Fabric softening bar compositions containing fabric softener and enduring perfume

TECHNICAL FIELD
The present invention relates to a fabric softening bar composition comprising a fabric softening compound, an efficient enduring perfume, and optionally, but preferably, nonionic surfactant and water. The composition contains naturally, and/or synthetically, derived perfumes which are substantive to fabrics. These compositions provide better perfume deposition on treated fabrics, thus minimizing the perfume lost during the laundry processes, and subsequently are not substantially lost during the rinse and drying processes. This invention also relates to a method of using this fabric softening bar composition and/or the process of making these compositions.
BACKGROUND OF THE INVENTION
In laundering it is common to treat fabrics such as cotton, polyester, etc. with fabric softening agents to render the fabrics soft to the touch, to reduce tangling, knotting or wrinkling, to render the fabrics free of static electricity, to render the fabrics bacteria-resistant, to deodorize the fabrics, and to otherwise condition the fabrics. The use of fabric conditioners also permits dried clothing to be sorted and folded more easily and quickly.
In various geographies of the world, certain consumers use detergent bars to launder their clothing without washing machines. To soften these laundered items, these consumers must soak clothing in a container so that they can add liquid softeners. In the alternative, these consumers can soften these laundered items by using a laundry bar also containing a fabric softening agent. Unfortunately the combination laundry/softening bars do not provide optimal cleaning and/or softening performance. Laundry/softener combination bars require a rinsing step after application to remove suds which potentially will remove the fabric softener actives.
Therefore, an object of the present invention is to provide a non-detersive, fabric softening bar composition to be used during or after the rinse step, preferably of a hand laundering process, which provides optimal deposition of the fabric softening actives onto fabrics and optimal softening performance.
Another object of the present invention is to provide a non-detersive fabric softening bar composition which provides improved transfer of the hydrophobic fabric softening compound from the bar composition to the fabric, especially in cold water.
A further object of the present invention is to provide a non-detersive fabric softening bar composition which provides efficient, substantive perfume delivery to fabric and an enduring perfume presence, even after the rinsing and drying steps.
SUMMARY OF THE INVENTION
The present invention relates to low sudsing, low lathering, non-detersive fabric softening bar compositions having improved softness, delivery and/or antistatic effects which provide long lasting perfume effects. These compositions comprise, as essential ingredients:
(A) from about 40% to about 90%, preferably from about 45% to about 85%, more preferably from about 50% to about 75%, and even more preferably from about 50% to about 70%, by weight of the composition, of a hydrophobic, preferably biodegradable, fabric softening compound selected from the group consisting of quaternary ammonium compounds, carboxylic acid salts of tertiary amines, carboxylic acid salts of tertiary ester amines, sorbitan esters of fatty alcohols, glycerol and polyglycerol esters, fatty amines, fatty acids, alkyl or alkenyl succinic acids, and mixtures thereof;
(B) from about 0.01% to about 10% of an enduring perfume composition comprising at least about 70% of enduring perfume ingredients selected from the group consisting of: ingredients having a boiling point of at least about 250.degree. C. and a ClogP of at least about 3; cis-jasmone; dimethyl benzyl carbinyl acetate; ethyl vanillin; geranyl acetate; alpha-ionone; beta-ionone; gamma-ionone; koavone; lauric aldehyde; methyl dihydrojasmonate; methyl nonyl acetaldehyde; gamma-nonalactone; phenoxy ethyl iso-butyrate; phenyl ethyl dimethyl carbinol; phenyl ethyl dimethyl carbinyl acetate; alpha-methyl-4-(2-methylpropyl)-benzenepropanal; 6-acetyl-1,1,3,4,4,6-hexamethyl tetrahydronaphthalene; undecylenic aldehyde; vanillin; 2,5,5-trimethyl-2-pentyl-cyclopentanone; 2-tert-butylcyclohexanol; verdox; para-tert-butylcyclohexyl acetate; and mixtures thereof, the level of ingredients having a boiling point of at least about 250.degree. C. and a ClogP of at least about 3 being less than about 70%, preferably less than about 65%, and more preferably less than about 60%, so that the perfume composition with only those ingredients is not an enduring perfume;
(C) from 0%, preferably from about 5%, to about 30%, preferably from about 8% to about 25%, more preferably from about 10% to about 20%, by weight of the composition, of a nonionic surfactant selected from the group consisting of ethoxylated amines, ethoxylated alcohols, alkyl phenol ethoxylates, sorbitan esters of fatty alcohols, glycerol and polyglycerol esters, polyoxyethylene/polyoxypropylene block polymers; polyoxyethylene/polyoxypropylene block polymers of ethylene diamine, polyhydroxy fatty acid amides, amine oxides, alkylpolysaccharides, and mixtures thereof; and
(D) from 0%, preferably from about 5% to about 30%, preferably from about 8% to about 25%, more preferably from about 10% to about 20%, by weight of the composition, of water; wherein when (A) is a sorbitan ester of a fatty alcohol, glycerol ester, or a polyglycerol ester, then (C) cannot also be a sorbitan ester of a fatty alcohol, glycerol ester, or a polyglycerol ester.
Components (C) and (D) are miscible with (A) to form a new crystalline phase at room temperature, which more easily transfers to wet fabrics when rubbed against said fabrics.
All percentages and ratios used herein are by weight of the total composition unless otherwise indicated. All measurements made are at ambient temperature (25.degree. C.), unless otherwise designated. The invention herein can comprise, consist of, or consist essentially of, the essential components as well as the optional ingredients and components described herein.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to low sudsing, low lathering, non-detersive fabric softening bar compositions having improved softness, delivery and/or antistatic effects which provide long lasting perfume effects. These compositions comprise, as essential ingredients:
(A) from about 40% to about 90%, preferably from about 45% to about 85%, more preferably from about 50% to about 75%, and even more preferably from about 50% to about 70%, by weight of the composition, of a hydrophobic, fabric softening compound selected from the group consisting of quaternary ammonium compounds, carboxylic acid salts of tertiary amines, carboxylic acid salts of tertiary ester amines, sorbitan esters of fatty alcohols, glycerol and polyglycerol esters, fatty amines, fatty acids, alkyl or alkenyl succinic acids, and mixtures thereof;
(B) from about 0.01% to about 10% of an enduring perfume composition comprising at least about 70% of perfume ingredients selected from the group consisting of: ingredients having a boiling point of at least about 250.degree. C. and a ClogP of at least about 3; cis-jasmone; dimethyl benzyl carbinyl acetate; ethyl vanillin; geranyl acetate; alpha-ionone; beta-ionone; gamma-ionone; koavone; lauric aldehyde; methyl dihydrojasmonate; methyl nonyl acetaldehyde; gamma-nonalactone; phenoxy ethyl iso-butyrate; phenyl ethyl dimethyl carbinol; phenyl ethyl dimethyl carbinyl acetate; alpha-methyl-4-(2-methylpropyl)-benzenepropanal; 6-acetyl-1,1,3,4,4,5-hexamethyl tetrahydronaphthalene; undecylenic aldehyde; vanillin; 2,5,5-trimethyl-2-pentyl-cyclopentanone; 2-tert-butylcyclohexanol; verdox; para-tert-butylcyclohexyl acetate; and mixtures thereof, the level of ingredients having a boiling point of at least about 250.degree. C. and a ClogP of at least about 3 being less than about 70% so that the composition with only those ingredients is not an enduring perfume;
(C) optionally, from 0%, preferably from about 5%, to about 30%, preferably from about 8% to about 25%, more preferably from about 10% to about 20%, by weight of the composition, of a nonionic surfactant selected from the group consisting of ethoxylated amines, ethoxylated alcohols, alkyl phenol ethoxylates, sorbitan esters of fatty alcohols, glycerol and polyglycerol esters, polyoxyethylene/polyoxypropylene block polymers; polyoxyethylene/polyoxypropylene block polymers of ethylene diamine, polyhydroxy fatty acid amides, amine oxides, alkylpolysaccharides, and mixtures thereof; and
(D) optionally, from 0%, preferably from about 5% to about 30%, preferably from about 8% to about 25%, more preferably from about 10% to about 20%, by weight of the composition, of water;
wherein when (A) is a sorbitan ester of a fatty alcohol, glycerol ester, or a polyglycerol ester, then (C) cannot also be a sorbitan ester of a fatty alcohol, glycerol ester, or a polyglycerol ester.
Components (C) and (D) are miscible with (A) to form a new crystalline phase at room temperature, which more easily transfers to wet fabrics when rubbed against said fabrics.
The bars of the present invention preferably do not contain detersive surfactants, i.e. these bars are preferably not laundry bars or personal cleansing bars. These bars are preferably essentially free of detergent builders, anionic surfactants, soap, etc.
(A) FABRIC SOFTENING COMPOUND
Compositions of the present invention contain from about 40% to about 90%, preferably from about 45% to about 85%, more preferably from about 50% to about and even more preferably from about 50% to about 70%, by weight of the composition, of a fabric softening compound, preferably biodegradable, selected from the group consisting of the compounds of Formulas I, II, III, IV, V and VI, sorbitan esters of fatty alcohols, glycerol and polyglycerol esters, fatty amines, fatty adds, alkyl or alkenyl succinic acids, and mixtures thereof.
QUATERNARY AMMONIUM COMPOUNDS AND CARBOXYLIC ACID SALTS OF TERTIARY AMINES AND ESTER AMINES
The quaternary ammonium compounds and carboxylic acid salts of tertiary amines and ester amines of the present invention are selected from the group consisting of the compounds of Formulas I, II, III, IV, V, VI, and mixtures thereof.
Formula I comprises:
(R).sub.4-m --N.sup.+ --[(CH.sub.2).sub.n --Y--R.sup.2 ].sub.m X.sup.-(I)
wherein
each Y is --O--(O)C--, --C(O)--O--; --NH--C(O)--; --(O)C--NH--; and mixtures thereof; preferably --O--(O)C--, --C(O)--O--; and mixtures thereof,
m is 1 to 3; preferably 2;
each n is 1 to 4; preferably 2;
each R substituent is H, a branched or straight chained C.sub.1 -C.sub.6 alkyl group, (C.sub.y H.sub.2y O).sub.w H where y is from 1 to 5, preferably 2 and w is from 1 to 5, preferably 3; benzyl group, and mixtures thereof, preferably a C.sub.1 -C.sub.3, alkyl group, e.g., methyl (most preferred);
each R.sup.2 is a long chain, saturated and/or unsaturated (IV of from about 3 to about 60), C.sub.8 -C.sub.30 hydrocarbyl, or substituted hydrocarbyl substituent and mixtures thereof, preferably a saturated C.sub.12 -C.sub.18 alkyl group, more preferably a saturated C.sub.16 -C.sub.18 alkyl group; and the counterion, X.sup.-, can be any softener-compatible anion, for example, methylsulfate, ethylsulfate, chloride, bromide, formate, sulfate, lactate, nitrate, benzoate, and the like, preferably methylsulfate.
It will be understood that substituents R and R.sup.2 of Formula I can optionally be substituted with various groups such as alkoxyl or hydroxyl groups. The preferred compounds can be considered to be diester variations of ditallow dimethyl ammonium methyl sulfate (DTDMAMS), which is a widely used fabric softener.
Compounds of Formulas I to VI prepared with fully saturated acyl groups are excellent softeners and are preferred over unsaturated compounds described herein due to their higher melting points which can enhance bar firmness. However, compounds prepared with at least partially unsaturated acyl groups have advantages and are acceptable for consumer products when certain conditions are met.
Variables that must be adjusted to obtain the benefits of using unsaturated acyl groups include the Iodine Value (IV) of the starting fatty acids, the odor of fatty acid starting material, and/or the quaternary ammonium compound and/or amine compound. Any reference to IV values hereinafter refers to IV of fatty acyl groups and not to the resulting quaternary ammonium compound and/or amine compound.
Some highly desirable, readily available sources of fatty acids such as tallow, possess odors that remain with the quaternary ammonium compound and/or amine compound despite the chemical and mechanical processing steps which convert the raw tallow to finished quaternary ammonium compound and/or amine compound. Such sources must be deodorized, e.g., by absorption, distillation (including stripping such as steam stripping), etc., as is well known in the art. In addition, care must be taken to minimize contact of the resulting fatty acyl groups to oxygen and/or bacteria by adding antioxidants, antibacterial agents, etc. The additional expense and effort associated with the unsaturated fatty acyl groups is justified by the superior static performance.
Generally, hydrogenation of fatty acids to reduce polyunsaturation and to lower the Iodine Value to insure good color and odor stability leads to a high degree of trans configuration in the molecule. Therefore, diester compounds derived from fatty acyl groups having low IV values can be made by mixing fully hydrogenated fatty acid with touch hydrogenated fatty acid at a ratio which provides an IV of from about 3 to about 60. The polyunsaturation content of the touch hardened fatty acid should be less than about 5%, preferably less than about 1%. During touch hardening the cis/trans isomer weight ratios are controlled by methods known in the art such as by optimal mixing, using specific catalysts, providing high H.sub.2 availability, etc.
It has also been found that for good chemical stability of the unsaturated diester quaternary compounds in molten storage, water levels in the raw material must be minimized to preferably less than about 1% and more preferably less than about 0.5%. Storage temperatures should be kept as low as possible while still maintaining a fluid material, ideally in the range of from about 120.degree. F. to about 150.degree. F. The optimum storage temperature for stability and fluidity depends on the specific IV of the fatty acid used to make the diester quaternary compound and the level/type of processing solvent selected which are described below. Also, exposure to oxygen should be minimized to keep the unsaturated groups from oxidizing. It can therefore be important to store the material under a reduced oxygen atmosphere such as a nitrogen blanket. It is important to provide good molten storage stability to provide a commercially feasible raw material that will not degrade noticeably in the normal transportation/storage/handling of the material in manufacturing operations.
The following are non-limiting examples of the quaternary ammonium compound of Formula I (wherein all long-chain alkyl substituents are straight-chain):
Saturated
[C.sub.2 H.sub.5 ].sub.2.sup.+ N[CH.sub.2 CH.sub.2 OC(O)C.sub.17 H.sub.35 ].sub.2 (CH.sub.3 SO.sub.4).sup.-
[HO--CH(CH.sub.3)CH.sub.2 ][CH.sub.3 ].sup.+ N[CH.sub.2 CH.sub.2 CO(O)C.sub.15 H.sub.31 ].sub.2 Br.sup.-
[CH.sub.3 ][C.sub.2 H.sub.5 ].sup.+ N[CH.sub.2 CH.sub.2 OC(O)C.sub.13 H.sub.27 ].sub.2 (HCOO).sup.-
[C.sub.3 H][C.sub.2 H.sub.5 ].sup.+ N[CH.sub.2 CH.sub.2 OC(O)C.sub.11 H.sub.23 ].sub.2 (CH.sub.3 SO.sub.4).sup.-
[CH.sub.3 ].sub.2.sup.+ N[CH.sub.2 CH.sub.2 OC(O)C.sub.17 H.sub.35 ]--CH.sub.2 CH.sub.2 OC(O)C.sub.15 H.sub.31 (CH.sub.3 SO.sub.4).sup.-
[CH.sub.3 ].sub.2.sup.+N[CH.sub.2 CH.sub.2 OC(O)R.sup.2 ].sub.2 (CH.sub.3 SO.sub.4).sup.-
where --C(O)R.sup.2 is derived from saturated tallow.
A preferred compound for the bar compositions of the present invention is di(hydrogenated tallowoyloxyethyl)dimethyl ammonium chloride.
Unsaturated
[CH.sub.3 ].sub.2.sup.+ N[CH.sub.2 CH.sub.2 OC(O)C.sub.17 H.sub.33 ].sub.2 (CH.sub.3 SO.sub.4).sup.-
[HO--CH(CH.sub.3)CH.sub.2 ][CH.sub.3 ].sup.+ N[CH.sub.2 CH.sub.2 OC(O)C.sub.15 H.sub.29 ].sub.2 (HCOO).sup.-
[C.sub.2 H.sub.5 ].sub.2.sup.+ N[CH.sub.2 CH.sub.2 OC(O)C.sub.17 H.sub.33 ].sub.2 Cl.sup.-
[CH.sub.3 ][C.sub.2 H.sub.5 ].sup.+ N[CH.sub.2 CH.sub.2 OC(O)C.sub.13 H.sub.25 ].sub.2 (C.sub.6 H.sub.5 COO).sup.-
[CH.sub.3 ].sub.2.sup.+ N[CH.sub.2 CH.sub.2 C(O)C.sub.17 H.sub.33 ]--CH.sub.2 CH.sub.2 OC(O)C.sub.15 H.sub.29 (CH.sub.3 CH.sub.2 SO.sub.4).sup.-
[CH.sub.2 CH.sub.2 OH][CH.sub.3 ].sup.+ N[CH.sub.2 CH.sub.2 OC(O)R.sup.2 ].sup.2 (CH.sub.3 SO.sub.4).sup.-
[CH.sub.3 ].sub.2.sup.+ N[CH.sub.2 CH.sub.2 OC(O)R.sup.2 ].sub.2 (CH.sub.3 SO.sub.4).sup.-
where --C(O)R.sup.2 is derived from partially hydrogenated tallow or modified tallow having the characteristics set forth herein.
For Formula I when Y is --NH--C(O)-- or --(O)C--NH-- then one R is preferably (C.sub.y H.sub.2y O).sub.w H and the other R is preferably a methyl group. These compounds known as Di(2-amidoethyl)methyl quaternary ammonium salts are disclosed in U.S. Pat No. 4,134,840, Minegishi et al., issued Jan. 16, 1979; U.S. Pat. No. 4,439,335, Burns, issued Mar. 27, 1984; and U.S. Pat. No. 4,767,547, Straathof et al., issued Aug. 30, 1988, all of which are incorporated herein by reference in their entirety.
Exemplary materials of this case are di(2-hydrogenatedtallowamidoethyl) ethoxylated (2 ethoxy groups) methylammonium methylsulfate, di(2-oleoylamidoethyl) propoxylated (3-propoxy groups) methyl ammonium bromide, di(2-palmitoleoylamidoethyl)dimethyl ammonium ethylsulfate and di(2-stearylamidoethyl) propoxylated (2 propoxy groups) methyl ammonium methylsulfate.
An exemplary commercial material suitable for use as the fabric softening compound herein is di(2-tallowamidoethyl) ethoxylated methyl ammonium methylsulfate sold under the name Vailsoft.RTM. 222, from Witco Chemical Company.
Another Formula I compound in this class is methyl bis(oleyl amidoethyl) 2-hydroxyethyl ammonium methyl sulfate.
In addition to Formula I compounds, the compositions and articles of the present invention comprise quaternary ammonium compounds of Formula II: ##STR1## wherein, for any molecule: each Q is --O--(O)C--, or --C(O)--O--;
each R.sup.1 is branched or straight chained C.sub.1 -C.sub.6 alkyl or hydroxy alkyl group,
preferably a straight chained C.sub.1 -C.sub.4 alkyl group;
n, X.sup.-, and each R.sup.2 are the same as defined hereinbefore for Formula I; and
wherein preferably R.sup.1
is a methyl group, n is 1, Q is --O--(O)C--;
each R.sup.2 is a C.sub.14 -C.sub.18 alkyl group, and X.sup.- is methyl sulfate.
Tallow is a convenient and inexpensive source of long chain alkyl and alkenyl materials.
A specific example of a biodegradable Formula II quaternary ammonium compound suitable for use in the fabric softening compositions herein is: 1,2-bis(tallowyl oxy)-3-trimethyl ammoniopropane methylsulfate (DTTMAPMS).
Other examples of suitable Formula II quaternary ammonium compounds of this invention are obtained by, e.g., replacing "tallowyl" in the above compounds with, for example, cocoyl, lauryl, oleyl, stearyl, palmityl, or the like;
replacing R.sup.1, i.e., "methyl", in the above compounds with ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl, or the hydroxy substituted analogs of these radicals;
replacing the anion X.sup.-, i.e., "methylsulfate", in the above compounds with chloride, ethylsulfate, bromide, formate, sulfate, lactate, nitrate, and the like, but methylsulfate is preferred.
In addition to Formula I and Formula H compounds, the compositions and articles of the present invention comprise quaternary ammonium compounds of Formula III: ##STR2## wherein R.sup.3 is a C.sub.1 -C.sub.6 hydroxyalkyl group preferably a C.sub.1 -C.sub.4 hydroxyalkyl group;
R, n, Y, R.sup.2, m, and X.sup.- are as previously defined for Formula I.
A specific example of a biodegradable Formula III compound suitable for use in the fabric softening compositions herein is N-methyl-N,N-di-(.beta.-C.sub.14 -C.sub.18 -acyloxy ethyl), N-.beta.-hydroxyethyl ammonium methylsulfate. A preferred compound is N-methyl, N,N-di-(2-oleyloxyethyl) N-2-hydroxyethyl ammonium methylsulfate.
These compounds are generally described in U.S. Pat. No. 3,915,867, Kang et al. issued Oct. 28, 1975, which is herein incorporated by reference in its entirety.
Preferably, Component (A) of the present invention is a biodegradable quaternary ammonium compound, i.e., a quaternary ammonium compound having at least one ester group in the long alkyl chain.
The above described compounds herein can be prepared by standard esterification and quaternization reactions, using readily available starting materials. General methods for preparation are disclosed in U.S. Pat. No. 4,137,180, incorporated herein by reference.
The fabric softening compounds of the present invention can also comprise of monoalkyl quaternary ammonium compounds, dialkyl quaternary ammonium compounds, trialkyl quaternary ammonium compounds, and mixtures thereof of Formula (IV):
(R).sub.4-m --N.sup.+ --[R.sup.2 ].sub.m X.sup.- (IV)
wherein R, m, R.sup.2, and X.sup.- are defined as hereinbefore for Formula I compound. Preferred alkyl quaternary ammonium compounds of Formula IV are variations of ditallow dimethyl ammonium chloride which is a widely used fabric softener.
The fabric softening compounds of the present invention can also comprise of alkyl benzene quaternary ammonium compounds of the Formula (V): ##STR3## wherein R.sup.1, R.sup.2, and X.sup.- are as defined hereinbefore for Formula I and Formula II.
In addition to the above compounds the softening compound of the present invention can also comprise a carboxylic acid salt of a tertiary amine and/or ester amine of Formula (VI): ##STR4## wherein R.sup.5 is a long chain aliphatic group containing from about 8 to about 30 carbon atoms; each R.sup.4 and R.sup.6 are selected from the group consisting of an aliphatic group containing from about 1 to about 30 carbon atoms, a hydroxyalkyl group of the formula: R.sup.8 OH wherein R.sup.8 is an alkylene group of from about 2 to about 30 carbon atoms, and alkyl ether groups of the formula: R.sup.9 O(C.sub.s H.sub.2s O).sub.r wherein R.sup.9 is alkyl or alkenyl group having from about 1 to about 30 carbon atoms or a hydrogen atom, s is from 1 to 5, preferably 2 or 3, and r is from about 1 to about 30; wherein R.sup.4, R.sup.5, R.sup.6, R.sup.8, and R.sup.9 can be ester interrupted groups; and wherein R.sup.7 is selected from the group consisting of unsubstituted alkyl, alkenyl, aryl, alkaryl and aralkyl groups having from about 8 to about 30 carbon atoms and substituted alkyl, alkenyl, aryl, alkaryl, and aralkyl of from about 1 to about 30 carbon atoms wherein the substituents are selected from the group consisting of halogen, carboxyl, and hydroxyl group, said composition having a thermal softening point of from about 35.degree. C. to about 100.degree. C.
This softener compound provides the following benefits: superior odor, and/or improved fabric softening performance, compared to similar compositions which utilize primary amine or ammonium compounds as the sole fabric conditioning agent. Either R.sup.4, R.sup.5, R.sup.6, R.sup.7, R.sup.8, and/or R.sup.9 chains can contain unsaturation.
Additionally, tertiary amine salts of carboxylic acids have superior chemical stability, compared to primary and secondary amine carboxylate salts. For example, primary and secondary amine carboxylates tend to form amides when heated, e.g., during processing. Also, they absorb carbon dioxide, thereby forming high melting carbamates which can build up as an undesirable residue on treated fabrics.
Preferably, R.sup.5 is an aliphatic chain containing from about 12 to about 30 carbon atoms, R.sup.6 is an aliphatic chain of from about 1 to about 30 carbon atoms, and R.sup.4 is an aliphatic chain of from about 1 to about 30 carbon atoms. Particularly preferred tertiary amines for static control performance are those containing unsaturation; e.g., oleyldimethylamine and/or soft tallowdimethylamine.
Examples of preferred tertiary amines as starting material for the reaction between the amine and carboxylic acid to form the tertiary amine salts are: lauryldimethylamine, myristyldimethylamine, stearyldimethylamine, tallowdimethylamine, coconutdimethylamine, dilaurylmethylamine, distearylmethylamine, ditallowmethylamine, oleyldimethylamine, dioleylmethylamine, lauryldi(3-hydroxypropyl)amine, stearyldi(2-hydroxyethyl)amine, trilaurylamine, laurylethylmethylamine, and ##STR5##
Preferred fatty acids are those wherein R.sup.7 is a long chain, unsubstituted alkyl or alkenyl group of from about 8 to about 30 carbon atoms, more preferably from about 11 to about 17 carbon atoms.
Examples of specific carboxylic acids as a starting material are: formic acid, acetic acid, lauric acid, myristic acid, palmitic acid, stearic acid, oleic acid, oxalic acid, adipic acid, 12-hydroxy stearic acid, benzoic acid, 4-hydroxy benzoic acid, 3-chloro benzoic acid, 4-nitro benzoic acid, 4-ethyl benzoic acid, 4-(2-chloroethyl)benzoic acid, phenylacetic acid, (4-chlorophenyl)acetic acid, (4-hydroxyphenyl)acetic acid, and phthalic acid.
Preferred carboxylic acids are stearic, oleic, lauric, myristic, palmitic acid, and mixtures thereof.
The amine salt can be formed by a simple addition reaction, well known in the art, disclosed in U.S. Pat. No. 4,237,155, Kardouche, issued Dec. 2, 1980, which is incorporated herein by reference. Excessive levels of free amines may result in odor problems, and generally free amines provide poorer softening performance than the amine salts.
Preferred amine salts for use herein are those wherein the amine moiety is a C.sub.8 -C.sub.30 alkyl or alkenyl dimethyl amine or a di-C.sub.8 -C.sub.30 alkyl or alkenyl methyl amine, and the acid moiety is a C.sub.8 -C.sub.30 alkyl or alkenyl monocarboxylic acid. The amine and the acid, respectively, used to form the amine salt will often be of mixed chain lengths rather than single chain lengths, since these materials are normally derived from natural fats and oils, or synthetic processed which produce a mixture of chain lengths. Also, it is often desirable to utilize mixtures of different chain lengths in order to modify the physical or performance characteristics of the softening composition.
Specific preferred amine salts for use in the present invention are oleyldimethylamine stearate, stearyldimethylamine stearate, stearyldimethylamine myristate, stearyldimethylamine oleate, stearyldimethylamine palmitate, distearylmethylamine palmitate, distearylmethylamine laurate, tallowyldimethylamine stearate, and mixtures thereof. A particularly preferred mixture is oleyldimethylamine stearate and distearylmethylamine myristate, in a ratio of 1:10 to 10:1, preferably about 1:1.
SORBITIAN ESTER OF FATTY ALCOHOLS
Fabric softening compounds of the present invention also include fatty acid partial esters of polyhydric alcohols, or anhydrides thereof, wherein the alcohol, or anhydride, contains from about 2 to about 18, preferably from about 2 to about 8, carbon atoms, and each fatty acid moiety contains from about 8 to about 30, preferably from about 12 to about 20, carbon atoms. Typically, such softeners contain from about one to about 3, preferably about 2 fatty acid groups per molecule.
The polyhydric alcohol portion of the ester can be ethylene glycol, glycerol, poly (e.g., di-, tri-, tetra, penta-, and/or hexa-) glycerol, xylitol, sucrose, erythritol, pentaerythritol, sorbitol or sorbitan.
The fatty acid portion of the ester is normally derived from fatty acids having from about 8 to about 30, preferably from about 12 to about 22, carbon atoms. Typical examples of said fatty acids being lauric acid, myristic acid, palmitic acid, stearic acid, oleic acid, and behenic acid.
Other nonionic softening agents for use in the present invention are C.sub.10 -C.sub.26 acyl sorbitan esters and polyglycerol monostearate. Sorbitan esters are esterified dehydration products of sorbitol. The preferred sorbitan ester comprises a member selected from the group consisting of C.sub.10 -C.sub.26 acyl sorbitan monoesters and C.sub.10 -C.sub.26 acyl sorbitan diesters and ethoxylates of said esters wherein one or more of the unesterfied hydroxyl groups in said esters preferably contain from 1 to about 6 oxyethylene units, and mixtures thereof. For the purpose of the present invention, sorbitan esters containing unsaturation (e.g., sorbitan monooleate) can be utilized.
Sorbitol, which is typically prepared by the catalytic hydrogenation of glucose, can be dehydrated in well known fashion to form mixtures of 1,4- and 1,5-sorbitol anhydrides and small mounts of isosorbides. (See U.S. Pat. No. 2,322,821, Brown, issued Jun. 29, 1943, incorporated herein by reference.)
The foregoing types of complex mixtures of anhydrides of sorbitol are collectively referred to herein as "sorbitan." It will be recognized that this "sorbitan" mixture will also contain some free, uncyclized sorbitol.
The preferred sorbitan softening agents of the type employed herein can be prepared by esterifying the "sorbitan" mixture with a fatty acyl group in standard fashion, e.g., by reaction with a fatty acid halide, fatty acid ester, and/or fatty acid. The esterification reaction can occur at any of the available hydroxyl groups, and various mono-, di-, etc., esters can be prepared. In fact, mixtures of mono-, di-, tri-, etc., esters almost always result from such reactions, and the stoichiometric ratios of the reactants can be simply adjusted to favor the desired reaction product.
For commercial production of the sorbitan ester materials, etherification and esterification are generally accomplished in the same processing step by reacting sorbitol directly with fatty acids. Such a method of sorbitan ester preparation is described more fully in MacDonald; "Emulsifiers:" Processing and Quality Control:, Journal of the American Oil Chemists' Society, Vol. 45, October 1968.
Details, including formula, of the preferred sorbitan esters can be found in U.S. Pat. No. 4, 128,484, incorporated hereinbefore by reference.
Certain derivatives of the preferred sorbitan esters herein, especially the "lower" ethoxylates thereof (i.e., mono-, di-, and tri-esters wherein one or more of the unesterified --OH groups contain one to about twenty oxyethylene moieties [Tweens.RTM.] are also useful in the composition of the present invention. Therefore, for purposes of the present invention, the term "sorbitan ester" includes such derivatives. An example of a preferred material is Polysorbate 61 known as Tween.RTM. 61 from ICI America.
For the purposes of the present invention, it is preferred that a significant mount of di- and tri- sorbitan esters are present in the ester mixture. Ester mixtures having from 20-50% mono-ester, 25-50% di-ester and 10-35% of tri- and tetra-esters are preferred.
The material which is sold commercially as sorbitan mono-ester (e.g., monostearate) does in fact contain significant amounts of di- and tri-esters and a typical analysis of sorbitan monostearate indicates that it comprises about 27% mono-, 32% di- and 30% tri- and tetra-esters. Commercial sorbitan monostearate therefore is a preferred material. Mixtures of sorbitan stearate and sorbitan palmitate having stearate/palmitate weight ratios varying between 10:1 and 1:10, and 1,5-sorbitan esters are useful. Both the 1,4- and 1,5-sorbitan esters are useful herein.
Other useful alkyl sorbitan esters for use in the softening compositions herein include sorbitan monolaurate, sorbitan monomyristate, sorbitan monopalmitate, sorbitan monobehenate, sorbitan monooleate, sorbitan dilaurate, sorbitan dimyristate, sorbitan dipalmitate, sorbitan distearate, sorbitan dibehenate, sorbitan dioleate, and mixtures thereof, and mixed tallowalkyl sorbitan mono- and di-esters. Such mixtures are readily prepared by reacting the foregoing hydroxy-substituted sorbitans, particularly the 1,4- and 1,5-sorbitans, with the corresponding acid, ester, or acid chloride in a simple esterification reaction. It is to be recognized, of course, that commercial materials prepared in this manner will comprise mixtures usually containing minor proportions of uncyclized sorbitol, fatty acids, polymers, isosorbide structures, and the like. In the present invention, it is preferred that such impurities are present at as low a level as possible.
The preferred sorbitan esters employed herein can contain up to about 15% by weight of esters of the C.sub.20 -C.sub.26, and higher, fatty acids, as well as minor amounts of C.sub.8, and lower, fatty esters.
Other preferred sorbitan esters are disclosed in U.S. Pat. No. 4,022,938, Zaki et al., issued May 10, 1977, which is incorporated herein by reference in its entirety.
GLYCEROL AND POLYCEROL ESTERS
Glycerol and polyglycerol esters, especially glycerol, diglycerol, triglycerol, and polyglycerol mono- and/or di- esters, preferably mono-, are also preferred herein (e.g., polyglycerol monostearate with a trade name of Radiasurf 7248). Glycerol esters can be prepared from naturally occurring triglycerides by normal extraction, purification and/or interestification processes or by esterification processes of the type set forth hereinbefore for sorbitan esters. Partial esters of glycerin can also be ethoxylated to form usable derivatives that are included within the term "glycerol esters."
Useful glycerol and polyglycerol esters include mono-esters with stearic, oleic, palmitic, lauric, isostearic, myristic, and/or behenic acids and the diesters of stearic, oleic, palmitic, lauric, isostearic, behenic, and/or myristic acids. It is understood that the typical mono-ester contains some di- and tri-ester, etc.
The "glycerol esters" also include the polyglycerol, e.g., diglycerol through octaglycerol esters. The polyglycerol polyols are formed by condensing glycerin or epichlorohydrin together to link the glycerol moieties via ether linkages. The mono- and/or diesters of the polyglycerol polyols are preferred, the fatty acyl groups typically being those described hereinbefore for the sorbitan and glycerol esters.
Preferred materials include: PEG-8 stearate known as Pegosperse.RTM. 400 MS from Glyco Corp., and PEG-200 Trihydroxystearin known as Surfactol.RTM. 590 from Chas. Chem.
The selection of the fabric softening compound will, to a great extent, determine the bar firmness properties, which are defined hereinafter.
OTHER FABRIC SOFTENING COMPOUNDS
The fabric softening compounds of the present invention can also comprise of C.sub.8 to C.sub.22, preferably C.sub.12 to C.sub.18, primary fatty amines, secondary fatty amines, tertiary fatty amines, and mixtures thereof. Preferred are C.sub.12 to C.sub.18 secondary and tertiary fatty amines, and mixtures thereof.
The fabric softening compounds of the present invention can also comprise of C.sub.8 to C.sub.22, preferably C.sub.12 to C.sub.18, fatty acids, and mixtures thereof. Preferred are C.sub.12 to C.sub.18 fatty acids, and mixtures thereof.
The fabric softening compounds of the present invention can also comprise of C.sub.8 to C.sub.22, preferably C.sub.12 to C.sub.18, alkyl or alkenyl succinic acids, and mixtures thereof. Preferred are C.sub.12 to C.sub.18 alkyl succinic acids, and mixtures thereof.
(B) ENDURING PERFUME COMPOSITION
Fabric softener compositions in the art commonly contain perfumes to provide a good odor to fabrics. These conventional perfume compositions are normally selected mainly for their odor quality, with some consideration of fabric substantivity. Typical perfume compounds and compositions can be found in the art including U.S. Pat. No. 4,145,184, Brain and Cummins, issued Mar. 20, 1979; U.S. Pat. No. 4,209,417, Whyte, issued Jun. 24, 1980; U.S. Pat. No. 4,515,705, Moeddel, issued May 7, 1985; and U.S. Pat. No. 4,152,272, Young, issued May 1, 1979, all of said patents being incorporated herein by reference.
A substantial mount of perfume from the softening bar compositions can be lost, either when the fabrics are rinsed after treatment, so that the perfume is lost with the rinse water and/or in the subsequent drying step, typically line drying. This results in both a waste of perfumes and a contribution to the general air pollution from the release of volatile organic compounds to the air.
People, skilled in the art, usually by experience, have some knowledge of some particular perfume ingredients that are "fabric substantive". Fabric substantive perfume ingredients are those odorous compounds that effectively deposit on fabrics in the laundry process and are detectable on the laundered fabrics by people with normal olfactory acuity. The knowledge on what perfume ingredients are substantive is spotty and incomplete.
We have now discovered a class of enduring perfume ingredients that can be formulated into bar fabric softener compositions and are substantially deposited and remain on fabrics throughout the rinse and drying steps. These perfume ingredients, when used in conjunction with the highly preferred rapidly biodegradable fabric softener ingredients, represent the most environmentally friendly fabric softener compositions, with minimum material waste, which still provide the good fabric feel and smell the consumers value.
These enduring perfume ingredients are selected from the group consisting of: cis-jasmone; dimethyl benzyl carbinyl acetate; ethyl vanillin; geranyl acetate; alphaionone; beta-ionone; gamma-ionone; koavone; lauric aldehyde; methyl dihydrojasmonate; methyl nonyl acetaldehyde; gamma-nonalactone; phenoxy ethyl iso-butyrate; phenyl ethyl dimethyl carbinol; phenyl ethyl dimethyl carbinyl acetate; alpha-methyl-4-(2-methylpropyl)-benzenepropanal (Suzaral T); 6-acetyl-1,1,3,4,4,6-hexamethyl tetrahydronaphthalene (Tonalid); undecylenic aldehyde; vanillin; 2,5,5-trimethyl-2-pentyl-cyclopentanone (veloutone); 2-tert-butylcyclohexanol (verdol); verdox; para-tert-butylcyclohexyl acetate (vertenex); and mixtures thereof. Enduring perfume compositions can be formulated using these enduring perfume ingredients, preferably at a level of at least about 5%, more preferably at least about 10%, and even more preferably at least about 20%, by weight of the enduring perfume composition, the total level of enduring perfume ingredients, as disclosed herein, being at least about 70%, all by weight of said enduring perfume composition. Other suitable enduring perfume ingredients are characterized by are characterized by their boiling points (B.P.) and their octanol/water partitioning coefficient (P). Octanol/water partitioning coefficient of a perfume ingredient is the ratio between its equilibrium concentration in octanol and in water. The other perfume ingredients of this invention have B.P.s, measured at the normal, standard pressure, of about 250.degree. C. or higher, e.g., about 260.degree. C. or higher; and octanol/water partitioning coefficients P of about 1,000 or higher. Since the partitioning coefficients of these other perfume ingredients of this invention have high values, they are more conveniently given in the form of their logarithm to the base 10, logP. Thus these other perfume ingredients of this invention have logP of about 3 or higher, e.g, about 3.1, preferably about 3.2, or higher. The logP of many perfume ingredients has been reported; for example, the Pomona92 database, available from Daylight Chemical Information Systems, Inc. (Daylight CIS), Irvine, Calif., contains many, along with citations to the original literature. However, the logP values are most conveniently calculated by the "CLOGP" program, also available from Daylight CIS. This program also lists experimental logP values when they are available in the Pomona92 database. The "calculated logP" (ClogP) is determined by the fragment approach on Hansch and Leo (cf., A. Leo, in Comprehensive Medicinal Chemistry, Vol. 4, C. Hansch, P. G. Sammens, J. B. Taylor and C. A. Ransden, Eds., p. 295, Pergamon Press, 1990, incorporated herein by reference). The fragment approach is based on the chemical structure of each perfume ingredient, and takes into account the numbers and types of atoms, the atom connectivity, and chemical bonding. The ClogP values, which are the most reliable and widely used estimates for this physicochemical property, are preferably used instead of the experimental logP values in the selection of these other perfume ingredients which are useful in the present invention.
The boiling points of many perfume ingredients are given in, e.g., "Perfume and Flavor Chemicals (Aroma Chemicals)," S. Arctander, published by the author, 1969, incorporated herein by reference. Other boiling point values can be obtained from different chemistry handbooks and databases, such as the Beilstein Handbook, Lange's Handbook of Chemistry, and the CRC Handbook of Chemistry and Physics. When a boiling point is given only at a different pressure, usually lower pressure than the normal pressure of 760 mm Hg, the boiling point at normal pressure can be approximately estimated by using boiling point-pressure nomographs, such as those given in "The Chemist's Companion," A. J. Gordon and R. A. Ford, John Wiley & Sons Publishers, 1972, pp. 30-36. When applicable, the boiling point values can also be calculated by computer programs, based on molecular structural data, such as those described in "Computer-Assisted Prediction of Normal Boiling Points of Pyrans and Pyrroles," D. T. Stanton et al, J. Chem. Inf. Comput. Sci., 32 (1992), pp. 306-316, "Computer-Assisted Prediction of Normal Boiling Points of Furans, Tetrahydrofuran, and Thiophenes," D. T. Stanton et al, J. Chem. Inf. Comput. Sci., 31 (1992), pp. 301-310, and references cited therein, and "Predicting Physical Properties from Molecular Structure," R. Murugan et al, Chemtech, June 1994, pp. 17-23. All the above publications are incorporated herein by reference.
Thus, when a perfume composition which is composed primarily of: ingredients having a boiling point of at least about 250.degree. C. and a ClogP of at least about 3; cis-jasmone; dimethyl benzyl carbinyl acetate; ethyl vanillin; geranyl acetate; alpha-ionone; beta-ionone; gamma-ionone; koavone; lauric aldehyde; methyl dihydrojasmonate; methyl nonyl acetaldehyde; gamma-nonalactone; phenoxy ethyl iso-butyrate; phenyl ethyl dimethyl carbinol; phenyl ethyl dimethyl carbinyl acetate; alpha-methyl-4-(2-methylpropyl)-benzenepropanal; 6-acetyl-1,1,3,4,4,6-hexamethyl tetrahydronaphthalene; undecylenic aldehyde; vanillin; 2,5,5-trimethyl-2-pentyl-cyclopentanone; 2-tert-butylcyclohexanol; verdox; para-tert-butylcyclohexyl acetate; and mixtures thereof, the level of ingredients having a boiling point of at least about 250.degree. C. and a ClogP of at least about 3 being less than about 70%, is used in a softener composition, the perfume is very effectively deposited on fabrics and remains substantive on fabrics after the rinsing and drying, e.g., line drying steps.
TABLE 1______________________________________Examples of Other Enduring Perfume Ingredients ApproximatePerfume Ingredients B.P. (.degree.C.) (a) ClogP______________________________________BP .gtoreq. 250.degree. C. and ClogP .gtoreq. 3.0Allyl cyclohexane propionate 267 3.935Ambrettolide 300 6.261Ambrox DL (Dodecahydro-3a,6,6,9a- 250 5.400tetramethyl-naphtho[2,1-b]furan)Amyl benzoate 262 3.417Amyl cinnamate 310 3.771Amyl cinnamic aldehyde 285 4.324Amyl cinnamic aldehyde dimethyl acetal 300 4.033iso-Amyl salicylate 277 4.601Aurantiol 450 4.216Benzophenone 306 3.120Benzyl salicylate 300 4.383para-tert-Butyl cyclohexyl acetate +250 4.019iso-Butyl quinoline 252 4.193beta-Caryophyllene 256 6.333Cadinene 275 7.346Cedrol 291 4.530Cedryl acetate 303 5.436Cedryl formate +250 5.070Cinnamyl cinnamate 370 5.480Cyclohexyl salicylate 304 5.265Cyclamen aldehyde 270 3.680Dihydro isojasmonate +300 3.009Diphenyl methane 262 4.059Diphenyl oxide 252 4.240Dodecalactone 258 4.359iso E super +250 3.455Ethylene brassylate 332 4.554Ethyl methyl phenyl glycidate 260 3.165Ethyl undecylenate 264 4.888Exaltolide 280 5.346Galaxolide +250 5.482Geranyl anthranilate 312 4.216Geranyl phenyl acetate +250 5.233Hexadecanolide 294 6.805Hexenyl salicylate 271 4.716Hexyl cinnamic aldehyde 305 5.473Hexyl salicylate 290 5.260alpha-Irone 250 3.820Lilial (p-t-bucinal) 258 3.858Linalyl benzoate 263 5.2332-Methoxy naphthalene 274 3.235gamma-n-Methyl ionone 252 4.309Musk indanone +250 5.458Musk ketone MP = 137.degree. C. 3.014Musk tibetine MP = 136.degree. C. 3.831Myristicin 276 3.200Oxahexadecanolide-10 +300 4.336Oxahexadecanolide-11 MP = 35.degree. C. 4.336Patchouli alcohol 285 4.530Phantolide 288 5.977Phenyl ethyl benzoate 300 4.058Phenylethylphenylacetate 325 3.767Phenyl heptanol 261 3.478Phenyl hexanol 258 3.299alpha-Santalol 301 3.800Thibetolide 280 6.246delta-Undecalactone 290 3.830gamma-Undecalactone 297 4.140Undecavertol (4-methyl-3-decen-5-ol) 250 3.690Vetiveryl acetate 285 4.882Yara-yara 274 3.235Ylangene 250 6.268______________________________________ (a) M.P. is melting point; these have a B.P. higher than 250.degree. C.
Table 1 gives some non-limiting examples of enduring perfume ingredients, useful in softener compositions of the present invention. The enduring perfume compositions of the present invention contain at least about 3 different enduring perfume ingredients, more preferably at least about 4 different enduring perfume ingredients, and even more preferably at least about 5 different enduring perfume ingredients. Furthermore, the enduring perfume compositions of the present invention contain at least about 70 Wt. % of enduring perfume ingredients, preferably at least about 75 Wt. % of enduring perfume ingredients, more preferably at least about 85 Wt. % of enduring perfume ingredients, the level of ingredients having a B.P. of at least about 250.degree. C. and a ClogP of more than about 3 being at a level of less than about 70%, preferably less than about 65%, and more preferably less than about 60%, so that the composition with only those ingredients is not an enduring perfume. Fabric softening compositions of the present invention contain from about 0.01% to about 10%, preferably from about 0.05% to about 5%, more preferably from about 0.1% to about 4%, and even more preferably from about 0.15% to about 3%, of an enduring perfume composition.
In the perfume art, some materials having no odor or very faint odor are used as diluents or extenders. Non-limiting examples of these materials are dipropylene glycol, diethyl phthalate, triethyl citrate, isopropyl myristate, and benzyl benzoate. These materials are used for, e.g., diluting and stabilizing some other perfume ingredients. These materials are not counted in the formulation of the enduring perfume compositions of the present invention.
TABLE 2______________________________________Examples of Non-Enduring Perfume Ingredients ApproximatePerfume Ingredients B.P. (.degree.C.) ClogP______________________________________BP < 250.degree. C. and ClogP < 3.0Benzaldehyde 179 1.480Benzyl acetate 215 1.960laevo-Carvone 231 2.083Geraniol 230 2.649Hydroxycitronellal 241 1.541Linalool 198 2.429Nerol 227 2.649Phenyl ethyl alcohol 220 1.183alpha-Terpineol 219 2.569BP > 250.degree. C. and ClogP < 3.0Coumarin 291 1.412Eugenol 253 2.307iso-Eugenol 266 2.547Indole 254 decompos 2.142Methyl cinnamate 263 2.620Methyl-N-methyl anthranilate 256 2.791beta-Methyl naphthyl ketone 300 2.275BP < 250.degree. C. and ClogP > 3.0iso-Bornyl acetate 227 3.485Carvacrol 238 3.401alpha-Citronellol 225 3.193para-Cymene 179 4.068Dihydro myrcenol 208 3.030d-Limonene 177 4.232Linalyl acetate 220 3.500______________________________________
Non-enduring perfume ingredients, which are preferably minimized in softener compositions of the present invention, are those having a B.P. of less than about 250.degree. C., or having a ClogP of less than about 3.0, or having both a B.P. of less than about 250.degree. C. and a ClogP of less than about 3.0. Table 2 gives some non-limiting examples of non-enduring perfume ingredients. In some particular fabric softener compositions, some non-enduring perfume ingredients can be used in small amounts, e.g., to improve product odor. However, to minimize waste and pollution, the enduring perfume compositions of the present invention contain less than about 30 Wt. % of non-enduring perfume ingredients, preferably less than about 25 Wt. % of non-enduring perfume ingredients, more preferably less than about 20 Wt. % of non-enduring perfume ingredients, and even more preferably less than about 15 Wt. % of non-enduring perfume ingredients.
(C) NONIONIC SURFACTANT
An optional, but highly preferred component of the present invention is a hydrophilic nonionic surfactant. These nonionic surfactants are preferably solids at room temperature with a melting point above about 25.degree. C., preferably above about 30.degree. C. Bar compositions of the present invention made with lower melting nonionic surfactants are generally too soft, not meeting the bar firmness requirements of the present invention.
Also, as the level of nonionic surfactant increases, i.e., above about 20% by weight of the surfactant, the bar can generally become oily.
The level of nonionic surfactant in the compositions of the present invention, when present, is typically from about 5% to about 30%, preferably from about 8% to about 25%, more preferably from about 10% to about 20%, by weight of the composition.
Suitable nonionic surfactants include addition products of ethylene oxide and, optionally, propylene oxide, with fatty alcohols, fatty acids, fatty amines, etc.
Any of the alkoxylated materials of the particular type described hereinafter can be used as the nonionic surfactant. Suitable compounds are substantially water-soluble surfactants of the general formula:
R.sup.2 --Y--(C.sub.2 H.sub.4 O).sub.z --C.sub.2 H.sub.4 OH
wherein R.sup.2 is selected from the group consisting of primary, secondary and branched chain alkyl and/or acyl hydrocarbyl groups; primary, secondary and branched chain alkenyl hydrocarbyl groups; and primary, secondary and branched chain alkyl- and alkenyl-substituted phenolic hydrocarbyl groups; said hydrocarbyl groups having a hydrocarbyl chain length of from about 8 to about 22, preferably from about 14 to about 18 carbon atoms. More preferably the hydrocarbyl chain length for liquid nonionic surfactants is from about 16 to about 18 carbon atoms and for solid nonionic surfactants is from about 10 to about 14 carbon atoms. In the general formula for the ethoxylated nonionic surfactants herein, Y is typically --O--, --C(O)O--, --C(O)N(R)--, or --C(O)N(R)R--, in which R is a short chain C.sub.1 -C.sub.6 alkyl group, preferably a methyl or ethyl group; for solid nonionic surfactants z is at least about 7, preferably at least about 10-11, more preferably at least about 15; for liquid nonionic surfactants z is at least about 10-11, preferably at least about 15.
The nonionic surfactants herein are characterized by an HLB (hydrophiliclipophilic balance) of from about 7 to about 20, preferably from about 8 to about 15. Of course, by defining R.sup.2 and the number of ethoxylate groups, the HLB of the surfactant is, in general, determined.
Examples of nonionic surfactants follow. The nonionic surfactants of this invention are not limited to these examples. In the examples, the integer defines the number of ethoxyl (EO) groups in the molecule.
STRAIGHT-CHAIN, PRIMARY ALCOHOL ALKOXYLATES
The deca-, undeca-, dodeca-, tetradeca-, and pentadecaethoxylates of n-hexadecanol, and n-octadecanol having an HLB within the range recited herein are useful phase modifiers in the context of this invention. Exemplary ethoxylated primary alcohols useful herein as the phase modifiers of the compositions are n-C.sub.18 EO(10); n-C.sub.14 EO(13); and n-C.sub.10 EO(11). The ethoxylates of mixed natural or synthetic alcohols in the "tallow" chain length range are also useful herein. Specific examples of such materials include tallowalcohol-EO(11), tallowalcohol-EO(18), and tallowalcohol-EO(25).
STRAIGHT-CHAIN, SECONDARY ALCOHOL ALKOXYLATES
The deca-, undeca-, dodeca-, tetradeca-, pentadeca-, octadeca-, and nonadecaethoxylates of 3-hexadecanol, 2-octadecanol, 4-eicosanol, and 5-eicosanol having and HLB within the range recited herein are useful phase modifiers in the context of this invention. Exemplary ethoxylated secondary alcohols useful herein as the phase modifiers of the compositions are: 2-C.sub.16 EO(11); 2-C.sub.20 EO(11); and 2-C.sub.16 EO(14).
ALKYL PHENOL ALKOXYLATES
As in the case of the alcohol alkoxylates, the hexa- through octadecaethoxylates of alkylated phenols, particularly monohydric alkylphenols, having an HLB within the range recited herein are useful as the phase modifiers of the instant compositions. The hexa- through octadeca-ethoxylates of p-tridecylphenol, m-pentadecylphenol, and the like, are useful herein. Exemplary ethoxylated alkylphenols useful as the phase modifiers of the mixtures herein are: p-tridecylphenol EO(11) and p-pentadecylphenol EO(18). Especially preferred is Nonyl Nonoxynol-49 known as Igepal.RTM. DM-880 from Rhone-Poulenc Inc.
As used herein and as generally recognized in the art, a phenylene group in the nonionic formula is the equivalent of an alkylene group containing from 2 to 4 carbon atoms. For present purposes, nonionics containing a phenylene group are considered to contain an equivalent number of carbon atoms calculated as the sum of the carbon atoms in the alkyl group plus about 3.3 carbon atoms for each phenylene group.
OLEFINIC ALKOXYLATES
The alkenyl alcohols, both primary and secondary, and alkenyl phenols corresponding to those disclosed immediately hereinabove can be ethoxylated to an HLB within the range recited herein and used as the phase modifiers of the instant compositions.
BRANCHED CHAIN ALKOXYLATES
Branched chain primary and secondary alcohols which are available from the well-known "OXO" process can be ethoxylated and employed as the phase modifiers of compositions herein.
The above ethoxylated nonionic surfactants are useful in the present compositions alone or in combination, and the term "nonionic surfactant" encompasses mixed nonionic surface active agents.
SORBITIAN ESTERS OF FATTY ALCOHOLS
The nonionic surfactant of the present invention can also comprise sorbitol esters and ethoxylated sorbitol esters of fatty alcohols, described in detail hereinbefore in section (A). It is to be understood that when the nonionic surfactant comprises a sorbitol ester of a fatty alcohol, the fabric softening compound must be selected from the group of compounds listed in Section (A), other than sorbitan esters of a fatty alcohol. Conversely, when the fabric softening compound is a sorbitan ester of a fatty alcohol, then the nonionic surfactant cannot also be a sorbitol ester of a fatty alcohol.
GLYCEROL AND POLYGLYCEROL ESTERS
The nonionic surfactant of the present invention can also comprise glycerol and polyglycerol esters described in detail hereinbefore in section (A). It is to be understood that when the nonionic surfactant comprises glycerol and polyglycerol esters, the fabric softening compound must be selected from the group of compounds listed in Section (A), other than glycerol and polyglycerol esters. Conversely, when the fabric softening compound is a glycerol or polyglycerol ester, then the nonionic surfactant cannot also be a a glycerol or polyglycerol ester.
POLYETHYLENE OXIDE/POLYPROPYLENE OXIDE BLOCK POLYMERS
Other suitable nonionic surfactants of the present invention include polyoxyethylene/polyoxypropylene block polymers that conform generally to the formula: ##STR6## wherein x and z are integers from 2 to 130; and y is an integer from 16 to 70. These compounds are known as Poloxamine and are available under the tradename of Pluracare/Pluronic.RTM. from BASF.
Still further suitable nonionic surfactants of the present invention include polyoxyethylene/polyoxypropylene block polymers of ethylene diamine that conform generally to the formula: ##STR7## wherein x is an integer from 4 to 32 and y is an integer from 2 to 122. These compounds are known as Poloxamine and are available under the tradename of Tetronic.RTM. from BASF.
POLYHYDROXY FATTY ACID AMIDES
The N-alkoxy and N-aryloxy polyhydroxy fatty acid nonionic surfactants used herein comprise amides of the formula: ##STR8## wherein: R.sup.1 is C.sub.2 -C.sub.8 hydrocarbyl including straight-chain, branched-chain and cyclic (including aryl, and is preferably C.sub.2 -C.sub.4 alkylene, i.e., --CH.sub.2 CH.sub.2 --, --C.sub.2 CH.sub.2 C.sub.2 -- and --C.sub.2 (C.sub.2).sub.2 C.sub.2 --; and R.sup.2 is C.sub.1 -C.sub.8 straight-chain, branched-chain and cyclic hydrocarbyl including aryl and oxy-hydrocarbol, and is preferably C.sub.1 -C.sub.4 alkyl or phenyl; and Z is a polyhydroxhydrocarbyl moiety having a liner hydrocarbyl chain with at least 2 (in the case of glyceraldehyde) or at least 3 hydroxyls (in the case of other reducing sugars) directly connected to the chain, or an alkoxylated derivative (preferably ethoxylated or propoxylated) thereof. Z preferably will be derived from a reducing sugar in a reductive amination reaction; more preferably Z is a glycityl moiety. Suitable reducing sugars include glucose, fructose, maltose, lactose, galaclose, mannose, and xylose, as well as glyceraldehyde. As raw materials, high dextrose corn syrup, high fructose corn syrup, and high maltose corn syrup can be utilized as well as the individual sugars listed above. These corn syrups may yield a mix of sugar components for Z. It should be understood that it is by no means intended to exclude other suitable raw materials. Z preferably will be selected from the group consisting of --CH.sub.2 --(CHOH).sub.n --CH.sub.2 OH, --CH(CH.sub.2 OH)--(CHOH).sub.n --CH.sub.2 OH, --CH.sub.2 --(CHOH).sub.2 (CHOR')(CHOH)--CH.sub.2 OH, where n is an integer from 1 to 5, inclusive, and R' is H or a cyclic mono- or poly- saccharide, and alkoxylated derivatives thereof. Most preferred are glycityls wherein n is 4, particularly --CH.sub.2 --(CHOH).sub.4 --CH.sub.2 OH.
In compounds of the above formula, nonlimiting examples of the amine substituent group --R.sup.1 --O--R.sup.2 can be, for example: 2-methoxyethyl-, 3-methoxypropyl-, 4-methoxybutyl-, 5-methoxypentyl-, 6-methoxyhexyl-, 2-ethoxyethyl-, 3-ethoxypropyl-, 2-methoxypropyl, methoxybenzyl-, 2-isopropoxyethyl-, 3-isopropoxypropyl-, 2-(t-butoxy)ethyl-, 3-(t-butoxy)propyl-, 2-(isobutoxy)ethyl-, 3-(isobutoxy)propyl-, 3-butoxypropyl, 2-butoxyethyl, 2-phenoxyethyl-, methoxycyclohexyl-, methoxycydohexylmethyl-, tetrahydrofurfuryl-, tetrahydropyranyloxyethyl-, 3-[2-methoxyethoxy]propyl-, 2-[2-methoxyethoxy]ethyl-, 3-[3 -methoxypropoxy]propyl-, 2-[3-methoxypropoxy]ethyl-, 3-[methoxypolyethyleneoxy]propyl-, 3-[4-methoxybutoxy]propyl-, 3-[2-methoxyisopropoxy]propyl-, CH.sub.3 O--CH.sub.2 CH(CH.sub.3)-- and CH.sub.3 OCH.sub.2 CH(CH.sub.3)CH.sub.2 --O--(CH.sub.2)3--.
R.sup.2 --C(O)--N-- can be, for example, cocamide, stearamide, oleamide, lauramide, myristamide, capricamide, palmitamide, tallowamide, etc.
While the synthesis of N-alkoxy or N-aryloxy polyhydroxy fatty acid amides can prospectively be conducted using various processes, contamination with cyclized by-products and other colored materials may be problematic. As an overall proposition, the synthesis method for these surfactants comprises reacting the appropriate N-alkoxy or N-aryloxy-substituted aminopolyols with, preferably, fatty acid methyl esters with or without a solvent using an alkoxide catalyst at temperatures of about 85.degree. C. to provide products having desirable low levels (preferably, less than about 10%) of ester amide or cyclized by-products and also with improved color and improved color stability, e.g., Gardner Colors below about 4, preferably between 0 and 2. If desired, any unreacted N-alkoxy or N-aryloxy amino polyol remaining in the product can be acylated with an acid anhydride, e.g., acetic anhydride, maleic anhydride, or the like, in water at 50.degree. C.-85.degree. C., to minimize the overall level of such residual amines in the product. Residual sources of straight-chain primary fatty acids, which can suppress suds, can be depleted by reaction with, for example, monoethanolamine at 50.degree. C.-85.degree. C.
If desired, the water solubility of the solid N-alkoxy polyhydroxy fatty acid amide surfactants herein can be enhanced by quick cooling from a melt. While not intending to be limited by theory, it appears that such quick cooling re-solidifies the melt into a metastable solid which is more soluble in water than the pure crystalline form of the N-alkoxy polyhydroxy fatty acid amide. Such quick cooling can be accomplished by any convenient means, such as by use of chilled (0.degree. C.-10.degree. C.) rollers, by casting the melt onto a chilled surface such as a chilled steel plate, by means of refrigerant coils immersed in the melt, or the like.
By "cyclized by-products" herein is meant the undesirable reaction by-products of the primary reaction wherein it appears that the multiple hydroxyl groups in the polyhydroxy fatty acid amides can form ring structures. It will be appreciated by those skilled in the chemical arts that the preparation of the polyhydroxy fatty acid amides herein using the di- and higher saccharides such as maltose will result in the formation of polyhydroxy fatty acid amides wherein linear substituent Z (which contains multiple hydroxy substituents) is naturally "capped" by a polyhydroxy ring structure. Such materials are not cyclized by-products, as defined herein.
A more detailed discussion of these materials is present in U.S. Pat. No. 5,318,728, Surutzidis et al., issued Jun. 7, 1994, which is herein incorporated by reference in its entirety.
AMINE OXIDES
Other suitable nonionic surfactants of the present invention include amine oxides of the formula: ##STR9## wherein each R.sup.1 and R.sup.2 is a short chain C.sub.1 -C.sub.4 alkyl group, preferably a methyl group; and R.sup.2 is a straight chained C.sub.8 -C.sub.22 alkyl group, preferably a C.sub.12 -C.sub.18 alkyl group.
ALKYLPOLYSACCHARIDES
Still further suitable nonionic surfactants of this invention include alkylpolysaccharides, preferably alkylpolyglycosides of the formula:
R.sup.2 O(C.sub.n H.sub.2n O).sub.t (Z).sub.x
wherein
Z is derived from glycose;
R.sup.2 is a hydrophobic group selected from the group consisting of a C.sub.10 -C.sub.18, preferably a C.sub.12 -C.sub.14, alkyl group, alkyl phenyl group, hydroxyalkyl group, hydroxyalkylphenyl group, and mixtures thereof;
n is 2 or 3; preferably 2;
t is from 0 to 10; preferably 0; and
x is from 1.5 to 8; preferably 1.5 to 4; more preferably from 1.6 to 2.7.
These surfactants are disclosed in U.S. Pat. No. 4,565,647, Llenado, issued Jan. 21, 1986; U.S. Pat. No. 4,536,3 18, Cook et al., issued Aug. 20, 1985, U.S. Pat. No. 4,536,317, Llenado et al., issued Aug. 20, 1985; U.S. Pat. No. 4,599,188, Llenado, issued Jul. 8, 1986; and U.S. Pat. No. 4,536,319, Payne, issued Aug. 20, 1985, all of which are incorporated herein by reference.
The compositions of the present invention can also comprise of mixtures of the above nonionic surfactants.
(D) WATER
The bar compositions of the present invention comprise, optionally, but preferably, from about 5% to about 30%, preferably from about 8% to about 25%, more preferably from about 10% to about 20%, by weight of the composition, water. When the level of water is too high (i.e. above about 30%), the bar compositions no longer remain in a homogeneous state during processing, and a separate phase develops in the bar molds. At least some minimum level of water is essential to form the crystalline phase comprising the softening compound, nonionic surfactant and water.
The bar compositions of the present invention form a crystalline phase which comprises water, the softening compound, and the nonionic surfactant. This crystalline phase is characterized in that the composition containing this crystalline phase melts at a higher temperature than the melting point of either the starting softening compound and/or the starting nonionic surfactant. This crystalline phase is more hydrophilic than ingredient (A) alone. Therefore, the formation of this crystalline phase contributes to the excellent transferability of the composition to the fabric.
(E) OPTIONAL INGREDIENTS
Well known optional components included in fabric conditioning compositions are narrated in U.S. Pat. No. 4,103,047, Zaki et al., issued Jul. 25, 1978, for "Fabric Treatment Compositions," incorporated herein by reference.
The bar compositions of the present invention may optionally comprise processing aids in order to lower the viscosity of the molten fabric softener mixture during processing so that the molten homogeneous mixture is more easily poured into the bar molds. These processing aids allow processing to occur at lower temperatures so that less water and perfume are lost from the bar during processing.
The compositions of the present invention can optionally comprise from about 0.1% to about 5%, preferably from about 0.5% to about 2% of a processing aid. Processing aids include salts and/or low molecular alcohols such as monohydric, dihydric (glycol, etc.), trihydric (glycerol, etc.), and polyhydric (polyols) alcohols. Especially preferred processing aids are ethanol, propylene glycol, sodium sulfate, sodium citrate, PEG 400, butane diol, and mixtures thereof.
The bar compositions of the present invention may also optionally comprise of water insoluble particulate material components, i.e., fillers. These insoluble materials include clays, talc, calcium silicates, magnesium silicate, calcium sulfate, silica, calcium phosphate, and calcium carbonate, and mixtures thereof. Preferably insoluble materials are calcium carbonate, talc and clay such as bentonite, preferably sodium bentonite. Especially preferred filler materials are those materials which also possess fabric softening properties.
OPTIONAL SOIL RELEASE AGENT
Optionally, the compositions herein contain from 0% to about 10%, preferably from about 0.1% to about 5%, more preferably from about 0.1% to about 2%, of a soil release agent. Preferably, such a soil release agent is a polymer. Polymeric soil release agents useful in the present invention include copolymeric blocks of terephthalate and polyethylene oxide or polypropylene oxide, and the like. U.S. Pat. No. 4,956,447, Gosselink/Hardy/Trinh, issued Sept. 11, 1990, discloses specific preferred soil release agents comprising cationic functionalities, said patent being incorporated herein by reference.
A preferred soil release agent is a copolymer having blocks of terephthalate and polyethylene oxide. More specifically, these polymers are comprised of repeating units of ethylene and/or propylene terephthalate and polyethylene oxide terephthalate at a molar ratio of ethylene terephthalate units to polyethylene oxide terephthalate units of from about 25:75 to about 35:65, said polyethylene oxide terephthalate containing polyethylene oxide blocks having molecular weights of from about 300 to about 2000. The molecular weight of this polymeric soil release agent is in the range of from about 5,000 to about 55,000.
U.S. Pat. No. 4,976,879, MacDonaldo/Trinh/Gosselink, issued Dec. 11, 1990, discloses specific preferred soil release agents which can also provide improved antistat benefit, said patent being incorporated herein by reference.
Another preferred polymeric soil release agent is a crystallizable polyester with repeat units of ethylene terephthalate units containing from about 10% to about 15% by weight of ethylene terephthalate units together with from about 10% to about 50% by weight of polyoxyethylene terephthalate units, derived from a polyoxyethylene glycol of average molecular weight of from about 300 to about 6,000, and the molar ratio of ethylene terephthalate units to polyoxyethylene terephthalate units in the crystallizable polymeric compound is between 2:1 and 6:1. Examples of this polymer include the commercially available materials Zelcon.RTM. 4780 (from DuPont) and Milease.RTM. T (from ICI).
A more complete disclosure of these highly preferred soil release agents is contained in European Pat. Application 185,427, Gosselink, published Jun. 25, 1986, incorporated herein by reference.
OPTIONAL CYCLODEXTRIN/PERFUME COMPLEXES AND FREE PERFUME
The bars herein can also contain from about 0.1% to about 20%, preferably from about 1% to about 5%, cyclodextrin/perfume inclusion complexes, as disclosed in U.S. Pat. No. 5,139,687, Borcher et al., issued Aug. 18, 1992; and U.S. Pat. No. 5,234,610, Gardlik et al., issued Aug. 10, 1993, which are incorporated herein by reference. Non-enduring perfumes, as described hereinbefore, can usually benefit from protection, and can be complexed with cyclodextrin.
The free perfume ingredients and compositions of this invention are essentially the enduring perfume compositions described hereinbefore, although some conventional perfumes known in the art can also be present, especially in the cyclodextrin/perfume inclusion complex form. Selection of any perfume component, or amount of perfume, is based on aesthetic considerations. Suitable perfume compounds and compositions can be found in the art including U.S. Pat. No. 4,145,184, Brain and Cummins, issued Mar. 20, 1979; U.S. Pat. No. 4,209,417, Whyte, issued Jun. 24, 1980; U.S. Pat. No. 4,515,705, Moeddel, issued May 7, 1985; and U.S. Pat. No. 4,152,272, Young, issued May 1, 1979, all of said patents being incorporated herein by reference. Many of the art recognized perfume compositions are relatively substantive to maximize their odor effect on substrates. However, it is a special advantage of perfume delivery via the perfume/cyclodextrin complexes that non-enduring (nonsubstantive) perfumes are also effective.
If a product contains both free and complexed perfume, the escaped perfume from the complex contributes to the overall perfume odor intensity, thus also giving rise to a longer lasting perfume odor impression.
As disclosed in U.S. Pat. No. 5,234,610, Gardlik/Trinh/Banks/Benvegnu, issued Aug. 3, 1993, said patent being incorporated herein by reference, by adjusting the levels of free perfume and perfume/CD complex it is possible to provide a wide range of unique perfume profiles in terms of timing (release) and/or perfume identity (character).
OPTIONAL CELLULASE
The cellulase usable in the compositions herein can be any bacterial or fungal cellulase. Suitable cellulases are disclosed, for example, in GB-A-2 075 028, GB-A-2 095 275 and DE-OS-24 47 832, all incorporated herein by reference in their entirety.
Examples of such cellulases are cellulase produced by a strain of Humicola insolens (Humicola grisea var. thermoidea), particularly by the Humicola strain DSM 1800, and cellulase 212-producing fungus belonging to the genus Aeromonas, and cellulase extracted from the hepatopancreas of a marine mullosc (Dolabella Auricula Solander).
The cellulase added to the composition of the invention may be in the form of a non-dusting granulate, e.g. "marumes" or "prills", or in the form of a liquid, e.g., one in which the cellulase is provided as a cellulase concentrate suspended in e.g. a nonionic surfactant or dissolved in an aqueous medium.
Preferred cellulases for use herein are characterized in that they provide at least 10% removal of immobilized radioactive labeled carboxymethyl-cellulose according to the C.sup.14 CMC-method described in EPA 350,098 (incorporated herein by reference in its entirety) at 25.times.10.sup.6 % by weight of cellulase protein in the laundry test solution.
Most preferred cellulases are those as described in International Patent Application WO 91/17243, incorporated herein by reference in its entirety. For example, a cellulase preparation useful in the compositions of the invention can consist essentially of a homogeneous endoglueanase component, which is immunoreactive with an antibody raised against a highly purified 43 kD cellulase derived from Humicola insolens, DSM 1800, or which is homologous to said 43 kD endoglucanase.
The cellulases herein should be used in the fabric-conditioning compositions of the present invention at a level equivalent to an activity from about 1.0 to about 100 CEVU/gram of composition [CEVU=Cellulase Equivalent Viscosity Unit, as described, for example, in WO 91/13136, incorporated herein by reference in its entirety], and preferably an activity of from about 5 to about 50, more preferably from about 10 to about 25 CEVU/gram of the bar composition.
OPTIONAL STABILIZER
Stabilizers can be present in the compositions of the present invention. The term "stabilizer," as used herein, includes antioxidants and reductive agents. These agents are present at a level of from 0% to about 2%, preferably from about 0.01% to about 0.2%, more preferably from about 0.05% to about 0.1% for antioxidants and more preferably from about 0.01% to about 0.2% for reductive agents. These assure good odor stability under long term storage conditions for the compositions. Use of antioxidants and reductive agent stabilizers is especially critical for unscented or low scent products (no or low perfume).
Examples of antioxidants that can be added to the compositions of this invention include butylated hydroxytoluene, available from UOP Process Division under the trade name Sustane.RTM. BHT; tertiary butylhydroquinone, Eastman Chemical Products, Inc., as Tenox.RTM. TBHQ; natural tocopherols, Eastman Chemical Products, Inc., as Tenox.RTM. GT-1/GT-2; and butylated hydroxyanisole, Eastman Chemical Products, Inc., as BHA.
Examples of reductive agents include sodium borohydride, hypophosphorous acid, and mixtures thereof.
OTHER OPTIONAL INGREDIENTS
The present invention can include other optional components (minor components) conventionally used in textile treatment compositions, for example, dyes, colorants, preservatives, optical brighteners, opacifiers, stabilizers such as guar gum, antifoam agents, silicones, and the like.
(F) USAGE
The bar compositions of this invention can be used for imparting the above-described fabric treatment composition to fabric to provide softening and/or antistatic effects to fabric during or after the rinse step of the laundry process, especially a hand washing laundry process. Generally, the method of using the bar compositions of the present invention comprises: washing a bundle of fabrics or a single fabric item with an effective amount of a detergent composition, rinsing the bundle of laundered fabrics or the single item of fabric with water; and applying an effective amount of the fabric treatment bar composition to the bundle of laundered fabrics or the single item of fabric. The entire bundle of fabrics can be sorted so that only selected fabrics are softened. An effective amount of the fabric treatment bar composition is that amount which is transferred to a fabric item when the consumer rubs the bar back and forth over the fabric item for about 5 seconds to about 1 minute, preferably for about 5 seconds to about 15 seconds. Preferably the rubbing is accomplished while the fabric item is laying fiat over a scrubboard. Thereafter, the fabric item is rubbed over the scrub board for about 5 seconds to about 1 minute, preferably for about 10 seconds to about 20 seconds, to evenly spread the composition over the fabric item. The consumer thereafter squeezes the excess water from the fabric item and hangs the fabric item to dry.
Because the consumer rubs the compositions of the present invention directly on the fabric item, excellent deposition of the softening actives occurs.
Preferably, after application of the fabric softening composition to the fabric item, the consumer does not have to re-rinse the fabric item because little or no sudsing and/or lather are formed. This, in turn, promotes greater perfume deposition.
(G) METHOD OF MAKING THE BAR COMPOSITION
The bar compositions of the present invention are preferably made by the following frame process:
I. forming a homogeneous pourable molten mixture of the water, fabric softener compound, and nonionic surfactant and any non-perfume optional ingredients in a mixing vessel with stirring at a temperature of from about 50.degree. C. (120.degree. F.) to about 95.degree. C. (205.degree. F.), preferably from about 75.degree. C. to about 95.degree. C.;
II. adding perfume;
III. pouring or discharging the homogeneous pourable molten mixture into a bar shaped mold; and
IV. crystallizing the molded molten mixture by cooling to room temperature (i.e. from about 20.degree. C. to about 25.degree. C.).
The bars are thereafter removed from the molds.
The process Step IV cooling can be done under refrigeration or freezing conditions.
Step I can optionally be completed under an atmosphere containing no/low water, i.e., under an inert gas such as N.sub.2, especially for diester quaternary ammonium compounds.
Preferably a processing aid is added to Step I as an optional ingredient to lower the viscosity of the molten mixture so that the homogeneous mixture is more easily poured into the bar molds.
The compositions of the present invention can optionally comprise from about 0.1% to about 5%, preferably from about 0.25% to about 2% of a processing aid. Processing aids include salts and/or low molecular alcohols such as monohydric, dihydric (glycol, etc.), trihydric (glycerol, etc.), and polyhydric (polyols) alcohols. Especially preferred processing aids are ethanol, propylene glycol, sodium sulfate, sodium citrate, PEG 400, butane diol, and mixtures thereof.
The mixture of Step I comprises: from about 5% to about 30% of the water, from about 40% to about 90% of the fabric softening compound, and from about 5% to about 30% of the nonionic surfactant, with from 0.25% to about 2% of ethanol to reduce the viscosity of the molten composition.
(H) BAR FIRMNESS
The bar firmness, i.e., strength of the structure, can be measured by the resistance to penetration of the bar using a Precision Scientific Penetrometer Probe, as measured at 25.degree. C., having a conical needle attached to a 11 inch (22.9 cm) shaft, with standard weights of 50 grams, 100 grams, and 150 grams on top of said shaft.
The bars of the present invention have the following acceptable bar firmness characteristics as outlined in the following table (Table A):
TABLE A______________________________________Weight in grams above theshaft of the Precision Scientific AcceptablePenetrometer Probe Penetrometer Values______________________________________ 50 grams Up to about 8 mm, preferably up to about 7 mm, more preferably up to about 5 mm.100 grams Up to about 10 mm, preferably up to about 8 mm, more preferably up to about 7 mm.150 grams Up to about 12 mm, preferably up to about 10 mm, more preferably up to about 8.5 mm.______________________________________
All percentages, ratios, and parts herein, in the Specification, Examples, and Claims, are by weight and are approximations unless otherwise stated.

EXAMPLES
The following examples further describe and demonstrate embodiments within the scope of the present invention. The examples given are solely for the purpose of illustration and are not to be construed as limitations of the present invention, as many variations thereof are possible without departing from the spirit and scope of the invention.
______________________________________ ApproximatePerfume Ingredients B.P. (.degree.C.) ClogP Wt. %______________________________________Perfume ATonalid -- -- 20Ethylene brassylate 332 4.554 20Phantolide +300 5.482 20Hexyl cinnamic aldehyde 305 5.473 20Tetrahydro linalool 191 3.517 20 Total 100Perfume B Woody Floral - Jasmin TypeGeranyl acetate -- -- 8beta-Ionone -- -- 5Cis-Jasmone -- -- 1Methyl dihydrojasmonate -- -- 10Suzaral T -- -- 3para-tert-Butyl cyclohexyl acetate -- -- 10Amyl cinnamic aldehyde 285 4.324 4iso-Amyl salicylate 277 4.601 8Benzophenone 306 3.120 2Cedrol 291 4.530 3Cedryl formate +250 5.070 1Hexyl cinnamic aldehyde 305 5.473 10Musk indanone +250 5.458 3Patchouli alcohol 285 4.530 2Phenyl hexanol 258 3.299 8Ylangene 250 6.268 2Benzyl Acetate 215 1.960 6Linalool 198 2.429 7Linalyl acetate 220 3.500 7 Total 100M.P, is melting point; this ingredient has a B.P. higher than 250.degree.C.Perfume C Fruity Floralgamma-Nonalactone -- -- 3Tonalid -- -- 10Vertenex -- -- 5Verdox -- -- 3Allyl cyclohexane propionate 267 3.935 4Amyl benzoate 262 3.417 2Amyl cinnamic aldehydedimethyl acetal 300 4.033 5Aurantiol 450 4.216 3Dodecalactone 258 4.359 3Ethylene brassylate 332 4.554 5Ethyl methyl phenyl glycidate 260 3.165 2Galaxolide (50% in IPM) +250 5.482 12Hexyl cinnamic aldehyde 305 5.473 10Hexyl salicylate 290 5.260 10Lilial (p-t-bucinal) 258 3.858 10Undecavertol 250 3.690 2Allyl caproate 185 2.772 3Fructone -- -- 8 Total 100Perfume D Rose FloralDimethyl benzyl carbinyl acetate -- -- 5Phenyl ethyl dimethyl carbinol -- -- 5Phenyl ethyl dimethyl carbinyl -- -- 5acetateiso-Amyl salicylate 277 4.601 10Benzophenone 306 3.120 5Cyclamen aldehyde 270 3.680 5Diphenyl oxide 252 4.240 10Geranyl phenyl acetate +250 5.233 1Hexyl cinnamic aldehyde 305 5.473 10gamma-n-Methyl ionone 252 4.309 5Lilial (p-t-bucinal) 258 3.858 10Phenyl hexanol 258 3.299 6Phenyl heptanol 261 3.478 2Phenyl ethyl alcohol 220 1.183 15alpha-Terpineol 219 2.569 6 Total 100Perfume E Woody Muskalpha-Ionone -- -- 2gamma-Ionone -- -- 2Koavone -- -- 8Methyl dihydrojasmonate -- -- 6Phenoxy ethyl iso-butyrate -- -- 8Tonalid -- -- 8Ambrettolide 300 6.261 5Ambrox DL 250 5.400 2Exaltolide 280 5.346 5Galaxolide (50% in IPM) +250 5.482 10Hexadecanolide 294 6.805 1gamma-n-Methyl ionone 252 4.309 5iso E super +250 3.455 8Musk indanone +250 5.458 9Musk tibetine MP = 136.degree. C.(*) 3.831 5Pachouli alcohol 283 4.530 5Vetiveryl acetate 285 4.882 5Cetalox -- -- 1Coumarin 291 1.412 5 Total 100(*)M.P. is melting point, this ingredient has a B.P. higher than250.degree. C.Perfume F Fruity Floral PowderEthyl Vanillin -- -- 2Lauric Aldehyde -- -- 1Methyl dihydrojasmonate -- -- 3Methyl nonyl acetaldehyde -- -- 1Suzaral T -- -- 5Tonalid -- -- 5Veloutone -- -- 2Verdol -- -- 3Allyl cyclohexane propionate 267 3.935 3Amyl cinnamic aldehydedimethyl acetal 300 4.033 8Cyclamen aldehyde 270 3.680 5Cedryl acetate 303 5.436 2Ethylene brassylate 332 4.554 8Hexyl cinnamic aldehyde 305 5.473 11Hexyl salicylate 290 5.260 5Pachouli alcohol 283 4.530 5Phenyl hexanol 258 3.299 10Benzoin Claire 50% in DEP 344 2.380 3Cinnamic alcohol 258 1.950 2Citral 228 3.120 3Geranyl nitrile 222 3.139 5d-Limonene (Orange terpenes) 177 4.232 8 Total 100______________________________________
The following perfumes containing large amounts of other enduring perfume ingredients can also be used, with the addition of sufficient perfume ingredients selected from the group consisting of: cis-jasmone; dimethyl benzyl carbinyl acetate; ethyl vanillin; geranyl acetate; alpha-ionone; beta-ionone; gamma-ionone; koavone; lauric aldehyde; methyl dihydrojasmonate; methyl nonyl acetaldehyde; gamma-nonalactone; phenoxy ethyl iso-butyrate; phenyl ethyl dimethyl carbinol; phenyl ethyl dimethyl carbinyl acetate; alpha-methyl-4-(2-methylpropyl)-benzenepropanal; 6-acetyl-1,1,3,4,4,6-hexamethyl tetrahydronaphthalene; undecylenic aldehyde; vanillin; 2,5,5-trimethyl-2-pentyl-cyclopentanone; 2-tert-butylcyclohexanol; verdox; para-tert-butylcyclohexyl acetate; and mixtures thereof, so that the level of ingredients having a boiling point of at least about 250.degree. C. and a ClogP of at least about 3 is less than about 70% of the composition.
______________________________________ ApproximatePerfume Ingredients B.P. (.degree.C.) ClogP Wt. %______________________________________Perfume GBenzyl acetate 215 1.960 4Benzyl salicylate 300 4.383 12Coumarin 291 1.412 4Ethylene brassylate 332 4.554 10Galaxolide - 50%.sup.(a) +300 5.482 10Hexyl cinnamic aldehyde 305 4.853 20Lilial 258 3.858 15Methyl dihydro isojasmonate +300 3.009 5gamma-n-Methyl ionone 252 4.309 10Patchouli alcohol 283 4.530 4Tetrahydro linalool 191 3.517 6 Total 100.sup.(a) used as a 50% solution in isopropyl myristate which is notcounted in thecomposition. Perfume G contains about 86% of enduring perfume componentshaving BP > 250.degree. C. and ClogP > 3.0.Perfume H Fruity FloralAllyl cyclohexane propionate 267 3.935 4Amyl benzoate 262 3.417 2Amyl cinnamic aldehyde 300 4.033 5dimethyl acetalAurantiol 450 4.216 3Dodecalactone 258 4.359 3Ethylene brassylate 332 4.554 5Ethyl methyl phenyl glycidate 260 3.165 2Exaltolide 280 5.346 5Galaxolide (50% in IPM) +250 5.482 1 5Hexyl cinnamic aldehyde 305 5.473 13Hexyl salicylate 290 5.260 10iso E super +250 3.455 8Lilial (p-t-bucinal) 258 3.858 10gamma-Undecalactone 297 4.140 3.5delta-Undecalactone 290 3.830 0.5Allyl caproate 185 2.772 3Fructone -- -- 8 Total 100Perfume I FloralBenzyl salicylate 300 4.383 5iso-Butyl quinoline 252 4.193 1beta-Caryophyllene 256 6.333 1Cyclohexyl salicylate 304 5.265 2Dihydro isojasmonate +300 3.009 9Ethyl undecylenate 264 4.888 2Galaxolide (50% in IPM) +250 5.482 10Hexyl cinnamic aldehyde 305 5.473 15Hexenyl salicylate 271 4.716 1.9alpha-Irone 250 3.820 0.1Lilial (p-t-bucinal) 258 3.858 16Methyl dihydrojasmonate .about.300 2.420 92-Methoxy naphthalene 274 3.235 2Phenyl ethyl benzoate 300 4.058 2Phenylethylphenylacetate 325 3.767 2Tonalid 248 6.247 4Citronellol 225 3.193 9Phenyl ethyl alcohol 220 1.183 10 Total 100Perfume J Rose Floraliso-Amyl salicylate 277 4.601 10Benzophenone 306 3.120 5Cyclamen aldehyde 270 3.680 5Diphenyl oxide 252 4.240 19Geranyl phenyl acetate +250 5.233 1Hexyl cinnamic aldehyde 305 5.473 10gamma-n-Methyl ionone 252 4.309 5Lilial (p-t-bucinal) 258 3.858 10Phenyl hexanol 258 3.299 8Phenyl heptanol 261 3.478 2Phenyl ethyl alcohol 220 1.183 15alpha-Terpineol 219 2.569 10 Total 100Perfume K Woody MuskAmbrettolide 300 6.261 5para-tert-Butyl cyclohexyl acetate +250 4.019 10Cedrol 291 4.530 10Exaltolide 280 5.346 5Galaxolide (50% in IPM) +250 5.482 15Hexadecanolide 294 6.805 1gamma-n-Methyl ionone 252 4.309 10iso E super +250 3.455 8Musk indanone +250 5.458 9Musk tibetine MP = 136.degree. C.(*) 3.831 5Pachouli alcohol 283 4.530 5Vetiveryl acetate 285 4.882 5Methyl dihydrojasmonate +300 2.420 6Cetalox -- -- 1Coumarin 291 1.412 5 Total 100(*)M.P. is melting point; this ingredient has a B.P. higher than250.degree. C.Perfume L Fruity Floral PowderAllyl cyclohexane propionate 267 3.935 3Amyl cinnamic aldehydedimethyl acetal 300 4.033 8Aurantiol .about.300 4.216 3Cyclamen aldehyde 270 3.680 5Cedryl acetate 303 5.436 2Ethylene brassylate 332 4.554 8Gataxolide (50% in IPM) +250 5.482 5Hexyl cinnamic aldehyde 305 5.473 12Hexyl salicylate 290 5.260 5Lilial (p-t-bucinal) 258 3.858 5Myristicin 276 3.200 2Pachouli alcohol 283 4.530 5Phenyl hexanol 258 3.299 10Anisic Aldehyde 248 1.779 1Benzoin Claire 50% in DEP 344 2.380 3Cinnamic alcohol 258 1.950 2Citral 228 3.120 3Decyl aldehyde 209 4.008 1Ethyl Vanillin .about.303 1.879 0.5Geranyl nitrile 222 3.139 5Methyl dihydrojasmonate .about.300 2.420 3.5d-Limonene (Orange terpenes) 177 4.232 8 Total 100Perfume M Woody Powder FloralAmyl cinnamate 310 3.771 5Amyl cinnamic aldehyde 285 4.324 8para-tert-Butyl cyclohexyl acetate +250 4.019 10Cadinene 275 7.346 1Cedrol 291 4.530 5Cinnamyl cinnamate 370 5.480 5Diphenyl methane 262 4.059 3Dodecalactone 258 4.359 3Exaltolide 280 5.346 2Geranyl anthranilate 312 4.216 2Lilial (p-t-bucinal) 258 3.858 3.5gamma-Methyl ionone 252 4.309 5Musk indanone +250 5.458 5Musk ketone MP = 137.degree. C.(*) 3.014 0.5Musk tibetine MP = 136.degree. C.(*) 3.831 3beta-Naphthol methyl ether 274 3.235 2(yara-yara)Pachouli alcohol 283 4.530 4Phantolide 288 5.977 5alpha-Santalol 301 3.800 3Ethyl cinnamate 271 2.990 1Hexyl cinnamic aldehyde 305 5.473 10Anisic Aldehyde 248 1.779 0.5Linalyl acetate 220 3.500 2Linalool 198 2.429 2Methyl anthranilate 237 2.024 0.5Benzoin Claire 50% in DEP 344 2.380 4Ethyl Vanillin .about.303 1.879 1Methyl cinnamate 263 2.620 1Vanillin 285 1.275 3 Total 100______________________________________
______________________________________Examples I-III I II IIIINGREDIENT (wt %) (wt %) (wt %)______________________________________Tallowyl Dimethyl Amine Stearate 62.7 -- --DTDMAC.sup.1 -- 63 --Softener Compound.sup.2 -- -- 63Steareth-10.sup.3 19 19 19Ethanol -- 10 3Perfume A 0.4 -- --Perfume B -- 0.2 --Perfume C -- -- 0.15Dye, Misc. 0.51 0.01 0.01Water 17.39 7.79 14.84Total 100 100 100______________________________________ .sup.1 Ditallowdimethyl ammonium chloride available under the tradename Adogen .RTM. 448E from Sherex Co. .sup.2 Di(tallowoyloxyethyl) dimethyl ammonium chloride. .sup.3 polyethylene glycol ether of stearyl alcohol with approximately 10 ethylene oxide units available under the Tradename Brij .RTM. 76 from ICI Americas.
______________________________________Examples IV-VI IV V VIINGREDIENT (wt %) (wt %) (wt %)______________________________________Tallowyl Dimethyl Amine Stearate -- 70 70Sorbitan Monostearate 63 -- --Steareth-10.sup.1 19 -- --Pareth-45-7.sup.2 -- 13 --Pareth-45-13.sup.3 -- -- 13Ethanol 2 2 --Perfume D 0.1 -- --Perfume E -- 0.1 --Perfume F -- -- 0.4Dye, Misc. 0.01 0.01 0.46Water 15.89 14.89 16.14Total 100 100 100______________________________________ .sup.1 Polyethylene glycol ether of stearyl alcohol with approximately 10 ethylene oxide units available under the Tradename Brij .RTM. 76 from ICI America. .sup.2 C.sub.14 -C.sub.15 Pareth7 available under the Tradename Neodol .RTM. 457 from Shell Co. .sup.3 C.sub.14 -C.sub.15 Pareth13 available under the Tradename Neodol .RTM. 4513 from Shell Co.
______________________________________Examples VII-X VII VIII IX X (wt %) (wt %) (wt %) (wt %)______________________________________Tallowyl Dimethyl Amine Stearate 70 69.7 69.3 69Polysorbate 61.sup.1 13 -- -- --PEG-8 Stearate.sup.2 -- 13 -- --PEG-200 Trihydroxystearin.sup.3 -- -- 13 --Nonyl Nonoxynol-49.sup.4 -- -- -- 13Ethanol 2 2 2 2Perfume B 0.1 -- -- --Perfume C -- 0.4 -- --Perfume D -- -- 0.7 --Perfume E -- -- -- 1Dye, Misc. 0.01 0.01 0.01 0.01Water 14.89 14.89 14.89 14.89Total 100 100 100 100______________________________________ .sup.1 Available under the Tradename Tween .RTM. 61 from ICI America. .sup.2 Available under the Tradename Pegosperse 400 MS from Glyco Corp. .sup.3 Available under the Tradename Surfactol .RTM. 590 from ChasChem. .sup.4 Available under the Tradename Igepal .RTM. DM880 from RhonePoulenc Inc.
The above bar compositions are made by the following process:
The fabric softening compound (tallowyldimethylamine stearate, ditallowdimethyl ammonium chloride, di(tallowoyloxyethyl)dimethyl ammonium chloride, and sorbitan monostearate), and the nonionic surfactant (i.e., Steareth-10, Pareth-457, Pareth 4513, Polysorbate 61, PEG-8 stearate, PEG-200 Trihydroxy stearin, and Nonyl Nonoxynol-49) are separately melted and charged into a jacketed mixing vessel containing a paddle mixer. The mixture is kept molten at about 75.degree.-85.degree. C. A pre-mix of water, ethanol, and dye are heated to the same temperature and pumped to the mixing vessel under low-moderate agitation for a very short interval. Perfume is added, and a very brief period of mixing is given. The contents of the vessel are then discharged into a heated pneumatic filler and dispensed into plastic molds to form the desired shape. The solid bars are ready to be removed from the molds within 2 hours.
All of the above bars produce very low levels of suds and/or lather. The compositions transfer readily onto fabric with minimal effort. All bar compositions maintain integrity (i.e., low/no smear) when immersed in water for extended periods of time. Fabrics treated with the above bars are very soft and possess a high level of fragrance. The bars' satisfactory firmness is reflected by their acceptable penetrometer values.
When the enduring perfumes in the above bars are replaced with Perfumes G-M, as modified, similar results are obtained in that the bars provide enduring perfume remits.

Number	Name	Date
3947971	Bauer	Apr 1976
4299716	Cottrell et al.	Nov 1981
4705644	Barone et al.	Nov 1987
5043091	Joshi et al.	Aug 1991
5053159	Joshi	Oct 1991
5500137	Bacon et al.	Mar 1996

Fabric softening bar compositions containing fabric softener and enduring perfume

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US Referenced Citations (6)

Non-Patent Literature Citations (2)

Entry
"A Quantitative Study of Factors that Influence the Substantivity of Fragrance Chemicals on Laundered and Dried Fabrics", Escher et al., JAOCS, vol. 71, No. 1 (Jan. 1994).
"What Makes a Fragrance Substantive?", Muller et al., Givaudan-Roure Research Ltd., CH-6800 Dubendorf Switzerland (Oct. 1992).