Alkaline metal cleaner comprising sulfonated-hydrophobically modified polyacrylate

Abstract

The present invention is directed to cleaning compositions for metal surfaces, including both concentrates and ready-to-use solutions. These compositions include a source of calcium ion, a source of alkalinity, a chelating agent, and a surfactant. In some embodiments, a water-soluble or water-dispersible acid-substituted polymer is also included. Additionally, in some embodiments, specific surfactants or chelating agents are used to enhance the performance of the composition.

Description

FIELD OF THE INVENTION

The invention relates to cleaning compositions and methods of cleaning surfaces with non-corrosive cleaning compositions. In particular, the invention relates to metal cleaning compositions useful in the cleaning articles or surfaces, including soft metal articles or surfaces.

BACKGROUND OF THE INVENTION

Many commercial and domestic articles include surface layers comprising alkaline-sensative metals, for example aluminum or aluminum containing alloys. Such articles are known to those skilled in a variety of occupations or domestic activities, particularly those working in industrial plants, maintenance and repair services, manufacturing facilities, kitchens, restaurants and the like. The types of equipment which can have surface layers including aluminum include, without limitation, sinks, cookware, utensils, surfaces, for example, machine parts, vehicles, tanker trucks, vehicle wheels, work surfaces, tanks, for example soak tanks, hot tanks, immersion vessels (with or without agitators), spray washers (continuous or batch), and ultrasonic baths.

Aqueous alkali cleaners are known as effective cleaning agents. However, many such alkali cleaners have disadvantages when used on alkaline-sensative metals, for example aluminum. One particular disadvantage of using aqueous alkali systems to clean metal surfaces is the potential to corrode or discolor the surfaces. It is difficult to obtain an aqueous detergent solution at an effective pH to remove the soils, such as greases and oils, which often contaminate metal surfaces, and which would not be corrosive to the metal substrate. While aqueous cleaning solutions having a high pH are often more corrosive than aqueous solutions having a relatively low pH, corrosion and discoloration can still be problematic with the more mild solutions.

Various corrosion inhibitors are known and have been used to prevent corrosion of surfaces that come into contact with aqueous alkaline solutions. Some known corrosive inhibitors include the silicates, such as sodium silicate. Unfortunately, the sodium silicates begin to precipitate from aqueous solution at pHs below 11, thus, greatly reducing the effectiveness of these materials to prevent corrosion of the contacted surfaces when used in aqueous cleaning solutions having a lower pH. Additionally, when the silicate-containing compositions or their residues are allowed to dry on the surface to be cleaned, films or spots are often formed, which are visible and which are themselves very difficult to remove. The presence of these silicon-containing deposits can affect the texture of the cleaned surface, the appearance of the surface, and on cooking or storage surfaces, can affect the taste of the materials that come into contact with the cleaned surfaces.

It is also known to include calcium ions within cleaning composition to inhibit the attack of hydroxide ion on alkali sensitive metals. However, it has proven to be difficult to introduce calcium ions into alkaline cleaners without inducing precipitation of hydroxides of the calcium. This is especially true for highly alkaline solutions, such as concentrated solutions that are intended for dilution into use solutions. Theoretically, the protection against corrosion in such systems is based on the presence of the calcium ion in solution, so precipitation of the calcium ions adversely affects the corrosion inhibiting effectiveness of the system. Additionally, the formulations could not include strong chelating agents that could bind with the calcium ion, and again reduce the effectiveness of the calcium ion as a corrosion inhibiter.

Another problem that has been encountered with some such systems is that concentrates, which are formulated to be diluted into use solutions, tend to be sensitive to the use of dilution water with varying amounts of hardness. It has been found that when certain hard water is added, the additional level of calcium added to the cleaning solution can adversely affect the performance of the solution.

SUMMARY OF THE INVENTION

In accordance with the purpose(s) of this invention, as embodied and broadly described herein, this invention, in a first aspect, relates to a cleaning composition that includes at least one source of calcium ion; a source of alkalinity; a sequestering agent capable of complexing with calcium ion in an alkaline environment; a surfactant; and a water-soluble or water-dispersible acid-substituted polymer.

In a second aspect, the present application relates to a cleaning composition that includes a source of calcium ion; a source of alkalinity; a sequestering agent capable of at least partially complexing with calcium ion; and a surfactant selected from primary or secondary alcohol ethoxylate, secondary alkane sulfonate, alpha olefin sulfonate, linear alkyl benzene sulfonate, primary alcohol ethoxy carboxylate, sarcosinates, or mixtures thereof.

In a third aspect, the present invention relates to a cleaning composition that includes a source of calcium ion; a source of alkalinity; a sequestering agent capable of at least partially complexing with calcium ion; and a silicone-containing surfactant.

Another aspect of the present invention includes the cleaning composition of the first, second and third aspects described herein, such that the compositions are made by admixing the components with a solvent.

A further aspect of the present invention relates to a method of treating a metal surface with the cleaning compositions described in the first, second and third aspects, wherein the method includes applying the composition to the metal surface and removing the solution from the metal surface.

Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

DETAILED DESCRIPTION OF THE INVENTION

The present invention may be understood more readily by reference to the following detailed description of the invention and their previous and following description.

While the present invention will be described in combination with a particular sequence in the methods, it will be understood that various configurations could be designed within the spirit and scope of this invention to accomplish the methods. Further, the steps of the inventive methods of the present invention may be performed in any order including simultaneously, unless performance of a step requires the product of a previous step. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

In this specification and in the claims that follow, reference will be made to a number of terms that shall be defined to have the following meanings:

Reference in the specification and concluding claims to parts by weight of a particular element or component in a composition denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed.

The aqueous cleaning solutions of this invention may be used at any temperature, including an elevated temperature of from about 90-180° F. After contact with the cleaning solution, the solution is removed from the metal surface. The contact time of the aqueous cleaning solution with the metal substrates will vary depending upon the degree of contamination but broadly will range between a few seconds or about 1 minute to 30 minutes with 3 minutes to 15 minutes being more typical.

By “alkaline-sensitive metal” as used herein is meant metals including, but not limited to, soft metals such as aluminum, nickel, tin, zinc, copper, brass, bronze and mixtures thereof.

Cleaning compositions for metal surfaces, including both concentrates and ready-to-use solutions, can be provided as compositions including at least one source of calcium ion, at least one source of alkalinity, at least one sequestering agent capable of complexing with calcium ion in an alkaline environment, and at least one surfactant. In some embodiments, at least one water-soluble or water-dispersible acid-substituted polymer is also included. Additionally, in some embodiments, specific surfactants or chelating agents are used to enhance the performance of the composition.

Additional optional additives that are commonly used in moderate to high pH metal cleaning solutions can also be present within the composition. In some embodiments, the composition is an aqueous solution, and an aqueous concentrate system would be diluted prior to application to surfaces. The system can have low levels of silicates or be entirely free of silicates to reduce, avoid or completely eliminate silicon containing deposits from the solution onto the metal surface.

Source of Calcium Ion

The source of calcium ion in the composition can be any source of calcium ion generally known in the art that is compatible with the other components of the composition being used. For example, the source of calcium ion can include calcium salts, calcium oxides, and the like. Some specific examples of sources of calcium ion include calcium acetate and other non-corrosive calcium salts, calcium oxide, calcium chloride, calcium gluconate, and the like.

Source of Alkalinity

The source of alkalinity in the composition can be any source of alkalinity known that is compatible with the other components of the composition being used. Suitable alkaline sources or mixtures thereof useful in the present invention are those capable of providing the desired pH. Alkalinity sources can comprise, for example, inorganic alkalinity sources, such as an alkali metal hydroxide, an alkali metal salt, or the like, or mixtures thereof.

Suitable alkali metal hydroxides include those generally known that are compatible with the other components of the composition being used. Some examples include sodium hydroxide or potassium hydroxide, and the like. An alkali metal hydroxide may be added to the composition in a variety of forms, including for example in the form of solid beads, dissolved in an aqueous solution, or a combination thereof. Alkali metal hydroxides are commercially available as a solid in the form of pilled solids or beads having a mix of particle sizes ranging from about 12-100 U.S. mesh, or as an aqueous solution, as for example, as a 45 wt %, 50 wt % and a 73 wt % solution.

Suitable alkali metal salts include those generally known that are compatible with the other components of the composition being used. Some examples of alkali metal salts include alkali metal silicates, sulfates, borates, acetates, citrates, tartrates, succinates, edates, and the like, and mixtures thereof. Other examples of sources of alkalinity can include ethanolamines and amines; and other like alkaline sources.

Sequestering Agent

The sequestering agent in the composition can be any sequestering agent, including any chelating agent, known that is capable of complexing with the calcium ion in the solution in the desired manner, and that is compatible with the other components of the composition. The sequestering agent is preferably capable of complexing with the calcium ion in an alkaline environment, and is capable of keeping the calcium ions in solution. However, the sequestering agent must not be a strong sequestering agent that would bind with the calcium ion and substantially reduce the effectiveness of the calcium ion to act as a corrosion inhibitor. Therefore, moderately weak calcium chelating agents are preferred. For example, preferred chelating agents include those that are capable of complexing with the calcium ion in concentrated solutions at a pH of 13 and above, with reduced complexing with calcium ion in diluted or use solutions at a pH of below 13.

Exemplary sequestering agents include hydroxymonocarboxylic acid compounds and hydroxypolycarboxylic acid compounds. Suitable hydroxymonocarboxylic acid compounds include, but are not limited to, gluconic acid; glycolic acid; glucoheptanoic acid; lactic acid; methyllactic acid; 2-hydroxybutanoic acid; mandelic acid; phenyllactic acid; glyceric acid; 2,3,4-trihydroxybutanoic acid; and alpha hydroxylauric acid. Preferred hydroxymonocarboxylic acid compounds include gluconic acid and glucoheptanoic acid. Suitable hydroxypolycarboxylic acid compounds include, but are not limited to, citric acid, isocitric acid, tartronic acid; malic acid; tartaric acid; glucaric acid; galactaric acid; mannaric acid; and gularic acid. Preferred hydroxypolycarboxylic acid compounds include citric acid.

Surfactant

The surfactant of the present invention may be any surfactant generally known in the art, such as an anionic surfactant, non-ionic surfactant, cationic surfactant, amphoteric surfactant, or zwitterionic surfactant. In one embodiment, the surfactant has only one surfactant functional group. In a preferred composition of such an embodiment, the surfactant is primary or secondary alcohol ethoxylate, secondary alkane sulfonate, linear alkyl benzene sulfonate, primary alcohol ethoxy carboxylate, sarcosinates, or mixtures thereof.

Anionic surfactants are well known in the detergent, polymer, solution, emulsion and other material arts, and are usually defined by the fact that the hydrophilic segment of the molecule is anionic. The anionic surfactant is usually in the form of a salt, but may also be zwitterionic or an internal salt. Examples include, but are not limited to dimers, trimers, oligomers polymers (copolymers, graft polymers, block polymers, etc.) having anionic surfactant groups thereon, such as amine groups, phosphate groups, or other polar charge centers with hydrophilic and/or hydrophobic contribution segments. Further examples of suitable anionic surfactants include alkali metal salts of alkyl sulfates and alkyl ether sulfates where alkyl is at least C 10 and the number of alkylene oxide groups is from 2 to 4.

Specific examples of suitable anionic surfactants are water-soluble salts of the higher alkyl sulfates, such as sodium lauroyl sulfate or other suitable alkyl sulfates having 8 to 18 carbon atoms in the alkyl group, alcohol ethoxy carboxylates, secondary alkane sulfonates, linear alkyl benzene sulfonates such as sodium dodecyl benzene sulfonate, and the substantially saturated higher aliphatic acyl amides of lower aliphatic amino carboxylic acid compounds, such as those having 12 to 16 carbons in the fatty acid, alkyl or acyl radicals, and the like. Examples of the last mentioned amides are N-lauroyl sarcosinate, and the sodium, potassium, and ethanolamine salts of N-lauroyl, N-myristoyl, or N-palmitoyl sarcosinate.

Other surfactants can be used in the compositions of this invention other than or in addition to the above-described surfactants. For example, Applicants have surprisingly discovered that silicone-containing surfacants are desirable surfactants due to their corrosion inhibiting properties. Silicone surfacants, for the purpose of this invention, are defined as those surfacants that have a polydimethyl siloxane backbone with functional groups including one or more of quaternary ammonium, carboxyl, betaine, copolyol, and the like. One preferred silicone-containing surfactant is silicone poly-betaine.

Suitable non-ionic surfactants include ethoxylated long chain alcohols such as those sold by Tomah Chemical Co. under the trade name “Tomadol.” Further exemplary non-ionic surfactants include alcohol alkoxylates and amine oxides such as alkyl dimethylamine oxide.

Acid Substituted Polymer

The acid-group substituted polymer must be at least water-dispersible and preferably water-soluble, such as acid-substituted acrylic polymers (both acrylic and some methacrylic polymers and copolymers). The acid-substituted polymer may comprise a dispersing agent for aqueous alkaline solutions, and acts to both reduce the corrosion effects of the solution on metal (specifically on aluminum) and to stabilize the tolerance of the solution to hard water addition. Polymers may have a wide range of molecular weights, exemplified, but not limited by the range of 250 to 50,000, or 400 to 25,000, or 400 to 5,000, or 400 to 1,500.

In one embodiment, the acid-substituted polymer contains an acrylic polymer. The acrylic polymer may have acid groups such as sulfonic acid, sulfinic acid, phosphoric acid, phosphonic acid, and carboxylic acid substituted on the polymer. Moreover, the acrylic polymer may contain a sulphonated-hydrophobically modified polyacrylate, or a hydrophobically modified copolymer. Such a hydrophobically modified polyacrylate or copolymer may be modified with styrene or a C 3 -C 22 alkyl group.

Other Additives

Other additives may be included in the present metal cleaning compositions and solutions. Other additives may include, but are not limited to, additional surfactants, hydrotropes, additional corrosion inhibitors, antimicrobials, fungicides, fragrances, dyes, antistatic agents, UV absorbers, reducing agents, buffering compounds, corrosion inhibitors, viscosity modifying (thickening or thinning) agents, and the like.

Hydrotopes

Examples of the hydrotropes useful in this invention include the sodium, potassium, ammonium and alkanol ammonium salts of xylene, toluene, ethylbenzoate, isopropylbenzene, naphthalene, alkyl naphthalene sulfonates, phosphate esters of alkoxylated alkyl phenols, phosphate esters of alkoxylated alcohols, short chain (C 6 or less) alkyl polyglycoside, and sodium, potassium and ammonium salts of the alkyl sarcosinates. The hydrotropes are useful in maintaining the organic materials including the surfactant readily dispersed in the aqueous cleaning solution and, in particular, in an aqueous concentrate which is an especially preferred form of packaging the compositions of the invention and allow the user of the compositions to accurately provide the desired amount of cleaning composition into the aqueous wash solution. A particularly preferred hydrotrope is one that does not foam.

Additional Corrosion Inhibitors

Additional corrosion inhibitors which may be optionally added to the aqueous metal cleaning compositions of this invention include magnesium and/or zinc ions and Ca(NO 2 ) 2 . Preferably, the metal ions are provided in water soluble form. Examples of useful water soluble forms of magnesium and zinc ions are the water soluble salts thereof including the chlorides, nitrates and sulfates of the respective metals. If any of the alkalinity providing agents are the alkali metal carbonates, bicarbonates or mixtures of such agents, magnesium oxide can be used to provide the Mg ion. The magnesium oxide is water soluble in such solutions and is a preferred source of Mg ions. In order to maintain the dispersibility of the magnesium and/or zinc corrosion inhibitors in aqueous solution, and in the presence of agents which would otherwise cause precipitation of the zinc or magnesium ions, e.g., carbonates, phosphates, etc., it might be advantageous to include a carboxylated polymer to the solution. The useful carboxylated polymers may be generically categorized as water-soluble carboxylic acid polymers such as polyacrylic and polymethacrylic acids or vinyl addition polymers, in addition to the acid-substituted polymers used in the present invention. Of the vinyl addition polymers contemplated, maleic anhydride copolymers as with vinyl acetate, styrene, ethylene, isobutylene, acrylic acid and vinyl ethers are examples. The polymers tend to be water-soluble or at least colloidally dispersible in water. The molecular weight of these polymers may vary over a broad range although it is preferred to use polymers having average molecular weights ranging between 1,000 up to 1,000,000. These polymers have a molecular weight of 100,000 or less and between 1,000 and 10,000.

The polymers or copolymers (either the acid-substituted polymers or other added polymers) may be prepared by either addition or hydrolytic techniques. Thus, maleic anhydride copolymers are prepared by the addition polymerization of maleic anhydride and another comonomer such as styrene. The low molecular weight acrylic acid polymers may be prepared by addition polymerization of acrylic acid or its salts either with itself or other vinyl comonomers. Alternatively, such polymers may be prepared by the alkaline hydrolysis of low molecular weight acrylonitrile homopolymers or copolymers. For such a preparative technique see Newman U.S. Pat. No. 3,419,502.

The metal cleaning compositions of the present invention are useful for removing any type of contaminant from a metal surface including greases, cutting fluids, drawing fluids, machine oils, antirust oils such as cosmoline, carbonaceous soils, sebaceous soils, particulate matter, waxes, paraffins, used motor oil, fuels, etc. Any metal surface can be cleaned including iron-based metals such as iron, iron alloys, e.g., steel, tin, aluminum, copper, tungsten, titanium, molybdenum, etc., for example. The structure of the metal surface to be cleaned can vary widely and is unlimited. Thus, the metal surface can be as a metal part of complex configuration, sheeting, coils, rolls, bars, rods, plates, disks, etc. Such metal components can be derived from any source including for home use, for industrial use such as from the aerospace industry, electronics industry, etc., wherein the metal surfaces have to be cleaned. Treatment of aluminum surfaces with the compositions of this invention has been found particularly effective.

The aqueous alkaline metal cleaning solutions of this invention comprising the cleaning composition in water have a pH above 7.5, above 9.0, above 10.0, above 11.0, and even up to 13.5. Most preferably, the aqueous alkaline cleaning solutions have a pH which is effective to remove the dirt, grease, oil and other contaminants from the metal surface without causing tarnishing or discoloration of the metal substrate.

It is preferred that the solution have reduced silicate, and more preferred that the compositions of the invention are free of silicates. For example, the concentrate and/or the solution may have less than 0.2 wt. % silicates, less than 0.15 wt. % silicates, less than 0.1 wt. % silicates, less than 0.05 wt. % silicate and less than 0.1 wt. % silicate (down to and preferably including 0 wt. % silicate) and perform in accordance with the teachings of this invention. The addition of larger amounts of silicate is not believed to add benefit to the residue reducing aspects of the present invention, but may not otherwise destroy the cleaning function of the compositions and solutions of this invention. Additionally, in some embodiments, it is preferred to maintain the compositions of this invention substantially silicate-free due to silicate film formation and difficulty in formulating a composition which will remain soluble in aqueous solution at a pH of 11.0 or less when silicates are present. Note, however that this reduced silicate preference does not limit the amount of silicone in the solution as silicone is not included in this definition of silicate.

The composition may be prepared by admixing the components with a solvent, such as an aqueous solution, to form a solution. Commonly, the aqueous solution is water. In general, when the concentration of the composition in the solution is above about 25 wt. %, the solution is considered to be a concentrated solution; and when the concentration of the composition in the solution is below about 25 wt. %, the solution is considered to be a use solution. In either the concentrated or use solution, it is preferred that the ingredients of the composition do not precipitate out when the water has a hardness of 14 grains per gallon or less. In particular, it is preferred that salts of the calcuim do not precipitate out of the composition when the water has a hardness of 14 grains per gallon or less.

Some examples of representative constituent concentrations for concentrate compositions embodying the invention can be found in Table 1.

TABLE 1
Component	Preferred Range	More Preferred Range
Calcium Ion	about 0.001 mole per liter	about 0.001 mole per liter to
	to about 1 moles per liter	about 0.05 mole per liter
Source of	about 0.1 wt. % to about	about 1 wt. % to about 10
Alkalinity	20 wt. %	wt. %
Chelating	about one mole or more	about one to two moles per
Agent	per mole of calcium ion	mole of calcium ion
Surfactant	about 0.05 wt. % to about	about 0.25 wt. % to about 10
	20 wt. %	wt. %
Acid-	0 wt. % to about 10 wt. %	about 0.25 wt. % to about 10
substituted		wt. %
polymer

Some examples of representative constituent concentrations for use solution compositions embodying the invention can be found in Table 2.

TABLE 2
Component	Preferred Range	More Preferred Range
Calcium Ion	about 0.00001 mole per	about 0.0001 mole per liter to
	liter to about 0.1 mole per	about 0.0005 mole per liter
	liter
Source of	about 0.01 wt. % to about	about 0.05 wt. % to about 5
Alkalinity	10 wt. %	wt. %
Chelating	about one mole or more per	about one to two moles or
Agent	mole of calcium ion	more per mole of calcium ion
Surfactant	about 0.001 wt. % to about	about 0.005 wt. % to about 2
	10 wt. %	wt. %
Acid-	0 wt. % to about 1 wt. %	about 0.01 wt. % to about 1
substituted		wt. %
polymer

The cleaners of the invention may exist in a use solution or concentrated solution that is in any form including liquid, gel, paste, solids, slurry, and foam. The cleaning solutions are suitable to treat any metal surface contaminated with a wide variety of contaminants. Exemplary contaminants include grease, clay, dirt, and oxide by-products The present solutions may be used by contacting the contaminated metal parts with an effective amount of the aqueous solution. Preferred contact methods include immersion or some type of impingement in which the cleaning solution is circulated or continuously agitated against the metal part or is sprayed thereon. Alternatively, agitation can be provided as ultrasonic waves.

Experimental

The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the methods claimed herein are made and evaluated, and are intended to be purely exemplary of the invention and are not intended to limit the scope of what the inventors regard as their invention. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.) but some errors and deviations should be accounted for. Unless indicated otherwise, percent is percent by weight given the component and the total weight of the composition, temperature is in ° C. or is at ambient temperature, and pressure is at or near atmospheric.

The following chemicals were used as exemplary embodiments or as ingredients in the formulations of the examples:

Chemical Name   Chemical Content
Alcosperse 725  Sulphonated hydrophobically modified polymer
                solution 35%
SAS             Secondary alkane sulphonate 30%
SXS             Sodium xylene sulphonate 40%
Hamposil O      Oleoyl sarcosine 94%
Gerapon TC-42   Sodium N-methyl-N-cocoyl taurate 24%
Stepanol CS-460 Sodium lauroyl ether sulphate 60%
Glucopon 625    C12-16 alkyl polyglycoside 50%
Supra 2         Cocamine oxide 30%
Gafac RA-600    Linear alcohol ethoxylate phosphate ester 99%
Chemax AC 5144  Complex amine carboxylate
Bioterge AS-40  C14-16 Alpha olefin sulphonate 40%
Mirataine CBS   Cocamidopropyl hydroxy sultaine 50%
LAS             Linear alkyl benzene sulphonic acid 97%
Hampshire LED3  N-Lauroyl N,N′,N′ ethylenediaminetetraacetate
Abil B9950      Dimethicone propyl PG betaine 30%
Variquat CC42   PPG Diethylmonium chloride 99%

EXAMPLE 1

Base formula reference FORMULA 1
Ingredients            Weight %
Water                  66.596
Alcosperese 725        6.25
Calcium Oxide          0.954
Gluconic Acid (50%)    13.35
NaOH (50%)             12.85

Calcium oxide and gluconic acid react in situ to form calcium gluconate. To the above base formula, we add an anionic surfactant that further enhances the base formula's corrosion inhibition. Hydrotrope can be added as needed. The following is an example:

Ingredients  Weight %
Base Formula 66.67
SAS 30%      6.93
SXS 40%      26.40

That the combination of the alkalinity source, calcium gluconate, sulphonated polyacrylate copolymer, and the anionic surfactant produce a concentrate which, on dilution to a use solution concentration of 2.5%, forms an effective aluminum cleaner. The cleaner is silicate free, non-corrosive to aluminum, and can produce clear 2.5% use solution in a range of water hardness of up to 15 grains per gallon.

The synergistic aluminum corrosion reduction performance of the combination of specific anionic surfactants and calcium when combined in a highly alkaline solution is unusual.

The addition of gluconic acid to form calcium gluconate was necessary for concentrate stability and use solution stability in certain combinations.

The addition of Alcosperese 725 provides further enhancement of the corrosion reduction and also increases the levels of water hardness from which the use solutions can be prepared.

The combination of these elements surprisingly allows for the preparation of stable non-silicated alkaline concentrates from which use solutions that are non-corrosive to aluminum can be made. It is also unusual that the use solutions of the above concentrate can be prepared with water having a range of hardness from softened to fifteen grain well water and remain precipitate free.

FORMULA	1-1	1-2	1-3	1-4
Raw Material	Wt %	Wt %	Wt %	Wt %
Hamposil O	2.5
Gerapon TC-42		8.68
NaOH 50%	0.57
Stepanol CS-460			4.15
SAS 30%				6.94
Base Formula	79.95	66.65	79.11	66.66
SXS 40%	16.98	24.67	7.91	26.40
Soft Water		0	8.83
Total	100.00	100.00	100.00	100.00
Panel Appearance	Untouched	Whitened all	Whitened all	Whitened a
		over	over	little on
				the bottom
Corrosion (mil/yr)	1.5	71.2	103.2	2.1
@20.5%
Std Deviation	1.8	27.2	9.2	1.0
(mil/year)
(mil = 0.001 in.)

Corrosion Testing With Al 6061
				10234
	Panel			Surface	Conc.	Time	Initial	Final	Wt	Adjusted
Product	#	Mat'l	Density	Area	(%)	(hours)	Wt	Wt	Loss	Wt Loss
1.1	1	Al	2.81	6.5000	2.5	6.0	8.1900	8.0786	0.0304	0.0298
	2	Al	2.81	6.5000	2.5	6.0	8.0859	8.0542	0.0317	0.0311
	3	Al	2.81	6.5000	2.5	6.0	8.2185	8.1924	0.0216	0.0255
1.2	4	Al	2.81	6.5000	2.5	6.0	8.1459	8.1428	0.0031	0.0025
	5	Al	2.81	6.5000	2.5	6.0	8.2160	8.2133	0.0027	0.0021
	6	Al	2.81	6.5000	2.5	6.0	8.2453	8.2421	0.0032	0.0026
1.3	7	Al	2.81	6.5000	2.5	6.0	8.2238	8.2019	0.0219	0.0213
	8	Al	2.81	6.5000	2.5	6.0	8.1015	8.0735	0.0280	0.0274
	9	Al	2.81	6.5000	2.5	6.0	8.0266	8.0021	0.0245	0.0239
1.4	10	Al	2.81	6.5000	2.5	6.0	8.0810	8.0782	0.0028	0.0022
	11	Al	2.81	6.5000	2.5	6.0	7.9927	7.9891	0.0036	0.0030
	12	Al	2.81	6.5000	2.5	6.0	8.1039	8.1020	0.0019	0.0013
Control	13	Al	2.81	6.5000	na	6.0	8.0757	8.0757	0.0000	−0.0006
	14	Al	2.81	6.5000	na	6.0	8.0427	8.0427	0.0000	−0.0006
	15	Al	2.81	6.5000	na	6.0	8.1789	8.1783	0.0006	0.0000

The testing performed for this research effort consisted of immersing the test panels of aluminum 6061 grade alloy in a 2.5% formula test solution for six hours at room temperature. The panels were then removed and the panels' appearance was evaluated and results recorded. Post-treatment cleaning was then performed and the resulting MPY (thousands of an inch per year) corrosion rate was calculated.

A variation of Ecolab Food & Beverage Test # 6B Chelation Test For Liquid Alkaline Products consists of heating natural well water with 14-15 grains of hardness in a microwave to greater than 140 degree Fahrenheit and mixing this hot water with room temperature well water from the same source to obtain 135 degree Fahrenheit well water. The correct amount of water and test formula are then combined and mixed well. The test solution is then allowed to cool while sitting at room temperature and the solution is observed for reaction and appearances are recorded.

EXAMPLE 2

The procedure of Example 1 was followed by preparing Formula 1 (base formula), described in Example 1, with various surfactants, as shown for formulas 19-1, 19-2, 19-3 and 19-4 below:

	FORMULA
		19-1	19-2	19-3	19-4
	Raw Material	Wt %	Wt %	Wt %	Wt %
	Gafac FA600				0.85
	Chemax AC5144			3.33	2.20
	NaOH 50%		0.5		0.22
	Bioterge AS40		1.25
	LAS 97%		2.06
	Mirataine CBS	5.75
	Base Formula	80.00	80.00	80.00	80.00
	SXS 40%	14.25		16.67	16.73
	Soft Water		16.19
	Total	100	100	100	100

All solutions are diluted to 2.5% with soft water to 1000 g. The soft water was allowed to sit in a 5 L pitcher. Three panels are preweighed and placed into the solution with 7-10 minutes between immersion sets. Pre- and post-weights are displayed in the following table. Sample #19-4 was diluted to 27.5 g to 1000 g with soft water instead of 25 g to 1000 g total weight as with the other three samples.

Results: All four samples were found to provide below 250 mil/year corrosion.

Corrosion Testing With A1 6061
	Panel		Average	Standard	Percent
Product	#	Mil per Year	Mil per Year	Deviation	Standard
19.1	1	145.36	140.48	14.30	10%
	2	151.70
	3	124.39
19.2	4	12.19	11.71	1.29	11%
	5	10.24
	6	12.68
19.3	7	103.90	118.05	14.93	13%
	8	133.65
	9	116.58
19.4	10	10.73	10.57	4.15	39%
	11	14.63
	12	6.34
Control	13	−2.93	−1.95	1.69	−87%
(water)	14	−2.93
	15	0.00

EXAMPLE 3

Alkaline Cleaning Composition

The following solution was prepared as a base formula to check the reaction of a 3% solution of the base formula with Aluminum 6061.

Formula 1.5
	Raw Material	Wt %
	A.	Soft Water	69.60
	B.	APG-Glucopan 625	10.00
	C.	Supra 2	6.67
	D.	NaOH 50%	13.00
	E.	CaCl 2 .2H 2 O	0.73

The above composition was fairly viscous and opaque.

Preparing the following A and B solutions examined the effect of addition of Alcosperse 725 to the base formula.

Solutions A and B were prepared as follows:

A. A 3% solution of formula 1.5 was prepared by diluting 15.0 g of formula 1.5 to 500.0 g with soft water.

B. A 3% solution of formula 1.5 with the equivalent of the base formula containing 1.0% Alcosperse 725 was prepared by adding 15.0 G formula 1.5 to 470.0 g soft water and mixing. To this solution was added 3% of a 1% Alcosperses 725 solution −15.0 g 1% Alcosperese 725.

An untreated 3″×1″ (7.6 cm by 2.5 cm) aluminum panel of alloy 6061 was immersed in each solution A and B for one hour.

At this time, the aluminum panel from solution A had a small amount of bubbles evolving from the surface, indicating some reaction was occurring. The aluminum panel in solution B had no bubbles on the surface indicating no reation was occurring.

Further observations were made to the effect that after 19 hours, 24 minutes: the panel in solution A showed a slight haze in the solution and the panels appeared uncorroded; there were a small amount of bubbles visible on the panel's surface. The panel in solution B remained as a clear solution, the panel looked very good with no negative appearance, no bubbles, and no indication of any reaction.

EXAMPLE 4

Silicone-Containing Surfactant Formulas

Silicone-containing surfactant formulas were prepared with the ingredients described below:

Ingredients	RM#	13	14	15	16	34
Water	100016	48.8	44.0	39.3	34.6	43.8
Gluconic Acid 50%	830070	8.8	13.2	17.6	22.0	8.8
Calcium Oxide		0.6	0.9	1.3	1.8	0.6
NaOH 50%	114132	8.5	8.5	8.5	8.5	8.5
SAS	180761	6.93	6.93	6.93	6.93	6.93
SXS		26.40	26.40	26.40	26.40	26.40
Hampshire LED3		—	—	—	—	5.00
Total		100.0	100.0	100.0	100.0	100.0
Ingredients	RM#	38	39	40	41	42
Water	100016	43.39	41.39	28.88	26.88	41.39
Gluconic Acid 50%	830070	8.90	8.90	22.25	22.25	8.90
Calcium Oxide		0.64	0.64	1.80	1.80	0.64
NaOH 50%	114132	8.57	8.57	8.57	8.57	8.57
SAS	180761	6.93	6.93	6.93	6.93	6.93
SXS		26.40	26.40	26.40	26.40	26.40
Alcospere 725		4.17	4.17	4.17	4.17	4.17
Abil B 9950		1.00	3.00	1.00	3.00	—
Variquat CC-42-5NS						3.00
Total		100.0	100.0	100.0	100.0	100.0

The formulas were tested for corrosion as described in example 3, and the following results were obtained:

	Coupon	Initial	Final	Total	Wt Loss	Average	Adjusted	Corrosion Rate	Final
%	#	Wt (g)	Wt (g)	Wt Loss (g)	(mg)	Wt Loss (mg)	Wt Loss (mg)	mils/year	Appearance
Formula #13
Control	0	12.8115	12.8108	0.0007	0.7	0.7000
Water
A1 6061
Degreaser	1	12.8146	12.8118	0.0028	2.8	2.8000	2.1000	9.8246	Shiny silver
@ 2%
A1 6061
Degreaser	2	12.8329	12.7583	0.0746	74.6	74.6000	73.9000	345.7319	Dull silver
@ 4%
A1 6061
Degreaser	3	12.8385	12.4552	0.3833	383.3	383.3000	382.6000	1789.9462	Dull silver; some white
@ 8%									markings
A1 6061
Degreaser	4	12.8374	12.0214	0.816	816	816.0000	815.3000	3814.2790	Dull silver; some
@ 16%									pitting & brown tinting
A1 6061
Degreaser	5	12.8104	11.1377	1.6727	1672.7	1672.7000	1672.0000	7822.2428	Dull silver; heavy
@ 32%									pitting.
A1 6061
Formula #14
Degreaser	6	12.7874	12.7859	0.0015	1.5	1.5000	0.8000	3.7427	Shiny silver; white
@ 2%									deposits
A1 6061
Degreaser	7	12.8794	12.8516	0.0278	27.8	27.8000	27.1000	126.7840	Dull silver; heavy white
@ 4%									streaks
A1 6061
Degreaser	8	12.8384	12.4694	0.369	369	369.0000	368.3000	1723.0455	Dull white with little pit
@ 8%									& tan markings
A1 6061
Degreaser	9	12.8264	12.0168	0.8096	809.6	809.6000	808.9000	3784.3374	Dull with pitting & tan
@ 16%									markings
A1 6061
Degreaser	10	12.8870	11.2792	1.6078	1607.8	1607.8000	1607.1000	7518.6163	Heavy deep pitting
@ 32%
A1 6061
Formula #15
Degreaser	11	12.9584	12.9487	0.0097	9.7	9.7000	9.0000	42.1054	Shiny with white
@ 2%									streaks
A1 6061
Degreaser	12	12.8401	12.8176	0.0225	22.5	22.5000	21.8000	101.9886	Dull with white & tan
@ 4%									streaks
A1 6061
Degreaser	13	12.8410	12.4974	0.3436	343.6	343.6000	342.9000	1604.2147	Slight pitting & tan
@ 8%									coloring
A1 6061
Degreaser	14	12.8751	12.1046	0.7705	770.5	770.5000	769.8000	3601.4130	Pitting with tan
@ 16%									coloring
A1 6061
Degreaser	15	12.8119	11.2305	1.5814	1581.4	1581.4000	1580.7000	7395.1072	Heavy deep pitting
@ 32%
A1 6061
Formula #16
Degreaser	16	12.8397	12.8309	0.0088	8.8	8.8000	8.1000	37.8948	Shiny with white
@ 2%									streaks
A1 6061
Degreaser	17	12.8599	12.8462	0.0137	13.7	13.7000	13.0000	60.8189	Shiny with white
@ 4%									streaks
A1 6061
Degreaser	18	12.8258	12.5116	0.3142	314.2	314.2000	313.5000	1466.6705	Dull slight pitting & tan
@ 8%									markings
A1 6061
Degreaser	19	12.7049	11.9928	0.7121	712.1	712.1000	711.4000	3328.1959	Lots of tiny pitting;
@ 16%									some tan markings
A1 6061
Degreaser	20	12.8951	11.4567	1.4387	1438.7	1438.7000	1438.0000	6727.5031	Heavy pitting
@ 32%
A1 6061
Formula #34
Degreaser	21	12.8451	12.8448	0.0003	0.3	0.3000	0.3000	1.4035	Shiny
@ 2%
A1 6061
Degreaser	22	12.8386	12.8049	0.0337	33.7	33.7000	33.7000	157.6612	Dull; covered with
@ 4%									white deposits
A1 6061
Degreaser	23	12.7980	12.6177	0.1803	180.3	180.3000	180.3000	843.5110	Shiny with white
@ 8%									markings & a few tan
A1 6061
Degreaser	24	12.8543	12.3444	0.5099	509.9	509.9000	509.9000	2385.5033	Very tiny pitting
@ 16%
A1 6061
Degreaser	25	12.8457	11.8785	0.9672	967.2	967.2000	967.2000	4524.9242	Some pitting
@ 32%
A1 6061
Formula #38
Control	0	12.8321	12.8326	−0.0005	−0.5	−0.5000			Shiny silver
(Water)
A1 6061
Degreaser	1	12.7553	12.7548	0.0005	0.5	0.5000	1.0000	4.6784	Shiny with white
@ 2%									streaks
A1 6061
Degreaser	2	12.8140	12.7672	0.0468	46.8	46.8000	47.3000	221.2871	White dull finish
@ 4%
A1 6061
Degreaser	3	12.8481	12.5081	0.34	340	340.0000	340.5000	1592.9866	White dull finish with
@ 8%									some grooves marking
A1 6061
Degreaser	4	12.8343	12.0563	0.778	778	778.0000	778.5000	3642.1148	Silver with heavy small
@ 16%									pit markings
A1 6061
Degreaser	5	12.8431	11.2685	1.5746	1574.6	1574.6000	1575.1000	7368.9083	Coupon is thinner with
@ 32%									heavy deep pitting
A1 6061
Formula #39
Degreaser	6	12.8760	12.8761	−1E−04	−0.1	−0.1000	0.4000	1.8713	Shiny with white
@ 2%									streaks
A1 6061
Degreaser	7	12.7546	12.7417	0.0129	12.9	12.9000	13.4000	62.6902	Heavy white streaks
@ 4%
A1 6061
Degreaser	8	12.8627	12.5790	0.2837	283.7	283.7000	284.2000	1329.5941	White dull finish with
@ 8%									some grooves markings
A1 6061
Degreaser	9	12.8660	12.1074	0.7586	758.6	758.6000	759.1000	3551.3544	Silver with heavy small
@ 16%									pit markings
A1 6061
Degreaser	10	12.8415	11.2872	1.5543	1554.3	1554.3000	1554.8000	7273.9372	Coupon is thinner with
@ 32%									heavy deep pitting
A1 6061
Formula #40
Degreaser	11	12.8333	12.8336	−0.0003	−0.3	−0.3000	0.2000	0.9357	Shiny with very little
@ 2%									white markings
A1 6061
Degreaser	12	12.8705	12.8693	0.0012	1.2	1.2000	1.7000	7.9532	Shiny with little
@ 4%									grooves
A1 6061
Degreaser	13	12.8344	12.8259	0.0085	8.5	8.5000	9.0000	42.1054	Shiny with little
@ 8%									grooves and 2 white
A1 6061									marks
Degreaser	14	12.8288	12.3509	0.4779	477.9	477.9000	478.4000	2238.1345	Dull with very tiny
@ 16%									pitting markings
A1 6061
Degreaser
@ 32%	15	12.8621	11.8031	1.059	1059	1059.0000	1059.5000	4956.7382	Dull with very tiny
A1 6061									pitting markings
Formula #41
Degreaser	16	12.5314	12.5317	−0.0003	−0.3	−0.3000	0.2000	0.9357	Shiny with very little
@ 2%									white markings
A1 6061
Degreaser	17	12.8756	12.874	0.0016	1.6	1.6000	2.1000	9.8246	Shiny with little
@ 4%									grooves
A1 6061
Degreaser	18	12.8251	12.8175	0.0076	7.6	7.6000	8.1000	37.8948	Shiny with little
@ 8%									grooves
A1 6061
Degreaser	19	12.7719	12.3903	0.3816	381.6	381.6000	382.1000	1787.6070	Shiny with little
@ 16%									grooves and 2 white
A1 6061									marks
Degreaser	20	12.8328	11.8318	1.001	1001	1001.0000	1001.5000	4685.3924	Shiny with little
@ 32%									grooves and 2 white
A1 6061									marks
Formula #42
Degreaser	21	12.8267	12.8235	0.0032	3.2	3.2000	3.2000	14.9708	⅓ of coupon covered
@ 2%									with white film
A1 6061
Degreaser	22	12.8386	12.6682	0.1704	170.4	170.4000	170.4000	797.1951	Dull with white film
@ 4%
A1 6061
Degreaser	23	12.7980	12.4924	0.3056	305.6	305.6000	305.6000	1429.7114	Dull with small pit
@ 8%									markings
A1 6061
Degreaser	24	12.8543	12.0498	0.8045	804.5	804.5000	804.5000	3763.7526	Heavy pitting
@ 16%
A1 6061
Degreaser	25	12.8457	11.429	1.4167	1416.7	1416.7000	1416.7000	6627.8537	Larger deep pit
@ 32%									markings
A1 6061

Throughout this application, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which this invention pertains.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Claims

1. A cleaning composition comprising:a) a source of calcium ion; b) a source of alkalinity; c) a sequestering agent capable of complexing with calcium ion in an alkaline environment; d) a surfactant; and e) a sulphonated-hydrophobically modified polyacrylate.

2. The composition of claim 1, wherein the sulphonated-hydrophobically modified polyacrylate is modified with styrene or a C3-C22 alkyl group.

3. The composition of claim 1, wherein the composition further comprises a solvent to form a use solution, and the concentration of the composition in the use solution, and the concentration of the composition in the use solution is from about 0.5 wt. % to about 20 wt. % of the total use solution.

4. The composition of claim 1, wherein the composition has less than about 0.5 wt. % by total weight of the composition as silicate.

5. The composition of claim 1, wherein the composition is prepared by admixing the components a, b, c, d, and e with a solvent.

6. The composition of claim 1, wherein the composition has a molar concentration of calcium ion from about 0.00 1 to about 1 moles per liter of composition.

7. The composition of claim 6, wherein the composition has about one or more moles of sequestering agent for every mole of calcium ion in the concentrated composition.

8. The composition of claim 1, wherein the composition comprises a concentrated cleaning solution comprising:a) from about 0.001 mole to about 1 mole of calcium ion per liter of solution; b) from about 0.1 wt. % to about 20 wt. % source of alkalinity; c) about one mole or more of sequestering agent for each mole of calcium ion; d) from about 0.05 wt. % to about 20 wt. % surfactant; and e) from about 0.25 wt. % to about 10 wt. % sulphonated-hydronhobically modified polyacrylate.

9. The composition of claim 1, wherein the composition comprises a use solution comprising:a) from about 0.00001 mole to about 0.1 mole of calcium ion per liter of solution; b) from about 0.01 wt. % to about 10 wt. % source of alkalinity; c) about one mole or more of sequestering agent for each mole of calcium ion; d) from about 0.001 wt. % to about 10 wt. % surfactant; and e) from about 0.01 wt. % to about 1 wt. % sulphonated-hydrophobically modified polyacrylate.

10. A cleaning composition comprising:a) a source of calcium ion; b) a source of alkalinity; c) a sequestering agent capable of at least partially complexing with calcium ion; d) a surfactant selected from the group consisting of: primary or secondary alcohol ethoxylate, secondary alkane sulfonate, secondary alcohol sulfonate, alpha olefin sulfonate, linear alkyl benzene sulfonate, primary alcohol ethoxy carboxylate, sarconsinates, or mixtures thereof; and e) sulphonated-hydrophobically modified polyarcylate.

11. The composition of claim 10, wherein the surfactant is N-acylsarcosinate, secondary alcohol sulfonate, or linear alkyl benzene sulfonate.

12. The composition of claim 10, wherein the surfactant is secondary alcohol sulfonate.

13. The composition of claim 10, wherein the composition further comprises a solvent to form a use solution, and the concentration of the composition in the use solution is from about 0.5 wt. % to about 20 wt. % of the total use solution.

14. The composition of claim 10, wherein the composition has less than about 0.5 wt. % by total weight of the composition as silicate.

15. The composition of claim 10, wherein the composition is prepared by admixing the components a, b, c, and d with a solvent.

16. The composition of claim 10, wherein the composition has a molar concentration of calcium ion from about 0.001 to about 1 moles per liter of composition.

17. The composition of claim 10, wherein the composition has about one or more moles of sequestering agent for every mole of calcium ion in the concentrated composition.

18. The composition of claim 10, wherein the composition comprises a concentrated cleaning solution comprising:a) from about 0.001 mole to about 1 mole of calcium ion per liter of solution; b) from about 0.01 wt. % to about 20 wt. % source of alkalinity; c) about one mole or more of sequestering agent for each mole of calcium ion; and d) from about 0.05 wt. % to about 20 wt. % surfactant.

19. The composition of claim 10, wherein the composition comprises a use solution comprising:a) from about 0.0001 mole to about 0.1 mole of calcium ion per liter of solution; b) from about 0.01 wt. % to about 10 wt. % source of alkalinity; c) about one mole or more of sequestering agent for each mole of calcium ion; and d) from about 0.001 wt. % to about 10 wt. % surfactant.

20. A cleaning composition comprising:a) a source of calcium ion; b) a source of alkalinity; c) a sequestering agent capable of at least partially complexing with calcium ion; d) a silicone-containing surfactant; and e) a sulphonated-hydrophobically modified polyacrylate.

21. The composition of claim 20, wherein the surfactant is dimethicone propyl PG betaine.

22. The composition of claim 20, wherein the composition further comprises a solvent to form a use solution, and the concentration of the composition in the use solution is from about 0.5 wt. % to about 20 wt. % of the total use solution.

23. The composition of claim 20, wherein the composition has less than about 0.5 wt. % by total weight of the composition as silicate.

24. The composition of claim 20, wherein the composition is prepare by admixing the components a, b, c, and d with a solvent.

25. The composition of claim 20, wherein the composition has a mol concentration of calcium ion from about 0.001 to about 1 moles per liter of composition.

26. The composition of claim 20, wherein the composition has about one or more moles of sequestering agent for every mole of calcium ion in the concentrated composition.

27. The composition of claim 20, wherein the composition comprise a concentrated cleaning solution comprising:a) from about 0.001 mole to about I mole of calcium ion per liter of solution; b) from about 0.1 wt. % to about 20 wt. % source of alkalinity; c) about one mole or more of sequestering agent for each mole of calcium ion; and d) from about 0.05 wt. % to about 20 wt. % surfactant.

28. The composition of claim 20, wherein the composition comprise a use solution comprising:a) from about 0.00001 mole to about 0.1 mole of calcium ion per liter of solution; b) from about 0.01 wt. % to about 10 wt. % source of alkalinity; c) about one mole or more of sequestering agent for each mole of calcium ion; and d) from about 0.001 wt. % to about 10 wt. % surfactant.

29. A method of treating a metal surface, the method comprising: contacting a metal surface with an aqueous cleaning solution comprising the composition of claim 1, 10, or 20; and removing the solution from the metal surface.

30. The method of claim 29 wherein said metal surface comprises an aluminum surface.

31. A cleaning composition comprising:a) a source of calcium ion; b) a source of alkalinity; c) a sequestenng agent capable of at least partially complexing with calcium ion; and d) dimethicone propyl PG betaine.

32. The composition of claim 10, wherein the acid-substituted acrylic polymer is a suiphonated-hydrophobically modified polyacrylate.