Agglomerated abrasive material, compositions comprising same, and processes for its manufacture

BACKGROUND OF THE INVENTION
The present invention relates to agglomerated abrasive material, in particular of the polymer-agglomerated inorganic filler type, which is particularly suitable for, although not limited to, the use in liquid abrasive cleaning compositions commonly used in the household.
FIELD OF THE INVENTION
The invention also relates to processes for the manufacture of such agglomerated abrasive material, and to abrasive cleaning compositions containing such material.
THE RELATED ART
The use of agglomerated abrasive material in liquid abrasive cleaning compositions is known from e.g. European Patent Application No. 0 104 679. It has been shown that in scouring cleaning compositions application of agglomerated abrasive material provides advantages over conventional abrasive materials in that it allows the application of normally (i.e. in unagglomerated form) ineffective particle size ranges of the abrasive material and results in reduced scratching of sensitive substrate surfaces while providing effective soil removal.
In general, agglomerated abrasive material consists of two components, the basic abrasive material often of very low average particle size, and a binding agent therefor. The binding agent may be selected from a great variety of classes including resins, gums, gels, waxes and polymers.
The proper selection of the binding agent is dependent on the chemical and mechanical/physical characteristics one desires, and is often a compromise between binding capability, mechanical strength (flexural strength, micro-hardness, friability) and chemical stability under the conditions of application and storage. In particular, under the alkaline conditions of the liquid abrasive cleaner medium it has proven difficult to strike the right balance between the chemical stability and required mechanical strength.
A conventional method to manufacture agglomerated abrasive material involves the mixing of the small sized inorganic filler material and a binding agent, such as a paraffin or low molecular weight ethylene wax including a suitable degree of oxidation, to obtain a homogeneous melt, which is subsequently solidified and milled to the desired particle size range.
An alternative route, which is particularly applicable when polymeric binding agents are used, involves using solutions or emulsions of the polymeric binding agent to make a slurry with the inorganic filler material, followed by heat-drying to drive off the solvent. The cast or spray-dried solids are then milled to the desired particle size range.
It is now an object of the present invention to provide agglomerated abrasive material which is chemically and physically stable in the often alkaline liquid abrasive cleaner media, and allows a process for its manufacture which is simpler and more economical than the conventional processes, in particular in that it avoids the use of solvents and the relatively expensive steps of heat-drying and milling.
It has been found that a specific selection of polymers as binding agents, to be described in detail hereunder, results in agglomerated abrasive material which has very good physical and chemical stability, and which can be manufactured by a very simple process wherein the mixing of the two ingredients automatically results in a spontaneous crumbling process into agglomerated abrasive material the size range of which is determined by the selections and amounts of starting materials.
SUMMARY OF THE INVENTION
Accordingly, in a first aspect of the present invention, agglomerated abrasive material is provided which comprises an inorganic filler and a polymeric binding agent selected from the group consisting of the high molecular weight polyalkylenes, the copolymers thereof with each other, the copolymers thereof with up to 30% by weight of monomers containing a carboxylic acid or ester group, and the mixtures thereof.
In a second aspect, the invention provides a process for the manufacture of agglomerated abrasive material, the process comprising a first step in which a continuous melt of an inorganic filler material and a polymeric binding agent selected from the group of the high molecular weight polyalkylenes, the copolymers thereof with each other, the copolymers thereof with up to 30% by weight of monomers containing a carboxylic acid or ester group, and the mixtures thereof, and optionally a blowing agent, is prepared, the weight ratio of the inorganic filler to the polymeric binding agent being below the spontaneous crumbling level, and a second step in which sufficient inorganic filler is added to the continuous melt to raise the weight ratio of inorganic filler to polymeric binding agent above the spontaneous crumbling level.
In a third aspect, the present invention provides a scouring cleaning composition which comprises a detergent surfactant, agglomerated abrasive material and conventional scouring detergent composition adjuncts, the agglomerated abrasive material comprising an inorganic filler and a polymeric binding agent selected from the group consisting of the high molecular weight polyalkylenes, the copolymers thereof with each other, the copolymers thereof with up to 30% by weight of monomers containing a carboxylic acid or ester group, and the mixtures thereof.

DETAILED DESCRIPTION OF THE INVENTION
The selection of the inorganic filler is not very critical. Suitably, particle sizes may range from about 7 nm (currently available smallest size) up to about 10 micrometers. Particle sizes within the range of from 0.1 to 10 micrometers have been found most suitable. As particles of such smallness exhibit a reduced to non-scratching behaviour, irrespective of their hardness on Moh's scale, a wide range of inorganic fillers may be used. Thus, minerals selected from the dolomites, aragonites, feldspars, silica (sand, quartz), ground glass, the hard silicate minerals, silicon carbide, pumice, aluminas, gypsum, clays, kaolins, and the like, or mixtures thereof are all suitable basic filler materials.
Particularly suitable is calcite, for instance limestone, chalk or marble, such as those forms of calcite referred to in British Patent Specification No. 1,345,119.
An essential feature in accordance with the present invention is the selection of the polymeric binding agent. Suitable binding agents are polyalkylenes of or analogous to the high-density polyethylene (HDPE) type.
The HDPE polymers are a well-known class of relatively high molecular weight polyethylenes with no or only short-chain branching, characterised by densities within the range of from about 0.94 to 0.96 g/cm.sup.3 and molecular weights of over 20,000.
Accordingly, suitable polymers in accordance with the present invention are the high-density polyethylenes, linear low-density polyethylene, low-density polyethylene, polypropylenes, polybutylenes, the copolymers thereof with each other, such as the copolymers of ethylene and propylene and/or isobutylene, and the copolymers thereof with monomers containing carboxylic groups in an amount of up to 30% by weight on polymer basis. Suitable monomers of the latter type are, in particular, the C.sub.2 -C.sub.4 carboxylic or carboxylate monomers, such as vinyl acetate, (meth)acrylic acid and the methyl or ethyl esters thereof.
In order to have the full advantages of the present invention, the weight ratio of the inorganic filler material to the polymeric binding agent must lie above the spontaneous crumbling level of the particular combination of the filler material and the binding agent used. The spontaneous crumbling level, which is dependent on the type and size of the filler and the type and molecular weight of the polymeric binding agent, can be easily determined for each filler/binding agent combination by preparing a melt of the binding agent and slowly adding the inorganic filler material until crumbling occurs.
In general, the amount of filler may range from 10 to 97% by weight of the final agglomerate. Preferred are amounts of over 70% by weight, amounts within the range of 80 to 90% by weight being preferred most.
Accordingly, the amount of polymeric binding agent in general lies within the range of from 3 to 80% by weight of the agglomerate, preferably is below 20% by weight, the range of from 8 to 20% by weight being preferred most.
The agglomerates in accordance with the invention can be manufactured simply by preparing a melt of the polymeric binding agent and mixing in the total amount of inorganic filler material in one step.
Suitable temperatures for preparing the melt depend upon the polymeric binding agent used, but normally lie within the range of from 170.degree. C. to 250.degree. C., and preferably within the range of from 180.degree. C. to 230.degree. C.
In a particularly preferred embodiment of the present invention 50% to 80% by weight of the total amount of the inorganic filler is introduced in the first step, and 20% to 50% by weight is introduced after the continuous mixture has been achieved to effectuate the crumbling and agglomeration processes.
A significant weight fraction of the agglomerated abrasive material resulting from the process according to the present invention has a particle size within the range suitable for direct inclusion in scouring detergent products. Agglomerates which are too fine or too coarse can be removed by a simple sieving step and recycled batch-wise or continuously into a melt of the binding agent before the crumbling step. If so desired, the part of the agglomerated abrasive material which is too coarse can also be subjected to a limited milling step to reduce size.
To influence the mechanical properties of the agglomerates resulting from the process according to the invention, it may be of advantage to add in the first step of the process, i.e. the preparation of the continuous melt of the inorganic filler and the polymeric binding agent, a suitable amount of a chemical or physical blowing agent. Chemical blowing agents are those compounds which, blended with the polymeric binding agent, decompose on heating under formation of gas, thereby foaming the polymeric melt. Suitable examples are carbonate or bicarbonate salts, ethylene carbonate, organic or inorganic nitrites, aromatic or aliphatic azo compounds, hydrazine salts, hydrazides, carbonyl or sulphonyl azides. Physical blowing agents are either volatile organic liquids such as heptanes, hexanes and the like, or gasses such as N.sub.2, CO.sub.2 or fluorocarbons, which are injected into the polymer melt at high pressure.
Alternatively, both chemical or liquid physical blowing agents can be mixed with the filler which is subsequently blended with polymer and melted to obtain foamed polymer melt.
The blowing agent can suitably be used in amounts up to 25% by weight of the polymeric binding agent component without adversely influencing the chemical stability of the agglomerated abrasive material thus prepared. Preferably, the blowing agent is introduced into the polymer melt in an amount of from 0.5 to 15% by weight.
The agglomerated abrasive material is particularly suitable for inclusion in scouring cleaning compositions, which may be in powder or liquid form.
In such scouring cleaning compositions, generally also one or more surface-active agents are included. Suitable as surfactants in the compositions of the present invention are any of the detergent-active compounds normally used in scouring cleansers, including anionic, nonionic, cationic, zwitterionic and amphoteric compounds.
Suitable anionic surfactants are alkali metal or alkanolamine salts of C.sub.12 -C.sub.18 branched- or straight-chain alkyl aryl sulphonates, of C.sub.12 -C.sub.18 paraffin sulphonates, of C.sub.8 -C.sub.12 branched- or straight-chain alkyl sulphonates, of C.sub.10 -C.sub.18 alkyl EO.sub.1-10 sulphates, of sulphosuccinates, of C.sub.10 -C.sub.24 fatty acid soaps, etc. It is often desirable to include also a nonionic or zwitterionic detergent material, especially in the liquid type of scouring compositions. Suitable examples of nonionic detergents are water-soluble condensation products of ethylene oxide and/or propylene oxide with linear primary or secondary C.sub.8 -C.sub.18 alcohols, with C.sub.8 -C.sub.18 fatty acid amides or fatty acid alkylolamides (both mono- and diamides), with C.sub.9 -C.sub.18 alkyl phenols and so on. The alkoxylated C.sub.8 -C.sub.18 fatty mono- and dialkylolamides should contain more than one alkylene oxide unit, for instance they should be condensed with e.g. 2-5 moles of alkylene oxide such as ethylene oxide. Fatty acid mono- or dialkylolamides in which the fatty acid radical contains 10-16 carbon atoms are also suitable nonionics, such as e.g. cocofatty acid monoethanolamide. Suitable zwitterionic detergents are trialkylolamine oxides having one long alkyl chain (C.sub.8 -C.sub.18) and two short alkyl chains (C.sub.1 -C.sub.4), betaines and sulphobetaines. Other surfactants and combinations of surfactants are those referred to for use in scouring cleanser compositions described in British Patent Specification Nos. 822 569, 955 081, 1 044 314, 1 167 597, 1 181 507, 1 262 280, 1 303 810, 1 308 190, 1 345 119 and 1 418 671.
It is often desirable that scouring compositions of the present invention contain adjuncts, especially builder salts such as alkali metal silicates, carbonates, orthophosphates, pyrophosphates and polyphosphates, nitrilotriacetates, citrates, and mixtures thereof, colouring agents, perfumes, fluorescers, hydrotropes, soil-suspending agents, bleaching agents and precursors therefor, enzymes, opacifiers, germicides, humectants and salt electrolytes such as those referred to in the above patent specifications.
Particularly valuable are scouring compositions that are free-flowing powders. Such cleansers can contain from 0.1 to 40% by weight of surfactant, from 5 to 99% by weight of abrasive powder and from 0 to 95% by weight of scouring cleanser adjuncts. Also particularly valuable are scouring cleansers that are pasty or pourable aqueous liquid compositions. Such cleansers can contain from 0.1 to 50% by weight of surfactant and from 5 to 60% by weight of abrasive powder, the remainder being scouring cleanser adjuncts and water. Preferably, the abrasive powder is dispersed in the aqueous medium of the cleanser, and the aqueous medium comprises a micellar or polymeric suspending system which maintains the powder in dispersion. Suitable aqueous media are those described in British Patent Specification Nos. 1 167 597, 1 181 607, 1 262 280, 1 303 810, 1 308 190 and 1 418 671.
The invention will further be described by way of the following examples.
EXAMPLE 1
Before describing the batch and continuous processes to obtain agglomerates, it ia necessary to determine the values of the filler concentration at crumbling, C.sub.c, as a function of the filler particle size for a given binder. Crumbling concentration depends on the physical and chemical nature of the binder and filler. The characteristics of the fillers are tabulated in Table 1, those of polymers and waxes are tabulated in Table 2 and those of the chemical blowing agents are tabulated in Table 3.
Determination of the crumbling concentration C.sub.c was carried out using a small Z-blade mixer in which the torque on the mixing blades could be recorded and the rotational speed of the mixer was kept at 60 rpm. After melting the polymer, small amounts of the filler were added and mixing was continued until a homogeneous melt was obtained which was reflected in increasing torque. Crumbling occurred when a homogeneous melt could no longer be obtained after the addition of a small amount of filler, and the torque was very low. Crumbling concentration was then determined.
In Table 4, crumbling concentration C.sub.c is tabulated for three different fillers and a number of waxes and polymers. The process temperature in these examples A1-A15 are the typical processing temperature for each binder.
In Table 5, the variation of the crumbling concentration C.sub.c (as volume fraction) with the filler particle size is shown for silica or calcium carbonate fillers when the binder is a HDPE. When log (particle size) is plotted against the volume fraction of the filler at crumbling, a linear relationship is obtained which can then be used to estimate the crumbling concentration for other fillers.
TABLE 1______________________________________Characteristics of the fillers MEAN PARTICLEIDENTIFYING SIZECODE NAME (/um)______________________________________Aerosil 380 Pyrogenic silica 0.007 (Bet surface area = 380 m.sup.2 /g)Aerosil 130 Pyrogenic silica 0.016 (Bet surface area = 130 m.sup.2 /g)Aerosil TT600 Pyrogenic silica 0.040 (Bet surface area = 200 m.sup.2 /g)Garosil N Silica 1.0Socal U3 Precipitated calcium carbonate 0.020 (99% CaCO.sub.3)Durcal 2 Dry milled calcite 2.0 (contains 1.5% MgCO.sub.3)Queensfil 10 Dry milled calcite 2.0 (95.4% CaCO.sub.3)Queensfil 25 Dry milled calcite 3.0 (95.4% CaCO.sub.3)Polcarb Dry milled calcite 1.0 (97% CaCO.sub.3)Polcarb-S Stearate-coated version of 1.0 Polcarb______________________________________
TABLE 2__________________________________________________________________________Characteristics of the polymers and waxes used as binding agents inagglomeratesIDENTIFYING T.sub.mpCODE NAME M.sub.w.sup.(1) (.degree.C.).sup.(2)__________________________________________________________________________P.W. Paraffin Wax 500 60AC1702 Polyethylene homopolymer 1100 92AC617 Polyethylene homopolymer 1500 102AC735 Polyethylene homopolymer -- 110AC9 Polyethylene homopolymer 3500 117AC680 Oxidised polyethylene homopolymer 1950 110AC540 Ethylene-acrylic acid copolymer with Acid Number = 40 mg 3000g 108AC5120 Ethylene-acrylic acid copolymer with Acid Number = 120 mg 3500g 92AC405 Ethylene-vinyl acetate copolymer (Vinyl acetate content = 2000 96AC400 Ethylene-vinyl acetate copolymer (Vinyl acetate content = 3500 95Rigidex 140-60 High density polyethylene (homopolymer) 6.5 .times. 10.sup.4 170Rigidex XGR791 High density polyethylene (homopolymer) 1.1 .times. 10.sup.5 170Rigidex HO20 High density polyethylene (homopolymer) 3.7 .times. 10.sup.5 170Hostalen GD6250 High density polyethylene (homopolymer) 8 .times. 10.sup.4 170Lupolen 5031LX High density polyethylene (homopolymer) 6.4 .times. 10.sup.4 170Rigidex HO60 Ethylene-hexene-1 copolymer with one butyl branch 6.4 .times. 10.sup.4 170 per 1000 carbon atomsHostalen GUR412 Ultra-high molecular weight homopolymer 3 .times. 10.sup.6 200UHMW 1900 Ultra-high molecular weight homopolymer 5 .times. 10.sup.6 200GXM43 Polypropylene 3.9 .times. 10.sup.5 200__________________________________________________________________________ .sup.(1) M.sub.w is the weight average molecular weight. .sup.(2) T.sub.mp is the minimum processing temperature.
TABLE 3______________________________________Characteristics of the chemical blowing agentsNAME (GENITRONSERIES*) EPB EPC EPD______________________________________DECOMPOSITION 170-200 160-200 200-220TEMPERATURE(.degree.C.)______________________________________ *GENITRON CHEMICAL BLOWING AGENTS are based on azodicarbonamide which decomposes with the release of nitrogen, carbon monoxide, carbon dioxide and ammonia.
TABLE 4__________________________________________________________________________Variation of the crumbling concentration (C.sub. c) with the weightaverage molecularweight (M.sub.w) of the continuous phase (binder) and mean primaryparticle size (d)the filler at various processing temperatures (T.sub.p). FILLER CONCENTRATION ATContinu- CRUMBLING C.sub.c (Wt. %) ous Durcal Socal AerosilExample Phase T.sub.p 2 U3 380Number (Binder) M.sub.w (.degree.C.) d = 2/um d = 0.02/um d = 0.007/um__________________________________________________________________________A1 P.W. 500 90 91 -- --A2 AC1702 1100 95 84 -- --A3 AC617 1500 110 82 -- --A4 AC9 3500 125 81 56 --A5 AC680 1950 120 81 -- --A6 AC5120 3500 100 85 -- --A7 AC405 2000 100 82 -- --A8 AC400 3500 100 81 -- --A9 Rigidex 6.5 .times. 10.sup.4 180 -- -- 46 140-60A10 Rigidex 1.1 .times. 10.sup.5 180 78 49 40 XGR791A11 Rigidex 3.7 .times. 10.sup.5 200 -- -- 31 HO20A12 Rigidex 2.8 .times. 10.sup.5 200 -- -- 36 HO60A13 Hostalen 3 .times. 10.sup.6 240 -- -- 16 GUR412A14 UHMW 5 .times. 10.sup.6 240 -- -- 10 1900A15 GXM43 3.9 .times. 10.sup.5 220 -- -- 35__________________________________________________________________________
TABLE 5______________________________________Variation of the volume fraction of filler at crumbling with meanprimary size when the continuous phase is Rigidex XGR 791(high density polyethylene with M.sub.w = 1.1 .times. 10.sup.5) at180.degree. C. PARTICLE VOLUMEExample SIZE FRACTIONNumber FILLER (.mu.m) AT CRUMBLING______________________________________A16 Aerosil 380* 0.007 0.22A17 Aerosil 130* 0.016 0.28A18 Aerosil TT600* 0.040 0.32A19 Garosil N* 1.0 0.52A20 Socal U3.sup.+ 0.020 0.29A21 Durcal 2.sup.+ 2.0 0.57______________________________________ *Silica fillers; .sup.+ Calcium carbonate fillers.
EXAMPLE 2
A number of agglomerates were prepared using the following batch method of preparation:
The batch processing was carried out in a small Z-blade mixer. The mixer was externally heated using an oil bath. The torque on the mixing blades could be recorded and the rotational speed of the blades was kept at 60 rpm. The important processing parameters were:
(1) Mean filler concentration in the product, C.sub.p (by weight;
(2) Filler concentration at crumbling, C.sub.c ;
(3) Processing temperature T.sub.p ;
(4) Processing time, t.sub.p.
Polymer powder or pellets were placed in the mixer and allowed to melt, followed by homogenisation by mixing for two minutes. The addition of the filler was conducted in two different ways. These are summarised below:
1. After obtaining the homogeneous polymer melt, half of the total filler was added to the polymer melt so that at this stage the filler concentration was less than the crumbling concentration. The temperature of the mix was kept constant throughout the mixing process. When all of the polymer was mixed with the filler, the remaining filler was added. Since C.sub.p was greater than C.sub.c, crumbling occurred, even though the temperature of the filler was equal to that of the mixture. The crumbling was reflected by the sudden decrease in the torque.
2. The filler was added gradually. i.e. in four stages, to the homogeneous polymer melt and subsequently mixed therewith after each addition.
When a chemical blowing agent was used, the first method of filler addition was followed. After the first addition of the filler and obtaining a homogeneous melt, the blowing agent was added while mixing was being carried out. Following the blowing action, the second half of the filler was introduced and mixing was continued until the desired mixing time was reached.
The products obtained were subsequently fractionated by sieving to obtain agglomerates with a certain size range. Table 6 tabulates the raw material characteristics, process conditions and agglomerate size distribution in batch-processed abrasives.
TABLE 6__________________________________________________________________________The effect of processing conditions and raw material properties on theagglomerate sizedistribution in batch processingRAW MATERIALS BLOWING PROCESSING AGGLOMERATE SIZE METHOD AGENT CONDITIONS DISTRIBUTION (.mu.m) OFExample POLYMER CALCITE (5 wt. % T.sub.p Time 45- 250- FILLERNumber NAME Wt. % FILLER polymer) (.degree.C.) (min) <45 250 1700 >1700 ADDITION__________________________________________________________________________B1 P.W. + O.P.E. 8 Durcal 2 -- 90 120 6 16 65 13 2B2 AC405 9 Durcal 2 -- 100 120 -- 10 81 9 2B3 AC617 10 Durcal 2 -- 110 120 -- 5 86 9 2B4 AC1702 14 Durcal 2 -- 95 120 -- 9 84 7 2B5 AC735 10 Durcal 2 -- 115 120 -- 9 85 6 2B6 AC5102 9 Durcal 2 -- 100 120 -- 2 91 7 2B7 Rigidex XGR791 42 Solvay U3 -- 200 120 15 27 34 24 2B8 Rigidex XGR791 13 Queensfil 10 EPC 180 135 3 56 40 1 1B9 Rigidex XGR791 12 Durcal 2 -- 180 60 29 34 30 7 1 B10 Rigidex XGR791 12 Durcal 2 EPC 180 60 19 33 43 5 1 B11 Rigidex XGR791 12 Durcal EPC 180 100 15 41 40 4 1__________________________________________________________________________
EXAMPLE 3
A series of agglomerates were produced using the following continuous processing:
The continuous processing of polymer-bound agglomerates was conducted using a twin-screw extruder fitted with an additional filler feeding zone and a purpose-built outlet die. The extruder barrel and the outlet die had heating or cooling facilities. The severity of the mixing could be changed by changing the number of mixing units (paddles) in the mixer.
In all the examples, the filler and polymer were dry blended (80% filler by weight), and any blowing agent used was also added to this mixture. The resulting blend was fed into the extruder and melted while being mixed. After the first melting stage, the remaining filler was fed in cold to induce crumbling. The second mixing stage had a cooling zone at the end of the extruder.
The mixing conditions were characterised by the number of mixing elements in each mixing stage and by the temperature profile along the mixer. The product from the extruder was subsequently fed into a milling machine at temperatures ranging from 25.degree.-100.degree. C.
Table 7 tabulates the mixing conditions and Table 8 tabulates the various processing conditions. Tables 9 and 10 tabulate the particle size distributions before and after milling.
TABLE 7______________________________________Screw configurations and set temperatures inthe heating zone NUMBER OFSCREW MIXING HEATING ZONECON- PADDLES TEMPERATURES*FIG- AFTER AFTER (.degree.C.)URA- 1st 2nd 1st 2nd 3rd 4thTION FEED FEED ZONE ZONE ZONE ZONE______________________________________1 7 21 160 200 80 302 7 15 80 180 20 30______________________________________ *Set temperature in the 2nd heating zone is 220.degree. C. for the Examples C1 and C2.
TABLE 8__________________________________________________________________________The effect of processing conditions and raw material properties on theagglomerate sizedistribution following milling BLOW- MAX. AGG- ING SCREW TEMP. LOM- AGENT CON- DUR- ERATE and FIG. OUT- ING CRUMB- SIZEPOLYMER CONCEN- URA- PUT PRO- PROD. LING MILLING Wt. %Ex. CONC. TRATION TION RATE CESS- TEMP. POSS- TEMP. RATE belowNo NAME (Wt. %) FILLER (Wt. %) (+) (kg/hr) ING (.degree.C.) IBLE? (.degree.C.) (kg/hr) 250__________________________________________________________________________ .mu.mC1 Rigidex 13 Queensfil -- 1 11 230 125 YES -- -- -- HO20 25C2 Rigidex 13 Queensfil 5% EPD 1 16 240 145 YES 25 5.2 80* HO20 25C3 Rigidex 11 Queensfil -- 1 22 240 -- YES 25 7.5 87* HO20 25C4 Rigidex 11 Queensfil -- 2 11 197 140 YES 100 6.0 65 HO20 25C5 Rigidex 15 Queensfil 2% EPD 1 13 240 105 YES 25 3.3 68* HO20 25C6 Rigidex 15 Queensfil 2% EPD 1 14 210 -- YES 25 3.6 58* HO20 25C7 Rigidex 11 Queensfil 5% EPD 2 13 196 120 YES 100 6.6 70 HO20 25C8 Rigidex 9 Queensfil 5% EPD 2 12 204 125 YES 80 5.0 70 HO20 25C9 Rigidex 14 Durcal 2 -- 2 14 230 152 YES 40 4.8 65 HO20C10 Rigidex 15 Polcarb-S -- 2 12 178 135 Yes 40 1.2 54 HO20C11 Rigidex 12 Polcarb -- 2 9 -- 130 YES 40 3.0 63 HO20C12 Lupolen 11 Queensfil -- 2 18 186 -- YES 40 -- 95 5031LX 25C13 Hostalen 7 Queensfil -- 2 -- -- -- NO -- -- -- GD6250 25C14 Rigidex 12 Queensfil -- 2 22 177 -- YES 40 -- 50 HO60 25C15 Rigi- 12 Queensfil -- 2 10 179 135 YES 30 6.0 68 dex + 25 HO60 + AC680__________________________________________________________________________ *In these examples, weight percent of agglomerate below 212 .mu.m is given. +(1) Set temperature in the second heating zone is 200.degree. C. for the Examples B1 and B2. (2) The size of the holes at the outlet of the extruder is 2 mm for the Examples B1 and B2. If no crumbling occurs, no screen is present at the outlet.
TABLE 9__________________________________________________________________________Agglomerate size distribution in continuouslyprocessed samples before millingSIZE RANGE.mu.m .dwnarw. WEIGHT PERCENT IN EACH SIZE RANGEEXAMPLE N.degree..fwdarw. C1 C2 C3 C4__________________________________________________________________________>1700 20.1 7.1 27.3 44.61700-1000 40.6 43.0 20.4 16.61000-500 20.5 25.3 20.6 17.2500-355 6.4 7.4 7.6 6.1355-250 4.8 6.1 6.3 5.1250-45 7.4 10.3 14.8 9.8<45 0.2 0.6 0.9 0.6PROCESSING 2 mm 2 mm 3 mm 3 mmCHARACTER- OUTLET OUTLET OUTLET OUTLETISTICS SCREEN SCREEN SCREEN SCREEN AND LOW BLOWING PROCESS AGENT TEMPERATURES__________________________________________________________________________
TABLE 10______________________________________Agglomerate size distribution after millingof the coarse agglomerate obtained from thetwin-screw extruder. Milling temperature is25.degree. C.SIZE RANGE.mu.m .dwnarw.EXAMPLE N.degree. WEIGHT PERCENT IN EACH SIZE RANGE.fwdarw. C2 C4 C5 C6______________________________________>212 19.6 13.0 32.3 45.3212-200 4.6 3.3 7.9 7.2200-150 15.1 13.6 15.8 16.6150-100 21.3 21.0 17.7 14.3100-75 11.7 14.6 7.3 6.975-63 6.3 6.0 5.4 2.5<63 21.4 28.5 13.6 7.2______________________________________
EXAMPLE 4
Scratch and detergency (removal of 15 .mu.m thick microcrystalline wax soil) of the agglomerates were tested using two types of liquid detergent compositions which did not contain any particulate matter for the purpose of soil removal. These compositions are in Table 11.
Detergency and scratch characteristics of the agglomerates are assessed with respect to a standard liquid abrasive detergent composition which contains 50% by weight of unagglomerated calcite with mean particle size of 17 .mu.m, in which the particle size ranges from 10 .mu.m to 40 .mu.m.
BATCH PROCESSED AGGLOMERATES
(a) To the freshly made STP-containing liquid detergent was added 50% by weight of the agglomerate in various narrow size range. These compositions were tested for scratching by placing approximately 10 g of the composition on a perspex sheet and rubbing against an aluminium block which is covered with a soft cloth under a weight of 1 kg. The number of oscillations was 50. The surface of the perspex sheet was then photographed for comparison with the standard liquid abrasive composition which contained 50% by weight of unagglomerated calcite filler with a mean size of 17 .mu.m. It was found that, upon storage at 37.degree. C. for 3 months, only the agglomerate bound by polymers was unaffected in the STP-containing liquid while the others disintegrated. Furthermore, if the unagglomerated calcite filler was used in the STP-containing liquid detergent, hard solid crystals were grown which subsequently caused extensive scratching on perspex.
(b) To the freshly made citrate-containing liquid detergent were added 25% agglomerate (within a narrow size distribution) 25% unagglomerated Durcal 2. Scratching of a perspex surface by these compositions was compared with the standard liquid abrasive composition. The results are shown in Table 12.
TABLE 11______________________________________Composition of the liquid detergents STP- CITRATE- containing containing liquid liquidCOMPONENTS (Wt. %) (Wt. %)______________________________________Na alkylbenzene sulphonate 3.8 4.95K or Na soap 1.25 --Coconut diethanolamide 4.45 6.05Sodium tripolyphosphate (STP) 10.0 --Trisodium citrate dihydrate -- 5.0Perfume 0.3 0.4Water Balance Balance______________________________________
TABLE 12__________________________________________________________________________Scratching characteristics of the agglomerates -In all cases the fillerin the agglomerate was Durcal 2and the batch processing time was 120 min. No blowingagent was used. EFFECT ON PERSPEXWT PERCENT AND AGGLOMERATE STP- CITRATE-TYPE OF SIZE RANGE containing containingPOLYMER (/um) liquid liquid__________________________________________________________________________3% Rigidex XGR791 75-125 Equal Better5.5% Rigidex XGR791 250-355 Worse --12% Rigidex XGR791 180-250 -- Worse5% AC400 75-125 -- Worse5% AC9 75-125 Better Worse5% AC9 355-500 Worse --13% AC1702 180-250 Better --7% AC5120 180-250 Worse --6% (P.W. + O.P.E.)* 75-125 -- Equal6% (AC9 + P.W.).sup.+ 75-125 -- Better7% (AC9 + P.W.).sup.+ 180-250 - Equal__________________________________________________________________________ *Contains 14 parts paraffin wax and 1 part oxidised polyethylene. Contains 7 parts AC9 and 3 parts paraffin wax.
EXAMPLE 5
In this set of combined detergency and scratch tests, 50% agglomerate was mixed with 50% unagglomerated Durcal 2 and the resulting powder was added to an equal weight of the citrate-containing liquid detergent. The detergency is quantified by the number of rubs required to remove 15 micrometer thick microcrystalline wax from the perspex surface, and the results were compared with the standard liquid abrasive cleaning composition.
The results are tabulated in Table 13.
TABLE 13__________________________________________________________________________Combined detergency and scratching tests forthe continuously processed agglomeratesafter milling AGGLOMERATE MEANEXAMPLE SIZE RANGE SIZEN.degree. .dwnarw. (.mu.) (.mu.) DETERGENCY SCRATCHING__________________________________________________________________________STANDARD .fwdarw. 10-40 17 12 EqualC2 <212 104 9 Much betterC3 <212 95 9 Much betterC5 <212 119 9 Slightly betterC6 <212 122 9 Slightly betterC4 75-125 100 16 BetterC7 75-125 100 9 BetterC8 75-125 100 14 EqualC9 75-125 100 11 BetterC10 75-125 100 11 BetterC11 75-125 100 13 BetterC12 75-125 100 10 BetterC13 75-125 100 11 BetterC14 75-125 100 17 BetterC15 75-125 100 11 Better__________________________________________________________________________

Number	Name	Date
3955942	Cordon et al.	May 1976
4089943	Roberts et al.	May 1978
4110083	Benedict	Aug 1978
4111666	Kalbow	Sep 1978
4311489	Kressner	Jan 1982
4537604	Dawson	Aug 1985
4541842	Rostoker	Sep 1985
4626364	Bauman	Dec 1986
4652275	Bloecher et al.	Mar 1987
4799939	Bloecher et al.	Jan 1989

Agglomerated abrasive material, compositions comprising same, and processes for its manufacture

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