Concentrated surfactant compositions

Abstract

This invention provides concentrated surfactant compositions comprising an alkylalkoxylated sulfate surfactant and a rheology modifier. The invention also provides methods for preparing such concentrated surfactant compositions, detergent compositions prepared from such concentrated surfactant compositions, and methods for preparing such detergent compositions.

Description

[0001] This application is a divisional application of the PCT international application filed on January 26, 2018, with PCT international application number PCT / US2018 / 015354 and Chinese national application number 201880008278.X, entitled "Concentrated Surfactant Composition". Technical Field

[0002] This disclosure relates to concentrated surfactant compositions comprising alkylalkoxylated sulfate surfactants and rheology modifiers, and methods for preparing such compositions. This disclosure also relates to detergent compositions prepared from such concentrated surfactant compositions, and methods for preparing such detergent compositions. Background Technology

[0003] Concentrated surfactant compositions can be used to prepare detergent compositions, such as laundry detergent compositions or dishwashing detergent compositions. Due to their high activity, they can be delivered relatively efficiently. Furthermore, they can be combined with other detergent ingredients or carriers, and diluted with other detergent ingredients or carriers to achieve desired activity levels in liquid products. Additionally, such concentrated surfactant compositions can be mixed with other detergent ingredients with minimal drying to form solid or semi-solid powder or other solid dosage form products.

[0004] However, concentrated surfactant compositions, especially those containing a high proportion of anionic alkylalkoxylated sulfate surfactants, can also present challenges in terms of viscosity and / or stability. Such compositions can have relatively high viscosity, making them difficult to pump or discharge, for example, from railcars or storage tanks to the production line. The compositions can also undergo phase separation, which can lead to inconsistencies and / or aesthetic problems in the final product. Even when diluted with water, concentrated compositions containing anionic alkylalkoxylated sulfate surfactants can form a highly viscous hexagonal phase, which can be very difficult to process.

[0005] To overcome viscosity and / or stability issues, organic solvents can be added to concentrated surfactant compositions. For example, low molecular weight polyethylene glycol (PEG) with a relatively low molecular weight (e.g., 4000) has historically been used to mitigate phase behavior challenges in the preparation, processing, and use of highly concentrated surfactant compositions. However, organic solvents offer few additional functionalities and can increase costs without providing many performance benefits in the final product.

[0006] There is a need for improved concentrated surfactant compositions that have relatively high activity levels, limited solvent content, and desired viscosity and / or phase stability. Summary of the Invention

[0007] This disclosure relates to a concentrated surfactant composition comprising: about 70% to about 90% by weight of a surfactant system, the surfactant system comprising: about 50% to about 100% by weight of anionic alkylalkoxylated sulfate surfactant; and about 0.1% to about 25% by weight of a rheology modifier selected from alkoxylated amines (preferably alkoxylated polyamines, more preferably quaternized or non-quaternized alkoxylated polyethylene glycol). The composition comprises: an alkyleneimide, wherein the alkoxylated polyalkyleneimide has a polyalkyleneimide core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkyleneimide core; an ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer (where x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70); and mixtures thereof; not more than about 5% by weight of the composition of an amino-free organic solvent; and water.

[0008] This disclosure also relates to a detergent composition comprising a concentrated surfactant composition and detergent additives as described herein.

[0009] This disclosure also relates to a method for manufacturing a concentrated surfactant composition, the method comprising the steps of: providing an anionic alkylalkoxylated sulfate surfactant (optionally anionic sulfonated surfactant), a rheology modifier selected from alkoxylated amines (preferably alkoxylated polyamines, more preferably quaternized or non-quaternized alkoxylated polyethyleneimines, wherein the alkoxylated polyalkylimine has a polyalkylimine core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkylimine core), and an ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer (where x1 and x2 are each in the range of about 2 to about 140, and...). The composition comprises: y in the range of about 15 to about 70, and mixtures thereof; an organic solvent optionally free of amino functional groups; and water; and the components are combined in the following proportions to form a concentrated surfactant composition: a sufficient amount of anionic alkylalkoxylated sulfate surfactant and optionally anionic sulfonated surfactant to form a surfactant system, wherein the surfactant system is present in an amount of about 70% to about 90% by weight of the composition, and wherein the anionic alkylalkoxylated sulfate surfactant is present in an amount of about 50% to about 100% by weight of the surfactant system; a rheology modifier of about 0.1% to about 25% by weight of the composition; not more than 5% of an amino-free organic solvent; and water.

[0010] This disclosure also relates to a method for manufacturing a detergent composition, the method comprising the steps of: providing a concentrated surfactant composition as described herein; and combining the concentrated surfactant composition with a detergent additive to form a detergent composition.

[0011] This disclosure also relates to the use of rheology modifiers for reducing the viscosity of concentrated surfactant compositions, the rheology modifiers being selected from alkoxylated amines (preferably alkoxylated polyamines, more preferably quaternized or non-quaternized alkoxylated polyethyleneimines, wherein the alkoxylated polyalkylimine has a polyalkylimine core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkylimine core), ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymers (where x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70), and mixtures thereof, wherein the composition comprises about 70% to about 90% by weight of a surfactant system; the surfactant system comprises about 50% to about 100% anionic alkylalkoxylated sulfate surfactants. Detailed Implementation

[0012] This disclosure relates to concentrated surfactant compositions comprising relatively high amounts of alkylalkoxylated sulfate surfactants such as alkylethoxylated sulfate surfactants (“AES”).

[0013] Surprisingly, it has been found that rheology modifiers can be added to concentrated compositions to provide beneficial effects on viscosity and / or stability, thereby enabling a reduction in the content of organic solvents. These rheology modifiers are selected from alkoxylated amines (preferably alkoxylated polyamines, more preferably quaternized or non-quaternized alkoxylated polyethyleneimines, wherein the alkoxylated polyalkyleneimine has a polyalkyleneimine core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkyleneimine core), ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymers (where x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70), and mixtures thereof. Such polymers are commonly used in combination with AES in end products such as laundry detergents and provide more beneficial performance effects, such as cleaning benefits, compared to organic solvents. Concentrated compositions incorporate these polymers (which can be relatively upstream in the manufacturing process) to maintain a relatively high level of activity in the final product without sacrificing formulation space or incurring unnecessary costs.

[0014] The components and properties of the concentrated surfactant compositions disclosed herein are described in more detail below.

[0015] As used herein, the articles “a” and “an” when used in a claim are to be understood to refer to one or more things protected or described by the claims. As used herein, the terms “comprising,” “including,” and “containing” are intended to be non-limiting. The compositions of this disclosure may comprise, consist substantially of, or be composed of the components of this disclosure.

[0016] This document may use the terms "substantially free of" or "substantially absent". This means that the referred material is present in very small amounts, not intentionally added to the composition to form a portion of the composition, or preferably not present at an analytically detectable level. This means that the composition includes the referred material only as an impurity among other intentionally added materials. If present, the referred material may be present in an amount of less than 1%, less than 0.1%, less than 0.01%, or even 0% by weight of the composition.

[0017] As used herein, the term "fabric care composition" includes compositions and formulations designed to treat fabrics. Such compositions include, but are not limited to, laundry cleaning compositions and detergents, fabric softening compositions, fabric strengthening compositions, fabric freshening compositions, laundry pre-wash agents, laundry pretreatment agents, laundry additives, spray products, dry cleaning agents or compositions, laundry rinsing additives, washing additives, post-rinse fabric treatment agents, ironing aids, unit-dose formulations, delayed-delivery formulations, detergents on or incorporated into porous substrates or nonwoven sheets, and other suitable forms that are apparent to those skilled in the art from the teachings herein. Such compositions may be used as laundry pretreatment agents, laundry posttreatment agents, or may be added during rinsing or washing cycles of a laundry operation.

[0018] As used herein with respect to surfactants that may be in acidic form, "neutralized" means that the surfactant is in salt form, such as a sodium salt. As used herein with respect to surfactants that may be in acidic form, "pre-neutralized" means that the surfactant is in salt form before being combined with at least one other component of the composition disclosed herein. Such (pre-)neutralized surfactants may have a pH of about 7 or higher in a 10% aqueous solution.

[0019] As used herein, "isotropic" means a clear mixture (without obvious turbidity and / or dispersed particles) and having a uniform, transparent appearance. For example, the compositions of this disclosure are characterized by a transmittance of greater than about 80% or greater than about 90% at a wavelength of 570 nm, measured at room temperature using a Beckman DU spectrophotometer via a standard 10 mm path length cuvette, in the absence of dyes and / or opacifiers, using deionized water as a blank.

[0020] As used herein, the term "alkoxy" is intended to include C1-C8 alkoxy groups and C1-C8 alkoxy derivatives of polyols having repeating units such as butane oxide, glycidyl oxide, ethylene oxide, or propylene oxide. The terms "ethylene oxide," "propylene oxide," and "butane oxide" may be indicated herein by their typical designations "EO," "PO," and "BO," respectively.

[0021] As used herein, “average molecular weight” is reported as weight-average molecular weight, as determined by its molecular weight distribution; due to their manufacturing methods, the polymers disclosed herein may contain a distribution of repeating units in their polymer portions.

[0022] Unless otherwise specified, all component or composition contents are for the active portion of the component or composition and do not include impurities, such as residual solvents or byproducts, that may be present in commercially available sources of such components or compositions.

[0023] Unless otherwise specified, all temperatures in this document are in degrees Celsius (°C). Unless otherwise specified, all measurements in this document were taken at 20°C and atmospheric pressure.

[0024] In all embodiments of this disclosure, unless otherwise specified, all percentages are by weight of the total composition. Unless otherwise specified, all ratios are by weight.

[0025] It should be understood that each maximum numerical limit given in this specification includes each lower numerical limit, as expressly stated herein. Each minimum numerical limit given in this specification includes each higher numerical limit, as expressly stated herein. Each numerical range given in this specification includes each narrower numerical range falling within that larger numerical range, as expressly stated herein in its entirety.

[0026] Concentrated surfactant composition

[0027] This disclosure relates to concentrated surfactant compositions. The compositions described herein may be intermediate compositions intended to be combined with other ingredients to form a final product. The concentrated surfactant compositions of this disclosure are sometimes considered surfactant pastes.

[0028] Concentrated surfactant compositions may comprise, or may consist substantially of, the following components: a surfactant system, which may include alkylalkoxylated sulfate surfactants; a rheology modifier selected from alkoxylated amines (preferably alkoxylated polyamines, more preferably quaternized or non-quaternized alkoxylated polyethyleneimines, wherein the alkoxylated polyalkylimine has a polyalkylimine core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkylimine core), ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymers (where x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70), and mixtures thereof; an organic solvent system; and water. These components are described in more detail below.

[0029] The concentrated surfactant composition may comprise: about 70% to about 90% by weight of the composition of a surfactant system, wherein the surfactant system comprises about 50%, or about 60%, or about 70%, or about 80% to about 100% of an alkylalkoxylated sulfate surfactant; about 0.1% to about 25% by weight of the composition of a rheology modifier selected from alkoxylated amines (preferably alkoxylated polyamines, more preferably quaternized or non-quaternized alkoxylated polyethyleneimines, wherein the alkoxylated polyalkylimine has a polyalkylimine core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkylimine core), ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymers (where x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70), and mixtures thereof; less than about 5% by weight of the composition of an organic solvent system; and water. In some or all cases, in addition to typical impurities such as unreacted reactants, byproducts or desired hydrolysis products, the composition may contain no more than two or no more than one additional (active) ingredient.

[0030] Concentrated surfactant compositions can have a 1000s -1 Viscosities less than about 3,000 cps, or less than about 2,000 cps, or less than about 1,500 cps, or less than about 1,000 cps, measured at 60°C. Concentrated surfactant compositions may have viscosities less than 1000 s⁻¹. -1 Viscosities measured at 60°C are approximately 10 cps, or approximately 50 cps, or approximately 100 cps to approximately 3,000 cps, or approximately 2,000 cps, or approximately 1,500 cps, or approximately 1,000 cps. Unless otherwise specified, viscosity is determined according to the shear viscosity test method described herein.

[0031] Having relatively low viscosity can be advantageous for transporting, pumping, and / or processing compositions. For example, the viscosity of a concentrated composition can affect whether the composition can be pumped out of a railcar via the top or bottom of the vehicle. In another example, the viscosity of a concentrated composition can affect the processing of solid dosage form products, such as the agglomeration of detergency powders to prepare granular detergents.

[0032] Concentrated surfactant compositions may be expected to be phase-stable and / or have a clear appearance, as such compositions are easier to process and / or incorporate into the final product. Concentrated surfactant compositions may be isotropic, which indicates phase stability. Concentrated surfactant compositions retain as a single-phase, isotropic solution after 2 weeks at 20°C and / or after 2 weeks at 40°C. Concentrated surfactant compositions have a transmittance percentage (T%) of at least about 80%, or at least about 85%, or at least about 90%, or at least about 95%, or at least about 98%, or at least about 99% at 570 nm. The transmittance percentage is determined according to the transmittance percentage method provided in the Test Methods section below.

[0033] The concentrated surfactant composition may have an alkaline pH in a 10% (weight / volume) solution of the composition at 20°C ± 2°C. The concentrated surfactant composition is characterized by having a pH greater than 8, 9, 10, or 11 in a 10% (weight / volume) solution of the composition at 20°C ± 2°C. The concentrated surfactant composition may have a pH of about 9 to about 13, or preferably about 10 to about 13, in a 10% (weight / volume) solution of the composition at 20°C ± 2°C.

[0034] Concentrated surfactant compositions are characterized by a reserve alkalinity (RA) value. RA is a measure of the buffering capacity (g / NaOH / 100g detergent composition) of the detergent composition, determined by titrating a 1% (w / v) solution of the detergent composition with hydrochloric acid to pH 7.5, and determined according to the methods provided in the Test Methods section below. Concentrated surfactant compositions are characterized by a reserve alkalinity of less than about 2, or less than about 1.5, or less than about 1, or less than about 0.8. Concentrated surfactant compositions are characterized by a reserve alkalinity of about 0.1, or about 0.3, or about 0.5 to about 2.0, or about 1.5, or about 1.0, or about 0.8. Such reserve alkalinity helps maintain the alkaline pH of the compositions described herein. Because alkylalkoxylated sulfate surfactants can undergo acid-catalyzed hydrolysis in acidic environments, compositions containing such surfactants are particularly desirable to have a certain reserve alkalinity.

[0035] The concentrated surfactant composition disclosed herein can remain a single-phase solution after 2 weeks at 20°C and / or 2 weeks at 40°C.

[0036] surfactant system

[0037] The concentrated surfactant compositions disclosed herein comprise a surfactant system. The concentrated surfactant compositions may comprise about 70% to about 90% of the surfactant system by weight of the composition.

[0038] Surfactant systems may contain anionic surfactants. The anionic surfactant in a surfactant system may comprise or consist substantially of alkylalkoxylated sulfate surfactants, linear alkylbenzene sulfonate surfactants, or mixtures thereof. Surfactant systems may be substantially free of nonionic surfactants, cationic surfactants, amphoteric surfactants, and / or zwitterionic surfactants.

[0039] A surfactant system may consist essentially of no more than two types of surfactants. However, it should be recognized that a surfactant system may contain small amounts of, for example, raw material inputs, hydrolysis reaction products, other impurities related to the surfactants that constitute the main part of the surfactant system, or other impurities.

[0040] Surfactants present in surfactant systems may exist partially or entirely in acid form, or as salts (usually water-soluble salts). Suitable counterions include alkali metal cations (usually sodium), or ammonium or substituted ammonium (usually sodium). The surfactant (alone or together) may be pre-neutralized before being combined with one or more other components of a concentrated surfactant system.

[0041] Alkyl alkoxylated sulfates

[0042] Surfactant systems may contain alkylalkoxylated sulfate surfactants. Alkylalkoxylated surfactants can be the main component of the surfactant system. Alkylalkoxylated surfactants can be linear, branched, or a combination thereof.

[0043] The alkylalkoxylated sulfate surfactant may be present in the composition in an amount of about 50%, or about 60%, or about 70%, or about 80% to about 100% by weight of the surfactant system. The alkylalkoxylated sulfate surfactant may be present in an amount of about 70% to about 90%, preferably about 75% to about 85%, more preferably about 77% to about 82% by weight of the composition.

[0044] The alkylalkoxylated sulfate surfactant can be an alkylethoxylated sulfate surfactant, an alkylpropoxylated surfactant, or a mixture thereof, preferably an alkylethoxylated sulfate surfactant. The alkylalkoxylated sulfate surfactant may have a weight-average alkoxylation degree of about 1 to about 3, more preferably about 1 to about 2.5, or even more preferably about 1 to about 2, preferably a weight-average ethoxylation degree.

[0045] When the alkylalkoxylated sulfate surfactant is a mixture of alkylalkoxylated sulfate surfactants, the degree of alkoxylation is the weight-average alkoxylation of all components of the mixture (weight-average alkoxylation). The weight of the alkylalkoxylated sulfate surfactant component that does not have an alkoxylating group should also be included in the weight-average alkoxylation calculation. The weight-average alkoxylation is calculated as follows:

[0046] Weight-average alkoxylation degree = (x1 * alkoxylation degree of surfactant 1 + x2 * alkoxylation degree of surfactant 2 + ...) / (x1 + x2 + ...)

[0047] Where x1, x2, ... are the weights (in grams) of each sulfated anionic surfactant in the mixture, and the degree of alkoxylation is the number of alkoxy groups in each sulfated anionic surfactant.

[0048] Alkyl alkoxylated sulfate surfactants can be alkyl ethoxylated surfactants with a narrow range of ethoxylation degrees. Alkyl ethoxylated surfactants may include a certain distribution of alkyl ethoxylated surfactants, wherein less than about 7% by weight of the total alkyl ethoxylated surfactants are alkyl ethoxylated surfactants with n ≥ 3, and less than about 35% by weight of the total alkyl ethoxylated surfactants are alkyl ethoxylated surfactants with n = 0, where n is the surfactant (AE) n The number of ethoxylated (EO) groups in S).

[0049] Alkyl alkoxylated sulfates may have a weight-average alkyl chain length of about 8 to about 18 or about 10 to about 16 carbon atoms, preferably about 12 to about 15 carbon atoms, and even more preferably about 14 to about 15 carbon atoms.

[0050] Alkyl alkoxylated sulfates can be alkyl ethoxylated surfactants having an average alkyl chain length of about 14 to about 15 carbon atoms and an average degree of ethoxylation of about 1 to about 2.5. Alkyl alkoxylated sulfates can be C45 AE... 2.5 S, which has a weight-average alkyl chain length of 14 to 15 carbons and a weight-average degree of ethoxylation of 2.5. Alkylalkoxylated sulfates can be C45 AE. 1.0S, which has a weight-average alkyl chain length of 14 to 15 carbons and a weight-average ethoxylation degree of about 1.0.

[0051] If the alkyl alkoxylated sulfate is a branched alkyl alkoxylated sulfate, the branching group may be an alkyl group. The alkyl group may be selected from methyl, ethyl, propyl, butyl, pentyl, cyclic alkyl groups, and mixtures thereof. One or more alkyl branches may be present on the main hydrocarbon chain of one or more starting alcohols used to prepare the sulfated anionic surfactant of the present invention. The branched alkyl alkoxylated sulfated anionic surfactant may be an alkyl ethoxylated sulfate.

[0052] Alkylalkoxylated sulfate surfactants are commercially available in a variety of chain lengths, degrees of ethoxylation, and degrees of branching. Commercially available sulfates include those based on Shell Company's Neodol alcohol, Sasol Company's Lial-Isalchem ​​and Safol, and the natural alcohols of The Procter & Gamble Chemicals Company.

[0053] Sulfonated surfactants

[0054] The composition or surfactant system may also contain anionic sulfonated surfactants, preferably alkylbenzene sulfonate surfactants, more preferably linear alkylbenzene sulfonate (LAS) surfactants.

[0055] The sulfonated surfactant may be present in an amount of about 0% to about 50%, or about 1% to about 50%, or about 10% to about 40%, or about 20% to about 35%, or about 25% to about 30% by weight of the composition. The sulfonated surfactant may be present in an amount of about 0%, or about 1%, or about 5%, or about 10%, or about 20%, or about 25% to about 50%, or about 40%, or about 35%, or about 30% by weight of the surfactant system. The sulfonated surfactant may be present in an amount of about 35% to about 45% by weight of the surfactant system, and the alkylalkoxylated sulfate may be present in an amount of about 55% to about 65% by weight of the surfactant system.

[0056] Linear alkylbenzene sulfonate surfactants have a weight-average alkyl chain length of about 10 to about 16, preferably about 11 to about 13 carbon atoms. The weight-average alkyl chain length of LAS can be about 11.8 carbon atoms. LAS can exist in acid form or as a salt, preferably as a sodium salt.

[0057] The weight ratio of AES to LAS in a surfactant system can range from about 99:1 to about 1:1, or about 25:1 to about 1:1, or about 10:1 to about 1.5:1, or about 7:1 to about 2:1, or about 5:1 to about 3:1. The weight ratio of AES to LAS in a surfactant system can also range from about 2:1 to about 1:1.

[0058] The sulfonated surfactant may be present in an amount of about 35% to about 45% by weight of the surfactant system, and the alkylalkoxylated sulfate may be present in an amount of about 55% to about 65% by weight of the surfactant system.

[0059] Suitable alkylbenzene sulfonates (LAS) are available and are preferably obtained by sulfonating commercially available linear alkylbenzenes (LABs). Suitable LABs include lower 2-phenyl LABs, such as those marketed under the trade name Isochem. ® Those supplied by Sasol or marketed under the trade name Petrelab ® Those supplied by Petresa, other suitable LABs include advanced 2-phenyl LABs, such as those marketed under the trade name Hyblene. ® Those supplied by Sasol. Suitable anionic detergency surfactants are alkylbenzene sulfonates obtained by DETAL catalysis, although other synthetic routes such as those catalyzed by hydrofluoric acid (HF) may also be suitable.

[0060] rheology modifiers

[0061] As used herein, the term "rheology modifier" refers to a material that interacts with a concentrated surfactant, preferably a concentrated surfactant having a mesocrystalline phase structure, in a manner that substantially reduces the viscosity and elasticity of said concentrated surfactant. Suitable rheology modifiers include, but are not limited to: sorbitol ethoxylates; glycerol ethoxylates; dehydrated sorbitol esters; tallow alkyl ethoxylated alcohols; ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymers, wherein x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70; alkoxylated amines; alkoxylated polyamines; polyethyleneimine (PEI); alkoxylated variants of PEI, and preferably ethoxylated PEI; and mixtures thereof. Rheology modifiers may comprise a combination of one of the above polymers (e.g., ethoxylated PEI) with polyethylene glycol (PEG) having a weight-average molecular weight of about 2,000 Daltons to about 8,000 Daltons.

[0062] As used herein, the term "functional rheology modifier" refers to a rheology modifier that has additional detergent functionality. In some cases, the dispersant polymers described below may also be used as functional rheology modifiers. The functional rheology modifier may be present in an amount of about 0.1% to about 25%, or about 1% to about 20%, or about 1% to about 15% by weight of the composition, preferably about 2% to about 12%, and more preferably about 4% to about 8%.

[0063] Alkoxylated amines

[0064] Alkoxylated amines may be partially or fully protonated or deprotonated across the entire pH range of concentrated surfactant mixtures. Alternatively, alkoxylated amines may be partially or fully quaternized. Alkoxylated amines may be non-quaternized. Alkoxylated amines may contain an ethoxylated (EO) group.

[0065] Alkoxylated amines can be linear, branched, or a combination thereof, preferably branched.

[0066] Alkoxylated amines can contain two or more amine moieties, such as N,N,N',N'-tetra(2-hydroxyethyl)ethylenediamine (also described as a class of hydroxylamines). N,N,N',N'-tetra(2-hydroxyethyl)ethylenediamine is also used as a chelating agent.

[0067] Alkoxylated amines may include (or be) alkoxylated amines, including alkoxylated polyalkylene imides. Alkoxylated polyalkylene imides may be alkoxylated polyethyleneimine (PEI).

[0068] Typically, alkoxylated polyalkylene imide polymers comprise a polyalkylene imide backbone. The polyalkylene imide may contain C2 alkyl groups, C3 alkyl groups, or mixtures thereof, preferably C2 alkyl groups. Alkoxylated polyalkylene imide polymers may have a polyethyleneimine (“PEI”) backbone.

[0069] Alkoxylated PEI may comprise a polyethyleneimine backbone having a weight-average molecular weight of about 400 to about 1000, or about 500 to about 750, or about 550 to about 650, or about 600, as determined prior to ethoxylation.

[0070] Prior to alkoxylation, the PEI backbone of the polymers described herein may have the empirical general formula:

[0071] ,

[0072] B represents the continuation of the structure through branching. In some respects, n+m is equal to or greater than 8, or 10, or 12, or 14, or 18, or 22.

[0073] The alkoxylated polyalkylene imine polymer comprises an alkoxylated nitrogen group. The alkoxylated polyalkylene imine polymer may independently contain up to about 50, or up to about 40, or up to about 35, or up to about 30, or up to about 25, or up to about 20 alkoxylated groups on an average of each alkoxylated nitrogen group. The alkoxylated polyalkylene imine polymer may independently contain at least about 5, or at least about 10, or at least about 15, or at least about 20 alkoxylated groups on an average of each alkoxylated nitrogen group.

[0074] Alkoxylated polyalkylene imide polymers, preferably alkoxylated PEI, may contain ethoxylated (EO) groups, propoxylated (PO) groups, or combinations thereof. Alkoxylated polyalkylene imide polymers, preferably alkoxylated PEI, may contain ethoxylated (EO) groups. Alkoxylated polyalkylene imide polymers, preferably alkoxylated PEI, may not contain propoxylated (PO) groups.

[0075] Alkoxylated amines, preferably alkoxylated polyalkylene imine polymers, more preferably alkoxylated PEIs, may contain about 1 to 50 ethoxylated (EO) groups and about 0 to 5 propoxylated (PO) groups on average per alkoxylated nitrogen. Alkoxylated polyalkylene imine polymers, preferably alkoxylated PEIs, may contain about 1 to 50 ethoxylated (EO) groups on average per alkoxylated nitrogen and are free of propoxylated (PO) groups. Alkoxylated polyalkylene imine polymers, preferably alkoxylated PEIs, may contain about 10 to 30 ethoxylated (EO) groups on average per alkoxylated nitrogen, preferably about 15 to 25 ethoxylated (EO) groups.

[0076] Suitable polyamines include low molecular weight, water-soluble, and mildly alkoxylated ethoxylated / propoxylated polyalkylene imine polymers. "Mildly alkoxylated" means that the polymers of the present invention have an average degree of alkoxylation of about 0.5 to about 20 or 0.5 to about 10 per nitrogen. The polyamine may be "substantially uncharged," meaning that at pH 10 or pH 7, the main chain of the polyalkylene imine polymer contains no more than about 2 positive charges per about 40 nitrogen atoms; however, it is recognized that the charge density of the polymer can vary with pH.

[0077] Suitable alkoxylated polyalkylene imides such as PEI600 EO20 were purchased from BASF (Ludwigshafen, Germany).

[0078] ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer

[0079] In the ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer, x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70. The ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer preferably has an average propylene oxide chain length of 20 to 70, more preferably 30 to 60, and more preferably 45 to 55 propylene oxide units.

[0080] Preferably, the ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer has a weight-average molecular weight of about 1,000 Daltons to about 10,000 Daltons, preferably about 1,500 Daltons to about 8,000 Daltons, more preferably about 2,000 Daltons to about 7,000 Daltons, even more preferably about 2,500 Daltons to about 5,000 Daltons, and most preferably about 3,500 Daltons to about 3,800 Daltons.

[0081] Preferably, each ethylene oxide block or chain independently has an average chain length of 2 to 90, more preferably 3 to 50, and more preferably 4 to 20 ethylene oxide units.

[0082] Preferably, the copolymer comprises a copolymer of ethylene oxide blocks in a combination of 10% to 90% by weight, preferably 15% to 50% by weight, and most preferably 15% to 25% by weight. Most preferably, the total ethylene oxide content is equally distributed across the two ethylene oxide blocks. Equal distribution herein means that each ethylene oxide block contains an average of 40% to 60%, preferably 45% to 55%, even more preferably 48% to 52%, and most preferably 50% of the total number of ethylene oxide units, with the combined percentage of the two ethylene oxide blocks reaching 100%. Some ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymers (where x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70) improve cleaning ability.

[0083] Preferably, the copolymer has a weight-average molecular weight of about 3,500 to about 3,800 Daltons, a propylene oxide content of 45 to 55 propylene oxide units, and an ethylene oxide content of 4 to 20 ethylene oxide units per ethylene oxide block.

[0084] Preferably, the ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer has a weight-average molecular weight of 1,000 Daltons to 10,000 Daltons, preferably 1,500 Daltons to 8,000 Daltons, and more preferably 2,000 Daltons to 7,500 Daltons. Preferably, the copolymer comprises a combination of 10% to 95% by weight, preferably 12% to 90% by weight, and most preferably 15% to 85% by weight of ethylene oxide blocks. Some ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymers (where x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70) improve solubility.

[0085] Suitable ethylene oxide-propylene oxide-ethylene oxide triblock copolymers are available from BASF Company in Pluronic PE series or from Dow Chemical Company in Tergitol L series. A particularly suitable material is Pluronic PE 9200.

[0086] Organic solvents without amino functional groups

[0087] The concentrated surfactant compositions of this disclosure may contain an amino-free organic solvent. Organic solvents can contribute to the desired viscosity and stability characteristics of the compositions of this disclosure. However, it may be desirable to keep the amount of amino-free solvent to a minimum while still maintaining the desired viscosity and / or stability, since the solvent has little effect on the beneficial effects on the performance of the final product.

[0088] The concentrated surfactant composition disclosed herein may contain no more than about 5% by weight of the composition of an amino-free organic solvent. The amino-free organic solvent may be present in an amount of less than about 5%, or less than about 4%, or less than about 3%, preferably less than about 2%, preferably less than about 1%, and preferably about 0% by weight of the composition. The concentrated surfactant composition may contain about 0% to about 55%, or about 0% to about 1%, or about 0% by weight of the composition of an amino-free organic solvent.

[0089] Concentrated surfactant compositions may be substantially free of amino-free organic solvents.

[0090] If present, an amino-free organic solvent may contain at least one, at least two, or at least three organic solvents. An amino-free organic solvent may contain no more than four, three, two, or one organic solvent.

[0091] If present, amino-free organic solvents may include solvents selected from: monohydric alcohols, such as ethanol, propanol, butanol, and isopropanol; dihydric alcohols, such as diethylene glycol, propylene glycol, butanediol, and glycols (wherein the dihydric alcohols have hydroxyl groups attached to adjacent atoms); polyalkylene glycols, such as polyethylene glycol; polyhydric alcohols, such as glycerol; alkoxylated glycerol, alkoxylated glycols, and combinations thereof. Amino-free organic solvents may include solvents selected from: glycerol, ethanol, propylene glycol, diethylene glycol, dipropylene glycol, polyalkylene glycols (e.g., PEG4000), butanediol, and combinations thereof.

[0092] The organic solvent system may contain propylene glycol. The organic solvent system may contain propylene glycol and at least one other organic solvent. The organic solvent system may contain propylene glycol and diethylene glycol. The weight ratio of propylene glycol to diethylene glycol may be from about 1:2 to about 4:1. Alternatively, the organic solvent system may be substantially free of diethylene glycol.

[0093] The organic solvent system may contain propylene glycol and ethanol. The weight ratio of propylene glycol to ethanol may be from about 1:1 to about 2.5:1, or from about 1.05:1 to about 2.11:1, or from about 1.5:1 to about 2.1:1.

[0094] water

[0095] The concentrated surfactant compositions disclosed herein may contain water. Water can also be used as a solvent for surfactant systems, in addition to organic solvent systems. When formulating the concentrated compositions of the present invention, some of the organic solvent systems that may otherwise be necessary can be replaced by water. Water is commonly present in at least some final detergent products, such as heavy-duty liquid detergent compositions, and is generally less expensive than organic solvents.

[0096] The concentrated surfactant compositions disclosed herein may comprise the components described herein (including surfactant systems, organic solvent systems, and alkalizing agents), with the remainder being water. The concentrated surfactant compositions disclosed herein may comprise about 5%, or about 10%, to about 30%, or about 25%, or about 20%, or about 16%, or about 14% water by weight of the composition.

[0097] Water may be added as free water or pure water. In some respects, water may be incorporated into the composition as a component of other ingredients, for example, as a carrier of sodium hydroxide or organic acids. It should be understood that water may also be formed by neutralization of acids in the composition, such as alkyl ethoxylated sulfates (HAES) or LAS (HLAS) in acidic form.

[0098] Alkalizing agent

[0099] The concentrated surfactant composition disclosed herein may contain an alkalizing agent. The concentrated surfactant composition may contain about 0.1% to about 5.5% of an alkalizing agent. The alkalizing agent may be sufficient to neutralize the amount of surfactant present in the concentrated surfactant composition. When the surfactants are neutralized, whether they are incorporated into a pre-neutralized composition or neutralized by adding an alkalizing agent, for example, a small amount of excess alkalizing agent, such as about 0.1% to about 1% by weight of the concentrated surfactant composition, may be present in the composition.

[0100] The alkalizing agent can be a caustic agent. Suitable caustic agents include alkali metal hydroxides, alkaline earth metal hydroxides, ammonium hydroxide (substituted or unsubstituted), or mixtures thereof. The alkalizing agent can be an alkali metal hydroxide, preferably sodium hydroxide.

[0101] The alkalizing agent can be an alkanolamine, such as monoethanolamine (MEA) or triethanolamine (TEA).

[0102] Other components

[0103] The concentrated surfactant compositions described herein (although the number of components is typically limited) may contain other suitable components. Suitable components may include polymers, antimicrobial agents, other surfactants (including branched anionic surfactants and / or amine oxides), water-soluble growth promoters (such as sodium isopropylbenzene sulfate), fatty acids and / or their salts, or mixtures of any of the foregoing substances. The concentrated surfactant compositions described herein may be substantially free of fatty acids (preferably carboxylic acids) and / or their salts.

[0104] Detergent composition

[0105] The concentrated surfactant compositions disclosed herein can be used to prepare detergent compositions. The detergent compositions may be intermediate compositions and / or end-use products intended for sale to and used by consumers or institutions. Therefore, this disclosure also relates to detergent compositions. The detergent compositions disclosed herein may comprise the concentrated surfactant compositions and detergent auxiliaries as described herein. The detergent compositions may be fabric care compositions.

[0106] Detergent compositions may be in any form suitable for end-consumer use, such as liquids, gels, powders, bars, tablets, combined dosage forms such as sachets (single or multi-compartment), fibers, webs, or sheets. Detergent compositions may be in the form of liquids, gels, one or more granules, one or more sheets, one or more fibers, or combinations thereof.

[0107] The detergent composition may contain about 5% to about 76%, or about 8% to about 50%, or about 10% to about 40% of a concentrated surfactant composition by weight of the detergent composition. The detergent composition may contain a sufficient amount of the concentrated surfactant composition to provide the detergent composition with about 5% to about 80%, or about 8% to about 50%, or about 10% to about 30% of the surfactant by weight of the detergent composition.

[0108] Detergent compositions may contain detergent auxiliaries. Any suitable detergent auxiliaries may be added. Detergent auxiliaries may be selected from additional surfactants, structural agents, builders, fabric softeners, polymers or oligomers, enzymes, enzyme stabilizers, bleaching systems, brighteners, colorants, chelating agents, defoamers, conditioning agents, wetting agents, fragrances, fragrance microcapsules, fillers or carriers, alkaline systems, pH control systems, buffer solutions, alkanolamines, and mixtures thereof.

[0109] Detergent additives may contain additional surfactants. These additional surfactants may be selected from anionic surfactants, nonionic surfactants, amphoteric surfactants, cationic surfactants, and combinations thereof. Suitable anionic surfactants may include additional LAS or branched anionic surfactants. Suitable nonionic surfactants may include ethoxylated alcohol surfactants. Suitable amphoteric surfactants may include amine oxides.

[0110] Method for manufacturing concentrated surfactant compositions

[0111] This disclosure relates to a method for manufacturing the concentrated surfactant compositions disclosed herein. The step may include the following steps: providing an anionic alkylalkoxylated sulfate surfactant (optionally anionic sulfonated surfactant), a rheology modifier selected from alkoxylated amines (preferably alkoxylated polyamines, more preferably quaternized or non-quaternized alkoxylated polyethyleneimines, wherein the alkoxylated polyalkylimine has a polyalkylimine core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkylimine core), and an ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer (where x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70). The composition comprises: an anionic alkylalkoxylated sulfate surfactant and, optionally, an anionic sulfonated surfactant, in an amount of about 70% to about 90% by weight of the composition, and wherein the anionic alkylalkoxylated sulfate surfactant is present in an amount of about 50% to about 100% by weight of the surfactant system; a rheology modifier of about 0.1% to about 25% by weight of the composition; not more than 5% of an amino-free organic solvent; and water.

[0112] The method may include the following steps: providing anionic alkylalkoxylated sulfate surfactant, a rheology modifier selected from alkoxylated amines (preferably alkoxylated polyamines, more preferably quaternized or non-quaternized alkoxylated polyethyleneimines, wherein the alkoxylated polyalkylimine has a polyalkylimine core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkylimine core), and an ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer. The composition comprises: a polymer (where x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70), and mixtures thereof; an organic solvent optionally free of amino functional groups; and water; and the components are combined in the following proportions to form a concentrated surfactant composition: about 70% to about 90% by weight of the composition of anionic alkylalkoxylated sulfate surfactant; about 0.1% to about 10% by weight of the composition of a rheology modifier; not more than 5% by weight of an amino-free organic solvent; and water.

[0113] This method may include providing a pre-neutralized form, preferably pre-neutralized with sodium (e.g., via sodium hydroxide), of an alkylalkoxylated sulfate surfactant and / or a linear alkylbenzene sulfonate surfactant. The method may include the step of combining the alkylalkoxylated sulfate surfactant and / or the linear alkylbenzene sulfonate surfactant with an alkalizing agent to pre-neutralize one or more surfactants before combination with an organic solvent system. The alkalizing agent (e.g., sodium hydroxide) combined with one or more surfactants may be at least about 50% by weight active, or at least about 60% by weight active, or at least about 70% by weight active. A higher active concentration of the alkalizing agent generally means adding a smaller amount of water to the concentrated surfactant composition, thereby leaving more formulation space for the active ingredient (e.g., more surfactant) and / or other processing aids.

[0114] The composition may contain a small excess of an alkalizing agent, preferably a caustic alkalizing agent such as sodium hydroxide, above which the surfactant needs to be neutralized, regardless of whether the surfactant is provided as pre-neutralized. Therefore, a concentrated surfactant composition may contain about 0.1% to about 1% by weight of an alkalizing agent, preferably a caustic alkalizing agent such as sodium hydroxide. Pre-neutralization of the surfactant may be desirable to allow for more effective pH control.

[0115] A method for manufacturing a concentrated surfactant composition according to this disclosure may include a step of removing water from an intermediate concentrated composition. Removing water provides a more concentrated surfactant composition, thereby improving the efficiency of transport, processing, and / or product preparation. Water can be removed by any suitable method, such as by using a wet film evaporator. Other removal methods may include, but are not limited to, distillation, rotary evaporation, bubbling, and freeze drying. In the water removal step, the amount of water present in the intermediate composition may differ (e.g., decrease) by at least 5%, or at least 10%, or at least 20%, or at least 30%, or at least 40%, or at least 50% compared to the amount of water present in the final concentrated surfactant composition.

[0116] Method for manufacturing a detergent composition

[0117] This disclosure relates to a method for manufacturing a detergent composition. The detergent composition may be in any form suitable as an intermediate detergent component or for end-use by a consumer, such as liquid, gel, powder, rod, tablet, combined dosage form such as sachets (single or multi-compartment), fiber, mesh, or sheet.

[0118] The method may include the following steps: providing a concentrated surfactant composition as described herein, and combining the concentrated surfactant composition with at least one auxiliary agent to form a detergent composition.

[0119] The concentrated surfactant compositions disclosed herein can be used as surfactant intermediates that can be incorporated into detergent compositions for various end uses. Therefore, this disclosure relates to a method for manufacturing multiple detergent compositions, the method comprising the steps of: providing a first portion of a concentrated surfactant composition as described herein; combining the first portion with a first detergent auxiliary to form a first detergent composition; providing a second portion of the concentrated surfactant composition as described herein; and combining the second portion with a second detergent auxiliary to form a second detergent composition that is compositionally different from the first detergent composition. For the method described herein, the concentrated surfactant composition may be provided in a single batch and then divided into the first and second portions, but this is not necessary. The first and second portions may be provided as separate batches, manufactured at separate locations or at separate times.

[0120] The second detergent composition may differ from the first detergent composition in the following ways: the amount of additives, the relative proportions of the additives and / or concentrated surfactant composition, pH, aesthetics (including color and / or fragrance), or any other suitable compositional differences.

[0121] Use of rheology modifiers

[0122] This disclosure also relates to the use of the rheology modifier described above, preferably alkoxylated polyalkylene imine, for reducing the viscosity of concentrated surfactant compositions, wherein the composition comprises about 70% to about 90% by weight of anionic alkylalkoxylated sulfate surfactant, preferably anionic alkylethoxylated sulfate surfactant.

[0123] This disclosure also relates to the use of the rheology modifier described above, preferably an alkoxylated polyalkylene imide, for reducing the viscosity of a concentrated surfactant composition, wherein the composition comprises about 70% to about 90% by weight of a surfactant system, wherein the surfactant system comprises about 50% to about 100% of anionic alkylalkoxylated sulfate surfactant. The surfactant system may also comprise about 1% to about 50% by weight of anionic sulfonated surfactant, preferably an alkylbenzene sulfonate surfactant, more preferably a linear alkylbenzene sulfonate surfactant.

[0124] Suitable compositions and their components are described in more detail above.

[0125] combination

[0126] The specific combinations contemplated in this disclosure are described herein in paragraphs indicated by the following letters. These combinations are illustrative in nature and not limiting.

[0127] A. A concentrated surfactant composition comprising: about 70% to about 90% by weight of the composition of a surfactant system comprising about 50% to about 100% of anionic alkylalkoxylated sulfate surfactant; about 0.1% to about 25% by weight of the composition of a rheology modifier selected from alkoxylated amines (preferably alkoxylated polyamines, more preferably quaternized or non-quaternized alkoxylated polyethyleneimines, wherein the alkoxylated polyalkylimine has a polyalkylimine core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkylimine core), ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymers (where x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about 15 to about 70), and mixtures thereof; no more than about 5% by weight of the composition of an amino-free organic solvent; and water.

[0128] B. The concentrated surfactant composition according to paragraph B, wherein the rheology modifier is an alkoxylated amine comprising an ethoxylated (EO) group, a propoxylated (PO) group, or a combination thereof, preferably an ethoxylated (EO) group.

[0129] C. A concentrated surfactant composition according to any one of paragraphs A to B, wherein the alkoxylated amine comprises alkoxylated polyalkylene imine.

[0130] D. A concentrated surfactant composition according to any one of paragraphs A to C, wherein the alkoxylated polyalkylene imine comprises about 1 to 50 ethoxylated (EO) groups and about 0 to 5 propoxylated (PO) groups on average per alkoxylated nitrogen.

[0131] E. A concentrated surfactant composition according to any one of paragraphs A to D, wherein the alkoxylated polyalkylene imine comprises about 1 to 50 ethoxylated (EO) groups on average per alkoxylated nitrogen and is free of propoxylated (PO) groups.

[0132] F. A concentrated surfactant composition according to any one of paragraphs A to E, wherein the alkoxylated polyalkylene imine comprises about 10 to 30 ethoxylated (EO) groups, preferably about 15 to 25 ethoxylated (EO) groups, on average per alkoxylated nitrogen.

[0133] G. A concentrated surfactant composition according to any one of paragraphs A to F, wherein the alkoxylated polyalkylene imide is alkoxylated polyethyleneimine (PEI).

[0134] H. A concentrated composition according to any one of paragraphs A to G, wherein the alkoxylated PEI comprises a polyethyleneimine backbone having a weight-average molecular weight of about 400 to about 1000, or about 500 to about 750, or about 550 to about 650, or about 600, as determined prior to ethoxylation.

[0135] I. A concentrated surfactant composition according to any one of paragraphs A to H, wherein the alkoxylated amine is present in an amount of about 1% to about 15%, preferably about 2% to about 12%, preferably about 4% to about 8% by weight of the concentrated composition.

[0136] J. A concentrated surfactant composition according to any one of paragraphs A to I, wherein the alkoxylated amine is non-quaternized.

[0137] K. A concentrated surfactant composition according to any one of paragraphs A to J, wherein the alkylalkoxylated sulfate surfactant is an alkylethoxylated surfactant, which preferably has an average degree of ethoxylation of about 1 to about 3.5, more preferably about 1 to about 3, and even more preferably about 1 to about 2.

[0138] L. A concentrated surfactant composition according to any one of paragraphs A to K, wherein the alkyl alkoxylated sulfate has an average alkyl chain length of about 10 to about 16 carbon atoms, preferably about 12 to about 15 carbon atoms, and even more preferably about 14 to about 15 carbon atoms.

[0139] M. A concentrated surfactant composition according to any one of paragraphs A to L, wherein the composition comprises about 75% to about 85%, preferably about 77% to about 82% of a surfactant system by weight of the composition.

[0140] N. A concentrated surfactant composition according to any one of paragraphs A to M, wherein the composition comprises less than 3%, preferably less than 2%, preferably less than 1%, preferably about 0% by weight of the composition an amino-free organic solvent.

[0141] O. A concentrated surfactant composition according to any one of paragraphs A to N, wherein the organic solvent is selected from: monohydric alcohols; dihydric alcohols; polyalkylene glycols; polyhydric alcohols; alkoxylated glycerols; alkoxylated diols; and combinations thereof.

[0142] P. A concentrated surfactant composition according to any one of paragraphs A to O, wherein the organic solvent system comprises a solvent selected from the group consisting of glycerol, ethanol, propylene glycol, diethylene glycol, dipropylene glycol, polyalkylene glycol, butanediol, and combinations thereof.

[0143] Q. The concentrated surfactant composition according to any one of paragraphs A to P, wherein when at 60°C for 1000 s -1 When measured, the composition has a viscosity of less than about 3,000 cps, or about 100 cps to about 2,000 cps, or about 300 cps to about 1,500 cps, or about 400 cps to about 1,000 cps, as determined by the shear viscosity test method described herein.

[0144] R. A concentrated surfactant composition according to any one of paragraphs A to Q, wherein the composition remains a single-phase solution after two weeks at 20°C and / or after two weeks at 40°C.

[0145] S. A concentrated surfactant composition according to any one of paragraphs A to R, wherein the composition is substantially free of fatty acids and / or their salts, preferably substantially free of carboxylic acids and / or their salts.

[0146] T. A concentrated surfactant composition according to any one of paragraphs A to S, wherein the composition is characterized by an alkaline pH, preferably greater than 8, or greater than 9, or greater than 10, or greater than 11 in a 10% (weight / volume) solution of the composition at 20°C ± 2°C.

[0147] U. A concentrated surfactant composition according to any one of paragraphs A to T, wherein the composition is characterized by having a reserve alkalinity of less than about 2, or less than about 1.5, or less than about 1, or less than about 0.8.

[0148] V. A concentrated surfactant system according to any one of paragraphs A to U, wherein the anionic alkyl alkoxylated sulfate surfactant is neutralized by a caustic agent, preferably a metal hydroxide, more preferably sodium hydroxide.

[0149] W. A concentrated surfactant composition according to any one of paragraphs A to V, wherein the surfactant system further comprises about 1% to about 50% by weight of an anionic sulfonated surfactant, preferably an alkylbenzene sulfonate surfactant, more preferably a linear alkylbenzene sulfonate surfactant.

[0150] X. A concentrated surfactant composition according to any one of paragraphs A to W, wherein the surfactant system comprises about 10% to about 40%, preferably about 20% to about 35% by weight of the surfactant system, an anionic sulfonated surfactant, preferably an alkylbenzene sulfonate surfactant, more preferably a linear alkylbenzene sulfonate surfactant.

[0151] Y. A detergent composition comprising a concentrated surfactant composition and detergent additives according to any one of paragraphs A to X.

[0152] Z. The detergent composition according to paragraph Y, wherein the detergent auxiliaries are selected from additional surfactants, structural agents, washing aids, fabric softeners, polymers or oligomers, enzymes, enzyme stabilizers, bleaching systems, brighteners, colorants, chelating agents, defoamers, conditioning agents, humectants, fragrances, fragrance microcapsules, fillers or carriers, alkaline systems, pH control systems, buffer solutions, alkanolamines, and mixtures thereof.

[0153] AA. A detergent composition according to any one of paragraphs Y to Z, wherein the detergent composition has a form selected from liquid, gel, granules, sheet, fiber, or combinations thereof.

[0154] BB. A method for manufacturing a concentrated surfactant composition, the method comprising the steps of: providing an anionic alkylalkoxylated sulfate surfactant (optionally anionic sulfonated surfactant), a rheology modifier selected from alkoxylated amines (preferably alkoxylated polyamines, more preferably quaternized or non-quaternized alkoxylated polyethyleneimines, wherein the alkoxylated polyalkylimine has a polyalkylimine core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkylimine core), and an ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer (where x1 and x2 are each in the range of about 2 to about 140, and y is in the range of about... The composition comprises: (15 to 70%), mixtures thereof, optionally an amino-free organic solvent, and water; and the components are combined in the following proportions to form a concentrated surfactant composition: a sufficient amount of anionic alkylalkoxylated sulfate surfactant and optionally anionic sulfonated surfactant to form a surfactant system, wherein the surfactant system is present in an amount of about 70% to about 90% by weight of the composition, and wherein the anionic alkylalkoxylated sulfate surfactant is present in an amount of about 50% to about 100% by weight of the surfactant system; about 0.1% to about 25% by weight of the composition of a rheology modifier; not more than 5% of an amino-free organic solvent; and water.

[0155] CC. A method for manufacturing a detergent composition, the method comprising the steps of: providing a concentrated surfactant composition according to any one of paragraphs A to X; and combining the concentrated surfactant composition with a detergent additive to form a detergent composition.

[0156] DD. Alkoxylated polyalkylene imide, preferably alkoxylated polyalkylene imide for use in reducing the viscosity of concentrated surfactant compositions, wherein the composition comprises about 70% to about 90% by weight of a surfactant system, wherein the surfactant system comprises about 50% to about 100% of anionic alkylalkoxylated sulfate surfactant.

[0157] EE. A concentrated surfactant composition according to any one of paragraphs A to X, wherein the rheology modifier further comprises polyethylene glycol, wherein the polyethylene glycol has a weight-average molecular weight of about 2,000 Daltons to about 8,000 Daltons.

[0158] FF. A concentrated surfactant composition according to any one of paragraphs A to X, wherein the ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer has an average propylene oxide chain length of 20 to 70, preferably 30 to 60, more preferably 45 to 55 propylene oxide units.

[0159] GG. A concentrated surfactant composition according to any one of paragraphs A to X, wherein the ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer has a weight-average molecular weight of 1,000 Daltons to 15,000 Daltons, preferably 1,500 Daltons to 5,000 Daltons, more preferably 2,000 Daltons to 4,500 Daltons, even more preferably 2,500 Daltons to 4,000 Daltons, and most preferably 3,500 Daltons to 3,800 Daltons.

[0160] HH. A concentrated surfactant composition according to any one of paragraphs A to X, wherein each ethylene oxide block or chain of the ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer independently has an average chain length of 2 to 90, preferably 3 to 50, and more preferably 4 to 20 ethylene oxide units.

[0161] II. A concentrated surfactant composition according to any one of paragraphs A to X, wherein the ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer comprises 10% to 90%, preferably 15% to 50%, and most preferably 15% to 25% of a combination of ethylene oxide blocks based on the weight of the copolymer.

[0162] JJ. A concentrated surfactant composition according to any one of paragraphs A to X, wherein the total ethylene oxide content of the ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer is equally distributed across two ethylene oxide blocks, preferably each ethylene oxide block contains an average of 40% to 60%, more preferably 45% to 55%, even more preferably 48% to 52%, and most preferably 50% of the total number of ethylene oxide units, wherein the combined percentage of the two ethylene oxide blocks reaches 100%.

[0163] KK. A concentrated surfactant composition according to any one of paragraphs A to X, wherein the ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer has a weight-average molecular weight of 3500 Daltons to 3800 Daltons, an ethylene oxide content of 45 to 55 propylene oxide units, and an ethylene oxide content of 4 to 20 ethylene oxide units per ethylene oxide block.

[0164] Test methods

[0165] Shear viscosity test method

[0166] The shear viscosity test method is used to measure the change of shear viscosity of a fluid sample with shear rate.

[0167] Viscosity tests were performed on a TA Instruments Discovery HR-3 rheometer equipped with a 40 mm diameter parallel plate geometry, using Peltier plates. The instrument was controlled via Trios software provided by TA Instruments. A nominal gap of 1.0 mm was used. The sample was placed in the center of the lower plate, and then the upper plate was lowered to contact the material, while maintaining the gap at approximately 1.0 mm. Excess material was then trimmed to ensure consistent sample volume. After equilibration to 25°C and holding for 1 minute, the test continued. The instrument was programmed to increase stress and measure the resulting viscosity stepwise. TA software refers to this as flow purging, and the process was performed over 5 seconds at a stress range from 0.1 Pa to 1000 Pa in logarithmic format (5 points per decimal). The test was conducted at 25°C, controlled via a Peltier plate temperature control unit used as the lower plate. In the Trios software, motor mode was set to automatic, and equilibration and averaging times were set to 45 seconds and 15 seconds, respectively.

[0168] Once the upper stress limit is reached, the test is complete. At this point, the instrument stops, and the user removes the sample and cleans the fixture. The data is then plotted as a curve of viscosity (Pa-s) versus stress (Pa). The results are reported as the viscosity value measured at 1 Pa.

[0169] Transmission percentage

[0170] Transmittance percentage is measured using a UV-Vis spectrophotometer such as the Beckman Coulter DU. ® Measured at 800°C. Samples were measured using standard 10mm path length cuvettes and compared with a deionized water blank. Samples were measured in the absence of dyes and / or opacifiers and at a temperature of 20°C ± 2°C.

[0171] pH

[0172] Unless otherwise stated herein, the pH of the composition is defined as the pH of a 10% (w / v) aqueous solution of the composition at 20°C ± 2°C. Any measuring instrument capable of measuring pH to ±0.01 pH units is suitable. An Orion measuring instrument (Thermo Scientific, Clintinpark – Keppekouter, Ninovesteenweg 198, 9320 Erembodegem – Aalst, Belgium) or equivalent is acceptable. The pH meter should be equipped with a suitable glass electrode with a calomel or silver / silver chloride reference. An example includes the Mettler DB 115. The electrode should be stored in the electrolyte solution recommended by the manufacturer.

[0173] Prepare a 10% detergent aqueous solution according to the following procedure. Weigh 10 g ± 0.05 g of the sample using a balance accurate to ± 0.02 g. Transfer the sample to a 100 mL volumetric flask, dilute to the mark with purified water (deionized and / or distilled water is suitable, provided the conductivity of the water is < 5 µS / cm), and mix thoroughly. Pour approximately 50 mL of the resulting solution into a beaker, adjust the temperature to 20 °C ± 2 °C, and measure the pH according to the pH meter manufacturer's standard procedure. The pH unit should be set and calibrated according to the manufacturer's instructions.

[0174] Reserve alkalinity

[0175] As used herein, the term "reserve alkalinity" is a measure of the buffering capacity of a detergent composition (g / NaOH / 100g detergent composition), determined by titrating a 1% (w / v) solution of the detergent composition with hydrochloric acid to pH 7.5. That is, to calculate the reserve alkalinity as defined herein:

[0176] The reserve alkalinity (up to pH 7.5) is calculated as alkali % per g NaOH / 100g product.

[0177] T×M×40×Vol

[0178] 10×Wt×equal sample

[0179] T = Titration volume (ml) up to pH 7.5

[0180] M = molar concentration of HCl = 0.2

[0181] 40 = Molecular weight of NaOH

[0182] Vol = Total volume (i.e., 1000ml)

[0183] Wt = Product weight (10g)

[0184] Equal portions of sample = (100ml)

[0185] Obtain a 10g sample of the fully formulated detergent composition, accurately weighed to two decimal places. The sample should be obtained using a Pascall sampler in a dust cabinet. Add 10g of the sample to a plastic beaker and add 200ml of carbon dioxide-free deionized water. On a stirring table, use a magnetic stirrer at 150rpm until completely dissolved and stir for at least 15 minutes. Transfer the contents of the beaker to a 1L volumetric flask and bring the volume to 1L with deionized water. Mix thoroughly and immediately use a 100ml pipette to take an aliquot of 100ml ± 1ml. Using a pH meter capable of reading to ±0.01 pH units, measure and record the pH and temperature of the sample, stirring to ensure the temperature is 21℃ ± 2℃. Titrate with 0.2M hydrochloric acid while stirring until the pH is accurately measured to be 7.5. Record the volume of hydrochloric acid used. Take the average titer from three identical replicates. Perform the above calculations to calculate the RA up to pH 7.5.

[0186] Example

[0187] The examples provided below are intended to be illustrative in nature and not to be limiting. Unless otherwise specified, ingredient contents are provided in weight percent.

[0188] Example 1. Method for preparing concentrated surfactant compositions .

[0189] Ethoxylated alcohols are provided. Ethoxylated alcohols are sulfated by known methods to form alkyl ethoxylated sulfate surfactants, a method comprising a sulfation reactor and a neutralization loop. In addition to the sulfated alcohol, the following substances are added to the neutralization loop while being mixed under high shear: optionally an organic solvent, ethoxylated PEI, optionally water, and a neutralizing agent. The neutralization method is exothermic, thus generating heat, which is preferably removed by a heat exchanger in the recirculating neutralization loop. Due to the heat exchanger, the temperature can drop by at least 5°C or at least 10°C, for example from about 70°C to about 60°C. The effectiveness of the heat exchanger depends on the viscosity of the surfactant paste; if the viscosity is too high, the pressure drop across the entire heat exchanger may become excessive. Viscosity can be reduced by adding water; however, adding water is undesirable for the preparation of solid dosage form detergents. Alternatively, viscosity can be reduced by adding ethoxylated PEI to the neutralization loop; this allows the paste to be neutralized with minimal water content.

[0190] Alternatively or otherwise, ethoxylated PEI may be added after the neutralization loop, with an additional high-shear mixing step. Ethoxylated PEI may be added as, for example, a concentrated aqueous solution with a solid concentration of about 80%, or as a substantially anhydrous liquid hot melt.

[0191] Water can be further removed from the paste composition, for example, using a wet film evaporator within or after the neutralization loop.

[0192] Example 2. Viscosity of concentrated surfactant paste .

[0193] The viscosity of several concentrated surfactant paste compositions was measured; some of the pastes can be used to prepare particles according to this disclosure, and some can be used to prepare comparative particles.

[0194] Preparation of surfactant paste The surfactant paste composition was prepared as follows: The selected rheology modifier and water were added to a scintillation vial and mixed until the rheology modifier was completely dissolved to form a rheology modifier solution; the rheology modifier solution was combined with an ethoxylated alkyl sulfate (AES) solution (AES dissolved in water to the desired concentration, e.g., 21.95%) and sodium carbonate, and mixed using a high-speed mixing cup at 3500 rpm for 30 seconds in a FlakTek DAC 500 high-speed mixer; the mixture was then transferred to a wide-mouth glass flask and allowed to stand for 24 hours to degas the mixture.

[0195] In the examples below, 69.2 g of AES solution (21.95% active material) was added to 8.1 g of PEG 4000 solution (30% active material, PEG 4000 dissolved in water to provide 30% activity) and 2.8 g of sodium carbonate. The actual weight fraction of each material is listed in the rightmost column of the table.

[0196]

[0197] The shear viscosity of each paste was measured using the shear viscosity test method described herein, and the viscosity is reported as an average of the values ​​obtained under low stress. Shear viscosities are shown in the table below. Rheology modifiers marked with an asterisk (*) are shown as having reduced viscosity; however, these rheology modifiers typically do not provide detergent functionality.

[0198]

[0199] 1 Ethoxylated polyethyleneimine (polyethyleneimine (600MW), 20 ethoxylates per NH4+)

[0200] 2 Bifunctional block copolymers terminated with primary hydroxyl groups

[0201] 3 Polysorbate 20

[0202]

[0203] Example 3. Concentrated surfactant paste containing anionic surfactant and rheology modifier .

[0204] The following shows a sample formulation of a concentrated surfactant composition. Amounts are provided as a weight percentage of the composition. Ingredients include: AES = alkoxylated alkyl sulfate anionic detergency surfactant, neutralized with sodium; LAS = alkylbenzene sulfonate surfactant, neutralized with sodium; rheology modifier = PE 20, ethoxylated polyethyleneimine; miscellaneous items include excess alkalinity, salts, and unreacted alcohols.

[0205]

[0206] The dimensions and values ​​disclosed herein should not be construed as strictly limited to the precise numerical values ​​cited. Rather, unless otherwise specified, each such dimension is intended to represent the stated value and the range around which it is functionally equivalent. For example, the disclosed dimension “40mm” is intended to mean “approximately 40mm”.

[0207] Unless expressly excluded or otherwise limited, every reference cited herein, including any cross-references or related patents or patent applications, and any patent application or patent claiming priority to or benefiting from it, is incorporated herein by reference in its entirety. Reference to any reference is not an endorsement of it as prior art to any disclosed or protected art herein, nor is it an endorsement of any such invention, either on its own or in combination with any one or more references. Furthermore, where any meaning or definition of a term in this invention conflicts with any meaning or definition of the same term in referenced documents, the meaning or definition given to that term in this invention shall prevail.

[0208] While specific embodiments of the invention have been illustrated and described by way of example, it will be apparent to those skilled in the art that many other changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, it is intended that all such changes and modifications falling within the scope of the invention be covered by the appended claims.

Claims

1. A concentrated surfactant composition, said concentrated surfactant composition comprising: The surfactant system comprises 70% to 90% by weight of the concentrated surfactant composition. The surfactant system comprises 50% to 100% anionic alkylalkoxylated sulfate surfactants; 0.1% to 25% by weight of the concentrated surfactant composition of the above-mentioned rheology modifier, the rheology modifier being selected from N,N,N',N'-tetra(2-hydroxyethyl)ethylenediamine; alkoxylated polyethyleneimine, and mixtures thereof, wherein the alkoxylated polyalkylimine has a polyalkylimine core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkylimine core; ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer, wherein x1 and x2 are each in the range of 2 to 140, and y is in the range of 15 to 70; and mixtures thereof; No more than 5% by weight of an amino-free organic solvent based on the concentrated surfactant composition; and water, The concentrated surfactant composition is used to prepare a detergent composition by combining the concentrated surfactant composition with a detergent additive, the detergent composition comprising 8% to 50% of the surfactant system by weight of the detergent composition.

2. The concentrated surfactant composition according to claim 1, wherein the alkoxylated polyalkylimide comprises, on average, 1 to 50 ethoxylated (EO) groups and 0 to 5 propoxylated (PO) groups on each alkoxylated nitrogen.

3. The concentrated surfactant composition according to claim 1, wherein the alkoxylated polyalkylimide comprises, on average, 1 to 50 ethoxylated (EO) groups on each alkoxylated nitrogen and is free of propoxylated (PO) groups.

4. The concentrated surfactant composition according to any one of the preceding claims, wherein the alkoxylated polyalkylimide comprises an average of 10 to 30 ethoxylated (EO) groups on each alkoxylated nitrogen.

5. The concentrated surfactant composition according to any one of the preceding claims, wherein the alkoxylated polyalkylene imine comprises an average of 15 to 25 ethoxylated (EO) groups on each alkoxylated nitrogen.

6. The concentrated surfactant composition according to any one of the preceding claims, wherein the alkoxylated polyalkylene imide is alkoxylated polyethyleneimine (PEI), the alkoxylated PEI comprising a polyethyleneimine backbone having a weight-average molecular weight of 400 to 1000 as determined prior to ethoxylation.

7. The concentrated surfactant composition according to any one of the preceding claims, wherein the rheology modifier is present in an amount of 1% to 15% by weight of the concentrated surfactant composition.

8. The concentrated surfactant composition according to any one of the preceding claims, wherein the alkylalkoxylated sulfate surfactant is an alkylethoxylated surfactant.

9. The concentrated surfactant composition according to claim 8, wherein the alkyl ethoxylated surfactant has an average degree of ethoxylation of 1 to 3.

5.

10. The concentrated surfactant composition according to any one of the preceding claims, wherein the alkylalkoxylated sulfate has an average alkyl chain length of 10 to 16 carbon atoms.

11. The concentrated surfactant composition according to any one of the preceding claims, wherein the concentrated surfactant composition comprises 75% to 85% of the surfactant system by weight of the concentrated surfactant composition.

12. The concentrated surfactant composition according to any one of the preceding claims, wherein the concentrated surfactant composition comprises less than 3% by weight of the amino-free organic solvent of the concentrated surfactant composition.

13. The concentrated surfactant composition according to any one of the preceding claims, wherein the organic solvent is selected from: monohydric alcohols; dihydric alcohols; polyalkylene glycols; polyols; alkoxylated glycerols; alkoxylated diols; and combinations thereof.

14. The concentrated surfactant composition according to any one of the preceding claims, wherein the organic solvent system comprises a solvent selected from glycerol, ethanol, propylene glycol, diethylene glycol, dipropylene glycol, polyalkylene glycol, butanediol, and combinations thereof.

15. The concentrated surfactant composition according to any one of the preceding claims, wherein when at 60°C for 1000 s -1 When measured, the concentrated surfactant composition has a viscosity of less than 3,000 cps, or 100 cps to 2,000 cps, or 300 cps to 1,500 cps, or 400 cps to 1,000 cps, as determined by the shear viscosity test method described herein.

16. The concentrated surfactant composition according to any one of the preceding claims, wherein the surfactant system further comprises 1% to 50% by weight of an anionic sulfonated surfactant.

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