Spray-dried aluminosilicate detergents containing silicate and metaborate

BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to granular detergent compositions which are capable of providing superior performance during conventional textile laundering and cleaning operations. The compositions of this invention contain an essential components a water-insoluble aluminosilicate ion exchange material, an organic surface active agent, and a mixture of an alkali metal oxide silicate solid with a SiO.sub.2 :alkali metal oxide weight ratio of from about 0.8:1 to 2.3:1 and an alkali metal metaborate or the equivalent.
The use of water-insoluble synthetic aluminosilicates in detergent compositions in combination with organic surface active agents is described in British Patent Specification No. 1,429,143. The compositions of British Patent Specification No. 1,429,143 and indeed all laundry detergent compositions, generally require the presence of a metal corrosion inhibitor to protect the washing machine and also generally require an agent to render granules crisp so as to confer free-flowing characteristics. In typical granular detergent compositions, satisfactory corrosion inhibition and granule crispness are obtained through the incorporation of sodium silicate. For optimum granule crispness of a SiO.sub.2 :Na.sub.2 O weight ratio of from about 2.2:1 to about 3.5:1 is generally employed.
2. Background Art
U.S. Pat. No. 3,985,669 issued Oct. 12, 1976, describes the incorporation of from about 0.5% to about 5% of sodium silicate in detergent compositions containing aluminosilicate ion exchange materials. This patent points out that the use of higher levels of silicate solids in combination with aluminosilicates can present fabric deposition problems due to insolubility of the components.
U.S. Pat. No. 4,180,485, issued Dec. 25, 1979, discloses the incorporation of salts of organic acids in detergent compositions to alleviate insolubility problems caused by a combination of aluminosilicates and silicate solids.
It is an object of the present invention to provide granular detergent compositions containing water-insoluble aluminosilicate ion exchange materials and levels of alkali metal oxide silicate solids capable of providing effective corrosion inhibition in free-flowing granules.
It is a further object of this invention to provide detergent compositions containing water-insoluble aluminosilicates and alkali metal oxide silicate solids that do not provide a problem of fabric appearance due to deposition of insoluble material.
It is a still further object of this invention to provide a process for making said detergent compositions.
SUMMARY OF THE INVENTION
The present invention is based on the discovery that detergent compositions with satisfactory physical properties can contain aluminosilicate detergency builders and also alkali metal oxide silicate solids, if the SiO.sub.2 :alkali metal oxide weight ratio in the finished composition is from about 0.8:1 to about 2.3:1 and said composition is prepared by drying a slurry containing, on a finished product basis, of a mixture of a silicate and an alkali metal metaborate, or the equivalent, to provide a B.sub.2 O.sub.3 :SiO.sub.2 weight ratio of from about 0.1 to about 4.0. In particular, the compositions of this invention are granular detergent compositions in the form of crisp, free-flowing granules comprising:
(a) from about 5% to about 40% of a water-soluble organic surface active agent selected from the group consisting of anionic, nonionic, zwitterionic, and ampholytic detergents, and mixtures thereof;
(b) from about 10% to about 60% of a finely divided aluminosilicate ion exchange material selected from the group consisting of:
(1) crystalline aluminosilicate material of the formula:
Na.sub.z [(AlO.sub.2).sub.z.(SiO.sub.2).sub.y ].xH.sub.2 O
wherein z and y are at least 6, the molar ratio of z to y is from 1.0 to 0.5 and x is from 10 to 264, said material having a particle size diameter of from about 0.1 micron to about 10 microns, a calcium ion exchange capacity of at least about 200 mg. CaCO.sub.3 eq./g. and a calcium ion exchange rate of at least about 2 grains Ca.sup.++ /gallon/minute/gram/gallon;
(2) amorphous hydrated aluminosilicate material of the empirical formula:
M.sub.z (zAlO.sub.2.ySiO.sub.2)
wherein M is sodium, potassium, ammonium, or substituted ammonium, z is from about 0.5 to about 2, y is 1 and said material has a magnesium ion exchange capacity of at least about 50 milligram equivalents of CaCO.sub.3 hardness per gram of anhydrous aluminosilicate and a Mg.sup.++ exchange rate of at least about 1 grain/gallon/minute/gram/gallon and
(3) mixtures thereof; and a mixture of
(c) from about 2.0% to about 15% of an alkali metal oxide silicate solid having a weight ratio of SiO.sub.2 :alkali metal oxide of from about 0.8:1 to about 2.3:1; and
(d) an alkali metal metaborate to provide a B.sub.2 O.sub.3 :SiO.sub.2 weight ratio of from about 0.1 to about 4.0.
The detergent slurry generally contains from about 25% to about 50% water as compared to the dried granules with from about 2% to about 15% water. The level of components other than water in the slurry will thus be approximately 30% lower than in the finished product, i.e., from about 3.5% to about 30% for the surface active agent, from about 7% to about 45% for the aluminosilicate and from about 1.5% to about 10% for the silicate solids.
The detergent composition herein can contain, in addition to the essential components listed, various other ingredients commonly employed in detergent compositions. In particular, auxiliary water-soluble detergent builders can be employed to aid in the removal of calcium and magnesium water hardness.
DETAILED DESCRIPTION OF THE INVENTION
The compositions of this invention comprise: (1) a water-insoluble aluminosilicate ion exchange material; (2) an organic surface active agent; and a mixture of (3) an alkali metal oxide silicate with a weight ratio of SiO.sub.2 :alkali metal oxide of from about 0.8:1 to about 2.3:1; and (4) an alkali metal metaborate or the equivalent. These essential ingredients are discussed in detail hereinafter. Unless stated to the contrary, the "percent" indications are percent by weight.
Aluminosilicate Ion Exchange Materials
From about 10% to about 60%, preferably from about 15% to about 35%, and most preferably from about 20% to about 30% of an aluminosilicate ion exchange material is incorporated in the compositions of the invention.
The crystalline aluminosilicate ion exchange materials useful in the practice of this invention have the formula
Na.sub.z [(AlO.sub.2).sub.z.(SiO.sub.2).sub.y ].xH.sub.2 O
wherein z and y are at least about 6, the molar ratio of z to y is from about 1.0 to about 0.5 and x is from about 10 to about 264. Amorphous hydrated aluminosilicate materials useful herein have the empirical formula
M.sub.z (zAlO.sub.2.ySiO.sub.2)
wherein M is sodium, potassium, ammonium, or substituted ammonium, z is from about 0.5 to about 2, y is 1 and said materials have a magnesium ion exchange capacity of at least about 50 milligram equivalents of CaCO.sub.3 hardness per gram of anhydrous aluminosilicate.
The aluminosilicate ion exchange builder materials herein are in hydrated form and contain from about 10% to about 28% of water by weight if crystalline and potentially even higher amounts of water if amorphous. Highly preferred crystalline aluminosilicate ion exchange materials contain from about 18% to about 22% water in their crystal matrix. The crystalline aluminosilicate ion exchange materials are further characterized by a particle size diameter of from about 0.1 micron to about 20 microns. Amorphous materials are often smaller, e.g., down to less than about 0.01 micron. Preferred ion exchange materials have a particle size diameter of from about 0.2 micron to about 4 microns. The term "particle size diameter" herein represents the average particle size diameter of a given ion exchange material as determined by conventional analytical techniques such as, for example, microscopic determination utilizing a scanning electron microscope. The crystalline aluminosilicate ion exchange materials herein are usually further characterized by their calcium ion exchange capacity, which is at least about 200 mg. equivalent of CaCO.sub.3 water hardness/gm. of aluminosilicate, calculated on an anhydrous basis, and which generally is in the range of from about 300 mg. eq./g. to about 352 mg. eq./g. The aluminosilicate ion exchange materials herein are still further characterized by their calcium ion exchange rate which is at least about 2 grains Ca.sup.++ /gallon/minute/gram/gallon of aluminosilicate (anhydrous basis), and generally lies within the range of from about 2 grains/gallon/minute/gram/gallon to about 6 grains/gallon/minute/gram/gallon, based on calcium ion hardness. Optimum aluminosilicate for builder purposes exhibit a calcium ion exchange rate of at least about 4 grains/gallon/minute/gram/gallon.
The amorphous aluminosilicate ion exchange materials usually have a Mg.sup.++ exchange capacity of at least about 50 mg. eq. CaCO.sub.3 /g. (12 mg. Mg.sup.++ /g.) and a Mg.sup.++ exchange rate of at least about 1 grain/gallon/minute/gram/gallon. Amorphous materials do not exhibit an observable diffraction pattern when examined by Cu radiation (1.54 Angstrom Units).
Aluminosilicate ion exchange materials useful in the practice of this invention are commercially available. The aluminosilicates useful in ths invention can be crystalline or amorphous in structure and can be naturally-occurring aluminosilicates or synthetically derived. A method for producing aluminosilicate ion exchange materials is discussed in U.S. Pat. No. 3,985,669, issued Oct. 12, 1976, incorporated herein by reference. Preferred synthetic crystalline aluminosilicate ion exchange materials useful herein are available under the designations Zeolite A, Zeolite B, and Zeolite X. In an especially preferred embodiment the crystalline aluminosilicate ion exchange material has the formula
Na.sub.12 [(AlO.sub.2).sub.12 (SiO.sub.2).sub.12 ].xH.sub.2 O
wherein x is from about 20 to about 30, especially about 27.
Organic Surface Active Agents
The detergent compositions of the instant invention can contain all manner of organic, water-soluble surface active agents, often designated surfactants. The aluminosilicate ion exchange materials and other essential components of the detergent composition are compatible with all such materials. The surface active component is used in an amount from about 5% to about 40%, preferably from about 7% to about 20% and most preferably from about 10% to about 18% of the detergent compositions. A typical listing of the classes and species of compounds useful herein appears in U.S. Pat. No. 3,664,961, incorporated herein by reference. The following list of detergent compounds and mixtures which can be used in the instant compositions is representative of such materials, but is not intended to be limiting.
Water-soluble salts of the higher fatty acids, i.e., "soaps", are useful as the surface active component of the compositions herein. This includes alkali metal soaps such as the sodium, potassium, ammonium, and alkylolammonium salts of higher fatty acids containing from about 8 to about 24 carbon atoms and preferably from about 10 to about 20 carbon atoms. Soaps can be made by direct saponification of fats and oils or by the neutralization of free fatty acids. Particularly useful are the sodium and potassium salts of the mixtures of fatty acids derived from coconut oil and tallow, i.e., sodium or potassium tallow and coconut soap.
Another class of surface active agents include water-soluble salts, preferably the alkali metal, ammonium and alkylolammonium salts, of organic sulfuric reaction products having in their molecular structure an alkyl group containing from about 10 to about 20 carbon atoms and a sulfonic acid or sulfuric acid ester group. (Included in the term "alkyl" is the alkyl portion of acyl groups.) Examples of this group of synthetic detergents which form a part of the compositions of the present invention are the sodium and potassium alkyl sulfates, especially those obtained by sulfating the higher alcohols (C.sub.8 -C.sub.18 carbon atoms) such as those produced by reducing the glycerides of tallow or coconut oil; and sodium and potassium alkyl benzene sulfonates, in which the alkyl group contains from about 9 to about 15 carbon atoms, in straight chain or branched chain configuration, e.g., those of the type described in U.S. Pat. Nos. 2,220,099 and 2,477,383. Especially valuable are linear straight chain alkyl benzene sulfonates in which the average of the alkyl groups is about 11 to 13 carbon atoms, abbreviated as C.sub.11-13 LAS.
Other anionic surface active agents herein include the sodium alkyl glyceryl ether sulfonates, especially those ethers of higher alcohols derived from tallow and coconut oil; sodium coconut oil fatty acid monoglyceride sulfonates and sulfates; sodium or potassium salts of alkyl phenol ethylene oxide ether sulfates containing about 1 to about 10 units of ethylene oxide per molecule and wherein the alkyl groups contain from about 8 to about 12 carbon atoms and sodium or potassium salts of alkyl ethylene oxide ether sulfates containing about 1 to about 10 units of ethylene oxide per molecule and wherein the alkyl group contains from about 10 to about 20 carbon atoms.
Water-soluble nonionic surface active agents are also useful in the compositions of the invention. Such nonionic materials include compounds produced by the condensation of alkylene oxide groups (hydrophilic in nature) with an organic hydrophobic compound, which may be aliphatic or alkyl aromatic in nature. The length of the polyoxyalkylene group which is condensed with any particular hydrophobic group can be readily adjusted to yield a water-soluble compound having the desired degree of balance between hydrophilic and hydrophobic elements.
A well-known class of nonionic surface active agents is available on the market under the trade name of "Pluronic". These compounds are formed by condensing ethylene oxide with a hydrophobic base formed by the condensation of propylene oxide with propylene glycol. Other suitable nonionic surface active agents include the polyethylene oxide condensates of alkyl phenols, e.g., the condensation products of alkyl phenols having an alkyl group containing from about 6 to 12 carbon atoms in either a straight chain or branched chain configuration, with ethylene oxide, the ethylene oxide being present in amounts equal to 5 to 25 moles of ethylene oxide per mole of alkyl phenol.
The water-soluble condensation products of aliphatic alcohols having from 8 to 22 carbon atoms, in either straight chain or branched configuration, with ethylene oxide, e.g., a coconut alcohol-ethylene oxide condensate having from 5 to 30 moles of ethylene oxide per mole of coconut alcohol, the coconut alcohol fraction having from 10 to 14 carbon atoms, are also useful nonionic surface active agents.
Semi-polar nonionic surface active agents include water-soluble amine oxides containing one alkyl moiety of from about 10 to 28 carbon atoms and 2 moieties selected from the group consisting of alkyl groups and hydroxyalkyl groups containing from 1 to about 3 carbon atoms; water-soluble phosphine oxides containing one alkyl moiety of about 10 to 28 carbon atoms and 2 moieties selected from the group consisting of alkyl groups and hydroxyalkyl groups containing from about 1 to 3 carbon atoms; and water-soluble sulfoxides containing one alkyl moiety of from about 10 to 28 carbon atoms and a moiety selected from the group consisting of alkyl and hydroxyalkyl moieties of from 1 to 3 carbon atoms.
Ampholytic surface active agents include derivatives of aliphatic or aliphatic derivatives of heterocyclic secondary and tertiary amines in which the aliphatic moiety can be straight chain or branched and wherein one of the aliphatic substituents contains from about 8 to 18 carbon atoms and at least one aliphatic substituent contains an anionic water-solubilizing group.
Zwitterionic surface active agents include derivatives of aliphatic quaternary ammonium, phosphonium, and sulfonium compounds in which the aliphatic moieties can be straight chain or branched, and wherein one of the aliphatic substituents contains from about 8 to 18 carbon atoms and one contains an anionic water solubilizing group.
Other useful anionic surface active agents herein include the water-soluble salts of esters of alpha-sulfonated fatty acids containing from about 6 to 20 carbon atoms in the fatty acid group and from about 1 to 10 carbon atoms in the ester group; water-soluble salts of 2-acyloxy-alkane-1-sulfonic acids containing from about 2 to 9 carbon atoms in the acyl group and from about 9 to about 23 carbon atoms in the alkane moiety; alkyl ether sulfates containing from about 10 to 20 carbon atoms in the alkyl group and from about 1 to 30 moles of ethylene oxide; water-soluble salts of olefin sulfonates containing from about 12 to 24 carbon atoms; and beta-alkyloxy alkane sulfonates containing from about 1 to 3 carbon atoms in the alkyl group and from about 8 to 20 carbon atoms in the alkane moiety.
Particularly preferred surface active agents herein include linear alkylbenzene sulfonates containing from about 11 to 14 carbon atoms in the alkyl group; the tallow range alkyl sulfates; the coconut alkyl glyceryl ether sulfonates; alkyl ether sulfates wherein the alkyl moiety contains from about 14 to 18 carbon atoms and wherein the average degree of ethoxylation varies between 1 and 6; the sulfated condensation products of tallow alcohol with from about 1 to 10 moles of ethylene oxide; olefin or paraffin sulfonates containing from about 14 to 16 carbon atoms; alkyldimethyl amine oxides wherein the alkyl group contains from about 11 to 16 carbon atoms; alkyldimethylammonio propane sulfonates and alkyldimethylammonio hydroxy propane sulfonates wherein the alkyl group in both types contains from about 14 to 18 carbon atoms; soaps, as hereinabove defined; the condensation product of tallow fatty alcohol with about 11 moles of ethylene oxide; and the condensation product of a C.sub.13 (avg.) secondary alcohol with 9 moles of ethylene oxide.
Specific preferred surface active agents for use herein include: sodium linear C.sub.10-18 alkylbenzene sulfonate; triethanolamine C.sub.10-18 alkylbenzene sulfonate; sodium tallow alkyl sulfate; sodium coconut alkyl glyceryl ether sulfonate; the sodium salt of a sulfated condensation product of a tallow alcohol with from about 1 to about 10 moles of ethylene oxide; the condensation product of a coconut fatty alcohol with about 6 moles of ethylene oxide; the condensation product of tallow fatty alcohol with about 11 moles of ethylene oxide; 3-(N,N-dimethyl-N-coconutalkylammonio)-2-hydroxypropane-1-sulfonate; 3-(N,N-dimethyl-N-coconutalkylammonio-propane-1-sulfonate; 6-(N-dodecylbenzyl-N,N-dimethylammonio)hexanoate; dodecyl dimethyl amine oxide; coconut alkyldimethyl amine oxide; and the water-soluble sodium and potassium salts of higher fatty acids containing 8 to 24 carbon atoms.
It is to be recognized that any of the foregoing surface active agents can be used separately herein or as mixtures. Examples of preferred mixtures herein are as follows.
An especially preferred alkyl ether sulfate component of the instant compositions is a mixture of alkyl ether sulfates, said mixture having an average (arithmetic mean) carbon chain length within the range of from about 12 to 16 carbon atoms, preferably from about 14 to 15 carbon atoms, and an average (arithmetic mean) degree of ethoxylation of from about 1 to 4 moles of ethylene oxide, preferably from about 2 to 3 moles of ethylene oxide.
Specifically, such preferred mixtures comprise from about 0.05% to 5% by weight of mixture of C.sub.12-13 compounds, from about 55% to 70% by weight of mixture of C.sub.14-15 compounds, from about 25% to 40% by weight of mixture of C.sub.16-17 compounds and from about 0.1% to 5% by weight of mixture of C.sub.18-19 compounds. Further, such preferred alkyl ether sulfate mixtures comprise from about 15% to 25% by weight of mixture of compounds having a degree of ethoxylation of 0, from about 50% to 65% by weight of mixture of compounds having a degree of ethoxylation from 1 to 4, from about 12% to 22% by weight of mixture of compounds having a degree of ethoxylation from 5 to 8 and from about 0.5% to 10% by weight of mixture of compounds having a degree of ethoxylation greater than 8.
Examples of alkyl ether sulfate mixtures falling within the above-specified ranges are set forth in Table I.
TABLE I______________________________________MIXTURE CHARACTERISTICS______________________________________Average carbon chain I II III IVlength (No. C Atoms) 14.86 14.68 14.86 14.88______________________________________12-13 carbon atoms (wt. %) 4% 1% 1% 3%14-15 carbon atoms (wt. %) 55% 65% 65% 57%16-17 carbon atoms (wt. %) 36% 33% 33% 38%18-19 carbon atoms (wt. %) 5% 1% 1% 2%______________________________________Average degree of ethoxy-lation (No. Moles EO) 1.98 2.28 2.25 3.0______________________________________0 moles ethylene oxide (wt. %) 15% 21% 22.9% 18%1-4 moles ethylene oxide (wt. %) 63% 59% 65% 55%5-8 moles ethylene oxide (wt. %) 21% 17% 12% 22%9+ moles ethylene oxide (wt. %) 1% 3% 0.1% 5%______________________________________Salt K Na Na Na______________________________________
Alkali Metal Silicate Solids
The alkali metal silicate solids are used in an amount from about 2.0% to about 15% and preferably from about 2% to about 6%. Suitable silicate solids have a weight ratio of SiO.sub.2 :alkali metal oxide in the range of from about 0.8:1 to about 2.3:1 and preferably from about 1.0:1 to about 1.6:1. The alkali metal silicate suitable herein include commercial preparations of the combination of silicon dioxide and alkali metal oxide or carbonate fused together in varying proportions according to, for example, the following reaction: ##STR1## The value of m, frequently designated by the molar or weight ratio of SiO.sub.2 :Na.sub.2 O, ranges from about 0.5 to about 4 depending on the proposed use of the sodium silicate. The term "alkali metal silicate" as used herein refers to silicate solids with any ratio of SiO.sub.2 to alkali metal oxide. Crystalline silicate solids normally possess a high alkalinity content; in addition water of hydration is frequently present as, for example, in metasilicates which can exist having 5, 6, or 9 molecules of water. The alkalinity is provided through the alkali metal oxide such as, for example, sodium, potassium, and lithium oxide, and mixtures thereof. Sodium silicate solids are generally used in granular detergent compositions.
The alkali metal oxide silicates are incorporated into the detergent compositions of this invention during the crutching operation together with the other essential constituents. This may be in the form of solid alkali metal silicate or in the form of soluble or colloidal silicates available as 20 to 50% aqueous solutions or suspensions.
As discussed hereinbefore, silicate solids, particularly sodium silicate solids, are frequently added to granular detergent compositions as corrosion inhibitors to provide protection to the metal parts of the washing machine in which the detergent composition is utilized. In addition, silicates have been used to provide a degree of crispness and pourability to detergent granules which is very desirable to avoid lumping and caking. As also discussed hereinbefore, however, silicate solids could not easily be incorporated into detergent compositions comprising major amounts of water-insoluble aluminosilicate ion exchange materials. In such compositions, the incorporation of silicates have the tendency of enhancing the deposition of water-insoluble particles on the textiles being laundered. This is due, in part, to the polymerization of silicate solids in the detergent granule on drying and subsequent CO.sub.2 absorption with storage. It has now been found that alkali metal oxide silicate solids may be utilized in such compositions within the range of from about 2% to about 15% without adversely affecting deposition of insolubles if the weight ratio of SiO.sub.2 :alkali metal oxide is from about 0.8:1 to about 2.3:1, provided that said composition is prepared by drying a slurry containing the essential components of the invention described herein including an alkali metal metaborate to provide a B.sub.2 O.sub.3 :SiO.sub.2 weight ratio of from about 0.1 to about 4.0, preferably from about 0.3 to about 1.5.
Alkali Metal Metaborate
The alkali metal metaborate used in the practice of the invention has the nominal formula M.sub.2 B.sub.2 O.sub.4, M being an alkali metal. Preferred metaborates are sodium metaborate tetrahydrate and sodium metaborate octahydrate. Weight and percentage levels used herein are on an anhydrous basis.
The formula of a metaborate can also be expressed as
M.sub.2 O.B.sub.2 O.sub.3
M being an alkali metal. The molar ratio of M.sub.2 O:B.sub.2 O.sub.3 can vary from the theoretical 1:1. An excess of M.sub.2 O allows the use of somewhat higher ratios of SiO.sub.2 :M.sub.2 O in the silicate solids without solubility problems. Alternately the alkali metal metaborate may be formed in situ by a mixture of, for example, borax
[Na.sub.2 B.sub.4 O.sub.7 or Na.sub.2 O.2(B.sub.2 O.sub.3)]
and a strongly alkaline material such as sodium hydroxide or a silicate solids with a relatively low SiO.sub.2 :M.sub.2 O ratio. Sufficient alkalinity expressed as M.sub.2 O must be present in the detergent slurry prior to drying to satisfy the requirements to produce metaborate and yet have the specified ratio of SiO.sub.2 :M.sub.2 O for the alkali metal silicate after reaction. Silicate SiO.sub.2 :M.sub.2 O ratios below about 1.5 and generally necessary to accomplish conversion of tetraborate to metaborate and have a reacted SiO.sub.2 :M.sub.2 O ratio of 2.3 or less. It has been found particularly advantageous to employ silicates with weight ratios of 1.0 or lower.
Without being bound to any particular theory or mechanism of the invention, it can be theorized that the presence of the metaborate provides for the formation of soluble complexes of
xM.sub.2 O.yB.sub.2 O.sub.3.zSiO.sub.2
that inhibit or otherwise prevent formation of insoluble polymers of SiO.sub.2 and M.sub.2 O, M being an alkali metal.
Optional Ingredients
The detergent compositions of the present invention can contain, in addition to the aluminosilicate ion exchange builders, auxiliary water-soluble builders such as those taught for use in detergent compositions. Such auxiliary builders can be employed to aid in the sequestration or precipitation of hardness ions.
Such auxiliary builders can be employed in concentrations consistent with the levels of essential ingredients, but preferably from about 5% to about 35% by weight, of the detergent compositions herein. The auxiliary builders herein include any of the conventional inorganic and organic water-soluble builder salts.
Such auxiliary builders can be, for example, water-soluble salts of phosphates, polyphosphates, phosphonates, carbonates, polyhydroxysulfonates, polyacetates, carboxylates, and polycarboxylates. Specific examples of inorganic phosphate builders include sodium tripolyphosphates, pyrophosphates, and metaphosphates. The polyphosphonates include, for example, the sodium salts of ethylene diphosphonic acid, the sodium salts of ethane 1-hydroxy-1,1-diphosphonic acid, and the sodium salts of ethane-1,1,2-triphosphonic acid. Examples of these and other phosphorus builder compounds are disclosed in U.S. Pat. Nos. 3,159,581, 3,213,030, 3,422,021, 3,422,137, 3,400,176 and 3,400,148, incorporated herein by reference.
Nonphosphorus containing sequestrants can also be selected for use herein as auxiliary builders.
Specific examples of nonphosphorus, inorganic auxiliary detergent builder ingredients include water-soluble inorganic carbonate and bicarbonate salts. The alkali metal, e.g., sodium and potassium, carbonates and bicarbonates are particularly useful herein.
Water-soluble, organic auxiliary builders are also useful herein. The alkali metal, ammonium and substituted ammonium polyacetates, carboxylates, polycarboxylates, and polyhydroxysulfonates are useful builders in the present compositions. Specific examples of the polyacetate and polycarboxylate builder salts include sodium, potassium, lithium, ammonium, and substituted ammonium salts of ethylenediaminetetraacetic acid, nitrilotriacetic acid, oxydisuccinic acid, mellitic acid, benzenepolycarboxylic acids, and citric acid.
Other auxiliary builders useful herein are the polycarboxylate builders set forth in U.S. Pat. No. 3,308,067, Diehl, incorporated herein by reference. Examples of such materials include the water-soluble salts of homo- and copolymers of aliphatic carboxylic acids such as maleic acid, itaconic acid, mesaconic acid, fumaric acid, aconitic acid, citraconic acid, methylenemalonic acid, 1,1,2,2-ethane tetracarboxylic acid, dihydroxy tartaric acid, and ketomalonic acid. Also useful herein are the polyacetal carboxylates disclosed in U.S. Pat. Nos. 4,144,226 and 4,146,495, both Crutchfield et al, incorporated herein by reference. Such polyacetal carboxylates are comprised of polymeric segments having the structure ##STR2## wherein M is a salt forming cation and n averages at least 4.
Additional preferred auxiliary builders herein include the water-soluble salts, especially the sodium and potassium salts, of carboxymethyloxymalonate, carboxymethyloxysuccinate, cis-cyclohexanehexacarboxylate, cis-cyclopentanetetracarboxylate, and phloroglucinol trisulfonate.
The detergent compositions herein can contain all manner of additional materials commonly foun in laundering and cleaning compositions. For example, such compositions can contain soil suspending agents such as carboxymethylcellulose and the like. Enzymes, especially the proteolytic, amylolytic, and lipolytic enzymes commonly used in laundry detergent compositions, can also be present herein. Various perfumes, optical bleaches, fillers, anticaking agents, fabric softeners and the like can be present in the compositions to provide the usual benefits occasioned by the use of such materials in detergent compositions. It is to be recognized that all such adjuvant materials are useful herein inasmuch as they are compatible and stable in the presence of the aluminosilicate ion exchange builders. Preferred anticaking agents that complement or supplement the benefit of the alkali metal metaborate of the present invention are the alkali metal salts of toluene sulfonate, the alkali metal salts of sulfosuccinic acid, and polyethylene glycol with a molecular weight of at least about 2000. To provide an anticaking benefit, these materials should be added to the water slurry of essential ingredients prior to removing water by spray drying or other means and be present at a level on a finished product basis of from about 0.1% to about 5%.
The granular detergent compositions here can also advantageously contain a peroxy bleaching component in an amount from about 3% to about 40% by weight, preferably from about 8% to about 33% by weight. Examples of suitable peroxy bleach components for use herein include perborates, persulfates, persilicates, perphosphates, percarbonates and more in general all inorganic and organic peroxy bleaching agents which are known to be adapted for use in the subject compositions.
The detergent compositions herein are employed in aqueous solutions to cleanse surfaces, especially fabric surfaces, using any of the standard laundering and cleansing techniques. For example, the compositions herein are particularly suited for use in automatic washing machines at concentrations of from about 0.05% to about 0.5% by weight. Optimum results are obtained when the compositions herein are employed in an aqueous laundry solution at a level of at least about 0.10% by weight. As in the case of most laundry detergent compositions, the granular compositions herein having a density of from about 0.3 g./cc. to about 0.5 g./cc. are usually added to a conventional aqueous laundry solution at a rate of about 1.0 cup for 12-17 gallons of wash water.

The following examples demonstrate the advantages derived from compositions and process of this invention and facilitate its understanding.
EXAMPLE I
The following compositions were prepared by spray drying aqueous slurries containing approximately 31% water.
______________________________________ A B C______________________________________Sodium C.sub.11-13 alkylbenzene 3.5 3.5 3.5sulfonateSodium C.sub.14-16 alkyl ethoxy-3 5.5 5.5 5.5sulfateSodium C.sub.16-18 alkyl sulfate 5.5 5.5 5.5Sodium aluminosilicate 25.0 25.0 25.0(hydrated Zeolite A--avg.particle size 3 microns)Sodium silicate 4.0 4.0 4.0(SiO:Na.sub.2 O = 1.6)Sodium tetraborate -- 5.2 --Sodium acetate -- -- --Sodium metaborate -- -- 6.5Sodium carbonate 6.0 6.0 6.0Water 6.0 6.0 6.0Sodium sulfate and miscellaneous balance balance balance______________________________________
The slurries were pumped through the spray nozzles of a spray drying tower. The tower was 50 feet in height and 10 feet in diameter. Air having a temperature of 650.degree. F. was introduced at the bottom of the tower and exited at the top of the tower.
Granules resulting from each spray drying operation were then tested for resistance to caking, and deposition of insolubles on fabric.
Compositions were evaluated for caking resistance by a test method which compresses a 21/2 inch high cylinder of detergent granules inside a 21/2 inch diameter cylindrical die with a 20 pound piston. After 1 minute the compacted detergent "cake" is placed on a flat surface and the force necessary to break the case when applied to the top surface of the detergent cylinder is measured.
______________________________________ A B C______________________________________Cake Grade--120.degree. F. 7 lbs. 12 lbs. 4 lbs.______________________________________
Higher values indicate a potential for poor pourability.
The products were evaluated for deposition of insoluble material on fabrics by filtering 1 liter of a 0.15% concentration of each composition through a circular black cotton fabric having a filterable area of 9.62 in..sup.2. A grade of 10 represents no visible deposition. A grade of 1 represents complete coverage with an easily visible deposit.
Results of the deposition test were as follows:
______________________________________ Deposition Grade______________________________________Composition A 5.0Composition B 6.0Composition C 8.5______________________________________
Substantially similar results are obtained when hydrated Zeolite B or hydrated Zeolite X are substituted by hydrated Zeolite A.
Substantially similar results are obtained when 121/2% amorphous hydrated aluminosilicate of the formula
Na(AlO.sub.2.SiO.sub.2).3.4H.sub.2 O
having an average particle size of less than 1 micron in diameter and a moisture content of about 30% is substituted for 121/2% of the hydrated Zeolite A.
Substantially similar results are obtained when a nonionic surface active produced by the reaction of 1 mole of a C.sub.12-15 alcohol and 4 moles of ethylene oxide is substituted for the sodium C.sub.14-16 alkyl ethoxy-3 sulfate.
Substantially similar results are obtained when a sodium C.sub.15 paraffin sulfonate or a sodium C.sub.15 olefin sulfonate are substituted for the sodium C.sub.11-13 alkylbenzene sulfonate.
EXAMPLE II
The following compositions were prepared by spray drying aqueous slurries containing approximately 31% water following the procedure of Example I except using a tower 110 feet in height and 20 feet in diameter.
______________________________________ D E______________________________________Sodium C.sub.11-13 alkylbenzene sulfonate 5.8% 7.0%Sodium C.sub.14-16 ethoxy-3 sulfate 4.6 5.5Sodium C.sub.16-18 alkyl sulfate 4.6 5.5Sodium aluminosilicate 18.2 24.4(hydrated Zeolite A--avg.particle size 2 microns)Sodium silicate (SiO.sub.2 :Na.sub.2 O = 1.6) 3.3 --Sodium silicate (SiO.sub.2 :Na.sub.2 O = 1.0)* -- 5.5Sodium metaborate 4.8 --Sodium tetraborate (borax)* -- 3.2Sodium carbonate 6.2 14.6Water 5.6 5.6Sodium sulfate and miscellaneous balance balance______________________________________ *react in situ to the equivalent of 4.2 parts sodium metaborate and 4.5 parts sodium silicate with 1.6 weight ratio of SiO.sub.2 :Na.sub.2 O.
The compositions had satisfactory physical properties including cake grades and deposition of insoluble materials.
EXAMPLE III
The solubilities of various borate-silicate combinations were evaluated in the laboratory. The mixtures were made in solution and dried by heating in a microwave oven. Samples were ground and allowed to dissolve for 5 minutes with stirring in 70.degree. F. water with a sample/water weight ratio of 0.1. The filtered and dried samples were weighed to determine % insoluble. "Soluble" was defined as having less than 5% insoluble; "moderately soluble" was defined as having 30-50% insoluble and "insoluble" as having more than 70% insoluble.
TABLE I______________________________________Solubilities of Sodium Metaborate-Sodium Silicate Combinations % Sodium Silicate SiO.sub.2 :% Na.sub.2 B.sub.2 O.sub.4 Silicate Na.sub.2 O ratio Solubility*______________________________________81 19 1.0 S49 51 1.0 S19 81 1.0 S70 30 1.6 S55 45 1.6 S19 81 1.6 M72 28 2.0 S40 60 2.0 S28 72 2.0 I76 24 2.4 S60 40 2.4 S42 58 2.4 I______________________________________ *S = soluble M = moderately soluble I = insoluble
TABLE II______________________________________Solubilities of Sodium Tetraborate-Sodium Silicate Combinations Initial After Reaction % Sodium Silicate SiO.sub.2 : Silicate SiO.sub.2 : Solu-% Na.sub.2 B.sub.4 O.sub.7 Silicate Na.sub.2 O ratio Na.sub.2 O ratio bility*______________________________________45 55 1.0 1.9 S29 71 1.0 1.3 S16 84 1.4 1.6 M32 68 1.6 2.6 I14 86 2.0 2.4 I______________________________________ *S = soluble M = moderately soluble I = insoluble
Results show the solubility advantage for B.sub.2 O.sub.3 :SiO.sub.2 weight ratios of at least about 0.1 and silicate SiO.sub.2 :Na.sub.2 O weight ratios not greater than about 2.3. In mixtures utilizing sodium tetraborate the Na.sub.2 O requirement to produce sodium metaborate is satisfied before calculation of the "after reaction" silicate SiO.sub.2 :Na.sub.2 O ratio.

Number	Name	Date
2623856	Sanders	Dec 1952
3701735	Finck	Oct 1981
3749675	Chang	Jul 1973
3985669	Krummel	Oct 1976
4000094	Fleming	Dec 1976
4019999	Ohren	Apr 1977
4083793	Jakobi	Apr 1978
4180485	Llenado	Dec 1979
4244834	Schwalley et al.	Jan 1981

Spray-dried aluminosilicate detergents containing silicate and metaborate

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