Patent Grant
11692153
The present application is US national stage of international application PCT/EP2019/067540, which had an international filing date of Jul. 1, 2019 and which was published on Jan. 9, 2020. The application claims priority under 35 USC § 119 to European application 18181831.1, filed in on Jul. 5, 2018. The contents of the priority application is hereby incorporated by reference in its entirety.
The invention relates to specific active compositions for producing highly viscous laundry and cleaning formulations, particularly laundry fabric softeners, to a method for the production thereof and to laundry and cleaning formulations comprising said active compositions. High viscosity can be achieved in the products according to the invention despite a low concentration of active compositions and without using additional thickeners.
In regional markets, Brazil for example, laundry and cleaning formulations, particularly fabric softeners, are required which have a high viscosity at low active contents, i.e. a low content of quaternary ammonium compounds.
Solely by the use of quaternary ammonium compounds, also referred to below as “quats” or “ester quats”, such as Rewoquat WE 18 for example, the required viscosity could not be achieved to date. For instance, using triethanolamine-based ester quats, as described for example in WO 2014/143182 A2, DE 10 2010 030 217 A1 and DE 197 43 687 C1, in the case of sole use of the quat, viscosities of only at most 500 mPas are achieved.
DE2928603 discloses, inter alia, so-called “hybrid” quats. These are characterized in that, in addition to alkanol and alkanol ester radicals, they also comprise a long-chain alkyl radical. The hybrid quats of DE2928603 are intended to impart a pleasant softness to the laundry. Viscosities of the fabric softeners produced with these hybrid quats are not specified in DE 2928603. However, it is indicated that further substances and auxiliaries have to be added to the fabric softener composition to adjust, inter alia, the viscosity. Such addition of auxiliaries, especially thickeners, is customary in the prior art, but is associated with ecological and economic disadvantages.
WO 2016/055341 describes active compositions comprising bis(2-hydroxypropyl)dimethylammonium methylsulfate fatty acid ester, with which aqueous and storage-stable fabric softener formulations can be produced having high viscosity. A disadvantage of these active compositions is that relatively large amounts have to be used to enhance viscosity.
US 2006/0264352 A1 describes fabric softener formulations comprising ester quats having high viscosity. In order to achieve high viscosity, long-chain alkylamines have to be added as viscosity regulators.
There is therefore a need for novel active compositions and of laundry and cleaning formulations, especially fabric softeners, which do not have the disadvantages of the prior art or only to a lesser degree, which preferably can render the use of thickeners obsolete.
It was therefore the object of the present invention to provide novel active compositions and novel laundry and cleaning formulations, especially fabric softener formulations, which do not have the disadvantages of the prior art or only to a lesser degree.
In one specific object, the laundry and cleaning formulations, solely by means of the active compositions according to the invention, without adding additional thickeners, should have a sufficiently high viscosity at the required low active content.
In a further object, it should be possible, solely by the use of the active compositions according to the invention, to be able to adjust the viscosity of laundry and cleaning formulations over a broad spectrum.
In a further preferred object, fabric softener products according to the invention should have at least a comparable fabric softening effect as products of the prior art.
A further object can be considered to be that of providing laundry and cleaning formulations, especially fabric softener products, which are biodegradable.
Other objects not explicitly mentioned will be apparent from the entirety of the present description, claims and examples.
Before the invention is described in detail, a number of terms will first be defined:
In the context of the present invention, “active compositions” are understood to mean compositions comprising mixtures of ester quats of the general formula I defined in more detail below. The activity of these ester quats is characterized, inter alia, by their thickening effect, but on the other hand also by their fabric softening effect. The active compositions may consist exclusively of ester quats of the general formula I, but they can also be diluted with a solvent, for example for better handling.
“Laundry and cleaning formulations” are understood to mean all types of laundry and cleaning formulations in which ester quats are customarily used. These preferably take the form of fabric softener formulations. The laundry and cleaning formulations according to the invention may comprise but also consist only of the active compositions according to the invention. Typically, they comprise at least a perfume oil and water in addition to the active compositions according to the invention.
In the context of the present invention, “high viscosity” is understood to mean a viscosity of more than 500 mPas, preferably more than 750 mPas, particularly preferably more than 1000 mPas.
In the context of the present invention, a laundry and cleaning formulation with “low active content” is understood to mean a laundry and cleaning formulation comprising in total a content of active compositions according to the invention of less than 5% by weight, more preferably less than 3% by weight, based on the total composition of the laundry and cleaning formulations.
Surprisingly, it has been found that active compositions according to claim 1 and laundry and cleaning formulations, especially fabric softener formulations, comprising these active compositions according to claim 7, solve the stated objects. The active compositions according to the invention comprise mixtures of specific ester quats of the general formula I defined further in more detail below. By means of their use, fabric softener formulations could be obtained which have a high viscosity despite having a low active content. The viscosities were at least 10% above the maximum achieved 500 mPas of the prior art and reached up to 2400 mPas. Therefore, solely by the use of the active compositions according to the invention, it has been possible to adjust the viscosity of the fabric softener formulation over a very broad spectrum at a low active ingredient content.
The ester quats used according to the invention enable the production of ecologically favourable laundry and cleaning formulations.
In addition, the laundry and cleaning formulations according to the invention can be produced with high viscosity at a low content of active compositions without adding thickeners. This increases the ecological, but also economic advantages. The fact that the laundry and cleaning formulations according to the invention can be produced without adding thickeners does not in principle exclude their use.
The present invention accordingly provides active compositions according to claim 1 and a method for the preparation thereof according to claim 6. Further provided are laundry and cleaning formulations, preferably fabric softener formulations, comprising the inventive active compositions according to claim 7 and the use of the inventive active compositions according to claim 8. Preferred embodiments are claimed in the dependent claims.
The present invention provides in particular active compositions for producing laundry and cleaning formulations, preferably fabric softener formulations, which are characterized in that they comprise a mixture of two or more quaternary ammonium salts of the general formula I)
where
where R1, R2 and R4 have the same definition as in formula I), being reacted with one or more fatty acids corresponding to R3 and R5, in the molar ratio of the sum of all amines of the general formula II) to the sum of all fatty acids of from 0.8 to 1.5, preferably 0.8 to 1.4, particularly preferably 0.85 to 1.3, and especially preferably 0.9 to 1.2.
As shown in comparative example V7, a too low molar ratio results in non-inventive active compositions having a distinctly lower thickening capacity. A molar ratio, which is too high, results in the same effect, i.e. in a decrease of the thickening capacity.
The selection of the alkylating agent for the quaternization, especially of X−, also has a crucial influence on the thickening capacity of the quats. As shown in comparative examples V1 and V2, thickening by quats where X−=Cl− is considerably worse than those where X−=MeSO4−.
Finally, the inventors found out that, surprisingly, the alkyl radical R1 should have a high mobility, i.e. a low number of double bonds, preferably no double bonds. This is shown in the examples in the comparison of R1=tallow (see comparative examples V3 to V6) with R1=hydrogenated tallow. The proportion of double bonds in R1 is expressed by the iodine number. The radicals R1 used in accordance with the invention have an iodine number of less than or equal to 10, preferably less than or equal to 8, particularly preferably from 0 to 5.
R1 is preferably a hydrocarbon radical which is the hydrocarbon radical of fatty alcohols. In the context of the present invention, a “hydrocarbon radical of a fatty alcohol” is the structure remaining after deletion of the OH group of the fatty alcohol. A preferred radical R1 is a hydrocarbon radical of an unbranched or branched monoalcohol having an alkyl group of 10 to 22 carbon atoms. Preferred radicals R1 are hydrocarbon radicals of cetyl alcohol, palmoleyl alcohol, stearyl alcohol, isostearyl alcohol, anteisostearyl alcohol, eicosanol, petroselinyl alcohol, Guerbet alcohol, arachyl alcohol, gadoleyl alcohol, and mixtures thereof, especially of technical-grade mixtures, preferably of technical-grade stearyl, palmityl or hydrogenated tallow fatty alcohols having 12 to 22, preferably having 14 to 20 carbon atoms, and also of the monounsaturated fatty alcohols such as oleyl alcohol, elaidyl alcohol, delta-9-cis-hexadecenol, delta-9-octadecenol, trans-delta-9-octadecenol, cis-delta-11-octadecenol, trans-10,cis-12-hexadecadien-1-ol, octacosa-10,19-dien-1-ol, wherein particular preference is given to hydrocarbon radicals of mixtures of stearyl or hydrogenated tallow fatty alcohols having 14 to 22, particularly preferably 14 to 18 and especially preferably 16 to 18 carbon atoms.
If mixtures of hydrocarbons of fatty alcohols are used as R1, especially technical-grade mixtures, the iodine number is the average iodine number of the mixture. The same applies to the fatty acids described further below, i.e. the radicals R3 and R5.
Since the quats of the general formula I are obtained by reacting one or more amine(s) of the general formula II) defined above with one or more fatty acids corresponding to R3 and R5, in the molar ratio defined above, the result is that a proportion of the OH groups of the amine as such remain intact. This is important in order to ensure the correct polarity of the quats. Furthermore, it follows from this that a mixture of different quats of the general formula I is obtained in the reaction in which either both OH groups or only one OH group or neither OH group is esterified. Therefore, R3 and R5 can either both be acyl or both H or one of the two is acyl and one is H. If the radicals R3 and R5 are both acyl radicals, they are preferably acyl esters of the same fatty acid or fatty acid mixture.
Preferred fatty acids for R3 and R5 are selected from
R2 and R4 are preferably identical and preferably both are C2H4 or both are C3H6; particularly preferably both are C2H4.
Particularly preferred active compositions according to the invention are mixtures of quaternary ammonium compounds of the general formula I), wherein the radicals R1 to R6 and X− are selected from the following groups:
The active compositions according to the invention result in that the laundry and cleaning formulations, preferably fabric softener formulations produced therewith, already have high viscosities at low contents of these active compositions and without additional thickeners. The laundry and cleaning formulations, preferably fabric softener formulations according to the invention, therefore include the active compositions according to the invention preferably in an amount from 1% by weight to 6% by weight, particularly preferably from 2% by weight to 5% by weight, where the percentages by weight refer to the total composition.
In addition, the laundry and cleaning formulations, preferably fabric softener formulations, may also comprise water and further additives and/or auxiliaries, e.g. selected from the group comprising emollients, pearlescent additives, dyes, insect repellents, preservatives, perfumes, dyes and defoamers, in the laundry and cleaning formulations. The amounts of the particular additives are determined by the intended use.
Typical guide formulations for the respective applications are known prior art and are contained for example in the brochures of the manufacturers of the particular basic materials and active ingredients. These existing formulations can generally be adopted unchanged. If necessary, the desired modifications can, however, be undertaken without complication by means of simple experiments for the purposes of adaptation and optimization.
The active compositions according to the invention are preferably prepared by a method comprising the following steps of:
Preferably, the active composition mixture obtained according to step b), for better handleability, is diluted in step
The active compositions according to the invention particularly preferably consist only of the mixture obtained according to step b) or the diluted mixture obtained according to step c).
Technologies for carrying out steps a) and b) are known per se to those skilled in the art.
The active compositions according to the invention obtained according to step b) or c) are further processed to produce the laundry and cleaning formulations, preferably fabric softener formulations according to the invention, preferably as follows:
Water is initially charged in a stirred vessel and heated to a temperature between 20 and 60° C. The active compositions are melted and brought to a temperature between 30 and 60° C. The melt is introduced into the water charge with vigorous stirring. The dispersion thus obtained is cooled and optionally further additives described in detail below are added.
As already mentioned, the active compositions according to the invention are used as active ingredients in laundry and cleaning formulations. They can in principle be used in any laundry and cleaning formulation in which quats are used in customary fashion. They are particularly preferably used in laundry and cleaning formulations which should have a high viscosity and especially preferably in those which should have a high viscosity at a low active content.
Most preferably, the laundry and cleaning formulations are fabric softeners. Preferred fabric softener formulations according to the invention for the household and industrial and institutional applications, comprising at least one of the active compositions according to the invention, are laundry detergents, laundry care products, disinfecting laundry detergents, heavy-duty laundry detergents, light-duty laundry detergents, wool laundry detergents, fabric softeners and impregnating agents, particular preference being given to laundry detergents, laundry care products, heavy-duty laundry detergents, light-duty laundry detergents, wool laundry detergents, fabric softeners, impregnating agents, especially fabric softeners.
A fabric softener formulation according to the invention preferably comprises the active compositions according to the invention in an amount of 1% by weight to 5% by weight, preferably of 2% by weight to 4% by weight, where the percentages by weight are based on the overall formulation. The remaining mass to 100% by weight preferably consists of water and/or at least one additive and/or auxiliary selected from the group of the emollients, viscosity regulators, pearlescent additives, dyes, insect repellents, preservatives, perfumes, dyes and defoamers.
The perfume used may be any of the fragrances or fragrance mixtures known to be suitable for fabric softeners from the prior art, preferably in the form of a perfume oil. Examples of fragrances or scents are disclosed inter alia in DE 197 51 151 A1, page 4, lines 11-17. More particularly, the compositions according to the invention may contain from 0.01% to 10% by weight, more preferably 0.1% to 5% by weight, based on the overall composition of the composition, of one or more perfumes.
Dyes used may be any dyes known to be suitable for fabric softeners from the prior art, preference being given to water-soluble dyes. Examples of suitable water-soluble commercial dyes are SANDOLAN® Walkblau NBL 150 (manufacturer: Clariant) and Sicovit® Azorubin 85 E122 (manufacturer: BASF). More particularly, the compositions according to the invention may contain from 0.001% to 0.1% by weight, more preferably from 0.002% to 0.05% by weight, of one or more dyes.
As already mentioned previously, no viscosity regulators are required in the laundry and cleaning formulations, especially fabric softener formulations according to the invention, since the viscosity can be adjusted solely with the aid of the active compositions according to the invention. However, the addition of other viscosity regulators is nevertheless not excluded. For instance, the viscosity regulator for reducing viscosity may be an alkali metal or alkaline earth metal salt, or mixtures thereof, preferably calcium chloride, preferably in an amount of 0.05% to 2% by weight, based on the overall composition of the composition.
As viscosity regulator for increasing the viscosity, the fabric softener may comprise a thickener known from the prior art, preference being given to the polyurethane thickeners known from WO 2007/125005. Examples of suitable thickeners are TEGO® Visco Plus 3030 (manufacturer: Evonik Tego Chemie), Acusol® 880 and 882 (manufacturer: Rohm & Haas), Rheovis® CDE (manufacturer: BASF), Rohagit® KF 720 F (manufacturer: Evonik Röhm GmbH) and Polygel® K100 from Neochem GmbH.
Defoamers used may be any defoamers known to be suitable for fabric softeners from the prior art. Examples of suitable commercial defoamers are Dow Corning® DB-110A and TEGO® Antifoam® 7001 XP. More particularly, the compositions according to the invention may contain from 0.0001% to 0.05% by weight, preferably from 0.001% to 0.01% by weight, of one or more different defoamers.
As preservative, the fabric softener may comprise active bactericidal and/or fungicidal ingredients known to be suitable from the prior art, preference being given to water-soluble active ingredients. Examples of suitable commercial bactericides are methylparaben, 2-bromo-2-nitropropane-1,3-diol, 2-methyl-4-isothiazolin-3-one and 5-chloro-2-methyl-4-isothiazolin-3-one. The aqueous fabric softener may likewise comprise an oxidation inhibitor as preservative. Examples of suitable commercial oxidation inhibitors are ascorbic acid, 2,6-di-tert-butyl-4-methylphenol (BHT), butylhydroxyanisole (BHA), tocopherol and propyl gallate. More particularly, the compositions according to the invention may contain from 0.0001% to 0.5%, more preferably 0.001% to 0.2% by weight, of one or more different preservatives. More particularly, the compositions according to the invention may contain from 0.001% to 0.1% by weight, preferably 0.001% to 0.01% by weight, of one or more different oxidation inhibitors.
The amounts of the particular additives are determined by the intended use.
Typical guide formulations for the respective applications are known prior art and are contained for example in the brochures of the manufacturers of the particular basic materials and active ingredients. These existing formulations can generally be adopted unchanged. If necessary, the desired modifications can, however, be undertaken without complication by means of simple experiments for the purposes of adaptation and optimization.
5.1 Determination of the Iodine Number
The iodine number specifies how many grams of halogen, calculated as iodine, of 100 g of an examined sample are bonded under the conditions of a method. In accordance with the invention, the measuring method by Wijs is applied in accordance with DIN 53241-1:1995-05.
Whereas the iodine number of the radical R1 on the amine of the general formula (II) can be measured directly, the iodine number of the quaternary ammonium compound of the general formula (I) is measured by firstly saponification of the acyl radicals using alkali and separation of the fatty acids and ammonium compounds thus obtained by known methods. The iodine number of R1, from the ammonium compound, and that of the fatty acids can then be determined according to the method of Wijs.
5.2 Determination of the Viscosity of the Laundry and Cleaning Formulations
The measurement of the viscosity is carried out using a Brookfield LVT viscometer and a spindle suitable for the viscosity range at a temperature of 25° C. and 30 rpm.
The examples adduced hereinafter describe the present invention by way of example, without any intention that the invention, the scope of application of which is apparent from the entirety of the description and the claims, should be restricted to the embodiments specified in the examples.
6.1 Starting Materials Used:
6.1.1 Amines of the General Formula II:
6.1.2 Fatty Acids:
6.1.3 Alkylating Agents
6.2 General Preparation Method of the Quaternary Ammonium Compounds:
571 g (1.588 mol) of amine A1 were placed in a three-necked flask equipped with column, distillation system and stirrer motor and heated to 80° C. under a nitrogen atmosphere. To this were added 352.2 g (1.271 mol) of fatty acid FA 3 and 0.46 g of 50% aqueous hypophosphorous acid. A vacuum of 100 mbar was applied and the mixture was cautiously heated to 195° C., wherein water of reaction was collected in the outflow of the distillation system. After 2.5 hours, the vacuum was lowered to 20 mbar and further reacted for 1.5 hours. The condensation product thus obtained had an acid number of 0.9 mg KOH/g and an amine number of 96.2 mg KOH/g. The reaction mixture was cooled to 80° C. Over one hour, 186.2 g (1.477 mol) of dimethyl sulfate were added dropwise with stirring, wherein the temperature was maintained in a range of 80-95° C. Subsequently, 120 g of anhydrous ethanol were added and the mixture was further stirred at 80° C. for one hour. The quat mixture thus obtained had an amine number of 3.1 mg KOH/g.
The further examples and comparative examples were carried out according to this procedure but with varied reactants or varied amount ratios—in each case as stated in tables 4 and 5 below.
6.3 Application Tests
Table 4 specifies various inventive laundry and cleaning formulations by way of example. In each case, according to the procedure of 6.2, quat mixtures were prepared corresponding to the data in table 4, and were mixed with water such that each formulation resulted in 3% by weight quat mixture (calculated based on the solids content), 0.2% perfume oil, and water to 100%. The viscosity of the formulation obtained was determined in each case.
For comparison, non-inventive examples are shown in table 5 in which:
The comparisons of V1 with E2 and of V2 with E6 show that the use of DMS instead of MeCl as alkylating agent contributes significantly to the solution to the problem of the present invention.
The comparisons of V3 with E7, V4 with E6, V5 with E7 and V6 with E2 show that the use of radicals R1 with an iodine number of less than 10 instead of a radical R1 with a higher iodine number, at otherwise identical conditions, results in significantly higher viscosities.
The comparison of V7 with E1 to E3 shows the influence of the molar ratio of fatty acid to amine. If this is too low, as in V7, an insufficient thickening effect is achieved.
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