Low bulk density natural alkali metal carbonate salt

Abstract

The present invention relates to an alkali metal carbonate, more particularly to a natural alkali metal carbonate having lowered bulk density. The present inventors have found that a natural alkali metal carbonate having a bulk density less than 1000 Kg / m3 and an absorption pre size of more than 10 nanometers as measured using BET nitrogen absorption method provides the benefits of improved dispersibility, enhanced liquid carrying capacity.

Description

[0001] P0001182 CPL

[0002] 1

[0003] LOW BULK DENSITY NATURAL ALKALI METAL CARBONATE SALT

[0004] Field of the Invention

[0005] 5 The present invention relates to an alkali metal carbonate, more particularly to a natural alkali metal carbonate having lowered bulk density.

[0006] Background of the Invention

[0007] Sodium carbonate also known as soda ash is widely used as builder in homecare compositions. Sodium carbonates is commercially available as light soda ash and dense soda ash based on their average bulk density. Commercially available dense soda ash generally has an average bulk density of 900 Kg / m3to 1250 Kg / m3whereas the light soda ash generally has an average bulk density ranging from 400 Kg / m3to 800 Kg / m3.

[0008] 15 Sodium carbonate can also be produced by mining trona ore followed by surface treatment to produce soda ash. This is often called natural soda ash. Sodium carbonate is recovered from its ore by two processes namely the sesquicarbonate process and the monohydrate process, named after their respective crystallization products. Generally, the natural soda ash and is obtained by drying crystalline sodium carbonate monohydrate to remove its water of hydration.

[0009] 20

[0010] Light density sodium carbonate are desirable as they don’t form lumps or aggregates along with a surfactant in slurries. Light density sodium carbonate is typically produced by a synthetic route such as the Hou process and Solvay process. The synthetically prepared sodium carbonate are not environmentally friendly and tend to be associated with and result in greenhouse gas

[0011] 25 emissions than natural soda ash, because process for preparing natural soda ash involves less energy. Light density sodium carbonate has a lower absorption pore size which does not enable it to be used in wider applications.

[0012] It is desired to provide a low bulk density alkali metal carbonate which has higher absorption pore size while maintaining lower bulk density to provide for wider home care applications.

[0013] It is further desired to provide such low bulk density alkali metal carbonate which is also environmentally friendly and involves lower green-house gas emissions while maintaining desirable properties.

[0014] 35 P0001182 CPL

[0015] 2

[0016] It is further desired to provide a low bulk density alkali metal carbonate which has improved dispersibility.

[0017] Summary of the Invention

[0018] 5 The present inventors have found that a low bulk density carbonate builder composition comprising an alkali metal carbonate having a weight average bulk density less than 1000 Kg / m3and a BET absorption pore size of 10 nanometers or more than 10 nanometers as measured using BET nitrogen absorption method and specific polymer provides the benefits of improved dispersibility, and enhanced liquid carrying capacity. Preferably the alkali metal carbonate is from a natural source. The low bulk density alkali metal carbonate, according to the present invention having unique low bulk density and a higher absorption pore size which makes it suitable for wider applications.

[0019] It was further found that the low bulk density alkali metal carbonate in accordance with the first

[0020] 15 aspect of the present invention has improved porosity and a lowered bulk density while maintaining desired particle size.

[0021] According to the first aspect of the present invention provided is low bulk density carbonate builder composition comprising an alkali metal carbonate having a weight average bulk density

[0022] 20 less than 1000 Kg / m3and a BET absorption pore size of 10 nanometers or more than 10 nanometers as measured using BET nitrogen absorption method and a polymer selected from the group consisting of polyepoxysuccinic acid polymer, modified polyaspartic acid polymer, copolymer of acrylic acid and maleic acid or a salt thereof and mixture thereof, wherein the modified polyaspartic acid polymer is selected from the group consisting of

[0023] 25 polyaspartic acid modified with anionic pendant unit selected from the group consisting of aspartic acid, iminodiacetic acid, glutamic acid, citric acid and a salt thereof; wherein the copolymer of acrylic acid and maleic acid or a salt thereof has a molar weight ratio of maleic acid segment to the acrylic acid segment greater than 1 :1.

[0024] Detailed Description of the Invention

[0025] According to the first aspect of the present invention provided is a low bulk density carbonate builder composition comprising an alkali metal carbonate comprising a bulk density less than 1000 Kg / m3and a BET absorption pore size of 10 nanometers or more than 10 nanometer as measured using BET nitrogen absorption method.

[0026] 35 P0001182 CPL

[0027] 3

[0028] Preferably the low bulk density carbonate builder composition is a low bulk density alkali metal carbonate composition. More preferably a low bulk density sodium carbonate builder composition.

[0029] 5 Preferably the alkali metal carbonate is sodium carbonate.

[0030] Preferably the sodium carbonate in accordance with the present invention has a weight average bulk density ranging from 400 Kg / m3to 900 Kg / m3, still preferably a weight average bulk density ranging from 500 Kg / m3to 800 Kg / m3.

[0031] Preferably the alkali metal carbonate according to the present invention has an absorption pore size ranging from 10 nanometers to 50 nanometers, still preferably 10 nanometers to

[0032] 30 nanometers. Preferably the alkali metal carbonate according to the present invention has an absorption pore size ranging from greater than 10 nanometers to 50 nanometers, still preferably

[0033] 15 greater than 10 nanometers to 30 nanometers.

[0034] Absorption pore size

[0035] Test method 1 The absorption pore size is determined by BET analysis using a Micrometrics 3-

[0036] Flex analyzer. Prior to the measurement the alkali metal carbonate samples were prepared by

[0037] 20 degassed for 2 hours at 100°C to 120°C under vacuum using Nitrogen gas at 77 K as the adsorptive.. The Rouquerol criteria for measuring BET surface area was followed.

[0038] For the measurement using BET, reference is made to Chapter 3 in “Analytical Method in Fine Particle Technology by Paul A Webb and Clyde Orr published by Micrometrics Instrument Corp

[0039] 25 (ISBN-13 978-0965678308).

[0040] Relative bulk density

[0041] Test method 2 To measure the relative bulk density, a container is chosen that can accommodate the size of sample under test. For the initial reference, the weight of the container is determined. It is then filled with light soda ash. When full, the vessel is tapped repeatedly to ensure the powder has completely settled - if the level drops below the top of the vessel, more soda ash is added. When the level remains constant, a flat blade is drawn across the top of the vessel to render it flat. The vessel is then re-weighed so that the amount of soda ash contained can be calculated. This value (in grams) is given the value of 1. The process is then repeated

[0042] 35 using dense soda ash and the different low bulk density builder composition according to the present invention. P0001182 CPL

[0043] 4

[0044] The relative bulk density is calculated by dividing the weight of the sample by the weight of light soda ash taken control. For example, if the weight of the light soda ash control was 100g and the weight of the same volume of dense soda ash was 180g then the relative bulk density would be (180- 00) = 1.8. Thus, a relative bulk density of greater than 1 indicates a higher bulk

[0045] 5 density than light soda ash while a relative bulk density of 1 or less indicates the same or lower bulk density than light soda ash respectively.

[0046] The low bulk density carbonate builder composition in accordance with the present invention also comprises a polymer. The polymer is selected from the group consisting of polyepoxysuccinic acid polymer, modified polyaspartate, copolymer of acrylic acid and maleic acid and mixtures thereof. Preferably the polymer acts as a crystal growth modifier.

[0047] Polyepoxysuccinic acid polymer (PESA):

[0048] Preferably the polymer is a polyepoxysuccinic acid polymer. The polyepoxysuccinic acid

[0049] 15 polymer has a general formula: wherein:

[0050] R1and R2are independently selected from H, Ci-Ce alkyl, -OH, -COOM;

[0051] 20 M is selected from H, Na, K, NH4, or substituted ammonium;

[0052] Y is selected from -OH, -OR’, -NH2, -NHR’, -NR’2, in which R’ is selected from Ci-Ce alkyl; and n is from 2 to 20.

[0053] Preferably R1and R2are independently selected from H, CH3; M is selected from H, alkali

[0054] 25 metal; Y is selected from OH, -OR’, -NH2 in which R’ selected from Ci to Ce alkyl; and n is from 2 to 15. Still more preferably R1and R2are both H; M is selected from H, Na; Y is selected from - OH, and n is from 2 to 10. Preferably R1and R2are H. Preferably M is alkali metal, still preferably M is sodium.

[0055] 30 More preferably the polyepoxysuccinic acid can be represented by the structure P0001182 CPL

[0056] 5 wherein M is H or Na, and n is from 2 to 10.

[0057] The polyepoxysuccinic acid polymer may be used singularly or in mixture. The "n" represents

[0058] 5 an average number. Preferably when polyepoxysuccinic acid polymer is a mixture, the polymer sample may be dominated by samples where n ranges from 2 to 7, more preferably from 3 to 6.

[0059] A most preferred polyepoxysuccinic acid polymer can be identified using CAS number: 5 51274-37-4 (M= H), or 109578-44-1 (M = sodium).

[0060] Commercially available polyepoxysuccinic acid polymer is available as the sodium salt from Sirius International under the tradename Briteframe PESA.

[0061] Preferably the polyepoxysuccinic acid polymer is added in an amount ranging from 0.1 wt.% to

[0062] 15 5 wt.%, still preferably from 0.1 wt.% to 3 wt.% based on the dry weight of the sodium carbonate added to the aqueous solution. For example, if 1000 Kg of sodium carbonate by dry weight is added to the aqueous solution then a 3 wt.% of polyepoxysuccinic acid polymer as provided herein will amount to 3% of 1000 which is 30 Kg of the polyepoxysuccinic acid polymer.

[0063] 20 Preferably the polyepoxysuccinic acid polymer is present in an amount ranging from 0.1 to 5 wt.% by weight of the low bulk density carbonate builder composition, preferably in an amount ranging from 0.5 wt.% to 5 wt.%, still preferably from 1 wt.% to 5 wt.% and most preferably from 1 wt.% to 3 wt.% by weight of the low bulk density carbonate builder composition.

[0064] Modified polyaspartate:

[0065] Preferably the polymer is a modified polyaspartate. The modified polyaspartic acid polymer is selected from polyaspartic acid modified with anionic pendant unit selected from the group consisting of aspartic acid, iminodiacetic acid, glutamic acid, citric acid and / or sodium citrate.

[0066] 30 Preferably the modified polyaspartic acid is prepared from polysuccinimide (PSI) precursor. Preferably the polysuccinimide (PSI) precursor is reacted with a nucleophile. Preferably, the nucleophile involved in the ring opening reaction of the polysuccinimide (PSI) precursor P0001182 CPL includes but is not limited to those selected from alkali metal hydroxide, amines and alcohols. Preferably the alkali metal hydroxide is sodium hydroxide. Preferably the nucleophile is a combination of alkali metal hydroxide and amines or alcohol(s).

[0067] 5 Preferably the amine or alcohol nucleophile also contains covalently bonded anionic groups. Preferably these anionic groups are carboxylate(s), sulfonate(s) or sulfate(s). More preferably the nucleophile is selected from the group consisting of aspartic acid, iminodiacetic acid, glutamic acid, citric acid and / or sodium citrate. The ring opening of the polysuccinimide (PSI) precursor by the amine or alcohol nucleophile forms a modified polyaspartic acid, wherein some

[0068] 10 or all the constitutional repeat units in the modified polyaspartic acid comprises an anionic pendant unit.

[0069] Preferably the polymer includes a combination of polyaspartic acid and modified polyaspartic acid or salts thereof.

[0070] Preferably the polymer is a modified polyaspartate modified with aspartic acid or a salt thereof wherein the modified polyaspartate is represented by the general formula (I): Formula (I)

[0071] 20 wherein n + m has a value ranging from 5 to 100, more preferably between 10 and 40; and wherein o + p has a value ranging from 0 to 100, more preferably between 5 and 40. wherein -M is independently selected from a H atom or an alkali metal. Preferably M is an alkali metal and more preferably M is sodium.

[0072] 25

[0073] Preferably the polymer is a modified polyaspartate modified with glutamic acid or a salt thereof wherein the modified polyaspartate is represented by the general formula (II): P0001182 CPL Formula (II) wherein n + m has a value ranging from 5 to 100, more preferably between 10 and 40; and wherein o + p has a value ranging from 0 to 100, more preferably between 5 and 40.

[0074] 5 wherein -M is independently selected from a H atom or an alkali metal. Preferably M is an alkali metal and more preferably M is sodium.

[0075] Preferably the polymer is a modified polyaspartate modified with iminodiacetic acid or a salt thereof wherein the modified polyaspartate is represented by the general formula (III):

[0076] 10 Formula (III) wherein n + m has a value ranging from 5 to 100, more preferably between 10 and 40; and wherein o + p has a value ranging from 0 to 100, more preferably between 5 and 40. wherein -M is independently selected from a H atom or an alkali metal. Preferably M is an alkali metal and more preferably M is sodium.

[0077] Preferably the polymer is a modified polyaspartate modified with citric acid or a salt thereof wherein the modified polyaspartate is represented by the general formula (IV):

[0078] 20 Formula (IV) P0001182 CPL

[0079] 8 wherein n + m has a value ranging from 5 to 100, more preferably between 10 and 40; and wherein o + p has a value ranging from 0 to 100, more preferably between 5 and 40. wherein -M is independently selected from a H atom or an alkali metal. Preferably M is an alkali metal and more preferably M is sodium.

[0080] 5

[0081] Preferably the modified polyaspartate is added in an amount ranging from 0.1 wt.% to 5 wt.%, still preferably from 0.1 wt.% to 3 wt.% based on the dry weight of the sodium carbonate added to the aqueous solution. For example, if 1000 Kg of sodium carbonate by dry weight is added to the aqueous solution then a 3 wt.% of modified polyaspartate polymer as provided herein will amount to 3% of 1000 Kg which is 30 Kg of the polyepoxysuccinic acid polymer.

[0082] Preferably the modified polyaspartate polymer is present in an amount ranging from 0.1 to 5 wt.% by weight of the low bulk density carbonate builder composition, preferably in an amount ranging from 0.5 wt.% to 5 wt.%, still preferably from 1 wt.% to 5 wt.% and most preferably from

[0083] 15 1 wt.% to 3 wt.% by weight of low bulk density carbonate builder composition.

[0084] Copolymer of acrylic acid and maleic acid:

[0085] Preferably the polymer may be a copolymer of acrylic acid and maleic acid or a salt thereof. According to the present invention, the copolymer of the acrylic acid and maleic acid or a salt

[0086] 20 thereof comprises a mole ratio of maleic acid segment to the acrylic acid segment of greater than 1 :1. More preferably the mole ratio of maleic acid segment to the acrylic acid segment ranges from 1.2:1 to 9:1, still preferably 1.2:1 to 2.33:1 , more preferably from 1.25:1 to 2.33:1 , still more preferably from 1.3:1 to 2.33:1, furthermore preferably from to 1.5:1 to 2.33:1, still further preferably from 1.75:1 to 2.33:1, still furthermore preferably from 1.8:1 to 2.33:1.

[0087] 25

[0088] The copolymer of acrylic acid and maleic acid preferably has a weight average molecular weight ranging from 10000 to 100000, more preferably from 10000 to 75000, more preferably 10000 to 65000, still more preferably from 10000 to 60000, still more preferably from 10000 to 50000, still more preferably from 15000 to 50000, still more preferably from 20000 to 50000, more preferably from 25000 to 50000.

[0089] It is highly preferred that the copolymer has a weight average molecular weight in the range from 10000 to 100000 and a mole ratio of maleic acid segment to the acrylic acid segment greater than 1 :1, still preferably from a weight average molecular weight in the range from

[0090] 35 10000 to 100000 and a mole ratio of maleic acid segment to the acrylic acid segment ranging from 1.5:1 to 2.33:1 and still further preferably where the weight average molecular weight in P0001182 CPL

[0091] 9 the range from 10000 to 50000 and a mole ratio of maleic acid segment to the acrylic acid segment ranging from 1.5:1 to 2.33:1.

[0092] Water-soluble salts of the copolymer of acrylic acid and maleic acid are also suitable for the

[0093] 5 present invention. The salts include those selected from non-limiting examples selected from alkali metal, ammonium and substituted ammonium salts.

[0094] Preferably the copolymer of acrylic acid and maleic acid or a salt thereof is added in an amount ranging from 0.1 wt.% to 5 wt.%, still preferably from 0.1 wt.% to 3 wt.% based on the dry weight of the sodium carbonate added to the aqueous solution. For example, if 1000 Kg of sodium carbonate by dry weight is added to the aqueous solution then a 3 wt.% copolymer of acrylic acid and maleic acid as provided herein will amount to 3% of 1000 which is 30 Kg of the copolymer of acrylic acid and maleic acid.

[0095] 15 Preferably the copolymer of acrylic acid and maleic acid or a salt thereof having a mole ratio of maleic acid segment to the acrylic acid segment of greater than 1 : 1 is present in an amount ranging from 0.1 to 5 wt.% by weight of the low bulk density carbonate builder composition, preferably in an amount ranging from 0.5 wt.% to 5 wt.%, still preferably from 1 wt.% to 5 wt.% and most preferably from 1 wt.% to 3 wt.% by weight of the low bulk density carbonate builder

[0096] 20 composition.

[0097] Also, preferably the polymer may additionally include a copolymer having a mole ratio of maleic acid and acrylic acid less than 1:1 which means that the copolymer has greater levels of acrylic acid as compared to the maleic acid segment and / or more than 9:1 which means that the

[0098] 25 copolymer has still greater levels of the maleic acid.

[0099] Homecare composition

[0100] According to a second aspect of the present invention provided is a homecare composition comprising the low bulk density carbonate composition according to the first aspect.

[0101] As used herein, the term " home care composition" includes, unless otherwise indicated, granular or powder-form all-purpose or "heavy-duty" washing agents, especially cleaning detergents; liquid, gel or paste-form all-purpose washing agents, especially the so-called heavy- duty liquid types; liquid fine-fabric detergents; hand dishwashing agents or light duty

[0102] 35 dishwashing agents, machine dishwashing agents, including the various tablet, granular, liquid and rinse-aid types for household and institutional use; liquid cleaning and disinfecting agents, P0001182 CPL

[0103] 10 including antibacterial hand-wash types, cleaning bars, bathroom cleaners including toilet bowl cleaners; and metal cleaners, fabric conditioning products including softening and / or freshening that may be in liquid, solid and / or dryer sheet form; as well as cleaning auxiliaries such as bleach additives and "stain-stick" or pre-treat types, substrate-laden products such as dryer

[0104] 5 added sheets, dry and wetted wipes and pads, nonwoven substrates, and sponges; as well as sprays and mists. All of such products which were applicable may be in standard, concentrated or even highly concentrated form even to the extent that such products may in certain aspect be non-aqueous. Homecare composition includes products suitable for treating fabrics or surfaces within the home (including internal and external hard surfaces such as patios)

[0105] Preferably the home care composition is a fabric care composition. The fabric care composition may be a laundry composition, more preferably a laundry detergent or fabric conditioner.

[0106] Homecare composition may include one or more adjunct ingredients which is selected from the

[0107] 15 group consisting of deposition aids, fluorescent whitening agents, rheology modifiers, builders, perfumes, microcapsule, surfactant, bleach activator, chelating agent, dye transfer inhibiting agent, dispersant, enzyme, and enzyme stabilizer, catalytic metal complex, polymeric dispersing agent, clay and soil removal / anti-redeposition agent, brightener, suds suppressor, dyes, additional perfume and perfume delivery system, structure elasticizing agent, fabric

[0108] 20 softener, carrier, hydrotrope, processing aid and / or pigment. However, when one or more adjunct ingredients are present, such one or more adjuncts may be present as detailed below. The following is a non-limiting list of suitable additional adjuncts.

[0109] Surfactant:

[0110] 25 The homecare composition of the present invention preferably comprises a surfactant. The surfactant may be selected from anionic surfactant, cationic surfactant, non-ionic surfactant, zwitterionic surfactant, amphoteric surfactant and combinations thereof. Preferably the surfactant comprises surfactant selected from anionic surfactant, cationic surfactant, nonionic surfactant and combinations thereof. When the composition is a laundry detergent, it preferably comprises anionic and / or non-ionic surfactant. When the composition is a fabric conditioner, the composition preferably comprises cationic and / or non-ionic surfactant, preferably cationic surfactant.

[0111] Preferably the surfactant is selected from the group consisting of linear or branched alkyl

[0112] 35 benzene sulfonate, alkyl sulfate, alkyl ethoxy sulfate, alkyl ethoxylate, alkyl glyceryl sulfonate, quaternary ammonium surfactant, ester quaternary ammonium compound and mixtures thereof. P0001182 CPL

[0113] 11

[0114] The homecare composition preferably comprises 1 wt. % to 90 wt. % surfactant, more preferably 1 .5 wt. % to 80 wt.% surfactant, even more preferably 2 wt. % to 70 wt.% surfactant, even more preferably 2.5 wt. % to 60 wt.%, even more preferably 3 wt. % to 50 wt.% surfactant by weight of the homecare composition.

[0115] 5

[0116] Useful anionic surfactant can themselves be of several different types. For example, water- soluble salts of the higher fatty acids, i.e. , "soaps", are useful anionic surfactants in the compositions herein. This includes alkali metal soaps such as the sodium, potassium, ammonium, and alkylolammonium salts of higher fatty acids containing from about 8 to about 24 carbon atoms, or even from about 12 to about 18 carbon atoms. Soaps can be made by direct saponification of fats and oils or by the neutralization of free fatty acids. Particularly useful are the sodium and potassium salts of the mixtures of fatty acids derived from coconut oil and tallow, i.e., sodium or potassium tallow and coconut soap.

[0117] 15 Useful anionic surfactant include the water-soluble salts, particularly the alkali metal, ammonium and alkylolammonium (e.g., monoethanolammonium or triethanolammonium) salts, of organic sulfuric reaction products having in their molecular structure an alkyl group containing from about 10 to about 20 carbon atoms and a sulfonic acid or sulfuric acid ester group. (Included in the term "alkyl" is the alkyl portion of aryl groups.) Examples of this group of

[0118] 20 synthetic surfactants are the alkyl sulfates and alkyl alkoxy sulfates, especially those obtained by sulphating the higher alcohols (Cs to Cis carbon atoms).

[0119] Other useful anionic surfactant herein include the water-soluble salts of esters of alphasulfonated fatty acids containing from about 6 to 20 carbon atoms in the fatty acid group and

[0120] 25 from about 1 to 10 carbon atoms in the ester group; water-soluble salts of 2-acyloxy-alkane-l- sulfonic acids containing from about 2 to 9 carbon atoms in the acyl group and from about 9 to about 23 carbon atoms in the alkane moiety; water-soluble salts of olefin sulfonates containing from about 12 to 24 carbon atoms; and p-alkyloxy alkane sulfonates containing from about 1 to 3 carbon atoms in the alkyl group and from about 8 to 20 carbon atoms in the alkane moiety.

[0121] Preferably the anionic surfactant may comprise a C8-C22 alkyl benzene sulfonate surfactant; a C10 to C20 alkyl sulfate surfactant; a C10 to C18 alkyl alkoxy sulfate surfactant, having an average degree of alkoxylation of from 1 to 30, wherein the alkoxy comprises a Ci to C4 chain and mixtures thereof; a mid-chain branched alkyl sulfate surfactant; a mid-chain branched alkyl

[0122] 35 alkoxy sulfate surfactant having an average degree of alkoxylation of from 1 to 30, wherein the alkoxy comprises a Ci to C4 chain and mixtures thereof; a C10 to C18 alkyl alkoxy carboxylates P0001182 CPL

[0123] 12 comprising an average degree of alkoxylation of from 1 to 5; a C12 to C20 methyl ester sulfonate surfactant, a C10 to C18 alpha-olefin sulfonate surfactant, a Ce to C20 sulfosuccinate surfactant, and a mixture thereof.

[0124] 5 In addition to the anionic surfactant, the homecare composition of the present invention may further contain a nonionic surfactant. The compositions of the present invention can contain up to about 30%, alternatively from about 0.01% to about 20%, more alternatively from about 0.1 % to about 10%, by weight of the composition, of a nonionic surfactant. Preferably the nonionic surfactant may comprise an ethoxylated nonionic surfactant. Suitable for use herein are the ethoxylated alcohols and ethoxylated alkyl phenols of the formula R(OC2 H4 )nOH, wherein R is selected from the group consisting of aliphatic hydrocarbon radicals containing from about 8 to about 20 carbon atoms and alkyl phenyl radicals in which the alkyl groups contain from about 8 to about 12 carbon atoms, and the average value of n is from about 5 to about 15.

[0125] Suitable nonionic surfactants are those of the formula R1(OC2H4)nOH, wherein R1 is a C10 to

[0126] 15 C16 alkyl group or a Cs to C12 alkyl phenyl group, and n is from 3 to about 80. In one aspect, particularly useful materials are condensation products of C9 to C15 alcohols with from about 5 to about 20 moles of ethylene oxide per mole of alcohol.

[0127] Organic builders:

[0128] 20 Preferably the home care composition may include polyacetates, carboxylates, polycarboxylates and polyhydroxy sulfonates as preferred organic builders. Examples of polyacetate and polycarboxylate builders are the sodium, potassium, lithium, ammonium and substituted ammonium salts of ethylene diamine tetraacetic acid, nitrilotriacetic acid, oxydisuccinic acid, mellitic acid, benzene polycarboxylic acids, and citric acid. Other suitable

[0129] 25 polycarboxylates for use herein are the polyacetal carboxylates, oxydisuccinates and the ether carboxylate builder.

[0130] Enzymes:

[0131] The home care composition may contain one or more detergent enzymes which provide cleaning performance and / or fabric care benefits. Examples of suitable enzymes include hemicellulases, peroxidases, proteases, cellulases, xylanases, lipases, phospholipases, esterases, cutinases, pectinases, keratinases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases, tannases, pentosanases, malanases, p-glucanases, arabinosidases, hyaluronidase, chondroitinase, laccase, and amylases, or mixtures thereof. A

[0132] 35 typical combination may be a cocktail of conventional applicable enzymes like protease, lipase, cutinase and / or cellulase in conjunction with amylase. Enzymes can be used at their art- taught P0001182 CPL

[0133] 13 levels, for example at levels recommended by suppliers such as Novozymes and Genencor. Typical levels in the compositions are from about 0.0001% to about 5%. When enzymes are present, they can be used at very low levels, e.g., from about 0.001% or lower; or they can be used in heavier-duty laundry detergent formulations at higher levels, e.g., about 0.1% and

[0134] 5 higher. In accordance with a preference of some consumers for "non-biological" detergents, the compositions may be either or both enzyme-containing and enzyme-free.

[0135] Brighteners:

[0136] The homecare composition may also comprise a brightener (also referred to as "optical brightener") and may include any compound that exhibits fluorescence, including compounds that absorb UV light and re-emit as "blue" visible light. Non-limiting examples of useful brighteners include derivatives of stilbene or 4,4'-diaminostilbene, biphenyl, five-membered heterocycles such as triazoles, pyrazolines, oxazoles, imidiazoles, etc., or six-membered heterocycles (coumarins, naphthalamide, s-triazine, etc.). Cationic, anionic, nonionic,

[0137] 15 amphoteric and zwitterionic brighteners can be used. Suitable brighteners include those commercially marketed under the trade name Tinopal-UNPA-GX® by Ciba Specialty Chemicals Corporation (High Point, NC).

[0138] Perfume:

[0139] 20 Compositions may further comprise a perfume. The inclusion of perfumes into laundry detergent compositions is known perse.

[0140] When the composition is used at very low levels of product dosage, it is advantageous to ensure that perfume is employed efficiently.

[0141] 25

[0142] A particularly preferred way of ensuring that perfume is employed efficiently is to use an encapsulated perfume. Use of a perfume that is encapsulated reduces the amount of perfume vapour that is produced by the composition before it is diluted. This is important when the perfume concentration is increased to allow the amount of perfume per wash to be kept at a reasonably high level.

[0143] It is even more preferable that the perfume is not only encapsulated but also that the encapsulated perfume is provided with a deposition aid to increase the efficiency of perfume deposition and retention on fabrics. The deposition aid is preferably attached to the encapsulate

[0144] 35 by means of a covalent bond, entanglement or strong absorption, preferably by a covalent bond or entanglement. P0001182 CPL

[0145] 14

[0146] Solid laundry composition

[0147] According to a second aspect of the present invention, preferably the homecare composition is a solid laundry composition comprising the low bulk density carbonate builder composition in accordance with the first aspect of the invention.

[0148] 5

[0149] Preferably the solid laundry composition is a particulate laundry composition. The term “particulate laundry detergent” in the context of this invention denotes free-flowing or compacted solid forms such as powders, granules, pellets, flakes, bars, briquettes or tablets and which are intended for and capable of wetting and cleaning domestic laundry such as clothing, linens and other household textiles.

[0150] It is to be understood that there is a range of compositions falling under the definition of particulate detergent composition for laundering textile depending on their manner of use. These include particulate detergent composition for use in front loading automatic washing machines,

[0151] 15 top loading washing machines, particulate detergent composition for hand washing of fabrics.

[0152] Examples of laundry detergents include heavy-duty detergents for use in the wash cycle of automatic washing machines, as well as fine wash and colour care detergents such as those suitable for washing delicate garments (e.g. those made of silk or wool) either by hand or in the

[0153] 20 wash cycle of automatic washing machines.

[0154] The solid laundry composition herein can take a variety of physical solid forms including forms such as powder, particulate, granule, ribbon, noodle, paste, tablet, flake, pastille, and bar, and preferably the composition is in the form of powder, granules, or a tablet, still preferably the

[0155] 25 composition is in the form of a powder. The composition may be in the form of a unit dose formulation, delayed delivery formulation, detergent contained on or in a porous substrate or nonwoven sheet, and other suitable forms that may be apparent to one skilled in the art in view of the teachings herein. The composition according to the present invention may preferably be in a form selected from powder, unit dose or pouch form, tablet, gel, paste, bar, or flake. Preferably the composition is for manual-washing or machine-washing. Preferably the solid laundry composition is a spray-dried powder composition. Preferably the solid laundry composition is an agglomerate powder or granular laundry composition. Preferably the solid laundry composition is a shaped laundry composition, still preferably a bar composition.

[0156] 35 Preferably the solid laundry composition is a unit dose article. P0001182 CPL

[0157] 15

[0158] Preferably the solid laundry composition is a laundry sheet composition. Preferably the laundry sheet composition is water-soluble or dispersible. Preferably the laundry sheet composition is fibrous, woven or non-woven. Preferably the laundry sheet composition is non-fibrous.

[0159] Preferably the laundry sheet composition comprises a water-soluble or water-dispersible

[0160] 5 polymer. Preferably the laundry sheet composition is flexible. Preferably the laundry sheet composition is multi-layered.

[0161] The solid laundry composition preferably has a pH ranging from 8 to 13 as measured in an aqueous solution with distilled water at 25°C. Preferably the solid laundry detergent composition according to the present invention has a pH from 8.5 to 10.5, more preferably 8.5 to 10.5, when measured using a 1 wt.% solution with distilled water at 25°C.

[0162] The solid laundry composition according to the present invention may include further adjunct ingredients as described hereinabove which may be made via a variety of conventional

[0163] 15 methods known in the art and those which includes but is not limited to the mixing of ingredients, including dry-mixing, compaction such as agglomerating, extrusion, tabletting, or spray-drying of the various compounds comprised in the detergent component, or mixtures of these techniques, whereby the components herein also can be made by for example compaction, including extrusion and agglomerating, or spray-drying. The solid laundry

[0164] 20 composition may be made by any of the conventional processes, especially preferred is the technique of slurry making and spray drying.

[0165] Preferably the solid laundry composition is in the form of a spray -dried powder. The compositions preferably have a density of more than 350 grams / litre, more preferably more than

[0166] 25 450 grams / litre or even more than 570 grams / litre. Preferably the composition is in the form of an agglomerate particle having a density of 300 to 1000 g / L, more preferably from 400 to 850 g / L.

[0167] The solid laundry composition according to the present invention preferably has from 2 wt.% to 50 wt.% low bulk density carbonate builder composition according to the present invention. Preferably the amount of low bulk density carbonate builder composition is at least 3 wt.%, still preferably is at least 10 wt.%, more preferably is at least 15 wt.% by weight in the detergent composition but the low bulk density carbonate builder composition in the solid laundry composition is preferably not more than 40 wt.%, still preferably not more than 30 wt.%.

[0168] 35 P0001182 CPL

[0169] 16

[0170] The solid laundry composition according to the present invention preferably has from 0 wt.% to 4 wt.% phosphate builder. Preferably the amount of phosphate builder is less than 3 wt.%, still preferably less than 2 wt.%, more preferably less than 1 wt.% by weight in the detergent composition and most preferably the detergent composition is substantially free of phosphate

[0171] 5 builder.

[0172] The solid laundry composition according to the present invention preferably has from 0 wt.% to 12 wt.% zeolite builder, more preferably 0 wt.% to 10 wt.% zeolite builder. Preferably the amount of zeolite builder is less than 5 wt.%, still preferably less than 3 wt.%, more preferably less than 2 wt.% by weight in the detergent composition and most preferably the detergent composition is substantially free of zeolite builder.

[0173] The solid laundry detergent composition according to the present invention preferably has from 0 wt.% to 17 wt.% alkali metal silicate, more preferably 0 wt.% to 5 wt.% alkali metal silicate.

[0174] 15 Preferably the amount of alkali metal silicate is less than 5 wt.%, still preferably less than 3 wt.%, more preferably less than 2 wt.% by weight in the detergent composition and most preferably the detergent composition is substantially free of alkali metal silicate.

[0175] The term “substantially free” means that the indicated component is at the very minimum, not

[0176] 20 deliberately added to the composition to form part of it, or, more typically, is not present at analytically detectable levels. It is meant to include compositions whereby the indicated material is present only as an impurity in one of the other materials deliberately included.

[0177] The low-density carbonate builder composition, preferably comprising sodium carbonate as the

[0178] 25 alkali metal carbonate and a polymer in accordance with the first aspect of the present invention was found to provide the solid laundry composition with good powder properties and the powder was resistant to caking, this is because of the good liquid carrying capacity.

[0179] Preferably the solid laundry composition is in the form of a unit dose article. Preferably the unit dose article comprises a solid laundry composition enclosed in a water-soluble or water- dispersible package.

[0180] Preferably the solid laundry is a bar composition comprising the low-density sodium carbonate according to the present invention. Preferably the detergent composition is a tablet composition

[0181] 35 comprising the low bulk density carbonate builder composition, the builder composition P0001182 CPL

[0182] 17 preferably comprising sodium carbonate as the alkali metal carbonate according to the present invention.

[0183] Preferably the detergent composition is a sheet composition comprising the low bulk density

[0184] 5 builder composition, the builder composition preferably comprising sodium carbonate as the alkali metal carbonate according to the present invention, a surfactant and a water-soluble polymer. Preparation of a low bulk density carbonate builder

[0185] 15 grams of a natural high density sodium carbonate was taken and dissolved in 60 mL of demineralized water at a temperature of 50°C to form an aqueous solution. 0.45 grams of polyepoxysuccinic acid sodium salt was added to the aqueous solution, and the solution was

[0186] 15 then placed in a 500 mL powder flask (pear shaped flask with four side indents). The flask was then placed on a rotary evaporator (water bath at 70°C, vacuum at 110 mbar) and the water removed. When the water was completely removed, the precipitate was removed and placed in an oven at 110°C for 120 minutes to form the low bulk density carbonate builder composition.

[0187] 20 The low bulk density carbonate builder composition was then evaluated. The alkali metal carbonate had a weight average bulk density less than 1000 Kg / m3and a BET absorption pore size of more than 10 nanometers as measured using BET nitrogen absorption method.

[0188] Evaluation of the low bulk density carbonate builder in a solid laundry composition

[0189] 25 Different solid laundry compositions were made by mixing the ingredients listed in the amounts provided in table 1 below. Ex A was prepared using a low-density sodium carbonate prepared by a synthetic Solvay process having a weight average bulk density less than 1000 Kg / m3and a BET absorption pore size as measured using BET nitrogen absorption method of less than 10 nanometers.

[0190] Solid laundry composition (Ex B) was prepared using a dense sodium carbonate prepared by a trona process having a weight average bulk density greater than 1000 Kg / m3and a BET absorption pore size as measured using BET nitrogen absorption method of more than 10 nanometers.

[0191] 35 P0001182 CPL

[0192] 18

[0193] Solid laundry composition (Ex 1) according to the present invention was prepared using a low bulk density sodium carbonate as provided in Example 1.

[0194] Table 1

[0195] 5

[0196] The solid laundry composition according to the present invention (Ex 1) having the low bulk density carbonate builder comprising an alkali metal carbonate having weight average bulk density less than 1000 Kg / m3and a BET absorption pore size of more than 10 nanometers as measured using BET nitrogen absorption method was found to suitable for wider applications.

[0197] Example 2: Evaluation of different low bulk density alkali metal carbonate builder composition having different polymers

[0198] 15 Different sodium carbonate builder compositions as provided in table 2 were tested for the bulk density.

[0199] Measurement of the relative bulk density:

[0200] The relative bulk density of the low bulk density sodium carbonate builder composition was

[0201] 20 determined relative to a light density soda ash taken as the standard.

[0202] A suitably sized receptacle (e.g. a 7mL glass vial) was taken and weighed (W1). It is then filled with light soda ash (with gentle tapping to ensure proper packing) until it begins to overflow. A flat blade is then drawn across the top to remove any excess powder and the vial weighed again (W2). From this, the weight of soda ash (W3) can be determined - W3 = W2 - W1.

[0203] To determine the relative bulk density of the low bulk density sodium carbonate composition, the weight of the low bulk density sodium carbonate builder composition (W4) was divided by W3 to give a relative bulk density of the low bulk density sodium carbonate builder composition.

[0204] 30 P0001182 CPL

[0205] 19

[0206] For example, if the weight of light soda ash was 10 grams and an equivalent volume of a low bulk density sodium carbonate builder composition weighed 14.6 grams then the relative bulk density would be 14.6 / 10 = 1.46.

[0207] 5 Thus, low bulk density sodium carbonate builder composition that is less porous than light soda ash (e.g. dense soda ash) will have a relative bulk density of greater than 1, whereas low bulk density sodium carbonate composition that is more porous will have a relative bulk density of less than 1.

[0208] The following compositions were tested for bulk density and then their relative bulk density was determined.

[0209] • Control builder composition which has 100 wt.% light soda ash.

[0210] • Comparative Ex B having a builder composition comprising sodium carbonate and a copolymer of acrylic acid and maleic acid with molar weight ratio of acrylic acid segment

[0211] 15 to the maleic acid segment is 70:30 (Sokalan CP5)

[0212] • Inventive Ex 2 is a builder composition comprising sodium carbonate and modified polyaspartate of Formula II

[0213] • Inventive Ex 3 is a builder composition comprising sodium carbonate and modified polyaspartate of Formula IV

[0214] 20 • Inventive Ex 4 is a builder composition comprising sodium carbonate and copolymer of acrylic acid and maleic acid with molar weight ratio of maleic acid segment to the acrylic acid segment greater than 1:1

[0215] Table 2

[0216] 25 The data provided in table 2 shows that a builder composition according to the present invention provides a lower bulk density as compared to the comparative composition according to prior art or the light soda ash.

Claims

P0001182 CPL20CLAIMS1. A low bulk density carbonate builder composition comprising an alkali metal carbonate having a weight average bulk density less than 1000 Kg / m3and a BET absorption pore size of 10 nanometers or more than 10 nanometers as measured using BET nitrogen absorption method and a polymer selected from the group consisting of polyepoxysuccinic acid polymer, modified polyaspartic acid polymer, copolymer of acrylic acid and maleic acid or a salt thereof and mixture thereof, wherein the modified polyaspartic acid polymer is selected from the group consisting of: polyaspartic acid modified with anionic pendant unit selected from the group consisting of aspartic acid, iminodiacetic acid, glutamic acid, citric acid or a salt thereof; wherein the copolymer of acrylic acid and maleic acid or a salt thereof has a molar weight ratio of maleic acid segment to the acrylic acid segment greater than 1 :1.

2. A low bulk density carbonate builder composition according to claim 1 wherein the weight average bulk density of the alkali metal carbonate ranges from 400 Kg / m3to 900 Kg / m3, still preferably from 500 Kg / m3to 800 Kg / m3.

3. A low bulk density carbonate builder composition comprises a BET absorption pore size ranging from 10 nanometers to 50 nanometers, preferably 10 nanometers to 30 nanometers as measured using a BET nitrogen absorption method.

4. A low bulk density carbonate builder composition according to any one of the preceding claims wherein the modified polyaspartate is selected from the group consisting of:(i) a modified polyaspartate modified with aspartic acid or a salt thereof wherein the modified polyaspartate is represented by the general formula (I):Formula (I)P0001182 CPL21 wherein n + m has a value ranging from 5 to 100, more preferably between 10 and 40; wherein o + p has a value ranging from 0 to 100, more preferably between 5 and 40; wherein -M is independently selected from a H atom or an alkali metal, preferably -M is alkali metal more preferably sodium; and / or,(ii) a modified polyaspartate modified with glutamic acid or a salt thereof wherein the modified polyaspartate is represented by the general formula (II):Formula (II) wherein n + m has a value ranging from 5 to 100, more preferably between 10 and 40; wherein o + p has a value ranging from 0 to 100, more preferably between 5 and 40; wherein -M is independently selected from a H atom or an alkali metal, preferably -M is alkali metal more preferably sodium; and / or,(iii) a modified polyaspartate modified with iminodiacetic acid or a salt thereof wherein the modified polyaspartate is represented by the general formula (III):Formula (III) wherein n + m has a value ranging from 5 to 100, more preferably between 10 and 40; wherein o + p has a value ranging from 0 to 100, more preferably between 5 and 40; wherein -M is independently selected from a H atom or an alkali metal, preferably -M is alkali metal more preferably sodium; and / or,(iv) a modified polyaspartate modified with citric acid or a salt thereof wherein the modified polyaspartate is represented by the general formula (IV):P0001182 CPL22Formula (IV) wherein n + m has a value ranging from 5 to 100, more preferably between 10 and 40; wherein o + p has a value ranging from 0 to 100, more preferably between 5 and 40; wherein -M is independently selected from a H atom or an alkali metal, preferably -M is alkali metal more preferably sodium.

5. A low bulk density carbonate builder composition according to any one of the preceding claims wherein the polyepoxysuccinic acid polymer has a general formula:wherein:R1and R2are independently selected from H, Ci-Ce alkyl, -OH, -COOM;M is selected from H, Na, K, NH4, or substituted ammonium;Y is selected from -OH, -OR’, -NH2, -NHR’, -NR’2, in which R’ is selected from Ci-Ce alkyl; and n is from 2 to 20.

6. A low bulk density carbonate builder composition according to any one of the preceding claims wherein the copolymer of acrylic acid and maleic acid has a molar weight ratio of maleic acid segment to the acrylic acid segment ranging from 1.2:1 to 9: 1 , still preferably 1.2:1 to 2.33 :1.

7. A homecare composition comprising the low bulk density carbonate builder according to any one of the preceding claims.P0001182 CPL238. A homecare composition according to claim 7 wherein the composition is a solid laundry composition.

9. A homecare composition according to claim 8 wherein the solid laundry composition is selected from a spray-dried laundry composition, agglomerated laundry composition, water-soluble or water-dispersible unit dose laundry article, tablet composition, bar composition, laundry sheet and combinations thereof.

Images