition; (d) optionally, a surfactant of the R0S03M type, as disclosed- herein, preferably wherein R is C12-C14 (avg.), said surfactant preferably comprising from about 1% to about 10% by weight of the compositions;
(e) a liquid carrier, especially water or water-alcohol mixtures;
(f) optionally, but most preferably, effective amounts of enzyme stabilizers, typically about 1% to about 10%, by weight of the composition;
(g) water-soluble polycarboxylate builders, typically at about 4% to about 25% by weight of the composition; (h) optionally, the various detersive adjuncts, brighteners, etc., noted hereinabove, typically (if used) at about 1% to about 10% by weight of the composition; and (i) the composition is substantially free from LAS. EXAMPLE 24
Ingredients Wt.%
C14-15 alkyl polyethoxylate (2.25) sulfonic acid 21.00
C12-14 fatty acid N-methyl glucamide1 7.00
Sodium tartrate mono- and di-succinate (80:20 mix) 4.00 Citric acid 3.80
C12-14 fatty acid 3.00
Tetraethylene pentaamine ethoxylate(15-18) 1.50
Ethoxylated copolymer of polyethylene 0.20
- polypropylene terephthalate polysulfonic acid Protease B (34g/l)2 0.68
Lipase (100KLU/g)3 0.47
Cellulase (5000 cevu/g)4 0.14
Brightener 365 0.15
Ethanol 5.20 Monoethanolamine 2.00
Sodium formate 0.32
1,2 propane diol 8.00
Sodium hydroxide 3.10
Silicone suds suppressor 0.0375 Boric acid 2.00
Water/misc. Balance to 100
Prepared as disclosed above.
2Protease B is a modified bacterial serine protease described in European Patent Application Serial No. 87 303761 filed April 28, 1987, particularly pages 17, 24 and 98.
3Lipase used herein is the lipase obtained by cloning the gene from Humicola lanuginosa and expressing the gene in Aspergi l lus oryzae, as described in European Patent Application 0 258068, commercially available under the trade name LIPOLASE (ex Novo Nordisk A/S, Copenhagen Denmark).
4Cellulase used herein is sold under the trademark CAREZYME (Novo Nordisk, A/S, Copenhagen Denmark). 5Brightener 36 is commercially available as TINOPAL TAS 36.
The brightener is added to the composition as a separately prepared pre-mix of brightener (4.5%), monoethanolamine (60%) and water (35.5%).
EXAMPLE 25
The following illustrates a perborate bleach-plus-bleach activator detergent composition of the present invention which is prepared by admixing the listed ingredients in a mixing drum.
In the example, Zeolite A refers to hydrated crystalline Zeolite A containing about 20% water and having an average particle size of 1 to 10, preferably 2 to 5, microns; LAS refers to sodium ci2.3 linear alkylbenzene sulfonate; AS refers to sodium C14-C15 alkyl sulfate; nonionic refers to coconut alcohol condensed with about 6.5 moles of ethylene oxide per mole of alcohol and stripped of unethoxylated and monoethoxylated alcohol, also abbreviated as CnAE6.5T.; and DTPA refers to sodium diethylenetriamine pentaacetate.
Parts by Weight of
NOBS Granules3 3.88 100.00
NOBS 3.15 81.19
LAS 0.12 3.09
PEG 8000 0.19 4.90 Misc. 0.42 10.82
Zeolite Granules4 12.00 100.00
Sodium aluminosilicate 7.39 61.58
PEG 8000 1.50 12.47
Nonionic 1.16 9.70 Moisture 1.66 13.83
M^sc. 0.29 2.42
Admix
Sodium SKS-6 layered silicate 15.84 Protease
(0.078 mg/g activity) 0.52 Sodium perborate monohydrate 1.33
Citric acid 6.79 C12-C14 N-methyl glucamide 1.58
Total of final composition 100.00
-The base granules are produced by spray drying an aqueous crutcher mix of the listed ingredients.
2A freshly-prepared sample of NAPAA wet cake, which typically consists of about 60% water, about 2% peroxyacid available oxygen
(AvO) (corresponding to about 36% NAPAA), and the rest (about 4%) unreacted starting material, is obtained. This wet cake is the crude reaction product of NAAA (monononyl imide of a.dipic icid), sulfuric acid, and hydrogen peroxide which is subsequently quenched by addition to water followed by filtration, washing with distilled water, phosphate buffer washing and final suction filtration to recover the wet cake. A portion of the wet cake is air-dried at room temperature to obtain a dry sample which typically consists of about 5% AvO (corresponding to about 90% NAPAA) and about 10% unreacted starting material. When dry, the sample pH is about 4.5.
NAPAA granules are prepared by mixing about 51.7 parts of the dried NAPAA wet cake (containing about 10% unreacted), about 11.1 parts of sodium C12.3 linear alkyl benzene sulfonate (LAS) paste (45% active), about 43.3 parts of sodium sulfate, and about 30 parts of water in a CUISINART mixer. After drying, the granules (which contain about 47% NAPAA) are sized by passing through a No. 14 Tyler mesh sieve and retaining all particles not passing through a No. 65 Tyler mesh. The average amide peroxyacid particle (agglomerate) size is about 5-40 microns and the median particle size is about 10-20 microns, as determined by Malvern particle size analysis.
3The NOBS (nonanoyloxybenzene sulfonate) granules are prepared according to U.S. Patent 4,997,596, Bowling et al , issued March 5, 1991, incorporated herein by reference.
4Zeolite granules having the following composition are made by mixing Zeolite A with PEG 8000 and CnAE6.5T in an Eirich R08 energy intensive mixer. Parts by Wei ht
The PEG 8000 is in an aqueous form containing 50% water and is at a temperature of approximately 55*F (12.8'C). The CnAE6.5T is in a liquid state and is held at approximately 90'F (32.2"C). The two liquids are combined by pumping through a 12 element static mixer. The resulting binder material has an outlet temperature of- approximately 75'F (23.9'C) and a viscosity of approximately 5000 cps. The ratio of PEG 8000 and CnAE6.5T through the static mixer is 72:28 respectively.
The Eirich R08 energy intensive mixer is operated in a batch type mode. First, 34.1 kg of powdered Zeolite A is weighed into the pan of the mixer. The mixer is started by first rotating the pan in a counterclockwise direction at approximately 75 rotations per minute (rpm), and then rotating the rotor blade in a clockwise direction at 1800 rpm. The binder material is then pumped from the static mixer directly into the Eirich R08 energy intensive mixer which contains Zeolite A. The feed rate of the binder material is about 2 minutes. The mixer continues to mix for an additional 1 minute for a total batch time of approximately 3 minutes. The batch is then discharged and collected in a fiber drum.
The batch step is repeated until approximately 225 kg of wet product has been collected. This discharged product is then dried in a fluid bed at 240-270'F (116-132'C). The drying step removes most of the free water and changes the composition as described above. The total energy input by the mixer to the product in a batch mode is approximately 1.31X1012 erg/kg. at a rate of approximately 2.18X109 erg/kg-s. The resulting free flowing agglomerates have a mean particle size of about 450-500 microns.
EXAMPLE 26 A liquid laundry detergent composition suitable for use at the relatively high concentrations common to front-loading automatic washing machines, especially in Europe, and over a wide range of temperatures is as follows.
Ingredient Wt. %
Coconutal yl (C12) N-methyl glucamide 14
C14.15E0(2.25) sulfate, Na salt 10.0 C14.15E0(7) 4.0
C12.14 alkenylsuccinic anhydride1 4.0
C12.14 fatty acid* 3.0
Citric acid (anhydrous) 4.6
Protease (enzyme)2 0.37 Termamyl (enzyme)3 0.12
Lipolase (enzyme)4 0.36
Carezyme (enzyme)5 0.12
Dequest 2060S6 1.0
NaOH (pH to 7.6) 5.5 1,2 propanediol 4.7
Ethanol 4.0
Sodium metaborate 4.0
CaCl2 0.014
Ethoxylated tetraethylene pentamine7 0.4 Brightener8 0.13
Silane9 0.04
Soil release polymer10 0.2 Silicone (suds control)11 0.4
Silicone dispersant12 0.2
Water and minors Balance xAs SYNPRAX 3 from ICI or DTSA from Monsanto. 2As Protease B as described in EPO 0342177 November 15, 1989, percentage at 40 g/1.
3Amylase, from NOVO; percentage at 300 KNU/g. 4Lipase, from NOVO; percentage at 100 KLU/g. 5Cellulase from NOVO; percentage at 5000 CEVU/1. available from Monsanto.
7From BASF as LUTENSOL P6105. 8BLANK0PH0R CPG766, Bayer.
9Silane corrosion inhibitor, available as A1130 from Union Carbide or DYNASYLAN TRIAMINO from Hϋls. 10Polyester, per U.S. Patent 4,711,730.
11Silicone suds control agent available as 02-3302 from Dow Corning.
12Dispersant for silicone suds control agent available as DC-3225C from Dow Corning. *Preferred fatty acid is topped palm kernel, comprising 12% oleic acid and 2% each of stearic and linoleic.
EXAMPLE 27 A granular laundry detergent composition suitable for use at the relatively high concentrations common to front-loading automatic washing machines, especially in Europe, and over a wide range of temperatures is as follows.
Ingredient Wt. %
SOKALAN CP5 (100% active as Na salt)1 3.52
DEQUEST 2066 (100% as acid)2 0.45 TINOPAL DMS3 0.28
MgS04 0.49
Zeolite A (anhydrous 2-5 μ) 17.92
CMC (100% active)4 0.47
Na2C03 9.44 Citric acid 3.5
Layered Silicate SKS-6 12.9
Tallow alkyl sulfate (100% active; Na salt) 2.82 C14-C15 alkyl sulfate (100% active; Na salt) C12-C15 alkyl E0(3) sulfate C16-C18 N-methyl glucamide DOBANOL C12-C15 E0(3) LIPOLASE (100,000 LU/g)5 SAVINASE (4.0 KNPU)8 Perfume X2-34197 Starch Stearyl alcohol
Sodium percarbonate (coated) Tetraacetylethylenediamine (TAED) Zinc phthalocyanin Water (ex zeolite) ^OKALAN is sodium poly-acrylate/maleate Hoechst.
2Monsanto brand of pentaphosphonomethyl diethylenetriamine.
30ptical brightener available from Ciba Geigy.
4Trade name FINNFIX available from Metasaliton. 5LIP0LASE lipolytic enzyme from NOVO.
6SAVINASE protease enzyme from NOVO.
7X2-3419 is a silicone suds suppressor available from Dow Corning.
The procedure for preparing the granules comprises various tower-drying, agglomerating, dry-additions, etc., as follows. The percentages are based on the finished composition.
A. Crutched and Blown Through the Tower
Using standard techniques the following components are crutched and tower-dried. S0KALAN CP5 3.52%
DEQUEST 2066 0.45%
TINOPAL DMS 0.28%
Magnesium sulfate 0.49%
ZEOLITE A as anhydrous 7.1% CMC 0.47% B. Surfactant Agglomerates
Bl. Agglomeration of Sodium Salt of Tallow Alkyl Sulfate and Sodium Salt of C1?.1B E0(3) Sulfate Pastes - A 50% active paste of tallow alkyl sulfate and a 70% paste of C12-C15 E0(3) sulfate are agglomerated with Zeolite A and sodium carbonate according to the following formula (contribution to the detergent formulation after the drying of the agglomerate).
Tallow alkyl sulfate 2.82%
C12.15 E0(3) sulfate 1.18% Zeolite A 5.3%
Sodium carbonate 4.5% Ethoxy Sulfate. DOBANOL C17-C1C E0(3) and C,«-Cι. N-methyl glucose amide - The C16-C18 glucose amide nonionic material is synthesized with DOBANOL C12.15E0(3) present during the reaction of methyl ester and N-methyl glucamine. The C12.15E0(3) acts as a melting point depressor which allows the reaction to be run without forming cyclic glucose amides which are undesirable.
A surfactant mixture of 20% DOBANOL C12.15 E0(3) and 80% C16-C18 N-methyl glucose amide is obtained and coagglomerated with 10% sodium carbonate.
Second, the above particle is then coagglomerated with a high active paste (70%) of a sodium salt of C14-C15 alkyl sulfate and C12.15 E0(3) sulfate and Zeolite A and extra sodium carbonate. This particle evidences a good dispersibility in cold water of the- C16-C18 N-methyl glucose amide.
The overall formulation of this particle (contribution to the detergent formulation after the drying of the agglomerate) is: C16-C18 N-methyl glucose amide 4.1% DOBANOL C12.15 E0(3) 0.94%
Sodium carbonate 4.94%
Zeolite A 5.3%
Na C14-C15 alkyl sulfate 3.5%
Na C12.15 E0(3) sulfate 0.59% C. Dry Additives
The following ingredients are added.
Percarbonate 22.3%
TAED (tetraacetylethylenediamine) 5.9% Layered silicate SKS 6 from Hoechst
Citric acid
Lipolase
SAVINASE 4.0 KNPU
Zinc phthalocyanin (photobleach) D. Spray on DOBANOL C12.15 E0(3) Perfume E. Suds Suppressor
The silicone suds suppressor X2-3419 (95%-97% high molecular weight linear silicone; 3%-5% hydrophobic silica) ex Dow Corning is coagglomerated with Zeolite A (2-5 μ size), starch and stearyl alcohol binder. This particle has the following formulation: Zeolite A 0.22%
Starch 1.08%
X2-3419 0.22%
Stearyl alcohol 0.35%
The detergent preparation exhibits excellent solubility, superior performance and excellent suds control when used in European washing machine, e.g., using 85 g detergent in a AEG-brand washing machine in 30'C, 40'C, 60'C and 90"C cycles.
EXAMPLE 28
In any of the foregoing examples, the fatty acid glucamide surfactant can be replaced by an equivalent amount of the maltamide surfactant, or mixtures of glucamide/maltamide surfactants derived from plant sugar sources. In the compositions the use of ethanol- amides appears to help cold temperature stability of the finished formulations. Moreover, the use of sulfobetaine (aka "sultaine") surfactants provides superior sudsing.
In the event that especially high sudsing compositions are desired, it is preferred that less than about 5%, more preferably less than about 2%, most preferably substantially no C14 or higher fatty acids be present, since these can suppress sudsing. Accord- ingly, the formulator of high sudsing compositions will desirably avoid the introduction of suds-suppressing amounts of such fatty acids into high sudsing compositions with the polyhydroxy fatty acid amides, and/or avoid the formation of C14 and higher fatty acids on storage of the finished compositions. One simple means is to use C12 ester reactants to prepare the polyhydroxy fatty acid amides herein. Fortunately, the use of amine oxide or sulfobetaine surfactants can overcome some of the negative sudsing effects caused by the fatty acids.
The formulator wishing to add anionic optical brighteners to liquid detergents containing relatively high concentrations (e.g., 10% and greater) of anionic or polyanionic substituents such as the polycarboxylate builders may find it useful to pre-mix the bright¬ ener with water and the polyhydroxy fatty acid amide, and then to add the pre-mix to the final composition.
Polyglutamic acid or polyaspartic acid dispersants can be usefully employed with zeolite-built detergents. AE fluid or flake and DC-544 (Dow Corning) are other examples of useful suds control agents herein.
It will be appreciated by those skilled in the chemical arts that the preparation of the polyhydroxy fatty acid amides herein using the di- and higher saccharides such as maltose will result in the formation of polyhydroxy fatty acid amides wherein linear substituent Z is "capped" by a polyhydroxy ring structure. Such materials are fully contemplated for use herein and do not depart from the spirit and scope of the invention as disclosed and claimed.

Claims

1. A polycarboxylate-built detergent composition, comprising one or more anionic, nonionic or cationic detersive surfactants, or mixtures thereof, optional detersive adjuncts, and optional auxiliary builders, said composition characterized in that it contains:
(a) at least 1% by weight of a polycarboxylate detergency builder; and
(b) at least 1% by weight of a polyhydroxy fatty acid amide material of the formula
0 Rl R2 - C - N - Z wherein R- is H, C1-C4 hydrocarbyl, 2-hydroxy ethyl, 2 hydroxy propyl, or a mixture thereof, R2 is C5-C31 hydrocarbyl, and Z is a polyhydroxyhydrocarbyl having a linear hydrocarbyl chain with at least 3 hydroxyls directly connected to said chain, or an alkoxylated derivative thereof.
2. A composition according to Claim 1 wherein the ratio of polycarboxylate builder to polyhydroxy fatty acid amide is from 1:10 to 10:1.
3. A detergent composition according to Claim 2 wherein said composition comprises at least 3%, by weight, of said polycar¬ boxylate builder and at least 3%, by weight, of said polyhydroxy fatty acid amide.
4. A detergent composition according to Claim 1 wherein the polycarboxylate builder is selected from the group consisting of ether polycarboxylates, ether hydropolycarboxylates, preferably oxydisuccinate, tartrate monosuccinate, or tartrate disuccinate, citrates, polyacetates, and succinates, and mixtures thereof.
5. A composition according to Claim 3 wherein, with respect to said polyhydroxy fatty acid amide, Rl is methyl, R2 is C11-C17 alkyl or alkenyl, Z is -CH2(CHOH)nCH2θH, and n is an integer from 3 to 5, inclusive.
6. A composition according to Claim 1 wherein, with respect to said polyhydroxy fatty acid amide, Z is derived from maltose.
7. A composition according to Claim 1 wherein, with respect to said polyhydroxy fatty acid amide, Z is derived from a mixture of monosaccharides, disaccharides and, optionally, higher sacchar¬ ides, said mixture comprising at least 1% of at least one disac- charide, preferably maltose.
8. A composition according to Claim- 1 which is in a liquid form and comprises a liquid carrier.
9. A composition according to Claim 3 in which the weight ratio of polycarboxylate:polyhydroxy fatty acid amide is in the range of from 7:1 to 1:5, preferably 7:1 to 1:1.
10. A detergent composition according to Claim 1, comprising one or more anionic sulfate or sulfonate surfactants selected from the group consisting of alkyl sulfates, alkyl ester sulfonates, preferably methyl ester sulfonates, alkyl ethoxylated sulfates, and alkyl benzene sulfonates.
11. A detergent composition according to Claim 10, comprising greater than 10%, by weight, of a polycarboxylate builder.
12. A method for improving the fabric cleaning performance of a detergent composition comprising one or more anionic, nonionic, or cationic surfactants, or mixtures thereof, polycarboxylate builder, optional detergent adjuncts, and optional auxiliary builder, characterized in that said method comprises incorporating into said detergent composition at least 1% by weight of a polyhydroxy fatty acid amide material of the formula
0 Rl R2 - C - N - Z wherein Rl is H, C1-C4 hydrocarbyl, 2-hydroxy ethyl, 2-hydroxy propyl, or a mixture thereof, R is C5-C31 hydrocarbyl, and Z is a polyhydroxyhydrocarbyl having a linear hydrocarbyl with at least 3 hydroxyls, preferably C11-C17 N-methyl glucamide, C11-C17 N-methyl maltamide, or mixtures of said glucamide and maltamide, or an alkoxylated derivative thereof, wherein the ratio of polycarboxyl¬ ate builder to polyhydroxy fatty acid amide is from 1:10 to 10:1 and laundering fabrics therewith in conventional fashion.
13. A method according to Claim 12 wherein said Z moiety in said polyhydroxy fatty acid amide is derived from mixed monosacchar- ides, disaccharides and polysaccharides available from plant sources.
14. A method according to Claim 12 wherein said R2 moiety in said polyhydroxy fatty acid amide is C15-C17 alkyl, alkenyl, or mix¬ tures thereof.
EP91918544A 1990-09-28 1991-09-25 Polyhydroxy fatty acid amides in polycarboxylate-built detergents Expired - Lifetime EP0551393B1 (en)

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NO931077D0 (en) 1993-03-24
MA22300A1 (en) 1992-04-01
JP3007152B2 (en) 2000-02-07
FI931365A (en) 1993-03-26
CN1061244A (en) 1992-05-20
CA2090238C (en) 1998-09-01
CN1030926C (en) 1996-02-07
GR3024156T3 (en) 1997-10-31

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