PPE-free tablet degreaser and multi-purpose cleaner

Abstract

A solid cleaning composition that is safe to contact without the use of personal protective equipment (PPE) and has optimal dissolution rate and degreasing performance. Specifically, solid cleaning compositions are disclosed that include a non-hydroxide alkali metal alkali source, an acid, a water conditioner, a cleaning surfactant including an amphoteric, anionic, and / or nonionic surfactant, and / or a coating surfactant including a nonionic surfactant, and provide optimal dissolution and performance without the need for PPE. Methods of providing concentrates and / or use solutions of the solid cleaning compositions, and methods of using the same, are also disclosed.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority under 35 U.S.C. § 112 to U.S. Provisional Patent Application No. 63 / 363,034, filed April 15, 2022, which is incorporated herein by reference in its entirety, including but not limited to the specification, claims, and abstract, and any figures, tables, appendices, or drawings.

[0002] FIELD OF THEINVENTION The present invention relates to a solid cleaning composition that is safe to contact without the use of personal protective equipment (PPE) and has optimal dissolution rate and degreasing performance. Specifically, the solid cleaning composition comprises a non-hydroxide alkali metal alkali source, an acid, a water conditioner, a cleaning surfactant comprising an amphoteric, anionic and / or nonionic surfactant, and / or a coating surfactant comprising a nonionic surfactant, and provides optimal dissolution and performance without the need for PPE. Methods of providing concentrates and / or use solutions of the solid cleaning composition, as well as methods of using the same, are also provided. [Background technology]

[0003] A variety of liquid detergents and cleaning products are commercially available and known in the art. The formulation of alkaline liquid detergents requires both cleaning performance (i.e., removal of dirt and muddy soils) and maintaining a stable emulsion, suspension and / or solution in the liquid product. The transportation and storage of liquid cleaning products can present various challenges. Therefore, it may be desirable to replace liquid formulations with solid cleaning compositions. However, it can be difficult to provide a solid formulation that provides a liquid use composition that is storage stable and also stable over an extended period of time while maintaining (or exceeding) cleaning performance. Furthermore, it can be difficult to provide a concentrated liquid use composition because solids can be highly concentrated, whereas liquids are inherently limited in concentration by solubility.

[0004] Furthermore, because many known surfactants are widely used in solid detergent formulations, prior innovations have not recognized the need for reduced dissolution times in generating use solutions. It remains a challenge to provide solid compositions that are readily dissolved in liquid use compositions, preferably in less than 20 minutes or even less than 10 minutes.

[0005] Accordingly, an object of the present compositions is to provide a cleaning composition that provides at least substantially similar concentrations of surfactants and / or alkalinity as compared to liquid concentrated cleaning compositions.

[0006] A further object is to develop solid hard surface and all-purpose cleaning compositions that provide at least equivalent or superior cleaning performance to solid compositions.

[0007] It is a further object of the present invention to provide a stable hard surface cleaning composition that provides optimal dissolution in a stable ready-to-use formulation.

[0008] It is a further object of the present invention to provide a solid hard surface cleaning composition that is free of alkali hydroxides, is safe to contact without the use of personal protective equipment (PPE), and is compatible with soft metals.

[0009] Other objects, embodiments and advantages of the present invention will be apparent to those skilled in the art in view of the following disclosure, drawings, and appended claims. Summary of the Invention

[0010] The following objects, features, advantages, aspects, and / or embodiments are not exhaustive and do not limit the entire disclosure. No single embodiment necessarily provides each and every object, feature, or advantage. Any of the objects, features, advantages, aspects, and / or embodiments disclosed herein may be fully or partially integrated with one another.

[0011] The primary object, feature, and / or advantage of the present invention is to improve upon or overcome shortcomings in the art. A further object is to provide a solid cleaning composition comprising a non-hydroxide alkali metal alkali source, an acid, at least one water conditioner comprising an amino carboxylic acid, a polycarboxylic acid, an amino phosphonate, or a combination thereof, a cleaning surfactant comprising an amphoteric, anionic, and / or nonionic surfactant, and / or a coating surfactant comprising a short chain nonionic and / or polymeric surfactant, wherein the composition is substantially free of alkali hydroxides and does not require PPE.

[0012] A further object is to provide a solid cleaning composition comprising an alkali metal carbonate, alkali metal bicarbonate, and / or alkali metal silicate alkali source; at least two water conditioners including a polycarboxylic acid having 2-4 carboxyl groups, an amino carboxylic acid, and a polycarboxylic acid; a cleaning surfactant including an amine oxide amphoteric surfactant, and / or a coating surfactant including a short chain PEG 200-800, an alcohol ethoxylate, a polymeric surfactant, or a combination thereof; and a corrosion inhibitor including an alkali metal silicate and / or an alkali metal metasilicate, wherein the composition is substantially free of alkali hydroxides and does not require PPE.

[0013] A still further object is to provide a method of preparing a cleaning composition, the method comprising adding a solid cleaning composition described herein to a diluent to dissolve the solid cleaning composition into a concentrate or use solution, wherein the dissolution time of the solid cleaning composition is less than about 20 minutes, or preferably less than about 10 minutes. These and / or other objects, features, advantages, aspects, and / or embodiments will become apparent to those skilled in the art after reviewing the following brief and detailed description of the drawings. Additionally, the present disclosure encompasses aspects and / or embodiments not expressly disclosed but which can be understood by reading the present disclosure, including at least (a) combinations of the disclosed aspects and / or embodiments, and / or (b) reasonable modifications not shown or described.

[0014] While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. [Brief description of the drawings]

[0015] Certain embodiments in which the invention may be practiced are shown and described in detail, and like reference characters represent like elements throughout the several views. The drawings are presented for illustrative purposes and may not be to scale unless otherwise indicated.

[0016] [Figure 1] 1 shows a graph comparing the dissolution times of solid cleaning compositions evaluated with different percentages of added citric acid.

[0017] [Diagram 2] 1 shows a graph comparing the dissolution times of solid cleaning compositions evaluated with different percentages of added citric acid.

[0018] [Diagram 3] 1 shows a graph comparing the dissolution times of evaluated solid cleaning compositions having various weight percentages of different coating surfactants.

[0019] [Figure 4] 1 shows a graph comparing the dissolution times of evaluated solid cleaning compositions having various weight percentages of an exemplary coating surfactant, PEG400.

[0020] [Diagram 5] 1 shows a graph comparing the dissolution times of evaluated solid cleaning compositions having different surfactant types.

[0021] [Figure 6]1 shows a graph comparing the dissolution times of evaluated solid cleaning compositions having various ratios of two exemplary surfactants, Barlox 12® and Tomadol® 91-6.

[0022] [Figure 7] 1 shows a graph comparing the dissolution times of evaluated solid cleaning compositions using liquid and solid amine oxides.

[0023] [Figure 8] 1 shows a graph comparing the dissolution times of evaluated solid cleaning compositions with and without a sulfonated surfactant.

[0024] [Figure 9] 1 shows a graph comparing the foam height over time of evaluated solid cleaning compositions.

[0025] [Figure 10] 1 shows a graph evaluating the average removal of protein and fatty food stains (i.e., red stains) of the evaluated solid cleaning compositions compared to PPE-free liquid and PPE-free solid comparison formulations. [Figure 11] 1 shows a graph evaluating the average removal of protein and fatty food stains (i.e., red stains) of the evaluated solid cleaning compositions compared to PPE-free liquid and PPE-free solid comparison formulations.

[0026] [Figure 12] FIG. 1 shows a graph comparing the dissolution time of evaluated alcohol alkoxylate surfactants having various numbers of EO groups, showing the decrease in dissolution time with decreasing EO groups.

[0027] [Figure 13] 1 shows a graph of the percent change in volume of compressed tablets over an 8 week period under various environmental conditions.

[0028] Various embodiments of the present invention will now be described in detail with reference to the drawings, in which like reference numerals represent like parts throughout the several views. Reference to various embodiments is not intended to limit the scope of the present invention. The figures presented herein are presented for illustrative purposes only, and are not intended to limit the various embodiments according to the present invention. Those skilled in the art will not need to evaluate the nearly infinite number of different variations of the features described in the following detailed description in separate figures in order to facilitate an understanding of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] The present invention relates to a solid cleaning composition that provides improved cleaning efficacy, such as optimal dissolution rate and degreasing performance. The present disclosure should not be limited to what is described herein, and can be modified and understood by those skilled in the art. Unless otherwise specified, the features shown or described are not essential to enable the basic operation of the present invention. Furthermore, it should be understood that all terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting in any manner or scope. For example, as used in this specification and the appended claims, the singular forms "a", "an", and "the" can include plural referents unless the content clearly indicates otherwise. Furthermore, all units, prefixes, and symbols can be denoted in their SI-recognized form.

[0030] Numerical ranges recited herein are inclusive of the numbers defining the range and include each integer within the defined range. Throughout this disclosure, various aspects of the invention are presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Thus, the description of a range should be considered to have specifically disclosed all possible subranges, fractions, and individual numbers within that range. For example, description of a range such as 1-6 should be considered to have specifically disclosed subranges such as 1-3, 1-4, 1-5, 2-4, 2-6, 3-6, etc., as well as individual numbers within that range, such as 1, 2, 3, 4, 5, and 6, and decimals and fractions, such as 1.2, 3.8, 1 and 1 / 2, and 4 and 3 / 4. This applies regardless of the breadth of the range.

[0031] As used herein, the term "and / or" (e.g., "X and / or Y") should be understood to mean either "X and Y" or "X or Y" and should be interpreted as providing explicit support for both meanings or either meaning, e.g., A and / or B includes the options i) A, ii) B, or iii) A and B.

[0032] It should be understood that certain features that are, for clarity, described herein in the context of separate embodiments, can also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, can also be provided separately or in any subcombination.

[0033] The methods and compositions of the invention may comprise, consist essentially of, or consist of the components and ingredients of the invention, as well as other components described herein. As used herein, "consisting essentially of" means that the methods, systems, devices, and compositions may include additional steps, components, or ingredients, but only if the additional steps, components, or ingredients do not materially alter the basic and novel characteristics of the claimed methods, systems, devices, and compositions.

[0034] Unless otherwise defined, all technical and scientific terms used above have the same meaning as commonly understood by one of ordinary skill in the art to which embodiments of the present invention pertain.

[0035] The terms "invention" or "the present invention" do not refer to a single embodiment of a particular invention, but rather encompass all possible embodiments described in the specification and claims.

[0036] As used herein, the term "about" refers to the variation of a quantity that can be made, for example, through typical measurement techniques and equipment, for any quantifiable variable, including, but not limited to, mass, volume, time, temperature, pH, and bacterial or viral log counts. Furthermore, given the solid and liquid handling procedures used in the real world, there are certain inadvertent errors and variations that are likely through differences in the manufacture, source, or purity of ingredients used to make a composition or carry out a method, etc. The term "about" also encompasses these variations. Whether or not modified by the term "about", the claims include the equivalent to the amount.

[0037] The terms "actives" or "percent actives" or "percent by weight actives" or "actives concentration" are used interchangeably herein and refer to concentrations expressed as a percentage of those ingredients involved in cleaning minus inactive ingredients such as water or salt. Sometimes they are given as a percentage in parentheses, e.g., "chemical (10%)."

[0038] As used herein, the term "alkyl" or "alkyl group" refers to a saturated hydrocarbon having one or more carbon atoms, and includes straight-chain alkyl groups (e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, etc.), cyclic alkyl groups (or "cycloalkyl" or "alicyclic" or "carbocyclic" groups) (e.g., cyclopropyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, etc.), branched-chain alkyl groups (e.g., isopropyl, tert-butyl, sec-butyl, isobutyl, etc.), and alkyl substituted alkyl groups (e.g., alkyl substituted cycloalkyl groups and cycloalkyl substituted alkyl groups).

[0039] Unless otherwise specified, the term "alkyl" includes both "unsubstituted alkyls" and "substituted alkyls." As used herein, the term "substituted alkyl" refers to alkyl groups having substituents replacing one or more hydrogens on one or more carbons of the hydrocarbon backbone. Such substituents may include, for example, alkenyl, alkynyl, halogeno, hydroxyl, alkylcarbonyloxy, arylcarbonyloxy, alkoxycarbonyloxy, aryloxy, aryloxycarbonyloxy, carboxylate, alkylcarbonyl, arylcarbonyl, alkoxycarbonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkylthiocarbonyl, alkoxyl, phosphate, phosphonato, phosphinato, cyano, amino (including alkylamino, dialkylamino, arylamino, diarylamino, and alkylarylamino), acylamino (including alkylcarbonylamino, arylcarbonylamino, carbamoyl, and ureido), imino, sulfhydryl, alkylthio, arylthio, thiocarboxylate, sulfate, alkylsulfinyl, sulfonate, sulfamoyl, sulfonamido, nitro, trifluoromethyl, cyano, azido, heterocyclic, alkylaryl, or aromatic (including heteroaromatic) groups.

[0040] In some embodiments, the substituted alkyl can include heterocyclic groups. As used herein, the term "heterocyclic group" includes closed ring structures similar to carbocyclic groups, in which one or more of the carbon atoms in the ring are elements other than carbon, such as nitrogen, sulfur, or oxygen. Heterocyclic groups can be saturated or unsaturated. Exemplary heterocyclic groups include, but are not limited to, aziridine, ethylene oxide (epoxide, oxirane), thiirane (episulfide), dioxirane, azetidine, oxetane, thietane, dioxetane, dithietane, dithiete, azolidine, pyrrolidine, pyrroline, oxolane, dihydrofuran, and furan.

[0041] As used herein, the term "antimicrobial agent" refers to a compound or composition that reduces or inactivates microbial populations, including but not limited to bacteria, viruses, fungi, and algae, within about 10 minutes, within about 8 minutes, within about 5 minutes, within about 3 minutes, within about 2 minutes, within about 1 minute, or within about 30 seconds. Preferably, the term antimicrobial agent refers to a composition that provides at least about a 3 log, 3.5 log, 4 log, 4.5 log, or 5 log reduction in microbial populations within about 10 minutes, within about 8 minutes, within about 5 minutes, within about 3 minutes, and within about 2 minutes, within about 1 minute, or within about 30 seconds.

[0042] As used herein, the term "cleaning" refers to methods used to promote or assist in the removal of stains, bleaching, reduction of microbial populations, and any combination thereof. As used herein, the term "microorganism" refers to any non-cellular or unicellular (including colonial) organism. Microorganisms include all prokaryotes. Microorganisms include bacteria (including cyanobacteria), spores, lichens, fungi, protozoa, virinos, viroids, viruses, phages, and some algae. As used herein, the term "microbe" is synonymous with microorganism.

[0043] As used herein, the word "exemplary" refers to an example, instance, or illustration, and does not refer to a most preferred embodiment, unless specifically stated otherwise.

[0044] As used herein, the phrase "food processing surfaces" refers to surfaces of utensils, machines, equipment, structures, buildings, etc., used as part of food processing, preparation, or storage activities. Examples of food processing surfaces include surfaces of food processing or preparation equipment (e.g., slicing equipment, canning equipment, or transport equipment, including waterways), surfaces of food processing supplies (e.g., utensils, dishes, wash ware, and bar glasses), and surfaces of floors, walls, or fixtures of structures in which food processing occurs. Food processing surfaces are found and used in food spoilage prevention air circulation systems, aseptic packaging sanitization, food refrigeration and cooler cleaners and sanitizers, warewashing sanitization, bleach cleaning and sanitization, food packaging materials, cutting board additives, third-sink sanitization, beverage chillers and warmers, meat cooling or scalding water, automatic dish sanitizers, sanitizing gels, cooling towers, antimicrobial clothing sprays for food processing, and non-aqueous to low-aqueous food preparation lubricants, oils, and rinse additives.

[0045] As used herein, the term "free" refers to a composition that is completely devoid of the component, or a composition that has such a small amount of the component that it does not affect the performance of the composition. The component may be present as an impurity or contaminant and is less than 0.5% by weight. In another embodiment, the amount of the component is less than 0.1% by weight, and in yet another embodiment, the amount of the component is less than 0.01% by weight.

[0046] The term "generally" encompasses both "about" and "substantially."

[0047] The term "hard surface" refers to solid, substantially inflexible surfaces such as countertops, tiles, floors, walls, panels, windows, plumbing fixtures, kitchen and bath fixtures, appliances, engines, circuit boards, dishes, mirrors, windows, monitors, touch screens, and thermostats. Hard surfaces are not limited by material, for example, hard surfaces can be glass, metal, tile, vinyl, linoleum, composites, wood, plastic, etc. Hard surfaces can include, for example, health care surfaces and food processing surfaces.

[0048] As used herein, the phrase "healthcare surfaces" refers to surfaces of instruments, devices, carts, cages, furniture, structures, buildings, and the like, that are used as part of a healthcare operation. Examples of healthcare surfaces include medical or dental instruments, medical or dental devices, electronic equipment used to monitor the health of a patient, and floor, wall, or fixture surfaces of structures in which healthcare is performed. Healthcare surfaces are found in hospitals, operating rooms, doctor's offices, birthing rooms, funeral homes, and clinical diagnostic rooms. These surfaces may be typified as "hard surfaces" (e.g., walls, floors, toilets, etc.), or textile surfaces, such as knitted, woven, and nonwoven surfaces (e.g., surgical clothing, curtains, bed linens, bandages, etc.), or patient care equipment (e.g., ventilators, diagnostic equipment, shunts, body scopes, wheelchairs, beds, etc.), or surgical and diagnostic equipment. Healthcare surfaces include articles and surfaces used in animal healthcare.

[0049] As used herein, the term "microorganism" refers to any non-cellular or unicellular (including colonial) organism. Microorganisms include all prokaryotes. Microorganisms include bacteria (including cyanobacteria), spores, lichens, fungi, protozoa, virinos, viroids, viruses, phages, and some algae. As used herein, the term "microbe" is synonymous with microorganism.

[0050] As used herein, the term "polymer" refers to a molecular complex composed of 10 or more monomeric units, and generally includes, but is not limited to, homopolymers, copolymers, such as block, graft, random and alternating copolymers, terpolymers, and higher order "x"-mers, and further includes analogs, derivatives, combinations, and blends thereof. Furthermore, unless specifically limited otherwise, the term "polymer" is intended to include all possible isomeric configurations of the molecule, including, but not limited to, isotactic, syndiotactic, and random symmetries, and combinations thereof. Furthermore, unless specifically limited otherwise, the term "polymer" is intended to include all possible geometric configurations of the molecule.

[0051] The scope of the present invention is defined by the appended claims, along with the full scope of equivalents to which such claims are entitled. The scope of the present invention is further limited as including any possible modifications to any of the aspects and / or embodiments disclosed herein, which modifications result in other embodiments, combinations, subcombinations, etc., that will be apparent to those skilled in the art.

[0052] As used herein, the term "soil" or "stain" refers to any soil, including, but not limited to, non-polar oily and / or hydrophobic materials with or without particulate matter, such as industrial soils, inorganic clays, sand, natural mineral matter, carbon black, graphite, kaolin, environmental dust, and / or food-based soils, such as blood, proteinaceous soils, starchy soils, greasy soils, and cellulosic soils.

[0053] The term "substantially" refers to a large extent or to a great extent. Thus, given the appropriate context, "substantially" can refer to a plurality, a majority, and / or a vast portion of such quantifiable variable.

[0054] As used herein, the term "substantially free" refers to a composition that is completely devoid of a component or has such a small amount of the component that it does not affect the performance of the composition, which may be present as an impurity or contaminant, and is less than 0.5% by weight. In another embodiment, the amount of the component is less than 0.1% by weight, and in yet another embodiment, the amount of the component is less than 0.01% by weight.

[0055] The term "substantially similar cleaning performance" refers to generally the same degree of cleaning (or at least not significantly less) or generally the same expenditure of effort (or at least not significantly less), or both, typically achieved by a substitute cleaning product or a substitute cleaning system.

[0056] The term "surfactant" or "surface active agent" refers to an organic compound that, when added to a liquid, changes the properties of the liquid at a surface.

[0057] As used herein, the term "ware" refers to items such as eating and cooking utensils, tableware, and other hard surfaces such as showers, sinks, toilets, bathtubs, countertops, windows, mirrors, transportation vehicles, and floors. As used herein, the term "warewashing" refers to washing, cleaning, or rinsing of ware. Utensils also refer to items made of plastic. Types of plastics that can be washed with the compositions according to the present invention include, but are not limited to, those that include polypropylene polymers (PP), polycarbonate polymers (PC), melamine formaldehyde resins or melamine resins (melamine), acrylonitrile-butadiene-styrene polymers (ABS), and polysulfone polymers (PS). Other exemplary plastics that can be washed using the compounds and compositions of the present invention include polyethylene terephthalate (PET) polystyrene polyamide.

[0058] The terms "weight percent," "wt-%," "percent by weight," "% by weight," and variations thereof, as used herein, refer to the concentration of a substance obtained by dividing the weight of that substance by the total weight of the composition and multiplying by 100. As used herein, it is understood that "percent," "%," and the like are intended to be synonymous with "weight percent," "% by weight," and the like.

[0059] Solid cleaning composition

[0060] According to an embodiment, the solid cleaning composition includes an alkalinity source, an acid, a water conditioner, and a surfactant (cleaning and / or coating surfactant). The solid cleaning composition may include additional functional formulation ingredients. Exemplary solid cleaning compositions are shown in Tables 1A-1C in weight percent. Note that while an ingredient may have a 100% efficacy percentage, Tables 1A-1C do not list the efficacy percentage of the ingredient, but rather list the total weight percent (wt%) of the ingredients (i.e., efficacy concentration + inactive ingredients).

[0061] [Table 1]

[0062] [Table 2]

[0063] [Table 3]

[0064] Exemplary embodiments of the solid cleaning composition can comprise, consist essentially of, or consist of a non-hydroxide alkali metal alkali source, an acid, at least one water conditioner including an amino carboxylic acid, a polycarboxylic acid, an amino phosphonate, or a combination thereof, a cleaning surfactant including an amphoteric, anionic, and / or nonionic surfactant, and / or a coating surfactant including a short chain nonionic and / or polymeric surfactant, wherein the composition is substantially free of alkali hydroxides and does not require PPE.

[0065] As referred to herein, the solid cleaning composition is provided in a single-use composition and packaging, so that no PPE is required. In some embodiments, the solid cleaning composition is individually packaged in packaging that does not require the use of PPE, such as a foil pack, so that no PPE is required. In addition, the solid composition once dissolved in the use solution has a pH of less than about 10.5, a pH of about 5 to about 10.5, or about 8 to about 10, so that no PPE is required.

[0066] Exemplary embodiments of the solid cleaning composition can comprise, consist essentially of, or consist of an alkali metal carbonate, alkali metal bicarbonate, and / or alkali metal silicate alkaline source; at least two water conditioners including polycarboxylic acids having 2-4 carboxyl groups, amino carboxylic acids and polycarboxylic acids; a cleaning surfactant including an amine oxide amphoteric surfactant and / or a coating surfactant including short chain PEG 200-800, alcohol ethoxylates, polymeric surfactants, or combinations thereof; and a corrosion inhibitor including an alkali metal silicate and / or alkali metal metasilicate, wherein the composition is substantially free of alkali hydroxides and does not require PPE.

[0067] A solid cleaning composition is a solid concentrate that is diluted to form a use composition. Generally, a concentrate refers to a composition that is intended to be diluted with water to provide a use solution that contacts an object to provide the desired cleaning, disinfection, etc. The solid cleaning composition that contacts the article to be cleaned can be referred to as a concentrate or a use composition (or use solution), depending on the formulation used in the method. It should be understood that the concentration of ingredients in a solid cleaning composition will vary depending on the concentrated nature of the formulation and its desired use solution.

[0068] The solid hard surface cleaning composition provides a storage stable solid composition. The solid hard surface cleaning composition is storage stable for at least 8 weeks at elevated storage temperatures, including temperatures up to at least 50°C (or 100°F), with a growth index (i.e., solid dimensional or volumetric change) of less than about 15%, or less than about 10%, and demonstrates storage stability at room or ambient temperatures for at least about 2 years for tablet compositions (which have an increased growth index compared to solid block compositions). Exhibiting both solid stability and use composition stability over extended periods of time is an important advantage for solid cleaning compositions.

[0069] In some embodiments, the solid cleaning concentrate is shelf stable or has a shelf life of more than 6 months, more than 1 year, or more than 2 years. In some embodiments, the solid cleaning concentrate has a shelf life of about 2 years.

[0070] In some embodiments, the ready-to-use solution of the solid cleaning concentrate that is diluted to form a use composition is shelf stable or has a shelf life of 1 day, or more than 1 day, or more than 1 week, or more than 2 weeks. In some embodiments, the ready-to-use diluted form of the solid composition has a shelf life of about 2 weeks.

[0071] In some embodiments, the solid composition has a pH of less than about 10.5, a pH of about 5 to about 10.5, or a pH of about 8 to about 10 when diluted to form a use composition.

[0072] Alkaline source The solid cleaning composition comprises an effective amount of one or more alkaline sources to enhance cleaning of substrates and improve soil removal performance at a working pH of less than about 10.5, or from about 8 to about 10.5. A preferred pH is less than about 10.5 to ensure that the use of PPE is not required. The solid cleaning composition comprises from about 20% to about 90% by weight, from about 30% to about 90% by weight, from about 40% to about 90% by weight, from about 40% to about 80% by weight, or from about 40% to about 70% by weight of the alkaline source.

[0073] Examples of alkaline sources suitable for solid hard surface cleaning compositions include, but are not limited to, alkali metal carbonates, bicarbonates, sesquicarbonates, and mixtures thereof.Exemplary alkali metal carbonates that can be used include, but are not limited to, sodium or potassium carbonates, bicarbonates, sesquicarbonates, and mixtures thereof.Additional alkaline sources include, for example, alkali metal silicates, such as sodium or potassium silicates or metasilicates, metal carbonates, such as sodium or potassium carbonates, bicarbonates, sesquicarbonates, metal borates, such as sodium or potassium borates, and ethanolamines and amines.

[0074] Preferred solid cleaning compositions are free of any alkali metal hydroxides, such as potassium hydroxide or sodium hydroxide, and are comprised of alkali metal carbonates, alkali metal bicarbonates and / or alkali metal silicates.

[0075] acid The solid cleaning composition includes an effective amount of acid to assist as a dissolution aid for the solid composition. Without being bound to a particular mechanism of action, the acid reacts with an alkaline source in the composition to cause foaming and increase the rate or speed of physical decomposition of the solid composition. The solid cleaning composition includes about 1% to about 40% by weight, about 10% to about 40% by weight, about 15% to about 40% by weight, about 15% to about 30% by weight, or about 20% to about 30% by weight of acid.

[0076] As referred to herein, the solid composition comprises an acid or a salt thereof. Preferably, the acid has a water solubility of 0.1 g / L to 1500 g / L at 20° C., more preferably 0.25 g / L to 500 g / L at 20° C., and most preferably 0.25 to 100 g / L at 20° C. As used herein, the g / L designation refers to the mass of acid added with sufficient aqueous medium (e.g., water) to form 1 liter of solution. Preferably, the acid is a polycarboxylic acid. More preferably, the acid is a polycarboxylic acid having 2 to 4 carboxyl groups. More preferably, the polycarboxylic acid is a dicarboxylic acid or tricarboxylic acid. Preferred acids include, but are not limited to, citric acid, adipic acid, ethylenediaminetetraacetic acid, isocitric acid, glutamic acid, glutaric acid, malic acid, propane-1,2,3-tricarboxylic acid, succinic acid, tartaric acid, salts thereof, and mixtures thereof.

[0077] In one embodiment, the acid is adipic acid, which provides the desired tablet stability, hi a further embodiment, the acid is citric acid, which provides the desired balance of tablet stability and dissolution rate.

[0078] Water Conditioner The solid cleaning composition includes at least one water conditioning agent, which may include a chelating or complexing agent or a water conditioning polymer.

[0079] Various chelating agents may be utilized as water conditioning agents that coordinate (i.e., bind) metal ions commonly found in natural waters to prevent the metal ions from interfering with the action of other detergent ingredients of the cleaning composition. In general, chelating agents may be generally referred to as a type of builder, and when included in an effective amount, may also function as an ion threshold agent. The solid cleaning composition may include from about 0.1% to about 40% by weight, from about 0.1% to about 25% by weight, from about 1% to about 25% by weight, from about 1% to about 20% by weight, from about 5% to about 20% by weight, or from about 10% to about 20% by weight of the water conditioning agent.

[0080] Preferred chelating agents as water conditioners are aminocarboxylic acids, such as methylglycine diacetic acid (MGDA), N,N-dicarboxymethylglutamic acid (GLDA), N-hydroxyethyliminodiacetic acid, nitrilotriacetic acid (NTA), ethylenediaminetetraacetic acid (EDTA), N-hydroxyethyl-ethylenediaminetriacetic acid (HEDTA), diethylenetriaminepentaacetic acid (DTPA), ethylenediaminetetrapropionic acid, triethylenetetraaminehexaacetic acid (TTHA), and their respective alkali metal, ammonium and substituted ammonium salts.

[0081] Additional chelating agents as water conditioners include phosphonates such as phosphonic acids, phosphates such as condensed phosphates, e.g., sodium and potassium orthophosphate, sodium and potassium pyrophosphate, sodium tripolyphosphate, sodium hexametaphosphate, and the like, organic chelating agents including both polymeric and small molecule chelating agents, e.g., organic carboxylate compounds or organic phosphate chelating agents, polymeric chelating agents such as polyanionic compositions, e.g., polyacrylic acid compounds.

[0082] The water conditioner may also be a polymer, including water-soluble polycarboxylate polymers, such as homopolymer and copolymer compositions having pendant (-COOH) carboxylic acid groups, including polyacrylic acid, polymethacrylic acid, polymaleic acid, acrylic acid-methacrylic acid copolymers, acrylic-maleic acid copolymers, hydrolyzed polyacrylamide, hydrolyzed methacrylamide, hydrolyzed acrylamide-methacrylamide copolymers, hydrolyzed polyacrylonitrile, hydrolyzed polymethacrylonitrile, hydrolyzed acrylonitrile methacrylonitrile copolymers, or mixtures thereof. Water-soluble salts or partial salts of these polymers or copolymers, such as their respective alkali metal (e.g., sodium or potassium) or ammonium salts, may also be used. The weight average molecular weight of the polymer is about 400 to about 20,000 g / mole. An example of a commercially available polycarboxylic acid (polycarboxylate) is ACUSOL 445 (Dow Chemicals), a homopolymer of acrylic acid with an average molecular weight of 4500. ACUSOL 445 is available as a partially neutralized liquid detergent polymer.

[0083] Exemplary polymers include polyacrylic acid, partial sodium salts of polyacrylic acid or sodium polyacrylate having an average molecular weight in the range of 4000 to 8000. Further exemplary polymers include polycarboxylates such as polyacrylic acid, maleic / olefin copolymers, acrylic / maleic copolymers, polymethacrylic acid, acrylic acid-methacrylic acid copolymers, hydrolyzed polyacrylamides, hydrolyzed polymethacrylamides, hydrolyzed polyamide-methacrylamide copolymers, hydrolyzed polyacrylonitrile, hydrolyzed polymethacrylonitrile, and hydrolyzed acrylonitrile-methacrylonitrile copolymers.

[0084] In an exemplary embodiment, the water conditioning agent comprises an amino carboxylic acid that is one or more of methylglycine diacetic acid (MGDA), N-hydroxyethyliminodiacetic acid, nitrilotriacetic acid (NTA), ethylenediaminetetraacetic acid (EDTA), N-hydroxyethyl-ethylenediaminetriacetic acid (HEDTA), diethylenetriaminepentaacetic acid (DTPA), ethylenediaminetetrapropionic acid, and triethylenetetraaminehexaacetic acid, and the water conditioning polymer is a homopolymer of acrylic acid.

[0085] Surfactants The solid cleaning composition includes a combination of surfactants to provide both degreasing effectiveness (i.e., performance) and optimal dissolution rate. A variety of surfactants can be used to provide performance and dissolution. Preferred surfactants suitable for use with the composition include, but are not limited to, amphoteric (including zwitterionic), anionic and / or nonionic cleaning surfactants, and / or nonionic coating surfactants. The solid cleaning composition includes from about 1% to about 60% by weight, from about 5% to about 50% by weight, from about 5% to about 40% by weight, from about 5% to about 30% by weight, from about 1% to about 25% by weight, from about 5% to about 25% by weight, from about 5% to about 20% by weight, or from about 5% to about 15% by weight of surfactant.

[0086] The use of cleaning surfactants and / or coating surfactants is disclosed. In an embodiment, amphoteric surfactants are the preferred cleaning surfactants for providing degreasing effect in the composition. In an embodiment, nonionic surfactants are the preferred coating surfactants for providing optimal dissolution of the composition.

[0087] Amphoteric Surfactants - Cleaning Surfactants Amphoteric or ampholytic surfactants contain both basic and acidic hydrophilic groups and organic hydrophobic groups.These ionic entities can be either anionic or cationic groups as described herein for other types of surfactants.Basic nitrogen and acidic carboxylate groups are typical functional groups employed as basic and acidic hydrophilic groups.In some surfactants, sulfonate, sulfate, phosphonate, or phosphate provide negative charge.

[0088] The solid cleaning composition comprises from about 0% to about 40% by weight, from about 1% to about 40% by weight, from about 5% to about 40% by weight, from about 5% to about 30% by weight, from about 5% to about 25% by weight, from about 5% to about 20% by weight, or from about 5% to about 15% by weight of an amphoteric surfactant (including a zwitterionic surfactant).

[0089] Amphoteric surfactants can be broadly described as derivatives of aliphatic secondary and tertiary amines, where the aliphatic radical may be linear or branched, one of the aliphatic substituents contains about 8-18 carbon atoms, and one contains an anionic water-solubilizing group, such as carboxy, sulfo, sulfato, phosphato, or phosphono. Amphoteric surfactants are known to those skilled in the art and are subdivided into two main classes described in "Surfactant Encyclopedia" Cosmetics & Toiletries, Vol. 104(2) 69-71 (1989), the entirety of which is incorporated herein by reference. The first class includes acyl / dialkylethylenediamine derivatives (e.g., 2-alkylhydroxyethylimidazoline derivatives) and their salts. The second class includes N-alkylamino acids and their salts. Some amphoteric surfactants can be envisioned as falling into both classes.

[0090] Amphoteric surfactants can be synthesized by methods known to those skilled in the art. For example, 2-alkylhydroxyethyl imidazolines are synthesized by condensation and ring closure of long-chain carboxylic acids (or derivatives) with dialkylethylenediamines. Commercial amphoteric surfactants are derivatized, for example with chloroacetic acid or ethyl acetate, followed by hydrolysis and opening of the imidazoline ring by alkylation. During alkylation, one or two carboxy-alkyl groups react to form a tertiary amine and an ether bond, with different alkylating agents resulting in different tertiary amines. Long-chain imidazole derivatives generally have the following general formula: [ka] where R is an acyclic hydrophobic group containing about 8-18 carbon atoms, and M is a cation, typically sodium, for neutralizing the charge of the anion. Commercially well-known imidazoline-derived amphoteric compounds that can be used in the composition include, for example, cocoamphopropionate, cocoamphocarboxy-propionate, cocoamphoglycinate, cocoamphocarboxy-glycinate, cocoamphopropyl-sulfonate, and cocoamphocarboxy-propionic acid. Amphocarboxylic acids can be generated from aliphatic imidazolines, where the dicarboxylic acid functional group of the amphodicarboxylic acid is diacetic acid and / or dipropionic acid.

[0091] The carboxymethylated compounds (glycinates) described herein above are often referred to as betaines, which are a special class of amphoteric compounds described herein below in the section entitled Zwitterionic Surfactants.

[0092] Long-chain N-alkylamino acids are easily prepared by the reaction RNH2, where R is C8-C 18They are fatty amines with straight or branched chain alkyl, halogenated carboxylic acids. Alkylation of the primary amino group of amino acids results in secondary and tertiary amines. The alkyl substituent may have two or more amino groups providing multiple reactive nitrogen centers. Most commercial N-alkyl amine acids are alkyl derivatives of beta-alanine or beta-N(2-carboxyethyl)alanine. Examples of commercial N-alkyl amino acid ampholytes having use in the present invention include alkyl beta-amino dipropionates, RN(C2H4COOM)2 and RNHC2H4COOM. In certain embodiments, R can be an acyclic hydrophobic group containing about 8 to about 18 carbon atoms and M is a cation to neutralize the charge of the anion.

[0093] Suitable amphoteric surfactants include those derived from coconut products such as coconut oil or coconut fatty acids. Additional suitable coconut derived surfactants include as part of their structure an ethylenediamine moiety, an alkanolamide moiety, an amino acid moiety such as glycine, or combinations thereof, and an aliphatic substituent of about 8 to 18 (e.g., 12) carbon atoms. Such surfactants may also be considered alkyl amphodicarboxylic acids. These amphoteric surfactants include those derived from coconut products such as coconut oil or coconut fatty acids. Additional suitable coconut derived surfactants include as part of their structure an ethylenediamine moiety, an alkanolamide moiety, an amino acid moiety such as glycine, or combinations thereof, and an aliphatic substituent of about 8 to 18 (e.g., 12) carbon atoms. Such surfactants may also be considered alkyl amphodicarboxylic acids. 12 -Alkyl-C(O)-NH-CH2-CH2-N + (CH2-CH2-CO2Na)2-CH2-CH2-OH or C 12 -Alkyl-C(O)-N(H)-CH2-CH2-N + It may include a chemical structure represented as (CH2-CO2Na)2-CH2-CH2-OH. Disodium cocoamphodipropionate is one suitable amphoteric surfactant, and is commercially available under the trade name Miranol™ FBS, manufactured by Rhodia Inc., Cranbury, NJ. Another suitable coconut-derived amphoteric surfactant, having the chemical name disodium cocoamphodiacetate, is sold under the trade name Mirataine™ JCHA, also manufactured by Rhodia Inc., Cranbury, NJ.

[0094] Additional suitable surfactants include those of the formula: [ka] and amine oxide surfactants having the formula: 3 is an alkyl, hydroxyalkyl, or alkylphenyl 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 a mixture thereof, x is from 0 to about 3, and each R 5 R 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. 5 The groups may be linked together, for example, through an oxygen or nitrogen atom to form a ring structure. Exemplary amine oxide surfactants are C10-C18 alkyl dimethyl amine oxide and C8-C12 alkoxy ethyl dihydroxy ethyl amine oxide. Further exemplary amine oxides include lauramine oxide, also known as lauryl dimethyl amine oxide, lauryl dimethyl amine N-oxide, dodecyl dimethyl amine N-oxide, dodecyl dimethyl amine oxide, C 14 H 31 The answer is NO.

[0095] A typical listing of amphoteric classes and species of these surfactants is described in U.S. Patent No. 3,929,678, issued to Laughlin and Heuring on December 30, 1975. Further examples are given in "Surface Active Agents and Detergents" (Vol. I and II by Schwartz, Perry and Berch).

[0096] Zwitterionic Surfactants Zwitterionic surfactants are a subset of amphoteric surfactants and may contain anionic charges. Zwitterionic 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 sulfonium compounds. Typically, zwitterionic surfactants contain a positively charged quaternary ammonium, or sometimes sulfonium or phosphonium ion, a negatively charged carboxyl group, and an alkyl group. Zwitterions generally contain cationic and anionic groups that ionize to about the same extent in the isoelectric region of the molecule, which can create a strong "inner salt" attraction between the positive-negative charge centers. Examples of such zwitterionic synthetic surfactants include derivatives of aliphatic quaternary ammonium, phosphonium, and sulfonium compounds in which the aliphatic radical may be straight-chained or branched, one of the aliphatic substituents containing from 8 to 18 carbon atoms, and one containing an anionic water-solubilizing group, such as carboxy, sulfonate, sulfate, phosphate, or phosphonate.

[0097] Betaine and sultaine surfactants are exemplary zwitterionic surfactants for use herein. The general formula for these compounds is: [ka] where R 1 contains an alkyl, alkenyl, or hydroxyalkyl radical of 8 to 18 carbon atoms having 0 to 10 ethylene oxide moieties and 0 to 1 glyceryl moiety, Y is selected from the group consisting of nitrogen, phosphorus, and sulfur atoms, R 2 is an alkyl or monohydroxyalkyl group containing 1 to 3 carbon atoms, x is 1 when Y is a sulfur atom, and is 2 when Y is a nitrogen atom or a phosphorus atom, R 3 is an alkylene or hydroxyalkylene or hydroxyalkylene of 1 to 4 carbon atoms, and Z is a group selected from the group consisting of a carboxylate group, a sulfonate group, a sulfate group, a phosphonate group, and a phosphate group.

[0098] Examples of zwitterionic surfactants having the above structure include 4-[N,N-di(2-hydroxyethyl)-N-octadecylammonio]-butane-1-carboxylate, 5-[S-3-hydroxypropyl-S-hexadecylsulfonio]-3-hydroxypentane-1-sulfate, 3-[P,P-diethyl-P-3,6,9-trioxatetracosanephosphonio]-2-hydroxypropane-1-phosphate, 3-[N,N-dipropyl-N-3-dodecoxy-2-hydroxypropyl-ammonio]-propane-1-phosphonate, 3-(N,N-dimethyl-N-hexadecylammonio)-propane-1-sulfonate, 3-(N,N-dimethyl-N-hexadecylammonio)-propane-1-sulfonate, 3-(N,N-dimethyl-N- Examples of suitable surfactants include S[N,N-di(3-hydroxypropyl)-N-hexadecylammonio]-2-hydroxy-propane-1-sulfonate, 4-[N,N-di(2(2-hydroxyethyl)-N(2-hydroxydodecyl)ammonio]-butane-1-carboxylate, 3-[S-ethyl-S-(3-dodecoxy-2-hydroxypropyl)sulfonio]-propane-1-phosphate, 3-[P,P-dimethyl-P-dodecylphosphonio]-propane-1-phosphonate, and S[N,N-di(3-hydroxypropyl)-N-hexadecylammonio]-2-hydroxy-pentane-1-sulfate. The alkyl groups contained in the detergent surfactants may be linear or branched, saturated or unsaturated.

[0099] Zwitterionic surfactants suitable for use in the present compositions have the following general structure: [ka] Contains betaine.

[0100] These surfactant betaines typically do not exhibit strong cationic or anionic characteristics at extreme pH, nor do they exhibit reduced water solubility in their isoelectric range. Unlike "external" quaternary ammonium salts, betaines can coexist with anions. Examples of suitable betaines include coconut acylamidopropyl dimethyl betaine, hexadecyl dimethyl betaine, C 12~14Acylamidopropyl betaine, C 8~14 Acylamidohexyl diethyl betaine, 4-C 14~16 Acylmethylamidodiethylammonio-1-carboxybutane, C 16~18 Acylamide dimethyl betaine, C 12~16 Acylamide pentane diethyl betaine, and C 12~16 Acylmethylamidodimethylbetaine is an example.

[0101] Particularly suitable sultaines include those of the formula (R(R 1 )2N + R 2 SO 3- In the formula, R is a C6 to C 18 is a hydrocarbyl group, and each R 1 are typically independently C1-C3 alkyl, e.g., methyl, and R 2 is a C1 to C6 hydrocarbyl group, for example a C1 to C3 alkylene or hydroxyalkylene group.

[0102] A representative listing of these zwitterionic classes and species of surfactants is given in U.S. Patent No. 3,929,678, issued to Laughlin and Heuring on December 30, 1975. Further examples are given in "Surface Active Agents and Detergents" (Vol. I and II by Schwartz, Perry and Berch). Each of these references is incorporated herein in its entirety.

[0103] In some embodiments, the solid hard surface cleaning composition comprises an amine oxide and / or a betaine and / or a sultaine.

[0104] Anionic Surfactants - Cleaning Surfactants The solid cleaning composition can include at least one anionic surfactant as a cleaning surfactant. Anionics are surfactants that have a negative charge on the hydrophobic material or the hydrophobic part of the molecule does not have a charge unless the pH is raised to neutral or above (e.g., carboxylic acid). Carboxylate, sulfonate, sulfate, and phosphate are polar (hydrophilic) solubilizing groups found in anionic surfactants. Of the cations (counterions) associated with these polar groups, sodium, lithium, and potassium impart water solubility, ammonium and substituted ammonium ions provide both water solubility and oil solubility, and calcium, barium, and magnesium promote oil solubility. As will be understood by those skilled in the art, anionics are excellent cleaning surfactants and are therefore preferred additions to heavy duty cleaning compositions.

[0105] Anionic sulfate surfactants suitable for use in the composition include alkyl ether sulfates, alkyl sulfates, linear and branched primary and secondary alkyl sulfates, alkyl ethoxy sulfates, fatty oleyl glycerol sulfates, alkylphenol ethylene oxide ether sulfates, C5-C 17 Included are acyl-N-(C1-C4 alkyl) and -N-(C1-C2 hydroxyalkyl) glucamine sulfates, as well as sulfates of alkyl polysaccharides, such as sulfates of alkyl polyglucosides. Also included are alkyl sulfates, alkyl poly(ethyleneoxy)ether sulfates, and aromatic poly(ethyleneoxy)sulfates, such as sulfates or condensation products of ethylene oxide and nonylphenol (usually having 1 to 6 oxyethylene groups per molecule). Anionic sulfonate surfactants suitable for use also include alkyl sulfonates, linear and branched primary and secondary alkyl sulfonates, and aromatic sulfonates with or without substituents.

[0106] Anionic carboxylate surfactants suitable for use include carboxylic acids (and salts) such as alkanoic acids (and alkanoates), ester carboxylic acids (e.g., alkyl succinates such as sodium dioctyl sulfosuccinate), ether carboxylic acids, sulfonated fatty acids such as sulfonated oleic acid, and the like. Such carboxylates include alkyl ethoxy carboxylates, alkylaryl ethoxy carboxylates, alkyl polyethoxy polycarboxylate surfactants, and soaps (e.g., alkyl carboxyls). Secondary carboxylates useful in the present compositions include those that contain a carboxyl unit connected to a secondary carbon. The secondary carbon may be in a ring structure, for example, as in p-octyl benzoic acid, or as in alkyl-substituted cyclohexyl carboxylates. Secondary carboxylate surfactants typically do not contain ether linkages, ester linkages, and hydroxyl groups. Furthermore, they typically lack a nitrogen atom in the head group (amphiphilic portion). Suitable secondary soap surfactants typically contain a total of 11-13 carbon atoms, although more carbon atoms may be present (e.g., up to 16). Suitable carboxylates also include acyl amino acids (and salts), such as acyl glutamates, acyl peptides, sarcosinates (e.g., N-acylsarcosinates), taurates (e.g., N-acyltaurates, and fatty acid amides of methyl tauride), and the like.

[0107] Suitable anionic surfactants include those having the following formula: RO-(CH2CH2O) n (CH2) m -CO2X(3) is an alkyl or alkylaryl ethoxy carboxylate, wherein R is a C 22 an alkyl group, or [ka] and R 1 is C4~C 16In some embodiments, R is an alkyl group, n is an integer from 1 to 20, m is an integer from 1 to 3, and X is a counterion such as hydrogen, sodium, potassium, lithium, ammonium, or an amine salt such as monoethanolamine, diethanolamine, or triethanolamine. In some embodiments, n is an integer from 4 to 10 and m is 1. In some embodiments, R is a C8 to C 16 In some embodiments, R is an alkyl group. 12 ~C 14 It is an alkyl group, n is 4, and m is 1.

[0108] In other embodiments, R is [ka] and R 1 is C6~C 12 In still yet other embodiments, R 1 is a C9 alkyl group, n is 10, and m is 1.

[0109] Non-ionic Surfactants - Cleaning and / or Coating Surfactants The solid cleaning composition may contain at least one nonionic surfactant as a cleaning surfactant and / or coating surfactant. Useful nonionic surfactants are generally characterized by the presence of an organic hydrophobic group and an organic hydrophilic group, and are typically produced by condensation of an organic aliphatic, alkyl aromatic, or polyoxyalkylene hydrophobic compound with a hydrophilic alkaline oxide moiety, the common practice being ethylene oxide or its polyhydration products, polyethylene glycol. In fact, any hydrophobic compound having a hydroxyl, carboxyl, amino, or amide group with a reactive hydrogen atom can be condensed with ethylene oxide, or its polyhydration adducts, or mixtures thereof with alkoxylene such as propylene oxide, to form a nonionic surfactant. The length of the hydrophilic polyoxyalkylene moiety condensed with any particular hydrophobic compound can be easily adjusted to produce a water-dispersible or water-soluble compound with the desired degree of balance between hydrophilic and hydrophobic properties. Useful nonionic surfactants include:

[0110] Polyethylene glycol (PEG) is a product of condensation of ethylene oxide and water, which may have various derivatives and functional groups. PEG is [ka] As shown in the formula (I), the PEG coating surfactant is composed of polyether compounds with repeating ethylene glycol units according to the constituent monomers or parent molecules (as ethylene glycol, ethylene oxide, or oxyethylene), where n is any integer of at least 1. Preferably, the PEG coating surfactant is a short chain PEG 200-800, e.g., PEG 200, PEG 400, PEG 600, or PEG 800.

[0111] Block polyoxypropylene-polyoxyethylene polymer compounds based on propylene glycol, ethylene glycol, glycerol, trimethylolpropane, and ethylenediamine as the initiator reactive hydrogen compound. Examples of polymer compounds made from sequential propoxylation and ethoxylation of the initiator are commercially available from BASF Corp. One class of compounds are difunctional (two reactive hydrogen) compounds formed by condensation of ethylene oxide with a hydrophobic base formed by addition of propylene oxide to the two hydroxyl groups of propylene glycol. This hydrophobic portion of the molecule weighs from about 1,000 to about 4,000. Ethylene oxide is then added to sandwich this hydrophobe between the hydrophilic groups, controlled by length to comprise from about 10% to about 80% by weight of the final molecule. Another class of compounds are tetrafunctional block copolymers obtained from the sequential addition of propylene oxide and ethylene oxide to ethylenediamine. The molecular weight of the propylene oxide hydrotype is in the range of about 500 to about 7,000, and the hydrophilic substance ethylene oxide is added so as to constitute about 10% by weight to about 80% by weight of the molecule.

[0112] Condensation products of one mole of alkylphenols, the alkyl chain of which may be of linear or branched configuration, or of single or double alkyl constituents, containing from about 8 to about 18 carbon atoms, with from about 3 to about 50 moles of ethylene oxide. The alkyl groups may be represented, for example, by diisobutylene, di-amyl, polymerized propylene, iso-octyl, nonyl, and di-nonyl. These surfactants may be polyethylene, polypropylene, and polybutylene oxide condensates of alkylphenols. Examples of commercial compounds of this chemistry are available under the trade names Igepal® manufactured by Rhone-Poulenc, and Triton® manufactured by Union Carbide.

[0113] A condensation product of one mole of a saturated or unsaturated straight or branched chain alcohol having from about 6 to about 24 carbon atoms with from about 3 to about 50 moles of ethylene oxide. The alcohol portion may consist of a mixture of alcohols within the carbon range set forth above, or may consist of an alcohol having a specific number of carbon atoms within this range. Examples of similar commercial surfactants are available under the trade names Lutensol™, Dehydol™ from BASF, Neodol™ from Shell Chemical Co., and Alfonic™ from Vista Chemical Co.

[0114] The condensation product of one mole of a saturated or unsaturated straight or branched chain carboxylic acid having from about 8 to about 18 carbon atoms with from about 6 to about 50 moles of ethylene oxide. The acid portion may consist of a mixture of acids within the carbon atom range defined above, or may consist of an acid having a specific number of carbon atoms within this range. Examples of commercial compounds of this chemistry are available under the trade names Disponil or Agnique manufactured by BASF, and Lipopeg™ manufactured by Lipo Chemicals, Inc.

[0115] In addition to ethoxylated carboxylic acids, commonly referred to as polyethylene glycol esters, glycerides, glycerin, and other alkanoic acid esters formed by reaction with polyhydric (saccharide or sorbitan / sorbitol) alcohols have application in the present invention for specialized embodiments, particularly indirect food additive applications. All of these ester moieties have one or more reactive hydrogen sites on their molecules that can be subjected to further acylation or ethylene oxide (alkoxide) addition to control the hydrophilicity of these materials. Care must be taken when adding these fatty esters or acylated carbohydrates to the compositions of the present invention containing amylase and / or lipase enzymes due to possible incompatibilities.

[0116] Examples of non-ionic low foaming surfactants include: Compounds described herein that have been modified, essentially inverted, by adding ethylene oxide to ethylene glycol to provide a hydrophile of the specified molecular weight, and then adding propylene oxide to obtain a hydrophobic block on the outside (end) of the molecule. The hydrophobic portion has a molecular weight of about 1,000 to about 3,100, with the central hydrophile comprising 10% to about 80% by weight of the final molecule. These inverted Pluronics™ are manufactured by BASF Corporation under the trade name Pluronic™ R surfactants. Similarly, Tetronic™ R surfactants are manufactured by BASF Corporation by the sequential addition of ethylene oxide and propylene oxide to ethylenediamine. The hydrophobic portion of the molecule has a weight of about 2,100 to about 6,700, with the central hydrophile comprising 10% to about 80% by weight of the final molecule.

[0117] Compounds described herein that have been modified by "capping" or "end-blocking" the terminal hydroxy groups (of the polyfunctional moiety) to reduce foaming upon reaction with hydrophobic small molecules such as propylene oxide, butylene oxide, benzyl chloride, and short chain fatty acids, alcohols, or alkyl halides containing 1 to about 5 carbon atoms, and mixtures thereof. Also included are reactants such as thionyl chloride that convert the terminal hydroxy group to a chloride group. Such modifications to the terminal hydroxy group can result in all-block, block-heteric, heteric-block, or all-heteric nonionic materials.

[0118] Further examples of useful low foaming nonionics include: wherein R is an alkyl group having 8 to 9 carbon atoms, A is an alkylene chain having 3 to 4 carbon atoms, n is an integer from 7 to 16, and m is an integer from 1 to 10. [ka] The alkylphenoxypolyethoxyalkanols of U.S. Pat. No. 2,903,486, issued Sep. 8, 1959 to Brown et al., represented by the formula:

[0119] Polyalkylene glycol condensates of U.S. Pat. No. 3,048,548, issued Aug. 7, 1962 to Martin et al., having alternating hydrophilic oxyethylene chains and hydrophobic oxypropylene chains, with the molecular weight of the terminal hydrophobic chains, the molecular weight of the intermediate hydrophobic units, and the molecular weight of the linking hydrophilic units each accounting for approximately one-third of the condensate.

[0120] General formula Z[(OR) n OH] z wherein Z is an alkoxylatable material, R is a radical derived from an alkylene oxide which may be ethylene and propylene, n is an integer, for example, from 10 to 2,000 or more, and z is an integer determined by the number of reactive oxyalkylatable groups.

[0121] Formula Y(C3H6O) n (C2H4O) m The conjugated polyoxyalkylene compounds described in U.S. Pat. No. 2,677,700 issued May 4, 1954 to Jackson et al., corresponding to H, where Y is the residue of an organic compound having from about 1 to 6 carbon atoms and one reactive hydrogen atom, n has an average value of at least about 6.4 as determined by the hydroxyl number, and m has a value such that the oxyethylene moieties constitute from about 10% to about 90% by weight of the molecule.

[0122] Formula Y[(C3H6O n (C2H4O) m H] xConjugated polyoxyalkylene compounds according to U.S. Pat. No. 2,674,619 issued to Lundsted et al. on Apr. 6, 1954, having the formula: (wherein Y is the residue of an organic compound having about 2-6 carbon atoms and containing x reactive hydrogen atoms, x having a value of at least about 2, n having a value such that the molecular weight of the polyoxypropylene hydrophobic base is at least about 900, and m having a value such that the oxyethylene content of the molecule is about 10% to about 90% by weight). Compounds falling within the definition for Y include, for example, propylene glycol, glycerin, pentaerythritol, trimethylolpropane, ethylenediamine, and the like. The oxypropylene chains optionally, but advantageously, contain small amounts of ethylene oxide, and the oxyethylene chains also optionally, but advantageously, contain small amounts of propylene oxide.

[0123] Further conjugated polyoxyalkylene surfactants which may be advantageously used in the compositions of the present invention have the formula: P[(CHO) n (C2H4O) m H] x where P is the residue of an organic compound having from about 8 to 18 carbon atoms and containing x reactive hydrogen atoms, x has a value of 1 or 2, n has a value such that the molecular weight of the polyoxyethylene portion is at least about 44, and m has a value such that the oxypropylene content of the molecule is from about 10% to about 90% by weight. In either case, the oxypropylene chains may optionally, but advantageously, contain small amounts of ethylene oxide, and the oxyethylene chains may also optionally, but advantageously, contain small amounts of propylene oxide.

[0124] Suitable polyhydroxy fatty acid amide surfactants for use in the present compositions include those having the structural formula R2CON R1 Z, where R1 is H, a C1-C4 hydrocarbyl, 2-hydroxyethyl, 2-hydroxypropyl, ethoxy, propoxy group, or mixtures thereof, and R2 is a C5-C 31where Z is a polyhydroxyhydrocarbyl having a linear hydrocarbyl chain with at least three hydroxyls directly attached to the chain, or an alkoxylated derivative thereof (preferably ethoxylated or propoxylated). Z may be derived from a reducing sugar in a reductive amination reaction, such as a glycityl moiety.

[0125] Alkyl ethoxylate condensation products of aliphatic alcohols with about 0 to about 25 moles of ethylene oxide are suitable for use in the present compositions. The alkyl chain of the aliphatic alcohol can be either linear or branched, primary or secondary, and generally contains from 6 to 22 carbon atoms. Ethoxylated C6-C 18 Fatty alcohols and C6-C 18 Mixed ethoxylated and propoxylated fatty alcohols, especially those that are water soluble, are suitable surfactants for use in the present compositions. Suitable ethoxylated fatty alcohols include C6-C ... 18 Ethoxylated fatty alcohols are included.

[0126] Further examples of alcohol ethoxylate nonionic surfactants are those that are capped, for example, halogen or benzyl capped. Some non-limiting examples of commercially available alcohol ethoxylate nonionic surfactants include Dehypon LS 54 available from Henkel, Tomadol 91-6, Tomadol 1-9, Tomadol 1-5, and Tomadol 1-3 available from Tomah, Plurafac D-25 and SLF-18 available from BASF, Sasol C13-9EO, Sasol C8-10-6EO, Sasol TDA C13-6EO, and Sasol C6-10-12EO available from Sasol, Hetoxol 1-20-10 and Hetoxol 1-20-5 available from Laurachem, Huntsman L46-7EO available from Huntman, and Antarox BL 330 and BL 344, Pluronic N-3, Plurafac LF-221, Ls-36, Pluronic 25R2, Pluronic 10R5, Novel 1012GB, Pluronic LD-097, Pluronic D-097, Neodol 25-12. Antarox BL 330 and BL 344 are either branched or straight chain C12-C18 halogen capped alcohol ethoxylate nonionic surfactants.

[0127] Nonionic alkyl polysaccharide surfactants particularly suitable for use in the present compositions include those disclosed in U.S. Patent No. 4,565,647, issued Jan. 21, 1986, Llenado. These surfactants contain a hydrophobic group containing from about 6 to about 30 carbon atoms, and a polysaccharide, e.g., a polyglycoside, a hydrophilic group containing from about 1.3 to about 10 saccharide units. Any reduced saccharide containing 5 or 6 carbon atoms may be used, e.g., the galactosyl moiety may be replaced with glucose, galactose, and glucosyl moieties. (Optionally, the hydrophobic group is attached at the 2-, 3-, 4-, etc. position to produce glucose or galactose as opposed to a glucoside or galactoside.) The intersaccharide bond may be, for example, between one position of the additional saccharide unit and the 2-, 3-, 4-, and / or 6-position on the preceding saccharide unit.

[0128] Fatty acid amide surfactants suitable for use in the present compositions include those having the formula: RCON(R), where R is an alkyl group containing 7 to 21 carbon atoms and each R is independently hydrogen, C1-C4 alkyl, C1-C4 hydroxyalkyl, or --(CHO). X H, where x is in the range of 1 to 3.

[0129] A useful class of nonionic surfactants includes the class defined, at least in part, as alkoxylated amine or, most specifically, alcohol alkoxylated / aminated / alkoxylated surfactants. These nonionic surfactants can be represented by the general formula: 20 --(PO) S N--(EO) t H, R 20 --(PO) S N--(EO) t H(EO) t H and R 20 --N(EO) t H, where R 20is an alkyl, alkenyl, or other aliphatic group of 8 to 20, preferably 12 to 14 carbon atoms, or an alkyl-aryl group, EO is oxyethylene, PO is oxypropylene, s is 1 to 20, preferably 2 to 5, t is 1 to 10, preferably 2 to 5, and u is 1 to 10, preferably 2 to 5. Other variations in the scope of these compounds include the alternative formula: R 20 --(PO) V --N[(EO) w H][(EO) z H], where R 20 is as defined above, v is 1 to 20 (e.g., 1, 2, 3, or 4 (preferably 2)), and w and z are independently 1 to 10, preferably 2 to 5. These compounds are commercially represented by the line of products sold by Huntsman Chemicals as nonionic surfactants. Preferred chemicals in this class include Surfonic™ PEA 25 amine alkoxylates.

[0130] In some embodiments, nonionic surfactants for the composition include alcohol alkoxylates, alcohol ethoxylates, EO / PO block copolymers, and the like. Exemplary alcohol alkoxylates are shown in Table 2. Generally, alcohol alkoxylates have the following structure: RO-(EO) m -(PO) n where R is hydrogen, alkyl, alkenyl or other aliphatic group, or alkyl-aryl having 8 to 20 carbon atoms; EO is oxyethylene; and PO is oxypropylene. 、 m and n are independently integers ranging from 1 to 20. For example, commercially available alcohol alkoxylates such as Dehypon LS-54 (RO-(EO)5(PO)4, where R is C12-C14) and Dehypon LS-36 (RO-(EO)3(PO)6, where R is C12-C14).

[0131] [Table 4]

[0132] Additional alcohol ethoxylate nonionic surfactants can include polymeric surfactants such as those shown in Table 3.

[0133] [Table 5]

[0134] Preferred nonionic surfactants include alcohol alkoxylates having less than 10 EO groups for improved tablet stability and favorable dissolution rates. In some embodiments, the alcohol alkoxylates contain less than 10 EO groups, less than 9 EO groups, less than 8 EO groups, less than 7 EO groups, less than 6 EO groups, or less than 5 EO groups. In some embodiments, the alcohol alkoxylates contain 1-10 EO groups, 1-9 EO groups, 1-8 EO groups, 1-7 EO groups, 1-6 EO groups, 1-5 EO groups, 1-4 EO groups, or 1-3 EO groups.

[0135] The article Nonionic Surfactants, edited by Schick, MJ, Vol. 1 of the Surfactant Science Series, Marcel Dekker, Inc., New York, 1983, is an excellent reference for a wide range of nonionic compounds commonly used in the practice of the present invention. A typical list of nonionic classes and species of these surfactants is described in U.S. Patent No. 3,929,678, issued to Laughlin and Heuring on December 30, 1975. Further examples are described in "Surface Active Agents and Detergents" (Vol. I and Vol. II, Schwartz, Perry and Berch). Additional nonionic surfactants can include those often defined as semi-polar nonionic surfactants, the disclosure of which can be found in U.S. Patent Application Publication No. 2018-0110220, the entirety of which is incorporated herein by reference.

[0136] Coating Surfactants The solid cleaning composition comprises from about 0% to about 25%, from about 1% to about 25%, from about 5% to about 20%, from about 5% to about 15%, or from about 5% to about 10% by weight of a coating surfactant, including a nonionic and / or polymeric surfactant.

[0137] Additional Functional Ingredients The components of the solid cleaning composition can be further combined with various functional ingredients suitable for use as disclosed herein. In some embodiments, the solid cleaning composition comprising the alkalinity source, acid, water conditioner, and surfactant constitutes a majority, or even substantially all, of the total weight of the composition. For example, in some embodiments, there are few or no additional functional formulation ingredients therein.

[0138] In other embodiments, additional functional ingredients may be included in the composition. The functional ingredients provide the composition with desired properties and functionality. For the purposes of this application, the term "functional ingredients" includes materials that, when dispersed or dissolved in a use solution, such as an aqueous solution, and / or a concentrate solution, provide beneficial properties in a particular use. Some specific examples of functional materials are discussed in more detail below, although the specific materials discussed are provided merely as examples and a wide variety of other functional ingredients may be used. For example, many of the functional materials discussed below relate to materials used in cleaning. However, other embodiments may include functional ingredients for use in other applications.

[0139] In some embodiments, the solid cleaning composition may include optical brighteners, defoamers, anti-redeposition agents, bleaching agents, solubility modifiers, dispersants, metal protecting agents, soil anti-redeposition agents, stabilizers, preservatives, dissolution aids, corrosion inhibitors, aesthetic enhancers including builders / sequestering / chelating agents, enzymes, fragrances and / or dyes, additional rheology and / or solubility modifiers or thickeners, hydrotropes or couplers, buffers, solvents, additional cleaning agents, and the like.

[0140] In some embodiments, the solid detergent composition does not include an enzyme.

[0141] According to embodiments of the present invention, various additional functional formulation ingredients may be provided in the composition in an amount of about 0% to about 50% by weight, about 0% to about 40% by weight, about 0% to about 30% by weight, about 0.01% to about 30% by weight, about 0.1% to about 30% by weight, about 1% to about 30% by weight, about 1% to about 25% by weight, about 1% to about 20% by weight, about 1% to about 15% by weight, or about 1% to about 10% by weight. In addition, all ranges recited are inclusive of the numbers defining the range and include each integer within the defined range without being limited according to the present invention.

[0142] In some embodiments, a preservative, biocide, and / or dye is included in the solid composition. A preferred preservative is Kathon™ CG from Lanxess. A preferred biocide is Kathon™ 86F from Lanxess. In some embodiments, the solid composition includes about 0 to about 1% by weight dye, about 0 to about 0.5% by weight dye, about 0 to about 0.1% by weight dye, or about 0.01% to about 0.1% by weight dye. In some embodiments, the solid composition includes about 0 to about 5% by weight preservative, about 0 to about 4% by weight preservative, about 0 to about 3% by weight preservative, about 0 to about 2% by weight preservative, 0 to about 1% by weight preservative, or about 0.01% to about 1.5% by weight preservative. In some embodiments, the solid composition comprises about 0 to about 5% by weight of the biocide, about 0 to about 4% by weight of the biocide, about 0 to about 3% by weight of the biocide, about 0 to about 2% by weight of the biocide, 0 to about 1% by weight of the biocide, or about 0.01% to about 1.5% by weight of the biocide.

[0143] In some embodiments, the solid composition has a water content of less than about 15%, less than about 10%, less than about 5%, less than about 1%, less than about 0.5%, or less than about 0.1% by weight. In some embodiments, the solid composition does not include water as an ingredient, although water may be included among the components of the solid composition.

[0144] Corrosion Inhibitors The solid cleaning composition may include one or more corrosion inhibitors for use in cleaning alkali-sensitive metals, such as aluminum or aluminum-containing alloys. The corrosion inhibitor should not adversely affect the stability of the solid and / or use composition. Preferred corrosion inhibitors that maintain the stability of the composition include silicates and metasilicates, preferably alkali metal silicates and metasilicates, such as sodium silicate and sodium metasilicate. Anhydrous forms, such as anhydrous sodium metasilicate, may also be used.

[0145] Additional exemplary corrosion inhibitors include, for example, imidazoline compounds, quaternary ammonium compounds, pyridinium compounds, or combinations thereof. Further exemplary corrosion inhibitors can include, for example, phosphate esters, monomeric or oligomeric fatty acids, alkoxylated amines, or mixtures thereof. Disclosures of such exemplary corrosion inhibitors are described in U.S. Patent Application No. 16 / 775,417, the entire contents of which are incorporated herein by reference in their entirety.

[0146] In some embodiments, the solid hard surface cleaning composition comprises from about 0% to about 10% by weight of the corrosion inhibitor, from about 0.01% to about 10% by weight of the corrosion inhibitor, from about 0.01% to about 5% by weight of the corrosion inhibitor, from about 0.1% to about 10% by weight of the corrosion inhibitor, from about 0.1% to about 8% by weight of the corrosion inhibitor, or from about 1% to about 8% by weight of the corrosion inhibitor.

[0147] solid composition A solid cleaning composition is substantially homogeneous with respect to the distribution of ingredients throughout its mass and is dimensionally stable. A solid hard surface cleaning composition is a hardened composition that will not flow and will substantially retain its shape under moderate stress or pressure or simple gravity. The degree of hardness of a solid hard surface cleaning composition can range from that of a relatively dense and hard molten solid block, such as concrete, to a consistency characterized as a hardened paste. In addition, the term "solid" refers to the state of the solid hard surface cleaning composition under expected storage and use conditions. In general, a solid hard surface cleaning composition is expected to remain in solid form when exposed to temperatures up to about 100°F, preferably greater than about 120°F. A solid is dimensionally stable, meaning that the solid does not swell (or change dimensions due to swelling), as measured according to swelling of less than about 10-15% at temperatures up to 50°C (or 100°F) for at least 8 weeks. Such solid tablets are said to be dimensionally stable.

[0148] The solid hard surface cleaning compositions may take the form of, but not limited to, pressed solids, cast solid blocks, extruded, molded or formed solid pellets, blocks, tablets, powders, granules, flakes, or the formed solids may then be ground or formed into powders, granules, or flakes.

[0149] In some embodiments, the solid cleaning composition can be provided in the form of a unit dose.A unit dose refers to a composition unit of a size such that the entire unit is used in one cleaning cycle.When the solid hard surface cleaning composition is provided as a unit dose, it is preferably provided as a pressed solid, a cast solid, an extruded pellet, or a tablet having a size between about 1 gram and about 50 grams.

[0150] How to use The solid compositions disclosed herein are particularly suitable for replacing liquid compositions, advantageously providing at least substantially similar (or in some embodiments higher) concentrations of surfactants compared to liquid compositions to provide enhanced cleaning performance against a variety of soils, including oily, difficult-to-remove soils. Moreover, the compositions further advantageously provide solids with optimal dissolution rates that allow a customer or user of the solid composition to dissolve the solids for a use solution in a short period of time, e.g., less than about 20 minutes, less than about 15 minutes, or less than about 10 minutes.

[0151] The solid compositions dissolve to provide stable use compositions that dissolve rapidly in water to form stable, clear use solutions. Stable use compositions do not exhibit precipitation upon storage and / or use. Additionally, both the solid and liquid use compositions are safe for contact, including skin and eyes, and therefore do not require the use of personal protective equipment (PPE).

[0152] The use composition can be applied as a concentrated composition, i.e., can be further diluted. The use composition is a multi-use formulation, so it can be applied to a variety of surfaces. The solid cleaning composition is particularly suitable for cleaning hard surfaces. Suitable hard surfaces include those soiled with food soils, including food preparation surfaces that contain a large amount of oily soils. A variety of kitchen hygiene and hard surface applications are suitable for use with the use composition.

[0153] Exemplary food preparation surfaces include surfaces in restaurants, surfaces in grocery stores, and / or surfaces in the home.In addition, the hard surface cleaning compositions for use include various floor cleaning surfaces, including, for example, kitchen, restaurant, etc., and / or drive-through floors.Despite the removal of the alkali hydroxide source from the composition, the hard surface cleaning compositions disclosed herein that contain alkali carbonates and solidification matrix provide effective removal of food stains, including baked-on stains such as polymerized grease. EXAMPLES

[0154] The embodiments of the present invention are further defined in the following non-limiting examples. It should be understood that these examples, while showing specific embodiments of the present invention, are given by way of illustration only. From the above discussion and these examples, those skilled in the art can ascertain the essential features of the present invention, and can make various changes and modifications to the embodiments of the present invention to adapt it to various applications and conditions without departing from the spirit and scope of the present invention. Thus, in addition to those shown and described herein, various modifications of the embodiments of the present invention will be apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims.

[0155] The following materials were utilized in the examples:

[0156] Acusol® 445 ND: Polycarboxylic acid, sodium salt of acrylic polymer (sodium polyacrylate), partially neutralized, available from Dow Chemical.

[0157] Aerosol OT-75®: Sodium dioctyl sulfosuccinate, 75% in water / ethanol, available from Solvay.

[0158] Amine Oxide Granules: C12 Amine Oxide, 95%

[0159] Barlox 10S®: C10 amine oxide, 30%, available from Lonza.

[0160] Barlox 12®: C12 amine oxide, Lauramine Oxide 30% (Lauryl dimethylamine oxide (30%)), available from Lonza.

[0161] Bioterge® AS-90: Alpha Olefin Sulfonate Anionic Surfactant (Sodium C14-C16 Alpha Olefin Sulfonate), AOS Beads, available from Stepan.

[0162] Dehypon® LS 36: C12-14 alcohol alkoxylate, 3EO, 6PO, available from BASF Corporation.

[0163] Dehypon® LS 54: C12-14 alcohol alkoxylate, 5EO, 4PO, available from BASF Corporation.

[0164] Ecosurf EH-6®: 2-Ethylhexanol, EO-PO nonionic surfactant, available from Dow Chemical.

[0165] Ecosurf™ EH-9: 2-Ethylhexanol EO-PO, 9EO, available from Dow Chemical.

[0166] Glucopon 50 G®: C10-16 polyglucoside, available from BASF Corporation.

[0167] Glucopon 215 UP®: C8-10 polyglucoside, 63.5%, available from BASF Corporation.

[0168] Glucopon 225 DK®: C8-10 Polyglucoside, 70%, available from BASF Corporation.

[0169] Glucopon 425 N®: C8-10 polyglucoside, 25-35% / C10-16 polyglucoside, 15-25%, available from BASF Corporation.

[0170] Lutensol® XL 70: C10-Guerbet alcohol alkoxylate, 7EO, available from BASF Corporation.

[0171] Lutensol® XL 90: C10-Guerbet alcohol alkoxylate, 9EO, available from BASF Corporation.

[0172] PEG400: Polyethylene glycol 400mw, available from multiple sources.

[0173] Pluronic 25R2®: PO-EO-PO block copolymer, available from BASF Corporation.

[0174] Plurafac LF 902®: an alcohol alkoxylate surfactant, available from BASF Corporation.

[0175] Pylaklor Bright Amethyst LX-12379, Pylam

[0176] Available from Dyes.

[0177] Pylaklor New Alkali Purple LS-10695, available from Pylam Dyes.

[0178] Pylaklor Bright Violet LS-10966, available from Pylam Dyes.

[0179] Solid Betaine: Cocoamidopropyl Betaine, 75%

[0180] Tomadol 91-6®: C9-11 linear alcohol ethoxylate, 6EO, available from multiple sources.

[0181] Trilon M® Granules: The trisodium salt of methylglycine diacetic acid, N,N-bis(carboxymethyl)-tri-sodium salt, available from BASF.

[0182] Ufaryl DL 90 C®: Sodium dodecylbenzenesulfonate, 90%, powder, available from Unger.

[0183] Commonly used or widely available materials: light ash (sodium carbonate), citric acid, sodium bicarbonate, sodium silicate, propylene glycol, and glycerin.

[0184] Example 1 Dissolution Test. Exemplary solid cleaning compositions were prepared as compressed tablets by placing 3 g of the powder formulation into a 20 mm tablet mold and compressing at about 500 psi for 30 seconds. The tablets were then placed into a 1 liter beaker filled with 500 mL of 5 gpg water and the time it took for the tablet to completely disintegrate was measured. From this test, it was found that three mitigation strategies, namely, the addition of acid (e.g., citric acid), the use of coating surfactants, and the selection of cleaning surfactants, were useful in reducing tablet dissolution, i.e., the time it takes for the tablet to dissolve in water.

[0185] The addition of acid was evaluated to determine the effect on the dissolution rate of solid tablets. The tablet formulations evaluated are shown in Tables 4-5.

[0186] [Table 6]

[0187] [Table 7]

[0188] As seen in Figure 1, tablet formulations constructed according to Table 4 showed significantly reduced dissolution times as the amount of citric acid was increased. The addition of 10% citric acid reduced the dissolution time by more than half and continued to reduce at 20% citric acid. The dissolution times of tablet formulations 10-20% citric acid (see Table 5) were further tested as shown in Figure 2. Increasing the citric acid reduced the dissolution time due to a reaction occurring between the acid and base in the formulation, producing effervescence that physically disintegrated the tablet faster. Additionally, the inclusion of AOS surfactant significantly extended the dissolution time of the solid tablet.

[0189] These results demonstrate the benefit of including an acid such as citric acid in a solid cleaning composition. The desired dissolution time of less than about 10 minutes provides significant commercial advantages that are highly desirable to consumers.

[0190] Example 2 Additional dissolution studies were performed to evaluate the use of the coating surfactant described in Example 1. The addition of a coating surfactant was evaluated in the formulation shown in Table 6, where the coating surfactant was added after the light ash, allowing the ash to be coated onto the surfactant. This addition to the wet particles provides the desired adhesion and prevents the formation of hydrates that hold the solid composition together.

[0191] [Table 8]

[0192] [Table 9]

[0193] As shown in Figure 3, increasing weight percentages of different coating surfactants were tested. All coating surfactants showed a reduction in tablet dissolution time at 5%, but only two (Pluronic 25R2® and PEG400) continued to show a reduction in dissolution time at higher percentages. There appears to be diminishing returns for coating surfactants much above about 10% by weight. The use of this coating surfactant generally resulted in shorter dissolution times, which may be due to reduced ash binding when coated. PEG400 showed the most reduced dissolution time of the coating surfactants in Figure 3, which prompted further testing shown in Figure 4. Increasing the percentage of PEG400 in the tablet formulation according to Table 7 further reduced tablet dissolution time, as shown by the graph in Figure 4. In this particular embodiment, PEG did not exceed 8% because this tablet is approaching the maximum amount of liquid in the formulation that can be compressed. Further modifications to the tablet may allow additional PEG weight percentages to be added without experiencing exudation. Furthermore, if the solid composition is a cast or extruded solid rather than a compressed solid, additional coating surfactants may be used beyond the data demonstrated in this example.

[0194] Example 3 The impact of surfactant selection was further evaluated. The type of surfactant added to the formula plays a role in reducing the dissolution time. Formulations utilizing different surfactants were constructed according to Table 8, and the impact of dissolution time on the resulting tablets is shown in Figure 5. In Figure 5, the surfactants are separated by average carbon chain length based on surfactant class and literature reported chain length. In each surfactant class (lines in the graph) where two or more surfactants were tested, it was observed that the surfactants with shorter carbon chain lengths often had shorter dissolution times in liquid surfactants. It was also found that different classes of surfactants can have different dissolution times even though they have similar carbon chain lengths. For example, both C10 amine oxide (Barlox 10S) and C10 alcohol ethoxylate (Tomadol 91-6) have similar average carbon chain lengths, but the alcohol ethoxylate has a significantly lower dissolution time that may be due to structural differences.

[0195] This data shows the advantage of low carbon chains, such as C10 or less, when using detergent surfactants as stand-alone surfactants in cleaning compositions. In particular, when detergent surfactants are provided as liquid ingredients for formulation into solid compositions, low carbon chains, such as C10 or less, are important to ensure short, optimal dissolution times, less than about 10 minutes. However, surfactants added in dry granular form are not constrained by the low carbon chain threshold.

[0196] As described herein, either a cleaning surfactant, a coating surfactant, or a combination of a cleaning surfactant and a coating surfactant may be included in the formulation. In some embodiments, the cleaning surfactant is a non-ionic surfactant, which then also serves the purpose of a coating surfactant.

[0197] [Table 10]

[0198] Various cleaning and / or coating surfactants can be used, such as, for example, Tomadol 91-6® or Glucopon 215 UP® or Glucopon 225 DK® or Glucopon 425 N® or Ecosurf EH-6® or Plurafac LF 902® or Barlox 10S® or Barlox 12®, the classification of each surfactant being described in the Materials section of the Examples.

[0199] Furthermore, in FIG. 6, one can see the difference in dissolution time between Barlox 12® and Tomadol 91-6®, and how the ratio between these surfactants contributes to the dissolution time. The formula of the composition shown in FIG. 6 can be found in Table 9. FIG. 6 shows that as the proportion of Tomadol 91-6, which has a short chain length, increases, the dissolution time decreases. Furthermore, it was found that the physical form of the surfactant (either liquid or solid) plays a large role in the dissolution time. As seen in FIG. 7, the formulation containing the liquid amine oxide surfactant (Barlox 12®) has a significantly longer dissolution time compared to the solid amine oxide surfactant (amine oxide granules), the formula of which is shown in Table 10.

[0200] [Table 11]

[0201] [Table 12]

[0202] Example 4 Additional dissolution tests were performed to show the formulations made with and without sulfonated surfactant. Formulations 1, 3, and 5 were made according to Table 11 with Bioterge AS-90® beads (AOS). As seen in Figure 8, each pair of formulations demonstrates that removal of sulfonated surfactant results in a shorter dissolution time for the tablets. Formulation 1 (20% isononanoate) dissolved in 80 minutes, while without AOS, the formulation (formulation 2) dissolved in 52 minutes. Similarly, 20% citric acid formulations without AOS (formulations 3 and 4) and ash coated in PEG400 (formulations 5 and 6) dissolved faster than the formulations with AOS (formulation 3 dissolved in 90 minutes, formulation 4 dissolved in 55 minutes, formulation 5 dissolved in 111 minutes, and formulation 6 dissolved in 90 minutes).

[0203] [Table 13]

[0204] Each pair of formulations demonstrates that removal of the sulfonated surfactant, in this case AOS, results in a decrease in tablet dissolution time, as further summarized in Table 12.

[0205] [Table 14]

[0206] Example 5 The foam test was evaluated to compare solid cleaning compositions prepared as powders and made into ready-to-use solutions, then tested for their foam height as shown in Table 13. The formulations were tested in 5 gpg water at a concentration of 0.0127 g / mL (equivalent to three 3 g tablets per 710 mL) and the foam height was measured for 6 minutes according to the test method of the Manual Detergent Test Procedure Cylinder Foam Test Method (preparing the test solution and adding 40 mL of the test solution to a 250 mL graduated cylinder). This process was repeated for each product and all cylinders were labeled. The next step was to loosen the stoppers and heat the cylinders containing the solutions to 80° F. and the second set to 110° F. The soil (45% Crisco shortening, 30% wheat flour, 15% powdered whole egg, 10% oleic acid) was then liquefied on a low temperature hot plate set at 104° F. The stoppered cylinders were placed in the apparatus and secured securely. The cylinder was rotated for 240 seconds (4 minutes) and the initial foam height was recorded. Two drops (0.5 g) of soil were added with a disposable pipette and the cylinder was then rotated for 120 seconds (2 minutes). The foam height was then recorded. Two drops (0.5 g) of soil were then added again with a disposable pipette and this process continued for a total of 6 minutes (foam height values ​​were measured at the beginning, 2 minutes, 4 minutes and 6 minutes).

[0207] [Table 15]

[0208] As shown in Figure 9, all formulations tested provided higher foam levels than the benchmark solid comparative composition (a commercial all-purpose PPE-free tablet), with formulation F (containing solid betaine as a cleaning surfactant) providing the highest and most stable foam height over time. The liquid comparative formulation is a commercial heavy duty PPE-free degreaser formulation.

[0209] Example 6 Performance is another important attribute of a PPE-free tablet degreaser or multi-use tablet composition. Traditionally, the stains targeted by degreasers are tough enough that they require high alkalinity or solvents. The formulations evaluated herein use surfactants to aid in performance. Performance testing focused on testing a food stain (red stain). A red stain was prepared to contain egg protein, two fat sources (lard and oil), and a dye (iron(III) oxide (for coloring)) for the first test (results are described below and shown in Figure 10). Approximately 30 grams of lard was mixed with approximately 30 grams of corn oil, approximately 15 grams of powdered whole egg, and approximately 1.5 grams of Fe2O3. This stain has a protein content of 20%. For the second test, only the two fat sources and the dye (except for egg protein) were included in the modified red stain (results are described below and shown in Figure 11).

[0210] The evaluated Formulations A, E, and F are listed in Table 13 of Example 5. The controls used were the same as in Example 5 (negative control (water), liquid comparative formulation (in-line PPE-free heavy duty degreaser), and solid comparative formulation (in-line PPE-free multi-purpose tablet formulation).

[0211] The back grooved surface of several 3x3 inch white vinyl tiles were soiled with a red food stain using a 3" sponge brush. The tiles were allowed to dry overnight at room temperature. This incubation period allows the bonds holding the triglycerides and proteins in the stain together to crystallize and begin to link together. The next day the tiles were placed in a dip tray containing the test composition for approximately 1 minute. To clearly differentiate between the formulations, tests were run using 5 gpg water at the higher concentration of 0.038 g / mL. For the solid comparative formulation and the three test formulations, a concentration of 0.038 g / mL was used as well. The liquid comparative formulation was tested at 0.340 g / mL, three times the typical use concentration of that product.

[0212] The stain removal test was performed using a Gardner Straightline Apparatus equipped with a synthetic sponge. = The tiles were placed in the Gardner Straightline Apparatus with the tile's texture parallel to the direction of sponge travel. The tiles were scrubbed with a damp synthetic sponge at approximately 2 pounds of pressure for 16 cycles, rotating the tiles 90 degrees every 4 cycles to rotate the tile a full 360 degrees. The tiles were then rinsed with tap water and allowed to dry overnight at room temperature. The Mach 5 reflectance of the soiled and cleaned tiles was measured to determine the average percent stain removal.

[0213] The results are shown in Figure 10, where average stain removal using a conventional red stain was improved with the use of Formulations A, E, and F compared to the solid comparative formulation. The average stain removal results were substantially equivalent to the liquid comparative formulation. Additional results are shown in Figure 11, where Formulations A, E, and F again performed higher than the solid comparative formulation and closer to or better than the liquid comparative formulation.

[0214] Example 7 Additional dissolution tests were performed to evaluate alcohol alkoxylate structure versus dissolution time. Formulations were made according to Table 8, except the surfactant was one of Dehypon® LS 36 (C12-14 alcohol alkoxylate, 3EO, 6PO), Dehypon® LS 54 (C12-14 alcohol alkoxylate, 5EO, 4PO), Lutensol® XL 70 (C10-Guerbet alcohol alkoxylate, 7EO), Lutensol® XL 90 (C10-Guerbet alcohol alkoxylate, 9EO), or Ecosurf™ EH-9 (2-ethylhexanol EO-PO, 9EO, number of PO groups not publicly available).

[0215] The results are shown in Figure 12, where there is a trend towards shorter dissolution times correlating with the decreasing number of EO groups in the alcohol alkoxylate surfactant. In many commercial embodiments, dissolution times of 15 minutes, or even 10 minutes or less are preferred.

[0216] Example 8 Exemplary solid cleaning compositions according to Table 14 were prepared as compressed tablets using about 500 psi for about 30 seconds. The tablets were sealed in glass containers under the following conditions: room temperature, 40° C. 65% relative humidity, 50° C., and in a freezer. The stability of each tablet was evaluated by visual observation over an 8-week period, and photographs were taken at the beginning, 1, 3, 4, and 8 weeks. Some tablets showed color non-uniformity, but this is considered a cosmetic attribute since the color of the RTU solution was unaffected.

[0217] [Table 16]

[0218] Ready-to-use (RTU) solutions were made from tablets according to Formulations G and H in Table 14 to visually evaluate the stability of the formulations. RTU solutions were made at a concentration of 0.013 g / mL (3 tablets per 710 mL) using 0 grain water, 5 grain water, and 17 grain water. Two of each of the RTU solutions were stored at room temperature and 40° C. and visually monitored for two weeks, photographed initially and after one and two weeks. Both formulations were stable for two weeks at both room temperature and 40° C. with no significant color loss. A slight amount of precipitation was observed in one sample, but quickly returned to solution after one inversion.

[0219] Example 9 Tablet stability tests were conducted to evaluate the dimensional stability of tablets in different environments. Exemplary solid cleaning compositions according to Table 15 were prepared as compressed tablets by placing 3 g of powder formulation into a 20 mm tablet mold and compressing at about 500 psi for about 30 seconds. Each tablet was weighed and diameter and height measurements were taken using calipers. The average value of three measurements was used for diameter and height to account for imperfections on the tablet surface. The tablets were placed in sealed glass jars and placed in one of four storage conditions for 8 weeks: room temperature, 40°C 65% relative humidity, 50°C dry oven, or freezer. Diameter, height, and weight measurements were taken for each tablet at the beginning and every week thereafter. The percentage change in tablet volume and weight was calculated based on the measurements.

[0220] [Table 17]

[0221] The calculated volume changes are summarized in Table 16 and shown graphically in FIG.

[0222] [Table 18]

[0223] All tablets were dimensionally stable with less than 10% volume change over 8 weeks. The tablets were dimensionally stable even at elevated temperature (50° C.) for 8 weeks, which correlates to a shelf life of at least 2 years.

[0224] The present disclosure is further defined by the following embodiments. 1. A solid cleaning composition comprising, or consisting essentially of, (a) a non-hydroxide alkali metal alkali source; (b) an acid; (c) at least one water conditioner comprising an amino carboxylic acid, a polycarboxylic acid, an amino phosphonate, or a combination thereof; (d) a cleaning surfactant comprising an amphoteric, anionic, and / or a nonionic surfactant, and / or a coating surfactant comprising a short chain nonionic and / or polymeric surfactant, and optionally further comprising, or consisting essentially of, (e) an alkali metal silicate and / or an alkali metal metasilicate corrosion inhibitor, a dye, a preservative, and / or a biocide, wherein the composition is substantially free of alkali hydroxides and no PPE is required.

[0225] 1. A solid cleaning composition comprising, or consisting essentially of, (a) an alkali metal carbonate, alkali metal bicarbonate, and / or alkali metal silicate alkali source; (b) a polycarboxylic acid having 2-4 carboxyl groups; (c) at least two water conditioners comprising an amino carboxylic acid and a polycarboxylic acid; (d) a cleaning surfactant comprising an amine oxide amphoteric surfactant, and / or a coating surfactant comprising a short chain PEG 200-800, an alcohol ethoxylate, a polymeric surfactant, or a combination thereof; and (e) a corrosion inhibitor comprising an alkali metal silicate and / or an alkali metal metasilicate, and optionally further comprising, or consisting essentially of, (f) a dye, a preservative, and / or a biocide, wherein the composition is substantially free of alkali hydroxides and no PPE is required.

[0226] Although the present invention has been described in conjunction with its detailed description, it should be understood that the foregoing description is intended to be illustrative and not limiting of the scope of the present invention, which is defined by the scope of the appended claims. Other embodiments, advantages, and modifications are within the scope of the following claims. Any references to the accompanying drawings that form a part of this specification are provided by way of example only. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present disclosure. All publications discussed and / or referenced herein are incorporated herein in their entirety.

[0227] The features disclosed in the foregoing description, or in the following claims, or the accompanying drawings, which may be presented in a particular form or in terms of means for performing a disclosed function, or a method or process for achieving a disclosed result, may be utilized, either separately or in any combination of such features, as appropriate, to realise the invention in diverse forms thereof.

Claims

1. 1. A solid cleaning composition comprising: (a) a non-hydroxide alkali metal alkali source; (b) an acid; (c) at least one water conditioner comprising an amino carboxylic acid, a polycarboxylic acid, an amino phosphonate, or a combination thereof; (d) cleaning surfactants including amphoteric, anionic and / or nonionic surfactants, and / or coating surfactants including short chain nonionic and / or polymeric surfactants; The composition is a solid cleaning composition that is substantially free of alkali hydroxides and does not require PPE.

2. 2. The composition of claim 1, wherein the non-hydroxide alkali metal alkali source is at least one of an alkali metal carbonate, an alkali metal bicarbonate, and / or an alkali metal silicate.

3. 3. The composition of claim 1 or 2, comprising about 20-90% by weight of said non-hydroxide alkali metal alkali source, about 10-40% by weight of said acid, about 0.1-25% by weight of said water conditioner, about 0-25% by weight of said cleaning surfactant, and about 0-15% by weight of said coating surfactant, wherein at least one of said cleaning surfactant or said coating surfactant is included in said composition.

4. The composition according to any one of claims 1 to 3, wherein the acid is a polycarboxylic acid having 2 to 4 carboxyl groups.

5. The composition according to any one of claims 1 to 4, wherein the water conditioner is an amino carboxylic acid and / or a polycarboxylic acid.

6. 6. The composition of claim 5, wherein the amino carboxylic acid is one or more of methylglycine diacetic acid (MGDA), N-hydroxyethyliminodiacetic acid, nitrilotriacetic acid (NTA), ethylenediaminetetraacetic acid (EDTA), N-hydroxyethyl-ethylenediaminetriacetic acid (HEDTA), diethylenetriaminepentaacetic acid (DTPA), ethylenediaminetetrapropionic acid, and triethylenetetraaminehexaacetic acid, and the polycarboxylic acid water conditioner is a homopolymer of acrylic acid.

7. A composition according to any one of the preceding claims, wherein the cleansing surfactant comprises amphoteric, anionic and / or non-ionic surfactants in an amount of about 1-40% by weight.

8. The composition of any one of claims 1 to 6, wherein the coating surfactant comprises a short chain PEG 200-800, an alcohol alkoxylate, a polymeric surfactant, or a combination thereof.

9. 9. The composition of claim 8, wherein the coating surfactant has a chain length of C11 or less.

10. The composition of claim 8, wherein the coating surfactant is PEG 200-400.

11. The composition of any one of claims 1 to 10, further comprising about 0.01 to 5 wt. % of a corrosion inhibitor, said corrosion inhibitor being an alkali metal silicate and / or an alkali metal metasilicate.

12. The composition of any one of claims 1 to 11, wherein the solid is a pressed solid, a cast block, an extruded, molded or formed solid pellet, block, tablet, powder, granule or flake.

13. 13. The composition of claim 12, wherein the solid composition has dimensional stability as measured by a growth index of less than about 15% for at least 8 weeks at 50°C.

14. The composition of any one of claims 1 to 13, wherein the liquid use composition has a pH of less than about 10.

5.

15. 1. A solid cleaning composition comprising: (a) an alkali metal carbonate, alkali metal bicarbonate, and / or alkali metal silicate alkali source; (b) a polycarboxylic acid having 2 to 4 carboxyl groups; (c) at least two water conditioners comprising an amino carboxylic acid and a polycarboxylic acid; (d) a cleaning surfactant comprising an amine oxide amphoteric surfactant, and / or a coating surfactant comprising a short chain PEG 200-800, an alcohol alkoxylate, a polymeric surfactant, or a combination thereof; (e) a corrosion inhibitor comprising an alkali metal silicate and / or an alkali metal metasilicate; The composition is a solid cleaning composition that is substantially free of alkali hydroxides and does not require PPE.

16. 16. The composition of claim 15, comprising about 20-90 wt. % of said alkali metal carbonate, said alkali metal bicarbonate, and / or said alkali metal silicate alkaline source, about 10-40 wt. % of said acid, about 1-20 wt. % of said water conditioner, about 0-25 wt. % of said cleaning surfactant, about 0-15 wt. % of said coating surfactant, and about 0.01-10 wt. % of said corrosion inhibitor, wherein at least one of said cleaning surfactant or said coating surfactant is included in said composition.

17. A concentrate or use solution of the composition of any one of claims 1 to 16 formed by adding the solid composition of claim 1 to a diluent.

18. 1. A method for preparing a cleaning composition, the method comprising: adding the solid cleaning composition of any one of claims 1 to 16 to a diluent and dissolving the solid cleaning composition into a concentrate or use solution; The method, wherein the dissolution time of the solid cleaning composition is less than about 20 minutes, or preferably less than about 10 minutes.

19. The method of claim 17, wherein the diluent is water.

20. 1. A method for cleaning a hard surface, the method comprising:

20. A method comprising applying the concentrate or use solution of claim 17 to a hard surface in need of cleaning.

21. 21. The method of claim 20, wherein the hard surface is a food preparation surface, a surface in a restaurant, a surface in a grocery store, a household surface, a floor, and / or a drive-through surface, and / or the hard surface contains food stains, preferably baked-on food stains.

22. 22. The method of claim 20 or 21, wherein the hard surface is metal.

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