Note: Descriptions are shown in the official language in which they were submitted.
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PROCESS FOR MAKING A LIQUID FABRIC SOFTENING COMPOSITION
Field of the invention
The present invention relates to a process for preparing a dye containing
softening composition having effective freeze-thaw recovery properties.
Background of the invention
Fabric softening products are known in the art to provide effective softness
to
the treated fabrics. However, a problem encountered upon storage at low
temperature, i.e. at sub 0°C temperature, is the freezing of the
product which,
when placed at higher temperatures results in a product which does not recover
to a uniform dispersion with acceptable flow characteristics.
Accordingly, it is an object of the invention to provide a fabric softening
product
which has effective freeze-thaw recovery.
One solution to fulfil such need is described in GB-1,098,793 with the use of
sulphate salts of fatty amines in fabric softening compositions.
Still another solution is described in EP-A-0,507,478 which provides the
mixing
and melting of the cationic fabric softener with a nonionic stabilising agent
before dispersing it in water. However, a problem encountered with such a
process is that processing equipment such as high shear mixers are needed so
that the resulting cost of the formulation is increased.
Accordingly, it is also an object of the invention to provide a fabric
softening
product which only necessitates minimal processing equipment.
It has been observed that without high shear during the processing of a fabric
softening product,. the formation of dye speckles arises, whilst with high
shear
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the formation of undispersed dye particles in the fabric softening product is
avoided.
Accordingly, the formulator of a softening composition is faced with the dual
challenge of formulating a softening composition which has good dye
homogeneity, without the need for a high shear mixing equipment.
The Applicant has now found that the addition of the dye component together
with a nonionic alkoxylated surfactant to the finished cold softening product
fulfills such needs.
Indeed, application of the dye and nonionic alkoxylated surfactant to the cold
finished product is made by simple mixing. The composition obtained results in
an homogenous dispersion.
An advantage of the invention is that for resulting fabric softening products
in
diluted form made by the invention process, less mechanical shear is required
compared to products made by mixing the fabric softener and nonionic before
dispersion in water. Not to be bound by theory, it is believed that the
nonionic
surfactant micellizes the dye and subsequently forms mixed vesicles with the
softener active. fn this manner the dye is efficiently dispersed and the
product
acquires good freeze thaw recovery.
~~mmarv of the invention
The present invention relates to a process for making a liquid fabric
softening
composition which comprises the steps of:
a)-mixing and heating the fabric softener active and optional additives to
form a melt;
b)-dispersing the melt in water;
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c)-cooling the resulting dispersion to below the Krafft temperature of the
softener active before adding a dye and a nonionic alkoxylated stabilising
agent.
In another aspect, the present invention encompasses the use of a nonionic
alkoxylated stabilising agent in liquid fabric softening compositions as a
freeze-
thaw recovery agent.
Still in another aspect, the present invention encompasses the use of a
nonionic
alkoxylated stabilising agent to homogenise the dye in liquid fabric softening
compositions.
Defiled description of the invention
Nonionic alkoxvlated surfactant
A nonionic alkoxylated stabilising surfactant is an essential component of the
process invention. Suitable nonionic surfactants for use herein. include
addition
products of ethylene oxide with fatty alcohois, fatty acids, fatty amines,
etc.
Optionally, addition products of propylene oxide with fatty alcohols, fatty
acids,
fatty amines may be used.
Suitable compounds are surfactants of the general formula:
R2 - Y - (C2H40)z - C2H40H
wherein R2 is selected from the group consisting of primary, secondary and
branched chain alkyl andlor aryl hydrocarbyl groups; primary, secondary and
branched chain alkenyl hydrocarbyl groups; and primary, secondary and
branched chain alkyl- and alkenyl-substituted phenolic hydrocarbyl groups;
said
hydrocarbyl groups preferably having a hydrocarbyl chain length of from 8 to
20,
preferably from 10 to 18 carbon atoms. More preferably the hydrocarbyl chain
length is from 12 to 18 carbon atoms. In the general formula for the
ethoxyiated
nonionic surfactants herein, Y is -O-, -C(O)O-, -C(O)N(R)-, or -C(O)N(R)R-, in
which R, when present, is R2 or hydrogen, and z is at least 5, preferably at
least
8.
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The nonionic surfactants herein are characterised by an HLB (hydrophilic-
lipophilic balance) of from 7 to 20, preferably from 8 to 15. Of course, by
defining R2 and the number of ethoxylate groups, the HLB of the surfactant is,
in
general, determined. However, it is to be noted that the nonionic ethoxylated
surfactants useful herein contain relatively long chain R2 groups and are
relatively highly ethoxyiated. While shorter alkyl chain surfactants having
short
ethoxylated groups may possess the requisite HLB, they are not as effective
herein.
Examples of nonionic surfactants follow. The nonionic surfactants of this
invention are not limited to these examples. In the examples, the integer
defines
the number of ethoxyl (EO) groups in the molecule.
a. Straight-Chain Primary Alcohol Alkoxvlates
The tri-, yenta-, hepta-ethoxylates of dodecanol, and tetradecanol are useful
surfactants in the context of this invention. The ethoxylates of mixed natural
or
synthetic alcohols in the "coco" chain length range are also useful herein.
Commercially available straight-chain, primary alcohol alkoxylates for use
herein
are available under the tradename Marlipal~ 24170, Mariipal 241100, Marlipal
24/150 from Huls, and Genapol~ C-050 from Hoechst.
b. ~traiaht-Chain Secondary Alcohol Alkoxvlates
The tri-, yenta-, hepta-ethoxylates of 3-hexadecanol, 2-octadecanol, 4-
eicosanol, and 5-eicosanol are useful surfactants in the context of this
invention.
A commercially available straight-chain secondary alcohol ethoxylate for use
herein is the material marketed under the tradename Tergitol 15-S-7 from Union
Carbide, which comprises a mixture of secondary alcohols having an average
hydrocarbyl chain length of 11 to 15 carbon atoms condensed with an average 7
moles of ethylene oxide per mole equivalent of alcohol.
c. Alklrl Phenol Alkoxvlates
Suitable alkyl phenol alkoxylates are the polyethylene oxide condensates of
alkyl phenols, e.g., the condensation products of alkyl phenols having an
alkyl or
alkenyl group containing from 6 to 20 carbon atoms in a primary, secondary or
branched chain configuration, preferably from 8 to 12 carbon atoms, with
r
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ethylene oxide, the said ethylene oxide being preferably present in amounts
equal to 3 to less than 9 moles of ethylene oxide per mole of alkyl phenol.
The
alkyl substituent in such compounds may be derived from polymerized
propylene, diisobutylene, octane, and nonane.
Examples of this type of nonionic surfactants include Triton N-57~ a nonyl
phenol ethoxylate (5E0) from Rohm & Haas, Dowfax~ 9N5 from Dow and
Lutensol~ AP6 from BASF.
d. Olefinic Alkoxylates
The alkenyl alcohols, both primary and secondary, and alkenyl phenols
corresponding to those disclosed immediately hereinabove can be ethoxylated
and used as surfactants.
Commercially available olefinic alkoxylates for use herein are available under
the tradename Genapol O-050 from Hoechst.
e. Branched Chain Alkox I~ate_s
Branched chain primary and secondary alcohois which may be available from
the well-known "OXO" process or modification thereof can be ethoxylated.
Particularly preferred among these ethoxylates of the primary OXO alcohols are
the surfactants marketed under, the name Lutensoi by BASF or Dobanol by the
Shell Chemicals, U.K., LTD. The preferred Dobanols are primary alcohols with
hydrocarbyl groups of 9 to 15 carbon atoms, with the majority having a
hydrocarbyl group of 13 carbon atoms. Particularly preferred are Dobanols with
an average degree of ethoxylation of 3 to less than 9, and preferably 5 on the
average.
An example of this type of material is an aliphatic alcohol ethylene oxide
condensate having from 3 to less than 9 moles of ethylene oxide per mole of
aliphatic alcohol, the aliphatic alcohol fraction having from 9 to 14 carbon
atoms.
Other examples of this type of nonionic surfactants include certain of the
commercially available Dobanol~, Neodol~ marketed by Shell or Lutensol~
from BASF. For example Dobanol~ 23.5 {C12-C13 E05), Dobanol~ 91.5 (C9-
C11 EO 5) and Neodol 45 E5.
Other suitable nonionic alkoxylated surfactants are alkyl amines alkoxylated
with
at least 5 alkoxy moieties. Typical of this class of compounds are the
surfactants
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derived from the condensation of ethylene oxide with an hydrophobic alkyl
amine product. Preferably the hydrophobic alkyl group, has from 6 to 22 carbon
atoms. Preferably, the alkyl amine is alkoxylated with 10 to 40, and more
preferably 20 to 30 alkoxy moieties.
Example of this type of nonionic surfactants are the alkyl amine ethoxylate
commercially available under the tradename Genamin from Hoechst. Suitable
example for use herein are Genamin C-100, Genamin O-150, and Genamin S-
200.
Still other suitable type of nonionic surfactant among this class are the
N,N',N'-
polyoxyethyiene (12)-N-tallow 1,3 diaminopropane commercialised under the
tradename Ethoduomeen T22 from Akzo, and Synprolam from IC1.
The above ethoxylated nonionic surfactants are useful in the present process
invention alone or in combination, and the term "nonionic surfactant"
encompasses mixed nonionic surface active agents.
Preferred nonionic surfactants for use herein are the nonionic surfactants
commercially available under the tradenames Marlipal 24!100, Marlipal 24/150,
Genapol O-050, and Dobanol 91.5.
The nonionic surfactant will preferably be added in an amount of 0.05% to 5%
by weight, preferably from 0.1 % to 0.5% by weight of the finished fabric
softening composition
The dyne component
The dye is an essential component of the invention. Hence, by mixed the dye
together with the nonionic alkoxylated surfactants and subsequently
incorporating it into the cold finished product, it has been observed that the
formation of dyes speckles which occurs by incorporation of the dyes into the
molten fabric softening product is suppressed andlor reduced by the process of
the invention.
Preferred dye components are the water-soluble dye such as described in
EP 754749.
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Preferably, the dye'is a water soluble dye system characterised in that the
dye
system comprises a dye selected from the group consisting of
1. Quinoline Yellow 70 with color index no. 47005;
2. Tartrazine XX90 with color index no. 19140;
3. Orange RGL90 with color index no. 15985;
4. Ponceau 4RC82 with color index no. 16255;
5. Blue AE85 with color index no. 42090;
6. Patent Blue V85N50 with color index no. 42051; and
7. mixtures thereof.
The dye will preferably be added in an amount of 1 ppm to 200 ppm by weight,
preferably from 5 ppm to 100 ppm by weight of the finished fabric softening
composition.
The finished fabric softening composition conventionally comprises a cationic
fabric softener and optional additives.
Fabric softener
Typical levels of incorporation of the softening compound in the softening
composition are of from 1 % to 80% by weight, preferably from 5% to 75%, more
preferably from 15% to 70%, and even more preferably from 19% to 65%, by
weight of the composition.
The fabric softener compound is preferably selected from a cationic, nonionic,
amphoteric or anionic fabric softening component. Typical of the cationic
softening components are the quaternary ammonium compounds or amine
precursors thereof as defined hereinafter.
A) Quaternary Ammonium Fabric Softening Active Comcound
(1) Preferred quaternary ammonium fabric softening active compound have
the formula
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+ _
(R)~-m N (CH~)ri Q'Rl X
m
(1)
or the formula:
N (CE~,~" - ~ - CH, '- Q '- R~ X
cR~a.~"
m
Q - R~ (2)
wherein Q is a carbonyl unit having the formula:
2
-O-C- , -O-O- ~ -O~-0- ~ -N-C- ~ -O-N-
each R unit is independently hydrogen, C1-Cg alkyl, C1-Cg hydroxyalkyl, and
mixtures thereof, preferably methyl or hydroxy alkyl; each R1 unit is
independently linear or branched C11-C22 alkyl, linear or branched C11-C22
alkenyl, and mixtures thereof, R2 is hydrogen, C1-C4 alkyl, C1-C4
hydroxyalkyl,
and mixtures thereof; X is an anion which is compatible with fabric softener
actives and adjunct ingredients; the index m is from 1 to 4, preferably 1; the
index n is from 1 to 4, preferably 2.
An example of a preferred fabric softener active is a mixture of quaternized
amines having the formula:
O
+ II
R2-N (CH2~-O-C-R~ X
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wherein R is preferably methyl; R1 is a linear or branched alkyl or alkenyl
chain
comprising at least 11 atoms, preferably at least 15 atoms. In the above
fabric
softener example, the unit -02CR1 represents a fatty acyl unit which is
typically
derived from a triglyceride source. The triglyceride source is preferably
derived
from tallow, partially hydrogenated tallow, lard, partially hydrogenated lard,
vegetable oils and/or partially hydrogenated vegetable oils, such as, canola
oil,
safflower oil, peanut oil, sunflower oil, corn oil, soybean oil, tall oil,
rice bran oil,
etc. and mixtures of these oils.
The preferred fabric softening actives of the present invention are the
Diester
and/or Diamide Quaternary Ammonium (DEQA) compounds, the diesters and
diamides having the formula:
+ _
(R)4-m N (CH2)ri
m
wherein R, R1, X, and n are the same as defined herein above for formulas (1)
and (2), and Q has the formula:
O H O
II I II
-O-C._ or -N-C-
These preferred fabric softening actives are formed from the reaction of an
amine with a fatty aryl unit to form an amine intermediate having the formula:
R N (CH2)n-Q-RI
wherein R is preferably methyl, Q and R' are as defined herein before;
followed
by quaternization to the final softener active.
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Non-limiting examples of preferred amines which are used to form the DEQA
fabric softening actives according to the present invention include methyl
bis(2-
hydroxyethyl)amine having the formula:
CH3
HON OOH
methyl bis(2-hydroxypropyl)arnine having the formula:
CH3
~N
HO OH
methyl (3-aminopropyl) (2-hydroxyethyl)amine having the formula:
CH3
HON ~NH2
,
methyl bis(2-aminoethyl)amine having the forrnuia:
CH3
H2N ~''~N ~NH~
triethanol amine having the formula:
~OH
HON ~'OH
di(2-aminoethyl) ethanolamine having the formula:
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~OH ,
N
H,N~ ~NH~
The counterion, X{-) above, can be any softener-compatible anion, preferably
the anion of a strong acid, for example, chloride, bromide, methylsulfate,
ethylsulfate, sulfate, nitrate and the like, more preferably chloride or
methyl
sulfate. The anion can also, but less preferably. carry a double charge in
which
case X(-) represents half a group.
Tallow and canola oil are convenient and inexpensive sources of fatty acyl
units
which are suitable for use in the present invention as R1 units. The following
are non-limiting examples of quaternary ammonium compounds suitable for use
in the compositions of the present invention. The term "tallowyl" as used
herein
below indicates the R1 unit is derived from a tallow triglyceride source and
is a
mixture of fatty acyl un~s. Likewise, the use of the term canolyl refers to a
mixture of fatty acyl units derived from canola oil.
Table II
Fabric Softener Actives
N,N-di(tallowyl-oxy-ethyl)-N,N-dimethyl ammonium chloride;
N,N-di{canolyl-oxy-ethyI~N,N-dimethyl ammonium chloride;
N,N-di(tallowyl-oxy-ethyl)-N-methyl, N-(2-hydroxyethyl) ammonium chloride;
N,N-di(canolyl-oxy-ethyl)-N-methyl, N-(2-hydroxyethyl) ammonium chloride;
N,N-di(2-tallowytoxy-2-oxo-ethyl)-N,N-dimethyl ammonium chloride;
N,N-di(2-canolyloxy-2-oxo-ethyl)-N,N-dimethyl ammonium chloride
N,N-di(2-tallowyloxyethylcarbonyloxyethyl)-N,N-dimethyl ammonium chloride;
N,N-di(2-canolyloxyethylcarbonyloxyethyl)-N,N-dimethyl ammonium chloride;
N-(2-taliowoyloxy-2-ethyl)-N-(2-tallowyloxy-2-oxo-ethyl)-N,N-dimethyl ammonium
chloride;
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N-{2-canolyloxy-2-ethyl)-N-(2-canolyioxy-2-oxo-ethyl)-N,N-dimethyl ammonium
chloride;
N,N,N-tri(tallowyl-oxy-ethyl)-N-methyl ammonium chloride;
N,N,N-tricanolyl-oxy-ethyl)-N-methyl ammonium chloride;
N-(2-tallowyloxy-2-oxoethyl)-N-(tallowyl)-N,N-dimethyl ammonium chloride;
N-{2-canolyloxy-2-oxoethyl)-N-(canolyl)-N,N-dimethyl ammonium chloride;
1,2-ditallowyloxy-3-N,N,N-trimethylammoniopropane chloride; and
1,2-dicanolyloxy-3-N,N,N-trimethylammoniopropane chloride;
and mixtures of the above actives.
Other examples of quaternay ammoniun softening compounds are
methylbis(tallowamidoethyl)(2-hydroxyethyl)ammonium methylsulfate and
methylbis(hydrogenated tallowamidoethyl)(2-hydroxyethyl)ammonium
methyisulfate; these materials are available from Witco Chemical Company
under the trade names Varisoft~ 222 and Varisoft~ 110, respectively.
Particularly preferred is N,N-di(tallowoyl-oxy-ethyl)-N,N-dimethyl ammonium
chloride, where the tallow chains are at least partially unsaturated.
The level of unsaturation contained within the tallow, canola, or other fatty
acyl
unit chain can be measured by the Iodine Value (IV) of the corresponding fatty
acid, which in the present case should preferably be in the range of from 5 to
100 with two categories of compounds being distinguished, having a IV below or
above 25.
Indeed, for compounds having the formula:
+ _
(R)~-m N (CH2~-Q-R~ X
m
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derived from tallow fatty acids, when the Iodine Value is from 5 to 25,
preferably
15 to 20, it has been found that a cisltrans isomer weight ratio greater than
about 30!70, preferably greater than about 50150 and more preferably greater
than about 70/30 provides optimal concentrability.
For compounds of this type made from tallow fatty acids having a Iodine Value
of above 25, the ratio of cis to traps isomers has been found to be less
critical
unless very high concentrations are needed.
Other suitable examples of fabric softener actives are derived from fatty acyl
groups wherein the terms "tallowyl" and canolyl" in the above examples are
replaced by the terms "cocoyl, palmyl, lauryl, oleyl, ricinoleyl, stearyl,
palmityl,"
which correspond to the triglyceride source from which the fatty acyl units
are
derived. These alternative fatty acyl sources can comprise either fully
saturated,
or preferably at least partly unsaturated chains.
As described herein before, R units are preferably methyl, however, suitable
fabric softener actives are described by replacing the term "methyl" in the
above
examples in Table II with the units "ethyl, ethoxy, propyl, propoxy,
isopropyl,
butyl, isobutyl and t-butyl.
The counter ion, X, in the examples of Table II can be suitably replaced by
bromide, methylsulfate, formats, sulfate, nitrate, and mixtures thereof. In
fact,
the anion, X, is merely present as a counterion of the positively charged
quaternary ammonium compounds. The scope of this invention is not
considered limited to any particular anion.
For the preceding ester fabric softening agents, the pH of the compositions
herein is an important parameter of the present invention. Indeed, it
influences
the stability of the quaternary ammonium or amine precursors compounds,
especially in prolonged storage conditions.
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The pH, as defined in the present context, is measured in the neat
compositions
at 20 °C. While these compositions are operable at pH of less than
about 6.0,
for optimum hydrolytic stability of these compositions, the neat pH, measured
in
the above-mentioned conditions, must preferably be in the range of from about
2.0 to about 5, preferably in the range of 2.5 to 4.5, preferably about 2.5 to
about
3.5. The pH of these compositions herein can be regulated by the addition of a
Bronsted acid.
Examples of suitable acids include the inorganic mineral acids, carboxylic
acids,
in particular the low molecular weight (C1-C5) carboxylic acids, and
alkylsulfonic
acids. Suitable inorganic acids include HCI, H2S04, HN03 and H3P04.
Suitable organic acids include formic, acetic, citric, methylsulfonic and
ethylsulfonic acid. Preferred acids are citric, hydrochloric, phosphoric,
formic,
methylsulfonic acid, and benzoic acids.
As used herein, when the diester is specified, it will include the monoester
that is
normally present in manufacture. For softening, under no/low detergent
carry-over laundry conditions the percentage of monoester should be as low as
possible, preferably no more than about 2.5%. However, under high detergent
carry-over conditions, some monoester is preferred. The overall ratios of
diester
to monoester ace from about 100:1 to about 2:1, preferably from about 50:1 to
about 5:1, more preferably from about 13:1 to about 8:1. Under high detergent
cant'-over conditions, the dilmonoester ratio is preferably about 11:1. The
level
of monoester present can be controlled in the manufachiring of the softener
compound.
Mixtures of actives of formula (1 ) and (2) may also be prepared.
2)-Still other suitable quaternary ammonium fabric softening compounds for use
herein are cationic nitrogenous salts having two or more long chain acyciic
aliphatic Cg-C22 hydrocarbon groups or one said group and an arylalkyl group
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which can be used either alone or as part of a mixture are selected from the
group consisting of:
(i) acyclic quaternary ammonium salts having the formula:
Ra +
R8-N-RS A'
wherein R4 is an acyclic aliphatic Cg-C22 hydrocarbon group, R5 is a C1-
C4 saturated alkyl or hydroxyalkyl group, R$ is selected from the group
consisting of R4 and R5 groups, and A- is an anion defined as above;
(ii) diamino alkoxylated quaternary ammonium salts having the formula:
O RS O
R~-C-NH-R2-N-R2-NH-C-R1 A
I
(CH2CH~O~H
wherein n is equal to 1 to about 5, and R1, R2, R5 and A- are as defined
above;
(iii) mixtures thereof.
Examples of the above class cationic nitrogenous salts are the well-known
dialkyldi methylammonium salts such as ditallowdimethylammonium chloride,
ditallowdimethylammonium methylsulfate,
di(hydrogenatedtallow)dimethylammonium chloride, distearyldimethylammonium
chloride, dibehenyldimethylammonium chloride. Di(hydrogenatedtallow)di
methylammonium chloride and ditallowdimethylammonium chloride are
preferred. Examples of commercially available dialkyldimethyl ammonium salts
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usable in the present invention are di(hydrogenatedtallow)dimethylammonium
chloride (trade name. Adogen~ 442), ditallowdimethylammonium chloride (trade
name Adogen0 470, Praepagen~ 3445), distearyl dimethylammonium chloride
(trade name Arosurf~ TA-100), all available from Witco Chemical Company.
Dibehenyldimethylammoniurn chloride is sold under the trade name Kernamine
Q-2802C by Humko Chemical Division of Witco Chemical Corporation.
Dimethyistearylbenzyl ammonium chloride is sold under the trade names
Varisoft~ SDC by Witco Chemical Company and Ammonyx~ 490 by Onyx
Chemical Company.
B)-Amine Fabric Softening Active Compound
Suitable amine fabric softening compounds for use herein, which rnay be in
amine form or cationic form are selected from:
(i)- Reaction products of higher fatty acids with a polyamine selected from
the
group consisting of hydroxyalkylalkylenediamines and dialkylenetriamines and
mixtures thereof. These reaction products are mixtures of several compounds in
view of the multi-functional structure of the polyamines.
The preferred Component (i) is a nitrogenous compound selected from the
group consisting of the reaction product mixtures or some selected components
of the mixtures.
One preferred component (i) is a compound selected from the group consisting
of substituted imidazoline compounds having the formula:
N
R~-
N
R8-NH-C-R~
l l
O
wherein R7 is an acyclic aliphatic C15-C21 hydrocarbon group and R8 is a
divalent C1-C3 alkylene group.
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Component (i) materials are commercially available as: Mazamide~ 6, sold by
Mazer Chemicals, or Ceranine~ HC, sold by Sandoz Colors 8~ Chemicals;
stearic hydroxyethyl imidazoline sold under the trade names of Alkazine~ ST by
Alkaril Chemicals, Inc., or Schercozolinem S by Scher Chemicals. Inc.; N,N"-
ditallowalkoyldiethylenetriamine; 1-tallowamidoethyl-2-tallowimidazoline
(wherein
in the preceding structure R1 is an aliphatic C15-C17 hydrocarbon group and R$
is a divalent ethylene group).
Certain of the Components (i) can also be first dispersed in a Bronsted acid
dispersing aid having a pKa value of not greater than about 4; provided that
the
pH of the final composition is not greater than about 6. Some preferred
dispersing aids are hydrochloric acid, phosphoric acid, or methylsulfonic
acid.
Both N,N"-ditallowalkoyldiethylenetriamine and 1-tallow(amidoethyl)-2-
tallowimidazoline are reaction products of tallow fatty acids and
diethylenetriamine; and are precursors of the cationic fabric softening agent
methyl-1-tallowamidoethyl-2-tallowimidazolinium methylsulfate (see "Cationic
Surface Active Agents as Fabric Softeners," R. R. Egan, Journal of the
American Oil Chemicals' Society, January 1978, pages 118-121). N,N"-ditallow
alkoyldiethylenetriamine and 1-tallowamidoethyl-2-tallowimidazoline can be
obtained from Witco Chemical Company as experimental chemicals. Methyl-1-
tallowamidoethyl-2-tallowimidazolinium methylsulfate is sold by Witco Chemical
Company under the tradename Varisoft~ 475.
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(ii)-softener having the formula:
N
Rt
C
o N ( ) ~ ,~.>
Rs
R' C G R
wherein each R2 is a C1_g alkylene group, preferably an ethylene group; and G
is an oxygen atom or an -NR- group; and each R, R1, R2 and R5 have the
definitions given above and A- has the definitions given above for X-.
An example of Compound (ii) is 1-oleylamidoethyl-2-oleylimidazolinium chloride
wherein R1 is an acyclic aliphatic C15-C17 hydrocarbon group, R2 is an
ethylene group, G is a NH group, R5 is a methyl group and A- is a chloride
anion.
(iii)- softener having the formula:
H H
\N-R=-N
N N 2Ao
i R~
wherein R, R1, R2, and A- are defined as above.
An example of Compound (iii} is the compound having the formula:
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i H Hv
N-CH~CH~-N I CI O
N ~N
Rt IRt
wherein R1 is derived from oleic acid.
Additional fabric softening agents useful herein are described in U.S. Pat.
No.
4,661,269, issued April 28, 1987, in the names of Toan Trinh, Errol H. Wahl,
Donald M. Swartley, and Ronald L. Hemingway; U.S. Pat. No. 4,439,335, Burns,
issued March 27, 1984; and in U.S. Pat. Nos.: 3,861,870, Edwards and Diehl;
4,308,151, Cambre; 3,886,075, Bernardino; 4,233,164, Davis; 4,401,578,
Verbruggen; 3,974,076, Wiersema and Rieke; 4,237,016, Rudkin, Clint, and
Young; and European Patent Application publication No. 472,178, by Yamamura
et al., all of said documents being incorporated herein by reference.
Of course, the term "softening active" can also encompass mixed softening
active agents.
Preferred among the classes of softener compounds disclosed herein before are
the diester or diamido quaternary ammonium fabric softening active compound
(DEQA).
Another conventional optional ingredient of said liquid fabric softening
compositions is a liquid carrier. Suitable liquid carriers are selected from
water,
organic solvents and mixtures thereof. The liquid carrier employed in the
instant
compositions is preferably at least primarily water due to its low cost
relative
availability, safety, and environmental compatibility. The lave! of water in
the
liquid carrier is preferably at least 50%, most preferably at least 60%, by
weight
of the carrier. Mixtures of water and low molecular weight, e.g., <200,
organic
solvent, e.g., lower alcohol such as ethanol, propanol, isopropanol or butanol
are
useful as the carrier liquid. Low molecular weight alcohols include
monohydric,
dihydric (glycol, etc.) trihydric (glycerol, etc.), and higher polyhydric
(polyols)
alcohols.
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Oetional components
The composition may also optionally contain additional components such as pH
modifiers, perfumes, chelating agents, cationic surfactant concentration aids,
electrolyte concentration aids, thickeners, stabilisers, such as well known
antioxidants and reductive agents, soil release polymers, emulsifiers,
bacteriocides, colorants, preservatives, optical brighteners, anti ionisation
agents, antifoam agents, enzymes, dye fixing agent such as polyquaternary
ammonium compounds (e.g. Sandofix WE56 commercially available from
Hoechst, or Rewin SFR commercially available from CHT R. Beitlich ),
polyamino functional polymer such as disclosed in co-pending application EP
97201488.0, dispersible polyolefin such as Velustroi~ as disclosed in co-
pending application PCTIUS 97101644, and the like.
A typical amount of such optional components will be from 0% to 15% by weight.
Perfume
The word perfume encompasses individual perfume components and
compositions of perfume components. Selection of any perfume is based solely
on aesthetic considerations.
Perfume, in the sense of perfume components or compositions of perfume
components, can be any odoriferous materials or any materiats which act as a
malodour counteractent. The perfume will most often be liquid at ambient
temperatures, but also can be liquified solid such as the various
camphoraceous
perfumes known in the art. The perfume can be relatively simple in composition
or can comprise highly sophisticated, compact mixtures of natural or synthetic
chemical components, all chosen to provide any desired odour.
Useful perfumes are those odorous materials that deposit on fabrics during the
laundry process and are detectable by people with normal olfactory sensity.
Many of the perfume ingredients along with their odor corrector and their
physical and chemical properties are given in "Perfume and Flavor chemicals
(aroma chemicals)", Stephen Arctender, Vols. I and II, Aurthor, Montclair,
H.J.
and the Merck Index, 8th Edition, Merck 8~ Co., Inc. Rahway, N.J. Perfume
components and compositions can also be found in the art, e.g. US Patent Nos.
4,145,184, 4,152,272, 4,209,417 or 4,515,705.
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A wide variety of chemic2ls are known for perfume use including materials such
as aldehydes, ketones, esters and the like. More commonly, naturally occurring
plant and animal oils and exudates comprising complex mixtures of various
chemical components are known for use as perfume, and such materials can be
used herein. Typical perfumes can comprise e.g. woody/earthy bases
containing exotic materials such as sandalwood oil, civet and patchouli oil.
The
perfume also can be of a light floral fragrance e.g. rose or violet extract.
Further
the perfume can be formulated to provide desirable fruity odours e.g. lime,
lemon or orange.
Particular examples of useful perfume components and compositions are
anetole, benzaldehyde, benzyl acetate, benzyl alcohol, benzyl formate, iso-
bornyl acetate, camphene, cis-citral (neral), citronellal, citronellol,
citronellyl
acetate, paracymene, decanal, dihydrolinalool, dihydromyrcenol, dimethyl
phenyl carbinol, eucalyptol, geranial, geraniol, geranyl acetate, geranyl
nitrite,
cis-3-hexenyi acetate, hydroxycitronellal, d-limonene, linalool, linalool
oxide,
linalyl acetate, linalyl propionate, methyl anthranilate, alpha-methyl ionone,
a methyl nonyl acetaldehyde, methyl phenyl carbinyl acetate, laevo-menthyl
acetate, menthone, iso-menthone, myrcene, myrcenyl acetate, myrcenol, nerol,
neryl acetate, nonyl acetate, phenyl ethyl alcohol, alpha-pinene, beta-pinene,
gamma-terpinene, alpha-terpineol, beta-terpineol, terpinyl acetate, vertenex
(para-tertiary-butyl cyclohexyl acetate), amyl cinnamic aldehyde, iso-amyl
salicylate, beta-caryophyllene, cedrene, cinnamic alcohol, couramin, dimethyl
benzyl carbinyl acetate, ethyl vanillin, eugenol, iso-eugenol, flor acetate,
heliotrophine, 3-cis-hexenyl salicylate, hexyl salicylate, lilial (para-
tertiarybutyl-
alpha-methyl hydrocinnamic aldehyde), gamma-methyl ionone, nerolidol,
patchouli alcohol, phenyl hexanol, beta-selinene, trichloromethyl phenyl
carbinyl
acetate, triethyl citrate, vanillin, veratraldehyde, alpha-cedrene, beta-
cedrene,
C15H24sesquiterpenes, benzophenone, benzyl salicylate, ethylene brassylate,
galaxolide (1,3,4,6,7,8-hexahydro-4,6,6,7,8,8,-hexamethyl-cyclo-yenta-gamma-
2-benzopyran), hexyl cinnamic aldehyde, lyral (4-(4-hydroxy-4-methyl pentyl)-3-
cyclohexene-10-carboxaldehyde), methyl cedrylone, methyl dihydro jasmonate,
methyl-beta-naphthyl ketone, musk ambrette, musk idanone, musk ketone,
musk tibetine, musk xylol, aurantiol and phenylethyl phenyl acetate.
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Perfume can be present at a level of from 0% to 10%, preferably from 0.1 % to
5%, and more preferably from 0.2% to 3%, by weight of the finished
composition. Fabric softener compositions of the present invention provide
improved fabric perfume deposition.
Additional components
Concentration aids
Concentrated compositions of the present invention may require organic and/or
inorganic concentration aids to go to even higher concentrations and/or to
meet
higher stability standards depending on the other ingredients. Surfactant
concentration aids are typically selected from the group consisting of single
long
chain alkyl cationic surfactants; nonionic surfactants; amine oxides; fatty
acids;
or mixtures thereof, typically used at a level of from 0 to 15% of the
composition.
Inorganic viscosityldispersibility control agents which can also act like or
augment the effect of the surfactant concentration aids, include water-
soluble,
ionizable salts which can also optionally be incorporated into the
compositions of
the present invention. A wide variety of ionizable salts can be used. Examples
of suitable salts are the halides of the Group IA and IIA metals of the
Periodic
Table of the Elements, e.g., calcium chloride, magnesium chloride, sodium
chloride, potassium bromide, and lithium chloride. The ionizable salts are
particularly useful during the process of mixing the ingredients to make the
compositions herein, and later to obtain the desired viscosity. The amount of
ionizable salts used depends on the amount of active ingredients used in the
compositions and can be adjusted according to the desires of the formulator.
Typical levels of salts used to control the composition viscosity are from
about
20 to about 20,000 parts per million (ppm), preferably from about 20 to about
11,000 ppm, by weight of the composition.
Alkylene polyammonium sales can be incorporated into the composition to give
viscosity control in addition to or in place of the water-soluble, ionizable
salts
above. In addition, these agents can act as scavengers, forming ion pairs with
anionic detergent carried over from the main wash, in the rinse, and on the
fabrics, and may improve softness performance. These agents may stabilize the
viscosity over a broader range of temperature, especially at low temperatures,
compared to the inorganic electrolytes.
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Specific examples of alkylene polyammonium salts include I-lysine
monohydrochloride and 1,5-diammonium 2-methyl pentane dihydrochloride.
Enzymes
The compositions herein can optionally employ one or more enzymes such as
lipases, proteases, cellulase, amylases and peroxidases. A preferred enzyme
for
use herein is a cellulase enzyme. Indeed, this type of enzyme will further
provide
a color care benefit to the treated fabric. Cellulases usable herein include
both
bacterial and fungal types, preferably having a pH optimum between 5 and 9.5.
U.S. 4,435,307 discloses suitable fungal cellulases from Humicola insolens or
Humicola strain DSM1800 or a cellulase 212-producing fungus belonging to the
genus Aeromonas, and celluiase extracted from the hepatopancreas of a marine
mollusk, DolabeJla Auricula Solander. Suitable cellulases are also disclosed
in
GB-A-2.075.028; GB-A-2.095.275 and DE-OS-2.247.832. CAREZYME~ and
CELLUZYME~ (Novo) are especially useful. Other suitable cellulases are also
disclosed in WO 91117243 to Novo, WO 96/34092, WO 96134945 and EP-A-
0,739,982. In practical terms for current commercial preparations, typical
amounts are up to 5 mg by weight, more typically 0.01 mg to 3 mg, of active
enzyme per gram of the detergent composition. Stated otherwise, the
compositions herein will typically comprise from 0.001 % to 5%, preferably
0.01 %-1 % by weight of a commercial enzyme preparation. In the particular
cases where activity of the enzyme preparation can be defined otherwise such
as with cellulases, corresponding activity units are preferred (e.g. CEVU or
cellulase Equivalent Viscosity Units). For instance, the compositions of the
present invention can contain cellulase enzymes at a level equivalent to an
activity from about 0.5 to 1000 CEVU/gram of composition. Cellulase enzyme
preparations used for the purpose of formulating the compositions of this
invention typically have an activity comprised between 1,000 and 10,000
CEVU/gram in liquid form, around 1,000 CEVUlgram in solid form.
Soil Releas~Agents
In the present invention, an optional soil release agent can be added. The
addition of the soil release agent can occur in combination with the premix,
in
combination with the acid/water seat, before or after electrolyte addition, or
after
the final composition is made. The softening composition prepared by the
process of the present invention herein can contain from 0% to 10%, preferably
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from 0.2% to 5%, of a soil release agent. Preferably, such a soil release
agent
is a polymer.
Any polymeric soil release agent known to those skilled in the art can
optionally
be employed in the compositions 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.
If utilised, 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 following, all included herein by reference, describe soil release
polymers
suitable for use in the present invention. U.S. 3,959,230 Hays, issued May 25,
1976; U.S. 3,893,929 Basadur, issued July 8, 1975; U.S. 4,000,093, Nicol, ef
al., issued December 28, 1976; U.S. Patent 4,702,857 Gosselink, issued
October 27, 1987; U.S. 4,968,451, Scheibel et al., issued November 6; U.S.
4,702,857, Gosselink, issued October 27, 1987; U.S. 4,711,730, Gosseiink et
al., issued December 8, 1987; U.S. 4,721,580, Gosselink, issued January 26,
1988; U.S. 4,877,896, Maldonado et al., issued October 31, 1989; U.S.
4,956,447, Gosselink et al., issued September 11, 1990; U.S. 5,415,807
Gosselink et al., issued May 16, 1995; European Patent Application 0 219 048,
published April 22, 1987 by Kud, et al..
Further suitable soil release agents are described in U.S. 4,201,824, Violland
ef
al.; U.S. 4,240,918 Lagasse et al.; U.S. 4,525,524 Tung et al.; U.S.
4,579,681,
Ruppert et al.; U.S. 4,240,918; U.S. 4,787,989; U.S. 4,525,524; EP 279,134 A,
1988, to Rhone-Poulenc Chemie; EP 457,205 A to BASF (1991); and DE
2,335,044 to Unilever N. V., 1974 all incorporated herein by reference.
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Pcrius9sns~s
Commercially available soil release agents include the METOLOSE SM100,
METOLOSE SM200 manufactured by Shin-etsu Kagaku Kogyo K.K., SOKALAN
type of material, e.g., SOKALAN HP-22, available from BASF (Germany),
ZELCON 5126 (from Dupont) and MILEASE T (from ICI).
These soil release agents can also act as scum dispersants.
Stabilizers
Stabilizers can be present in the compositions of the present invention. The
term "stabilizer," as used herein, includes antioxidants and reductive agents.
These agents are present at a level of from 0% to about 2%, preferably from
about 0.01 % to about 0.2%, more preferably from about 0.035% to about 0.1
for antioxidants, and more preferably from about 0.01 % to about 0.2% for
reductive agents. These assure good odor stability under long term storage
conditions for the compositions and compounds stored in molten form. The use
of antioxidants and reductive agent stabilizers is especially critical for low
scent
products (low perfume).
Examples of antioxidants that can be added to the compositions of this
invention
include a mixture of ascorbic acid, ascorbic palmitate, propyl gallate,
available
from Eastman Chemical Products, Inc., under the trade names Tenox~ PG and
Tenox S-1; a mixture of BHT (butylated hydroxytoluene), BHA (butylated
hydroxyanisole), propyl gallate, and citric acid, available from Eastman
Chemical
Products, Inc., under the trade name Tenox-6; butylated hydroxytoluene,
available from UOP Process Division under the trade name Sustane~ BHT;
tertiary butylhydroquinone, Eastman Chemical Products, Inc., as Tenox TBHQ;
natural tocopherols, Eastman Chemical Products, Inc., as Tenox GT-1/GT-2;
and butylated hydroxyanisole, Eastman Chemical Products, Inc., as BHA; long
chain esters (Cg-C22) of gallic acid, e.g., dodecyl gallate; Irganox~ 1010;
Irganox~ 1035; irganox~ B 1171; Irganox~ 1425; Irganox~ 3114; Irganox~
3125; and mixtures thereof; preferably IrganoxC~ 3125, lrganox~ 1425, Irganox
~ 3114, and mixtures thereof; more preferably Irganox~ 3125 alone or mixed
with citric acid andlor other chelators such as isopropyl citrate, Dequest~
2010,
available from Monsanto with a chemical name of 1-hydroxyethylidene-1, 1-
diphosphonic acid (etidronic acid), and Tiron~, available from Kodak with a
chemical name of 4,5-dihydroxy-m-benzene-sulfonic acidlsodium salt, EDDS,
and DTPA~, available from Aldrich with a chemical name of
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diethylenetriaminepentaacetic acid. The chemical names and CAS numbers for
some of the above stabilizers are listed in Table II below.
TABLE II
Antioxidant CAS No. Chemical Name used in Code of Federal
Regulations
Irganox~ 1010 6683-19-8 Tetrakis (methylene(3,5-di-tert-butyl-4
hydroxyhydrocinnamate)) methane
Irganox~ 1035 41484-35-9Thiodiethylene bis(3,5-di-tert-butyl-4-
hydroxyhydrocinnamate
Irganox~ 1098 23128-74-7N,N'-Hexamethylene bis(3,5-di-tert-butyl-4-
hydroxyhydrocinnamamide
Irganox~ B 1171 31570-04-4
23128-74-7 1:1 Blend of Irganoxcl~ 1098 and
Irgafos~ 168
Irganox~ 1425 65140-91-2Calcium bis(monoethyl(3,5-di-tert-butyl-4-
hydroxybenzyl)phosphonate)
Irganox~ 3114 65140-91-2Calcium bis(monoethyl(3,5-di-tert-butyl-4-
hydroxybenzyl)phosphonate)
Irganox~ 3125 34137-09-23,5-Di-tert-butyl-4-hydroxy-hydrocinnamic
acid
triester with 1, 3, 5-tris(2-hydroxyethyl)-S-
triazine-2,4,6-(1 H, 3H, 5H)-trione
Irgafos~ 168 31570-04-4Tris(2,4-di-tert-butyl-phenyl)phosphite
Examples of reductive agents include sodium borohydride, hypophosphorous
acid, Irgafos~ 168, and mixtures thereof.
P rocess
The process for making a liquid fabric softening composition according to the
invention comprises the steps of:
a)-mixing and heating the fabric softener active and optional additives to
form a melt;
b)-dispersing the melt in water;
c)-cooling the resulting dispersion to below the Krafft temperature of the
softener active before adding a dye and a nonionic stabilising agent.
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By Krafft temperature, it is meant the temperature at which the solubility of
the
surfactant becomes equal to the critical micelle concentration (CMC), the CMC
being defined in M.J ROSEN, Surfactants and interfacial phenomena, 1988,
p.215.
Typically, the product is cooled to below 25°C.
Preferably, the mixing of Step a of the invention process is typically made
with a
marine type mixing impeller for 2 minutes.
The dispersion of step b of the process is conveniently made using a flat
blade
turbine impeller at 100 rpm for 10 minutes, the viscosity being measured using
a
Brookfield LVT viscositymeter.
The cooling step as defined under c) is conveniently made using a plate heat
exchanger (a level) at about 30 tonlhour using a positive displacement pump.
The dye and nonionic stabilising agent is mixed in the cooled product using a
marine type mixing impeller.
In another aspect of the invention, there is provided the use of said nonionic
ethoxylated stabilising agent in liquid fabric softening compositions as a
freeze-
thaw recovery agent.
By "freeze-thaw recovery agent", it is meant that the resulting product still
exhibits effective dispersibility property after prolonged exposure to freeze-
thaw
temperatures.
Still in another aspect; the present invention encompasses the use of a
nonionic
alkoxylated stabilising agent to homogenise the dye in liquid fabric softening
compositions.
The invention is illustrated in the following non limiting examples, in which
all
percentages are on a weight basis unless otherwise stated.
In the examples, the abbreviated component identifications have the following
meanings:
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DEQA : Di-(tallowyl-oxy-ethyl) dimethyl ammonium
chloride
DTDMAC : Ditallow dimethylammonium chloride
Fatty acid : Tallow fatty acid IV=18
Electrolyte : Calcium chloride
PEG : Polyethylene Glycol 4000
IPA : Isopropyl alcohol
Nonionic : Marlipal 241100 commercially available
from Huls
Example
The following resulting compositions were prepared in accordance with the
process invention:
Component A B C D E
DTDMAC - - - 4.5
DEQA 2.6 5.1 6.35 4.12 -
(85% IPA)
Fatty acid - - 0.2 -
Nonionic 0.1 0.25 0.3 0.35 0.25
Hydrochloride 0.02 0.02 0.02 0.02 0.02
acid
Perfume 0.10 0.15 0.21 0.28 0.25
Silicone 0.005 0.005 0.005 0.005 0.01
antifoam
Dye (ppm) 10 10 5 5 10
Wat er and nors lance 100
mi to to
ba
