Solid laundry composition

Abstract

A solid fabric conditioning composition comprising: a fabric softening active; 0.1 to 3% by weight of a fatty acid amide having a fatty acid chain length of 12 or more carbons; and a water-soluble carrier.

Description

Field of the Invention

[0001] The present invention relates to solid fabric conditioning compositions. Background of the Invention

[0003] Solid fabric conditioners provide consumers with an easy-to-use concentrated fabric conditioning composition. These compositions have various benefits, including that they can contain high levels of active ingredients and have a very low water content, resulting in easier storage and transportation.

[0004] Solid fabric conditioners exist in different shapes and sizes, for example, tablets, flakes, molded articles, etc. "Tackiness" or lack of "tackiness" is an important physical property of solid fabric conditioners. A tacky product may stick to other items, be difficult for consumers to handle, and may leave residues on the consumers' hands. Summary of the Invention

[0006] It has been found that adding a fatty acid amide having a fatty acid chain length of 12 or more carbons to a solid fabric conditioner improves the tackiness of the solid composition.

[0007] Accordingly, a first aspect of the present invention is to provide a solid fabric conditioning composition comprising:

[0008] a. an ester-linked quaternary ammonium compound fabric softening active;

[0009] b. 0.1 to 3% by weight of a fatty acid amide having a fatty acid chain length of 12 or more carbons; and

[0010] c. 5 to 70% by weight of a water-soluble carrier selected from polysaccharides.

[0011] The present invention also relates to a method for preparing a solid fabric conditioning composition, comprising the steps of:

[0012] a. preparing a premix of a water-soluble carrier and water;

[0013] b. adding to the premix a fabric softening active, 0.1 to 3% by weight of a fatty acid amide having a fatty acid chain length of 12 or more carbons and any remaining ingredients;

[0014] c. pouring the mixture onto a surface or into a mold; and

[0015] d. removing the water, preferably by evaporation. Detailed Description of the Invention

[0017] These and other aspects, features, and advantages will become apparent to those of ordinary skill in the art upon reading the following detailed description and the appended claims. For the avoidance of doubt, any feature of one aspect of the invention can be used in any other aspect of the invention. The word "comprising" is intended to mean "including" but not necessarily "consisting of" or "constituted by". In other words, the listed steps or options need not be exhaustive. Note that the examples given in the following description are intended to illustrate the invention and are not intended to limit the invention to these examples themselves. Similarly, unless otherwise specified, all percentages are weight / weight percentages. All numbers in this specification representing amounts of materials or reaction conditions, physical properties of materials, and / or uses, are to be understood as being modified by the word "about", except in the operating and comparative examples, or where otherwise expressly indicated. Numerical ranges expressed in the format "from x to y" are understood to include x and y. When multiple preferred ranges are described for a particular feature in the format "from x to y", it should be understood that all ranges combining different endpoints are also contemplated.

[0018] The inclusion content of all components is % by weight of the final solid fabric conditioner product.

[0019] Fabric softening active substance

[0020] The compositions described herein comprise an ester-linked quaternary ammonium fabric softening active substance.

[0021] The quaternary ammonium compound (QAC) preferably comprises at least one chain derived from a fatty acid, more preferably at least two chains derived from a fatty acid. Generally, a fatty acid is defined as an aliphatic monocarboxylic acid having a chain of 4 to 28 carbons. Fatty acids can be derived from various sources such as animal fats or plant sources. Preferably, the fatty acid chains are derived from plants. Preferably, the fatty acid chains of the QAC comprise 10 to 50% by weight of saturated C18 chains and 5 to 40% by weight of monounsaturated C18 chains based on the total weight of the fatty acid chains. In a further preferred embodiment, the fatty acid chains of the QAC comprise 20 to 40% by weight, preferably 25 to 35% by weight of saturated C18 chains and 10 to 35% by weight, preferably 15 to 30% by weight of monounsaturated C18 chains based on the total weight of the fatty acid chains.

[0022] The quaternary ammonium fabric softening active substance for the compositions described herein is a so-called "ester quaternary ammonium salt" or an ester-linked quaternary ammonium compound.

[0023] Particularly preferred materials are ester-linked triethanolamine (TEA) quaternary ammonium compounds which comprise a mixture of monoester, diester and triester linking components. Typically, TEA-based fabric softening compounds comprise a mixture of the monoester, diester and triester forms of the compound, wherein the diester-linked component comprises no more than 70% by weight, preferably no more than 60% by weight, for example no more than 55% or even no more than 45% of the fabric softening compound, and at least 10% by weight of the monoester-linked component.

[0024] A first group of quaternary ammonium compounds (QAC) suitable for use in the compositions is represented by formula (I):

[0025]

[0026] wherein each R is independently selected from C5 to C35 alkyl or alkenyl; R 1 represents C1 to C4 alkyl, C2 to C4 alkenyl or C1 to C4 hydroxyalkyl; T may be O-CO (i.e. an ester group attached through its carbon atom to R), or alternatively may be CO-O (i.e. an ester group attached through its oxygen atom to R); n is a number selected from 1 to 4; m is a number selected from 1, 2 or 3; X - is an anionic counterion such as a halide ion or an alkyl sulfate, for example chloride ion or methyl sulfate. The diester variant of formula I (i.e., m = 2) is preferred and generally has monoester and triester analogs associated therewith. These materials are particularly suitable for use in the compositions described herein.

[0027] A second group of QAC suitable for use in the compositions described herein is represented by formula (II):

[0028]

[0029] wherein each R 1 group is independently selected from C1 to C4 alkyl, hydroxyalkyl or C2 to C4 alkenyl; and wherein each R 2 is independently selected from C8 to C28 alkyl or alkenyl; and wherein n, T and X - are as defined above.

[0030] Preferred materials of this second group include 1,2-bis[tallowoyloxy]-3-trimethylammonium chloride, 1,2-bis[hydrogenated tallowoyloxy]-3-trimethylammonium chloride, 1,2-bis[oleyloxy]-3-trimethylammonium chloride and 1,2-bis[stearoyloxy]-3-trimethylammonium chloride. Such materials are described in US 4,137,180 (Lever Brothers). Preferably, these materials also contain a certain amount of the corresponding monoester.

[0031] A third group of QAC suitable for use in the compositions is represented by formula (III):

[0032] (R 1 )2-N + -[(CH2) n -T-R 2 2X - (III)

[0033] wherein each R 1 group is independently selected from C1-C4 alkyl, or C2-C4 alkenyl; and wherein each R 2 group is independently selected from C8-C28 alkyl or alkenyl; and n, T and X - are as defined above. Preferred materials for this third group include bis(2-tallowoyloxyethyl)dimethylammonium chloride, its partially hardened and hardened forms.

[0034] Specific examples of the fourth group of QACs are represented by formula (IV):

[0035]

[0036] The fifth group of QACs suitable for the composition is represented by formula (V)

[0037]

[0038] R1 and R2 are independently selected from C10-C22 alkyl or alkenyl, preferably C14-C20 alkyl or alkenyl. X - is as defined above.

[0039] The iodine value of the quaternary ammonium fabric conditioning material is preferably from 0 to 80, more preferably from 0 to 60, and most preferably from 0 to 45. The iodine value can be appropriately selected. Substantially saturated materials with an iodine value of 0 to 5, preferably 0 to 1, can be used in the compositions described herein. Such materials are referred to as "hardened" quaternary ammonium compounds.

[0040] A further preferred range of the iodine value is from 20 to 60, preferably from 25 to 50, and more preferably from 30 to 45. This type of material is a "soft" triethanolamine quaternary ammonium compound, preferably triethanolamine dialkyl ester methyl sulfate. This type of ester-linked triethanolamine quaternary ammonium compound contains unsaturated fatty chains. If a mixture of quaternary ammonium materials is present in the composition, the iodine value described above represents the average iodine value of the parent fatty acyl compounds or fatty acids of all the quaternary ammonium materials present. Similarly, if any saturated quaternary ammonium materials are present in the composition, the iodine value represents the average iodine value of the fatty acid parent acyl compounds of all the quaternary ammonium materials present.

[0041] The iodine value, as used in the context of the compositions described herein, refers to the measure of the degree of unsaturation present in the material from which the fatty acids used to produce the QAC are analyzed and determined by nmr spectral methods as described in Anal. Chem., 34, 1136 (1962) Johnson and Shoolery.

[0042] In a preferred embodiment, the fabric softening active comprises a mixture of a cationic quaternary ammonium compound having more than one long carbon chain in combination with a second surfactant selected from single-chain cationic surfactants and / or nonionic surfactants. Preferably, the cationic quaternary ammonium compound having more than one long carbon chain and the second surfactant are present in a ratio of 1:10 to 10:1, more preferably 1:5 to 5:1. The combination of a cationic quaternary ammonium compound having more than one long carbon chain with a second surfactant selected from single-chain cationic surfactants and / or nonionic surfactants provides a solid composition that can be diluted with water to form a stable liquid fabric softener and provides excellent softening. The cationic quaternary ammonium compound having more than one long carbon chain is as described above.

[0043] Suitable single-chain cationic surfactants preferably have the following general formula:

[0044] (R1)3-N + -R2X -

[0045] wherein each R1 independently comprises from 1 to 6 carbon atoms selected from alkyl, alkenyl, aryl or combinations thereof. Each R1 may independently comprise a hydroxyl group. Preferably at least two R1 groups correspond to methyl.

[0046] wherein R2 comprises at least 10 carbon atoms. The carbon atoms may be in the form of alkyl, alkenyl, aryl or combinations thereof. Preferably, the single-chain cationic surfactant comprises at least 12, preferably at least 14, most preferably at least 16 carbon atoms. R2 may further comprise additional functional groups such as ester groups or hydroxyl groups. X - is an anionic counterion such as a halide ion or an alkyl sulfate, for example, chloride ion or methyl sulfate.

[0047] Preferred cationic surfactants include hydroxyethyl lauryl dimethyl ammonium chloride, cetyl trimethyl ammonium chloride (CTAC), behenyl trimethyl ammonium chloride (BTAC), alkyl dimethyl hydroxyethyl ammonium chloride, such as Praepagen HY from Clariant GmbH.

[0048] Preferably, the compositions described herein comprise greater than 5% by weight of fabric softening active substance, more preferably greater than 10% by weight of fabric softening active substance, and most preferably greater than 20% by weight of fabric softening active substance, based on the weight of the composition. Preferably, the fabric conditioners described herein comprise less than 80% by weight of fabric softening active substance, more preferably less than 70% by weight of fabric softening active substance, and most preferably less than 65% by weight of fabric softening active substance, based on the weight of the composition. Suitably, the fabric conditioner comprises from 5 to 80% by weight of fabric softening active substance, preferably from 10 to 70% by weight of fabric softening active substance, and more preferably from 20 to 65% by weight of fabric softening active substance, based on the weight of the composition.

[0049] Fatty acid amide

[0050] The solid fabric conditioning composition comprises a fatty acid amide having a fatty acid chain length of 12 or more carbon atoms. Preferably, the fatty acid amide has a fatty acid carbon chain of less than 40. More preferably, the fatty acid chain is 14 to 30 carbon atoms in length, even more preferably 16 to 26 carbon atoms in length.

[0051] The fatty acid chain may be fully saturated, monounsaturated or polyunsaturated. The fatty acid chain may be substituted and / or may be branched. Preferably, the fatty acid chain is unsubstituted. Preferably the fatty acid chain is straight-chain (unbranched).

[0052] The composition comprises from 0.1 to 3% by weight of a fatty acid amide having a fatty acid chain length of 12 or more carbon atoms, based on the weight of the composition. Preferably, from 0.5 to 2.8% by weight, and even more preferably from 1 to 2.5% by weight of a fatty acid amide having a fatty acid chain length of 12 or more carbon atoms, based on the weight of the composition.

[0053] Water-soluble carrier

[0054] Examples of suitable carrier materials include: starch, xanthan gum, carboxymethyl cellulose.

[0055] The water-soluble carrier is selected from polysaccharides, more preferably cellulose derivatives, and most preferably cellulose ether derivatives. Typically, cellulose ether derivatives are obtained by substituting one or more hydroxy hydrogen atoms in the anhydroglucose units of cellulose with alkyl or substituted alkyl groups. The degree of substitution (DS) is one of the factors determining the properties of cellulose ether derivatives, particularly their solubility in water. It is defined as the number of substituted hydroxy groups per glucose molecule and ranges from 0 to 3. For example, cellulose ether derivatives with a degree of substitution value between 1.2 and 2.4 are soluble in cold water. Examples of cellulose ether derivatives suitable for the compositions described herein include methylcellulose (MC), hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC), hydroxypropylmethylcellulose (HPMC), carboxymethylcellulose (CMC) and sodium carboxymethylcellulose (SCMC).

[0056] Preferably, the cellulose ether derivative is selected from hydroxypropyl methylcellulose, methylcellulose, hydroxypropyl cellulose, and combinations thereof. The most preferred cellulose ether derivative is hydroxypropyl methylcellulose.

[0057] The compositions described herein comprise from 5 to 70% by weight, more preferably from 7.5 to 50% by weight and most preferably from 10 to 40% by weight of a water-soluble carrier material, based on the weight of the composition.

[0058] The water-soluble carrier preferably has a solubility of at least 0.5% by weight in distilled water at 25°C. Preferably, it has a solubility of at least 1.0% by weight, more preferably at least 2% by weight, and most preferably at least 3% by weight in distilled water at 25°C. In other words, it has a solubility of at least 5 mg / ml in distilled water at 25°C, preferably at least 10 mg / ml in distilled water at 25°C, more preferably at least 20 mg / ml in distilled water at 25°C, and most preferably 30 mg / ml in distilled water at 25°C.

[0059] Swelling disintegrant

[0060] The compositions described herein preferably comprise a swelling disintegrant. The swelling disintegrant herein refers to a component that swells upon contact with water. The swelling disintegrant acts synergistically with the fatty acid amide to improve the dissolution time and tackiness.

[0061] Preferably, the water absorption ratio (WAR) of the swelling disintegrant is greater than 1, more preferably greater than 1.5. The water absorption ratio (WAR) is a measure of how much water a material absorbs under controlled and defined conditions. The water absorption is expressed as the percentage increase in the weight of the sample:

[0062] % increase in weight = [(wet weight - conditioned weight) / conditioned weight] x 100

[0063] The method described in ASTM D570 is applicable to measuring the water absorption.

[0064] Specifically, the water absorption can be measured by the following method:

[0065] - Obtain a dry sample of the material to be tested

[0066] - Weigh the sample to be tested and then place it in a container of boiling distilled water for 120 minutes, ensuring that it is completely submerged

[0067] - Remove the sample and remove the excess water with filter paper.

[0068] - Immediately weigh the sample (wet weight)

[0069] - Dry the sample at 105°C for 20 minutes

[0070] - Reweigh the sample (conditioned weight)

[0071] The swellable disintegrant is preferably selected from sodium croscarmellose, sodium starch glycolate, crospovidone, C-TAG (co-ground treated agar) and C-TGG (co-ground treated guar gum), mucilage (e.g., from Isapgula or fenugreek seeds), chitin, cross-linked cellulose (e.g., microcrystalline cellulose), sodium starch glycolate, and mixtures thereof. More preferably, the swellable disintegrant is selected from cross-linked cellulose (preferably microcrystalline cellulose), sodium starch glycolate, and mixtures thereof. Even more preferably, the water-swellable disintegrant is selected from cross-linked cellulose, and most preferably, the water-swellable disintegrant is selected from microcrystalline cellulose.

[0072] The composition may comprise from 1 to 30% by weight of the swellable disintegrant, more preferably from 2 to 20% by weight, and most preferably from 3 to 15% by weight of the swellable disintegrant.

[0073] The compositions described herein may further comprise a non-swellable disintegrant. Non-swellable disintegrants herein refer to those having a water absorption ratio (WAR) of less than 1. Preferably, the non-swellable disintegrant is selected from polyvinylpyrrolidone, calcium silicate, starch, magnesium stearate, and mixtures thereof.

[0074] Carbonaceous material

[0075] The compositions described herein preferably comprise a carbonaceous material. The carbonaceous material improves the strength of the solid composition. Carbonaceous materials refer to materials having a 2D carbon lattice nanostructure. The 2D lattice can be flat (e.g., graphene) or can be shaped into a 3D shape (such as a carbon nanotube). The carbonaceous material can be part of a larger structure, such as a composite material, e.g., a clay-carbonaceous material composite. Preferably, the carbonaceous material comprises a material selected from carbon nanotubes, graphene, activated carbon, and combinations thereof. More preferably, the carbonaceous material preferably comprises graphene and / or its derivatives, and most preferably comprises graphene oxide.

[0076] Graphene is an allotrope formed by a single layer of carbon atoms arranged in a hexagonal lattice structure. Graphene can be obtained in two ways. The first is by peeling layers from graphite until a single layer of graphene is obtained. The second is called chemical vapor deposition (CVD), in which large-scale uniformity can be obtained and controlled.

[0077] Preferably, the graphene derivative suitable for the compositions described herein is graphene oxide. Graphene oxide can be manufactured by the Hummer's method. Graphene oxide is also commercially available and can be obtained from suppliers such as PlatonicNanotech.

[0078] The composition described herein preferably comprises from 0.001 to 2% by weight of a carbonaceous material, more preferably from 0.0025 to 1% by weight of a carbonaceous material, even more preferably from 0.005 to 0.5% by weight of a carbonaceous material, and most preferably from 0.01 to 0.25% by weight of a carbonaceous material.

[0079] Other ingredients

[0080] The composition described herein may comprise additional ingredients common in the field of solid fabric conditioners, such as fragrances, fragrance microcapsules, dyes, defoamers, insect repellents, coloring or color - adjusting dyes, preservatives (e.g., fungicides), pH buffers, fragrance carriers, hydrotropes, anti - redeposition agents, detergents, polyelectrolytes, anti - shrinkage agents, anti - wrinkle agents, antioxidants, colorants, sunscreens, anti - corrosion agents, drape - imparting agents, antistatic agents, chelating agents, and ironing aids. The composition described herein may comprise pearlescent agents and / or opacifying agents.

[0081] Preferably, the composition comprises a fragrance, more preferably from 0.1 to 25% by weight of a fragrance, even more preferably from 1 to 20% by weight of a fragrance, and most preferably from 2 to 15% by weight of a fragrance.

[0082] Water

[0083] The solid fabric conditioners described herein are preferably "water - free" when manufactured, however they may absorb moisture during storage. Thus, preferably, the composition comprises from 0 to 20% by weight, more preferably from 0 to 15% by weight, and most preferably from 0 to 12% by weight of water. The water content can be measured by thermogravimetric analysis, such as moisture balance.

[0084] Methods for preparing and using the composition

[0085] The solid fabric conditioner composition described herein can be in any suitable form. A single - dose composition can be a single item (e.g., a tablet or a sheet), a part of a single item (i.e., a part of a sheet separated by tearing off a section from a larger sheet), or can consist of multiple items (e.g., multiple granules of the composition). Preferably, the solid composition is in the form of an article having a minimum linear dimension greater than 1 mm in any direction. The solid fabric conditioner composition does not include powders. Preferably, the solid composition is in a form suitable for use as a single item (e.g., a tablet or a sheet). These can be referred to as "unit doses".

[0086] The solid fabric conditioner can be prepared by any suitable method. Preferred methods comprise the following steps:

[0087] a) Prepare a premix of a water - soluble carrier and water;

[0088] b) Add a fabric softening active substance, a fatty acid amide with a fatty acid chain length of 12 or more carbon atoms at 0.1 to 3% by weight, and any remaining components to the premix;

[0089] c) Cast the mixture onto a surface or into a mold; and

[0090] d) Remove water, preferably by evaporation.

[0091] Step a) preferably includes mixing and / or heating.

[0092] Step b) preferably includes mixing the fabric softening active substance, a fatty acid amide with a fatty acid chain length of 12 or more carbon atoms at 0.1 to 3% by weight, and any remaining components with water before adding them to the premix.

[0093] In step c), if casting is used, it is preferred to control the thickness using an applicator. The mixture is preferably cast onto a polytetrafluoroethylene (PTFE) surface, for example, a PTFE sheet, a PTFE-coated foil, or a PTFE-coated fabric.

[0094] Step d) is preferably carried out at a temperature higher than room temperature (higher than 25 °C), preferably below 100 °C, more preferably below 95 °C. Most preferably, the water is removed at a temperature of 70 to 90 °C. Preferably, the water is removed to achieve a water content in the composition of 0 to 20% by weight, more preferably 0 to 15% by weight, more preferably 0 to 10% by weight, even more preferably 0 to 5% by weight, and most preferably 0 to 2% by weight.

[0095] More specifically, a homogeneous premix of water and a water-soluble carrier is prepared by mixing. Subsequently, the fabric softening active substance, a fatty acid amide with a fatty acid chain length of 12 or more carbon atoms at 0.1 to 3% by weight, and any remaining components are mixed with water under high shear before adding them to the premix. Immediately, the premix is cast onto a surface to form a thin sheet or film with a certain thickness. Examples

[0096] Table 1: Example formulations

[0097]

[0098]

[0099] Quaternary ammonium compound 1 – TEA palm quaternary ammonium compound

[0100] Microcrystalline cellulose 2 - KEVICEL PH 102 from Keval Exports

[0101] The preparation was made by making a 10% polymer solution by dispersing hydroxypropyl methylcellulose in hot water. Under high shear, the quaternary ammonium compound and the fragrance were individually mixed into the remaining water to make an emulsion. The remaining ingredients were added to the emulsion and mixed. The final mixture was added to the polymer solution at room temperature and mixed well under high shear until a stable foam was formed. The foam was cast onto a smooth, hard surface and dried at 80 - 90 °C for 2 hours. The dried sheet was detached from the substrate upon cooling.

[0102] The dissolution time was measured by the following method. At room temperature, 300 ml of water was placed in a 500 ml beaker. The beaker was placed on a magnetic stirrer with a 1.5-inch magnetic bead therein. The stirring speed was set at 300 RPM. A 1-inch × 1-inch sheet (prepared as above) was added to the stirred water and the timer was started. The dissolution time was the time when no sheet residue was visible.

[0103] The dynamic coefficient of friction of the sheet was measured using a coefficient of friction (COF) tester from Packtest.

[0104] Table 2: Results

[0105]

[0106]

[0107] Fatty acid amides with a fatty acid chain length of 12 or more carbons at 0.1 to 3 wt% improved the coefficient of friction.

Claims

1. A solid fabric conditioning composition comprising: a. an ester-linked quaternary ammonium compound fabric softening active; b. 0.1 to 3% by weight of a fatty acid amide having a fatty acid chain length of 12 or more carbon atoms; and c. 5 to 70% by weight of a water-soluble carrier selected from polysaccharides.

2. The solid fabric conditioning composition according to any one of the preceding claims, wherein the fabric softening active comprises a mixture of a cationic quaternary ammonium compound having more than one long carbon chain in combination with a second surfactant selected from single-chain cationic surfactants and / or non-ionic surfactants.

3. The solid fabric conditioning composition according to any one of the preceding claims, wherein the composition comprises 5 to 80% by weight of the fabric softening active.

4. The solid fabric conditioning composition according to any one of the preceding claims, wherein the water-soluble carrier is selected from: cellulose derivatives and combinations thereof.

5. The solid fabric conditioning composition according to any one of the preceding claims, wherein the composition further comprises a carbonaceous material.

6. The solid fabric conditioning composition according to any one of the preceding claims, wherein the composition further comprises a fragrance.

7. The solid fabric conditioning composition according to any one of the preceding claims, wherein the composition further comprises a swellable disintegrant.

8. The solid fabric conditioning composition according to any one of the preceding claims, wherein the swellable disintegrant is selected from disintegrants having a water absorption rate (WAR) greater than 1.

9. The solid fabric conditioning composition according to any one of the preceding claims, wherein the composition comprises 1 to 30% by weight of the swellable disintegrant.

10. The solid fabric conditioning composition according to any one of the preceding claims, wherein the composition comprises a swellable disintegrant containing microcrystalline cellulose.

11. A method of preparing the solid fabric conditioning composition according to any one of the preceding claims, comprising the steps of: a. preparing a premix of the water-soluble carrier and water; b. adding to the premix the fabric softening active, 0.1 to 3% by weight of a fatty acid amide having a fatty acid chain length of 12 or more carbon atoms and any remaining ingredients; c. pouring the mixture onto a surface or into a mold; and d. removing the water, preferably by evaporation.

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