Fabric care article and method

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DESCRIPTION

Fabric care method and article.

Field of the invention

The present invention relates to a fabric care article composed of a solid or semi-solid matrix of materials for multiple use in a mechanical drying apparatus such as a tumble dryer.

Background of the invention

Even distribution of the conditioning agent in a tumble dryer to achieve effective contact of the conditioning agent with the fibrous materials of the washed fabrics is not conveniently easily achieved. For example, the risk of marking or staining, due to the local application of excessive conditioning agent, can be significant. The use of packaging articles has been widely used, which generally comprise a base or a substrate, which can retain the shape or can be flexible, can be coated and / or impregnated with conditioner. In use, conditioner can be removed from fabrics but staining can be intense. For example, stains developed due to contact of cationic conditioning agents, for example quaternary ammonium salts, with materials containing color bodies or heavy metal ions such as ferrous or ferric ion can only be removed, if removed, by dry cleaning.

Reusable permeable dispensing containers have been developed to dispense solid or semi-solid fabric conditioning agents that can be either attached to the tumble dryer or freely rotated in the dryer. For example, see US Patent Nos. 3,870,145 (Mizuno); 3,948,387 (Haertle); 4,004,685 (Mizuno, et al.); and 4,014,432 (Clothier, et al.).

The present invention is based on the discovery that a fabric care composition can be designed such that it does not require a dispenser container. The choice of specific components in specific amounts unexpectedly results in a solid dough matrix that does not require a dispenser container while it can be supplied in a controlled manner in an automatic mechanical tumble dryer. When the fabric care item runs out, it just disappears, signaling to the user that the item needs to be replenished.

Summary of the invention

The present invention satisfies the needs unmet by the prior art for a fabric care article comprised of a solid or semi-solid matrix having a unique fabric care composition (substantially free of cationic surfactant) and a method for use. multiple thereof in a mechanical drying apparatus such as a tumble dryer. A tumble dryer typically includes a heat source, which can be electric, gas or other, and is equipped with a rotating drum and an exhaust pipe. Fabric care composition includes:

(a) a structuring agent comprising a filler structuring agent and a polymeric structuring agent; wherein the filler structuring agent comprises from about 0.2% to about 10% and the polymeric structuring agent comprises from about 0.5 to about 20% by weight of the composition;

(b) up to about 25% of an anionic surfactant comprising soap;

(c) from about 10% to about 60% free fatty acid, which preferably has a melting point of from about 10 ° C to about 65 ° C; and (d) from about 1% to about 50% of a nonionic material.

The filler structuring agent is a nonwoven fabric that can be polyester, polyethylene, polypropylene, cellulose, and mixtures thereof. The polymeric structuring agent may be composed of polyamides, ethylene oxide-propylene oxide block copolymers having hydrophilic and lipophilic end groups, alkylphenol-poly (lower alkylene oxide) -lower alkanols, polymers of lower alkylene glycols, polyalkylene glycol ethers of higher fatty alcohols and polyalkylene glycol esters of higher fatty acids, polyoxyalkylenated fatty alcohols, polyurethanes, polylactide, polyacrylamide, polyacrylates, polyethylene, polyvinyl alcohol, and mixtures thereof.

Detailed description of the invention

The present invention relates to a fabric care article composed of a solid or semi-solid matrix having a single fabric care composition and to a method for multiple use thereof in a mechanical drying apparatus such as a tumble dryer. . A tumble dryer typically includes a source of

ES 2 327 151 T3 heat, which can be electric, gas or other, and is equipped with a rotating drum and an exhaust pipe. Fabric care composition includes:

(a) a structuring agent comprising a filler structuring agent and a polymeric structuring agent; wherein the filler structuring agent comprises from about 0.2% to about 10% and the polymeric structuring agent comprises from about 0.5 to about 20% by weight of the composition;

(b) up to about 25% of an anionic surfactant comprising soap;

(c) from about 10% to about 60% free fatty acid; and (d) from about 1% to about 50% of a nonionic material.

The matrix is ​​a consolidated three-dimensional mass of the combined materials, which can be cast to obtain a stick of about 10 to about 30 grams for multiple use in a tumble dryer, preferably about ten uses or cycles of the dryer. The matrix is ​​solid or semi-solid at room temperature of about 20 to about 25 ° C. The bar will soften when heated in a tumble dryer. The product is delivered to the fabrics by a rubbing / direct contact mechanism when the temperature and humidity in the dryer reach a certain point. The product is designed to thereby prevent staining. The solid shape of the product can enhance its aesthetics as it can be shaped into different shapes. When the fabric care item runs out, it simply disappears, signaling to the user that the item needs to be replenished.

No substrate, spreading agent, or packaging is required, thereby avoiding the cost of the material, the cost of the process of applying fabric care materials thereon, and the environmental cost. Optionally, the fabric care article further includes a container, which contains the matrix and allows delivery of the matrix composition on fabrics in a tumble dryer. For example, the package may include a reservoir for storing the fabric care composition. The package also controls the amount of materials dispensed onto the fabrics per tumble dryer cycle. Furthermore, optionally, the package may be provided with a delivery window, which can adsorb or absorb the matrix materials during operation of the tumble dryer. The absorbent material controls the delivery of the matrix materials onto the fabrics. The absorbent material can be a nonwoven material, preferably polyester, polypropylene, cellulose, and mixtures thereof. The container can preferably be mounted on the door of the dryer or on a leading edge of one of the blades of the dryer, or it can be kept inside a dryer until it disappears.

The term "multiple use" is used herein in its ordinary meaning to refer to the reuse during multiple tumble drying cycles of a mechanical drying apparatus such as a tumble dryer. The preferred number of multiple cycles is from about 3 to about 50 drying cycles, more preferred from about 3 to about 25 drying cycles, most preferred from about 3 to about 10 drying cycles.

The term "comprising" is used herein in its usual meaning and means including, consisting of, composed of, consisting of, and / or consisting essentially of. In other words, the term is defined as not being exhaustive of the steps, components, ingredients or characteristics to which it refers.

Except in comparative and operating examples, or where explicitly stated otherwise, all figures in this description indicating amounts or ratios of material or reaction conditions, physical properties of materials and / or use are to be understood. as modified by the word "approximately".

As used herein, the term "substantially free of" means that the amount of matter referred to will be limited to less than about 5% of the composition, preferably about 1% or less.

Fabric care composition

The fabric care composition improves the properties of the fabric. The inventive composition is described hereinafter and is present in multi-use reusable form.

Structuring agent

The fabric care composition includes a structuring agent that is comprised of a filler structuring material or agent and a polymeric structuring agent. Without wishing to be bound by any theory, it is believed that the structuring agent performs mainly two functions; one is simply structuring and the other is to control supply.

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Load structuring agent

The filler structuring agent can be composed of non-woven fabric. The nonwoven fabric can be composed of polyester, polyethylene, polypropylene, cellulose, and mixtures thereof. This agent also serves as an absorbent material.

Nonwoven materials are a sheet, a web or a block of natural and / or man-made filaments or fibers, excluding paper, which have not been made into threads and which are joined together by any of several means.

a) Add an adhesive;

b) thermally fusing the filaments or fibers to each other or to the other meltable powders or fibers;

c) fusing fibers by first dissolving and then re-solidifying their surfaces;

d) creating a physical flake or knots between the fibers;

e) stitching the filaments or fibers in place; me

f) combination of the above.

There are dry-laid, wet-laid, melt-blown, yarn and nanofiber nonwovens. Airlaid nonwovens with or without a binder are preferred. Most preferably, the airlaid nonwovens have a density of about 2 to about 15 ounces per square yard, a nominal thickness of about 1/6 "to about 1" (inches). The pore size or porosity can be characterized by ppi (pores per linear inch). The preferred porosity is from about 10 ppi to about 150 ppi. A more preferred pore size is from about 20 to about 100 ppi.

The filler structuring agent comprises from about 0.2% to about 10% of the solid or semi-solid matrix that constitutes the fabric care article of the present invention.

Polymeric structuring agents

The polymeric structuring agents increase the overall viscosity of the matrix composition and control the release of the matrix materials from the solid block in the tumble dryer. Matrix active agents other than structuring agents are in the high temperature molten state of the tumble dryer in operation. Without wishing to be bound by theory, it is believed that, without the polymeric structuring agent, the fabric care composition would be used up in a single tumble dryer cycle. Accordingly, the inclusion of polymeric structuring agents is important to the all-purpose fabric care article of the present invention. In accordance with the present invention, a controlled amount of fabric care materials is supplied to fabrics in each tumble dryer cycle. Polymeric structuring agents also help maintain the integrity of the fabric care article.

Polymeric structuring agents include nonionic surface materials, such as polyamides (for example high molecular fatty acid alkanolamides such as coconut monoethanolamide), ethylene oxide and propylene oxide block copolymers having hydrophilic and lipophilic end groups. , alkyl (preferably middle alkyl) phenol-poly (lower alkylene oxide) -lower alkanols, polymers of lower alkylene glycols (e.g. polyethylene glycol), polyalkylene glycol ethers of higher fatty alcohols and polyalkylene glycol esters of higher fatty acids, polyoxyalkylenated fatty alcohol, polyurethanes, polylactide, polyacrylamide, polyacrylates, polyethylene, polyvinyl alcohol, and mixtures thereof. All polymeric structuring agents are solid at room temperature, preferably having a melting point of from about 35 ° C to about 90 ° C.

Some of the structuring agents, preferably higher fatty alcohol polyalkylene glycol ethers and higher fatty acid polyalkylene glycol esters, polyoxyalkylenated fatty alcohol, polyethylene glycols, can help control lower temperature delivery.

Polyamides are available under the trademark UNICLEAR 100 from Arizona Chemical Co., as well as Sylvaclear AF1900, Sylvaclear A200 gelants.

Anionic surfactants

In order to achieve a level of fabric softening, the inventive fabric care compositions contain up to about 25% anionic surfactant by weight of the composition. Without wishing to be bound by theory, it is believed that anionic surfactants provide structuring, lubricity and / or antistatic benefits.

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The anionic surfactants used in this invention can be any anionic surfactant that is preferably soluble in water. "Water soluble" surfactants are defined herein, unless otherwise indicated, to include surfactants that are soluble or dispersible to at least the extent of 0.01% by weight in distilled water at 25 ° C. "Anionic surfactants" are defined herein as amphiphilic molecules with an average molecular weight of less than about 10,000, comprising one or more functional groups that exhibit a net anionic charge when in aqueous solution at normal wash pH of between 6 Y

eleven. It is preferred that at least one of the anionic surfactants used in this invention is an alkali or alkaline earth metal or amine, alkanolamine salt of a natural or synthetic fatty acid containing between 4 and 30 carbon atoms. It is especially preferred to use a mixture of carboxylic acid salts with one or more anionic surfactants. Another important class of anionic compounds are the water soluble salts, particularly the alkali metal salts, of organic sulfur reaction products having in their molecular structure an alkyl radical containing from about 6 to 24 carbon atoms and a selected radical from the group consisting of sulfonic and sulfuric acid ester radicals.

Carboxylic acid salts

R'COOM where R¹ is a linear or branched, saturated or unsaturated alkyl group of 4 to 30 carbon atoms or hydroxyalkyl of 10 to 30 carbon atoms and M is a solubilizing cation. The alkyl group represented by R¹ can represent a mixture of chain lengths and can be saturated or unsaturated, although it is preferred that at least two-thirds of the R groups¹ have a chain length of between 8 and 18 carbon atoms. Non-limiting examples of suitable sources of alkyl groups include the fatty acids derived from coconut oil, tallow, bogol oil, and palm kernel oil. However, for the purposes of minimizing odor, it is often desirable to use primarily saturated carboxylic acids. Such materials are available from many commercial sources, such as Uniqema (Wilmington, Del.) And Twin Rivers Technologies (Quincy, Mass.). The solubilizing cation, M, can be any cation that confers water solubility to the product, although monovalent moieties are generally preferred. Examples of acceptable solubilizing cations for use with this invention include alkali metals such as sodium and potassium, which are particularly preferred, and amines such as triethanolammonium, ammonium, and morpholinium. Although, if used, most of the fatty acid should be incorporated into the formulation as a neutralized salt, it is often preferable to leave a small amount of free fatty acid in the formulation, as discussed in more detail below in the present document, as this can help maintain the viscosity of the product.

Preferably, anionic surfactants for the purposes of the present invention include soap C₁₈, C₁₆ and C₁₂soluble in water or mixtures thereof. Fatty acid salts or their mixtures also aid structuring.

For example, tallow oil sodium soap, coconut oil (mainly C₁₂ saturated with some C₁₄), lauric acid (C₁₂ saturated), palmitic acid (C₁₆ saturated), stearic acid (C₁₈ saturated), tallow oil (mainly C₁₆-C₁₈, mixture of saturated and unsaturated), ricinoleic acid, hydroxystearic acid and mixtures thereof.

Free fatty acid

The free fatty acid in the formulation can help in maintaining the viscosity of the product. Without wishing to be bound by theory, it is believed that the free fatty acid can act as a brittle / or non-sticky release agent. Also, the fatty acid can control hygroscopicity.

The free fatty acid, for the purposes of the present invention, is a C fatty acid₄ to C₃₀, preferably a C8 to C24, saturated or unsaturated fatty acid or mixtures thereof. Free fatty acid for the purposes of the present invention has a melting point of from about 10 ° C to about 65 ° C.

Preferred fatty acids include stearic acid, hardened tallow fatty acid (available under the trade name Pristerene from Uniqema), ricinoleic acid, hydroxystearic acid, and mixtures thereof. The composition includes from about 10% to about 60% free fatty acid, and more preferably from about 20% to about 50%, by weight of the composition.

Non-ionic material

A nonionic material is present in order to improve control of the melting temperature of the composition or at least affect the temperature at which the composition flows. Nonionic surfactants are also useful solubilizers for any perfume that may be present in the matrix composition. Nonionic surfactants are also useful as antistatic agents, which act by adsorbing or maintaining moisture.

Nonionic materials include ethoxylated alcohols and alkylphenols having from about 12 to about 22 EO groups (ie, solid type), tertiary phosphine oxides, tertiary amine oxides, and combinations thereof.

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Preferably the nonionic material is solid at room temperature.

The nonionic material and the anionic surfactant are water soluble components of the composition. Nonionic material is present in the inventive compositions at from about 1% to about 50% by weight.

The fabric care composition of the present invention reduces static electricity carried by fabrics. The matrix is ​​substantially free of cationic surfactant. The ratio of anionic surfactant to fatty acid to nonionic material is preferably about 1 / 1.5 / 1 to about 1/10/2 by weight, preferably about 1 / 1.5 / 1 to about 1 / 2.5 / 2, in order to provide antistatic benefits that would otherwise be achieved using cationic surfactants.

Optional components

In addition to the main conditioning compounds, other components can also be included. For example, perfumes, brighteners, bactericides, solvents, thickening or hardening agents, stabilizers, and other materials can be incorporated into fabric care compositions. In some cases small amounts of water may be present, especially when the components form hydrates. The types and proportions of the various adjuvants used will be chosen so as not to interfere with the performance of the main fabric care compounds. Inorganic fillers can be incorporated, preferably silicate, fused precipitated fine silica and / or clay.

When the matrix materials are cast into a stick, additives can be used to improve the forming characteristics of the stick.

In use

The wet washed fabric is loaded into a mechanical tumble dryer for clothes. The dryer is activated by producing the relative movement between the fabric care article and the laundry. The combination of heat, moisture, and impact contact between the article and the laundry effects the release of the fabric care agents onto the tumbling fabric. Ordinarily, there will be from about 5 to about 50 drying air changes in the tumble dryer per minute and the air temperature will be from about 10 to 100 ° C and preferably from 50 to 80 ° C. The drum rotates at approximately 20 to 100 and preferably 4 to 80 revolutions per minute. Typically the laundry load averages from 4 to 12 pounds and will occupy 10 to 70% of the effective drying volume of the tumble dryer. Generally, drying takes from 5 minutes to 2 hours and usually from 20 to 60 minutes. Synthetic fabrics such as nylon and polyester typically require only 3 to 10 minutes while permanent press materials typically require 10 to 30 minutes.

Optionally, the fabric care article of the present invention may be provided with liquid-permeable absorbent sheet material to contain and distribute the composition of the fabric care article. For example, a container that includes an absorbent sheet material may be provided with a reservoir space to house the care article. The container can be a bag of flexible sheet material. Suitable materials include paper, nonwovens, plastic films, and laminates thereof. The care composition can absorb moisture through the fabric to the surface by capillary action. The fabric care article, after use, can be left in place and reloaded as necessary with a selected quantity of fabric care agents prior to use or subsequent reuse.

Generally, the all-purpose fabric care article is sufficient for at least twenty cycles of a tumble dryer for clothes, preferably about ten 50 min drying cycles. to 60 min. every drying cycle. From about 0.8 g to about 2 g of fabric care active agent is uniformly deposited on clothing in each cycle.

The following examples are provided for purposes of illustration only and are not intended to limit the invention. Parts are by weight unless otherwise indicated.

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Examples

The following starting materials were used in the examples.

TABLE 1

<td>Tradename</td><td>Description</td>

<td>Neodol 25-12</td><td>C12-C15 Fatty Alcohol Ethoxylated with 12 EO, Shell Chemical Co., Texas (Nonionic)</td>

<td>Surfonic L24-22</td><td>C12-C14 Linear Fatty Alcohol Ethoxylated with 22 EO, Huntsman Co., Texas (Nonionic)</td>

<td>Uniclear 100</td><td>Polyamide resin, Arizona Chemical (polymeric structuring agent)</td>

<td>PEG 8000</td><td>Polyethylene glycol, Dow Chemical Co., Midland, Michigan</td>

<td>Non-woven material</td><td>20% Air Set Polyester Resin, All 6 Denier, Karlee Corporation</td>

The following procedure was used to make fabric care compositions in accordance with the present invention.

Fatty acid and nonionic surfactant are added and mixed together in a metal container. After melting the mixture, an alkali is added to prepare the fatty acid salt in situ. Mixing is continued until the mixture is clear. Then, a structuring agent can be added and mixing is maintained until the structuring agent dissolves. Finally, various additives such as fragrance and plasticizers are added to complete the composition. A certain amount of the composition is poured into a mold, in which a non-woven material in the form of a sheet or fiber form is placed, at a ratio of composition to non-woven material of about 100: 2, and is Obtains a solid composition for fabric after cooling.

Example 1

Composition C according to the present invention and comparative examples A and B are presented in the table below.

TABLE 2

<td></td><td>TO</td><td>B</td><td>C</td>

<td>Surfonic L1214-22</td><td> 25,0</td><td> -</td><td> --</td>

<td>C1216EO12</td><td> -</td><td> 25,6</td><td> 34,4</td>

<td>Stearic acid</td><td> 65,0</td><td> 63,9</td><td> 54,1</td>

<td>Uniclear 100</td><td> -</td><td> -</td><td> 1,2</td>

<td>KOH</td><td> 4,0</td><td> 4,1</td><td> 3,4</td>

<td>H2O</td><td> 2,2</td><td> 2,3</td><td> 2,0</td>

<td>Various additives</td><td>up to 100.0</td><td>up to 100</td><td>up to 100</td>

The compositions were tested in a tumble dryer over 5 cycles as shown in the table below. Approximately 10 g solid matrix of the compositions was placed on the door.

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A, B and C. The amount of product delivered on the fabrics in each cycle was determined and is shown in the table below.

TABLE 3

<td>Composition</td><td>Cycle 1</td><td>Cycle 2</td><td>Cycle 3</td><td>Cycle 4</td><td>Cycle 5</td><td>Average</td><td>OF</td>

<td>TO</td><td> 1,95</td><td> 1,13</td><td> 0,80</td><td> 1,61</td><td> 1,16</td><td> 1,33</td><td> 0,45</td>

<td>B</td><td> 1,96</td><td> 1,45</td><td> 1,37</td><td> 1,00</td><td> 0,81</td><td> 1,32</td><td> 0,45</td>

<td>C</td><td> 1,85</td><td> 0,91</td><td> 1,28</td><td> 1,19</td><td> 1,53</td><td> 1,35</td><td> 0,36</td>

Deposition was at about 0.8g to about 2g / cycle. The results show that a uniform amount or dosage of fabric care actives was distributed to each load placed in the dryer. The average supply is approximately 1.33g and its standard deviation is approximately 0.40g each drying cycle. No spotting was observed.

Example 2

A fabric care matrix having a composition shown in the table below was prepared in accordance with the present invention.

TABLE 4

D

<td>C1216EO12</td><td> 33,9</td>

<td>Stearic acid</td><td> 54,8</td>

<td>KOH</td><td> 3,4</td>

<td>PEG8000</td><td> 1,0</td>

<td>Fragrance</td><td> 5,0</td>

<td>H2O</td><td> 1,9</td>

<td></td><td> 100,0</td>

Two samples were made with the above composition, but one sample was made with non-woven material and another was made without non-woven material. The samples contain 20 g of the composition.

Below are the supply data on the drying cycle. It is clear that the sample without non-woven material delivered the majority of the active agents in the first drying cycle, while the sample with non-woven material had a much better controlled delivery of the active agents throughout the multiple drying cycle.

TABLE 5

<td>Composition</td><td>Cycle 1</td><td>Cycle 2</td><td>Cycle 3</td><td>Cycle 4</td><td>Cycle 5</td><td>Average</td><td>OF</td>

<td>D (non-woven material)</td><td> 1,06</td><td> 1,25</td><td> 0,9</td><td> 0,79</td><td> 0,84</td><td> 0,97</td><td> 0,19</td>

<td>D (without non-woven material)</td><td> 14,11</td><td> 2,98</td><td> 0,31</td><td></td><td></td><td></td><td></td>