WO1997043396A1

WO1997043396A1 - Mild synthetic detergent base material and mild synthetic detergent bar produced therefrom

Info

Publication number: WO1997043396A1
Application number: PCT/US1997/007837
Authority: WO
Inventors: William C. Allison
Original assignee: Ppg Industries, Inc.
Priority date: 1996-05-14
Filing date: 1997-05-08
Publication date: 1997-11-20
Also published as: AU3000997A

Abstract

Described are novel, mild synthetic detergent base materials having a pH from 5.5 to 8.5 and consisting essentially of from 30 to 65 weight percent of mild synthetic anionic surfactant, salts thereof, or a mixture of the mild synthetic surfactant and salts thereof; from 7 to 40 weight percent of C8-C22 fatty acid; from 2 to 20 weight percent salt(s) of C8-22 fatty acid, i.e., soap; from 1.5 to 12 weight percent of water; from 1 to 10 weight percent of C8-C14 n-acyl sarcosine, salts thereof or a mixture of the n-acyl sarcosine and salts thereof; from 1 to 10 weight percent of hydrocarbon wax; and from 0.5 to 5 weight percent of isethionic acid, chloride or sulfate salt or mixtures of such salts. Also described are mild syndet bars prepared from the mild synthetic detergent base material and conventional soap bar adjuvants.

Description

MILD SYNTHETIC DETERGENT BASE MATERIAL AND MILD SYNTHETIC DETERGENT BAR PRODUCED THEREFROM

Description of the Invention The present invention relates to a mild synthetic detergent base material, and mild synthetic detergent bars produced using the synthetic detergent base material. More particularly, this invention relates to a synthetic detergent base material consisting essentially of mild anionic synthetic surfactant and/or salts thereof, C_β- C₂₂ fatty acids, soap, i.e., salts of C₈-C₂₂ fatty acids, water, C_β-C₁₄ acyl sarcosine and/or salts thereof, hydrocarbon wax, and isethionic acid, chloride and/or sulfate salts. Still more particularly, this invention relates to synthetic detergent bars that are prepared from the mild synthetic detergent base material.

Synthetic detergent bars, frequently referred to as "syndet bars" , are well known and are becoming increasingly popular. However, syndet bars have not replaced soap bars widely for a variety of reasons. One reason is that syndet bars, as compared to soap bars, are softer and smear more easily, i.e., partially dissolve or form a gel, with use.

Mild personal cleansing bar compositions have been described in U.S. Patent 5,294,363. Such compositions include essentially saturated long chain (C15-C22) synthetic surfactant, such as alkyl sulfate, alkyl sarcosinate and alkyl glyceryl ether sulfonate; paraffin wax; lathering mild synthetic surfactant, e.g., C₁₂"^C14 acyl isethionate, alkyl glyceryl ether sulfonate and/or sodium acyl sarcosinate (at least 10% of the bar being said lathering C^2^_c14 acyl isethionate; free fatty acid (stearic and/or lauric acid) ; soap; sodium isethionate; and water. Optionally sodium chloride and a cationic polymer may also be present. A key to the compositions described in U.S. patent 5,294,363 is asserted to be the long chain alkyl sulfate and the disclosed long chain synthetic surfactants.

It has now been discovered that a mild synthetic detergent base material, which combines a desirably high level of active ingredients, i.e., up to 75 weight percent total synthetic surfactant, and a low hot melt viscosity, which enables easy preparation of base material without special processing equipment, can be prepared without the need for long chain alkyl sulfates or long chain synthetic surfactants. The mild synthetic detergent base material of the present invention is substantially free of long chain synthetic surfactants, i.e., synthetic surfactants in which more than 50, usually more than 60, weight percent of the carbon chains comprising the synthetic surfactant are greater than 15 carbon atoms, e.g., within the range of between 15 and 22 carbon atoms.

The mild synthetic detergent base material of the present invention may be used with conventional adjuvant materials in skin cleansing compositions, e.g., bars, gels, pastes and liquids. Solid formulations of such compositions provide the desired physical properties associated with soap bars, such as acceptable bar smear, i.e., a rating of less than or equal to 6 in the Hewitt Soap Company Method No. 107; acceptable bar hardness properties, i.e., a rating less than 50, using a Precision Universal Penetrometer and the procedure described in association with the Examples; a low water temperature, e.g., less than or equal to 25°C, at which grit or granules are detectable in the bar; and good lather. The mild synthetic detergent base material of the present invention consists essentially of from 30 to 65 weight percent of mild, lathering anionic synthetic surfactant that are substantially free of long chain synthetic surfactants; from 7 to 40 weight percent of C₈-C₂₂ fatty acid; from 2 to 20 weight percent salt(s) of C_B-C₂₂ fatty acid; from 1.5 to 12 weight percent of water; from 1 to 10 weight percent of C₈-C₁₄ acyl sarcosine, salts thereof or a mixture of the acyl sarcosine and salts thereof; from 1 to 10 weight percent of hydrocarbon wax; and from 0.5 to 5 weight percent isethionic acid, chloride and/or sulfate salts or mixtures of such salts. The sodium salts of such acid salts are preferred. The pH of the synthetic detergent base ranges typically from 5.5 to 8.5, preferably from 6 to 8 and more preferably from 7.0 to 7.6. A syndet bar containing this detergent base and conventional soap bar adjuvant materials can be prepared using standard bar processing equipment.

Detailed Description of the Invention In accordance with the present invention, there is provided a synthetic detergent base material having a pH from 5.5 to 8.5 and consisting essentially of from 30 to 65 weight percent of mild, lathering anionic synthetic surfactant (or mixtures of mild lathering synthetic surfactants) that are substantially free of long chain synthetic surfactants; from 7 to 40 weight percent of C₈-C₂₂ fatty acid; from 2 to 20 weight percent salt(s) of C_β-C₂₂ fatty acid, i.e., soap; from 1.5 to 12 weight percent of water; from 1 to 10 weight percent of C_e-C₁₄ acyl sarcosine, salts thereof or a mixture of the acyl sarcosine and salts thereof; from 1 to 10 weight percent of hydrocarbon wax; and from 0.5 to 5 weight percent salts of isethionic acid, chloride, sulfate or mixtures thereof. The pH of the synthetic detergent base material, as used herein and in the claims, is determined by measuring the pH of a 10 weight percent aqueous solution of the synthetic detergent base material.

All numbers expressing quantities of ingredients, weight ratios, or reaction conditions used herein and in the claims are to be understood as modified in all instances by the term "about", except in the operating examples or where otherwise indicated. Also, all percentages used herein and in the claims are weight percents, unless otherwise noted, and are to be understood as based on the weight of the total composition of the material being described, e.g., the mild synthetic detergent base material and the mild synthetic detergent bar. Ingredients used in described formulations are used in amounts such that the formulation comprising all of such ingredients totals 100 percent. As used herein and in the claims, the term mild, lathering synthetic anionic surfactant, is intended to mean and include those surfactants which have a Relative Skin Barrier Penetration Value, as described in U.S. Patent 5,096,608 at column 4, line 46 to column 6, line 44, of from near zero to about 75. Further, the term mild synthetic anionic surfactant includes cosmetically acceptable salts of such surfactants. By cosmetically acceptable is meant that the salt may be used in cosmetic preparations, such as syndet bars. Examples of salts include the sodium, potassium, magnesium, ammonium, monoethanolammonium, diethanolammonium and triethanolammmonium salts and mixtures of such salts.

Examples of mild lathering synthetic anionic surfactants include methyl acyl taurates, n-acyl glutamates, acyl isethionates, mono-alkyl sulfosuccinateε and cosmetically acceptable salts of such mild surfactants . The acyl isethionates are preferred. Mixtures of such mild surfactants and/or the salts thereof may also be used. The alkyl and acyl groups for these mild surfactants typically contain from 8 to 14 carbon atoms (C₈-C₁₄) , i.e., more than 50, preferably more than 65, weight percent of the carbon chains comprising the surfactant are within the range of from 8 to 14 carbon atoms. Cocoyl is included in this group since it has a typical distribution of 12 percent C₈-C₁₀, 45 to 50 percent C₁₂, 15 to 20 percent C₁₄ , 12 to 16 percent C_ιe and 11 percent C₁₈. These mild synthetic anionic surfactants may also be considered as mild high lathering synthetic surfactants when compared to long chain C₁₅-C₂₂ synthetic surfactants.

Preferably, the amount of mild lathering or more preferably high lathering synthetic surfactant present in the synthetic base material ranges from 35 to 60, more preferably from 40 to 50, e.g., 44 to 48, weight percent, of the detergent base material and is selected from the group consisting of sodium and/or ammonium salts of acyl isethionates, e.g., cocoyl isethionates, such as sodium cocoyl isethionate, ammonium cocoyl isethionate and mixtures of such cocoyl isethionates. Commercially available sources of sodium cocoyl isethionate may be formulated with stearic acid and may also contain minor amounts of sodium isethionate and coconut fatty acid.

The synthetic detergent base material further contains from 7 to 40 weight percent of fatty acid. The lipophilic portion of the fatty acid may comprise alkyl-, alkenyl-, or hydroxyalkenyl- groups containing from about 8 to 22 carbon atoms, preferably from about 8 to 18 carbon atoms. The carbon chain may be linear, branched, even or odd numbered, saturated and/or unsaturated. When the fatty acid is derived from natural animal or vegetable sources, the acids generally comprise a mixture of the aforementioned lipophilic groups. For example, distilled mixed vegetable oil fatty acid may have the following carbon-chain distribution: 3 percent lauric fatty acid, 10-12 percent myristic acid, 15-20 percent palmitic acid, 18-25 percent stearic acid, 45-50 percent oleic acid and 5 percent linoleic acid. The fatty acid may be derived from an animal, e.g., beef tallow, or vegetable, e.g., coconut, palm, and soybean, source or produced by synthetic routes. The synthesis of acids having a similar carbon chain length as natural fatty acids may be achieved by using petroleum feedstocks in the Oxo or Ziegler processes to produce aldehydes or alcohols, respectively, which when subjected to further oxidation form the corresponding acids.

Preferably, the amount of fatty acid present in the detergent base material ranges from 15 to 35 weight percent and is selected from the group consisting of coconut fatty acid, tallow fatty acid, caprylic, capric, lauric, myristic, palmitic, stearic acids, and mixtures of such fatty acids, e.g. tallow/coconut fatty acid mixtures. More preferably, the fatty acid is present in the detergent base material in an amount of from 20 to 30, e.g., 25 to 28, weight percent.

Soap, i.e., salts of C₈-C₂₂ fatty acids, is present in the synthetic detergent base material in amounts of from 2 to 20 weight percent. Suitable salts of fatty acids include sodium salts, monoethanolammonium salts, diethanolammonium salts, triethanolammonium salts, ammonium salts, potassium salts, magnesium salts and mixtures of such salts. Preferably, the soap is present : amounts of from 5 to 18 weight percent and the salt is a idium salt. More preferably, the soap is present in amounts of from 8 to 12 weight percent.

The synthetic detergent base material contains from 1.5 to 12 weight perc ^■; of water, preferably from 3 to 10 weight percent, and more preferably from 5 to 8 weight percent, of water. Additional water may be added to the base material during processing to prepare the syndet bar.

The C₈-C₁₄ acyl sarcosine, salt(s) thereof or mixtures of such sarcosine and mixtures of such sarcosine salts may be present in the synthetic detergent base material in amounts of from 1 to 10 weight percent. Preferably the acyl sarcosines contain from Ci2~^ci4 carbon atoms and are n- acyl sarcosines. Preferred acyl sarcosines are selected from the group consisting of lauroyl sarcosine, cocoyl sarcosine and myristoyl sarcosine. Salts of the sarcosines may be selected from the group consisting of sodium salts, monoethanolammonium salts, diethanolammonium salts, triethanolammonium salts, ammonium salts, potassium salts, magnesium salts and mixtures of such salts. Preferably, the sarcosine component of the base material is present in amounts of from 1.5 to 8 weight percent, more preferably, from 2 or 3 to 5 weight percent. Preferably, the sarcosine and salts thereof are selected from the group consisting of lauroyl sarcosine, cocoyl sarcosine, sodium salts thereof, and mixtures of such sarcosines and their sodium salts.

The mild synthetic detergent base also contains hydrocarbon waxes which are composed of saturated aliphatic hydrocarbons that are typically solids at room temperature (22°C) , range in average molecular weight from 200 to 600, and have melting points from 49°C (120°F) to 93°C (200°F) . Preferably, the hydrocarbon waxes are selected from the group consisting of petroleum waxes, polyethylene waxes, synthetic waxes and mixtures of such waxes. More preferably, the hydrocarbon waxes are selected from the group consisting of paraffin waxes, polyethylene waxes and mixtures of such waxes. The hydrocarbon waxes may be present in amounts of from 1 to 10 weight percent, preferably from 1 to 5 weight percent, and more preferably, from 2 to 4 weight percent. Examples of petroleum waxes include refined paraffin waxes sold as Parvan® 127 by Exxon and Paraffin Wax 6971 sold by

National Wax. Polyethylene waxes include Polywax® 400 and 500 sold by Petrolite. Examples of synthetic waxes include Vybar® 253, reported to be a highly branched hydrocarbon made from polymerized olefins (a product of Petrolite) , and Fischer- Tropsch waxes such as polymethylene wax.

Salts of isethionic acid, chloride salts or sulfate salts (and mixtures of such salts) may also be present in the mild synthetic detergent base at levels from 0.5 to 5 weight percent, preferably, from 1 to 5 weight percent, and more preferably, from 1.5 to 2.5 weight percent. The salts of these materials are selected from the group consisting of sodium salts, monoethanolammonium salts, diethanolammonium salts, triethanolammonium salts, ammonium salts, potassium salts, magnesium salts and mixtures of such salts. Preferably, the salt is a sodium salt.

In embodiments contemplated herein, the weight ratio in the syndet bar of the sum total of synthetic surfactant, i.e., (i) the mild lathering anionic synthetic surfactants, (ii) C₈-C₁₄ acyl sarcosine, salt(s) thereof or mixtures of such sarcosines and their salts, or (iii) mixtures of such synthetic surfactants to fatty acid may range from 0.7:1 to 11:1, preferably, from 1:1 to 5:1, and more preferably, from 1.7:1 to 3:1. The weight ratio in the syndet bar of synthetic surfactant (i) : (ii) may range from 3:1 to 65:1, preferably, 4:1 to 40:1, and more preferably, from 8:1 to 12:1.

The synthetic detergent base material of the present invention may be prepared by the steps of : (a) combining the Cg-C-^i n-acyl sarcosine and/or salts thereof; mild lathering anionic synthetic surfactant; C₈-C₂₂ fatty acid; soap; hydrocarbon wax; isethionic acid, chloride and/or sulfate salts; and water in a suitable mixing vessel;

(b) heating the resultant mixture to liquify and form a uniform liquid mixture of these components, e.g., by heating the mixture with mixing at temperatures in the range of from 80 to 125°C; (c) adjusting, if necessary, the pH of the product of step (b) , e.g., to within the range of from about 5.5 to about 8.5, preferably from 6 to 8 and more preferably from 7.0 to 7.6, by adding an alkaline reagent to the mixture, and

(d) cooling the mixture to form a solid product. As a result of pH adjustment with the alkaline reagent, acidic starting materials, e.g., n-acyl sarcosine, may form their corresponding salts. Suitable alkaline reagents that may be used include ammonium, sodium and/or potassium hydroxide, or such salts of a C₈-C₂₂ fatty acid. In the event that the mixture becomes too alkaline, the pH can be adjusted downward with an appropriate acid, e.g., isethionic acid.

The solid product produced from step (d) may be produced in various physical forms, e.g., granulated, flaked and fragmented. Granulated material may be produced by cooling the uniform mixture in, for example, a ribbon blender and continuing the mixing operation to breakdown the solids into granules. Flaked material may be prepared by cooling the uniform mixture on a chill roller or a drum dryer and removing the solid product with a knife or scraper that results in the formation of flakes or chips. Fragmented material may be prepared by cooling the uniform mixture in containers such as shallow trays and subsequently breaking up the resulting solid pieces into fragments. Preferably, the product is produced in the flaked material form.

Synthetic detergent bars made from the base composition of the present invention may be prepared by methods known in the art, e.g., as described in U.S. Patent 5,096,608 column 9, line 44 to column 10, line 63. It will be understood by those skilled in the art that conventional adjuvant materials commonly added to soap bars may be added to the detergent base materials. Examples of such adjuvant materials include extenders, such as modified food starches, urea, clays, talc, titanium dioxide and the like; salts, such as metallic stearates, and hydrogenated vegetable glyceride phosphates to improve processing properties; and other conventional additives, such as fragrance, antioxidants, chelating agents, foam stabilizers, dyes, germicides, etc. Many of these additives are optional ingredients which are added in minor quantities and which do not materially effect the viscosity of base material mixture. Water will be present in the syndet bar in amounts usually in the range of 1.5 to 13, e.g., 2 to 12, weight percent.

The salts of the various components of the synthetic detergent base material, whether added as such or formed in situ, are preferably selected from the group consisting of sodium salts, monoethanolammonium salts, diethanolammonium salts, triethanolammonium salts, ammonium salts, potassium salts, magnesium salts and mixtures of such salts.

The present invention is more particularly described in the following example which is intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. EXAMPLE The formulations for the Examples and Comparative Examples (CE) listed in Tables 1 and 2, respectively, were produced using the ingredients listed in Tables 3 and 4. The numbers listed in Tables 1-4 are weight percentages. The ingredients listed in Part A of Tables 3 and 4 were added to a Littleford, Model M-5-G blender equipped with a Sterl-Tronic Temperature Controller. The blender was operated at a rotational speed setting of about 3 to 4. After all of the ingredients in Part A were added, mixing was continued for about 1 hour for Examples 1, 2, 7, 8 and 9 and all of the Comparative Examples except 9, 10 and 11. For Examples 3, 4, 5 and 6 and Comparative Examples 9, 10 and 11, mixing was continued until the desired temperature was reached. The desired temperature was about 105°C for all of the examples except Comparative Example 10 which was about 85°C. During the one hour mixing period, the temperature in the blender was maintained at about 105°C for Example 2 and CE 1, 3-7, 12 and 13; and at about 113°C for Examples 1, 7-9 and CE 2 , 8 and 14. The ingredients in Part B of Tables 3 and 4 for each of the Examples and Comparative Examples (CE) were added to the blender for all of the examples except Example 3 and CE 10, which were added with the ingredients in Part A. The addition of the ingredients in Part B occurred when the temperature of the batch cooled to about 85-90°C for all of the examples except Examples 4-6 and CE 9 and 11. For the latter examples, the addition of the ingredients in Part B occurred after the temperature of the batch reached the desired temperature of about 105°C. Afterwards, the batches were mixed for one hour for all of the examples except Example 2 and CE 1 and 3-7, which were mixed for 10 minutes. The temperature maintained during this mixing step was about 85°C for Example 2 and CE 1, 3-7 and 10; and about 105°C for the remainder of the examples. After this mixing step, the temperature of the batch was then reduced to 85°C. At this point, the viscosity was rated by the operator on a scale from 1 to 5, 1 being more fluid and 5 being the most viscous. The viscosity ratings are listed in Table 5. The temperature of the batch was then reduced to 35°C. Dry ice was added in an amount sufficient to complete the conversion of the liquid to a solid phase, e.g., from about 300 grams to about 1000 grams of dry ice. The resulting solid was subsequently broken up in the blender.

The resulting synthetic detergent base material was added to a ribbon blender and blended for about 5 to 10 minutes at room temperature. All of the examples were blended without addition of further ingredients except Comparative Example 9, to which was added 1.5 weight percent water and 2 weight percent coconut fatty acid; and Comparative Example 13, to which was added 6.3 weight percent water. The resulting blended product was added to a Mazzoni M-100 Simplex Refiner/Plodder maintained at a temperature of about 30 to 40°C. The product was successively forced or refined through a 20 mesh screen, a 30 mesh screen, and a 50 mesh screen. All of the examples were successfully refined except Comparative Example 13, which clogged the screens.

The refined product was then added to a Mazzcni M- 100 Simplex Refiner/Plodder having a nosecone heated to about 50 to 60°C. and- an extrusion plate in place of the screens. The billet exiting the extrusion plate was cut into slugs about 3.5 to 4 inches in length. Each slug was pressed into a bar using a Mazzoni STL hand press. The die of the hand press was treated with a thin coating of glycerin to aid in the release of the bar. The number of bars released after each die treatment was counted and is listed in Table 5. The pressed bars were evaluated for bar hardness and bar smear. Bar hardness was determined using a Precision Universal Penetrometer and a modified procedure of that described in Soap Technology For The 1990s edited by Luis Spitz, 1990, published by the American Oil Chemists' Society, page 282. The procedure was modified by running 5 penetrations on one side of the bar, totaling the results and doing 5 more penetrations on the other side and totaling the results. The average of both totals is reported in Table 5. The bar smear test was done following the Hewitt Soap Company Method No. 107 described on pp. 278 to 279 in Soap Technology For The 1990s . These results are also reported in Table 5.

Lather and grit testing were performed on the finished bars at least one hour after pressing. The lather test was conducted in a sink having a faucet equipped with a thermometer for measuring the temperature of the water. A stream of water at a flow rate of approximately one gallon per minute was adjusted to 35°C. The test bar was held in both hands in the stream of water and rotated in the hands through 10 complete revolutions. The hands and bar were removed from the stream of water and the bar was rotated in the hands through an additional 5 complete revolutions. The bar was set aside and the hands were rotated around each other through 10 revolutions to generate lather. The lather was removed from the hands and formed into a mound. The volume and quality of the lather were rated as follows:

Good: dense opaque mound of lather, approximately 4 inches in diameter and 3 inches in height; Fair: less dense and smaller volume of lather approximately 3 inches in diameter and 2 inches in height; and Poor: loose, wet lather which will not form a mound, or a low volume of lather approximately 2 inches in diameter and one inch in height. Grit testing was conducted on the bars after the lather test in the same sink. The bar was rotated in one hand under a stream of temperature controlled water while concentrating on the "feel" of the bar. The other hand was used to adjust the temperature of the water from 35°C downward until grit, i.e. granules, were felt. The temperature at which this occurred was recorded and reported in Table 5.

The performance results for the syndet bars produced from the Examples and Comparative Examples are included in Table 5. The following criteria was used to determine if the finished bar was acceptable:

Bars Released > 4

Temperature at Which < 25°C

Grit Was Detected

Lather ≥ Fair-Good

Bar Hardness < 50

Bar Smear < 6

Melt Viscosity < 2

Table 1

Ul

Example # Vβ

FORMULATION Sodium Cocoyl Isethionate (SCI) 46.4 50.8 50.8 50.8 51.7 49.6 46.4 46.4 49.3

Stearic Acid 20.5 19.3 19.3 19.3 19.7 18.8 17.5 16.2 19.2

Sodium Stearate 8.2 8.0 8.0 8.0 8.0 7.7 7.2 6.9 9.6

Coconut Acids 6.6 3.8 3.8 3.8 3.8 3.6 5.7 5.4 6.2

Sodium Lauroyl Sarcosinate 4.3 4.7 4.7 4.7 4.8 4.5 4.3 4.3 1.1 -» in

Paraffin 3.0 3.0 0.0 0.0 0.0 0.0 8.0 10.0 3.0

Polyethylene 0.0 0.0 3.0 0.0 1.5 6.0 0.0 0.0 0.0

Synthetic Wax 0.0 0.0 0.0 3.0 0.0 0.0 0.0 0.0 0.0

Sodium Cocoate 2.6 1.6 1.6 1.6 1.6 1.5 2.4 2.3 3.1 O i

CΛ Sodium Isethionate 2.1 2.5 2.5 2.5 2.6 2.5 2.1 2.1 2.3 is

Ul Water 6.3 6.3 6.3 6.3 6.3 6.1 6.3 6.4 6.3

Table 2 3 u> u»

Comparative

Examples 1 2 3 4 5 6 7 8 9 10 11 12 13 14

FORMULATION

Sodium Cocoyl

Isethionate (SCI) 50.8 46.4 50.8 50.8 50.8 50.8 50.8 46.4 54.7 50.6 50.9 46.4 54.2 41.7

Stearic Acid 21.4 14 19.3 19.3 19.3 19.3 19.3 20.5 19.5 19.5 21.1 19.7 20.6 18.5

Sodium Stearate 9 5.2 8 8 8 8 8 8.2 8 8.1 6.5 9 8.5 7.2

Coconut Acids 3.7 4.7 3.8 3.8 3.8 3.8 3.8 6.6 4.1 3.9 4.3 6.3 4.1 5.9 σι

Sodium Lauroyl

I

Sarcosinate 4.7 4.3 4.7 4.7 4.7 4.7 4.7 4.3 0 0 0 0 5 3.9

Cocamidopropyl

Hydroxysultaine 0 0 0 0 0 0 0 0 0 4.6 0 0 0 0

Coco Betaine 0 0 0 0 0 0 0 0 0 0 4.2 0 0 0

Potassium Amine *9 O

Oxide Phosphate 0 0 0 0 0 0 0 0 0 0 0 2.6 0 0

CO VO -4

Paraffin 0 15 0 0 0 0 0 0 0 3 3 3 3.2 2.7

Ul -1

Table 2 (cont.) U2:l

Comparative Jg

Examples 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ^Λ

FORMULATION

Mineral Oil 0 0 3 0 0 0 0 0 0 0 0 0 0 0

Polybutene 0 0 0 3 0 0 0 0 0 0 0 0 0 0

Petrolatum 0 0 0 0 3 0 0 0 0 0 0 0 0 0

Arachidyl

Alcohol (C-20) 0 0 0 0 0 3 0 0 0 0 0 0 0 0 _^

Polypropylene '

Glycol 0 0 0 0 0 0 3 0 0 0 0 0 0 0

Corn Oil (triglyceride) 0 0 0 0 0 0 0 3 0 0 0 0 0 0

Polyethylene 0 0 0 0 0 0 0 0 3 0 0 0 0 0

Sodium Cocoate 1.6 1.7 1.6 1.6 1.6 1.6 1.6 2.6 1.7 1.7 1.3 3 1.7 2.4 5

Sodium 2.5 2.1 2.5 2.5 2.5 2.5 2.5 2.1 2.7 2.4 2.4 2.1 2.7 1.9 1ξg

Isethionate 25

Water 6.3 6.5 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3 7.9 0 15.8

Table 3 vø -J

Example # t U>

Part A

Jordapon^® Cl³ 20 20 20 20.3 19.4

Jordapon^® CI-75² 71.3 51.5 51.5 51.5 52.3 50 71.3 71.3 76

Stearic Acid 10.3 6.4 4.8 9.2

Hydrogenated Coconut Acids 4 2.9 2.5 3.7

Sodium Stearate 15 15 15 15.2 14.6

Lauroyl Sarcos^' 4.3 4.3 4.3 4.4 4.2 I 00

Refined Paraffin Wax Melting Point 128/133°F 10

Refined Paraffin Wax Melting Point 127°F

Refined Paraffin Wax Melting Point 125/130°F

Polyethylene Wax Av. Mol. Wt. n H 500 1.5

V0 ~4

O -4 00

Vybar^® 253 ³ Ul

Table 3 (cont.) v©

Example #

NaOH 50 Wt.% 4.2 - - - - - 3.9 3.8 3.9

Water 3.2 6.3 6.3 6.3 6.4 6.1 3.5 3.6 3.5

1 - A powder that is approximately 85 weight percent sodium cocoyl isethionate, based on the total composition, the remainder being coconut fatty acid and sodium isethionate. 5

2 - Approximately 65 weight percent sodium cocoyl isethionate and 25 weight percent stearic acid, the remainder being coconut fatty acid and sodium isethionate. ' vO

3 - A synthetic wax having an average molecular weight of 520 made from polymerized olefins and sold by ' 10 Petrolite.

O

H

CA VO

0. ui

vo

Table 4 5j

*- u> u»

VC

Comparative 0\ Examples 10< 11 12 13 14

FORMULATION PART A

Jordapon^® CI¹ 14.2 20 20 20 20 20 11.2 5.9 0.4 20

Jordapon^® CI-75² 59.1 71.3 51.5 51.5 51.5 51.5 51.5 71.3 69.2 70 77.8 71.3 51.5 64.1

Stearic Acid 0.9 10.3 10.3 9.3

Hydrogenated ro Coconut Acids 1.4 3.6 o

Sodium Stearate 16.1 15 15 15 15 15 10.3 10.3 8.3 15

Hamposyl L

Lauroyl Sarcosine 4.3 4.3 4.3 4.3 4.3 4.3 4.3 3.6

Refined Paraffin Wax Melting Point 128/133°F 15 2.7 n

Refined Paraffin Wax Melting Point CO VO 142°F © u>

vo

Table 4 (cont. )

Comparative U)

U) Examples 5 6 7 8 9³ IO⁴ 11 12 13 14

FORMULATION

Mineral Oil (Av. Mol. wt. 480)

Polybutene (Av. Mol. Wt. 940)

Petrolatum

Arachidyl Alcohol

I

Polypropylene ro Glycol (Av. Mol. Wt. 2,000)

Corn Oil

Polyethylene

Wax (Av. Mol. Wt.

500)

*

Refined Paraffin Wax Melting Pt. c

V 125/130°F

S

Table 4 (cont.) !*

Comparative £

Examples 1 2 3 4 5 6 7 8 9³ IO⁴ 11 12 13 14 vo

FORMULATION

PART B

NaOH 50 Wt. % - 3.2 - - - - - 4.2 - - - 3.4 - 3.8

Water 6.3 4.2 6.3 6.3 6.3 6.3 6.3 3.2 6.3 1.7 - - - 13

Mafo^® CSB-50⁵ - - - - _ _ _ - - 9.2 - - - -

Mafo^® CB-40⁶ - - - - - - - - - - 10.5 - - ro ro

I

Mafox^® KC AO⁷ - - - - - - _ _ . _ . ₈ _ _

1 - A powder that is approximately 85 weight percent sodium cocoyl isethionate, based on the total composition, the remainder being coconut fatty acid and sodium isethionate.

2 - Approximately 65 weight percent sodium cocoyl isethionate and 25 weight percent stearic acid, the remainder being coconut fatty acid and sodium isethionate.

3 - Comparative Example 9 also contains 1.5 weight % water and 2 weight % coconut acids added during the bar making operation. „

4 - Comparative Example 13 also contains 6.3 weight % water and 2 weight % coconut acids added during the bar Q

10 making operation.

5 - Product containing 50% solids of cocoamidopropyl Hydroxysultaine and 50 weight % water sold by PPG vo

Industries, Inc. §

6 - Product containing 40% solids of cocobetaine and 60 weight % water sold by PPG Industries, Inc. oo

7 - Product containing 33 weight percent of potassium cocoamine oxide phosphate and 67 weight % water sold by ""* 15 PPG Industries, Inc.

Table 5

Temperature at

Bars which grit feit Bar Bar Melt

Examples pH Released (C°) Lather Hardness Smear Viscosity

1 7.2 5+ 20 good 32.2 4.3 1

2 7.4 4 to 5 20 good 38.2 1.8 1

3 7.2 4 <20 good 42.2 2.2 1

4 7.4 5 <20 good 23.3 1.2 1

5 7.6 5 <20 good 38 1.3 2

6 7.5 4 22 fair-good 41 1.02 i ro

CO

7 7.2 5+ 22 good 48.3 2.9 1 i

8 7.2 5+ <20 good 42.5 3.8 1

9 7.2 5+ <20 good 38 4.9 1

H co

VO

Ul ~4

³ ^93/4967 Table 5 (cont . )

Temperature at s

Comparative Bars which grit fisit Bar Melt

Examples pH Released (C°) Lather Hardness Bar Smear Viscosity

1 7.2 4 25.5 1.1 5

2 7.1 5 28 good 47 2.5 1

3 7.3 3 to 4 62 2.1 1

4 7.2 3 to 4 35 good 53.2 2.6 1

5 7.3 3 50.8 1.6 1

6 7.4 3 to 4 38.8 1.3 4 1

7 7.2 ro

5 45.8 2.2 5 ^J>

8 7.1 2 <20 poor 59 4.5 1 ¹

9 7.4 4 24 1 4

10 7.2 4 35 good 41.5 3.3 5

11 7.4 5 26 good 37.2 2.5 3

12 7.2 3 28 good 60 2

13 7.2 NA* 2

* Not Applic :able since product clogged screens and could not be pressed into bars.

06 U)

^9/3743! A review of the results of Table 5 revealed that Examples 1 through 9 of the present invention, produced acceptable syndet bars by matching all of the desired criteria. All of the Comparative Examples produced unacceptable syndet bars as evidenced by the lack of meeting all of the desired criteria. Specifically, Comparative Example 1, which had 0 weight percent paraffin, had a melt viscosity that was too high and Comparative Example 2, which had 15 weight percent paraffin, had poor lather. Comparative Examples 3 through 8, which contained hydrophobic materials other than the hydrocarbon waxes, as defined herein, either had too low of a number of bars released or the melt viscosity was too high. Comparative Example 9, which contained 0 weight percent lauroyl sarcosine, also had a melt viscosity that was too high. Comparative Examples 10, 11 and 12, which contained potential replacements for the sarcosine, i.e., cocoamidopropyl hydroxysultaine, cocobetaine and potassium cocoamine oxide phosphate, had detectable grit at a temperature above 25°C in addition to unacceptable melt viscosities for Comparative Examples 10 and ll and unacceptable bar hardness for Comparative Example 12. Comparative Example 13, which had 0 weight percent water in the hot melt, could not be processed through the screens and Comparative Example 14, which had 15 weight percent water in the hot melt, had an unacceptable melt viscosity and a low number of bars released.

Although the present invention has been described with reference to the specific details of particular embodiments, it is not intended that such details be regarded as limitations upon the scope of the invention except as and to the extent that they are included in the accompanying claims.

Claims

I claim :

1. A mild synthetic detergent base material consisting essentially of: (a) from 30 to 65 weight percent of mild lathering anionic synthetic surfactant;

(b) from 7 to 40 weight percent of C₈-C₂₂ fatty acid;

(c) from 2 to 20 weight percent salt(s) of C₈-C₂₂ fatty acid;

(d) from 1.5 to 12 weight percent of water;

(e) from 1 to 10 weight percent of C₈-C₁₄ acyl sarcosine, salt(s) thereof or a mixture of said sarcosine and said salt (s) ,- (f) from 1 to 10 weight percent of hydrocarbon wax that is a solid at room temperature; and

(g) from 0.5 to 5 weight percent of a salt selected from isethionic acid salt, chloride salt, sulfate salt or mixtures of such salts, said synthetic detergent base material having a pH of from 5.5 to 8.5.

2. The mild synthetic detergent base material of claim 1 wherein the ingredient salts are selected from the group consisting of sodium salts, monoethanolammonium salts, diethanolammonium salts, triethanolammonium salts, ammonium salts, potassium salts, magnesium salts and mixtures of such salts.

3. The mild synthetic detergent base material of claim 2 wherein the salts are sodium salts.

4. The mild synthetic detergent base material of claim 1 wherein:

(a) the mild anionic synthetic detergent is present in amounts of from 35 to 60 weight percent and is selected from the group consisting of methyl C₈-C₁₄ acyl taurates, C₈-C₁₄ n-acyl glutamates, C₈-C₁₄ acyl isethionates, mono (C₈-C₁₄) alkyl sulfosuccinates, and mixtures of said mild anionic surfactants;

(b) the C₈-C₂₂ fatty acid is present in amounts of from 15 to 35 weight percent;

(c) the salt(s) of C₈-C₂₂ fatty acid is present in amounts of from 5 to 18 weight percent;

(d) water is present in amounts of from 3 to 10 weight percent; (e) the C₈-C₁₄ acyl sarcosine, salt(s) thereof, or a mixture of said sarcosine and salt(s) thereof is present in amounts of from 1.5 to 8 weight percent;

(f) the hydrocarbon wax is present in amounts of from 2 to 8 weight percent and is selected from the group consisting of petroleum waxes, polyethylene waxes, synthetic waxes and mixtures of said waxes; and

(g) the isethionic acid salt, chloride salt, sulfate salt or mixtures of such salts is present in amounts of from 1 to 5 weight percent;

said synthetic detergent base material having a pH of from 6 to 8.

5. The mild synthetic detergent base material of claim 4 wherein:

(a) the mild anionic synthetic surfactant is present in amounts of from 40 to 50 weight percent; (b) the C₈-C₂₂ fatty acid is selected from the group consisting of coconut fatty acids, tallow fatty acids, caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid and mixtures of such acids, and such acid is present in amounts of from 20 to 30 weight percent;

(c) the salt(s) of C₈-C₂₂ fatty acid is present in amounts of from 8 to 12 weight percent;

(d) water is present in amounts of from 5 to 8 weight percent;

(e) the C₈-C₁₄ acyl sarcosine is selected from the group consisting of lauroyl sarcosine, cocoyl sarcosine, myristoyl sarcosine and mixtures of said sarcosines and is present in amounts of from 2 to 5 weight percent; (f) the hydrocarbon wax is present in amounts of from 3 to 8 weight percent and is selected from the group consisting of paraffin waxes, polyethylene waxes and mixtures of said waxes; and

(g) . the isethionic acid, chloride and sulfate salts are sodium salts and are present in amounts of from 1.5 to 2.5 weight percent;

said synthetic detergent base material having a pH from 7.0 to 7.6.

6. The mild synthetic detergent base material of claim 5 wherein said mild anionic synthetic surfactant is a sodium salt of C₈-C₁₄ acyl isethionate, ammonium salt of said isethionate, or a mixture of said sodium and ammonium salts; said C₈-C₁₄ acyl sarcosine and salts thereof are selected from the group consisting of lauroyl sarcosine, cocoyl sarcosine, sodium salts thereof, and mixtures of said sarcosines and εodium salts thereof; said C₈-C₂₂ fatty acid is selected from the group consisting of stearic acid, coconut acid and mixtures of said acids; and said hydrocarbon wax is a paraffin wax.

7. A mild synthetic detergent bar comprising soap bar ad uvants and a mild synthetic detergent base material consisting essentially of (a) synthetic surfactant of d) mild anionic synthetic surfactant and (ii) C₈-C₁₄ n-acyl sarcosine, salts thereof or a mixture of said n-acyl sarcosine and salts thereof; (b) C₈-C₂₂ fatty acid; (c) salts of C₈-C₂₂ fatty acid; (d) hydrocarbon wax that is solid at room temperature; and(e) isethionic acid, sulfate or chloride salts or mixtures of such salts,- wherein the weight ratio of synthetic surfactant d) to synthetic surfactant (ii) ranges from 3:1 to 65:1 and the weight ratio of total synthetic surfactant to C₈-C₂₂ fatty acid, ranges from 0.7:1 to 11:1; said salts of the surfactants, fatty acids, and isethionic acid, sulfate and chloride salts being selected from the group consisting of sodium salts, monoethanolammonium salts, diethanolammonium salts, triethanolammonium salts, ammonium salts, potassium salts, magnesium salts and mixtures of said salts.

8 The mild synthetic detergent bar of claim 7 wherein said weight ratio of synthetic surfactant d) to synthetic surfactant (ii) ranges from 4:1 to 40-1, and the weight ratio of the total synthetic surfactant to C₈-C₂₂ fatty acid ranges from 1:1 to 5:1.

9 The mild synthetic detergent bar of claim 8 wherein said weight ratio of synthetic surfactant d) to synthetic surfactant (ii) ranges from 8:1 to 25:1, and the weight ratio of the total synthetic surfactant to C₈-C₂₂ fatty acid ranges from 1.7:1 to 3:1.

10. A mild synthetic detergent bar comprising the mild synthetic detergent base material of claim 1 and soap bar adjuvants.

11. A mild synthetic detergent bar comprising the mild synthetic detergent base material of claim 3 and soap bar adjuvants.

12. A mild synthetic detergent bar comprising the mild synthetic detergent base material of claim 5 and soap bar adjuvants.

13. A mild synthetic detergent bar comprising the mild synthetic detergent base material of claim 6 and soap bar adjuvants .