Solid cleaning compositions exhibiting controlled collapse

Abstract

A solid cleaning composition comprising (I) a first phase and (II) a second phase, wherein (I) the first phase comprises a mixture of ingredients including (a) a solid surfactant, (b) a disintegrant, and (c) a lubricant, and (II) the second phase comprises (d) a superabsorbent polymer, and (e) a binder.

Description

Technical Field

[0001] The present invention relates to a cleaning composition. More particularly, the present invention relates to a solid cleaning composition and a method for obtaining the same.

Background Art

[0002] Cleaning compositions are widely used in our society. These compositions are typically used for bathing, handwashing, and cleaning the body and hair at almost all stages of people's lives, from newborns to the elderly. Cleaning compositions are also used for the care and hygiene of other mammals, including pets.

[0003] The most conventional form of a cleaning composition is bar soap obtained by saponification, which is a process of converting fats and oils into soap and alcohol by heating in the presence of an aqueous alkali such as sodium hydroxide. When obtained by saponification, the resulting cleaning formulation tends to exhibit a low pH that can disrupt the skin's balance. In addition to its pH, such formulations tend to remove lipids from the skin excessively, causing dryness or discomfort to the user. However, such bars are inexpensive to obtain and last for several cleaning procedures.

[0004] Furthermore, such bars are easy to use and are sufficient to create a cleaning foam simply by rubbing on wet skin. Advantageously, bar soap is bulky and thus helps the consumer to grip the bar soap during use.

[0005] As an alternative to bar soap obtained by saponification, there are cleansing formulations containing synthetic surfactants that are generally gentle on the skin and not harmful to the environment. Such formulations are commonly found in the form of liquid viscous substances. Despite their advantage of being gentle on the skin, these formulations need to be packaged in flasks or bottles. Furthermore, these formulations are preferably applied to the skin by a sponge to promote lathering and to avoid being rinsed off too quickly. Even more preferably, such bottles are equipped with complex dispensing mechanisms that help the user appropriately select the correct amount of the formulation to be poured onto a sponge or directly onto the skin.

[0006] Another disadvantage of liquid cleaning formulations is that they typically contain large amounts of water, which can result in larger volumes being transported and stored during sale. [Overview of the Initiative] [Means for solving the problem]

[0007] The inventors have discovered a novel cleaning composition that overcomes some of the disadvantages observed when using currently available cleaning compositions.

[0008] In a first embodiment, the present invention relates to a solid cleaning composition comprising (I) a first phase and (II) a second phase, wherein (I) the first phase comprises a mixture of components including (a) a solid surfactant, (b) a disintegrant, and (c) a lubricant, and (II) the second phase comprises (d) a superabsorbent polymer and (e) a binder.

[0009] In preferred embodiments of the present invention, a preferred (a) solid surfactant is Plantapon SUS (disodium lauryl sulfosuccinate), Coliform SLS (sodium lauryl sulfate), or Jordapon (coconut fatty acid, 2-sulfoethyl ester, sodium salt); a preferred (b) disintegrant is pregelatinized starch or lactose 200 mesh; a preferred (c) lubricant is magnesium stearate; a preferred (d) superabsorbent polymer is starch-grafted superabsorbent polymer (SGSAP); and a preferred (e) binder is water.

[0010] Furthermore, according to the present invention, (I) the first phase and (II) the second phase are arranged in layers adjacent to each other.

[0011] In a second embodiment of the present invention, the solid composition is a single-use solid cleaning composition that, upon exposure to a liquid, (I) the first phase generates foam and (II) the second phase swells. The solid composition remains in a unified state for a limited time during use, and disintegrates when that limit is reached. [Brief explanation of the drawing]

[0012] [Figure 1] The molds used to obtain the samples described herein are shown. [Figure 2] This is a graph showing the decay characteristics of the tested samples. [Modes for carrying out the invention]

[0013] In a first embodiment, the present invention relates to a solid cleaning composition comprising (I) a first phase and (II) a second phase, wherein (I) the first phase comprises a mixture of components including (a) a solid surfactant, (b) a disintegrant, and (c) a lubricant, and (II) the second phase comprises (d) a superabsorbent polymer and (e) a binder.

[0014] In preferred embodiments of the present invention, a suitable (a) solid surfactant is Plantapon SUS (disodium lauryl sulfosuccinate), Coliform SLS (sodium lauryl sulfate), or Jordapon (coconut fatty acid, 2-sulfoethyl ester, sodium salt). A suitable (b) disintegrant is pregelatinized starch or lactose 200 mesh. A suitable (c) lubricant is magnesium stearate. A suitable (d) superabsorbent polymer is starch-grafted superabsorbent polymer (SGSAP). A suitable (e) binder is water.

[0015] Furthermore, according to the present invention, (I) the first phase and (II) the second phase are arranged in layers adjacent to each other.

[0016] In a second embodiment of the present invention, the solid composition is a single-use solid cleaning composition that, upon exposure to a liquid, (I) the first phase generates foam and (II) the second phase swells. The solid composition remains integrated for a sufficient amount of time during use and disintegrates when it reaches its limit.

[0017] Surfactants are chemical substances that form clusters of self-assembled molecules called micelles in a solution (aqueous or oily phase) and adsorb to the interface between the solution and a different phase (gas / solid). Surfactants have a chemical structure with two different functional groups, called hydrophobic and hydrophilic, and must have different affinities within the same molecule. Typically, both surfactants have alkyl chains with 8 to 22 carbon atoms. This chain is a hydrophobic group and does not show affinity for water (surfactants are often used in aqueous systems, so their chains are called hydrophobic groups, but when used in lipid systems, their chains are called lipophilic groups). Surfactant molecules also have a functional group called a hydrophilic group that has affinity for water. Structures of this type with two opposing functions are known as amphiphilic structures (see Nakama, Y., "Chapter 15: Surfactants." in Sakamoto, K. et al. Cosmetic Science and Technology: Theoretical Principles and Applications (Cambridge, MA, Elsevier Inc., 2017). pp. 231-244). Suitable surfactants for the present invention are solid surfactants such as Plantapon SUS (disodium lauryl sulfosuccinate), Coliform SLS (sodium lauryl sulfate), or Jordapon (coconut fatty acid, 2-sulfoethyl ester, sodium salt).

[0018] As used herein, the term “disintegrant” and its variations relate to components included in a composition to promote the disintegration of its phase when wet. Since disintegrants can also act as diluents in addition to promoting disintegration, the term “disintegrant” as used herein also encompasses the function of a filler. As will be further considered, compressibility is an important property found in the disintegration of the solid compositions of the present invention. Suitable disintegrants are starches such as pregelatinized starch, or lactose 200 mesh.

[0019] As used herein, the term “lubricant” and its variations relate to an ingredient that facilitates proper mixing of components, and more specifically, an ingredient that facilitates the movement of mixed particles during the manufacture of a composition. According to the present invention, a preferred but not essential lubricant assists the movement of mixed particles, thereby facilitating the flow of mixed particles during the compression process. A preferred lubricant is magnesium stearate.

[0020] Superabsorbent polymers (SAPs) are a group of materials capable of absorbing large quantities of water—at least 10 times their own weight—in aqueous fluids under moderate pressure. Generally, SAPs consist of a network structure of crosslinked polymer chains to prevent dissolution. Typically, ionic functional groups are present along the polymer chains to facilitate the diffusion of water within the network structure. Polyacrylates are the most commonly found materials in the SAP industry. Superabsorbent polyacrylates are prepared by polymerizing acrylic acid with a crosslinking agent (see Nnadi, F. and Brave, C. Environmentally friendly superabsorbent polymers for water conservation in agricultural lands. Journal of Soil Science and Environmental Management, Vol.2(7)(July 2011), pp.206-211).

[0021] Preferably, the superabsorbent polymer contained in the cleaning composition of the present invention is a starch-grafted superabsorbent polymer (SGSAP), which exhibits higher biodegradability compared to ordinary superabsorbent polymers.

[0022] A suitable SGSAP is the starch-based sodium polyacrylate graft polymer, designated XGF 450, supplied by Corno Cascasdes LLC (Beaverton, Oregon, USA).

[0023] Other known SGSAPs include, among others, those sold under the names Sanfresh ST-100C, ST100MC, IM-300MC by Sanyo Chemical Industries, and those sold under the names Water Lock A-240, A-180, B-204, D-223, A-100, C-200, D-223 by Grain Processing, and FAVOR® max2010 and FAVOR® max2020 manufactured by Evonik.

[0024] Embodiments of the present invention A multi-layer single-use solid cleaning product, · At least one surfactant layer, comprising a solid surfactant (preferably about 20% to about 40% by weight of the surfactant layer), a disintegrant (preferably about 60% to about 80% by weight of the surfactant layer), and optionally a lubricant (preferably less than about 5% by weight of the surfactant layer, more preferably 1% to 5% by weight, even more preferably 2% to 5% by weight), at least one surfactant layer; · At least one structural layer comprising a structuring agent (SAP) and a binder; · A multi-layer single-use solid cleaning product that is disintegrating as described above.

[0025] The multi-layer single-use solid cleaning product described above, · The solid surfactant is a mild surfactant selected from the group consisting of alkyl sulfosuccinate, alkyl sulfate, aliphatic sulfonate ester, preferably sodium lauryl sulfosuccinate, sodium lauryl sulfate, or sodium 2-sulfoethyl ester of coco fatty acid, a multi-layer single-use solid cleaning product.

[0026] The multi-layer single-use solid cleaning product described above, A multilayer, single-use solid cleaning product in which the disintegrant is selected from a list including carboxymethylcellulose, sodium starch glycolate, polyvinylpyrrolidone, pregelatinized starch, or lactose, and is preferably selected from pregelatinized starch or lactose 200 mesh.

[0027] The multi-layer single-use solid cleaning product described above, A multi-layer, single-use solid cleaning product in which the solid cleaning product contains a lubricant, and the lubricant is magnesium stearate.

[0028] The multi-layer single-use solid cleaning product described above, A multilayer single-use solid cleaning product in which the structural agent is a superabsorbent polymer (preferably a starch-based sodium polyacrylate grafted polymer, preferably constituting at least about 50% by weight of the structural layer, more preferably 55% to 80% by weight of the structural layer).

[0029] The multi-layer single-use solid cleaning product described above, A multilayer single-use solid cleaning product in which the binder is selected from the group consisting of water, alcohol, glycerin, or glycerol (preferably the binder is water, preferably constituting less than about 50% by weight of the structural layer, more preferably 20% to 45% by weight of the structural layer).

[0030] The multi-layer single-use solid cleaning product described above, • A multi-layer, single-use solid cleaning product in which the solid surfactant, disintegrant, lubricant, and structural agent are biodegradable.

[0031] The multi-layer single-use solid cleaning product described above, A multilayer, single-use solid cleaning product comprising one surfactant layer and one structural layer.

[0032] The multi-layer single-use solid cleaning product described above, A multi-layer, single-use solid cleaning product containing one surfactant layer positioned between two structural layers.

[0033] The multi-layer single-use solid cleaning product described above, A multi-layer, single-use solid cleaning product containing one structural layer positioned between two surfactant layers.

[0034] The multi-layer single-use solid cleaning product described above, A multilayer, single-use solid cleaning product comprising 60% to 80% by weight, preferably 65% ​​to 75% by weight, of the surfactant layer.

[0035] The multi-layer single-use solid cleaning product described above, A multilayer single-use solid cleaning product comprising 20% ​​to 40% by weight, preferably 25% to 35% by weight of the structural layer.

[0036] The multi-layer single-use solid cleaning product described above, • A multi-layer, single-use solid cleaning product in which each layer is directly compressed with the others to obtain a tablet.

[0037] A method for manufacturing a multi-layer single-use solid cleaning product. The process involves placing at least one surfactant layer containing a solid surfactant, a disintegrant, and optionally a lubricant, and at least one structural layer containing a structural agent (SAP) and a binder, in contact with each other. A method comprising the step of compressing at least two superimposed layers to a direct compressive force of at least 700 psi for at least one cycle, optionally multiple cycles.

[0038] The multi-layer single-use solid cleaning product described above, • Use for cosmetic purposes in personal care products.

[0039] The multi-layer single-use solid cleaning product described above, A multi-layer, single-use solid cleaning product having a collapse time of 2 to 15 minutes, generating foam, and in which at least one structural layer swells to form a sponge texture.

[0040] The above description represents exemplary compositions that may be produced in accordance with the present invention, but it should be understood that various additions, modifications, and substitutions can be made therein without departing from the spirit and scope of the invention. Accordingly, the examples disclosed herein should be considered in all respects to be exemplary and not limiting, and the scope of the invention is indicated by the appended claims and is not limited to the foregoing description.

[0041] A suitable composition prepared to obtain the first phase of the solid composition of the present invention:

[0042] [Table 1]

[0043] A suitable composition prepared to obtain the second phase of the solid composition of the present invention:

[0044] [Table 2] [Examples]

[0045] The following samples were prepared and labeled as 4A, 4B, 5A, 5B, 5C, and 6A, respectively.

[0046] 5A comprises three layers: two layers of mixture 5 as the first phase, and a single layer of the second phase composition sandwiched in between.

[0047] 6A comprises two layers, each consisting of a single layer of mixture 6 as the first phase, opposite a single layer of the second phase composition.

[0048] 4A comprises two layers, each consisting of a single layer of mixture 4 as the first phase, opposite a single layer of the second phase composition.

[0049] 5B comprises two layers, each consisting of a single layer of mixture 5 as the first phase, opposite a single layer of the second phase composition.

[0050] The structure consisted of three layers: two layers of Phase 5C-2 and a single layer of mixture 5 sandwiched between them.

[0051] 4B consists of three layers: two layers as the second phase and a single layer of mixture 4 sandwiched between them.

[0052] The samples followed a 1:1 ratio of Phase 1 to Phase 2. Therefore, each composition sample weighed approximately 10 g and contained 5 g of Phase 1 composition and 5 g of Phase 2 composition. In embodiments containing only two layers, the Phase 1 and Phase 2 were provided adjacent to each other, whereas in embodiments containing three layers, one of the phases was equally divided into two thinner layers, and the other phase was sandwiched between the two thinner layers of the divided phase.

[0053] Furthermore, the composition of the first phase and the composition of the second phase were pre-mixed and set aside accordingly. The powder components of the first phase were weighed and added to a plastic bag, and mixed by hand for 1 minute. After preparation, the compositions were placed in layers in the mold, and the order of layering followed the form of the sample, i.e., two layers or sandwiched (three or more layers). As shown in Figure 1, the mold 10 had a disc-shaped cavity 12 with dimensions corresponding to the final dimensions of the "coin" shaped compressed product, and a plunger 14 that could be connected to the ram of the press machine. The mold 10 was prepared by 3D printing from ABS resin (ABS Plus-P430 manufacturing grade thermoplastic) with an inner diameter of 5 cm and a thickness / height of 1.5 cm.

[0054] After placing each composition in a mold, it was compressed with a pneumatic press at a pressure of 750 psi for 5 seconds, and this was repeated three times.

[0055] As a result of compression, the powdered composition became a substantially unified solid. More specifically, it became a solid cleaning composition in the shape of a "coin".

[0056] Disintegration assay The disintegration assay procedure was designed to simulate the performance of the cleaning composition in use. The solid composition was then submerged in water under a constant shear stress applied by water agitation. Parameters such as the change in mass, as well as other visual observations such as the integrity of the cleaning composition, were then evaluated.

[0057] Accordingly, a magnetic stirrer (IKA-model RH Basic) equipped with a stainless steel sieve, thermometer, glass beaker, magnetic bar, and heater was used in the disintegration assay described in more detail below.

[0058] The disintegration assay included the following steps:

[0059] Step 1: Pour 750 mL of regular tap water into a 1-liter glass beaker.

[0060] Step 2: Heat and maintain the water temperature at 37°C under constant stirring at 600 rpm.

[0061] Step 3: Use a stainless steel sieve to ensure the test sample is completely submerged in water before placing it in the beaker.

[0062] Step 4: After 1 minute, remove the stainless steel sieve from the beaker. Use a paper towel to remove any excess water.

[0063] Step 5: Weigh the stainless steel sieve together with the test sample using a precision chemical balance that has been pre-tared, and record the weight.

[0064] Step 6: Visually observe the integrity of the test sample and record it with a photograph taken using a photocamera.

[0065] Step 7: If still fused together, return the stainless steel sieve to the beaker along with the prototype.

[0066] Step 8: Repeat steps 3-7 until complete dissolution of the test sample is observed.

[0067] Test results When tested according to the disintegration assay, further differences in disintegration characteristics were observed between samples, as discussed above, with differences observed in the duration of integrity until disintegration and the change in mass.

[0068] When different mixtures were tested for the first phase, initial integrity could not be achieved after the compression process. It should be noted that all tested samples were manually inspected for integrity, and only samples that were known to be solid and integrated as unit pieces were tested.

[0069] Samples containing mixture 4 as the composition of the first phase are those that maintained the integrated state for a longer period of time. Sample 4B showed a duration of 15 minutes, and sample 4A showed a duration of 13 minutes.

[0070] Accordingly, sample 4B swelled, with its mass increasing to 116.8%.

[0071] Sample 5C was a sample with a short duration, maintaining a unified state for only one minute.

[0072] As shown in Figure 2, all samples showed an increase in mass during the test. This is thought to be because the first phase of each sample disintegrated under agitation with water, while the second phase, containing the superabsorbent, increased in mass due to water absorption.

[0073] Sample 6A was a sample that did not swell much before decaying. This sample swelled by increasing its mass by 33.6%.

[0074] Therefore, depending on several desired functionalities of the solid cleaning composition, different compositions and structures can be created to control the disintegration and swelling of the product during use. Significant swelling of the product is desirable in bath cleaning products, as it avoids the breakage and volume typically seen in new solid soap bars, while preventing the disadvantages of saponification. Products that dissolve more quickly can be highly valued in faster or finer cleaning procedures, such as hand washing or face washing.

[0075] [Implementation Method] (1) A solid cleaning composition comprising (I) a first phase and (II) a second phase, wherein the (I) first phase comprises a mixture of components comprising (a) a solid surfactant, (b) a disintegrant, and (c) a lubricant, and the (2) second phase comprises (d) a superabsorbent polymer and (e) a binder. (2) The solid composition according to Embodiment 1, wherein the (a) solid surfactant is selected from disodium lauryl sulfosuccinate, sodium lauryl sulfate, Jordapon, or a mixture thereof. (3) The solid composition according to Embodiment 1 or 2, wherein the disintegrant (b) is selected from pregelatinized starch, lactose 200 mesh, or a mixture thereof. (4) The solid composition according to any one of Embodiments 1 to 3, wherein the selected (c) lubricant is magnesium stearate. (5) The solid composition according to any one of Embodiments 1 to 4, wherein the superabsorbent polymer in (c) is selected from starch-grafted superabsorbent polymers or mixtures thereof.

[0076] (6) The solid composition according to any one of Embodiments 1 to 5, wherein the binder (d) is water. (7) The solid composition according to any one of embodiments 1 to 6, wherein the (I) first phase and the (II) second phase are arranged in layers, each including at least one layer of the respective phases. (8) The solid composition according to Embodiments 1 to 6, wherein the (I) first phase and the (II) second phase are arranged in layers, the first phase is divided into at least two layers, and the second phase is sandwiched between the two layers of the first phase. (9) The solid composition according to Embodiments 1 to 6, wherein the (I) first phase and the (II) second phase are arranged in layers, the second phase is divided into at least two layers, and the first phase is sandwiched between the two layers of the second phase. (10) The solid composition according to Embodiment 1, wherein the (I) first phase comprises about 50% to about 90% of a disintegrant, about 7% to about 47% of a surfactant, and about 1% to about 30% of a lubricant.

[0077] (11) The solid composition according to Embodiment 1, wherein the (I) first phase comprises about 60% to about 80% of a disintegrant, about 17% to about 37% of a surfactant, and about 1% to about 20% of a lubricant. (12) The solid composition according to Embodiment 1, wherein the (I) first phase comprises about 70% disintegrant, 27% surfactant, and 3% lubricant. (13) The solid composition according to Embodiment 1, wherein the mass ratio of the (I) first phase to the (II) second phase is approximately 1:1. (14) The solid composition according to Embodiment 1, which maintains an integral state for about 1 to about 15 minutes when subjected to the test assay described herein. (15) The solid composition according to Embodiment 1, which swells by increasing its mass by about 33% to about 116% when subjected to the test assay described herein.

Claims

1. A solid cleaning composition for personal care comprising (I) a first phase and (II) a second phase, wherein the (I) first phase comprises a mixture of components including (a) a solid surfactant, (b) a disintegrant, and (c) a lubricant, and the (II) second phase comprises (d) a superabsorbent polymer and (e) a binder. The solid surfactant (a) is selected from disodium lauryl sulfosuccinate; sodium lauryl sulfate; sodium salt of 2-sulfoethyl cocoate; or a mixture thereof. The aforementioned (b) disintegrant is pregelatinized starch, The (c) lubricant is magnesium stearate, The (d) superabsorbent polymer is a starch-based sodium polyacrylate graft polymer, The (e) binder is water, A solid cleaning composition in which the (I) first phase and the (II) second phase are arranged in layers adjacent to each other.

2. The solid cleaning composition according to claim 1, wherein the first phase is divided into at least two layers, and the second phase is sandwiched between the two layers of the first phase.

3. The solid cleaning composition according to claim 1, wherein the second phase is divided into at least two layers, and the first phase is sandwiched between the two layers of the second phase.

4. The solid cleaning composition according to claim 1, wherein the (I) first phase comprises 50% to 90% by weight of the disintegrant, 7% to 47% by weight of the solid surfactant, and 1% to 30% by weight of the lubricant, based on the weight of the first phase.

5. The solid cleaning composition according to claim 1, wherein the (I) first phase comprises 60% to 80% by weight of the disintegrant, 17% to 37% by weight of the solid surfactant, and 1% to 20% by weight of the lubricant, based on the weight of the first phase.

6. The solid cleaning composition according to claim 1, wherein the (I) first phase comprises, with respect to the weight of the first phase, 70% by weight of the disintegrant, 27% by weight of the solid surfactant, and 3% by weight of the lubricant.

7. The solid cleaning composition according to claim 1, wherein the mass ratio of the (I) first phase to the (II) second phase is 1:

1.

8. The (a) solid surfactant comprises disodium lauryl sulfosuccinate, The solid cleaning composition according to claim 1, wherein the (b) disintegrant comprises pregelatinized starch.

9. The (a) solid surfactant is disodium lauryl sulfosuccinate, The aforementioned (b) disintegrant is pregelatinized starch, The solid cleaning composition according to claim 8, wherein the (I) first phase consists only of the (a) solid surfactant, the (b) disintegrant, and the (c) lubricant.

10. The solid cleaning composition according to claim 9, wherein the (I) first phase consists only of 32.26% by weight of the (a) solid surfactant, 64.62% by weight of the (b) disintegrant, and 3.23% by weight of the (c) lubricant, based on the weight of the (I) first phase.

11. The solid cleaning composition according to claim 9 or 10, comprising two layers: a single layer of the second phase and a single layer of the first phase facing it.

12. The solid cleaning composition according to claim 9 or 10, comprising three layers: two layers as the second phase and a single layer as the first phase sandwiched between them.

13. A solid cleansing composition according to any one of claims 1 to 12, for a skin cleansing product for bathing.

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