Solidification of liquid amine oxide, betaine, and / or sultaine surfactants using a binder and an optional carrier

Abstract

To provide a technique that solidifies liquid amine oxide, betaine, and / or sultaine surfactants with a binder to form a solidified surfactant composition.SOLUTION: Specifically, the invention relates to solidification of liquid surfactants utilizing drying device(s), wherein the feed composition contains at least one liquid surfactant and a binder, and an optional carrier, to form a solidified surfactant composition. The solidified surfactant compositions can be useful in various cleaning compositions.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Application No. 62 / 622,356, filed on January 26, 2018, the entire contents of which, including without limitation the figures, tables, examples, and claims, are incorporated herein by reference.

[0002] This application is related to U.S. Provisional Application No. 62 / 622,403, filed on January 26, 2018, and U.S. Patent Application No. 62 / 258,969 [Attorney Docket No. P12389US01], filed on January 28, 2019, both of which are entitled "SOLIDIFYING LIQUID AMINE OXIDE, BETAINE, AND / OR SULTAINE SURFACTANTS WITH A CARRIER", the entire contents of which, including without limitation the figures, tables, examples, and claims, are incorporated herein by reference.

[0003] The present disclosure relates to the solidification of liquid amine oxide, sultaine, and / or betaine surfactants using a binder and an optional carrier. Specifically, it relates to the solidification of liquid amine oxide, betaine, and sultaine surfactants using a drying device(s), and the feed composition contains at least one surfactant and a water - soluble binder.

Background Art

[0004] Many amine oxide, betaine, and sultaine surfactants are only available in liquid form. In order to make solid washing compositions, it is desirable for many of these surfactants to be provided in solid form. Since many of these surfactants are only available in liquid form, they cannot be easily incorporated into solid formulations or the active concentrations that can be included in the formulations are limited.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Attempts have been made in the past to include certain liquid surfactants in solid form, but most of these have not been successful for various reasons. It has not been possible to convert liquid amine oxides, betaines, and sultaines into solid surfactants while maintaining their effectiveness. The conversion results in less desirable performance of the solid cleaning composition. Another problem is that solidified amine oxides, betaines, and sultaines surfactants are often sticky and thus plagued by caking, compaction, and agglomeration, making packaging, storage, proper dosing, and dispersion in the manufacturing process difficult. In addition, some methods for solidifying liquid amine oxides, betaines, and sultaines require a significant amount of binder and / or carrier, thereby reducing the active concentration of the surfactant in the final product. Other efforts to solidify liquid surfactants are, for example, by using compounds that are not sufficiently water-soluble, such as fumed silica, which have a solubility of about 0.2 g / L or less at 20°C, and this is a problem both in formulation and in the final end-use, typically in water. Therefore, there is a need for improvement.

[0006] Accordingly, an object of the claimed invention is to develop solidified amine oxide, betaine, and / or sultaine compositions from liquid amine oxides, betaines, and / or sultaines, and methods for making them.

[0007] A further object of the invention is to provide solidified amine oxide, betaine, and / or sultaine compositions that are free-flowing.

[0008] A further object of the invention is to provide a cleaning composition comprising a solidified amine oxide, betaine, and / or sultaine composition.

[0009] Other objects, advantages, and features of the present invention will become apparent from the following specification in conjunction with the accompanying drawings.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

[0011] Various embodiments are described in detail with reference to the drawings. References to various embodiments are not intended to limit the scope of the invention. The figures presented herein are not intended to limit the various embodiments according to the invention, but are presented for illustrative explanation of the invention.

Modes for Carrying Out the Invention

[0012] The present disclosure relates to solidifying a liquid amine oxide, betaine, and / or sultaine surfactant with a binder and an optional carrier to form a solidified surfactant composition. The solidified surfactant composition has many advantages over existing formulations, including surfactants in certain types of solid formulations, including but not limited to pressed solids, that contain surfactants in a liquid form that interfere with or prevent their use. For example, many amine oxides, betaines, and sultaines are found in liquid form and there are currently limitations to commercially available solid actives. Conversion of the liquid surfactant to a solidified surfactant composition enables their use at higher concentrations in solid compositions and expands their usefulness in solid formulations. Unexpectedly, it has been found that the solidification of liquid amine oxide, betaine, and sultaine surfactants in the solidified surfactant composition provides substantially similar performance with respect to foaming and soil removal characteristics, which are indicators of good overall surfactant performance. This demonstrates the usefulness of the solidified surfactant composition in solid cleaning compositions, including but not limited to pressed solids.

[0013] Embodiments can vary and are not limited to specific methods and / or products understood by one of ordinary skill in the art. It is further understood that all technical terms used herein are for the purpose of merely describing particular embodiments and are not intended to be limiting in any way or scope. For example, as used herein and in the appended claims, the singular forms "a", "an", and "the" can include plural referents unless the context clearly dictates otherwise. Further, all units, prefixes, and symbols can be expressed in their SI certified forms.

[0014] The numerical ranges described in this specification include the numbers defining the range and each integer within the defined range. Throughout the present disclosure, various aspects of the invention are presented in a range format. The description in range format is for convenience and brevity only and should not be construed as a rigid limitation on the scope of the invention. It should be understood, therefore, that the description of a range is to be considered as specifically disclosing all the possible sub-ranges, fractions, and individual numerical values within that range. For example, a description of a range such as 1 to 6 is to be considered as specifically disclosing sub-ranges such as 1 to 3, 1 to 4, 1 to 5, 2 to 4, 2 to 6, 3 to 6, etc., as well as the individual numbers within the range, such as 1, 2, 3, 4, 5, and 6, and also the integers and fractions, such as 1.2, 3.8, 1 and 1 / 2, and 4 and 3 / 4. This applies regardless of the breadth of the range.

[0015] For a better understanding of the present invention, certain terms are first defined. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which embodiments of the present invention pertain. Many methods and materials similar to, modifications of, or equivalent to those described herein can be used in the practice of embodiments of the present invention without undue experimentation, and the preferred materials and methods are described herein. In describing and claiming embodiments of the present invention, the following specialized terms are used in accordance with the definitions set forth below.

[0016] As used herein, the term "about" refers to a variation in quantity that can be made, for example, through typical measurement techniques and equipment, with respect to any quantifiable variable, including but not limited to mass, volume, time, and distance. Further, given the handling procedures of solids and liquids used in the real world, there are certain inadvertent errors and variations likely due to differences in the manufacture, source, or purity of the components used to make a composition or carry out a method such as a process. The term "about" also encompasses different amounts resulting from different equilibrium conditions for a composition arising from a particular initial mixture. The term "about" also encompasses these variations. Whether or not modified by the term "about", the claims include equivalents to that quantity.

[0017] The terms "active substance", "percent active substance", "weight percent active substance", or "active substance concentration" are used interchangeably herein and refer to the concentration of the components involved in cleaning, expressed as a percentage after subtracting inert components such as water or salts.

[0018] As used herein, the term "alkyl" or "alkyl group" refers to a saturated hydrocarbon having one or more carbon atoms and includes straight-chain alkyl groups (e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, etc.), cyclic alkyl groups (or "cycloalkyl" or "alicyclic" or "carbocyclic" groups) (e.g., cyclopropyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, etc.), branched-chain alkyl groups (e.g., isopropyl, tert-butyl, sec-butyl, isobutyl, etc.), and alkyl-substituted alkyl groups (e.g., alkyl-substituted cycloalkyl groups and cycloalkyl-substituted alkyl groups).

[0019] Unless otherwise specified, the term "alkyl" includes both "unsubstituted alkyl" and "substituted alkyl". As used herein, the term "substituted alkyl" refers to an alkyl group having a substituent that replaces one or more hydrogens of one or more carbons of the hydrocarbon backbone. Such substituents can include, for example, alkenyl, alkynyl, halogeno, hydroxyl, alkylcarbonyloxy, arylcarbonyloxy, alkoxycarbonyloxy, aryloxy, aryloxycarbonyloxy, carboxylate, alkylcarbonyl, arylcarbonyl, alkoxycarbonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkylthiocarbonyl, alkoxyl, phosphate, phosphonate, phosphinato, cyano, amino (including alkylamino, dialkylamino, arylamino, diarylamino, and alkylarylamino), acylamino (including alkylcarbonylamino, arylcarbonylamino, carbamoyl, and ureido), imino, sulfhydryl, alkylthio, arylthio, thiocarboxylate, sulfate, alkylsulfinyl, sulfonate, sulfamoyl, sulfonamide, nitro, trifluoromethyl, cyano, azide, heterocyclic, alkylaryl, or aromatic (including heteroaromatic) groups.

[0020] In some embodiments, substituted alkyl can include a heterocyclic group. As used herein, the term "heterocyclic group" includes a closed-ring structure similar to a carbocyclic group in which one or more carbon atoms in the ring are elements other than carbon, such as nitrogen, sulfur, or oxygen. The heterocyclic group can be saturated or unsaturated. Exemplary heterocyclic groups include, but are not limited to, aziridine, ethylene oxide (epoxide, oxirane), thiirane (episulfide), dioxolane, azetidine, oxetane, thietane, dioxetane, dithietane, dithiete, azolidine, pyrrolidine, pyrroline, oxolane, dihydrofuran, and furan.

[0021] "Redeposition inhibitor" refers to a compound that helps to remain suspended in water instead of redepositing on the object being washed. Redeposition inhibitors are useful in the present invention to assist in reducing the redeposition of removed dirt on the surface being washed.

[0022] As used herein, the term "washing" refers to a method used to promote or assist in dirt removal, bleaching, reduction of the microbiota, and any combination thereof.

[0023] The term "laundry" refers to an item or article to be washed in a washing machine. Generally, laundry refers to any item or article made of or containing textile materials, woven fabrics, non-woven fabrics, and knitted fabrics. Textile materials can include natural or synthetic fibers such as silk fibers, linen fibers, cotton fibers, polyester fibers, polyamide fibers such as nylon, acrylic fibers, acetate fibers, and blends thereof including cotton and polyester blends. The fibers can be treated or untreated. Examples of treated fibers include those that have been flame-retardant treated. The term "linen" should be understood to be used in many cases to describe certain types of laundry items including bed sheets, pillowcases, towels, table linen, tablecloths, bathmops, and uniforms. The present invention additionally provides compositions and methods for treating surfaces including non-laundry items and hard surfaces such as dishes, glass, and other products.

[0024] As used herein, the term "polymer" generally includes, but is not limited to, homopolymers, copolymers such as block, graft, random and alternating copolymers, terpolymers, and higher order "x"-mers, and further includes their derivatives, combinations and blends. Further, unless specifically limited otherwise, the term "polymer" is intended to include all possible isomeric configurations of the molecules, including, but not limited to, isotactic, syndiotactic and random symmetries, and combinations thereof. Further, unless specifically limited otherwise, the term "polymer" is intended to include all possible geometric configurations of the molecules.

[0025] As used herein, the term "soil" or "stain" refers to non-polar oily substances, which may or may not contain certain substances such as mineral viscosities, sand, natural minerals, carbon black, graphite, kaolin, environmental dust, etc.

[0026] As used herein, the term "substantially free of" refers to a composition that either completely lacks the component or has a small amount of the component that does not affect the performance of the composition. The component may be present as an impurity or as a contaminant and must be less than 0.5% by weight. In another embodiment, the amount of the component is less than 0.1% by weight, and in yet another embodiment, the amount of the component is less than 0.01% by weight.

[0027] The term "threshold agent" refers to a compound that inhibits the crystallization of hard water ions derived from a solution but does not need to form a specific complex with the hard water ions. Examples of threshold agents include, but are not limited to, polyacrylates, polymethacrylates, olefin / maleic acid copolymers, etc.

[0028] As used herein, the term "articles" refers to tableware and cooking utensils, dinnerware, and other hard surfaces such as showers, sinks, toilets, bathtubs, countertops, windows, mirrors, transport vehicles, and floors. As used herein, the term "article washing" refers to the washing, rinsing, or flushing of articles. Ware also refers to plastic items. Examples of types of plastics that can be washed with the compositions according to the present invention include, but are not limited to, polypropylene polymer (PP), polycarbonate polymer (PC), melamine formaldehyde resin or melamine resin (melamine), acrylonitrile-butadiene-styrene polymer (ABS), and polysulfone polymer (PS). Other exemplary plastics that can be washed using the compounds and compositions of the present invention include polyethylene terephthalate (PET), polystyrene, and polyamide.

[0029] As used herein, the terms "water-soluble" and "water-miscible" mean that a constituent (e.g., a binder or a solvent) can be dissolved or dispersed in water at a concentration of greater than about 0.2 g / L, preferably greater than about 1 g / L, more preferably 10 g / L or more, and most preferably about 50 g / L or more at about 20°C.

[0030] The terms "weight percent", "wt-%", "percent by weight", "% by weight", and variations thereof, as used herein, refer to the concentration of a substance obtained by dividing the weight of the substance by the total weight of the composition and multiplying by 100. It is understood that, as used herein, terms such as "percent", "%", etc. are intended to be synonymous with "weight percent", "wt-%", etc.

[0031] The methods, systems, devices, and compositions of the present invention may include, consist essentially of, or consist of the components and ingredients of the present invention and other ingredients described herein. As used herein, "consisting essentially of" means that a method, system, device, and composition may include additional steps, components, or ingredients, provided that the additional steps, components, or ingredients do not materially alter the basic and novel characteristics of the claimed method, system, device, and composition.

[0032] Method for solidifying surfactant Drying as a process function is utilized to remove liquid from a liquid-solid system to produce a dry solid. The liquid removed is generally water, but other organic liquids may be removed via the drying process. The choice of drying device and / or configuration depends on the state of the feed stream, the desired form of the product, and the temperature sensitivity of the feed, in addition to general considerations of hydrodynamics, heat and mass transfer, chemical reaction rates, and gas-solid interactions. The choice of equipment depends on material properties, drying characteristics of the material, product quality, and dust / solvent recovery.

[0033] Drying devices are typically classified into three methods. First, the operating mode of the drying device / system is classified into batch drying or continuous drying. Generally, batch drying is adopted when the required production rate is a dried product of 500 pounds or less per hour. When a dried product of more than 500 pounds per hour is required, continuous drying is preferred. Second, drying devices are classified according to the mode of heat transfer for moisture removal. Direct heating dryers (also known as adiabatic or convective dryers) bring the material into contact with a high-temperature gas to evaporate and remove moisture. When used in a continuous operating mode, the air flow can be designed to be countercurrent, cocurrent, or cross-current to the material. Indirect heating dryers (also known as non-adiabatic dryers) provide heat through conduction and / or radiation from a high-temperature surface. These dryers can be operated under vacuum to lower the temperature at which moisture evaporates. Third, dryers can also be classified based on the degree of agitation of the material. The feed can be either stationary or fluidized. A good drying device provides a transition zone at the inlet to atomize the fluid or premix the fluid with recycled solids to improve the flow. When heat-sensitive solids are present, a dryer with precise temperature control and / or vacuum conditions may be preferred. As will be understood by those skilled in the art, in order to select an appropriate drying device, the solidification of surfactants and other useful detergent chemicals requires careful consideration and weighing of process variables.

[0034] In one embodiment of the present invention, the drying device is, for example, a continuous tunnel dryer, a rotary dryer, a vacuum dryer, a tower concentrator, a vibrating conveyor concentrator, a drum dryer, a screw conveyor dryer, a fluidized bed, a jet fluidized bed, a pneumatic conveyor, a spray dryer, or a combination thereof. The drying devices can be arranged in parallel or in series, and one or more drying devices will be included in one row. Preferred drying devices include, but are not limited to, spray dryers and fluidized beds (also referred to as fluid beds).

[0035] In one embodiment of the present invention, the solidified surfactant composition contains less than about 10% by weight of water, preferably less than about 5% by weight of water, more preferably less than about 1% by weight of water, and most preferably less than about 0.5% by weight of water.

[0036] In a preferred embodiment of the present invention, the method according to the claimed invention provides a dry composition comprising at least about 10% by weight, preferably at least about 25% by weight, preferably at least 40% by weight, more preferably at least 50% by weight of an active surfactant.

[0037] Spray drying In a preferred embodiment of the present invention, the solidification of liquid amine oxides, betaines, and sultaine surfactants is carried out using a spray dryer. The spray dryer is compatible with slurry or solution feeding and provides the evaporation desired for heat-sensitive materials and lightweight and porous products. In the configuration of the spray dryer, it may be necessary to check the pressure effects on the liquid feed and the solid product in order to dry without damaging the product. Generally, a liquid or slurry is fed into the process unit of the dryer and then sprayed as fine droplets into a hot air stream. Therefore, the feed composition needs to be able to withstand the pressure required for droplet formation. When entering the spray dryer, the evaporation of the liquid occurs rapidly, but the temperature of the product remains relatively low. The process selection and design also need to consider the gas-solid interaction. Specifically, the inlet and outlet conditions of the solid, as well as the flow rate and residence time, should be designed taking into account the diffusion rate and heat transfer rate.

[0038] In one embodiment of the present invention, the inlet temperature of the inlet feed ranges from about 20°C to about 250°C, preferably from about 100°C to about 250°C, more preferably from about 150°C to about 200°C. In a further embodiment of the present invention, the outlet temperature, aspirator, and pump speed depend on the decomposition of the surfactant while in the spray dryer.

[0039] The value of the outlet temperature can vary based on the decomposition temperature of the components in the solidifying surfactant composition. Thus, in certain embodiments, the temperature may be higher or lower than that described herein. However, in one embodiment of the present invention, the outlet temperature is less than about 150°C, more preferably from about 0°C to about 120°C, and most preferably from about 20°C to about 100°C.

[0040] Fluidized bed In a preferred embodiment of the present invention, the solidification of liquid sulfate and sulfonate surfactants is carried out using a fluidized bed, in which a dry powder is supplied to the bed to which the liquid is applied and then dried with a hot gas. Without wishing to be limited by a particular configuration or theory of the present invention, a fluidized bed dryer is composed of a fluidization chamber, in which wet particles are fluidized by a hot gas blown into a plenum chamber under the floor through a heater and then pass through a distribution plate that fluidizes the upper particles.

[0041] The fluidized bed can carry out an agglomeration process involving a solid binder and / or carrier, or a granulation process involving only liquid components. The agglomeration process uses liquid addition to bind particles from a powder feed to form larger particles of a desired size and composition. The granulation process, unlike the agglomeration process in that a powder feed is not required, rather, the granulation process is carried out by continuously spraying a liquid coating onto a seed material from the process and continuously coating and drying the liquid to form solid granules of a desired size and composition. Furthermore, it has been found that this process can be carried out without using a seed material or, in fact, without using the material within the bed. In one embodiment where there is no material in the bed at the start of the process, the process may begin by granulating to form a seed material and then can continue by agglomeration or further granulation.

[0042] The airflow velocity within the fluidized bed depends on the characteristics of the starting material, the drying rate, and the desired particle size, and is typically in the range of about 0.001 to about 1000 feet per second, preferably about 0.01 to about 500 feet per second, more preferably about 0.1 to about 100 feet per second, and most preferably about 1 to about 60 feet per second.

[0043] Preferably, the liquid flow rate is from about 0.001 lb / min / lb of bed material to about 0.15 lb / min / lb of bed material, more preferably from about 0.01 lb / min / lb of bed material to about 0.10 lb / min / lb of bed material. In one embodiment where the process is started without including seed material and without using starting material, since the starting bed material is zero, it should be understood that the liquid flow rate per minute per mass of bed material is initially not calculable. However, since material is added to the bed for the first granulation, there is bed material shortly after the process starts. In such an embodiment, the ratio of liquid added to the bed material is initially higher due to the low amount of bed material. For example, the preferred liquid flow rate when there is no starting material in the bed is from about 0.1 lb / min / lb of bed material to about 2 lb / min / lb of bed material, more preferably from about 0.5 lb / min / lb of bed material to about 1.5 lb / min / lb of bed material.

[0044] The atomizing air pressure within the fluidized bed can be from about 0 to about 100 psig per nozzle, preferably from about 1 to about 75 psig per nozzle, more preferably from about 10 to about 60 psig per nozzle.

[0045] Solidifying surfactant composition Many amine oxides, betaines, and sultaine surfactants are primarily available in liquid form. Many such surfactants are desirably provided in solid form. One embodiment of the present invention is found in solidified amine oxide, betaine, and / or sultaine surfactant compositions. Another embodiment of the present invention is found in a method for preparing solidified amine oxide, betaine, and sultaine surfactant surfactant compositions. The solidified surfactant composition includes a liquid amine oxide, betaine, and / or sultaine surfactant, and a binder. Optionally, the solidified surfactant composition may include a carrier and / or a co-surfactant, preferably in solid form. Additional components may be present depending on the desired properties of the solidified surfactant composition.

[0046] In one aspect of the present invention, a carrier is added to a drying device together with a binder to form a solidified surfactant composition. The liquid composition supplied to the selected drying device(s) of the present invention includes at least one liquid surfactant and a solid binder.

[0047] The solidified surfactant composition is preferably a powder. Preferred powder forms include, but are not limited to, agglomerated solids and granulated solids. Thus, in some embodiments, the solidified surfactant composition is an agglomerated solid or a granulated solid.

[0048] Binder Suitable binders can be liquid (aqueous or non-aqueous), semi-solid, or solid. The solidifying surfactant composition contains at least one binder. In one aspect of the present invention, the binder is a solid in the form of bricks, powders, granules, beads, and flakes. Preferably, the binder is dissolved and then dried with the liquid surfactant. Preferred binders include, but are not limited to, natural polymer urea, urea derivatives, organic salts (such as sodium acetate), inorganic salts (such as sodium salts and sulfates including magnesium sulfate and sodium sulfate), polyacrylates, PEGs, alkali metal carbonates (including, but not limited to, sodium carbonate, potassium carbonate, bicarbonates, sesquicarbonates, and mixtures thereof), and combinations thereof. Preferred natural polymers include, but are not limited to, polysaccharides and their derivatives (e.g., gums, cellulose, cellulose esters, chitin, chitosan, starch, chemically modified starch, and combinations thereof), proteins (e.g., zein, whey, gluten, collagen), lignin, natural rubber, and combinations thereof. Preferably, the PEG has a melting point of at least about 40 °C, more preferably from about 42 °C to about 100 °C. Preferred PEGs include PEG1450, PEG3350, PEG4000, PEG4600, and PEG8000.

[0049] The binder and the liquid surfactant can be added to a suitable drying device in suitable amounts to achieve a solidifying surfactant product. The amount of each component can depend on the specific liquid surfactant to be solidified, the binder used, and any other optional components that may also be included in the solidifying surfactant product. Preferably, the binder and the surfactant are in an active amount ratio of about 5:1 to about 1:30, or about 4:1 to about 1:15, or about 3:1 to about 1:10, or about 2:1 to about 1:2.

[0050] One of the ultimate aims of the present invention is to be able to incorporate a liquid surfactant into a solid detergent composition in solid form. Therefore, it is preferable that the surfactant has a high concentration or ratio with respect to the binder and other components in the solidified surfactant composition. However, this is limited by the desired physical characteristics of the solidified surfactant composition. For example, in a preferred embodiment of the present invention, the surfactant is a solid granule and not a paste. In another preferred embodiment of the present invention, the solidified surfactant composition has a reduced adhesiveness or is non-adhesive so that they are free-flowing and do not cake during storage.

[0051] Liquid surfactant Many surfactants are mainly available in liquid form. It is desirable that many such surfactants be provided in solid form. In one embodiment of the present invention, a liquid surfactant is added to a drying device together with a binder to form a solidified surfactant composition. Any suitable liquid surfactant can be included in the solidified surfactant composition. Preferred liquid surfactants include, but are not limited to, amine oxides, betaines, sultaines, and combinations thereof.

[0052] Amine oxide is a tertiary amine oxide corresponding to the general formula, [Chemical formula] wherein the arrow is the conventional representation of a semi-polar bond, R 1 , R 2 , and R 3 can be aliphatic, aromatic, heterocyclic, alicyclic, or a combination thereof. Generally, in detergent-related amine oxides, R 1 is an alkyl radical of about 8 to about 18 carbon atoms, and R 2 and R 3 are alkyl or hydroxyalkyl of 1 to 3 carbon atoms, or a mixture thereof, and R 2 and R 3 can be bonded to each other through, for example, an oxygen or nitrogen atom to form a ring structure, R4 is alkaline or a hydroxyalkylene group containing 2 to 3 carbon atoms, and n ranges from 0 to about 20.

[0053] Suitable amine oxides include those selected from coconut or tallow alkyldi-(lower alkyl) amine oxides, and specific examples thereof are dodecyldimethylamine oxide, tridecyldimethylamine oxide, tetradecyldimethylamine oxide, pentadecyldimethylamine oxide, hexadecyldimethylamine oxide, heptadecyldimethylamine oxide, octadecyldimethylamine oxide, dodecyldipropylamine oxide, tetradecyldipropylamine oxide, hexadecyldipropylamine oxide, tetradecyldibutylamine oxide, octadecyldibutylamine oxide, bis(2-hydroxyethyl)dodecylamine oxide, bis(2-hydroxyethyl)-3-dodecoxy-1-hydroxypropylamine oxide, dimethyl-(2-hydroxydodecyl)amine oxide, 3,6,9-trioctadecyldimethylamine oxide, and 3-dodecoxy-2-hydroxypropyldi-(2-hydroxyethyl)amine oxide.

[0054] Betaine and sultaine surfactants are examples of zwitterionic surfactants for use herein. The general formula of these compounds is as follows:

Chemical formula

[0055] More specific betaine structures include the following [Chemical formula] In the formula, R' contains an alkyl, alkenyl, or hydroxyalkyl radical having 8 to 18 carbon atoms with 0 to 10 ethylene oxide moieties and 0 to 1 glyceryl moiety, R'' is an alkyl or monohydroxyalkyl group containing 1 to 3 carbon atoms, and R''' is an alkylene, hydroxyalkylene or hydroxyalkylene having 1 to 4 carbon atoms. These surfactant betaines typically do not exhibit strong cationic or anionic characteristics at extreme pHs and also do not show a reduction in water solubility within their isoelectric ranges. Unlike "external" quaternary ammonium salts, betaines can coexist with anions. Examples of suitable betaines include coconut acylamidopropyldimethylbetaine, hexadecyldimethylbetaine, C12-14 acylamidopropylbetaine, C 8-14 acylamidohexyldiethylbetaine, 4-C 14-16 acylmethylamidodiethylammonio-1-carboxybutane, C 16-18 acylamidodimethylbetaine, C 12-16 acylamidopentanedietylbetaine, and C 12-16 acylmethylamidodimethylbetaine.

[0056] Suitable sultaines can include compounds having the formula (R(R 1 )2N + R 2 SO 3- wherein R is a C6-C 18 hydrocarbyl group, each R 1 is typically independently a C1-C3 alkyl, such as methyl, and R 2is a C1-C6 hydrocarbyl group, such as a C1-C3 alkylene or hydroxyalkylene group.

[0057] Carrier / Additional Components Optionally, in addition to the liquid surfactant and binder, a carrier or other solid material may be included to assist in solidification or add functionality to the dry surfactant composition. Examples of carriers include solid anionic surfactants, solid organic salts, and solid inorganic salts. Preferred anionic surfactants include, but are not limited to, alpha olefin sulfonates, linear alkyl sulfonates, alkyl sulfates, sodium lauryl sulfate, sodium alkyl sulfate, and combinations thereof. Preferred organic salts include, but are not limited to, alkali carbonates and alkali metal carbonates (such as sodium carbonate and magnesium carbonate), alkali acetates and alkali metal acetates (such as sodium acetate and magnesium acetate), and combinations thereof. Preferred inorganic salts include, but are not limited to, alkali sulfates and alkali metal sulfates (such as sodium sulfate and magnesium sulfate), sodium chloride, and combinations thereof. Preferably, the carrier is solid at room temperature, however, in use in a granulation process, it may be in a dissolved liquid form.

[0058] Water and / or water-miscible solvents Many of the liquid surfactants are in an aqueous medium and contain water content. Preferred aqueous media include water, water-miscible, hydrogen peroxide, and mixtures thereof. In one aspect of the invention, the solidified surfactant composition contains less than about 20% by weight of added water, preferably less than about 10% by weight of added water, more preferably less than about 5% by weight of added water, even more preferably less than about 1% by weight of added water, and most preferably less than about 0.5% by weight of added water. Added water refers to the amount of water added to the composition and does not include the amount of water present in other components such as the alkali source or surfactant. Preferably, the solidified surfactant composition contains less than about 20% by weight of total moisture, preferably less than about 10% by weight of total moisture, more preferably less than about 5% by weight of total moisture, even more preferably less than about 1% by weight of total moisture, and most preferably less than about 0.5% by weight of total moisture. Total moisture refers to the water added to the composition and the water present in other components such as the alkali source or surfactant. It should be understood that when some methods require more water than others, the amount of added water and total moisture can depend on the type of solid composition being prepared.

[0059] In another aspect of the invention, the method according to the claimed invention provides a liquid feedstock in which at least about 30%, preferably at least about 50%, more preferably at least about 65%, and most preferably at least about 85% results in a solidified surfactant composition. The liquid feed is in an amount by mass of the liquid material added to the drying device.

[0060] Solid cleaning composition The solidified surfactant composition of the present invention can be included in a solid cleaning composition. Such cleaning compositions include, but are not limited to, detergent compositions including, for example, dishwashing compositions and laundry compositions, rinse aids, and hard surface cleaning compositions. Exemplary embodiments of such compositions are provided in Tables 1-3 below. Such compositions are exemplary and not limiting; for example, other cleaning compositions can be prepared with the solidified surfactant composition of the present disclosure, and the cleaning compositions reflected below are provided as examples of preferred formulations.

Table 1

Table 2

Table 3

[0061] In embodiments of the present invention, additional components can be included in the solid cleaning composition. The additional components provide the desired properties and functionality to the composition. For the purposes of this application, the term "functional component" includes materials that provide beneficial properties in specific uses. Some specific examples of functional materials are considered in more detail below, but the specific materials considered are merely examples and a wide variety of other functional components may be used. For example, many of the functional materials considered below relate to cleaning, specifically materials used in fabric cleaning applications. However, other embodiments may include functional components for use in other applications. Examples of such functional materials include, depending on the desired characteristics and / or functionality of the composition, chelating agents / sequestering agents, bleaching agents or activators, bactericides / antimicrobial agents, activators, builders or fillers, anti-redeposition agents, optical brighteners, dyes, odorants or fragrances, preservatives, stabilizers, processing aids, corrosion inhibitors, fillers, solidifying agents, hardening agents, solubility modifiers, pH adjusters, humectants, hydrotropes, or a wide variety of other functional materials. In the context of some embodiments disclosed herein, functional materials or components are optionally included within the solid cleaning composition for their functional properties. Some more specific examples of functional materials are considered in more detail below, but it should be understood by those skilled in the art and others that the specific materials considered are given merely as examples and a wide variety of other functional materials may be used.

[0062] In one aspect of the present invention, some of the additional components described below can be included in the solid surfactant composition. Preferred additional components that can be incorporated into the solid surfactant composition include, but are not limited to, co-surfactants, dyes, and / or fragrances (odorants).

[0063] Acid source In some embodiments of the present invention, the cleaning composition may contain an acid source. Suitable acid sources can include organic and / or inorganic acids. Examples of suitable organic acids include, but are not limited to, carboxylic acids such as hydroxyacetic acid (glycolic acid), citric acid, formic acid, acetic acid, propionic acid, butyric acid, valeric acid, caproic acid, trichloroacetic acid, urea hydrochloride, and benzoic acid. Among them, organic dicarboxylic acids such as oxalic acid, malonic acid, gluconic acid, itaconic acid, succinic acid, glutaric acid, maleic acid, fumaric acid, adipic acid, and terephthalic acid are also useful according to the present invention. Any combination of these organic acids can also be used or combined with other organic acids that enable the proper formation of the composition of the present invention.

[0064] Inorganic acids useful according to the present invention include, among others, sulfuric acid, sulfamic acid, methylsulfamic acid, hydrochloric acid, hydrobromic acid, and nitric acid. These acids may also be used in combination with other inorganic acids or the organic acids described above. In a preferred embodiment, the acid is an inorganic acid.

[0065] In some embodiments of the present invention, the cleaning composition may have an acidic pH. In such an embodiment, the pH is preferably from 1 to 7. In another aspect of the present invention, an acid source may be included as a pH adjuster or neutralizing agent in the basic composition to achieve the desired pH.

[0066] Activator In some embodiments, the use of the composition may result in a cleaning composition having improved antibacterial or bleaching effects by adding a material that reacts with active oxygen to form an activated component. For example, in some embodiments, peracids or peracid salts are formed. For example, in some embodiments, tetraacetylethylenediamine may be included in the composition to react with active oxygen to form a peracid or peracid salt that functions as an antibacterial agent. Other examples of active oxygen activators include transition metals and their compounds, compounds containing carboxyl, nitrile, or ester moieties, or other such compounds known in the art. In one embodiment, the activator includes tetraacetylethylenediamine; transition metals; compounds containing carboxyl, nitrile, amine, or ester moieties; or mixtures thereof.

[0067] In some embodiments, the activator component may be included in the cleaning composition in an amount ranging from up to about 75 wt% of the cleaning composition, in some embodiments, from about 0.01 to about 20 wt%, or in some embodiments, from about 0.05 to 10 wt% of the cleaning composition. In some embodiments, the activator of the active oxygen compound combines with the active oxygen to form an antibacterial agent.

[0068] The activator may be attached to the solid cleaning composition by any of a variety of methods for attaching one solid cleaning composition to another. For example, the activator may be in solid form and is bonded, affixed, pasted, or adhered to the solid cleaning composition. Alternatively, the solid activator may be formed around and may encompass the solid cleaning composition. As a further example, the solid activator may be attached to the solid cleaning composition by a container or packaging for the composition, such as by plastic or shrink wrap or film.

[0069] Alkali source The cleaning composition may include an effective amount of one or more alkali sources. The effective amount of one or more alkali sources should be considered as the amount that provides a composition having a pH of about 7 to about 14. In certain embodiments, the cleaning composition may have a pH of about 7.5 to about 13.5. During the cleaning cycle, the use solution may have a pH of about 6 to about 14. In certain embodiments, the use solution may have a pH of about 6 to 14. If the cleaning composition includes an enzyme composition, the pH may be adjusted to provide an optimal pH range for the effectiveness of the enzyme composition. In certain embodiments of the present invention incorporating an enzyme composition into the cleaning composition, the optimal pH is about 10 to about 11.

[0070] Examples of suitable alkali sources for the cleaning composition include, but are not limited to, carbonate-based alkali sources containing carbonates such as alkali metal carbonates, and caustic-based alkali sources containing alkali metal hydroxides. Other suitable alkali sources can include metal silicates, metal borates, and organic alkali sources. Exemplary alkali metal carbonates that can be used include, but are not limited to, sodium carbonate, potassium carbonate, bicarbonates, sesquicarbonates, and mixtures thereof. Exemplary alkali metal hydroxides that can be used include, but are not limited to, sodium hydroxide, lithium hydroxide, or potassium hydroxide. Exemplary metal silicates that can be used include, but are not limited to, sodium silicate or potassium silicate or sodium metasilicate or potassium metasilicate. Exemplary metal borates include, but are not limited to, sodium borate or potassium borate.

[0071] Organic alkali sources often include strong nitrogen bases such as ammonia (ammonium hydroxide), amines, alkanolamines, and amino alcohols. Typical examples of amines include primary, secondary, or tertiary amines and diamines carrying at least one nitrogen-bonded hydrocarbon group, which represent saturated or unsaturated linear or branched alkyl groups having at least 10 carbon atoms, preferably 16 - 24 carbon atoms, or aryl, aralkyl, or alkaryl groups containing up to 24 carbon atoms, and any other nitrogen-bonded group is optionally formed by a substituted alkyl group, aryl group, or aralkyl group or polyalkoxy group. Typical examples of alkanolamines include monoethanolamine, monopropanolamine, diethanolamine, dipropanolamine, triethanolamine, tripropanolamine, etc. Typical examples of amino alcohols include 2-amino-2-methyl-1-propanol, 2-amino-1-butanol, 2-amino-2-methyl-1,3-propanediol, 2-amino-2-ethyl-1,3-propanediol, hydroxymethylaminomethane, etc.

[0072] Generally, the alkali source is usually available in either aqueous or powder form. Preferably, the alkali source is in solid form. The alkalinity can be added to compositions in any form known in the art, including solid beads, granulated or particulate form dissolved in an aqueous solution, or combinations thereof.

[0073] Generally, it is expected that the cleaning composition will contain an alkali source in an amount of about 0.01 wt% to about 99 wt%. In some embodiments, the alkali source will be about 35 wt% to about 95 wt% of the total weight of the cleaning composition. When diluted in a use solution, the composition of the present invention can contain about 5 ppm to about 25,000 ppm of the alkali source.

[0074] Anti-redeposition agent The cleaning composition may optionally include an anti-redeposition agent capable of promoting the persistent suspension of dirt in the cleaning or rinsing solution and preventing the redeposition of the removed dirt onto the cleaned and / or rinsed material. Some examples of suitable anti-redeposition agents may include fatty acid amides, fluorocarbon surfactants, complex phosphoric acid esters, styrene maleic anhydride copolymers, and cellulose derivatives such as hydroxyethyl cellulose and hydroxypropyl cellulose. The cleaning composition may contain up to about 10% by weight, and in some embodiments, from about 1% to about 5% by weight of the anti-redeposition agent.

[0075] Bleaching agent The cleaning composition may optionally contain a bleaching agent. The bleaching agent may be used to brighten or whiten the substrate and is typically Cl2, Br2, -OCl - , and / or -OBr -It may contain a bleaching compound that can release active halogen species such as the like. Suitable bleaching agents for use may include chlorine-containing compounds such as chlorine, hypochlorite, chloramine, etc. Some examples of halogen-releasing compounds include alkali metal dichloroisocyanurate, sodium trichlorophosphate, alkali metal hypochlorite, monochloramine, and dichloramine, etc. The encapsulated chlorine source can also be used to improve the stability of the chlorine source in the composition (see, for example, U.S. Patent Nos. 4,618,914 and 4,830,773, the disclosures of which are incorporated herein by reference). The bleaching agent may also include an agent that contains an active oxygen source or functions as an active oxygen source. The active oxygen compound functions to provide an active oxygen source and can release active oxygen, for example, in an aqueous solution. The active oxygen compound can be inorganic or organic, or a mixture thereof. Some examples of the active oxygen compound include a peroxygen compound or a peroxygen compound additive. Some examples of the active oxygen compound or the active oxygen source include hydrogen peroxide, perboric acid, sodium carbonate peroxide, phosphate peroxohydrate, potassium peroxymonosulfate, and sodium perborate monohydrate and sodium perborate tetrahydrate, regardless of the presence or absence of an activator such as tetraacetylethylenediamine. The cleaning composition may contain a small but effective amount of a bleaching agent, for example, in some embodiments in the range of up to about 10% by weight, and in some embodiments in the range of about 0.1 to about 6% by weight.

[0076] Chelating agent / metal ion sequestering agent The cleaning composition may also contain an effective amount of a chelating agent / sequestering agent, also referred to as a builder. Additionally, the cleaning composition may optionally contain one or more additional builders as functional components. Generally, a chelating agent is a molecule that can coordinate (i.e., bind) metal ions commonly found in a water source so that the metal ions do not interfere with the action of other compositions of the rinsing aid or other cleaning compositions. The chelating agent / sequestering agent can also function as a water conditioner when included in an effective amount. In some embodiments, the cleaning composition may contain a chelating agent / sequestering agent in the range of up to about 70% by weight, or in the range of about 1 - 60% by weight.

[0077] Often, the cleaning composition is also phosphate- and / or sulfate-free. In embodiments of solid cleaning compositions that are phosphate-free, additional functional materials containing builders do not contain phosphorus-containing compounds such as condensed phosphates and phosphonates.

[0078] Suitable additional builders include aminocarboxylates and polycarboxylates. Some examples of aminocarboxylates useful as chelating agents / sequestering agents include N-hydroxyethyliminodiacetic acid, nitrilotriacetic acid (NTA), ethylenediaminetetraacetic acid (EDTA), N-hydroxyethyl-ethylenediaminetriacetic acid (HEDTA), diethylenetriaminepentaacetic acid (DTPA), and the like. Some examples of polymeric polycarboxylates suitable for use as sequestering agents include those having pendant carboxylate (--CO2) groups, such as polyacrylic acid, maleic acid / olefin copolymers, acrylic / maleic acid copolymers, polymethacrylic acid, acrylic acid-methacrylic acid copolymers, hydrolyzed polyacrylamide, hydrolyzed polymethacrylamide, hydrolyzed polyamide-methacrylamide copolymers, hydrolyzed polyacrylonitrile, hydrolyzed polymethacrylonitrile, hydrolyzed acrylonitrile-methacrylonitrile copolymers, and the like.

[0079] In embodiments of the phosphate-free solid cleaning composition, examples of the chelating agent / sequestering agent added may include, for example, condensed phosphates, phosphonates, and the like. Some examples of condensed phosphates include sodium orthophosphate and potassium orthophosphate, sodium pyrophosphate and potassium pyrophosphate, sodium tripolyphosphate, sodium hexametaphosphate, and the like. Condensed phosphates can also assist, to a limited extent, in the solidification of the composition by fixing the free water present in the composition as water of hydration.

[0080] In embodiments of the phosphate-free solid cleaning composition, the composition may include 1-hydroxyethane-1,1-diphosphonic acid CH3C(OH)[PO(OH)2]2, aminotri(methylenephosphonic acid) N[CH2PO(OH)2]3, aminotri(methylenephosphonate), sodium salt [Chemical formula] 2-hydroxyethyliminobis(methylenephosphonic acid) HOCH2CH2N\[CH2PO(OH)2] 2、 diethylenetriaminepenta(methylenephosphonic acid) (HO)2POCH2N\[CH2N\[CH2PO(OH)2]2] 2、 diethylenetriaminepenta(methylenephosphonate), sodium salt C9H (28-x) N3Na x O 15 P5(x = 7), hexamethylenediamine(tetramethylenephosphonate), potassium salt C 10 H (28-x) N2K x O 12It may contain phosphonates such as P4(x = 6), bis(hexamethylene)triamine(pentamethylenephosphonic acid)(HO2)POCH2N[(CH2)6N[CH2PO(OH)2]2]2, and phosphorus-containing acids such as H3PO3. In some embodiments, combinations of phosphonates such as ATMP and DTPMP may be used. When phosphonates are added, neutralized or alkaline phosphonates, or combinations of phosphonates and an alkali source before being added to the mixture, may be used so that little or no heat or gas is generated by the neutralization reaction.

[0081] For further consideration of chelating agents / sequestering agents, see Kirk - Othmer, Encyclopedia of Chemical Technology, 3rd Edition, Volume 5, pages 339 - 366 and Volume 23, pages 319 - 320, the disclosures of which are incorporated herein by reference.

[0082] Dye / odorant Odorants containing various dyes, fragrances, and other aesthetic improvers can also be included in the solid cleaning composition. Dyes can be included, for example, to change the appearance of the composition as FD&C Blue 1 (Sigma Chemical), FD&C Yellow 5 (Sigma Chemical), Direct Blue 86 (Miles), Fastusol Blue (Mobay Chemical Corp.), Acid Orange 7 (American Cyanamid), Basic Violet 10 (Sandoz), Acid Yellow 23 (GAF), Acid Yellow 17 (Sigma Chemical), Sap Green (Keyston Analine and Chemical), Metanil Yellow (Keystone Analine and Chemical), Acid Blue 9 (Hilton Davis), Sandolan Blue / Acid Blue 182 (Sandoz), Hisol Fast Red (Capitol Color and Chemical), Fluorescein (Capitol Color and Chemical), Acid Green 25 (Ciba-Geigy), etc.

[0083] Examples of fragrances or odors that can be included in the solid cleaning composition include terpenoids such as citronellol, aldehydes such as amyl cinnamaldehyde, jasmines such as C1S-jasmine or jasmal, vanillin, and the like.

[0084] Filler The solid cleaning composition can optionally contain one or more fillers in small but effective amounts. Some examples of suitable fillers include sodium chloride, starch, saccharides, C1-C such as propylene glycol 10Examples include alkylene glycol, sulfate, PEG, urea, sodium acetate, magnesium sulfate, sodium acetate, magnesium sulfate, sodium carbonate, etc. In some embodiments, the filler can be included in an amount ranging from up to about 50 wt%, and in some embodiments, from about 1 to 15 wt%.

[0085] Functional polydimethylsiloxane The solid cleaning composition may also optionally include one or more functional polydimethylsiloxanes. For example, in some embodiments, polyalkylene oxide-modified polydimethylsiloxanes, nonionic surfactants, or polybetaine-modified polysiloxane amphoteric surfactants can be used as additives. Both are, in some embodiments, linear polysiloxane copolymers in which a polyether or polybetaine is grafted thereto through a hydrosilylation reaction. Some examples of specific siloxane surfactants are known as SILWET® surfactants available from Union Carbide, or ABIL® polyether or polybetaine polysiloxane copolymers available from Goldschmidt Chemical Corp., and are described in U.S. Patent No. 4,654,161, the patent of which is incorporated herein by reference. In some embodiments, the specific siloxane used can be described as having, for example, low surface tension, high wetting ability, and excellent lubricity. For example, these surfactants are said to be some of the few surfactants capable of wetting the surface of polytetrafluoroethylene. The siloxane surfactant used as an additive can be used alone or in combination with a fluorosurfactant. In some embodiments, the fluorosurfactant optionally used as an additive in combination with a silane can be, for example, a nonionic fluorocarbon such as fluorinated alkyl polyoxyethylene ethanol, fluorinated alkyl alkoxylate, and fluorinated alkyl ester.

[0086] Further description of such functional polydimethylsiloxanes and / or fluorosurfactants can be found in U.S. Patent Nos. 5,880,088, 5,880,089, and 5,603,776, which are hereby incorporated by reference in their entirety. We have found, for example, that using certain polysiloxane copolymers in a mixture with hydrocarbon surfactants results in excellent rinsing aids for plasticware. We have also found that combinations of certain silicone polysiloxane copolymers and fluorocarbon surfactants with conventional hydrocarbon surfactants also result in excellent rinsing aids for plasticware. This combination has been found to be superior to the individual components, except when using certain polyalkylene oxide-modified polydimethylsiloxanes and polybetaine polysiloxane copolymers, which have approximately equal effectiveness. Thus, some embodiments include a polysiloxane copolymer alone, and the combination with a fluorocarbon surfactant may involve a polyether polysiloxane, which is a nonionic siloxane surfactant. The polybetaine polysiloxane copolymer, which is an amphoteric siloxane surfactant, may be employed alone as an additive in the cleaning composition to provide the same result.

[0087] In some embodiments, the composition may contain a functional polydimethylsiloxane in an amount ranging up to about 10 wt%. For example, some embodiments may optionally include a polyalkylene oxide-modified polydimethylsiloxane or a polybetaine-modified polysiloxane in the range of about 0.1 to 10 wt% in combination with a fluorinated hydrocarbon nonionic surfactant in the range of about 0.1 to 10 wt%.

[0088] Hardening / Curing Agent / Solubility Adjusting Agent In some embodiments, one or more solidifying agents may be included in the cleaning composition. Examples of solidifying agents include urea, amides, such as monoethanolamide stearate or diethanolamide laurate or alkylamide; sulfates or sulfated surfactants, and aromatic sulfonates; solid polyethylene glycol, or solid EO / PO block copolymers; starch made water-soluble by an acid or alkali treatment process; various inorganic substances that impart solidifying properties to the heated composition upon cooling. Such compounds can also vary the solubility of the composition in an aqueous medium during use so that the active ingredient can be dispensed from the solid composition over a long period of time.

[0089] Suitable aromatic sulfonates include, but are not limited to, sodium xylene sulfonate, sodium toluene sulfonate, sodium cumene sulfonate, potassium toluene sulfonate, ammonium xylene sulfonate, calcium xylene sulfonate, sodium alkyl naphthalene sulfonate, and / or sodium butyl naphthalene. Preferred aromatic sulfonates include sodium xylene sulfonate and sodium cumene sulfonate.

[0090] The amount of the solidifying agent included in the cleaning composition can be determined by the desired effect. Generally, an effective amount of the solidifying agent is considered to be an amount that acts to solidify the cleaning composition, regardless of the presence or absence of other substances. Typically, in solid embodiments, the amount of the solidifying agent in the cleaning composition ranges from about 10% to about 80% by weight of the cleaning composition, preferably from about 20% to about 75% by weight, more preferably from about 20% to about 70% by weight of the cleaning composition. In one aspect of the present invention, the solidifying agent is substantially free of sulfate. For example, the cleaning composition can have less than 1% by weight, preferably less than 0.5% by weight, more preferably less than 0.1% by weight of sulfate. In a preferred embodiment, the cleaning composition is sulfate-free.

[0091] In certain embodiments, it may be desirable to have a secondary curing agent. In a composition containing a secondary solidified product, the composition may contain the secondary curing agent in an amount ranging up to about 50% by weight. In some embodiments, the secondary curing agent may be present in an amount ranging from about 5% to about 35% by weight, often in the range of about 10% to about 25% by weight, and occasionally in the range of about 5% to about 15% by weight.

[0092] In some embodiments, one or more additional curing agents may be included in the solid cleaning composition if desired. Examples of curing agents include amides such as monoethanolamine stearate or diethanolamine laurate or alkylamide; solid polyethylene glycol, or solid EO / PO block copolymer; starch made water-soluble by an acid or alkali treatment process; various inorganic substances that impart solidifying properties to the heated composition upon cooling, etc. Such compounds can also vary the solubility of the composition in an aqueous medium during use so that the components can be dispensed from the solid composition over a long period. The composition may contain the secondary curing agent in an amount ranging up to about 30% by weight. In some embodiments, the secondary curing agent may be present in an amount ranging from about 5% to about 25% by weight, often in the range of about 10% to about 25% by weight, and occasionally in the range of about 5% to about 15% by weight.

[0093] Humectant The solid cleaning composition may also optionally contain one or more humectants. A humectant is a substance having an affinity for water. The humectant may be provided in an amount sufficient to help reduce the visibility of the film on the substrate surface. The visibility of the film on the substrate surface is of particular concern when the rinse water contains total dissolved solids exceeding 200 ppm. Thus, in some embodiments, the humectant is provided in an amount sufficient to reduce the visibility of the film on the substrate surface when the rinse water contains total dissolved solids exceeding 200 ppm as compared to a rinse agent composition that does not contain the humectant. The term "water-solid film formation" or "film formation" refers to the presence of a layer of a visible continuous substance on the substrate surface that gives the appearance that the substrate surface has not been cleaned.

[0094] Some exemplary humectants that can be used include materials that contain more than 5 wt% water (based on the dry humectant) equilibrated at 50% relative humidity and room temperature. Exemplary humectants that can be used include glycerin, propylene glycol, sorbitol, alkyl polyglycoside, polybetaine polysiloxane, and mixtures thereof. In some embodiments, the rinse composition can contain a humectant in an amount ranging up to about 75% by weight of the total composition, and in some embodiments, in an amount ranging from about 5 wt% to about 75 wt% by weight of the composition.

[0095] Hydratable salt The solid cleaning composition according to the present invention can optionally include at least one hydratable salt. In one embodiment, the hydratable salt is sodium carbonate (also known as soda ash or ash) and / or potassium carbonate (also known as potash). In a preferred aspect, the hydratable salt is sodium carbonate and does not contain potassium carbonate. The hydratable salt can be provided as a hydratable salt such as sodium carbonate in the range of approximately 20 wt% to approximately 90 wt%, preferably approximately 25 wt% to approximately 90 wt%, more preferably approximately 30 wt% to approximately 70 wt%. Those skilled in the art will understand other suitable concentration ranges of the components to obtain equivalent properties of the solid matrix.

[0096] In other embodiments, the hydratable salt may be combined with other hardeners. For example, the hydratable salt may be used with an additional hardener that is essentially inorganic and may optionally also act as an alkali source. In certain embodiments, secondary hardeners include, but are not limited to, additional alkali metal hydroxides, sodium carbonate anhydrous, sodium sulfate anhydrous, sodium acetate anhydrous, and other known hydratable compounds, or combinations thereof. According to a preferred embodiment, the secondary hydratable salt includes sodium metasilicate and / or anhydrous sodium metasilicate. The amount of secondary hardener required to achieve setting depends on several factors including the exact hardener employed, the amount of water in the composition, and the hydration capacity of the other cleaning composition components. In certain embodiments, the secondary hardener may also function as an additional alkali source.

[0097] Polymer The cleaning composition can include a polymer, or a polymer system composed of at least one polycarboxylic acid polymer, copolymer, and / or terpolymer. Particularly suitable polycarboxylic acid polymers of the present invention include, but are not limited to, polymaleic acid homopolymer, polyacrylic acid copolymer, and maleic anhydride / olefin copolymer.

[0098] Polymaleic acid (C4H2O3)x, or hydrolyzed polymaleic anhydride, or cis-2-butenedioic acid homopolymer has the following structural formula: [Chemical formula] where n and m are arbitrary integers. Examples of polymaleic acid homopolymers, copolymers, and / or terpolymers (and their salts) that can be used in the present invention are specific, and those having a molecular weight of about 0 to about 5000, more preferably about 200 to about 2000, are preferred (these MWs may be confirmed). Examples of commercially available polymaleic acid homopolymers include the Belclene 200 series of maleic acid homopolymers from BWA (trademark) Water Additives (979 Lakeside Parkway, Suite 925 Tucker, GA 30084, USA), and Aquatreat AR-801 available from AkzoNobel. About 0.01 wt% to about 30 wt% of the polymaleic acid homopolymer, copolymer, and / or terpolymer may be present in the cleaning composition.

[0099] The cleaning composition of the present invention may use polyacrylic acid polymers, copolymers, and / or terpolymers. Polyacrylic acid has the following structural formula: [Chemical formula] where n is an arbitrary integer. Examples of suitable polyacrylic acid polymers, copolymers, and / or terpolymers include, but are not limited to, polyacrylic acid, (C3H4O2) n , or 2-propenoic acid, acrylic acid, polyacrylic acid, polymers, copolymers, and / or terpolymers of propenoic acid.

[0100] In one embodiment of the present invention, particularly suitable acrylic acid polymers, copolymers, and / or terpolymers have a molecular weight of from about 100 to about 10,000, in a preferred embodiment from about 500 to about 7000, in an even more preferred embodiment from 1000 to about 5000, and in a most preferred embodiment from about 1500 to about 3500. Examples of polyacrylic acid polymers, copolymers, and / or terpolymers (or salts thereof) that can be used in the present invention include, but are not limited to, Acusol 448 and Acusol 425 from The Dow Chemical Company (Wilmington Delaware, USA). In certain embodiments, it may be desirable to have acrylic acid polymers (and salts thereof) having a molecular weight greater than about 10,000. Examples include, but are not limited to, both Acusol 929 (10,000 MW) and Acumer 1510 (60,000 MW) available from Dow Chemical, and AQUATREAT AR-6 (100,000 MW) from AkzoNobel (Strawinskylaan 2555 1077 ZZ Amsterdam Postbus 75730 1070 AS Amsterdam). From about 0.01 wt% to about 30 wt% of the polyacrylic acid polymer, copolymer, and / or terpolymer can be present in the composition and can be present in the cleaning composition.

[0101] The maleic anhydride / olefin copolymer is a copolymer of polymaleic anhydride and an olefin. Maleic anhydride ((C2H2(CO)2O has the following structure: [Chemical formula] Some of the maleic anhydride may be replaced with maleimide, N-alkyl(C 1-4 ) maleimide, N-phenylmaleimide, fumaric acid, itaconic acid, citraconic acid, aconitic acid, crotonic acid, cinnamic acid 10, alkyl(C 1-18 ) esters of the aforementioned acids, cycloalkyl(C 3-8 ) esters of the aforementioned acids, sulfated castor oil, etc. At least 95% by weight of the maleic anhydride polymer, copolymer, or terpolymer has a number average molecular weight in the range of about 700 to about 20,000, preferably about 1000 to about 100,000.

[0102] For the purposes of the present invention, a variety of linear and branched alpha-olefins can be used. Particularly useful alpha-olefins are butadiene, chloroprene, isoprene, and dienes containing 4 to 18 carbon atoms such as 2-methyl-1,5-hexadiene, and 2-methyl-1,5-hexadiene; isobutylene, 1-butene, 1-hexene, 1-octene, etc., containing 4 to 8 carbon atoms, preferably C 4-10 is a 1-alkene of.

[0103] In one embodiment of the present invention, particularly suitable maleic anhydride / olefin copolymers have a molecular weight of about 1000 to about 50,000, in a preferred embodiment about 5000 to about 20,000, and in the most preferred embodiment about 7500 to about 12,500. Examples of maleic anhydride / olefin copolymers that can be used in the present invention include, but are not limited to, Acusol 460N from The Dow Chemical Company (Wilmington Delaware, USA). About 0.01% to about 30% by weight of the maleic anhydride / olefin copolymer can be present in the cleaning composition.

[0104] Bactericide / antibacterial agent The cleaning composition can optionally contain a bactericide. A bactericide, also known as an antibacterial agent, is a chemical composition that can be used in solid functional materials to prevent microbial contamination and deterioration of material systems, surfaces, etc. Generally, these materials are classified into specific classes including phenols, halogen compounds, quaternary ammonium compounds, metal derivatives, amines, alkanolamines, nitro derivatives, anilides, organic sulfur and sulfur-nitrogen compounds, and other compounds.

[0105] It should be understood that active oxygen compounds such as those described above in the bleaching agent section can also function as antibacterial agents and even provide a bactericidal effect. In fact, in some embodiments, the ability of the active oxygen compound to function as an antibacterial agent reduces the need for additional antibacterial agents in the present composition. For example, percarbonate compositions have been shown to provide excellent antibacterial effects. Nevertheless, some embodiments incorporate additional antibacterial agents.

[0106] A given antibacterial agent, depending on its chemical composition and concentration, can simply limit further growth of the number of microorganisms or destroy all or part of the microbial population. The terms "microbe" and "microorganism" typically refer primarily to bacteria, viruses, yeasts, spores, and fungal microorganisms. When used, the antibacterial agent is typically formed into a solid functional material, which optionally forms an aqueous disinfectant or bactericidal composition that can contact various surfaces when diluted and dispensed, for example, using a water stream, to prevent the growth of or cause the killing of part of the microbial population. A 3log reduction of the microbial population results in a bactericidal composition. The antibacterial agent can be encapsulated, for example, to improve its stability.

[0107] Some examples of common antibacterial agents include phenolic antibacterial agents such as pentachlorophenol, orthophenylphenol, chlorop - benzylphenol, p - chlorom - xylenol, etc. Halogens containing antibacterial agents include sodium trichloroisocyanurate, sodium dichloroisocyanurate (anhydrous or dihydrate), iodine - poly(vinylpyrolidinone) complex, bromine compounds such as 2 - bromo - 2 - nitropropane - 1,3 - diol, and quaternary antibacterial agents such as benzalkonium chloride, didecyldimethylammonium chloride, choline diiodochloride, tetramethylphosphonium tribromide. Other antibacterial compositions such as dithiocarbamates like hexahydro - 1,3,5 - tris(2 - hydroxyethyl)-s - triazine, sodium dimethyldithiocarbamate, and various other substances are known in the art for their antibacterial properties.

[0108] In embodiments of solid cleaning compositions that do not contain phosphate and / or do not contain sulfate and also contain an antibacterial agent, the antibacterial agent is selected to meet these requirements. Embodiments of solid cleaning compositions containing only GRAS components may or may not omit the antibacterial agents described in this section.

[0109] In some embodiments, the cleaning composition contains an antibacterial component in the range of up to about 10% by weight of the composition, in some embodiments up to about 5% by weight, or in some embodiments in the range of about 0.01 - about 3% by weight, or 0.05 - 1% by weight of the composition.

[0110] Additional surfactant The solidified surfactant composition may contain an optional co-surfactant. Preferably, the co-surfactant is in solid form. Further, the solidified surfactant composition of the present invention can be incorporated into a cleaning composition. Examples of such cleaning compositions include, but are not limited to, detergent compositions, dishwashing compositions, laundry compositions, rinse aids, and hard surface cleaning compositions. Surfactants that can be included as co-surfactants in the solidified surfactant composition and / or as surfactants in the cleaning composition include nonionic surfactants, semi-polar nonionic surfactants, anionic surfactants, cationic surfactants, amphoteric surfactants, zwitterionic surfactants, and mixtures or combinations thereof.

[0111] When a co-surfactant carrier is included in the solidified surfactant composition of the present invention, the co-surfactant preferably has a weight ratio of about 1:0 to about 0:1 with respect to the liquid surfactant. In a further embodiment of the present invention, the co-surfactant carrier is present in an amount of about 20% to about 90% by weight, more preferably about 30% to about 90% by weight, and even more preferably about 40% to about 80% by weight.

[0112] Nonionic surfactants Useful nonionic surfactants are generally characterized by the presence of an organic hydrophobic group and an organic hydrophilic group and are typically formed by the condensation of an organic aliphatic, alkyl aromatic, or polyoxyalkylene hydrophobic compound with a hydrophilic alkaline oxide moiety that is generally ethylene oxide or its polyhydration product, polyethylene glycol. In practice, any hydrophobic compound having a hydroxyl, carboxyl, amino, or amide group with a reactive hydrogen atom can be condensed with ethylene oxide, or its polyhydration adduct, or a mixture thereof such as propylene oxide to form a nonionic surfactant. The length of the hydrophilic polyoxyalkylene moiety condensed with any particular hydrophobic compound can be readily adjusted to produce a water-dispersible or water-soluble compound having a desired degree of balance between hydrophilic and hydrophobic properties. Useful nonionic surfactants include

[0113] Initiators include propylene glycol, ethylene glycol, glycerol, trimethylolpropane, and ethylenediamine-based block polyoxypropylene-polyoxyethylene polymer compounds as reactive hydrogen compounds. One class of compounds is a bifunctional (with two reactive hydrogens) compound formed by condensing ethylene oxide with a hydrophobic base formed by adding propylene oxide to two hydroxyl groups of propylene glycol. This hydrophobic portion of the molecule has a molecular weight of about 1,000 to about 4,000. Then, ethylene oxide is added to sandwich this hydrophobic substance between hydrophilic groups and is controlled in length to constitute about 10 wt% to about 80 wt% of the final molecule. Another class of compounds is a trifunctional block copolymer obtained from the sequential addition of propylene oxide and ethylene oxide to ethylenediamine. The molecular weight of the propylene oxide hydrotype ranges from about 500 to about 7,000, and the hydrophilic ethylene oxide is added to constitute about 10 wt% to about 80 wt% of the molecule.

[0114] Condensation products of about 3 to about 50 moles of ethylene oxide with 1 mole of an alkylphenol in which the alkyl chain is of linear or branched configuration, or of single or double alkyl configuration and contains about 8 to about 18 carbon atoms. The alkyl group can be represented, for example, by diisobutylene, di-amyl, polymerized propylene, iso-octyl, nonyl, and di-nonyl. These surfactants may be polyethylene, polypropylene, and polybutylene oxide condensates of alkylphenols. Examples of commercial compounds of this chemistry are marketed under the trade names Igepal® by Rhone-Poulenc and Triton® by Union Carbide.

[0115] A condensation product of 1 mole of a saturated or unsaturated straight-chain or branched-chain alcohol having from about 6 to about 24 carbon atoms and from about 3 to about 50 moles of ethylene oxide. The alcohol moiety can consist of a mixture of alcohols within the carbon ranges described above or can consist of an alcohol having a specific number of carbon atoms within this range. Examples of equivalent commercially available surfactants are available under the trade name Neodol (trademark) manufactured by Shell Chemical Co. and the trade name Alfonic (trademark) manufactured by Vista Chemical Co.

[0116] A condensation product of 1 mole of a saturated or unsaturated straight-chain or branched-chain carboxylic acid having from about 8 to about 18 carbon atoms and from about 6 to about 50 moles of ethylene oxide. The acid moiety can consist of a mixture of acids within the carbon atom ranges defined above or can consist of an acid having a specific number of carbon atoms within this range. Examples of commercial compounds of this chemical are commercially available under the trade name Lipopeg (trademark) manufactured by Lipo Chemicals, Inc.

[0117] In addition to ethoxylated carboxylic acids, generally referred to as polyethylene glycol esters, other alkanoic acid esters formed by reaction with glycerides, glycerin, and polyhydric (saccharide or sorbitan / sorbitol) alcohols have uses herein for specialized embodiments, particularly for indirect food additive applications. All of these ester moieties have on their molecules one or more reactive hydrogen sites that can be subjected to further acylation or ethylene oxide (alkoxide) addition to control the hydrophilicity of these substances.

[0118] Examples of nonionic low-foaming surfactants include the following. Ethylene oxide is added to ethylene glycol to provide a hydrophilic substance of a specified molecular weight; then propylene oxide is added to obtain a hydrophobic block on the outer side (ends) of the molecule, thereby modifying the compound from (1) which is essentially inverted. The hydrophobic portion of the molecule has a molecular weight of about 1,000 to about 3,100, and the central hydrophilic substance comprises 10% to about 80% by weight of the final molecule. The hydrophobic portion of the molecule has a molecular weight of about 2,100 to about 6,700, and the central hydrophilic substance comprises 10% to about 80% by weight of the final molecule.

[0119] Compounds from groups (1), (2), (3) and (4) which are modified by "capping" or "end-blocking" the terminal hydroxy group(s) (of the polyfunctional moiety) by reaction with hydrophobic small molecules such as propylene oxide, butylene oxide, benzyl chloride; and short-chain fatty acids, alcohols or alkyl halides containing 1 to about 5 carbon atoms; and mixtures thereof. Reactants such as thionyl chloride which convert the terminal hydroxy group to a chloride group are also included. Such modification of the terminal hydroxy group can result in all-block, block-heteric, heteric-block, or all-heteric nonionic substances.

[0120] Additional examples of effective low-foaming nonionic substances include the following. Of U.S. Patent No. 2,903,486 issued to Brown et al. on September 8, 1959, [Chemical formula] An alkylphenoxypolyethoxyalkanol represented by the formula wherein R is an alkyl group of 8 to 9 carbon atoms, A is an alkylene chain of 3 to 4 carbon atoms, n is an integer of 7 to 16, and m is an integer of 1 to 10.

[0121] A polyalkylene glycol condensate of U.S. Patent No. 3,048,548 issued to Martin et al. on August 7, 1962, having alternating hydrophilic oxyethylene chains and hydrophobic oxypropylene chains, wherein the weight of the terminal hydrophobic chain, the weight of the intermediate hydrophobic unit, and the weight of the linking hydrophilic unit each represent approximately one-third of the condensate.

[0122] Z is a material capable of being alkoxylated, R is a radical derived from an alkylene oxide which can be ethylene and propylene, n is an integer of, for example, 10 to 2,000 or more, and z is an integer determined by the number of reactive oxyalkylatable groups, of the general formula Z[(OR n OH] z as disclosed in U.S. Patent No. 3,382,178 issued to Lissant et al. on May 7, 1968, which is an antifoaming nonionic surfactant.

[0123] Y is the residue of an organic compound having from about 1 to 6 carbon atoms and 1 reactive hydrogen atom, n has an average value of at least about 6.4 determined by the hydroxyl value, and m has a value such that the oxyethylene moiety constitutes from about 10% to about 90% by weight of the molecule, of the formula Y(C3H6O n (C2H4O) m H, corresponding to the conjugated polyoxyalkylene compound described in U.S. Patent No. 2,677,700 issued to Jackson et al. on May 4, 1954.

[0124] The formula Y[(C3H6O n (C2H4O) m H] x(In the formula, Y is a residue of an organic compound having from about 2 to 6 carbon atoms and containing x reactive hydrogen atoms (x has a value of at least about 2), n has a value such that the molecular weight of the polyoxypropylene hydrophobic base is at least about 900, and m has a value such that the oxyethylene content of the molecule is from about 10% to about 90% by weight), a conjugated polyoxyalkylene compound described in U.S. Patent No. 2,674,619 issued to Lundsted et al. on April 6, 1954. Compounds falling within the defined range for Y include, for example, propylene glycol, glycerin, pentaerythritol, trimethylolpropane, ethylenediamine, and the like. The oxypropylene chain is optional, but advantageously contains a small amount of ethylene oxide, and the oxyethylene chain is also optional, but advantageously contains a small amount of propylene oxide.)

[0125] Additional conjugated polyoxyalkylene surfactants advantageously used in the compositions of the present invention have the formula: P[(C3H6O) n (C2H4O) m H] x corresponding to the formula, wherein P is a residue of an organic compound having from about 8 to 18 carbon atoms and containing x reactive hydrogen atoms, x has a value of or 2, n has a value such that the molecular weight of the polyoxyethylene moiety is at least about 44, and m has a value such that the oxypropylene content of the molecule is from about 10% to about 90% by weight. In any case, the oxypropylene chain is optional, but advantageously may contain a small amount of ethylene oxide, and the oxyethylene chain is also optional, but advantageously may contain a small amount of propylene oxide.)

[0126] Suitable polyhydroxy fatty acid amide surfactants for use in the present compositions have the structural formula R2CON R1 Z (wherein R1 is H, a C1-C4 hydrocarbyl, 2-hydroxyethyl, 2-hydroxypropyl, ethoxy, propoxy group, or a mixture thereof; R2 may be a straight-chain C5-C 31is a hydrocarbyl; Z is a polyhydroxyhydrocarbyl having a hydrocarbyl straight chain having at least three hydroxyls directly connected to the chain, or an alkoxylated derivative thereof (preferably ethoxylated or propoxylated). Z can be obtained from a reducing sugar in a reductive amination reaction, such as a glycityl moiety.

[0127] Alkyl ethoxylate condensation products of about 0 to about 25 moles of ethylene oxide with aliphatic alcohols are suitable for use in the present composition. The alkyl chain of the aliphatic alcohol can be either straight-chain or branched-chain, primary or secondary, and generally contains 6 to 22 carbon atoms.

[0128] Ethoxylated C6-C 18 Fatty alcohols and C6-C 18 Mixed ethoxylated and propoxylated fatty alcohols, especially those that are water-soluble, are suitable surfactants for use in the present composition. Suitable ethoxylated fatty alcohols are C6-C having an ethoxylation degree of 3 to 50. 18 Contain ethoxylated fatty alcohols.

[0129] Particularly suitable nonionic alkyl polysaccharide surfactants for use in the present composition include those disclosed in U.S. Patent No. 4,565,647, issued January 21, 1986, to Llenado. These surfactants include a hydrophobic group containing about 6 to about 30 carbon atoms and a polysaccharide, such as a polyglycoside, and a hydrophilic group containing about 1.3 to about 10 saccharide units. Any reducing saccharide containing 5 or 6 carbon atoms can be used, for example, glucose, galactose, and the galactosyl moiety can be replaced with a glucosyl moiety. (Optionally, the hydrophobic group is bonded at the 2-position, 3-position, 4-position, etc., thus resulting in glucose or galactose as opposed to glucoside or galactoside.) The saccharide bond can be, for example, between one position of an additional saccharide unit and the 2-position, 3-position, 4-position, and / or 6-position on the preceding saccharide unit.

[0130] Fatty acid amide surfactants suitable for use in the present composition include those having the formula: R6CON(R7)2, wherein R6 is an alkyl group containing 7 to 21 carbon atoms, and each R7 is independently hydrogen, C1-C4 alkyl, C1-C4 hydroxyalkyl, or --(C2H4O) X H, wherein x is in the range of 1 to 3.

[0131] Useful classes of nonionic surfactants include alkoxylated amines, or, most specifically, the class defined as alcohol alkoxylated / aminated / alkoxylated surfactants. These nonionic surfactants are at least partially of the general formula: R 20 --(PO) S N--(EO) t H, R 20 --(PO) S N--(EO) t H(EO) t H, and R 20 --N(EO) t H, wherein R 20 is alkyl, alkenyl or other aliphatic group, or an alkyl-aryl group of 8 to 20, preferably 12 to 14 carbon atoms, EO is oxyethylene, PO is oxypropylene, s is 1 to 20, preferably 2 to 5, t is 1 to 10, preferably 2 to 5, and u is 1 to 10, preferably 2 to 5. Other variations within the scope of these compounds are the alternative formula: R 20 --(PO) V --N[(EO) w H][(EO) z H], wherein R 20is as defined above, where v is from 1 to 20 (e.g., 1, 2, 3, or 4 (preferably 2)), and w and z are independently from 1 to 10, preferably from 2 to 5. Commercially, these compounds are represented by product lines sold by Huntsman Chemicals as nonionic surfactants. Preferred chemicals of this class include Surfonic™ PEA25 amine alkoxylates. Preferred nonionic surfactants for the compositions of the present invention include alcohol alkoxylates, EO / PO block copolymers, alkylphenol alkoxylates, and the like.

[0132] The treatise, Nonionic Surfactants, edited by Schick, M.J., Vol. 1 of the Surfactant Science Series, Marcel Dekker, Inc., New York, 1983, is an excellent reference regarding the broad range of nonionic compounds commonly used in the practice of the present invention. The nonionic class, and a typical list of these surfactant species, are described in U.S. Patent No. 3,929,678 issued to Laughlin and Heuring on December 30, 1975. Further examples are described in “Surface Active Agents and detergents” (Volumes I and II, Schwartz, Perry, and Berch).

[0133] Semi-polar nonionic surfactants Semi-polar types of nonionic surfactants are another class of nonionic surfactants useful in the compositions of the present invention. Generally, semi-polar nonionic substances are high-foaming substances and foam stabilizers, which can limit their application in CIP systems. However, in the compositional embodiments of the present invention designed for high-foaming cleaning methods, semi-polar nonionic substances have immediate practicality. Semi-polar nonionic surfactants include amine oxides, phosphine oxides, sulfoxides, and their alkoxylated derivatives.

[0134] The amine oxide is a tertiary amine oxide corresponding to the general formula, [Chemical formula] In the formula, the arrow is the conventional representation of a semi-polar bond, and R 1 , R 2 , and R 3 can be aliphatic, aromatic, heterocyclic, alicyclic, or a combination thereof. Generally, in detergent-related amine oxides, R 1 is an alkyl radical having about 8 to about 24 carbon atoms, R 2 and R 3 are alkyl or hydroxyalkyl having 1 to 3 carbon atoms, or a mixture thereof, and R 2 and R 3 can be bonded to each other via, for example, an oxygen or nitrogen atom to form a ring structure, and R 4 is an alkali or a hydroxyalkylene group containing 2 to 3 carbon atoms, and n ranges from 0 to about 20.

[0135] Useful water-soluble amine oxide surfactants are selected from coconut or tallow alkyldi-(lower alkyl) amine oxides, and specific examples thereof are dodecyldimethylamine oxide, tridecyldimethylamine oxide, tetradecyldimethylamine oxide, pentadecyldimethylamine oxide, hexadecyldimethylamine oxide, heptadecyldimethylamine oxide, octadecyldimethylamine oxide, dodecyldipropylamine oxide, tetradecyldipropylamine oxide, hexadecyldipropylamine oxide, tetradecyldibutylamine oxide, octadecyldibutylamine oxide, bis(2-hydroxyethyl)dodecylamine oxide, bis(2-hydroxyethyl)-3-dodecoxy-1-hydroxypropylamine oxide, dimethyl-(2-hydroxydodecyl)amine oxide, 3,6,9-trioctadecyldimethylamine oxide, and 3-dodecoxy-2-hydroxypropyl di-(2-hydroxyethyl)amine oxide.

[0136] Useful semi-polar non-ionic surfactants also include water-soluble phosphine oxides having the following structure,

Chem.

[0137] Examples of useful phosphine oxides include dimethyldecylphosphine oxide, dimethyltetradecylphosphine oxide, methylethyltetradecylphosphine oxide, dimethylhexadecylphosphine oxide, diethyl-2-hydroxyoctyldecylphosphine oxide, bis(2-hydroxyethyl)dodecylphosphine oxide, and bis(hydroxymethyl)tetradecylphosphine oxide.

[0138] Useful semi-polar non-ionic surfactants herein also include water-soluble sulfoxide compounds having a structure,

Chem.

[0139] Useful examples of these sulfoxides include dodecylmethyl sulfoxide; 3-hydroxytridecylmethyl sulfoxide; 3-methoxytridecylmethyl sulfoxide; and 3-hydroxy-4-dodecyloxybutylmethyl sulfoxide.

[0140] The semi-polar nonionic surfactant for the composition of the present invention includes dimethylamine oxide such as lauryldimethylamine oxide, myristyldimethylamine oxide, cetyldimethylamine oxide, and combinations thereof. Useful water-soluble amine oxide surfactants are selected from octyl, decyl, dodecyl, isododecyl, coconut, or tallow alkyldi-(lower alkyl)amine oxides, and specific examples thereof are octyldimethylamine oxide, nonyldimethylamine oxide, decyldimethylamine oxide, undecyldimethylamine oxide, dodecyldimethylamine oxide, isododecyldimethylamine oxide, tridecyldimethylamine oxide, tetradecyldimethylamine oxide, pentadecyldimethylamine oxide, hexadecyldimethylamine oxide, heptadecyldimethylamine oxide, octadecyldimethylamine oxide, dodecyldipropylamine oxide, tetradecyldipropylamine oxide, hexadecyldipropylamine oxide, tetradecyldibutylamine oxide, octadecyldibutylamine oxide, bis(2-hydroxyethyl)dodecylamine oxide, bis(2-hydroxyethyl)-3-dodecoxy-1-hydroxypropylamine oxide, dimethyl-(2-hydroxydodecyl)amine oxide, 3,6,9-trioctadecyldimethylamine oxide, and 3-dodecoxy-2-hydroxypropyldi-(2-hydroxyethyl)amine oxide.

[0141] Suitable nonionic surfactants for use with the compositions of the present invention include alkoxylated surfactants. Suitable alkoxylated surfactants include EO / PO copolymers, capped EO / PO copolymers, alcohol alkoxylates, capped alcohol alkoxylates, mixtures thereof, and the like. Suitable alkoxylated surfactants for use as solvents include EO / PO block copolymers such as Pluronic and reverse Pluronic surfactants; alcohol alkoxylates such as Dehypon LS-54 (R-(EO)5(PO)4) and Dehypon LS-36 (R-(EO)3(PO)6); capped alcohol alkoxylates such as Plurafac LF221 and Tegoten EC11; mixtures thereof, and the like.

[0142] Anionic surfactant Surfactants classified as anionic substances because the charge of the hydrophobic substance is negative, or surfactants in which the hydrophobic part of the molecule has no charge unless the pH rises above neutral (for example, carboxylic acids) are also useful in the present invention. Carboxylates, sulfonates, sulfates, and phosphates are polar (hydrophilic) solubilizing groups found in anionic surfactants. Among the cations (counterions) associated with these polar groups, sodium, lithium, and potassium impart water solubility, ammonium and substituted ammonium ions provide both water solubility and oil solubility, and calcium, barium, and magnesium promote oil solubility. As will be understood by those skilled in the art, anionic substances are excellent detergent surfactants and are therefore preferred additives to heavy-duty detergent compositions.

[0143] Suitable anionic sulfate surfactants for use in the present composition include alkyl ether sulfates, alkyl sulfates, linear and branched primary and secondary alkyl sulfates, alkyl ethoxysulfates, fatty oleyl glycerol sulfates, alkylphenol ethylene oxide ether sulfates, C5-C 17Examples include acyl-N-(C1-C4 alkyl), as well as -N-(C1-C2 hydroxyalkyl) glucamine sulfate, and sulfates of alkyl polysaccharides such as sulfates of alkyl polyglucosides. Also included are alkyl sulfates, alkyl poly(ethyleneoxy) ether sulfates, and aromatic poly(ethyleneoxy) sulfates such as sulfates of ethylene oxide and nonylphenol or concentrated products (usually having 1 to 6 oxyethylene groups per molecule).

[0144] Also suitable as an anionic sulfonate surfactant for use in the present composition are alkyl sulfonates, linear and branched primary and secondary alkyl sulfonates, and aromatic sulfonates with or without substituents.

[0145] Suitable anionic carboxylate surfactants for use in the present composition include carboxylic acids (and salts), such as alkanoic acids (and alkanoates), ester carboxylic acids (e.g., alkyl succinates), ether carboxylic acids, sulfonated fatty acids, such as sulfonated oleic acid, and the like. Such carboxylates include alkyl ethoxy carboxylates, alkyl aryl ethoxy carboxylates, alkyl polyethoxy polycarboxylate surfactants, and soaps (e.g., alkyl carboxyls). Secondary carboxylates useful in the present composition include those containing a carboxyl unit connected to a secondary carbon. The secondary carbon may be in a ring structure, such as in p - octylbenzoic acid or in an alkyl - substituted cyclohexyl carboxylate. Secondary carboxylate surfactants typically do not contain ether bonds, ester bonds, and hydroxyl groups. Further, they typically lack a nitrogen atom within the head group (amphiphilic moiety). Suitable secondary soap surfactants typically contain 11 to 13 total carbon atoms, although more carbon atoms (e.g., up to 16) may be present. Suitable carboxylates also include acyl amino acids (and salts) such as acyl glutamates, acyl peptides, sarcosinates (e.g., N - acyl sarcosinates), taurates (e.g., fatty acid amides of N - acyl taurates and methyl tauride), and the like.

[0146] Suitable anionic surfactants include alkyl or alkyl aryl ethoxy carboxylates of the following formula: R - O - (CH2CH2O) n (CH2) m -CO2X (3) wherein R is a C8 - C 22 alkyl group or

Chemical formula

[0147] In other embodiments, R is

Chemical formula

[0148] Such alkyl and alkylaryl ethoxycarboxylates are commercially available. These ethoxycarboxylates are typically available in the acid form and can be readily converted to the anionic or salt form. Commercially available carboxylates include Neodox 23 - 4, C 12~13 alkyl polyethoxy(4) carboxylic acid (Shell Chemical), and Emcol CNP - 110, C9 alkylaryl polyethoxy(10) carboxylic acid (Witco Chemical). Carboxylates such as the product Sandopan® DTC, C 13 alkyl polyethoxy(7) carboxylic acid are also available from Clariant.

[0149] Cationic surfactant Surfactants are classified as cationic when the charge on the hydrotrope portion of the molecule is positive. Surfactants where the hydrotrope is uncharged until the pH is near neutral or lowered below, and then becomes cationic (e.g., alkylamines) are also included in this group. Theoretically, cationic surfactants can be synthesized from any combination of elements containing the "onium" structure RnX+Y-- and can include compounds other than nitrogen (ammonium) such as phosphorus (phosphonium) and sulfur (sulfonium). In practice, the field of cationic surfactants is probably dominated by nitrogen-containing compounds because the synthetic routes to nitrogen cationic surfactants are simple and easy, yielding high-yield products, which makes nitrogen cationic surfactants less expensive.

[0150] Cationic surfactants preferably contain at least one long carbon chain hydrophobic group and at least one nitrogen-containing compound with a positive charge, and more preferably refer to this. The long carbon chain group may be directly bonded to the nitrogen atom by simple substitution, or more preferably, indirectly bonded by the so-called crosslinking functional group(s) in interrupted alkylamines and amidoamines. Such functional groups can make the molecule more hydrophilic and / or more water-dispersible, easier to dissolve in water by a co-surfactant mixture, and / or water-soluble. For increasing water solubility, additional primary, secondary, or tertiary amino groups can be introduced, or the amino nitrogen can be quaternized with low molecular weight alkyl groups. Further, nitrogen can be part of a branched or straight-chain portion with various degrees of unsaturation, or part of a saturated or unsaturated heterocyclic ring. In addition, the cationic surfactant may contain complex linkages with two or more cationic nitrogen atoms.

[0151] Surfactant compounds classified as amine oxides, amphoterics, and zwitterions are generally near neutral to cationic in solutions of acidic pH and overlap surfactant classifications. Polyoxyethylated cationic surfactants generally behave like nonionic surfactants in alkaline solutions and like cationic surfactants in acidic solutions.

[0152] The simplest cationic amines, amine salts and quaternary ammonium compounds are as follows:

Chemical formula

[0153] Most of the large number of commercial cationic surfactants can be subdivided into four main classes and additional subgroups known to those skilled in the art and are described in “Surfactant Encyclopedia”, Cosmetics&Toiletries, Vol.104(2)86-96(1989). The first class includes alkyl amines and their salts. The second class includes alkyl imidazolines. The third class includes ethoxylated amines. The fourth class includes quaternaries such as, for example, alkyl benzyldimethylammonium salts, alkyl benzene salts, heterocyclic ammonium salts, tetraalkylammonium salts. Cationic surfactants are known to have a variety of properties that can be beneficial in the present compositions. These desirable properties can include detergency in compositions of neutral pH or below, antimicrobial efficacy, thickening or gelling in conjunction with other agents, etc.

[0154] Cationic surfactants useful in the compositions of the present invention include the formula R 1 m R 2 x YL Those having Z are mentioned, where each R 1 contains a linear or branched alkyl or alkenyl group, optionally substituted with up to 3 phenyl or hydroxy groups, and up to 4 of the following structures:

Chemical formula

Chemical formula

[0155] Amphoteric surfactant Amphoteric or ampholytic surfactants contain both basic and acidic hydrophilic groups, as well as organic hydrophobic groups. These ionic entities can be either anionic or cationic groups as described herein for other types of surfactants. Basic nitrogen and acidic carboxylate groups are typical functional groups used as basic and acidic hydrophilic groups. In some surfactants, sulfonate, sulfate, phosphonate, or phosphate provides a negative charge.

[0156] Amphoteric surfactants can be broadly described as derivatives of aliphatic secondary and tertiary amines, where the aliphatic radical can be straight or branched, one of the aliphatic substituents contains about 8 to 18 carbon atoms, and one contains an anionic water-solubilizing group, such as carboxy, sulfo, sulfato, phosphato, or phosphono. Amphoteric surfactants are known to those skilled in the art and are subdivided into two main classes described in "Surfactant Encyclopedia" Cosmetics&Toiletries, Vol. 104(2) 69 - 71(1989), which is hereby incorporated by reference in its entirety. The first class includes acyl / dialkylethylenediamine derivatives (e.g., 2-alkylhydroxyethylimidazoline derivatives) and their salts. The second class includes N-alkylamino acids and their salts. Some amphoteric surfactants can be assumed to fit into both classes.

[0157] Amphoteric surfactants can be synthesized by methods known to those skilled in the art. For example, 2-alkylhydroxyethylimidazoline is synthesized by the condensation and ring closure of a long-chain carboxylic acid (or derivative) with dialkylethylenediamine. Commercially available amphoteric surfactants are derivatized, for example, using chloroacetic acid or ethyl acetate, by subsequent hydrolysis and ring opening of the imidazoline ring by alkylation. During alkylation, one or two carboxy-alkyl groups react to form a tertiary amine and an ether bond, and different alkylating agents yield different tertiary amines.

[0158] The long-chain imidazole derivatives having the use in the present invention generally have the following general formula:

Chemical formula

Chemical formula

[0159] The above carboxymethylated compounds (glycinates) in this specification are often called betaines. Betaines are a special class of amphoteric compounds described hereinbelow in the section entitled zwitterionic surfactants.

[0160] Long-chain N-alkyl amino acids are readily prepared by the reaction RNH2, where R = C8-C 18It is a straight-chain or branched-chain alkyl or aliphatic amine having a halogenated carboxylic acid. Alkylation of the primary amino group of an amino acid results in secondary and tertiary amines. The alkyl substituent may have additional amino groups that provide multiple reactive nitrogen centers. The most commercially available N-alkylamino acids are alkyl derivatives of β-alanine or β-N(2-carboxyethyl)alanine. Examples of commercially available N-alkylamino acid ampholytes applicable to the present invention include alkyl β-aminodipropionate, RN(C2H4COOM)2, and RNHC2H4COOM. In one embodiment, R can be an acyclic hydrophobic group containing from about 8 to about 18 carbon atoms, and M is a cation for neutralizing the charge of the anion.

[0161] Suitable amphoteric surfactants include those derived from coconut products such as coconut oil or coconut fatty acids. Additional suitable coconut-derived surfactants include, as part of these structures, an ethylenediamine moiety, an alkanolamide moiety, an amino acid moiety, such as glycine, or combinations thereof, and an aliphatic substituent of from about 8 to 18 (e.g., 12) carbon atoms. Such surfactants can also be considered alkyl amphodicarboxylic acids. These amphoteric surfactants are C 12 -alkyl-C(O)-NH-CH2-CH2-N + (CH2-CH2-CO2Na)2-CH2-CH2-OH or C 12 -alkyl-C(O)-N(H)-CH2-CH2-N + (CH2-CO2Na)2-CH2-CH2-OH and may include chemical structures represented as. Disodium cocoamphodipropionate is one suitable amphoteric surfactant and is commercially available under the trade name Miranol™ FBS from Rhodia Inc., Cranbury, N.J. Another suitable coconut-derived amphoteric surfactant having the chemical name disodium cocoamphodiacetate is also sold under the trade name Mirataine™ JCHA from Rhodia Inc., Cranbury, N.J.

[0162] A typical list of amphoteric classes and the species of these surfactants are described in U.S. Patent No. 3,929,678 issued to Laughlin and Heuring on December 30, 1975. Further examples are described in "Surface Active Agents and Detergents" (Vol. I and II by Schwartz, Perry and Berch). Each of these references is hereby incorporated by reference in its entirety.

[0163] zwitterionic surfactant Zwitterionic surfactants can be considered a subset of amphoteric surfactants and may contain anionic charges. Zwitterionic surfactants can be broadly described as derivatives of secondary and tertiary amines, derivatives of heterocyclic secondary and tertiary amines, or derivatives of quaternary ammonium, quaternary phosphonium, or tertiary sulfonium compounds. Typically, zwitterionic surfactants contain a positively charged quaternary ammonium, or in some cases sulfonium or phosphonium ion, a negatively charged carboxyl group, and an alkyl group. Zwitterionic compounds generally contain cationic and anionic groups that are ionized to approximately the same extent in the isoelectric region of the molecule, resulting in a strong "inner salt" attraction between the positive and negative charge centers. Examples of such zwitterionic synthetic surfactants include derivatives of aliphatic quaternary ammonium, phosphonium, and sulfonium compounds, where the aliphatic group can be straight-chain or branched-chain, with one of the aliphatic substituents containing 8 to 18 carbon atoms and one containing an anionic water-solubilizing group, such as carboxy, sulfonate, sulfate, phosphate, or phosphonate.

[0164] Betaine and sultaine surfactants are examples of zwitterionic surfactants for use herein. The general formulas of these compounds are as follows: [Chemical formula] wherein R 1contains an alkyl, alkenyl, or hydroxyalkyl radical of 8 to 18 carbon atoms having from 0 to 10 ethylene oxide moieties and from 0 to 1 glyceryl moiety, Y is selected from the group consisting of a nitrogen atom, a phosphorus atom, and a sulfur atom, R 2 is an alkyl group or a monohydroxyalkyl group containing from 1 to 3 carbon atoms, when Y is a sulfur atom, x is 1, and when Y is a nitrogen atom or a phosphorus atom, it is 2, R 3 is an alkylene or hydroxyalkylene or hydroxyalkylene of 1 to 4 carbon atoms, and Z is a radical selected from the group consisting of a carboxylic acid group, a sulfonic acid group, a sulfuric acid group, a phosphonic acid group, and a phosphoric acid group.

[0165] Examples of the zwitterionic surfactant having the above structure include 4-[N,N-bis(2-hydroxyethyl)-N-octadecylammonio]-butane-1-carboxylate, 5-[S-3-hydroxypropyl-S-hexadecylsulfonio]-3-hydroxypentane-1-sulfate, 3-[P,P-diethyl-P-3,6,9-trioxatetracosanephosphonio]-2-hydroxypropane-1-phosphate, 3-[N,N-dipropyl-N-3-dodecoxy-2-hydroxypropyl-ammonio]-propane-1-phosphonate, 3-(N,N-dimethyl-N-hexadecylammonio)-propane-1-sulfonate, 3-(N,N-dimethyl-N-hexadecylammonio)-2-hydroxy-propane-1-sulfonate, 4-[N,N-bis(2(2-hydroxyethyl)-N(2-hydroxydodecyl)ammonio]-butane-1-carboxylate, 3-[S-ethyl-S-(3-dodecoxy-2-hydroxypropyl) sulfonio]-propane-1-phosphate, 3-[P,P-dimethyl-P-dodecylphosphonio]-propane-1-phosphonate, and S[N,N-bis(3-hydroxypropyl)-N-hexadecylammonio]-2-hydroxy-pentane-1-sulfate. The alkyl group contained in the detergent surfactant may be linear or branched and may be saturated or unsaturated.

[0166] Suitable zwitterionic surfactants for use in the present composition include betaines having the following general structure. [Chemical formula] These surfactant betaines typically do not exhibit strong cationic or anionic characteristics at extreme pH values, or do not show a decrease in water solubility within their isoelectric ranges. Unlike "external" quaternary ammonium salts, betaines can coexist with anions. Examples of suitable betaines include coconut acylamidopropyldimethylbetaine, hexadecyldimethylbetaine, C12-14 acylamidopropylbetaine, C 8-14 acylamidohexyldiethylbetaine, 4-C 14-16 acylmethylamidodiethylammonio-1-carboxybutane, C 16-18 acylamidodimethylbetaine, C 12-16 acylamidopentanedietylbetaine, and C 12-16 acylmethylamidodimethylbetaine.

[0167] Sultaines useful in the present invention include compounds having the formula (R(R 1 )2N + R 2 SO 3- wherein R is a C6-C 18 hydrocarbyl group, each R 1 is typically independently a C1-C3 alkyl, such as methyl, and R 2 is a C1-C6 hydrocarbyl group, such as a C1-C3 alkylene or hydroxyalkylene group.

[0168] A typical list of zwitterionic classes and species of these surfactants is described in U.S. Patent No. 3,929,678, issued to Laughlin and Heuring on December 30, 1975. Further examples are described in "Surface Active Agents and Detergents" (Vol.I and II by Schwartz, Perry and Berch). Each of these references is hereby incorporated by reference in its entirety.

[0169] Method for manufacturing a detergent composition The solid surfactant composition of the present invention can be included in various cleaning compositions. Preferably, the cleaning composition is a solid composition. Suitable solid cleaning compositions include, but are not limited to, granular and pelletized solid compositions, powders, solid block compositions, cast solid block compositions, extruded solid block compositions, pressed solid compositions, and the like. Preferably, the cleaning composition is a pressed solid.

[0170] The solid particulate cleaning composition can be made by simply blending the dry solid components formed according to the present invention in an appropriate ratio or by aggregating the materials in an appropriate aggregation system. The pelletized material can be produced by compressing the solid granular or aggregated material in an appropriate pelletizing facility to yield an appropriately sized pelletized material. The solid block and cast solid block materials can be made by introducing into a container either a block of pre-cured material or a castable liquid that cures to a solid block within the container. Preferred containers include disposable plastic containers or water-soluble film containers. Other suitable packagings for the composition include flexible bags, sachets, shrink wraps, and water-soluble films such as polyvinyl alcohol.

[0171] Solid cleaning compositions can be formed using batch or continuous mixing systems. In an exemplary embodiment, a single - or twin - screw extruder is used to combine and mix one or more components at high shear to form a homogeneous mixture. In some embodiments, the processing temperature is below the melting temperature of the components. The processed mixture can be dispensed from the mixer by forming, casting, or other suitable means when the cleaning composition hardens into a solid form. The structure of the matrix can be characterized according to its hardness, melting point, material distribution, crystal structure, and other similar properties by methods known in the art. Generally, solid cleaning compositions processed according to the methods of the present invention are substantially homogeneous throughout their mass with respect to the distribution of components and dimensionally stable.

[0172] In the extrusion process, liquid and solid components are introduced into a final mixing system and continuously mixed until the components form a substantially homogeneous semi - solid mixture in which the components are distributed throughout their mass. The mixture is then discharged from the mixing system into or through a die or other shaping means. The product is then packaged. In an exemplary embodiment, the formed composition begins to harden into a solid form in approximately 1 minute to approximately 3 hours. Specifically, the formed composition begins to harden into a solid form in approximately 1 minute to approximately 2 hours. More specifically, the formed composition begins to harden into a solid form in approximately 1 minute to approximately 20 minutes.

[0173] In the casting process, liquid and solid components are introduced into a final mixing system and continuously mixed until the components form a substantially homogeneous liquid mixture in which the components are distributed throughout their mass. In an exemplary embodiment, the components are mixed in the mixing system for at least approximately 60 seconds. When mixing is complete, the product is transferred to a packaging container where solidification occurs. In an exemplary embodiment, the cast composition begins to harden into a solid form in approximately 1 minute to approximately 3 hours. Specifically, the cast composition begins to harden into a solid form in approximately 1 minute to approximately 2 hours. More specifically, the cast composition begins to harden into a solid form in approximately 1 minute to approximately 20 minutes.

[0174] In the press solid process, flowable solids such as granular solids or other particulate solids are combined under pressure. In the process of compressed solids, the flowable solids of the composition are placed in a mold (e.g., a die or container). The method can include gently pressing the flowable solid within the mold to produce a solid cleaning composition. The pressure can be applied by, for example, a block machine or a rotary tablet press. The pressure can be applied at about 1 to about 3000 psi, about 5 to about 2500 psi, or about 10 psi to about 2000 psi. As used herein, the term "psi" or "pounds per square inch" refers to the actual pressure applied to the flowable solid being pressed and does not refer to the gauge or hydraulic pressure measured at a point within the pressing apparatus. The method can include a curing step to produce the solid cleaning composition. As referred to herein, an uncured composition containing flowable solids is compressed to provide sufficient surface contact between the particles that make up the flowable solids such that the uncured composition will solidify into a stable solid composition. A sufficient amount of contacting particles (e.g., granules) provides effective particle-to-particle bonding to produce a stable solid composition. The inclusion of an optional curing step can include solidifying the pressed solid for a period of several hours or about one day (or more). In an additional aspect, the method can include vibrating the flowable solid within the mold or die, such as the method disclosed in U.S. Patent No. 8,889,048, which is hereby incorporated by reference in its entirety.

[0175] The use of the pressed solid offers many advantages over conventional solid blocks or tablet compositions that require casting, which requires melting of compositions that consume high pressure or significant amounts of energy within a tablet press, and / or extrusion, which requires expensive equipment and advanced technical knowledge. The pressed solid overcomes such various limitations of other solid formulations that are required for the production of solid cleaning compositions. Further, the pressed solid composition retains its shape under conditions under which the composition can be stored or handled.

[0176] The term "solid" means that the cured composition will not flow under moderate stress or pressure or merely under gravity and will substantially retain its shape. Solids can be in various forms such as powders, flakes, granules, pellets, tablets, troches, packs, briquettes, bricks, solid blocks, unit doses, or other solid forms known to those skilled in the art. The hardness of the solid casting composition and / or the pressed solid composition can range, for example, from the hardness of a relatively dense and hard fused solid product such as concrete to the hardness characteristic of a cured paste. Additionally, the term "solid" refers to the state of the cleaning composition under the expected storage and use conditions of the solid cleaning composition. Generally, it is expected that the cleaning composition will remain in solid form when exposed to temperatures up to approximately 100°F, specifically up to approximately 120°F.

[0177] The resulting solid cleaning composition may take forms including, but not limited to, cast solid products; extruded, molded, or formed solid pellets, blocks, tablets, powders, granules, flakes, or the pressed solid or formed solid may subsequently be ground or formed into powders, granules, or flakes. In an exemplary embodiment, the extruded pellet material formed by the solidifying matrix has a weight of approximately 50 grams to approximately 250 grams, the extruded solid formed by the composition has a weight of approximately 100 grams or more, and the solid block detergent formed by the composition has a mass of approximately 1 to approximately 10 kilograms. The solid composition provides a stabilized source of the functional material. In some embodiments, the solid composition may be dissolved, for example, in an aqueous medium or other medium, to produce a concentrated solution and / or a use solution. This solution can be directed to a storage tank for subsequent use and / or dilution or can be applied directly to the point of use.

[0178] The following patents disclose various combinations of coagulants, binders, and / or hardeners that can be utilized in the solid cleaning compositions of the present invention. The following U.S. patents: U.S. Patent Nos. 7,153,820; 7,094,746; 7,087,569; 7,037,886; 6,831,054; 6,730,653; 6,660,707; 6,653,266; 6,583,094; 6,410,495; 6,258,765; 6,177,392; 6,156,715; 5,858,299; 5,316,688; 5,234,615; 5,198,198; 5,078,301; 4,595,520; 4,680,134; RE32,763; and RE32,818 are hereby incorporated by reference into this specification.

[0179] Liquid compositions can typically be made by forming the components in an aqueous liquid or aqueous liquid solvent system. Such systems are typically made by dissolving or suspending the active ingredients in water or a compatible solvent and then diluting the product to an appropriate concentration to form either a concentrate or its use solution. Gel compositions can likewise be made by dissolving or suspending the active ingredients in a compatible aqueous, aqueous liquid, or mixed aqueous-organic system containing a gelling agent at an appropriate concentration. All publications and patent applications herein are indicative of the level of those skilled in the art to which the present invention pertains. All publications and patent applications are hereby incorporated by reference into this specification to the same extent as if each individual publication or patent application was specifically and individually incorporated by reference.

Examples

[0180] Embodiments of the present invention are further defined in the following non-limiting examples. It should be understood that these examples illustrate specific embodiments of the invention but are provided for illustrative purposes only. From the above considerations and these examples, those skilled in the art can identify the essential features of the invention and make various changes and modifications to the embodiments of the invention without departing from the spirit and scope of the invention, and adapt it to various applications and conditions. Therefore, various modifications to the embodiments of the invention will be apparent to those skilled in the art in addition to those shown and described herein from the foregoing description. Such modifications are also intended to be within the scope of the appended claims.

[0181] The materials used in the following examples are provided herein. Ammonyx LO (30%), lauramine oxide available from Stepan Co. Amphosol CG, cocoamidopropyl betaine available from Stepan Co. Barlox 12, cocoamine oxide available from Lonza. Mackam CB35, coco-betaine available from Solvay. Macham LSB50, lauramidopropyl hydroxysultaine available from Rhodia. Macham 50SB, cocoamidopropyl hydroxysultaine available from Rhodia.

[0182] Additional components available from multiple commercial sources were employed, including lipase enzyme, polyether siloxane, sodium alpha olefin sulfate, tartaric acid, EDTA tetrasodium, and urea (microprilled).

[0183] Example 1 Liquid amine oxide solidified using urea as a binder The first tests of the spray drying device were carried out using amine oxide mixed with urea in a 1:1 ratio based on the active substance. The calculations of the starting materials and yields are shown in Table 4.

Table 4

[0184] Next, the obtained powder was added to an exemplary solid floor care formulation, and the foaming ability relative to a control prepared with a liquid amine oxide surfactant in liquid form was observed. The solid floor care formulation for testing is shown in Table 5.

Table 5

[0185] The solidified amine oxide had an active concentration of 50%. Thus, formulation A had an amine oxide with an active concentration of 6%. The third formulation was prepared by dissolving the control composition in water and adding an equivalent amount of 18 wt% liquid amine oxide having an active concentration of 30% to the dissolved floor care composition. This provided a composition containing 6% active amine oxide. The results of the drain pipe foaming ability by determining the drain pipe filling time in seconds are shown in Table 6.

Table 6

[0186] As shown in Table 6, formulation A provided an acceleration of the drain pipe filling time compared to a solid formulation without the surfactant dried according to the present invention.

[0187] In addition, three compositions were tested for effective foaming in the presence of dirt. To do this, the compositions were dissolved in water to form foam, drops of dirt were added to the foaming composition, and the height of the foam was measured to provide a foaming profile. Specifically, as described in Table 6, solutions of the compositions were prepared with five grain waters at room temperature. 40 mL of each solution was added to separate 250 mL graduated cylinders. An exemplary and uniform dirt containing shortening, flour, whole egg powder, and oleic acid was warmed to about 200°F to liquefy the dirt. The dirt was added dropwise to each graduated cylinder. After the dirt was added, the cylinders were rotated at 30 rpm for 4 minutes and the height of the foam was measured. The results of this test are shown in Table 1. Formulation A provided the best foaming profile. The results of this test are shown in Figure 2. As can be seen from Figure 2, Formulation A provided the best foam height.

[0188] Example 2 Amine oxide solidified with sodium acetate binder The first tests of the spray drying device were carried out using amine oxide mixed with sodium acetate in a ratio of 2:1 based on the active substance. The calculations of the starting materials and yields are shown in Table 7.

Table 7

[0189] The resulting powder was tested for effective foaming in the presence of dirt. To do this, liquid amine oxide was added to 40 mL of five grain waters to provide an active concentration of about 500 ppm of amine oxide and the height of the foam was measured. In addition, the solidified amine oxide surfactant was dissolved in 40 mL of five grain waters to provide an active concentration of about 500 ppm of amine oxide and the height of the foam was measured. The results are shown in Figure 3. As can be seen from Figure 3, the solidified amine oxide provided a foam height (490 mm - 415 mm) almost the same as that of the liquid amine oxide surfactant. This indicates that the surfactant can be solidified with little loss of its foaming ability as described herein.

[0190] Also, the compositions were tested and compared in the presence of oil. An exemplary and uniform soil containing shortening, wheat flour, dried whole egg, and oleic acid was warmed to about 200°F to liquefy the soil. The soil was added dropwise to each graduated cylinder. After the soil was added, the cylinder was rotated at 30 rpm for 4 minutes and the foam height was measured. The results of this test are shown in Table 4. The solidified amine oxide provided substantially similar foaming, indicating that the foaming ability was little or not lost by solidifying the liquid amine oxide surfactant.

[0191] Example 3 Liquid surfactant solidified with a binder and a carrier When solidifying exemplary amine oxides, betaines, and sultaines, further tests were conducted using a binder and an optional carrier to evaluate the compatibility with both the binder and the carrier. Urea was employed as the binder. Alpha olefin sulfonate was employed as the carrier. The components were pumped into a laboratory-scale fluidized bed according to the masses provided in Table 8. Other preparation conditions are shown in Table 8. [Table 8]

[0192] The dry powder according to Table 8 was then tested for foam height compared to a drug infusion concentration without the dry product. The ability to solidify multiple classes of surfactants (amine oxides, betaines, and sultaines) with a binder and a carrier was thereby confirmed according to the method described herein.

[0193] Soil was prepared with 45% shortening, 30% wheat flour, 15% dried whole egg, and 10% oleic acid. Surfactants were mixed and foams were prepared by measuring the foam volume. The soil was added dropwise and the foam volume was continuously measured to evaluate the performance of the surfactant in the presence of the soil. The data are provided in Table 9 below. When the measured value reached 45 mL, no further measurements were made (this is represented as n / a). [Table 9]

[0194] As can be seen from Table 9, each class of the solidified surfactant had performance very similar to that of the surfactant with liquid infusion. Many of the surfactants had the same initial foaming value, or if not, very close foaming values. Furthermore, even if the same or not improved, the performance with respect to the increase in the addition of dirt was substantially the same. This demonstrates that each of the classes of surfactants has a high active concentration in the solidified surfactant composition and can be solidified as described herein while retaining the desired properties of the surfactant.

[0195] The features disclosed in the foregoing description, figures, or the following claims, presented in a particular form, or from the perspective of means for carrying out the disclosed functions, or methods or processes for achieving the disclosed results, can be utilized, as appropriate, separately or in any combination of such features, to implement the present invention in its various forms.

[0196] From the fact that the present invention is thus described, it will be apparent that the present invention can be modified in many ways. Such modifications should not be regarded as departing from the spirit and scope of the present invention, and all such amendments are intended to be included within the following claims. The above specification provides an explanation of the manufacture and use of the disclosed compositions and methods. Since many embodiments can be made without departing from the spirit and scope of the present invention, the present invention belongs to the claims. Examples of embodiments of the present disclosure are listed in the following items [1] to

[49] . [1] A liquid surfactant containing one or more of amine oxide, betaine, and sultaine, A solid binder containing a natural polymer, urea, a urea derivative, polyacrylate, PEG, an inorganic salt, an organic salt, an aromatic sulfonate, or a combination thereof, the solidified liquid surfactant composition comprising: The solid binder and the liquid surfactant are in a ratio of about 5:1 to about 1:30 based on the active substance, The composition is solid, the liquid surfactant is solidified in the composition, and the solidified surfactant composition has less than about 5% by weight of water. [2] The solidified surfactant composition according to item 1, wherein the solid binder and the liquid surfactant are in a ratio of active substances of about 4:1 to about 1:15. [3] The solidified surfactant composition according to item 1 or 2, wherein the liquid surfactant is one or more of dodecyldimethylamine oxide, tridecyldimethylamine oxide, tetradecyldimethylamine oxide, pentadecyldimethylamine oxide, hexadecyldimethylamine oxide, heptadecyldimethylamine oxide, octadecyldimethylamine oxide, dodecyldipropylamine oxide, tetradecyldipropylamine oxide, hexadecyldipropylamine oxide, tetradecyldibutylamine oxide, octadecyldibutylamine oxide, bis(2-hydroxyethyl)dodecylamine oxide, bis(2-hydroxyethyl)-3-dodecyloxy-1-hydroxypropylamine oxide, dimethyl-(2-hydroxydodecyl)amine oxide, 3,6,9-trioctadecyldimethylamine oxide, and 3-dodecyloxy-2-hydroxypropyl di-(2-hydroxyethyl)amine oxide. [4] The liquid surfactant is coconut acylamidopropyldimethylbetaine, hexadecyldimethylbetaine, C 12-14 acylamidopropyl betaine, C 8-14 acylamidohexyldiethyl betaine, C 16-18 acylamidodimethyl betaine, C 12-16 acylamidopentanedietyl betaine, and C 12-16 acylmethylamidodimethyl betaine, the solidified surfactant composition according to any one of items 1 to 3. [5] The liquid surfactant has the formula (R(R 1 ) 2 N + R 2 SO 3- A compound having, where R is a C 6 -C 18 hydrocarbyl group, R 1 is a C 1 -C 3 alkyl, R 2 is a C 1 -C 6 hydrocarbyl group, the solid surfactant composition according to any one of items 1 to 4. [6] The solid surfactant composition according to any one of items 1 to 5, wherein the binder is urea, a urea derivative, or a combination thereof. [7] The solid surfactant composition according to any one of items 1 to 5, wherein the binder is sodium acetate, sodium chloride, sodium sulfate, magnesium sulfate, sodium xylene sulfonate, an alkali metal carbonate, or a combination thereof. [8] The solid surfactant composition according to any one of items 1 to 5, wherein the binder is gum, cellulose, cellulose ester, chitin, chitosan, starch, chemically modified starch, protein, lignin, natural rubber, or a combination thereof. [9] The solid surfactant composition according to any one of items 1 to 5, wherein the binder is a PEG having a melting point of at least about 40 °C.

[10] The solid surfactant composition according to any one of items 1 to 9, wherein the binder is PEG1450, PEG3350, PEG4000, PEG4600, PEG8000, or a combination thereof.

[11] The solid surfactant composition according to any one of items 1 to 10, further comprising a carrier.

[12] The solid surfactant composition according to item 11, wherein the binder and the carrier have a water solubility of about 0.2 g / L or more at 20 °C.

[13] The solid surfactant composition according to item 11 or 12, wherein the carrier is a solid anionic surfactant, a solid organic salt, a solid inorganic salt, or a combination thereof.

[14] The solid surfactant composition according to any one of items 11 to 13, wherein the carrier comprises alpha olefin sulfonate, linear alkyl sulfonate, sodium lauryl sulfate, sodium alkyl sulfate, sodium carbonate, magnesium carbonate, sodium acetate, magnesium acetate, sodium sulfate, magnesium sulfate, sodium chloride, or a combination thereof.

[15] The solid surfactant composition according to any one of items 1 to 14, having less than about 5% by weight of water.

[16] The solid surfactant composition according to any one of items 1 to 15, having less than about 2% by weight of water.

[17] The solidifying surfactant composition according to any one of items 1 to 16, wherein the solidifying surfactant composition contains at least about 10% by weight of an active surfactant.

[18] The solidifying surfactant composition according to any one of items 1 to 17, wherein the solidifying surfactant composition contains at least about 25% by weight of an active surfactant.

[19] The solidifying surfactant composition according to any one of items 1 to 18, wherein the solidifying surfactant composition contains at least about 50% by weight of an active surfactant.

[20] A method for preparing the solidifying surfactant composition according to any one of items 1 to 19, wherein the method comprises: Adding the liquid surfactant and the solid binder to a drying device; Drying the liquid surfactant and the solid binder to form a solidifying surfactant composition, wherein the liquid surfactant solidifies in the solidifying surfactant composition; The method, wherein the solidifying surfactant composition has less than about 5% by weight of water.

[21] The method according to item 20, wherein the drying device is a continuous tunnel dryer, a rotary dryer, a vacuum dryer, a tower condenser, a vibrating conveyor condenser, a drum dryer, a screw conveyor dryer, a fluidized bed, a jet fluidized bed, a pneumatic conveyor, a spray dryer, or a combination thereof.

[22] The method according to item 20 or 21, wherein there are at least two drying devices arranged in series or in parallel.

[23] The method according to any one of items 20 to 22, wherein the drying process is carried out in a batch system.

[24] The method according to any one of items 20 to 23, wherein the drying process is carried out in a continuous system.

[25] The method according to any one of items 20 to 24, wherein the drying device includes a fluidized bed.

[26] The method according to item 25, wherein the fluidized bed has an air flow rate of about 1 to about 100 feet per second.

[27] The method according to item 25 or 26, wherein the fluidized bed has a liquid flow rate of the bed material of about 0.001 to about 0.15 lb / min of pounds.

[28] The method according to any one of items 25 to 27, wherein the fluidized bed has an atomizing air pressure of about 0 psig to about 100 psig per nozzle.

[29] The method according to any one of items 25 to 28, wherein the method employs a granulation process and the binder is dissolved to form a liquid.

[30] The method according to any one of items 25 to 28, wherein the method employs an agglomeration process.

[31] The method according to any one of items 20 to 24, wherein the drying device includes a spray dryer.

[32] The method according to item 31, wherein the spray dryer has an inlet and an outlet, the inlet temperature is about 20°C to about 250°C, and the outlet temperature is less than about 150°C.

[33] The method according to item 32, wherein the inlet temperature is about 100°C to about 250°C, and the outlet temperature is about 20°C to about 100°C.

[34] A solid cleaning composition comprising the solidified surfactant composition according to any one of items 1 to 20, And a curing agent.

[35] The cleaning composition according to item 34, wherein the cleaning composition is a dishwashing composition, a laundry composition, or a hard surface composition.

[36] The cleaning composition according to item 35 or 36, further comprising an alkali source selected from the group consisting of alkali metal hydroxides, alkali metal carbonates, metal silicates, metal borates, alkanolamines, and combinations thereof.

[37] The cleaning composition according to item 36, wherein the alkali source is in an amount of about 0.01% to about 99% by weight of the cleaning composition.

[38] The cleaning composition according to item 36 or 37, wherein the alkali source is in an amount sufficient to provide a pH of about 7 to about 14 in the use solution.

[39] The cleaning composition according to any one of items 34 to 38, wherein the cleaning composition provides a pH of about 1 to about 7 in the use solution.

[40] The cleaning composition according to any one of items 34 to 39, further comprising an additional surfactant selected from the group consisting of nonionic surfactants, cationic surfactants, anionic surfactants, semi-polar nonionic surfactants, amphoteric surfactants, zwitterionic surfactants, and combinations thereof.

[41] The cleaning composition according to any one of items 34 to 40, wherein the cleaning composition is a granular solid, a pelletized solid, a cast solid, an extruded solid block, or a pressed solid.

[42] The cleaning composition according to item 41, wherein the cleaning composition is a pressed solid.

[43] The cleaning composition according to any one of items 34 to 42, further comprising at least one of the following additional components: an acid source, an activator, an anti-redeposition agent, a bleaching agent, a chelating agent, a dye, a fragrance, a filler, a functional polydimethylsiloxane, a curing agent, a hydratable salt, a polymer, or a bactericide.

[44] A method for cleaning a surface, the method comprising: Dissolving the cleaning composition according to any one of items 34 to 43 to form a liquid cleaning composition; Contacting the surface with the liquid cleaning composition.

[45] The method according to item 44, wherein the liquid cleaning composition is diluted.

[46] The method according to item 45, wherein the dilution of the liquid cleaning composition is performed after dissolution of the solid cleaning composition and before bringing the surface into contact with the liquid cleaning composition.

[47] The method according to any one of items 44 to 46, wherein the surface includes a hard surface, an article, or a laundry.

[48] The method according to any one of items 44 to 47, further comprising rinsing the surface with water.

[49] The method according to any one of items 44 to 48, wherein the cleaning composition provides substantially the same foaming characteristics as a cleaning composition having the same components except that the solidified surfactant composition is a liquid surfactant.

Claims

1. A solidified liquid surfactant composition comprising: a liquid surfactant selected from one or more amine oxides; and a solid binder comprising a natural polymer, urea, a urea derivative, a polyacrylate, PEG, an inorganic salt, an organic salt, an aromatic sulfonate, or a combination thereof, wherein the solid binder and the liquid surfactant are in a ratio of 5:1 to 1:30 based on the active substance, the composition is solid, the liquid surfactant is solidified in the composition, the solidified surfactant composition has less than 5 wt% water, and the solidified amine oxide has an active concentration of at least 50 wt%.

2. The solidified surfactant composition according to claim 1, wherein the solid binder and the liquid surfactant are in a ratio of active substances of 4:1 to 1:

15.

3. The solidified surfactant composition according to claim 1 or 2, wherein the liquid surfactant is one or more of dodecyldimethylamine oxide, tridecyldimethylamine oxide, tetradecyldimethylamine oxide, pentadecyldimethylamine oxide, hexadecyldimethylamine oxide, heptadecyldimethylamine oxide, octadecyldimethylamine oxide, dodecyldipropylamine oxide, tetradecyldipropylamine oxide, hexadecyldipropylamine oxide, tetradecyldibutylamine oxide, octadecyldibutylamine oxide, bis(2-hydroxyethyl)dodecylamine oxide, bis(2-hydroxyethyl)-3-dodecoxy-1-hydroxypropylamine oxide, dimethyl-(2-hydroxydodecyl)amine oxide, 3,6,9-trioctadecyldimethylamine oxide, and 3-dodecoxy-2-hydroxypropyl di-(2-hydroxyethyl)amine oxide.

4. The solidified surfactant composition according to any one of claims 1 to 3, wherein the binder is urea, a urea derivative, or a combination thereof.

5. The solidified surfactant composition according to any one of claims 1 to 3, wherein the binder is sodium acetate, sodium chloride, sodium sulfate, magnesium sulfate, sodium xylene sulfonate, an alkali metal carbonate, or a combination thereof.

6. The solidified surfactant composition according to any one of claims 1 to 3, wherein the binder is gum, cellulose, cellulose ester, chitin, chitosan, starch, chemically modified starch, protein, lignin, natural rubber, or a combination thereof.

7. The solidified surfactant composition according to any one of claims 1 to 3, wherein the binder is PEG having a melting point of at least 40°C.

8. The solidified surfactant composition according to any one of claims 1 to 7, wherein the binder is PEG1450, PEG3350, PEG4000, PEG4600, PEG8000, or a combination thereof.

9. The solidified surfactant composition according to any one of claims 1 to 8, further comprising a carrier.

10. The solidified surfactant composition according to claim 9, wherein the binder and the carrier have a water solubility of 0.2 g / L or more at 20°C.

11. The solidified surfactant composition according to claim 9 or 10, wherein the carrier is a solid anionic surfactant, a solid organic salt, a solid inorganic salt, or a combination thereof.

12. The solidified surfactant composition according to any one of claims 9 to 11, wherein the carrier comprises alpha olefin sulfonate, linear alkyl sulfonate, sodium lauryl sulfate, sodium alkyl sulfate, sodium carbonate, magnesium carbonate, sodium acetate, magnesium acetate, sodium sulfate, magnesium sulfate, sodium chloride, or a combination thereof.

13. The solidified surfactant composition according to any one of claims 1 to 12, having less than 5% by weight of water.

14. The solidified surfactant composition according to any one of claims 1 to 13, having less than 2% by weight of water.

15. A method for preparing the solidified surfactant composition according to any one of claims 1 to 14, the method comprising: adding the liquid surfactant and the solid binder to a drying device; drying the liquid surfactant and the solid binder to form a solidified surfactant composition, wherein the liquid surfactant solidifies in the solidified surfactant composition, and the solidified surfactant composition has less than 5% by weight of water.

16. The method according to claim 15, wherein the drying device is a continuous tunnel dryer, a rotary dryer, a vacuum dryer, a tower concentrator, a vibrating conveyor concentrator, a drum dryer, a screw conveyor dryer, a fluidized bed, a jet fluidized bed, a pneumatic conveyor, a spray dryer, or a combination thereof.

17. The method according to claim 15 or 16, having at least two drying devices arranged in series or in parallel.

18. The method according to any one of claims 15 to 17, wherein the drying process is carried out in a batch system.

19. The method according to any one of claims 15 to 17, wherein the drying process is carried out in a continuous system.

20. The drying device includes a fluidized bed, the fluidized bed has an air flow velocity of 1 to 100 feet (about 0.3 m to about 30.5 m) / second, the fluidized bed has a liquid flow rate of the bed material of 0.001 to 0.15 lb (about 0.45 to about 68.04 g) / minute, and the fluidized bed has an atomizing air pressure of 0 psig to 100 psig (0 to about 689.5 kPa) per nozzle. The method according to any one of claims 15 to 19.

21. The method according to claim 20, wherein the method employs a granulation process and the binder is dissolved to form a liquid.

22. The method according to claim 20, wherein the method employs an agglomeration process.

23. The drying device includes a spray dryer, the spray dryer has an inlet and an outlet, the inlet temperature is 20°C to 250°C, the outlet temperature is less than 150°C, the inlet temperature is 100°C to 250°C, and the outlet temperature is 20°C to 100°C. The method according to any one of claims 15 to 19.

24. A solid cleaning composition comprising the solidified surfactant composition according to any one of claims 1 to 14 and a solidifying agent. A solid cleaning composition comprising a solidifying agent.

25. The cleaning composition according to claim 24, wherein the cleaning composition is a dishwashing composition, a laundry composition, or a hard surface composition.

26. The cleaning composition according to claim 24 or 25, further comprising an alkali source selected from the group consisting of alkali metal hydroxides, alkali metal carbonates, metal silicates, metal borates, alkanolamines, and combinations thereof.

27. The cleaning composition according to claim 26, wherein the alkali source is in an amount of 0.01% to 99% by weight of the cleaning composition.

28. The cleaning composition according to claim 26 or 27, wherein the alkali source is in an amount sufficient to provide a pH of 7 to 14 in the use solution.

29. The cleaning composition according to any one of claims 24 to 27, wherein the cleaning composition provides a pH of 1 to 7 in the use solution.

30. The cleaning composition according to any one of claims 24 to 29, further comprising an additional surfactant selected from the group consisting of nonionic surfactants, cationic surfactants, anionic surfactants, semi-polar nonionic surfactants, amphoteric surfactants, zwitterionic surfactants, and combinations thereof.

31. The cleaning composition according to any one of claims 24 to 30, wherein the cleaning composition is a granular solid, a pelletized solid, a cast solid, an extruded solid block, or a pressed solid.

32. The cleaning composition according to claim 31, wherein the cleaning composition is a pressed solid.

33. The cleaning composition according to any one of claims 24 to 32, further comprising at least one of the following additional components: an acid source, an activator, an anti-redeposition agent, a bleaching agent, a chelating agent, a dye, a fragrance, a filler, a functional polydimethylsiloxane, a curing agent, a hydratable salt, a polymer, or a bactericide.

34. A method of cleaning a surface, the method comprising: dissolving the cleaning composition according to any one of claims 24 to 33 to form a liquid cleaning composition; and contacting the surface with the liquid cleaning composition.

35. The method according to claim 34, wherein the liquid cleaning composition is diluted.

36. The method according to claim 35, wherein the dilution of the liquid cleaning composition is performed after the dissolution of the solid cleaning composition and before contacting the surface with the liquid cleaning composition.

37. The method according to any one of claims 34 to 36, wherein the surface includes a hard surface, an article, or laundry.

38. The method according to any one of claims 34 to 37, further comprising rinsing the surface with water.

39. The method according to any one of claims 34 to 38, wherein the cleaning composition provides foaming characteristics substantially similar to those of a cleaning composition having the same components except that the solidified surfactant composition is a liquid surfactant.

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