BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The invention relates to a process for consolidating beds of particulate solids that
include some water into unitary porous solids. The invention also relates to various
useful cleaning products, especially to textile, dishwashing, and surface care cleaning
products in porous solid form, which can be made by the process. Still another aspect
of the invention relates to using the novel solid detergents, cleaners, soaps and
surface care products.
A product according to this invention is a "macrosolid", i.e., it is a unitary solid
three dimensional object that is (i) capable, at a minimum, of retaining a definite
shape and size under the influence of the normal ambient gravitational field at the
surface of the earth and of being moved as a unit by forces exerted at only one end
or edge thereof and (ii) sufficiently large to include within itself at least one
hypothetical cube having a length of 2.5 millimeters (hereinafter often abbreviated
"mm") on each edge. Preferably, with increasing preference in the order given, a macrosolid
product according to the invention is sufficiently large to include within a single
product a hypothetical cube having a length of 5, 6.5, 8.2, 10.0, 12.1, or 13.0 mm
on each edge. A macrosolid thus contrasts with a conventional granular or powdered
solid material, in which each unitary particle is normally no more than 2.2 mm in
at least one of its three principal geometric dimensions. (Granular or powdered solid
cleaners are often preferred for domestic use, where the amount of cleaning power
required often is highly variable from one use of the cleaner to the next. However,
granular or powdered cleaners require the performance of a separate volume or mass
measuring step in order to give reproducible results and efficient use of the cleaner.
Therefore, under industrial or other conditions where the amount of cleaning power
needed from one use of a cleaner to the next is fairly constant, and/or the value
of time saved is more economically important than the possible waste of small amounts
of cleaner, macrosolid cleaners are generally preferred, because a worker can quickly
select and use some small integral number, usually one, of the macrosolid cleaners
for each instance of use, without the need for any more time-consuming measurement
step.)
The units of the macrosolid cleaner according to this invention are commonly called
"tablets" or "blocks", and these terms are used herein for convenience in description
but are not to be understood in and of themselves to imply anything about the content,
strength, or application of the particular formulation. Smaller macrosolids on the
order of 10 to 50 grams in mass are generally referred to as "tablets" because such
relatively small macrosolids often are cylinders with a height substantially less
than the diameter, while larger macrosolids with masses on the order of 100 grams
(hereinafter often abbreviated "g") to several kilograms (hereinafter often abbreviated
"kg") are generally referred to as "blocks". Unless explicitly further qualified,
however, neither "tablet" or "block" should be understood herein as having any quantitative
implications.
Discussion of Related Art
[0002] Acidic to strongly alkaline cleaners and detergents find wide application in the
form of powders, granulates, tablets, pastes, and blocks. Tablets and blocks in the
prior art have generally been made by pressing of powdered solids or of paste-like
slurries of such solids, or by molding of molten constituents or of slurries of partially
solid constituents in some liquid that readily fills a mold. Many prior art processes
for the production of solid cleaning products or molded cleaners, for example, require
heating and mixing of the raw materials and/or aqueous solutions in order to insure
homogeneity in the final product. In addition, thickening, pouring, and cooling of
the heated mixtures either alone or with the use of molds or forms may also be required.
Most conventional prior art techniques for the production of tablets or molded cleaners
suffer from the disadvantage that they require the addition of certain additional
auxiliaries, such as tabletting aids, which must be added to the cleaning-effective
raw materials. These aids are required in order to stabilize the active ingredients
to form a slurry or paste mixture for further processing such as melting, pouring
or being pressed into the final desired product form. Such auxiliaries add no cleaning
power or other desired properties to the final product, but yet are often required
to enable raw materials to be conveniently pumped or otherwise conveyed within a-process,
or to facilitate heat transfer where raw materials exhibit different degrees of heat
stability. The use of such auxiliaries may also contribute to delivery and dissolving
problems. The use of tabletting aids also is disadvantageous because it increases
both raw materials and manufacturing costs.
[0003] US-A-4 118 333 discloses a brittle detergent product of cellular particulate structure
and bulk densities between 0.25 and 0.40 g/cm
3 by providing an aequous slurry and subjecting it to microwave irradiation. During
this process, the labile water evaporates while the water of crystallization is not
effected. The product of the disclosed process is a crumble mass which turns to powder
even under careful mechanical treatment
[0004] EP-A-0 224 129 discloses macrosolid cleaning products from silicates and phosphates
and optionally other components which can be produced by press moulding. The resulting
tablets do not dissolve quickly in water.
OBJECT OF THE INVENTION
[0005] The development of a process that did not involve increased pressures, or heating,
pumping, pouring, cooling of melts, and the like, with the attendant required steps
could potentially streamline the manufacturing process of solid detergents and cleaners.
Moreover, a savings of raw materials could also be realized if the addition of components
that are required solely for handling or heat stabilization purposes were no longer
required. Newer methods have been sought to overcome these disadvantages. Currently,
there is also a desire for higher performance products, which implies the use of lesser
quantities of auxiliaries and therefore greater quantities of active components in
smaller volumes. This gives rise to what is perceived as a "stronger" product. The
result is the tendency towards more concentrated raw materials mixtures which, during
the course of manufacture, may exist as fluids and/or molten streams, with attendant
handling and processing concerns. -It would therefore be advantageous to develop a
process for the manufacture of detergent or cleaner products that demonstrated the
required efficacy and featured ease and greater convenience in raw material handling
and processing.
[0006] It is therefore an object of the present invention to provide a process for the formation
of solid tablet or block cleaning products directly from powder or granular raw material
mixtures.
[0007] It is also an object of the present invention to provide a process for the formation
of solid tablet or block cleaning products directly from powdered or granular raw
material mixtures, which does not require the application of high pressures usually
required to obtain press-form macrosolids, or the bulk melting of raw material mixtures,
and which accommodates certain useful constituent materials that may be impractical
to use in a melt process because of temperature sensitivity or related considerations.
[0008] It is a still further object of the present invention to provide an alternate process
and associated formulations for the production of macrosolid detergents or cleaners
in which the need for non-active ingredients such as ballast, fillers, tabletting
aids, and the like is eliminated or at least reduced.
[0009] Still other objects of this invention will be apparent from the description below.
DESCRIPTION OF THE INVENTION
[0010] Unless there is an explicit statement to the contrary, the description below of groups
of chemical materials as suitable or preferred for a particular ingredient according
to the invention implies that mixtures of two or more of the individual group members
are equally as suitable or preferred as the individual members of the group used alone.
Furthermore, the specification of chemical materials in ionic form should be understood
as implying the presence of some counterions as necessary for electrical neutrality
of the total composition. In general, such counter ions should first be selected to
the extent possible from the ionic materials specified as part of the invention; any
remaining counterions needed may generally be selected freely, except for avoiding
any counterions that are detrimental to the objects of the invention. Also, unless
otherwise specified, figures expressed in terms of "percent" or "%" are to be understood
as percent by weight.
Summary of the Invention
[0011] It has surprisingly been discovered that high frequency electromagnetic energy in
the subinfrared range may be utilized for the rapid formation of macrosolids from
a volume of more to less tightly packed powder or granular raw material(s), when at
least part of these raw materials are hydrated, and that this process may be used
to produce particularly useful acidic to strongly alkaline cleaners in macrosolid
form. An important feature of the invention is that reusable molds or "receptacle
molds" can be employed to enable the formation of tablets or block macrosolids with
excellent reliability and reproducibility. An advantage of the technique is that it
eliminates the need for forming intermediate bulk molten or fluid phases and also
eliminates the alternative need for high pressure compression in order to generate
the final macrosolid product form. A further advantage of the invention is that certain
components, which heretofore could not practically be included in tablets produced
by the prior art technique of forming tablets under pressure, may be incorporated
directly into the macrosolids formed.
[0012] In this description, the term "cleaner" or "cleaning composition" includes any substance
that can readily be used to clean a hard surface or a textile, and thus includes compositions
otherwise known as detergents, cleaners, all-purpose cleaners, scouring cleaners,
pre-soak, and pre-wash products, whether formulated for domestic, institutional, or
industrial application or for manual or automatic laundry washing and dishwashing,
ware-washing, surface washing, floor care or hard surface cleaning in any shape.
[0013] The term "hydrated" as used herein is to be understood as qualified implicitly, if
not explicitly, to mean "hydrated at particular conditions of temperature, pressure,
and relative humidity of the atmosphere to which exposed or with which in equilibrium",
and if these conditions are not specified explicitly, they are to be understood as
those of the ambient atmosphere in a space within which the temperature is maintained
within the normal range for human comfort, i.e., 18 - 30 ° C, and the relative humidity
is between 5 and 95 %, and further as implying that at least one of the following
characterizations of the material is true: (i) The material is a solid including stoichiometrically
well characterized water of hydration or (ii) the material is liquid and/or solid
with a definite measurable mass and, if the temperature of the material is raised
by a sufficient amount above the reference temperature at which the material is hydrated,
and/or if the pressure and/or relative humidity of the gaseous atmosphere to which
the material is exposed is lowered by a sufficient amount from that with reference
to which the material is hydrated, the mass of water vapor in the atmosphere to which
the material is exposed will be increased and the mass of the solid and/or liquid
formerly hydrated material will decrease by an amount that is not more than 120 %,
or preferably, with increasing preference in the order given, not more than 115, 109,
106, 103 or 101, % of the amount by which the mass of the water vapor in the gaseous
atmosphere to which the formerly hydrated material is exposed has increased. A combination
of an initially anhydrous salt and liquid water which is temporarily absorbed by the
salt, or' even liquid water itself, can thus be a "hydrated" material as required
for certain embodiments of this invention, but generally at least some solid hydrated
material is preferred.
[0014] Normally, the above specified transfer of mass from the solid and/or liquid hydrated
material to a water vapor containing gaseous phase, in order for the material to be
useful in this invention, must occur to a measurable extent within 24 hours, or, with
increasing preference in the order given, will occur within 8, 5, 2, 1, 0.5, 0.2,
0.09, or 0.005, hours after a change including at least one of the following conditions:
The temperature is raised by 50° C; the pressure is reduced by 100 millibars; and/or
the relative humidity is reduced by 20 %.
[0015] Microwaves have frequencies above 300 megahertz (hereinafter often abbreviated as
"MHz"), and are generally regarded as having frequencies in the range of 300 to 300,000
MHz. Microwaves belong to the broader range of electromagnetic radiation herein referred
to as "subinfrared electromagnetic radiation" or "SER", which have frequencies ranging
from 3 to 300,000 MHz. The part of this portion of the electromagnetic spectrum not
occupied by microwaves is known as the "radio wave [or 'frequency'] range", and has
frequencies in the range of 3 to 300 MHz. Microwaves are therefore very small wavelength
subinfrared waves. According to the present invention, it is possible to use SER of
either range, microwave or radio wave, to form the macrosolids further described below.
[0016] The term "microwave treatment [or 'irradiation']" or "treatment by [or 'irradiation
with'] microwaves" as used herein refers to the exposure of a raw material or mixture
thereof to electromagnetic energy of the microwave region. The term "SER treatment
[or 'irradiation']" or "treatment by [or 'irradiation with'] SER" as used herein refers
to the exposure of a raw material or mixture thereof to electromagnetic fields of
frequencies from 3 to 300,000 MHz. The words "exposure" or "treatment" in connection
with "SER" or "SER energy" are also to be understood to be generally synonymous within
this context. Where it is necessary to further distinguish between lower frequency
subinfrared electromagnetic energy (i.e., radio waves or "RW" energy, which is generally
understood to mean 3' to 300 MHz), and higher frequency subinfrared electromagnetic
energy (microwave range energy or "MW" energy, which is generally understood to mean
300 to about 300,000 MHz), appropriate distinction will be made within the text.
[0017] Although the permitted radio frequencies vary from country to country, the most common
frequencies for industrial, scientific and medical use ("ISM bands") for radio frequency
include 13.56 and 27.12 MHz, while those for microwave frequency are 896 MHz and 2450
MHz.
[0018] For almost all non-conductive or dielectric chemical compounds that are stable at
normal ambient temperatures of 18 - 30 °C, SER is nonionizing, but it can cause motion
of some atoms in a material with respect to other atoms in the material by migration
of ions, rotation of molecules with dipole moments, or polarization of molecules within
the high frequency electromagnetic field. Exposure to SER does not cause permanent
changes in chemical bonding in such material.
[0019] The terms "particles", "particulate matter", and "powder(s)" imply, unless explicitly
stated to the contrary, that the material so described is in the solid phase. A "bed"
of particulate matter means a collection of particles that, by virtue of mutual physical
support among the particles, and, optionally, between some of the particles and at
least part of the wall or walls of a container for the bed and/or a solid insert within
the bed, has a gross shape that does not change and a size that does not decrease
by motion of the some of the constituent particles with respect to others of the constituent
particles under the influence of the ambient gravitational force at the surface of
the earth, in the absence of any localized vibration of the bed.
[0020] In addition to the solid particles in the bed, there may also be some liquid raw
material in the bed, so long as the volume of liquid relative to the volume of solid
in the bed is not so large as to excessively facilitate the motion of the solid particles
in the bed with respect to one another, so as to cause the bed to fail to satisfy
the conditions of having a gross shape and size unchanging under the influence' of
gravity as specified above.
[0021] The container in which a particle bed is present may be as simple as a flat sheet
on which a bed of particles rests, although ordinarily it will also have walls that
offer some lateral support to the particle bed. The bottom and walls if any of the
container may be of any material adequate to support the particle bed, i.e., not sufficiently
porous that the particles can pass through it under the influence of gravity and the
pressure of overlying parts of the particle bed.
[0022] The material chosen for the container used according to the present invention may
be any SER-compatible and -SER-penetrable material and, in those processes where higher
temperatures are achieved, preferably is a material that is capable of withstanding
temperatures up to, e.g., 160° C. For processes starting from raw material beds containing
NaOH in concentrations greater than 75 %, polystyrene or polyethylene molds preferably
are not used because of the danger of melting them. The material chosen for the container
or mold should also be one which can be formed into and maintain the desired shape
throughout repeated use, if such is desired. Suitable reusable container materials
include glass, polyethylene, polypropylene, plastic, ceramics, or composites thereof,
or any other SER-compatible material at the particular temperatures achieved, depending
upon formulation of the starting raw materials. In those instances where the raw material
mixture contains corrosive components, it is preferable to use a container made of
material resistant to the corrosive effect of the contents. Plastic films, including
water soluble films, may be effectively used as one time containers, which can be
sealed after formation of the macrosolid product within them and serve as a shipping
and dispensing container for the product.
[0023] The "bulk volume" of a bed of particulate matter or of a porous solid means the volume
of the smallest pore- and interstitial space-free solid that could be formed by filling
all the pores and interstitial spaces of the bed or porous solid, and the "pore volume"
of a particle bed or porous solid means the total volume required to fill all the
pores and interstitial spaces of the bed or porous solid to form such a smallest pore-
and interstitial space-free solid. The "density" of a bed of particulate matter or
of a porous solid means the ratio of the mass of the total of solid and liquid phases
contained within the bed or porous solid to the bulk volume of the bed or porous solid.
[0024] In one major embodiment, a process according to this invention comprises steps of:
(A) providing a container with walls penetrable by SER and having within the container
a bed of particles of raw material, at least part of said raw material being a hydrated
material; wherein at least 35 % by weight of the mass of the bed of particles of raw
material consists of material selected from the group consisting of alkali metal and
alkaline earth metal carbonates, hydrogen carbonates, sulfates, hydrogen sulfates,
silicates, phosphates, hydroxides, borates, and citrates, all of which may be hydrated
or anhydrous and
(B) irradiating the bed of particles provided in step (A) for a sufficient time with
SER of sufficient energy to cause the temperature of at least part of said raw material
to rise, and subsequently discontinuing the irradiation of raw material and cooling,
so as to transform the bed of particles into a macrosolid within said container, said
macrosolid having a bulk volume not greater than 1.20 times, or with increasing preference
in the order given, not more than 1.15, 1.11, 1.08, 1.05, 1.03, 1.01, or 1.00 times,
the bulk volume of the particle bed from which it was formed.
[0025] It is known that exposure to electromagnetic energy in the microwave range will cause
water molecules to experience an increase in rotational energy, which may subsequently
be imparted to neighboring molecules or ions in the form of heat. Similarly, electromagnetic
energy in the radio wave range will cause the dipoles within molecules of a susceptible
material to try to orient or align themselves with the electromagnetic field, thus
gaining energy. Because this field typically reverses in excess of 10 million times
a second (or in other words has a frequency of more than 10 MHz), internal friction
takes place among the molecules, which can subsequently be imparted to neighboring
molecules or ions in the form of heat. Particle beds processed according to this invention
in fact usually become heated while being irradiated with SER.
[0026] The phenomenon of using SER is also known as dielectric heating, which is distinct
from conventional heating. Conventional heating has to be applied externally and penetrates
into a material by conduction. Dielectric heating, on the other hand, produces heating
directly within the material, because all the molecules of the material are simultaneously
exposed to high frequency electromagnetic fields. Therefore, the "cooling" described
as part of step (B) above normally begins as soon as SER irradiation is discontinued,
and does not normally imply the use of any special cooling machinery, although such
could be used if desired.
[0027] For each material, there is a quantitative susceptibility to the heating effects
of high frequency electromagnetic energy, which can be measured as a function of frequency,
and generally varies considerably depending on the frequency. Every material or material
mixture therefore normally has an optimum frequency at which it is most receptive
to SER energy. Theoretically, this optimum frequency is the one that should be selected
for SER irradiation.
[0028] The amount of energy that a material absorbs at subinfrared electromagnetic frequencies
is known as its dielectric loss factor, e", which is the product of the dielectric
constant, e, and loss tangent, tan d. At the molecular level, the loss tangent can
be considered as an indication of the average "friction" effect contributed by each
polarized component, and is measured as the tangent of the phase angle between the
field in the material and the applied field. Water has a very high loss factor, and
is therefore particularly receptive to dielectric treatment with SER energy. By way
of comparison, the dielectric loss factor for water (0.1 molal NaCl) is 18 at 3,000
MHz, in the microwave range, but it is 100 at 10 MHz (in the radio wave range). Most
remaining raw material(s) of the present invention generally have much lower loss
factors, and therefore will be relatively little affected by SER irradiation. This
provides a useful limiting mechanism in many situations.
[0029] Scanning electron microscopy ("SEM") studies of macrosolids formed according to this
invention, particularly those exposed to microwave irradiation, show a "bridgework"
structure, in which the originally individual particles have been joined by sufficiently
thick "bridges" to join the former particle bed into a unitary macrosolid. The macrosolid
thus formed can simultaneously be described both as "hard" and "porous", due to the
presence of interstitial spaces as part of this bridgework structure. While applicants
do not wish to be bound by any particular theory, they believe that the heat induced
in the particle bed during irradiation, perhaps accompanied by volatilization of some
of the water initially present, causes a localized sintering of hydrated species alone
and/or accompanied by a concomitant temporary dissolution of other species present
in the raw material to form "bridges" between the initially separate particles in
substantially single point contact. This bridged-type structure may account for the
surprising strength and structural integrity of the macrosolids formed during most
processes according to the invention.
[0030] The application of a process according to this invention to certain kinds of particle
beds produces porous macrosolids with unique combinations of properties that are valuable
in many applications. Accordingly, another major embodiment of this invention is a
macrosolid article having the following characteristics:
(A) at least one of the following two conditions is satisfied:
(i) at least 30 %, more preferably at least 50 %, or still more preferably at least
60 %, of the mass of the macrosolid article consists of material selected from the
group consisting of alkali metal and alkaline earth metal sulfates (including hydrogen
sulfates), carbonates (including acid carbonates, also called bicarbonates), silicates,
optionally hydrated, the silicates preferably having a molar ratio of metal oxide
to silicon dioxide in the range from 1.0:1.0 to 1.0:2.5 (thus including metasilicates,
disilicates, and crystalline layered silicates), zeolites, phosphates (including condensed
phosphates such as pyrophosphates and tripolyphosphates), hydroxides, borates, and
citrates, with the alkali metal salts generally being preferred;
(ii) at least 5 %, or with increasing preference in the order given, at least 10,
20, 30, 40, 50, 60, 70, 80, or 90 %, but not more than 98 % consists of material selected
from the group consisting of materials satisfying both the following two conditions:
(ii.1) the material is solid at 25° C and (ii.2) a solution of 10 % of the material
in water, or a saturated solution of the material in water if its solubility is less
than 10 %, has a pH at 25° C of not more than 4, or with increasing preference in
the order given, of not more than 3.5, 3.0, 2.5, 2.0, 1.5, 1.0, 0.5, or 0.1; and if
as much as 10 % of the mass of the macrosolid is made up of strongly alkaline materials,
no more than 10 % and preferably no more than 5 % of the mass of the macrosolid is
made up of strongly acid materials; and if as much as 10 % of the mass of the macrosolid
is made up of strongly acid materials, no more than 10 % and preferably no more than
5 % of the mass of the macrosolid is made up of strongly alkaline materials, a material
being defined for this purpose as "strongly alkaline" if a 0.1 N solution of the material
in water at 25° C has a pH value of at least 12.0 and being defined as "strongly acid"
for this purpose if a 0.1 N solution of the material in water at 25° C has a pH value
of not more than 2.0;
(B) at least half of the mass of the macrosolid consists of chemical species that
are solid at 25° C and are soluble or homogeneously dispersible in water at 25° C
to form solutions containing at least 10 grams per liter of the dissolved or dispersed
solid chemical species; and
(C) upon immersion at 55° C in a volume of water that is at least ten times the bulk
volume of the macrosolid, the macrosolid dissolves, disintegrates, or both dissolves
and disintegrates, so that no part of the macrosolid remains in any single undissolved
particle having a largest dimension greater than 2.2 mm, within a time after immersion
that is not greater than 0.050 minutes, or with increasing preference in the order
given, not greater than 0.042, 0.036, 0.031, 0.027, 0.020, or 0.010 minutes, per cubic
centimeter of bulk volume of the macrosolid.
[0031] Although, as noted above, both strong acids and strong bases can be included within
the materials of a macrosolid according to this invention, caution should be exercised
during the manufacture of such macrosolids, because, as a result of conversion of
formerly solid acidic and alkaline materials in the raw materials into partly molten
or dissolved phases during manufacture according to this invention, exothermic neutralization
reaction between materials thus freed to react with each other can cause unwanted
temperature irregularities during the SER processing. A significant advantage of a
process according to the present invention is that additional pre-treatment processing
steps, such as pre-heating the raw material mixtures, fluidizing mixtures, pumping
heated fluids, or continuously sweeping streams of hot air through the microwave'
or radio wave treatment chamber, are not required, although it might sometimes be
advantageous. An advantage of the macrosolid tablets and blocks formed according to
the present invention is that a dissolving or pre-use step is not required. The macrosolid
tablet or block may be introduced directly into the cleaning space in which the product
is ultimately used, especially in the areas of industrial and household cleaning,
and particularly with respect to laundry and dishwasher applications.
[0032] As used herein, the term "cleaning space" is intended to encompass any space in which
there is contact between a solid surface, including a textile, and a liquid, liquid
slurry, or paste cleaning composition with the result that some soil material; the
presence of which is undesired on the solid surface, is transferred to the cleaning
composition. Thus, the cleaning space may be the tub or interior space of a clothes
or dishwashing machine, a spray zone of an industrial bottle washing machine, a sink
for manual dishwashing, a floor or wall and the space immediately surrounding the
part of it to be cleaned, the exterior surface of a solid object and the space immediately
surrounding the part of the exterior surface to be cleaned, and the like. In many
cases, the cleaning composition is supplied to the cleaning area from a reservoir,
which may be a stock tank in a washing machine, a spray bottle, a mop bucket, or the
like.
[0033] Still another embodiment of the invention is the use of macrosolid cleaning products
as described above in cleaning any of the wide variety of materials noted above. In
particular, many of the macrosolid cleaner embodiments of the invention are well suited
for use in a dispensing device and method of use as described in Figures 4 and 6 -
9 and in the text from column 9 line 47 through column 16 line 31 of U. S. Reissue
Patent 32,763 of October 11, 1988 to Fernholz et al.
[0034] The porous macrosolids produced according to the invention are also valuable in another
application area. Many cleaners currently on the market exist in liquid form as concentrates
or so-called cleaner "enhancers" which may contain alcohol or other organic solvents.
When combined with water in a use situation, a number of such cleaners suffer from
such undesirable phenomenon as phase separation and salting- or settling-out in solution.
Other cleaners incorporate supplemental additives or require formulations with high
water content in order to keep materials in solution during storage, transportation,
etc. One disadvantage in such instances is that it is costly to transport and provide
additional packaging materials for the larger required product volumes.
[0035] Certain attendant disadvantages of existing cleaner products may be overcome by combining
active components just prior to the dissolution and use of a solid cleaner, such that
there is insufficient opportunity for components to phase separate or fall out of
solution. The macrosolids of the present invention are particularly adaptable to such
an application because, as described briefly above, some of the macrosolid tablets
or blocks formed according to the SER process of the current invention exhibit remarkably
rapid dissolution, or a combination of dissolution and mechanical disintegration upon
exposure to water. Accordingly, another major embodiment of this invention is a two-component
or dual-pack article comprising, preferably consisting essentially of, or more preferably
consisting of:
(A) a macrosolid according to the invention as described above; and
(B) a liquid component, which may optionally contain dissolved solid substances.
[0036] In one preferred embodiment of the invention, a macrosolid and a liquid component
are individually added, or combined and then added, to an appropriate amount of water
to produce the desired cleaning solution for a particular cleaning application just
prior to use. As used herein, the term "just prior to use" is meant to indicate that
after the macrosolid component and liquid component have been combined with water
in preparation for use, the resulting cleaner is preferably used within a time that
is not greater than 480 minutes, or with increasing preference in the order given,
not greater than 240, 120, 60, 30, 15, 5, 1, 0.50, 0.25, 0.10, 0.05, 0.025 or 0.01
minutes of the time at which the macrosolid component and the liquid component are
first combined with water.
[0037] A particular advantage of the dual-pack product according to the present invention
is that it permits the incorporation of certain liquids and dissolved solid substances
into a liquid phase of a cleaning formulation, which for practical purposes cannot
readily be incorporated into the solid component. By way of illustration, such substances
might include liquid waxes or silicones, which are desirable in cleaners in the floor
care area, for example.
Description of Preferred Embodiments
[0038] Typical hydrated materials suitable for use in a process according to this invention
include materials that contain water of crystallization or hydration, i.e., water
molecules, present in a solid in definite stoichiometric ratio to another chemical
constituent of the solid, which can be expelled in whole or in some stoichiometrically
well defined part by raising the temperature of the solid and/or lowering the amount
of water vapor in the gaseous atmosphere to which the solid is exposed past a specific
threshold value; and materials, such as the alkali metal hydroxides, that, without
necessarily having any definite stoichiometric hydrates, may contain "free" water
molecule(s) in some more general association with the solid in continuously variable
amounts down to near zero.
[0039] Particular hydrated compounds useful in the practice of this invention include alkali
metal hydroxides, such as sodium hydroxide and potassium hydroxide; sulfates, such
as magnesium and sodium sulfate; silicates, such as sodium metasilicate; phosphates,
such as sodium tripolyphosphate or trisodium phosphate; carbonates, such as sodium
or potassium carbonate; bicarbonates, such as sodium or potassium bicarbonate; and
borates, such as sodium borate; etc.
[0040] A particularly preferred group of stoichiometrically well characterized hydrated
materials useful in this invention includes sodium metasilicate pentahydrate (Na
2SiO
3 · 5H
2O), sodium carbonate decahydrate (Na
2CO
3 · 10H
2O), sodium tetraborate tetrahydrate (borax, Na
2B
4O
7 · 10H
2O), (and) sodium tripolyphosphate hexahydrate (Ka
5P
3O
10 · 6H
2O), trisodium citrat dihydrate, sodium sulfate decahydrate and disodium hydrogen phosphate
dodecahydrate.
[0041] In some applications of the invention, it is preferred to include in the raw material
in the particle bed at least 4 % by volume, or with increasing preference in the order
given, at least 6, 10, 16, or 25 % by volume, but not more than 35 % by volume, of
solid material that melts at the temperature actually reached during irradiation according
to processes of the invention. This readily melted material may or may not be hydrated,
but often is hydrated. For example, it has been observed that borax, and sodium hydroxide
monohydrate all melt readily under microwave irradiation.
[0042] Another type of material that may be either hydrated or unhydrated and is often advantageously
included in the raw material for a process according to this invention is the type
known as crystalline layered silicates. Such materials are described in U. S. Patent
4,820,439. In brief, crystalline layered silicates consist essentially only of sodium,
silicon, oxygen, and, optionally hydrogen and are capable of acting as both alkalinizing
agents and builders in cleaning formulations. For certain products according to the
invention, at least 1 %, or with increasing preference in the order given, at least
5, 10, 15, 20, 24, 28, 32, 35, 45, or 50 % of the mass of the macrosolid article,
but not more than 90 % of the mass of the macrosolid article, consists of material
selected from the group consisting of crystalline layered silicates. A particularly
preferred crystalline layered silicate is the one described in the noted patent as
"Na-SKS-6" and commercially available under the same designation from Hoechst. Crystalline
layered silicates generally improve the mechanical strength and resistance to mechanical
damage of macrosolids according to the invention that contain them and also improve
the rate at which such macrosolids dissolve and/or disintegrate upon contact with
liquid water. Because of the first improvement noted, larger amounts of other materials
which have useful cleaning properties, but tend to lower the mechanical strength of
macrosolids containing them, can be incorporated into macrosolids according to this
invention than would be practical in the absence of the crystalline layered silicates.
Such desirable constituents of macrosolids according to the invention as abrasives,
and, especially, surfactants, fall into this class of materials that can be more practically
incorporated into macrosolids according to the invention when accompanied by crystalline
layered silicates.
[0043] A process according to the invention utilizes as one of its inputs a plurality, usually
a large plurality, of relatively small particles, which may be called powder, granules,
prills, or some similar term, to make a relatively large unitary solid. In most examples
of practical interest, the relatively small particles used are sufficiently small
that it is impractical to count and characterize each of them individually. Therefore,
all specifications herein that refer to quantitative geometrical characteristics of
individual raw material particles are to be understood as satisfied by consideration
of a sufficient number of individual particles as to give statistical assurance at
the 90 % confidence level or higher that the average of the specified geometrical
characteristic for the entire particle distribution is within 10 % of the value specified.
[0044] For the purposes of this description, the "largest dimension" of any unitary solid
body means the largest distance possible between two hypothetical parallel planes
both of which are touched by the solid body, while the "smallest dimension" of the
unitary solid body is the distance between the closest of all possible pairs of two
hypothetical parallel planes between which the solid body can fit. Preferably, with
increasing preference in the order given, the ratio between the largest dimension
and the smallest dimension of the particles utilized as raw material in a process
according to this invention is not greater than 10:1, 5:1, 2.0:1.0, 1.8:1.0, 1.55:1.00,
1.42:1.00, 1.33:1.00, 1.25:1.00, 1.18:1.00, 1.11:1.00, or 1.06:1.00.
[0045] Also, independently, with increasing preference in the order given, the ratio of
the smallest dimension of the macrosolid made by a process according to this invention
to the smallest dimension of the raw material particles used to make it is at least
5:1, 10:1.0, 30:1.0, 120:1.00, or 600:1.00. This condition shall be considered to
be satisfied if satisfied for the smallest dimension of the raw material particles
used as determined by a statistical analysis as described above, or alternatively
if satisfied by an "alternative smallest dimension" defined by the maximum size of
the openings in a screen, cloth mesh, or like structure that has openings of a known
maximum size and through which all the particles in the particle bed have been passed.
Independently, it is preferred that the average size of the raw material particles
used fall within the range from 1 mm to 2 mm, more preferably from 0.10 to 1.2 mm,
or still more preferably from 0.10 to 0.5 mm. Independently, it is preferred that
the maximum particle size of the solids used in the raw material not be, with increasing
preference in the order given, greater than 1.0, 0.84, 0.71, 0.60, 0.50, 0.42, 0.35,
0.30, 0.25, 0.21, 0.18, 0.15, 0.13, 0.10, 0.088, 0.074, or 0.063 mm.
[0046] Also, independently, with increasing preference in the order given, it is preferred
that at least 60, 70, 80, 87, 92, 97, or 99 % of the volume of the bed of particles
utilized in a process according to this invention be solid rather than liquid at the
temperature of the bed before beginning irradiation with SER; and, independently,
that the pore volume of the particle bed utilized in a process according to the invention
fall within the range of from 1 to 50, 3 to 45, 5 to 40, 7 to 35, 10 to 30, 13 to
28, 15 to 26, or 17 to 25, % of the bulk volume of the particle bed. Independently,
it is also preferred that the pore volume of the macrosolid formed at the end of process
step (B) as defined above in a process according to the invention fall within the
range of from 1 to 50, 3 to 45, 5 to 40, 7 to 35, 10 to 30, 13 to 28, 15 to 26, or
17 to 25, % of the bulk volume of the macrosolid.
[0047] Further, in at least one major embodiment of the invention, it is preferred that,
with increasing preference in the order given, at least 35, 50, 60, 65, 76, 82, 87,
91, or 94 % of the mass of the raw material in the particle bed utilized in a process
according to this invention or present in a macrosolid according to this invention
is selected from the group consisting of alkali metal and alkaline earth metal sulfates
(including hydrogen sulfates), carbonates, hydrogen carbonates, silicates, optionally
hydrated, having a molar ratio of metal oxide to silicon dioxide in the range from
1.0:1.0 to 2.5:1.0 for alkali metals and in the range from 0.5:1.0 to 1.25:1.0 for
alkaline earth metals (thus including metasilicates, disilicates, and crystalline
layered silicates), phosphates (including condensed phosphates such as pyrophosphates
and tripolyphosphates), hydroxides, borates, and citrates. For most purposes, the
alkali metal salts, particularly the sodium and potassium salts, are preferred over
the alkaline earth metal salts. Stoichiometric water of hydration and reversibly bound
water in solid phases are both to be considered as part of the salt or hydroxide to
which they are bound in determining what fraction of the raw material particle mass
is selected from this group of preferred constituents.
[0048] In many embodiments of the invention, it has been found that the most desirable products
are achieved when the content of water in the raw material particle bed is in the
range from 1 to 25 %, or more preferably from 2 to 20 %, of the total mass. In determining
the percentage of water in the total mass, any water of hydration present in the solids
forming the raw material particle bed is counted as water, as are any liquid water
present in the bed and any additional water that would be expelled as vapor from the
initially solid part of the bed upon heating the bed to 100° C, or to the maximum
temperature actually reached within the particle bed during any part of the process,
if such maximum temperature is known or controlled and is lower than 100° C. (This
value can be determined by measuring the expulsion of water vapor from a sample of
the same raw material or raw material mixture, with the same particle size for each
chemically distinct constituent, as forms the raw material particle bed used in the
process according to the invention.) Alternatively, the water content can be measured
by a modified Karl Fischer titration method.
[0049] The SER technique of the present invention may successfully be applied to a variety
of cleaning formulations such as detergents or ware-washing, pre-washes, dishwasher
detergents, carpet cleaners, floor care products, and general rinse/wash or all-purpose
cleaners, and the like, for textiles or hard surfaces. An advantage of this technique
is that the desired cleaner or detergent product may normally be obtained promptly
upon the conclusion of the SER treatment.
[0050] The temperature of the particle bed at the beginning of SER treatment in a process
according to this invention may be varied within wide limits, but for convenience
and economy generally is preferred to be within the range of 15 to 50, more preferably
from 20 to 35, still more preferably from 20 to 25, ° C. In addition, particularly
when the raw materials used in the process include such chemicals as the alkali metal
hydroxides with very high heats of solution in water, it is often advantageous in
a process according to the invention to control the temperature during step (B) of
the process by means of a device that discontinues or reduces the power of the subinfrared
electromagnetic irradiation when a preset temperature of a suitable probe, which is
electronically connected to the controls for generation of the SER radiation source
used in the process and is physically located in close proximity to, preferably within
1 mm of, at least a part of the initial particle bed, is exceeded. Such preferences
can not be stated on a general basis, as they depend on the particular materials processed,
but guidelines can be obtained from the examples below.
[0051] If more than one chemical species makes up the solid raw material of the particle
bed used in a process according to the invention, all the solid components are preferably
mixed with one another to form a substantially homogeneous particle bed which is exposed
to SER. Methods for such mixing will be generally known to those skilled in the art.
For example, hand or mechanical stirrers and/or shakers may be used, the roughly mixed
raw materials may be passed through a grinder or other comminution device, or the
like.
[0052] The duration of exposure of the raw material mixture to SER according to the process
of the current invention will depend upon a number of factors, the most important
of which are discussed here. These include: the power of the SER source; the initial
temperature of the raw materials in the particle bed; the water content of the raw
material; the temperature-sensitivity, if any, of the raw materials; the shape or
configuration of the container used; and the bulk of the material contained therein.
When temperature-insensitive materials are used, however, it is the time duration
required to achieve a sufficient temperature - that is, the temperature at which the
material is transformed from a bed of discrete particles into a unitary solid, or
into a material that will constitute a unitary solid when cooled to a normal ambient
temperature - that will usually govern the duration of exposure of the raw material
mixture to SER. The time of irradiation normally is preferably within the range of
5 seconds (hereinafter often abbreviated "sec") to 30 minutes (hereinafter often abbreviated
"min"), or more preferably from 30 sec to 20 min.
[0053] For example, exposure to microwave radiation in a MLS-1200 T device (Büchi) operating
at 2450 MHz and 250 Watts for times from 2 to 4 minutes has been found to be sufficient
to form 30 g tablets from raw materials that were stable to temperatures of up to
140 - 160 °C, while 250 g blocks at the same power level needed at least 12 minutes.
On the other hand, 30 g tablets can be formed in 15 seconds with the same microwave
radiator at 1000 watts power. With a Hotpoint Model RE600002.92KW microwave generator
rated and used at 240 watts of power output, samples on the order of 400 g in size
needed approximately 8 minutes, while 1 - 2 kg blocks may require 20 minutes or more.
Slightly longer times are needed if more temperature-sensitive raw materials are included
in the particle bed.
[0054] It is also within the teaching of the present invention to use more than one power
setting for different time periods, or to "pulse" a sample with SER radiation for
short intervals, interrupted by other short intervals in which power is discontinued.
"Pulsing" of this type has been found to be particularly advantageous when strongly
acidic macrosolids are desired as the output of a process according to the invention.
Prolonged SER-irradiation of highly acidic particle beds tends to result in oxidative
decomposition of the particle bed and a consequently weak macrosolid, or often failure
to form a macrosolid at all, but short pulses interrupted by periods without irradiation
often overcome this problem. In such circumstances, the time for a continuous interval
of irradiation preferably is, with increasing preference in the order given, not greater
than 120, 85, 60, 45, 30, 20, 15, 10, 8, 7, 6, or 4 sec, and each such continuous
interval of irradiation is independently preferably followed by an interval of at
least equal length in which irradiation is not applied to the particle bed. Generally,
the accumulated time of actual irradiation when using the pulsing technique is approximately
the same as for continuous irradiation in a single interval to form a macrosolid from
other materials, but the time will obviously be adjusted as necessary by those skilled
in the art. Any acid that is solid at the temperature of the particle bed can be successfully
incorporated by this technique. Examples include citric, maleic, oxalic, and sulfamic
acids, with the latter especially preferred for making strong acid cleaners, with
a pH value of as low as about 1 for a solution containing 1 % by weight of the cleaner,
that are especially useful for removing difficult to remove soils such as cement residues.
[0055] Measurements of the dielectric parameters made by means of a Hewlett-Packard HP85070M
Dielectric Probe Measurement System have demonstrated that radio wave irradiation
is suitable for a number of raw material mixtures as shown in Table 1. In all three
cases, the dielectric loss factor, e, in the radio wave range is higher than in the
microwave range, suggesting that the time required to form macrosolids of a particular
composition via radio wave irradiation according to the present invention should be
less than the amount of time required for formation of macrosolids via microwave radiation.
With increasing preference in the order given, the time required with radio wave irradiation
will be no more than 2.0, 1.75, 1.5, 1.25, 1.0, 0.75, 0.25 or 0.01 times the amount
of time required for formation of macrosolids via microwave radiation.
Table 1
Frequency Dependence of Dielectric Loss-Factors, ∈, for Three Raw Material Compositions
Measured at Room Temperature |
Dielectric Loss-Factor, ∈ |
Composition |
200 MHz (Radio Wave Range) |
2,000 MHz (Microwave Range) |
Composition 1 (Perclin™ Supra) |
∼ 13.5 |
∼ 2.5 |
Composition 2 (Sekumatic™ PR) |
∼ 1 |
∼ 0.5 |
Composition 3 (Imi™-powder) |
∼ 1 |
∼ 0.5 |
[0056] Macrosolid tablets and blocks according to the present invention preferably contain
at least 0.1 percent, but more preferably at least 2 % of water up to 15, or more
preferably up to 11, % of water, the difference, if any, in water content before and
after the subinfrared electromagnetic irradiation being believed to be due to the
evolution of some water which usually accompanies the process. More preferably, the
macrosolid products of some processes of the present invention contain from 0.5 to
10 percent of water, and still more preferably from 2 to 6 % of water. The amount
of water present in the macrosolid product may be determined by a conventional modified
Karl Fischer titration, which may be carried out as described in the indented paragraphs
immediately following below. This method determines the amount of water volatilized
from the sample by heating to 200 °C, including any water which is generated as a
result of any possible decomposition reaction that occurs, (e.g., the decomposition
of perborate). The method is accurate to about 0.1 % of water content.
[0057] Principle of the Method: Water is volatilized from the sample material to be tested by heating to 200 °C
in a special drying oven. The water vapor released is transferred in a dry nitrogen
stream into an connected automatic Karl Fischer titrator and therein is titrated.
Apparatus; The apparatus consists of a special drying oven (Metrohm™ E 613) and an automatic
Karl Fischer Titrator (e.g., Metrohm™ E 452). The outlet from the oven is connected
by a glass tube with an inlet capillary tube in the titration container of the titrator.
Nitrogen supply: Conventional compressed nitrogen in a steel tank is used. The pressure is reduced
with the help of a pressure reducing valve to about 2.5 kilopascals/cm2. The outlet
from the tank valve is connected via a hose, made of polyethylene and reinforced with
glass fibers, to a gas flow meter, equipped with a control valve; after the gas flow
meter, an empty safety washing bottle is placed in series, followed by a gas washing
bottle containing concentrated sulfuric acid.
[0058] The washing bottle is connected to a tubing tee, from which one branch leads to a
safety pressure-relief valve, e.g., a washing bottle highly overfilled with sulfuric
acid, prior to which again an empty safety bottle should be inserted in a serial connection.
[0059] From the other branch leading from the tee, a connection with the drying oven is
made via a glass tube, which is perfectly fitted and which is provided at the end
with a spherical ground glass joint. No silicone hose or polyethylene hose may be
used in place of the glass tube, as otherwise at high air humidity water will diffuse
into it and cause an erroneously high value for water.
[0060] Drying oven: The drying oven can be in essence used as delivered; however, the gas inlet and the
gas outlet on the internal attachment piece should be provided with a spherical joint.
[0061] Connection between the drying oven and the Karl-Fischer-titrator: The connection between the drying oven and the titrator consists of a glass tube
provided with spherical joints, the internal diameter of the tube being 1.5 - 2 mm
and the glass tube being attached to an inlet capillary tube of internal diameter
of 1.5 mm, also provided also with a spherical joint. These parts are preferably manufactured
specifically for this purpose and are adjusted to fit the spatial conditions and/or
the titration container. The interconnecting tube may be omitted, if the spatial placement
of the apparatus permits it. The connecting passageway between the oven and the titrator
preferably is provided with a heating device, such as a strip heater or the like,
which allows heating up to 80 - 100 ° C, because the water can otherwise condense
out in this zone.
Karl Fischer Titrator: A Karl Fischer titrator consists of 3 subunits, the titration container with a stirring
device, the control'and measuring electronics, and a dispenser, e.g., Metrohm DosimatTM
E 655. The cover of the titration container is provided with 5 passages. From among
them, the first opening is used for the reading electrode, the inlet capillary tube
is led into the second opening, the third is provided with a rubber stopper with a
hole drilled through, into which a thin polyethylene hose of internal diameter of
about 1 - 2 mm is inserted deep enough that it reaches into the titration container
up to about 3 centimeters (herein often abbreviated "cm") above its bottom. The other
end of the hose leads to a waste container for solvents. The inlet for the Karl Fischer
reagent is connected with the fourth opening, and the fifth opening is provided with
a ground joint stopcock. All passages must be sufficiently tightly fitting to avoid
penetration by water vapor in the air.
The performance of water determination: The drying oven is preheated to 200° C, and the heating of the connecting pipe between
the oven and the titrator is also begun. The nitrogen feed is opened and controlled
so that about 60 ml/min of nitrogen gas flow through the equipment, and the ground
joint stopcock located in the cover of the titration container is also opened. Fifty
ml of methanol is introduced into the titration container, the titrator is switched
on and the methanol is titrated. A one-component Karl Fischer reagent is used as the
titration agent, the pyridine-free Hydranal CompositeTM of Riedel de Haen Company
having proved satisfactory. When the equipment is completely sealed, the blank consumption
after the methanol titration must be below 0.4 ml/h.
[0062] The titrator is set to switch off after 30 seconds of operation. With the help of
a 50 ml syringe, 50 ml of water is added to the methanol previously titrated and the
titration is started again. The coefficient "F" of the reagent solution is calculated
from the equation:
[0063] This factor determination should be repeated at least three times, then an average
from the obtained values should be calculated.
[0064] If the titration container after the completion of the titration is more than 2/3
full, the stopcock in the cover is closed. The overpressure, building up subsequently,
will propel the liquid through the polyethylene hose into the solvent waste container,
until the liquid level reaches the lower edge of the PE hose, then the stopcock in
the cover is opened again.
Water determination in detergents and cleaning agents: The sample of which the water content is to be determined is placed in a small steel
boat (about 6 cm in length x 1.5 cm height x 1 cm width). If no small steel boat is
available, a small boat of comparable measurements can be shaped from a strip of aluminum
foil of 0.5 mm thickness. Into the boat, 300 - 500 mg of the substance to be analyzed
is weighed. For liquid alkaline samples a glazed porcelain boat should be substituted.
[0065] The small boat is introduced into the oven heated to 200° C, the titrator is pre-set
for 30 sec operation and the titration is started. During this process it should be
carefully assured that the methanol used had already been titrated.
[0066] Depending on the substance, the titration is completed after 10 to 20 minutes, the
titrator automatically switches itself off, and the value is recorded.
[0067] The water content of the substance is calculated as follows:
where a = the theoretical titer of the Karl Fischer reagent, F = coefficient of Karl-Fischer-reagent,
and E = sample mass in mg.
[0068] Reproducibility: The standard deviation for this determination, from 6 replications on one sample
with a mean value of 20.5 % water, is 1.1 %. relative.
The invention includes within its scope the formation of macrosolid tablets or blocks
which are formed from a mixture of raw materials containing all or nearly all of the
necessary components for a cleaner formulation. In general, the ingredients and the
relative proportions in which they are used in macrosolid cleaners according to this
invention are substantially the same as those intended to be used for the same purposes
in other solid cleaners of the prior art. The cleaner formulations suited to the present
invention include all-purpose cleaners, detergents, industrial or institutional cleaners,
ware-washing cleaners and automatic detergents for textile or hard-surface cleaning
purposes. In one embodiment of the invention, it is possible to form macrosolid cleaner
or macrosolid detergent tablets or blocks directly from raw material mixtures in disposable
packaging, which constitutes the container during processing. Water-soluble films
may be used for the disposable packaging, as discussed further below. The macrosolid
tablets or blocks of the present invention may further comprise one part of a multiple-part
cleaning combination.
[0069] In yet another embodiment of the invention, it is possible to after-treat tablets,
blocks, or molded macrosolids in which a particular component, such as a microwave-sensitive
substance such as an enzyme, or a surface coating designed to impart certain properties,
such as slower dissolution, for example, is excluded from the raw material mixture
prior to treatment. The SER technique permits the use of these substances by incorporating
them into the porous product from the end of step (B) in a process according to the
invention as defined above, due to the porous structure in the SER macrosolid thus
formed. Accordingly, substances such as those commonly used for coatings on cleaner
blocks to protect against skin contact (i.e., materials such as poly{alkylene}s, especially
poly{ethylene}; poly{alkylene glycol}s, especially poly{ethylene glycol}; fatty acids;
fatty acid amides; paraffin waxes; sorbitol; carbohydrates such as sucrose; and nonionic
surfactants) can be successfully incorporated into the initial macrosolid product
by dipping macrosolid blocks or tablets into appropriate liquid compositions and then
drying some or all of the liquid constituents into a solid contained within the pores
of the initially produced macrosolid.
[0070] Other conventional techniques such as spraying or otherwise applying the component
onto the SER macrosolid are also possible due to the open space structure of the SER-formed
products. On the other hand, if only a surface protective coating is desired, imbibition
of the coating material into the pores and interstitial spaces of the macrosolid cleaners
produced according to this invention may be minimized by coating with a relatively
viscous coating material. Providing protection against unwanted contact with the skin
of users of the macrosolid products of this invention, as with similar conventional
products of the prior art, is important for safety when the cleaners are strongly
alkaline in composition.
[0071] In this respect, the SER technique of the current invention presents a distinct advantage
in the formation of macrosolid products over several prior art techniques. For example,
in the formation of tablets by prior art techniques that involve elevated pressure,
the structure of the resulting solid product is such that the solid cannot readily
absorb additional materials once the tablet has been formed. Where an after-treatment
or incorporation of a SER-sensitive or heat-sensitive material is desired, the open
structure of the SER produced macrosolids permits incorporation of substances through
permeation of these interstices. In this way, a broader range of products in macrosolid
form, including products with most or all of the pores present in the initially formed
macrosolid filled with some solid material, may be achieved with the SER process of
the current invention than is possible with conventional techniques.
[0072] In addition to the preferred materials already described above, other materials that
are suitable and useful for at least some applications as part of the raw material
particle bed for a process according to this invention include the usual nonionic,
anionic, cationic and zwitterionic surfactants and mixtures thereof. The surfactant
or surfactants chosen for use as constituents of the particle bed in accordance with
the present invention in general comprise no more than 40 %, and preferably no more
than 25 %, more preferably no more than 15 % of the total raw material mixture, unless
the latter includes substantial amounts of crystalline layer silicates, in which case
the amount of surfactant may be increased to as much as 60 %. However, if desired,
as it is for certain products according to the invention, additional surfactant can
be added by imbibition into the pores and interstitial spaces of the initially produced
macrosolid product according to this invention.
[0073] Silicates that are useful in the process of the present invention include alkali
metal metasilicates, where the alkali metal is preferably sodium. Preferred sodium
metasilicates include the anhydrous form as well as sodium metasilicate · 5 H
2O. Silicates may preferably be present according to the present invention in amounts
from 0 to 90 %, more preferably 1 to 90 %. Hydrated forms of sodium silicate, particularly
sodium silicate · 5 H
2O, were found to aid in the SER solidifying process when used in ranges of at least
1 percent but less than 50 percent, and preferably between 1 to 30 percent. Also,
as already noted above, crystalline layer silicates are often highly preferred and
advantageous constituents of the particle beds to be consolidated according to this
invention.
[0074] Phosphates that may be used in the SER process of the present invention include alkali
metal tripolyphosphates, hydrogen phosphates and pyrophosphates, either in anhydrous
or hydrated forms or a combination thereof. The preferred alkali metal is sodium.
Preferred sodium phosphates include anhydrous sodium tripolyphosphate ("STPP"), STPP
· 6 H
2O, and trisodium phosphate (TSP) · 10 H
2O. Phosphates may preferably be used in amounts of up to 80 %, more preferably 5 to
80 %. Borates that may be used in the SER process of the present invention include
alkali metal borates, either in the hydrous or anhydrous forms or a combination thereof.
The alkali metal is preferably sodium. Preferred sodium borates include sodium borate
· 10 H
2O (borax). Borates may preferably be present in amounts of up to 20 %, and thus are
preferably used in combination with at least one other raw material.
[0075] Carbonates and bicarbonates that may be used in the SER process of the present invention
include alkali metal carbonates and alkali metal bicarbonates, either in the hydrous
or anhydrous forms, or a combination thereof. The alkali metal is preferably sodium
or potassium. Preferred sodium carbonates include anhydrous sodium carbonate and sodium
carbonate · 10 H
20. Mixtures of sodium carbonate and amorphous sodium silicate sold under the denomination
Nabion 15 by Rhône-Poulenc. The preferred bicarbonate is anhydrous, and sodium is
the preferred alkali metal. Suitably hydrated carbonates may preferably be used in
amounts of up to 100 %, more preferably 1 to 100 %, of the total raw materials mixture.
Bicarbonates, which are also known as hydrogen carbonates or acid carbonates, may
preferably be used in amounts of up to 40 %, more preferably 2 to 40 %, and are thus
preferably used in combination with at least dne other raw material. Where bicarbonates
are used in formulations for promoting hygiene, they are preferably used in amounts
of up to 20 %. Where bicarbonates are used for dishwasher formulations, they are preferably
used in amounts from 5 to 40 %. In certain cases, it is preferable to avoid using
bicarbonates in the same raw material mixture as either carbonates or citrates.
[0076] Alkali metal hydroxides may preferably be present in amounts of up to 80 percent,
and more preferably from 2 to 70 percent. Preferred hydroxides include sodium and
potassium hydroxide. For applications in the kitchen hygiene area, or wherever tablets
with high alkali content are especially desired, the process of the present invention
offers several advantages over prior art techniques. The manufacture of solids containing
high alkali content is not practical using pressing techniques of the prior art, for
example, due to moisture accumulation which occurs on the pressing apparatus during
the process. This is particularly bothersome where formulations containing both sodium
hydroxide and perborate are desired, to the extent that the manufacture of pressed
tablets containing such compositions is believed never to have been practical. Furthermore,
it is not possible to mechanically press tablets with high alkali content when there
is greater than 80 % moisture present in the air. The microwave process of the present
invention is not affected by either of these conditions, and macrosolid tablets that
are not only high in alkali content, but that also contain perborate, have successfully
been obtained.
[0077] Sulfates that may be used in the SER process of the present invention include alkali
metal sulfates and alkaline earth sulfates (in both cases including hydrogen sulfates),
although calcium sulfate is only rarely used because of its low solubility. Alkali
metal sulfates are preferably used in the non-hydrated form; alkaline earth sulfates
are preferably used in the hydrated form. Sodium is the preferred alkali metal for
alkali metal sulfates, and magnesium is the preferred alkaline earth metal for alkaline
earth sulfates. When an alkaline earth sulfate is used in the hydrated form, the preferred
alkaline earth sulfate is MgSO
4 · 7 H
2O. Alkali or alkaline earth sulfates may preferably be used in amounts of up to 80
% of the raw material, but more preferably are used in amounts of 1 to 30 %.
[0078] Citrates that may be used in the SER process of the present invention include hydrated
and non-hydrated alkali metal citrates, and sodium is the preferred alkali metal.
Especially preferred citrates are the mono-, di-, and pentahydrates of trisodium citrate.
Alkali metal citrates may preferably be present in amounts of up to 95 percent, more
preferably 1 to 95 %, of the total solid raw material, and are especially preferably
used in amounts of 30 to 50 % for general cleaning formulations. With respect to some
formulations for use in the dishwashing area, citrates are more preferably used in
amounts of 80 to 90 % of the total solid raw material.
[0079] Nonionic surfactants that may effectively be used in the SER process of the present
invention include those commonly used solid cleaners of similar chemical composition
in the prior art, such as alkylpoly- and -oligoglucosides, N-acylglucamides, alkyl-,
arylalkyl-, alkylaryl-, and aryl-polyoxyalkylenes, esters and amides of polyoxyalkylated
alcohols, preferably ethoxylated fatty alcohols and ethoxylated alkyl phenols. In
some particular applications, the most preferred ethoxylated fatty alcohol is tallow
alcohol condensed with an average of 14 moles of ethylene oxide per mole of tallow
alcohol (this alcohol-ether is hereinafter often abbreviated "TA 14") and the preferred
ethoxylated alkyl phenols are nonylphenol ethoxylates such as NPE 9.5 (with an average
of 9.5 molecules of EO per molecule of nonyl phenol). Nonionic surfactants may preferably
be present in amounts of up to 40 percent, and more preferably in amounts of 1 to
25 %, in the absence of crystalline layer silicates, but may be present in amounts
of up to 60 % in the presence of the latter.
[0080] Anionic surfactants that may be used in the practice of the present invention include
alkane sulfonates, α-olefin sulfonates, fatty acid sulfonates, fatty alkyl sulfates,
fatty alkyl ether sulfates, sulfosuccinates, fatty alkyl ether carboxylates, isethionates,
taurides, sarcosides, fatty acid sulfates, sulfonamidocarboxylates, salts of partial
organic esters of sulfuric and phosphoric acids, salts of sulfated esters and amides
of carboxylic acids, with a preferred group including fatty alkyl sulfates, fatty
alkyl ether sulfates, MersolatTM 95, and linear alkylbenzene sulphonates. Anionic
surfactants may preferably be present in amounts up to 40 percent, and more preferably
from 0.5 to 25 %, in the absence of crystalline layer silicates, but may be present
in amounts of up to 60 % in the presence of the latter.
[0081] Cationic and zwitterionic surfactants may preferably be present in amounts of up
to 25 %, and more preferably from 1 to 15 % of the total raw material mixture. Typical
raw materials of this type, all of which are suitable for use in this invention, include
amine oxides, amidazolinocarboxylates, betaines, and aminocarboxylic acids for zwitterionic
surfactants; and primary, secondary, tertiary, and quaternary ammonium salts, such
as alkanolammonium, imidazolinium, quinolinium and isoquinolinium salts, and thiazolinium
salts as well as the more common fatty ammonium salts, along with sulfonium and tropylium
salts, for cationic surfactants.
[0082] Optionally, the raw material mixture of the current invention may also contain additives
and auxiliaries. Additives preferably are present in amounts not greater than 60 %,
more preferably not greater than 40 %, or still more preferably in amounts of 0.5
to 15 %. Examples of suitable additives include, but are not necessarily limited to:
active oxygen sources and oxidizing materials; activators for active oxygen sources;
active chlorine sources and chlorinecontaining materials; enzymes; sequestrants; fillers
and builders; abrasives; turbidity promoters; dispersants and dispersing agents; corrosion
inhibitors; and disinfectants.
[0083] Auxiliaries may preferably be present in amounts of up to 10 %, and are more preferably
used in amounts of 0.1 to 2 %. Examples of auxiliaries include, but are not necessarily
limited to: perfumes; optical brighteners; dyes and pigments; defoamers and foam inhibitors;
solubilizers; anti-redeposition agents, and dye transfer inhibitors.
[0084] With respect to additives that may be used in the current invention, chlorine and
oxygen sources may be effectively used either coated or uncoated, and may be added
directly to the raw material mixture in either form. Alternately, these materials
may be incorporated into the SER-formed product subsequent to initial macrosolid formation.
Another advantage of the present invention, therefore, is that unlike prior art techniques
for casting or molding solid detergents, the SER process of the present invention
does not require that chlorine-containing components be included as a preformed plug,
cartridge, or core.
[0085] Typical chlorine sources that may be effectively used according to the present invention
include chloroisocyanurates such as di- or tri-chloroisocyanurates, and polychloroisocyanuric
acids. Two examples of the latter include CDB-56™ (available from Olin) and ACL-90™
(available from Monsanto). In the present invention, chlorine sources may preferably
be present in amounts of up to 30 percent, and more preferably from 1 to 5 percent.
It has been found that raw material mixtures that incorporate chlorine sources tend
to exhibit temperature sensitivity during the microwave process, and where such materials
are used, temperature controls should be preferably implemented such that the raw
material mixture does not exceed a particular temperature. In the case of chlorine
source materials, it was determined that temperatures should preferably be kept under
approximately 383 °K (110 °C).
[0086] Active oxygen sources are typically used in powder or granular detergent formulations,
but their use in uncoated form in the present process generally is not preferred,
although both coated and uncoated forms have successfully been used in the present
invention, with careful temperature control. If the raw material mixture achieves
too high a temperature during certain SER treatments, uncoated oxygen sources or oxidizing
sources such as sodium perborate or sodium percarbonate have been observed to decompose,
accompanied by the evolution of gas, which caused foaming in the sample being irradiated.
Accordingly, temperatures for raw material mixtures containing oxygen sources should
preferably be kept under approximately 343 °K (70 °C) during microwave processing
according to this invention. Short pulsed intervals of irradiation interrupted by
intervals without irradiation may be effectively used for such temperature control,
as already noted.
[0087] Coated oxygen sources, however, have surprisingly been found to demonstrate good
compatibility with the SER technique, and tablets and blocks containing coated perborate
or coated percarbonate have successfully been produced directly from pre-mixtures
containing these raw materials. Coated forms of oxygen sources are especially preferred
in applications where strongly alkaline formulations are desired. The use of these
coated compounds as an active oxygen source in the process of the present invention
is therefore preferred. Perborates, percarbonates, or other conventional oxygen sources
may preferably be present in amounts up to 30 percent, and more preferably from about
5 to about 25 percent. Perborates preferably used have the general formula MBO
3 · yH
2O, where M is an alkali metal, most preferably sodium, and y is a number from 1 to
4.
[0088] In addition to the active oxygen sources themselves, it is often advantageous to
include in the particle bed to be consolidated according to this invention and/or
in the macrosolids produced according to this invention one or more materials from
the class known in the cleaner art as "activators" or "bleach precursors". Suitable
such materials include pentaacetyl glucose ("PAG"), 1,5-diacetyl-2,4-dioxohexahydro-1,3,5-triazine
("DADHT"), and N,N,N',N'-tetraacetyl ethylene diamine ("TAED"), with the latter preferred.
Amounts of these activator materials are preferably from 1 - 10 % in particle beds
or macrosolids that also contain active oxygen sources.
[0089] Also belonging to the category of additives in the current invention are enzymes.
Where enzymes are used directly in the raw material mixture of the invention in solid
form, they preferably feature a coating or encapsulation. Uncoated enzymes that are
commercially available in fluid form may also be used. Alternately, enzyme solutions
may also be incorporated into the macrosolid SER tablet or block at a point in the
process subsequent to SER treatment. This incorporation is possible in the present
invention because of pores and/or interstitial spaces which are formed in the macrosolids
during exposure to SER radiation. These internal spaces permit the adsorption of enzymes,
or any other material, directly into the macrosolid tablet or block. According to
one embodiment of the present invention, where the final product contains enzymes,
they may preferably be either amylases or proteases. If desired, the enzymes may be
conventionally coated, as with sulfate coatings, to protect them from adverse interactions
with other constituents of the raw materials used. Enzymes may preferably be present
in amounts up to 10 percent, and more preferably from 0.1 to 5 percent.
[0090] The technique of the present invention represents a distinct advantage over melt-block
processes for the production of enzyme containing detergent formulations of the prior
art. Since the SER process of the current invention may be implemented for short durations
- minutes or even seconds, depending upon composition and size as discussed above
- enzymes such as lipases, cellulases, proteases, and amylases may be directly incorporated
into the macrosolids produced by this technique.
[0091] As indicated above, other conventional detergent or cleaner components may also be
used as additives to the raw materials mixtures according to the SER process of the
invention in addition to active oxygen sources, activators for these active oxygen
sources, chlorine sources, and enzymes. These substances include: sequestrants; fillers
and builders; abrasives; turbidity promoters, dispersants and dispersing agents; corrosion
inhibitors; heavy metal scavengers; waxes; and disinfecting substances.
[0092] Examples of builders are phosphonates and polycarboxylates (i.e., alkali metal salts
of homo- or co-polymers of acrylic acids), which may preferably be present in amounts
of up to 30 percent, and are more preferably used in amounts of 1 to 15 percent; crystalline
layer silicates, which may be used in amounts up to 90 %; and zeolites which may be
used in amounts up to 60 %, preferably in amounts of 10 to 40 %.
[0093] Abrasives that may preferably be used according to the present invention include
such substances as marble, quartz, and alumina powders, preferably of the polishing
grit or particle size, and they preferably are present in amounts not greater than
60 %, or more preferably not greater than 40 %. In one particular embodiment of the
present invention, it is possible to include abrasives of varying size directly into
the raw material particle bed prior to SER treatment, based on the application desired
for the final product. The incorporation of abrasives directly into the particle bed
therefore constitutes an advantage over milk-type scouring products (also called scouring
creams) of the prior art. Prior art products often have sedimentation problems due
to the presence of scouring powders and granular solids in the milk liquor, which
settle with time. In order to overcome these problems, prior art scouring creams often
require the use of suspension agents, which subsequently introduces a second problem.
That is, the use of a second, surfactant-containing cleaning product is often required
in order to wash away the scouring powder and granules after use of the first scouring
cream. This may further introduce rinsing problems. The SER technique of the present
invention avoids both problems, as scouring powders and granular solids of different
sizes may be incorporated, along with a surfactant, directly into a raw material pre-mix
formulation. Not only does this reduce the number of steps that may be required in
a particular cleaning operation, it also reduces the number of items and therefore
attendant packaging materials required.
[0094] Turbidity promoters include preferred styrene-vinylpyrrolidone copolymers in addition
to other usual turbidity promoters. Dispersants include, among known dispersants,
especially naphthalene sulfonic acid condensation products. Preferred corrosion inhibitors
include such materials as technical 2-buten-1,4-diols (available from Colus). Preferred
heavy metal scavengers include phosphonates, nitrilotriacetic acid ("NTA"), and ethylene
diamine tetraacetic acid ("EDTA"). Waxes preferably are present, if at all, in amounts
not greater than 5 percent, and more preferably in amounts from about 0.1 to 2 percent.
Disinfectants include the normal disinfecting substances that would be known by one
familiar with the cleaning arts, and may be used in conventional amounts.
[0095] Perfumes, optical brighteners, dyes and pigments may preferably be used in amounts
of up to 3 percent, and more preferably from 0.001 to 1 percent. Where foam inhibitors
or defoamers are used, they may be mixed directly with the raw materials of the particle
bed. One advantage over prior art techniques of casting or molding solid detergents
is that according to the SER process of the present invention, it is not necessary
to include the foam inhibitor component as a preformed plug or core, as has been taught
in some prior art.
[0096] Dedusters and defoamers such as paraffin oil and silicone oil respectively, for example,
may be present in amounts of up to 5 percent, and are preferably present in amounts
of 0.1 to 3 percent. Anti-redeposition agents may be present in amounts of up to 5
percent, and are preferably present in amounts of 0.1 to 3 percent. The preferred
anti-redeposition agent is carboxymethyl cellulose (CMC). The preferred solubilizers
are alkyl carbonic acids, cumene sulfonates, and toluene sulfonates, although other
solubilizers known to those familiar with the cleaner arts are also suitable. Dye
transfer inhibitors may also be used in amounts of up to 5 percent, and are preferably
present in amounts of 0.1 to 3 percent. The preferred dye transfer inhibitor is poly{vinyl
pyrrolidone} ("PVP").
[0097] When the particle bed to be irradiated according to the invention contains materials
likely to emit gas at elevated temperatures, such as enzymes, active oxygen sources,
activators for active oxygen sources, or sodium bicarbonate, irradiation under reduced
pressure may be advantageous.
[0098] In certain embodiments of the present invention, a separate liquid phase component
can be used in combination with a macrosolid component produced by the SER process
of the invention, resulting in a two component or "dual-pack" product system. Generally,
in the liquid phase component of such dual-packs, the ingredients which are used according
to this invention are substantially the same as those intended to be used for the
same purposes in other liquid cleaners of the prior art. The proportions can be varied
therefrom, however, as it may not be necessary to include water, or at least the same
amount of water as is required in prior art liquid compositions, as water will be
introduced to the liquid component and macrosolid just prior to use. Moreover, another
feature of such a dual-pack embodiment is that it is possible to manufacture more
concentrated products than is possible in the prior art, without having to compromise
final product quality.
[0099] In certain preferred embodiments, the liquids used in the dual-pack embodiment are
selected from the group consisting of known nitrogen-containing solvents such as ammonium
hydroxide or ethanolamines, propylene glycol ethers and glycol ether solvents such
as Propasol solvent B (Union Carbide), monophenyl glycols such as phenoxy ethanol,
and salts of cumene sulfonates, toluene and xylene sulfonates, with the sodium salt
generally being the preferred constituent, such as sodium cumene-sulfonate (40 % aqueous
solution). In general, all the usual water-dispersible materials and solubilizing
agents, such as alcohols, can also be used.
[0100] It is also anticipated that for certain applications, it may'be desirable to include
certain dissolved solids in the liquid component of the dual-pack embodiment according
to the present invention. Such may be the case, for example, if a material is not
amenable to treatment by SER and therefore cannot be incorporated into a macrosolid
produced according to the process of the invention, or for reasons of convenience
or handling, it is more advantageous to include such material in the liquid component
phase of the dual-pack product. Examples of such materials include low-boiling alcohols,
ethanolamines and perfumes with low boiling points that can be evaporated off during
treatment by SER. In other instances, it may be desirable both to dissolve certain
solids in the liquid component and also to include them in the macrosolid component
of the dual-pack product. One example of such a material is potassium hydroxide. In
yet additional embodiments of the invention, it is possible to combine a macrosolid
cleaner with different dual-pack fluid components, or to use a particular dual-pack
fluid component with different macrosolid cleaners in order to achieve a desired result.
These and other variations will be apparent to those skilled in the pertinent art.
[0101] The maximum temperature that is acceptable for the SER process of the present invention
will be below the decomposition temperature of any temperature-sensitive materials,
such as oxidizing materials or chlorine-containing materials, that are present in
the raw material processed.
[0102] In contrast to the press-forming of detergent tablets, it has been found that the
SER process of the present invention can be used to produce macrosolid products of
virtually unlimited size. It will be appreciated by those knowledgeable in the relevant
field, however, that certain practical constraints exist. The power of the SER source,
the size of the SER chamber, and the internal temperature that can be attained in
a sample within a convenient and economically practical amount of time are all factors
that determine the optimal size particle bed to be used. For example, it has been
successfully demonstrated that raw material samples ranging from 10 grams to several
thousand grams can be conveniently and reproducibly exposed to microwave radiation
for times as short as one to two minutes up to approximately twenty minutes in order
to yield tablets or block macrosolids according to the process of the present invention
without external application of pressure, although preforming of the raw material
mixture by application of low pressure might also be possible. The descriptions and
examples contained below contain further guides for successfully practicing the SER
method of the present invention.
[0103] It has also been found that the shape of the container used to hold the particulate
starting raw materials can be optimized in order to enable production of the most
advantageously stable macrosolid tablet or block formed. The container used is generally
open at the top to permit the escape of volatilized water that is generated from the
sample during SER treatment. Where the open end or open portion of a container has
an area "A", the ratio of the square root of A to the depth "D" of the particle bed,
i.e., the maximum distance, in a direction perpendicular to the plane of the area
"A", that is within the particle bed, is preferably within the range from 1:2 to 10:1,
or more preferably from 1:1 to 5:1. This range of ratios permits formation of macrosolid
blocks as well as "flatter" disc-shaped macrosolids that are surprisingly strong and
exhibit good integral strength, without compromising physical strength, so that the
product can be conveniently handled without being readily broken or producing much
powder.
[0104] Virtually any configuration may be used for a container in order to produce a macrosolid
tablet or block according to the present invention. A variety of particular forms
may be desired, for instance, based upon different machine applications. The dimensional
constraints for the tablet or block will depend upon the path that water molecules
must travel in order to escape from the bulk raw material mixture as part of the SER
process, and the length of time that exposure to SER is needed before exceeding the
temperature stability of any of the raw materials. Where a particular cleaner tablet
or block shape is desired that does not meet the above optimal dimension criteria,
such shape is still possible, providing that there are sufficient openings made in
the sides or at the periphery of the container to permit the evolution of water molecules
from the bulk of the raw material mixture during SER treatment.
[0105] The method of the invention is readily adapted for use on a continuous basis, wherein
a plurality of initial particle beds in a plurality of containers is continuously
introduced, by a conventional conveyor for example, into a SER heating zone and the
resultant macrosolid product is continuously removed from said zone, or from an intermediate
cooling zone, in macrosolid form. Not only is it possible to employ reusable containers
with the process of the present invention, but actual shipping or handling containers
can also be used as the containers during the SER processing in order to streamline
the production and packaging processes.
[0106] In one embodiment of the present invention, a container of a watersoluble film material
is used. The container preferably retains an opening to permit the evolution of water
molecules from the raw materials during SER treatment, and can be sealed in a subsequent
step. In yet another embodiment of the present invention, the container is a light-weight
packaging or a thin polymertype material, which may be especially desirable for dispensing
purposes in connection with the use of larger block macrosolids. In still another
embodiment of the present invention, rigid or flexible bags are used as containers.
[0107] In one embodiment of the invention when the container is a reusable one, it is advantageous
to use a container with walls that are capable of reversibly adsorbing and/or absorbing
water. This promotes more rapid solidification of the particle beds used in such containers.
In a variation, several such containers on a continuous belt that circulates in and
out of the SER cavity, and optionally to another source of high temperature to drive
out water from the container walls while the containers are empty, are used.
[0108] The dimensions of the final tablet or block macrosolid that is produced according
to the present invention will, as indicated above, depend upon the initial sample
size and the shape of the receptacle mold or container used. Thus, a sample of 30
g of raw material that was exposed to microwave radiation in a 100 ml Petri dish gave
rise to a tablet on the order of 5.4 cm in diameter by approximately 2.0 cm in height.
A macrosolid cylindrical block formed from a 250 g sample had dimensions of approximately
6 cm for both diameter and height. The dimensions for a cylindrical block formed from
1 kilogram of raw materials were approximately 16 cm in diameter by 4.5 cm. Dimensions
for other size tablets and blocks may be found in the examples below.
[0109] The tablet or block macrosolid formed via the SER process may usually be conveniently
and readily removed from a reusable solidifying container by merely inverting the
container to dislodge the item thus produced. If desired, a releasing agent such as
a silicone spray may also be used to pre-treat the mold before the raw material mixture
is introduced in to the mold.
[0110] As already briefly noted above, it has been surprisingly found that some of the macrosolid
tablets or blocks formed according to the SER process of the current invention including
conventional water soluble alkaline cleaner materials and/or crystalline layer silicates
exhibit remarkably rapid dissolution, or a combination of dissolution and mechanical
disintegration, upon exposure to water. In comparison studies, microwave macrosolids
produced by the current invention exhibited dissolution rates that were at least an
order of magnitude faster than commercially available solids. Thus, blocks on the
order of hundreds of grams up to kilogram size have been shown to disrupt and dissolve
readily when dropped into a beaker of water. One 400 g sample fell completely apart
and was entirely flushed out of the dispensing chamber into which it had been placed.
The bottom of the sink into which the material was dispensed had a build-up of undissolved
material from the block. The macrosolid block therefore allows for easier handling
than a powder and has similar - if not better - dissolving characteristics. This further
provides for less opportunity for operator exposure to partially dissolved tablets
or blocks. From the foregoing, the fact that such SER-produced macrosolid blocks offer
certain conveniences in handling and shipping would therefore be appreciated by those
knowledgeable in this field. Specific comparison data for relative dissolution/disintegration
rates are given in Table 2 below.
[0111] For additional handling convenience or modification of the block properties, it was
discovered that a thin coating layer of poly{ethylene glycol} (hereinafter often abbreviated
"PEG") can be introduced into blocks consolidated via the SER technique of the present
invention. By way of example, either the blocks were dipped into melted PEG after
microwave treatment, or PEG was added to
Table 2
Relative Dissolution Rates of Commercially Available Cleaner Tablets Compared to Microwave
Macrosolid Tablets Prepared by a Process of This Invention |
|
Sample Time for tablet to |
Sample used/Use |
Mass (g) |
completely dissolve (min.) |
Topmat Tabs™/industrial 40 |
∼ 5
40 |
(fresh tablet)
8 - 10 (older tablet) |
Topmat™ Dos extra/ind. |
60 |
23 - 26 |
Somat™ Tabs/household |
35 |
20 - 23 |
Somat™ Supra Tabs/h.hold |
25 |
13 - 15 |
Calgonit™ Tabs/household |
18 |
∼ 2 |
Huy™ Tabs/household |
20 |
8 - 10 |
Example 1.1 (below) |
30 |
∼ 0.2 (9 seconds) |
Larger scale product, with the same materials as |
230 |
∼ 0.8 (50 seconds) |
Example 1.1 |
|
|
Example 1.2 (below) |
30 |
∼ 0.2 (14 seconds) |
Example 1.6 (below) |
30 |
∼ 0.7 (40 seconds) |
Example 1.11 (below) |
30 |
0.3-0.4 (20-25 sec.) |
Notes for Table 2
Dissolution rates were measured in 1 liter of stirred tap water at 55 °C. The Calgonit™
Tabs contain special disintegrating promoting agents. |
the raw materials in powder or flake form prior to microwave treatment. In this manner,
PEG of various molecular weights may be incorporated into larger macrosolid blocks.
In particular, PEG 900, 1450, 3350, 8000, and 20,000 (the numbers representing weight
average molecular weights of the PEG) all gave acceptable results via either of the
above incorporation techniques. It should also be recognized that, where desired,
a combination of the dipping or incorporation techniques is also possible, and would
be consistent with the teaching of the present invention.
[0112] Macrosolid blocks that were dipped into PEG were exposed to the molten substance
for times that varied from approximately five to approximately sixty seconds. One
hundred gram samples were prepared that contained an additional 10 to 36 g of PEG
in the raw materials prior to microwave treatment. Dispensing rates for PEG-treated
blocks - either coated with PEG or with PEG incorporated therein - were then compared.
In general, PEG coated blocks dispensed at a somewhat slower rate than analogous blocks
containing solidified PEG in the raw materials.
Typical Methods of Making Products According to the Invention
[0113] While the following processes are described with reference to specific components,
it should be understood that other components and similar processes can be used together
with the SER process of the present invention in order to produce cleaners or detergents
in the form of tablet or block macrosolids.
[0114] Typically, the starting raw materials for the desired cleaner or detergent formulation
are mixed or combined together at ambient temperatures to form a pre-mix, which is
introduced into a reusable mold or a receiving container device. The minimum amount
of solid raw material which is normally used to form a macrosolid tablet or block
according to the present invention is one half gram (0.5 g).
[0115] The small amount of water required for the process of the invention is usually already
present in the solid raw materials. Where this is not the case, water may be added
to the raw materials prior to SER treatment to provide the water required, depending
upon the desired formulation. Where well-characterized hydrates are used, and the
other raw materials are not strongly hygroscopic, the water content may be calculated
based on the chemical formula and percent of the well-characterized hydrated raw material(s)
used in the pre-mix.
[0116] As will be apparent to those knowledgeable in the field, in certain instances it
may be desirable to pre-heat one or more raw materials or portions thereof prior to
SER treatment. Furthermore, preformed cores or plugs such as those described in U.S.
Re. No. 32,763 (Fernholz, et al.) can be introduced into the container for the raw
material particle bed, before or after the raw material mixture has been introduced
into the mold, but before it is exposed to SER radiation. Alternatively, it may also
be desirable to after-treat the macrosolid block or tablet thus formed via a subsequent
technique such as dipping, spraying or coating, etc., as discussed above. Such after-treatment
may be desirable where, for instance, a particular desired component of the final
product is not stable to SER irradiation, or a particular characteristic enhancement
or deterrent is desired.
[0117] The stability and uniformity of the subinfrared electromagnetic radiation in the
SER chamber or at the point of treatment is an important factor for the successful
practical application of the process according to the present invention. A non-uniform
distribution of SER energy has been observed to create localized hot spots in the
raw materials which can lead to uneven heating and temperature "runaway." Furthermore,
a constant and non-varying SER radiation intensity from one SER treatment to the next
is important, so that raw material formulations may be repeatedly and reproducibly
solidified by the technique. '
[0118] The amount of time required to form a macrosolid tablet or block is dependent on
the sample weight, the size and shape of the container used, and either penetration
depth of SER or the path length required for loss of volatilized water. In those instances
where larger amounts of water may be evolved during SER treatment, it may be desirable
to sweep the treatment chamber with air or an appropriate inert gas so as to prevent
condensation of undesired water within the chamber. With samples on the order of 30
g size, this was not necessary. However, even with the smaller 30 g tablets, where
production conditions require large numbers of samples to be simultaneously treated,
then, depending upon the size and configuration of the chamber and container in which
the samples are exposed to SER, the use of a sweeping stream may be advantageous.
[0119] The present invention may be further appreciated by reference to the following specific
examples and comparisons. As will be readily apparent to one skilled in the relevant
art, these examples are illustrative of various parameters of the present invention,
but they in no way limit its scope, except to the extent that any parameters shown
in the examples may be incorporated into the appended claims.
EXAMPLES GROUP 1
General Conditions for This Group
[0120] A Microwave Laboratory Systems Büchi Model MLS 1200 T microwave generator with 2450
MHz frequency microwaves was used at a power setting of 250 watts. The compounds specified
below were anhydrous (i.e., free from any stoichiometrically well characterized water
of hydration) unless noted to the contrary. The compounds used were initially in granular
or powdered form from conventional commercial sources. These were mixed together and
then ground for about one minute in a conventional domestic coffee grinder (Krups
Type D6, 150 watts power rating) for homogenization and some size reduction. The water
contents of the starting raw materials were determined by calculation from the known
hydrated materials used in each example.
[0121] Thirty grams of the ground raw material mix was put into place in a standard laboratory
Pyrex
R glass Petri dish 5.4 cm in diameter by 2.0 cm in height. The Petri dish was gently
tapped and shaken by hand to facilitate filling it with the ground raw material mix.
The top of the particle bed in the Petri dish was levelled with a scraper, and a cylindrical
block about 2 mm smaller in diameter than the Petri dish was used to apply gentle
pressure of about 0.1 Newton to lightly compact the particle bed before exposure to
the microwave radiation for a period of 2 to 4 minutes, except as noted. In some examples
where noted below, an electronic controller linked with a temperature probe kept inside
the microwave cavity in close proximity to the Petri dish containing the particle
bed was used to reduce microwave power as needed to maintain the probe temperature
at or below a preset level.
[0122] In each case a single macrosolid cleaner tablet with substantially the same dimensions
as the container in which it had been formed and, except for Example 1.11, a mass
of 30±3 grams was obtained. The product could be removed from the container within
a few seconds after discontinuing the microwave radiation.
EXAMPLE 1.1
[0123] A thirty gram (30 g) cleaner tablet was prepared according to the invention using
the following procedure. Approximately 60 parts of sodium metasilicate, 24 parts of
sodium tripolyphosphate (STPP), and 16 parts of sodium carbonate decahydrate were
mixed together. The resulting mixture, which had an initial water content of 10 %,
was introduced into a container which was then placed into a microwave compartment.
The mixture was exposed to microwave radiation for a few minutes, after which a macrosolid
cleaner tablet measuring approximately 5 cm in diameter by 1.5 cm high was obtained.
EXAMPLE 1.2
[0124] This sample was a variation of the formulation used in Example 1.1, in that it included
an uncoated chlorine source, and hydrated forms of sodium silicate and sodium tripolyphosphate,
but no sodium carbonate. The procedure used was the same as that described for Example
1.1, except that a temperature sensing probe spaced no more than 1 mm from the particle
bed container was utilized, and control of the microwave generator was implemented
such that the temperature was maintained below approximately 383° K (110° C). Accordingly,
2 parts of dichloroiso-cyanurate_2H2O, 47 parts of sodium metasilicate, 10 parts of
sodium silicate_5H2O, 40 parts of sodium tripolyphosphate_6H2O and 1 part of paraffin
oil were mixed together. The mixture, which had an initial water content of 14 %,
was exposed to microwave radiation for a few minutes, after which a macrosolid 30
g cleaner tablet measuring approximately 5 cm by 1.2 cm was obtained.
EXAMPLE 1.3
[0125] This example illustrates the difference in having NaOH replace the sodium metasilicate
of Example 1.1. In this instance, hydrous and anhydrous phosphates are also included.
The procedure that was used was the same as described in Example 1.1, except that
an external temperature control was implemented to prevent the temperature within
the microwave chamber from exceeding 383° K (110° C). Accordingly, 1 part of sodium
metasilicate, 14.5 parts of sodium tripolyphosphate, 14.5 parts of sodium tripolyphosphate
·6H2O ("STPP"), 10 parts of sodium carbonate · 10H
2O, and 60 parts of sodium hydroxide were mixed together to give a pre-mix that contained
10 % water. This mixture was exposed to microwave radiation for a few minutes, after
which a macrosolid 30 g tablet measuring approximately 5 cm by 1.2 cm was obtained.
It should be noted that localized "hot spots" and temperature runaway may be observed
with other similar raw materials mixes, especially those containing 65 % or more of
NaOH, when they are exposed to microwave radiation without any form of temperature
control. Temperature control, even with samples containing as much as 50 % NaOH, is
therefore recommended.
EXAMPLE 1.4
[0126] The purpose for this example was to provide a formulation that included sodium hydroxide
with an available chlorine source. Example 1.4 therefore represents a variation on
Example 1.3 above. The procedure followed was similar to that in Example 1.1. Accordingly,
57.7 parts of sodium hydroxide, 1.9 parts of coated dichloroisocyanurate · 2H
2O, 1 part of sodium silicate, 14 parts of sodium tripolyphosphate, 14 parts of sodium
tripolyphosphate · 6H
2O, 9.6 parts of sodium carbonate · 10H
2O, 0.9 parts of wax, and 0.9 parts of paraffin oil were mixed together. The mixture,
which contained approximately 10 % water, was exposed to microwave radiation for a
few minutes, after which a macrosolid 30 g tablet measuring approximately 5 cm by
1.2 cm was obtained.
[0127] The chlorine contents of the products from Examples 2 and 4 were determined by titration,
both before microwave treatment, and fourteen days thereafter. The results obtained,
which gave nearly the theoretical values, are given in Table 3 below.
TABLE 3
Available Chlorine (expressed as percent) |
Example No. |
Untreated Product |
Fourteen Days After Treatment |
1.2 |
1.10 |
1.04 |
1.4 |
0.77 |
0.76 |
EXAMPLE 1.5
[0128] This example illustrates a cleaner formulation that contained an uncoated perborate
as an available oxygen source. The sample was prepared according to the procedure
described in Example 1.1. Accordingly, 6 parts of uncoated sodium perborate · H
2O, 45 parts of sodium silicate, 15 parts of sodium silicate · 5H2O, 28 parts of sodium
tripolyphosphate, 3 parts of sodium carbonate, and 3 parts of sodium carbonate · 10H2O
were mixed together, to give a pre-mix which contained approximately 9 % water. Controls
were implemented such that the temperature was maintained below approximately 383°
K (110° C). Afterwards, a macrosolid 30 g cleaner tablet measuring approximately 5
cm by 1.2 cm was obtained.
EXAMPLE 1.6
[0129] The formulation in this example contained NaOH and a coated perborate as an available
oxygen source. The sample was prepared according to the procedure described in Example
1.1. Accordingly, 50 parts of sodium hydroxide, 10 parts of sodium hydroxide · 1H
2O, 6 parts of coated sodium perborate · H
2O, 1 part of sodium silicate · 5H
2O, 23 parts of sodium tripolyphosphate, and 10 parts of sodium carbonate · 10H
2O were mixed together. A macrosolid 30 g cleaner tablet measuring approximately 5
cm by 1.2 cm was obtained. Controls were again implemented so that the temperature
was maintained below approximately 343° K (70° C) during microwave treatment.
EXAMPLE 1.7
[0130] This was similar to Example 1.6 above, except that the raw materials contained less
sodium hydroxide and more coated sodium perborate. The procedure followed was that
as described in Example 1.1. Accordingly, 34 parts of sodium hydroxide, 8.5 parts
of sodium hydroxide · 1H
2O, 21.3 parts of coated sodium perborate · H
2O, 1.1 parts of sodium silicate · 5H
2O, 24.5 parts of sodium phosphate, and 10.6 parts of sodium carbonate · 10H
2O were mixed together to give a premix which contained approximately 14 % water. The
temperature was again maintained below approximately 343° K (70° C) during the microwave
treatment.
EXAMPLE 1.8
[0131] This example was also similar to Example 1.6 above, except that the available oxygen
source was coated instead of uncoated percarbonate. The procedure followed was that
as described in Example 1.1. Accordingly, 50 parts of sodium hydroxide, 10 parts of
sodium hydroxide · 1H
2O, 6 parts of sodium percarbonate · 2H
2O, 1 part of sodium silicate · 5H
2O, 23 parts of sodium tripolyphosphate, and 10 parts of sodium carbonate · 10H
2O were mixed together. The mixture contained approximately 13 % water. The temperature
was again maintained below approximately 343° K (70° C) during the microwave treatment.
[0132] The oxygen contents of the raw materials and products from Examples 5 - 8 were determined
using standard titration techniques, both before and after microwave treatment. The
results obtained, which gave nearly the theoretical values before treatment, are shown
in Table 4 below.
[0133] As may be seen from the data in Table 4, samples containing coated oxygen sources
retained at least 48 % of the activity of the initial raw material after microwave
treatment. The biggest difference in available oxygen content before and after microwave
treatment was seen with Example 1.5, where an uncoated oxygen source was used.
EXAMPLE 1.9
[0134] This example illustrates the incorporation of sodium sulfate, as well as an anionic
and a non-ionic surfactant, into a cleaner formulation. The procedure fol-
TABLE 4
Available Oxygen (expressed as percent) |
Example No. |
Before Microwave Treatment |
After Microwave Treatment |
Seven Days After Treatment |
1.5 |
0.9 (uncoated) |
< 0.1 |
not avail. |
1.6 |
0.41 (coated) |
0.40 |
0.42 |
1.7 |
1.51 (coated) |
1.38 |
not avail. |
1.8 |
0.75 (coated) |
0.36 |
not avail. |
lowed was similar to that as described in Example 1.1. Accordingly, 5 parts of sodium
silicate, 37.5 parts of sodium carbonate, 29 parts of sodium carbonate · 10H2O, 25
parts of sodium sulfate, 1 part of non-ionic surfactant (TA 14) and 2.5 parts of anionic
surfactant (MersolatTM 95) were mixed together to give a pre-mix that contained approximately
18 % water.
EXAMPLE 1.10
[0135] This example is similar to Example 1.9 above, except that less sodium sulfate and
more of the anionic surfactant was used. The procedure followed was that described
in Example 1.1. Accordingly, 5 parts of sodium silicate, 37.5 parts of sodium carbonate,
29 parts of sodium carbonate · 10H2O, 22.5 parts of sodium sulfate, 1 part of non-ionic
surfactant (TA 14™) and 5 parts of anionic surfactant (Mersolat™ 95) were mixed together
to give a pre-mix that contained approximately 18 % of water.
[0136] The detergent contents of the raw materials and products of Examples 9 and 10 were
determined both before and after microwave treatment. The results obtained, which
gave nearly the theoretical values, are shown in Table 5.
[0137] From these two examples, it may be seen that it is readily possible to incorporate
anionic and non-ionic surfactants into a raw material mixture that is then exposed
to microwave radiation to form a stable product that maintains an effective detergent
strength. It should be noted that the surfactants may be used in virtually any form:
pastes, liquids, solids, powders, flakes or granules.
TABLE 5
Detergent Composition (expressed as percent) |
Example No. |
Non-ionic Detergent Before / After Microwave Treatment |
Anionic Detergent Before / After Microwave Treatment |
1.9 |
0.99 / 0.96 |
1.83 / 1.83 |
1.10 |
0.99 / 0.96 |
3.90 / 3.85 |
EXAMPLE 1.11
[0138] Approximately 85.7 grams of sodium citrate · 2H
2O, 4.3 grams of sodium sulfate · 10H
2O, and 10 grams of Dehypon™ LT 104 (fatty alcohol polyglycol ether, terminally blocked,
nonionic surfactant, product of Henkel) were mixed together and placed into the container
which was introduced into a microwave compartment. The mixture was exposed to microwave
radiation for 3 minutes, after which a macrosolid tablet measuring approximately 5
cm by 1.2 cm was obtained.
EXAMPLE 1.12
[0139] Approximately 40.2 % of sodium sulfate, 34.5 % of sodium citrate dihydrate, 11.5
% of SOKALAN™ CP5, 11.5 % of sodium carbonate decahydrate, and 2.3 % of TAED, totalling
30 g in mass, are mixed together and placed into the container as above. The mixture
is exposed to microwave radiation for 3 minutes, after which a microsolid tablet measuring
approximately 5 cm by 1.2 cm is obtained.
EXAMPLE 1.13
[0140] Approximately 29 % of sodium tripolyphosphate, 1.0 % of sodium metasilicate, 8.5
% of sodium carbonate decahydrate, 41 % of sodium hydroxide, 15 % of sodium hydroxide
monohydrate, 1 % of defoamer, and 4.5 % of coated dichloroisocyanurate dihydrate,
totalling 30 g mass, are mixed together and placed into the container as above. The
mixture is exposed to microwave radiation for 3 minutes, after which a microsolid
tablet measuring approximately 5 cm by 1.2 cm is obtained.
EXAMPLES 1.14 - 1.22
[0141] These examples were all performed in the same general manner as for the preceding
examples in this group, with a total of 30 grams of raw material to produce a macrosolid
tablet approximately 5 cm by 1.2 cm. The compositions of the raw materials for each
of these examples are shown in Table 6. It might be advantageous to irradiate temperature-sensitive
raw material mixtures (e.g. containing sodium perborate or sodium hydrogen carbonate)
in a reduced pressure environment (example No. 1.21, 1.22).
EXAMPLES 1.24 - 1.27
[0142] These examples were all performed in the same general manner as for the other examples
in this group, with a total of 30 grams of raw material to produce a macrosolid tablet
approximately 5 cm by 1.2 cm, except for one important variation: The microwave radiation
was pulsed, alternating for 5 sec intervals with and without radiation until a total
of 45 sec of radiation time had accumulated for the samples. The compositions of the
raw materials for each of these examples, all of which included a substantial proportion
of the strong acid sulfamic acid, are shown in Table 7.
TABLE 7
Component of Raw Material |
Percent of Component in Example No.: |
|
1.24 |
1.25 |
1.26 |
1.27 |
Na2SO4 · 10H2O |
5 |
5 |
5 |
0 |
Na2HPO4 · 12H2O |
0 |
0 |
0 |
5 |
Na2SO4 |
0 |
5 |
0 |
0 |
Dehyphon™ LT 104 |
2 |
2 |
0 |
0 |
MERSOLAT™ H95 |
0 |
0 |
3 |
0 |
Sulfamic acid |
93 |
88 |
92 |
95 |
EXAMPLES 1.28 - 1.41
[0143] These examples were all performed in the same general manner as for the other examples
in this group (except Examples 1.23 - 1.27), with a total of 30 grams of raw material
to produce a macrosolid tablet approximately 5 cm by 1.2 cm. All of these examples
utilize a preferred crystalline layered silicate material already briefly noted above,
Na-SKS-6 commercially supplied by Hoechst AG. The compositions of the raw materials
for each of these examples are shown in Table 8. Compositions 1.32, 1.33, 1.35, and
1.36 consist only of water (as water of hydration) and alkaline cleaning agents. They
can be used, for example, as water softening compositions as part of a cleaner unit
construction system ("Baukastensystem")
EXAMPLES 1.42 - 1.47
[0144] These examples offer direct comparisons between macrosolids with crystalline layered
silicates and those with anhydrous sodium metasilicate instead of the crystalline
layered silicate. All these examples were performed in the same general manner as
for the other examples in this group (except Examples 1.23 - 1.27), with a total of
30 grams of raw material to produce a macrosolid tablet approximately 5 cm by 1.2
cm. The compositions of the raw materials for each of these examples are shown in
Table 9, along with some mechanical strength and disintegration rate comparisons for
the macrosolid products. The latter characteristics are reported according to scales
defined as follows:
|
disintegration rate |
mechanical strength |
++ |
1 g of macrosolid is dissolved in 1 l of stirred tap water at 55°C (20°C) in less
than 6 sec. (19 sec.) |
the macrosolid cannot be broken in two parts by hand |
+ |
1 g of macrosolid is dissolved in 1 l of stirred tap water at 55°C (20°C) in less
than 10 sec. (30 sec.) |
the macrosolid doesn't break when dropped on a tiled floor from 2 m height but can
be broken by hand |
- |
1 g of macrosolid is dissolved in 1 l of stirred tap water at 55°C (20°C) in a time
between 10 and 60 sec. (30 sec. and 5 min.) |
the macrosolid breaks in two parts when dropped on a tiled floor from 2 m height |
-- |
1 g of macrosolid is dissolved in 1 1 of stirred tap water at 55°C (20°C) in more
than 60 sec. (5 min.) |
the macrosolid breaks completely when dropped on a tiled floor from 2 m height |
TABLE 9
Component of Raw Material |
Percent of Component in Example No.: |
|
1.42 |
1.43 |
1.44 |
1.45 |
1.46 |
1.47 |
Pentasodium tripolyphosphate |
40 |
40 |
39.1 |
39.1 |
0 |
0 |
Na2SiO3 |
32 |
0 |
37.3 |
0 |
20 |
0 |
Na2SiO3 · 5H2O |
15 |
15 |
16 |
16 |
0 |
0 |
Na-SKS-6 |
0 |
32 |
0 |
37.3 |
0 |
20 |
Na2CO3 |
0 |
0 |
0 |
0 |
44.8 |
44.8 |
Na2CO3 · 10H2O |
8.5 |
8.5 |
7.6 |
7.6 |
30.2 |
30.2 |
Coated dichloroisocyanurate dihydrate |
4 |
4 |
0 |
0 |
0 |
0 |
DEHYPON™ LT 104 |
0.5 |
0.5 |
0 |
0 |
5 |
5 |
Mechanical strength rating |
+ |
++ |
+ |
++ |
- |
++ |
Disintegration rate rating |
+ |
++- |
+ |
++ |
+ |
++ |
EXAMPLES 1.48 - 1.51
[0145] These examples offer direct comparisons between macrosolids with crystalline layered
silicates and those with Zeolite A, waterglass, or anhydrous sodium metasilicate instead
of the crystalline layered silicate. All these examples were performed in the same
general manner as for the other examples in this group (except Examples 1.23 - 1.27),
with a total of 30 grams of raw material to produce a macrosolid tablet approximately
5 cm by 1.2 cm. The compositions of the raw materials for each of these examples are
shown in Table 10.
EXAMPLES 1.52 - 1.57
[0146] These examples all illustrate macrosolids that are particularly useful as laundry
or other textile cleaning products. They were all performed in the same general manner
as for the other examples in this group (except Examples 1.23 - 1.27), with a total
of 30 grams of raw material to produce a macrosolid tablet approximately 5 cm by 1.2
cm. Compositions of the particle bed used are shown in Table 11.
TABLE 10
Component of Raw Material |
Percent of Component in Example No.: |
|
1.48 |
1.49 |
1.50 |
1.51 |
Na2SiO3 |
0 |
0 |
34.5 |
0 |
PORTIL™ waterglass |
0 |
34.5 |
0 |
0 |
Na-SKS-6 |
34.5 |
0 |
0 |
0 |
Na2CO3 |
32.5 |
32.5 |
32.5 |
32.5 |
Na2CO3 · H2O |
33 |
33 |
33 |
33 |
Zeolite A |
0 |
0 |
0 |
34.5 |
Mechanical strength rating |
+ |
++ |
- |
-- |
Disintegration rate rating |
++ |
-- |
+ |
+ |
EXAMPLES 1.58 - 1.63
[0147] These examples all illustrate macrosolids that are particularly useful as the cleaners
for automatic dishwashing operations. They were all performed in the same general
manner as for the other examples in this group (except Examples 1.23 - 1.27), with
a total of 30 grams of raw material to produce a macrosolid tablet approximately 5
cm by 1.2 cm. Compositions of the particle bed used are shown in Table 12.
EXAMPLES 1.64 - 1.65
[0148] These examples all illustrate macrosolids that contain both acids and alkaline cleaning
agents. They were all performed in the same general manner as for the other examples
in this group (except Examples 1.23 - 1.27), with a total of 30 grams of raw material
to produce a macrosolid tablet approximately 5 cm by 1.2 cm. Compositions of the particle
bed used are shown in Table 13.
EXAMPLES GROUP 2
[0149] All the examples in this group were consolidated using a Hotpoint Model RE60002.92KW
microwave generator (serial number AT9789585) rated at 450 watts power output. The
general conditions were otherwise the same as for Group 1, except that the containers
were of high density polyethylene and the sizes of the containers were more varied,
corresponding to the sizes of the particle beds used, and that the raw materials were
not ground, but merely mixed together by hand, with no deliberate size reduction.
The particle sizes of the vari-
TABLE 11
Component of Raw Material |
Percent of Component in Example No.: |
|
1.52 |
1.53 |
1.54 |
1.55 |
1.56 |
1.57 |
C12-14 fatty acid soap |
2 |
2 |
1.2 |
2 |
1.2 |
0 |
C12-alkylbenzene sulfonate |
10 |
10 |
8.9 |
13 |
9 |
7 |
C12-18 fatty alcohol+5 EO1 |
4.5 |
4.5 |
2.6 |
4 |
2.6 |
10 |
Sokalan™ CP52 |
6 |
6 |
8.2 |
5 |
8.75 |
0 |
Hydroxyethane-1,1diphosphonate |
0.2 |
0.2 |
0.2 |
0.2 |
0.2 |
0 |
Na2CO3 · 10H2O |
14 |
14 |
21 |
20 |
21 |
23 |
Amorphous sodium disilicate |
3.5 |
3.5 |
2.4 |
0.8 |
2.4 |
8 |
Trisodium polyphosphate |
0 |
0 |
0 |
0 |
0 |
30 |
Zeolite A |
35 |
0 |
32 |
6 |
0 |
0 |
Na-SKS-6 |
0 |
35 |
0 |
43 |
32 |
0 |
Lipase |
0.5 |
0.5 |
0 |
0.5 |
1 |
1 |
Protease |
0.95 |
0.95 |
1 |
1 |
1 |
1 |
Silicone oil |
0.15 |
0.15 |
0.15 |
0.15 |
0.15 |
0 |
TAED |
5.5 |
5.5 |
5.5 |
0 |
5.5 |
0 |
Optical brightener |
0.2 |
0.2 |
0.2 |
0.2 |
0.2 |
0 |
Coated sodium perborate monohydrate |
16 |
16 |
12 |
0 |
12 |
0 |
Na2SO4 |
1.5 |
1.5 |
1.65 |
4.15 |
0 |
20 |
Footnotes for Table 11
1This product is made by condensing an average of 5 moles of ethylene oxide ("EO")
per mole of alcohol with a mixture of fatty alcohols of varying chain length as noted. |
2This is an acrylate-maleinate copolymer available commercially from BASF. |
ous raw materials were as shown immediately below. The sieve sizes (numbers) noted
are U. S. Standard Sieves, described in American Society for Testing and Materials
("ASTM") Standard E-11-61 as "Tyler equivalent designations".
TABLE 12
Component of Raw Material |
Percent of Component in Example No.: |
|
1.58 |
1.59 |
1.60 |
1.61 |
1.62 |
1.63 |
Na2CO3 |
0 |
27 |
0 |
19.5 |
0 |
0 |
NaHCO3 |
15 |
0 |
31 |
0 |
31.6 |
0 |
Na2CO3 · 10H2O |
0 |
0 |
16 |
5 |
8 |
5.9 |
Amorphous sodium disillcate |
20 |
20 |
0 |
0 |
0 |
0 |
Na-SKS-6 |
0 |
0 |
0 |
20 |
0 |
0 |
Trisodium citrate dihydrate |
40 |
26 |
36 |
26 |
44.9 |
0 |
Pentasodium tripolyphosphate |
0 |
0 |
0 |
0 |
0 |
29.6 |
Sodium metasilicate |
0 |
0 |
0 |
0 |
0 |
45.7 |
Sodium metasilicate pentahydrate |
0 |
0 |
0 |
0 |
0 |
17.5 |
Coated dichloroisocyanurate |
0 |
0 |
0 |
0 |
0 |
1.3 |
Sokalan™ CP5 |
10 |
10 |
0 |
0 |
0 |
0 |
Degapas™ 3104N1 |
0 |
0 |
0 |
12.5 |
0 |
0 |
Coated sodium perborate monohydrate |
7 |
10 |
10 |
10 |
10 |
0 |
Dehydol™ LS22 |
1 |
1 |
1 |
1 |
1 |
0 |
APG™ 2253 |
1 |
1 |
1 |
1 |
0.8 |
0 |
TAED |
3 |
3 |
3 |
3 |
1.9 |
0 |
Amylase |
1.5 |
1 |
1 |
1 |
1 |
0 |
Protease |
1.5 |
1 |
1 |
1 |
0.8 |
0 |
Footnotes for Table 11
1This is an aqueous solution containing 40 % solids of an acrylate polymer available
commercially from Degussa. |
2This is a fatty alcohol ethoxylate available commercially from Henkel KGaA. |
3This is a C8-10 fatty alkylpolyglucoside available commercially from Henkel Corporation. |
TABLE 13
Component of Raw Material |
Percent of Component in Example No.: |
|
1.64 |
1.65 |
Trisodium citrate dihydrate |
55 |
57 |
Sulfamic acid |
30 |
10 |
Sodium carbonate decahydrate |
5 |
13 |
Sodium carbonate |
10 |
20 |
[0150] Sodium tetraborate tetrahydrate: 0.5 % maximum retained on sieve # 40 (420 µm); 80
% minimum through sieve # 100 (149 µm); 10 maximum through sieve # 200 (74 µm). Trisodium
phosphate dodecahydrate: 99.0 % minimum through sieve # 20 (840 µm); 10 % maximum
through sieve # 100 (149 µm).
Tetrasodium pyrophosphate (anhydrous): 5.0 % maximum retained on sieve # 14 (1410
µm); 25 % maximum through sieve # 100 (149 µm).
Sodium tripolyphosphate hexahydrate: 1.0 % maximum retained on sieve # 14 (1410 µm);
15 % maximum retained on sieve # 20 (840 µm); 75.0 % minimum retained on sieve # 60
(250 µm); 10.0 % maximum through sieve # 100 (149 µm).
Sodium tripolyphosphate granules (anhydrous): 0.5 % maximum retained on sieve # 12
(1700 µm); 12 % maximum retained on sieve # 20 (840 µm); 5 % maximum through sieve
# 200 (74 µm).
Sodium tripolyphosphate powder (anhydrous): 5 % maximum retained on sieve # 60 (250
µm); 90 % minimum through sieve # 100 (149 µm).
Sodium metasilicate pentahydrate: 0.1 % maximum retained on sieve # 12 (1700 µm);
8.0 % maximum retained on sieve # 20 (840 µm); 80 % minimum retained on sieve # 50
(300 µm); 10 % maximum through sieve # 50 (300 µm) but retained on sieve # 60 (250
µm); 5 % maximum through sieve # 60 (250 µm) but retained on sieve # 100 (149 µm);
2 % maximum through sieve # 100 (149 µm).
Sodium metasilicate (anhydrous): 2.0 % maximum retained on sieve # 18 (1000 µm); 80
% minimum retained on sieve # 60 (250 µm); 5.0 % maximum through sieve # 60 (250 µm)
but retained on sieve # 100 (149 µm); 2.0 % maximum through sive # 100 (149 µm).
[0151] Sodium hydroxide (anhydrous): 1.0 maximum retained on sieve # 12 (1700 µm); 40.0
% maximum retained on sieve # 20 (840 µm); 80 % minimum retained on sieve # 60 (250
µm); 5.0 % maximum through sieve # 100 (149 µm).
Sodium carbonate (anhydrous): 0.5 maximum retained on sieve # 14 (1410 µm); 10.0 %
maximum retained on sieve # 20 (840 µm); 75 % minimum retained on sieve # 100 (149
µm); 5.0 % maximum through sieve # 200 (74 µm).
EXAMPLE 2.1
[0152] 20 g of sodium metasilicate · 5H
2O, 50 g of sodium metasilicate, and 30 g of sodium tripolyphosphate powder were mixed
together to give a premix which contained approximately 8.5 % water. The mixture was
exposed to microwave irradiation for 2 min to give a macrosolid tablet.
EXAMPLE 2.2
[0153] 20 g of sodium metasilicate · 5H
2O, 50 g of sodium metasilicate, and 30 g of sodium tripolyphosphate granules were
mixed together to give a premix which contained approximately 8.5 % water. The mixture
was exposed to microwave irradiation for 2 min to give a macrosolid tablet.
EXAMPLE 2.3
[0154] 20 g of sodium metasilicate · 5H
2O, 50 g of sodium metasilicate, and 30 g of sodium carbonate, were mixed together
to give a premix which contained approximately 8.5 % water. The mixture was exposed
to microwave irradiation for 2 min to give a macrosolid tablet.
EXAMPLE 2.4
[0155] 20 g of sodium metasilicate · 5 H
2O, 30 g of sodium metasilicate, 20 g of sodium carbonate, and 30 g of sodium tripolyphopshate
granules were mixed together to give a premix which contained approximately 8.5 %
water. The mixture was exposed to microwave irradiation for 2 min to give a macrosolid
tablet.
EXAMPLE 2.5
[0156] 10 g of sodium metasilicate · 5 H
2O, 55 g of sodium metasilicate, and 35 g of sodium tripolyphosphate granules were
mixed together to give a premix which contained approximately 4.3 % water. The mixture
was exposed to microwave irradiation for 2 min to give a macrosolid tablet.
EXAMPLE 2.6
[0157] 20 g of sodium tetraborate · 5H
2O, 30 g of sodium metasilicate, 20 g of sodium carbonate, and 30 g of sodium tripolyphosphate
granules were mixed together to give a premix which contained approximately 5.8 %
water. The mixture was exposed to microwave irradiation for 2.5 min to give a macrosolid
tablet.
EXAMPLE 2.7
[0158] 20 g of sodium tetraborate · 5H
2O, 50 g of sodium metasilicate, and 30 g of sodium tripolyphosphate granules were
mixed together to give a premix which contained approximately 5.8 % water. The mixture
was exposed to microwave irradiation for 1.5 min to give a macrosolid tablet.
EXAMPLE 2.8
[0159] 10 g of sodium tetraborate · 5H
2O, 40 g of sodium metasilicate, 20 g of sodium carbonate, and 30 g of sodium tripolyphosphate
granules were mixed together to give a premix which contained approximately 2.9 %
water. The mixture was exposed to microwave irradiation for 2 min to give a macrosolid
tablet.
EXAMPLE 2.9
[0160] 10 g of sodium tetraborate · 5H
2O, 55 g of sodium metasilicate, and 35 g of sodium tripolyphosphate granules were
mixed together to give a premix which contained approximately 2.9 % water. The mixture
was exposed to microwave irradiation for 100 sec to give a macrosolid tablet.
EXAMPLE 2.10
[0161] 10 g of trisodium phosphate · 12H
2O, 55 g of sodium metasilicate, and 35 g of sodium tripolyphosphate granules were
mixed together to give a premix which contained approximately 5.2 % water. The mixture
was exposed to microwave irradiation for 2 min to give a macrosolid tablet.
EXAMPLE 2.11
[0162] 20 g of trisodium phosphate · 12H
2O, 30 g of sodium metasilicate, 20 g of sodium carbonate, and 30 g of sodium tripolyphosphate
granules were mixed together to give a premix which contained approximately 10.4 %
water. The mixture was exposed to microwave irradiation for 2 min to give a macrosolid
tablet.
EXAMPLE 2.12
[0163] 20 g of trisodium phosphate · 12H
2O, 50 g of sodium metasilicate, and 30 g of sodium tripolyphosphate granules were
mixed together to give a premix which contained approximately 10.4 % water. The mixture
was exposed to microwave irradiation for 2 min to give a macrosolid tablet.
EXAMPLE 2.13
[0164] 200 g of sodium metasilicate · 5 H
2O, 500 g of sodium metasilicate, and 300 g of sodium tripolyphosphate granules were
mixed together to give a premix which contained approximately 8.5 % water. The mixture
was exposed to microwave irradiation for 17 min to give a solid block containing 3.0
% water.
EXAMPLE 2.14
[0165] 200 g of sodium metasilicate · 5H
2O, 435 g of sodium metasilicate, 300 g of sodium tripolyphosphate granules, 50 g of
sodium carbonate, 10 g of carboxymethylcellulose ("CMC") and 5 g of PVP were mixed
together to give a premix which contained approximately 8.5 % water. The mixture was
exposed to microwave irradiation for 18 min to give a solid block containing 3.0 %
water. The block discolored somewhat during the microwave irradiation, presumably
due to decomposition of CMC and PVP. The block was submerged in a liquid mixture of
20 % of poly(ethylene glycol) with an average molecular weight of about 8000 ("PEG
8000") and 80 % of nonylphenol ethoxylate having an average of 9.5 moles of ethylene
oxide per mole of nonylphenol ("NPE 9.5") at 70° C until there was no further visual
evidence of evolution of gas, which was assumed to be air being displaced from the
pores of the block. The block absorbed 319 g of solution, thus adding 33 % to its
former weight. This equals to having a block which contains 21 % of NPE 9.5.
EXAMPLES GROUP 3
[0166] The following examples are consolidated using a radio wave radiation source.
Examples 3.1 - 3.3
[0167] General conditions are otherwise the same as for Group 1. The compositions of the
raw materials for each of these examples are shown in Table 14.
EXAMPLES GROUP 4
[0168] The following examples feature compositions for a solid component comprising a macrosolid
cleaner tablet, and a liquid component, which together form a two component or "dual-pack"
product. The macrosolid cleaner tablets are prepared using SER under conditions which
are otherwise generally the same as for Group 1. In each case, a macrosolid cleaner
tablet is obtained with substantially the same dimensions as the container in which
it had been formed, and has a
TABLE 14
Component of Raw |
Percent of Component in Example No.: |
|
3.1 |
3.2 |
3.3 |
Sodium metasilicate |
1 |
40.9 |
5.5 |
Sodium metasilicate · 5H2O |
0 |
11.8 |
0 |
Coated dichloroisocyanurate dihydrate |
3.5 |
0 |
0 |
Sodium tripolyphosphate |
30 |
38.7 |
|
Sodium hydroxide |
41 |
0 |
0 |
Sodium hydroxide · H2O |
15 |
0 |
0 |
WUB™ 308 (defoamer) |
1 |
1.1 |
0 |
Sodium carbonate |
0 |
0 |
3.5 |
Sodium carbonate decahydrate |
8.5 |
7.5 |
31.5 |
Sodium sulfate |
0 |
0 |
27.7 |
MERSOLAT™95 |
0 |
0 |
2.7 |
TA 14 |
0 |
0 |
1.1 |
mass of 50±5 grams. The composition for the fluid component is given as percent volume
in a total of 260±26 ml.
Example 4.1
[0169] The first component of a dual-pack product according to the invention, a fifty gram
(50 g) macrosolid cleaner tablet, was prepared from approximately 58 parts of sodium
metasilicate, 24 parts of sodium tripolyphosphate, 16 parts of sodium carbonate decahydrate
and 2 parts of Dehypon™ LT 104 (non-ionic surfactant). The second dual-pack product
component, an accompanying liquid formulation totalling two hundred sixty milliliters
(260 ml), was prepared from 20 parts of monoethanolamine, 14.3 parts of PropasolTM
Solvent B, 14.3 parts of monophenyl glycol (technical grade) and 51.4 parts of 40
% aqueous solution of sodium cumene sulfonate.
Example 4.2
[0170] The first component of a dual-pack product according to the invention, a fifty gram
(50 g) macrosolid cleaner tablet similar in composition to that of Example 4.1, was
prepared from approximately 56 parts of sodium metasilicate, 26 parts of sodium tripolyphosphate,
16 parts of sodium carbonate decahydrate, 1.5 parts of DehyponTM LT 104 (non-ionic
surfactant) and 0.5 parts GenapolTM OX 060 (non-ionic surfactant commercially available
from Hoechst). The second dual-pack product component, an accompanying liquid formulation
totalling two hundred sixty milliliters (260 ml) was prepared as for the liquid component
from sample 4.2 above: 20 parts of monoethanolamine, 14.3 parts of PropasolTM Solvent
B, 14.3 parts of monophenyl glycol (technical grade) and 51.4 parts of 40 % sodium
cumene sulfonate in water solution.
1. A process for the formation of a unitary from a bed of particulate matter, said process
comprising steps of:
(A) providing a container with walls penetrable by SER and having within the container
a bed of particles of raw material, at least part of said raw material being a hydrated
material wherein at least 35 % by weight of the mass of the bed of particles of raw
material consists of material selected from the group consisting of alkali metal and
alkaline earth metal carbonates, hydrogen carbonates, sulfates, hydrogen sulfates,
silicates, phosphates, hydroxides, borates, and citrates, all of which may be hydrated
or anhydrous;
(B) irradiating the bed of particles provided in step (A) for a sufficient time with
SER of sufficient energy to cause the temperature of at least part of said raw material
to rise, and subsequently discontinuing the irradiation of raw material and cooling
it, so as to transform the bed of particles into a macrosolid within said container,
said macrosolid having a bulk volume that is not greater than 1.20 times the bulk
volume of the particle bed from which is was formed.
2. A process according to claim 1, wherein said SER has frequencies in the range from
300 to 300,000 MHz.
3. A process according to claim 1, wherein said SER has frequencies in the range from
3 to 300 MHz.
4. A process according to claim 2, wherein the bed of particles contains water in an
amount within the range from 1 to 25 % by weight.
5. A process according to claim 4, wherein the content of water in the bed of particles
is within the range from 2 to 20 % by weight.
6. A process according to claim 2, comprising a further step of introducing additional
material into the pores, interstitial spaces, or both pores and interstitial spaces
of the macrosolid object formed in step (B) and causing at least part of the additional
material so introduced to remain fixed within, on, or both within and on the macrosolid,
so as to produce a modified macrosolid.
7. A process according to claim 6, wherein the additional material comprises at least
one material selected from the group consisting of poly(alkylene glycol)s, fatty acids,
fatty acid amides, paraffin waxes, sorbitol, carbohydrates, abrasives, and nonionic
surfactants and the total additional material is present at the completion of the
process in a sufficient amount and is so distributed as to form a coating over the
material that was in the macrosolid before the introduction of the additional material.
8. A process according to claim 6, wherein said additional material comprises at least
one of poly(alkylene glycol) and anionic, cationic, nonionic, and zwitterionic surfactants.
9. A process according to claim 8, wherein the final modified macrosolid product contains
more than 5 % by weight of total surfactant.
10. A process according to claim 9, wherein the final modified macrosolid product contains
more than 25 % by weight of total surfactant.
11. A process according to claim 6, wherein the additional material comprises an enzyme.
12. A process according to claim 2, wherein the macrosolid product has a water content
within the range from 0.1 to 11 % by weight.
13. A process according to claim 12, wherein the water content is within the range from
0.5 to 10 % by weight.
14. A process according to claim 13, wherein the water content is within the range from
2 tos 6 % by weight.
15. A process according to claim 1, wherein at least half of the mass of the raw material
consists of chemical species that are solid at 25°C and are soluble or homogeneously
dispersible in water at 25°C to form solutions containing at least 10 grams per liter
of the dissolved or homogeneously dispersed solid chemical species; the ratio of the
smallest dimension of the macrosolid made by the process to the smallest dimension
of the particles in the bed of particles is at least 10:1; at least 60 % by weight
of the volume of the bed of particles is solid at the temperature of the bed of particles
before beginning irradiation with SER; and the pore volume of each of the bed of particles
and the macrosolid is within the range from 1 to 50 % by weight of the respective
bulk volumes.
16. A process according to claim 15, wherein said SER has frequencies in the range from
300 to 300,000 MHz.
17. A process according to claim 15, wherein said SER has frequencies, in the range from
3 to 300 MHz.
18. A process according to claim 2, wherein at least 50 % by weight of the mass of the
bed of particles of raw material consists of material selected from the group consisting
of sodium, potassium, and magnesium sulfates, hydrogen sulfates, carbonates, hydrogen
carbonates, silicates, phosphates, hydroxides, borates, and citrates; at least 70
% by weight of the volume of the bed of particles is solid at the temperature of the
bed of parcticles before beginning irradiation with SER; and the pore volume of each
of the bed of particles and the macrosolid is within the range from 3 to 45 % by weight
of the respective bulk volumes.
19. A process according to claim 2, wherein the macrosolid product produced by the process
has the property that upon immersion at 55°C in a volume of water that is at least
ten times the bulk volume of the macrosolid, the macrosolid dissolves, disintegrates,
or both dissolves and disintegrates, so that no part of the macrosolid remains in
any single undissolved particle having a largest dimension greater than 2.2 mm, within
a time after immersion that is not greater than 0.036 minutes per cubic centimeter
of bulk volume of the macrosolid.
20. A process according to claim 2, wherein the bed of particles contains at least one
material selected from the group consisting of coated chlorine sources, uncoated chlorine
sources, coated chlorine-containing materials, uncoated chlorine-containing materials,
coated active oxygen sources, and uncoated active oxygen sources.
21. A process according to claim 2, wherein the bed of particles contains at least 1 %
by weight of material selected from the group consisting of crystalline layered silicates.
22. A macrosolid cleaning product, having the characteristics that:
(A) at least one of the following two conditions is satisfied:
(i) at least 30 % by weight of the mass of the macrosolid article consists of material
selected from the group consisting of alkali metal sulfates, carbonates, optionally
hydrated silicates, zeolites, phosphates, hydroxides, borates, and citrates;
(ii) at least 5 % by weight, but not more than 98 % by weight consists of material
selected from the group consisting of materials satisfying both the following two
conditions:
(ii.1) the material is solid at 25°C and (ii.2) a solution of 10 % by weight of the
material in water, or a saturated solution of the material in water if its solubility
is less than 10 % by weight, has a pH at 25°C of not more than 4, and if as much as
10 % by weight of the mass of the macrosolid is made up of strongly alkaline materials,
no more than 10 % by weight of the mass of the macrosolid is made up of strongly acid
materials; and if as much as 10 % by weight of the mass of the macrosolid is made
up of strongly acid materials, no more than 10 % by weight of the mass of the macrosolid
is made up of strongly alkaline materials, a material being defined for this purpose
as "strongly alkaline" if a 0.1 N solution of the material in water at 25°C has a
pH value of at least 12.0 and being defined as "strongly acid" for this purpose if
a 0.1 N solution of the material in water at 25°C has a pH value of not more than
2.0;
(B) at least 50 % by weight of the mass of the macrosolid consists of chemical species
that are solid at 25°C and are soluble in water at 25°C to form solutions containing
at least 10 grams per liter of the dissolved solid chemical species; and
(C) upon immersion at 55°C in a volume of water that is at least ten times the bulk
volume of the macrosolid, the macrosolid dissolves, disintegrates, or both dissolves
and disintegrates, so that no part of the macrosolid remains in any single undissolved
particle having a largest dimension greater than 2.2 mm, within a time after immersion
that is not greater than 0.050 minutes per cubic centimeter of bulk volume of the
macrosolid.
23. A cleaning product according to claim 22 having a pore volume in the range from 1
to 60 % by weight of the bulk volume of the cleaning product and having at least 60
% by weight of its mass consisting of material selected from the group consisting
of sodium, potassium, and magnesium sulfates, carbonates, silicates, phosphates, hydroxides,
borates, and citrates.
24. A cleaning product according to claim 22 containing at least one of the following
types and amounts of surfactants: (i) from 1 to 25 % by weight of nonionic surfactants;
(ii) from 0.5 to 25 % by weight of anionic surfactants; and (iii) from 1 to 15 % by
weight of the total of cationic and zwitterionic surfactants, the surfactants being
selected subject to the constraint that the total amount of surfactant is not greater
than 60 % by weight.
25. A cleaning product according to claim 22 containing from 80 to 90 % by weight of material
selected from the group of alkali metal citrates.
26. A cleaning product according to claim 22 containing at least one of the following:
(1) from 1 to 90 % by weight of silicates;
(2) from 5 to 80 % by weight of phosphates;
(3) from 2 to 40 % by weight of bicarbonates;
(4) from 2 to 70 % by weight of alkali metal hydroxides;
(5) from 1 to 30 % by weight of sulfates selected from the group consisting of sodium
and magnesium sulfates;
(6) from 1 to 95 % by weight of citrates; and
(7) from 1 to 100 % by weight of carbonates.
27. A cleaning product according to claim 22 having a pore volume within the range from
5 to 40 % by weight of its bulk volume.
28. A process for cleaning a hard surface or a textile with the aid of a cleaner composition,
wherein the improvement comprises using a solid cleaning product according to claim
22 as the source of the cleaning-effective solute in a cleaning composition that is
an aqueous solution, this solution optionally including undissolved slurried solid
particle not greater than 2.2 mm in their smallest dimension.
29. A two-component cleaning article having the following characteristics:
(A) a solid first component, wherein said first component consists of a macrosolid
tablet or block prepared according to a process according to claim 1; and
(B) a liquid second component, wherein said second component consists of at least
one fluid component, and which further may optionally contain dissolved solid substances.
30. A process according to claim 28 comprising the following steps:
(A) placing the cleaning product in a dispensing device having a spray means, in a
position with respect to the horizontal and with respect to said spray means, for
dispensing cleaner downwardly from said cleaning product, wherein the solid cleaning
product is oriented to provide at least one surface thereof that is exposed and drainable;
(B) impining a spray of aqueous liquid from said spray means upon the exposed an drainable
surface of the solid cleaning product to dissolve or both dissolve and disintegrate
said solid cleaning product and thereby form an aqueous liquid solution of the cleaner
which drains downwardly simultaneously with said impinging.
31. A process according to claim 30, wherein said cleaning product in step (A) additionally
comprises a liquid component of a dual-pack product according to claim 29.
32. A process according to claim 30, wherein in step (A) the cleaner is dispensed to a
ware washing zone of a ware washing machine, a textile washing zone of a textile washing
machine, or a reservoir for later dispensing to a ware washing zone of a ware washing
machine or a textile washing zone of a textile washing machine.
33. A process according to claim 28, wherein the cleaning composition is dispensed into
a ware washing zone of a ware washing machine, a textile washing zone of a textile
washing machine, or a reservoir for later dispensing to a ware washing zone of a ware
washing machine or a textile washing zone of a textile washing machine.
1. Verfahren zur Bildung eines einteiligen Makrofeststoffs aus einem Bett aus teilchenförmigem
Material, bei dem man:
(A) einen Behälter mit SER-durchlässigen Wänden bereitstellt, der ein Bett aus Ausgangsmaterialteilchen
enthält, wobei es sich bei dem Ausgangsmaterial zumindest zum Teil um ein hydratisiertes
Material handelt, wobei mindestens 35 Gew.-% der Masse des Betts aus Ausgangsmaterialteilchen
aus Material aus der Gruppe bestehend aus Alkalimetall- und Erdalkalimetallcarbonaten,
-hydrogencarbonaten, -sulfaten, -hydrogensulfaten, -silicaten, -phosphaten, -hydroxiden,
-boraten und -citraten, die alle hydratisiert oder wasserfrei sein können, bestehen;
(B) das in Schritt (A) bereitgestellte Teilchenbett über einen ausreichend langen
Zeitraum mit SER so hoher Energie bestrahlt, daß die Temperatur von zumindest einem
Teil des Ausgangsmacerials ansteigt, und anschließend die Bestrahlung des Ausgangsmaterials
beendet und das Ausgangsmaterial abkühlt, wobei das Teilchenbett in dem Behälter in
einen Makrofeststoff umgewandelt wird, welcher ein Schüttvolumen aufweist, das nicht
mehr als 1,20-fache des Schüttvolumens des Teilchenbetts, aus dem er gebildet wurde,
beträgt.
2. Verfahren nach Anspruch 1, bei dem die SER Frequenzen im Bereich von 300 bis 300.000
MHz aufweist.
3. Verfahren nach Anspruch 1, bei dem die SER Frequenzen im Bereich von 3 bis 300 MHz
aufweist.
4. Verfahren nach Anspruch 2, bei dem das Teilchenbett Wasser in einer Menge im Bereich
von 1 bis 25 Gew.-% enthält.
5. Verfahren nach Anspruch 4, bei dem der Wassergehalt des Teilchenbetts im Bereich von
2 bis 20 Gew.-% liegt.
6. Verfahren nach Anspruch 2, bei dem man ferner zusätzliches Material in die Poren und/oder
Zwischenräume des in Schritt (B) gebildeten Makrofeststoff-Objekts einbringt und zumindest
einen Teil des so eingebrachten zusätzlichen Materials in und/oder auf dem Makrofeststoff
fixiert, wobei man einen modifizierten Makrofeststoff erhält.
7. Verfahren nach Anspruch 6, bei dem das zusätzliche Material zumindest ein Material
aus der Gruppe bestehend aus Polyalkylenglykolen, Fettsäuren, Fettsäureamiden, Paraffinwachsen,
Sorbit, Kohlenhydraten, Abrasivstoffen und nichtionischen Tensiden enthält und das
gesamte zusätzliche Material bei Beendigung des Verfahrens in einer so großen Menge
vorliegt und so verteilt ist, daß sich eine Beschichtung über dem vor dem Einbringen
des zusätzlichen Materials in dem Makrofeststoff vorhandenen Material bildet.
8. Verfahren nach Anspruch 6. bei dem das zusätzliche Material zumindest ein Material
aus der Gruppe bestehend aus Polyalkylenglykol und anionischen, kationischen, nichtionischen
und zwitterionischen Tensiden enthält.
9. Verfahren nach Anspruch 8, bei dem das fertige modifizierte Makrofeststoffprodukt
insgesamt mehr als 5 Gew.-% Tensid enthält.
10. Verfahren nach Anspruch 9, bei dem das fertige modifizierte Makrofescstoffprodukt
insgesamt mehr als 25 Gew.-% Tensid enthält.
11. Verfahren nach Anspruch 6, bei dem das zusätzliche Material ein Enzym enthält.
12. verfahren nach Anspruch 2, bei dem das Makrofeststoffprodukt einen Wassergehalt im
Bereich von 0,1 bis 11 Gew.-% aufweist.
13. Verfahren nach Anspruch 12, bei dem der Wassergehalt im Bereich von 0,5 bis 10 Gew.-%
liegt.
14. Verfahren nach Anspruch 13, bei dem der Wassergehalt im Bereich von 2 bis 6 Gew.-%
liegt.
15. Verfahren nach Anspruch 1, bei dem mindestens die Hälfte der Masse des Ausgangsmaterials
aus chemischen Spezies besteht, die bei 25°C fest und in Wasser bei 25°C unter Bildung
von Lösungen, die mindestens 10 Gramm pro Liter der gelösten oder homogen dispergierten
festen chemischen Spezies enthalten, löslich oder homogen dispergierbar sind; das
Verhältnis der kleinsten Abmessung des nach dem Verfahren hergestellten Makrofeststoffs
zur kleinsten Abmessung der Teilchen in dem Teilchenbett mindestens 10:1 beträgt;
mindestens 60 Gew.-% des Volumens des Teilchenbetts bei der Temperatur des Teilchenbetts
vor Beginn der Bestrahlung mit SER fest sind und das Porenvolumen des Teilchenbetts
und des Makrofeststoffs jeweils im Bereich von 1 bis 50 Gew.-% der jeweiligen Schüttvolumina
liegt.
16. Verfahren nach Anspruch 15, bei dem die SER Frequenzen im Bereich von 300 bis 300.000
MHz aufweist.
17. Verfahren nach Anspruch 15, bei dem die SER Frequenzen im Bereich von 3 bis 300 MHz
aufweist.
18. Verfahren nach Anspruch 2, bei dem mindestens 50 Gew.-% der Masse des Betts aus Ausgangsmaterialteilchen
aus Material aus der Gruppe bestehend aus Natrium-, Kalium- und Magnesiumsulfat, -hydrogensulfat,
-carbonat, -hydrogencarbonat, -silicat, -phosphat, -hydroxid, -borat und -citrat bestehen;
mindestens 70 Gew.-% des Volumens des Teilchenbetts bei der Temperatur des Teilchenbetts
vor Beginn der Bestrahlung mit SER fest sind und das Porenvolumen des Teilchenbetts
und des Makrofeststoffs jeweils im Bereich von 3 bis 45 Gew.-% der jeweiligen Schüttvolumina
liegt.
19. Verfahren nach Anspruch 2, bei dem das nach dem Verfahren hergestellte Makrofeststoffprodukt
die Eigenschaft besitzt, daß der Makrofeststoff beim Eintauchen in ein Wasservolumen,
das mindestens zehnmal so groß wie das Schüttvolumen des Makrofeststoffs ist, bei
55°C innerhalb eines Zeitraums nach dem Eintauchen von höchstens 0,036 Minuten pro
Kubikzentimeter Schüttvolumen des Makrofeststoffs aufgelöst wird und/oder zerfällt,
so daß kein Teil des Makrofeststoffs in einem einzigen ungelösten Teilchen mit einer
größten Abmessung von mehr als 2,2 mm verbleibt.
20. Verfahren nach Anspruch 2, bei dem das Teilchenbett mindestens ein Material aus der
Gruppe bestehend aus beschichteten Chlorquellen, unbeschichteten Chlorquellen, beschichteten
chlorhaltigen Materialien, unbeschichteten chlorhaltigen Materialien, beschichteten
Aktivsauerstoffquellen und unbeschichteten Aktivsauerstoffquellen enthält.
21. Verfahren nach Anspruch 2, bei dem das Teilchenbett mindestens 1 Gew.-% Material aus
der Gruppe bestehend aus kristallinen Schichtsilicaten enthält.
22. Makrofeststoff-Reinigungsprodukt mit den Kennzeichen, daß
(A) mindestens eine der folgenden zwei Bedingungen erfüllt ist:
(i) mindestens 30 Gew.-% der Masse des Makrofeststoff-Artikels bestehen aus Material
aus der Gruppe bestehend aus Alkalimetallsulfaten, Alkalimetallcarbonaten, gegebenenfalls
hydratisierten Alkalimetallsilicaten, Alkalimetallphosphaten, Alkalimetallhydroxiden,
Alkalimetallboraten und Alkalimetallcitraten;
(ii) mindestens 5 Gew.-%, aber nicht mehr als 98 Gew.-%, bestehen aus Material aus
der Gruppe von Materialien, die beide der folgenden zwei Bedingungen erfüllen:
(ii.1) das Material ist bei 25°C fest und
(ii.2) eine 10 gew.-%ige Lösung des Materials in Wasser oder eine gesättigte Lösung
des Materials in Wasser, sofern dessen Löslichkeit weniger als 10 Gew.-% beträgt,
weist bei 25°C einen pH-Wert von nicht mehr als 4 auf, und dann, wenn bis zu 10 Gew.-%
der Masse des Makrofeststoffs aus stark alkalischen Materialien bestehen, bestehen
nicht mehr als 10 Gew.-% der Masse des Makrofeststoffs aus stark sauren Materialien;
und dann, wenn bis zu 10 Gew.-% der Masse des Makrofeststoffs aus stark sauren Materialien
bestehen, bestehen nicht mehr als 10 Gew.-% der Masse des Makrofeststoffs aus stark
alkalischen Materialien, wobei ein Material für diesen Zweck als "stark alkalisch"
definiert ist, wenn eine 0,1 N Lösung des Materials in Wasser bei 25°C einen pH-Wert
von mindestens 12,0 aufweist, und als "stark sauer" definiert ist, wenn eine 0,1 N
Lösung des Materials in Wasser bei 25°C einen pH-Wert von nicht mehr als.2,0 aufweist;
(B) mindestens 50 Gew.-% der Masse des Makro- feststoffs aus chemischen Spezies bestehen,
die bei 25°C fest und bei 25°C in Wasser unter Bildung von Lösungen, die mindestens
10 Gramm pro Liter der gelösten festen chemischen Spezies enthalten, löslich sind;
und
(C) der Makrofeststoff beim Eintauchen in ein Wasservolumen, das mindestens zehnmal
so groß wie das Schüttvolumen des Makrofeststoffs ist, bei 55°C innerhalb eines Zeitraums
nach dem Eintauchen von höchstens 0,050 Minuten pro Kubikzentimeter Schüttvolumen
des Makrofeststoffs aufgelöst wird und/oder zerfällt, so daß kein Teil des Makrofeststoffs
in einem einzigen ungelösten Teilchen mit einer größten Abmessung von mehr als 2,2
mm verbleibt.
23. Reinigungsprodukt nach Anspruch 22, das ein Porenvolumen im Bereich von 1 bis 60 Gew.-%
des Schüttvolumens des Reinigungsprodukts aufweist und bei dem mindestens 60 Gew.-%
seiner Masse aus Material aus der Gruppe bestehend aus Natrium-, Kalium- und Magnesiumsulfat,
-carbonat, -silicat, -phosphat, -hydroxid, -borat und -citrat bestehen.
24. Reinigungsprodukt nach Anspruch 22, enthaltend mindestens einen der folgenden Tensidtypen
in den folgenden Mengen: (i) 1 bis 25 Gew.-% nichtionische Tenside; (ii) 0,5 bis 25
Gew.-% anionische Tenside und (iii) insgesamt 1 bis 15 Gew.-% kationische und zwitterionische
Tenside, wobei die Tenside unter der Maßgabe gewählt sind, daß die Tensidgesamtmenge
nicht größer als 60 Gew.-% ist.
25. Reinigungsprodukt nach Anspruch 22, enthaltend 80 bis 90 Gew.-% Material aus der Gruppe
der Alkelimetallcitrate.
26. Reinigungsprodukt nach Anspruch 22, enthaltend mindestens eines der folgenden Materialien:
(1) 1 bis 90 Gew.-% Silicate;
(2) 5 bis 80 Gew.-% Phosphate;
(3) 2 bis 40 Gew.-% Bicarbonate;
(4) 2 bis 70 Gew.-% Alkalimetallhydroxide;
(5) 1 bis 30 Gew.-% Sulfate aus der Gruppe bestehend aus Natrium- und Magnesiumsulfat;
(6) 1 bis 95 Gew.-% Citrate und
(7) 1 bis 100 Gew.-% Carbonate.
27. Reinigungsprodukt nach Anspruch 22, mit einem Porenvolumen im Bereich von 5 bis 40
Gew.-% seines Schüttvolumens.
28. Verfahren zur Reinigung einer harten Oberfläche oder einer Textilie mit Hilfe einer
Reinigungszusammensetzung, dadurch gekennzeichnet, daß man ein festes Reinigungsprodukt nach Anspruch 22 als Quelle des reinigungsaktiven
gelösten Stoffs in einer Reinigungszusammensetzung, bei der es sich um eine wäßrige
Lösung handelt, die gegebenenfalls ungelöste aufgeschlämmte Feststoffteilchen mit
einer kleinsten Abmessung von höchstens 2,2 mm enthalten, einsetzt.
29. Zweikomponenten-Reinigungsartikel mit den folgenden Kennzeichen:
(A) einer ersten festen Komponente, die aus einer nach einem Verfahren nach Anspruch
1 hergestellten Makrofeststofftablette oder einem nach einem Verfahren nach Anspruch
1 hergestellten Makrofeststoffblock besteht; und
(B) einer flüssigen zweiten Komponente, die aus mindestens einer fluiden Komponente
besteht und gegebenenfalls außerdem auch noch gelöste feste Substanzen enthalten kann.
30. Verfahren nach Anspruch 28, bei dem man:
(A) das Reinigungsprodukt in eine Abgabevorrichtung mit einer Sprüheinrichtung in
einer solchen Position bezüglich der Horizontalen und bezüglich der Sprüheinrichtung
einbringt, daß Reinigungsmittel vom Reinigungsprodukt nach unten abgegeben wird, wobei
das feste Reinigungsprodukt so orientiert ist, daß mindestens eine seiner Oberflächen
exponiert und drainierbar ist;
(B). ein Spray wäßriger Flüssigkeit aus der Sprüheinrichtung auf die exponierte und
drainierbare Oberfläche des festen Reinigungsprodukts auftreffen läßt, wodurch das
feste Reinigungsprodukt sich auflöst und/oder zerfällt und dadurch eine wäßrige flüssige
Lösung des Reinigungsmittels entsteht, die gleichzeitig mit dem Auftreffen nach unten
abfließt.
31. Verfahren nach Anspruch 30, bei dem das Reinigungsprodukt in Schritt (A) zusätzlich
eine flüssige Komponente eines Zweikomponentenprodukts gemäß Anspruch 29 enthält.
32. Verfahren nach Anspruch 30, bei dem in Schritt (A) das Reinigungsmittel in eine Geschirrspülzone
einer Geschirrspülmaschine, eine Textilwaschzone einer Textilwaschmaschine oder einen
Speicher zur späteren Abgabe in eine Geschirrspülzone einer Geschirrspülmaschine oder
eine Textilwaschzone einer Textilwaschmaschine abgegeben wird.
33. Verfahren nach Anspruch 28, bei dem die Reinigungszusammensetzung in eine Geschirrspülzone
einer Geschirrspülmaschine, eine Textilwaschzone einer Textilwaschmaschine oder einen
Speicher zur späteren Abgabe in eine Geschirrspülzone einer Geschirrspülmaschine oder
eine Textilwaschzone einer Textilwaschmaschine abgegeben wird.
1. Procédé pour la formation d'un unitaire d'un lit de matière particulaire, comportant
les étapes consistant à :
(A) fournir un récipient ayant des parois pénétrables par SER et ayant dans le récipient
un lit de particules de matériau brut, au moins une partie du matériau brut étant
un matériau hydraté dans lequel au moins 35 % en poids de la masse du lit des particules
du matériau brut est constitué d'un matériau choisi parmi le groupe constitué des
carbonates de métaux alcalins et de métaux alcaline-terreux, carbonates d'hydrogène,
sulfates, sulfate d'hydrogène, silicates, phosphates, hydroxydes, borates, et citrates,
chacun d'eux peuvent être hydratés ou anhydres ;
(B) irradier le lit des particules fournies dans l'étape (A) pendant un temps suffisant
avec un SER d'énergie suffisante pour engendrer l'élévation de la température au moins
d'une partie du matériau brut, et plus tard discontinuer l'irradiation du matériau
brut et le refroidir, afin de transformer le lit des particules en macrosolide dans
le récipient, le macrosolide ayant un volume apparent qui n'est pas supérieur à 1,20
fois le volume apparent du lit de particules duquel qui a été formé.
2. Procédé selon la revendication 1,
caractérisé en ce que
le SER a des fréquences dans la gamme allant de 300 à 300000 MHz.
3. Procédé selon la revendication 1,
caractérisé en ce que
ledit SER a des fréquences dans la gamme allant de 3 à 300 MHz.
4. Procédé selon la revendication 2,
caractérisé en ce que
le lit des particules contient de l'eau dans une quantité dans la gamme allant de
1 à 25 % en poids.
5. Procédé selon la revendication 4,
caractérisé en ce que
la teneur de l'eau dans le lit des particules est dans la gamme allant de 2 à 20 %
en poids.
6. Procédé selon la revendication 2,
comportant une autre étape pour introduire du matériau additionnel dans les pores,
les espaces interstitiels, ou les pores et espaces interstitiels de l'objet de macrosolide
formé dans l'étape (B) et engendrant au moins une partie du matériau additionnel ainsi
introduit à demeurer fixe à l'intérieur, dessus, ou dans et sur le macrosolide, afin
de produire un macrosolide modifié.
7. Procédé selon la revendication 6,
caractérisé en ce que
le matériau additionnel comporte au moins un matériau choisi parmi le groupe constitué
des poly(alkylène glycol), acides gras, amides d'acide gras, cires de paraffine, sorbitol,
hydrates de carbone, abrasifs, et tensioactifs non ioniques et la totalité du matériau
additionnel est présente à l'accomplissement du procédé dans une quantité suffisante
et est ainsi distribuée afin de former un revêtement au-dessus du matériau qui était
dans le macrosolide avant l'introduction du matériau additionnel.
8. Procédé selon la revendication 6,
caractérisé en ce que
le matériau additionnel comporte au moins un des poly(alkylène glycol) et tensioactifs
anioniques, cationiques, non ioniques, et d'ions hybrides.
9. Procédé selon la revendication 8,
caractérisé en ce que
le produit modifié final de macrosolide contient plus de 5 % en poids de tensioactif
total.
10. Procédé selon la revendication 9,
caractérisé en ce que
le produit modifié final de macrosolide contient plus de 25 % en poids de tensioactif
total.
11. Procédé selon la revendication 6,
caractérisé en ce que
le matériau additionnel comprend une enzyme.
12. Procédé selon la revendication 2,
caractérisé en ce que
le produit de macrosolide a une teneur en eau dans la gamme allant de 0,1 à 11 % en
poids.
13. Procédé selon la revendication 12,
caractérisé en ce que
la teneur en eau se trouve dans la gamme allant de 0,5 à 10 % en poids.
14. Procédé selon la revendication 13,
caractérisé en ce que
la teneur en eau se trouve dans la gamme allant de 2 à 6 % en poids.
15. Procédé selon la revendication 1,
caractérisé en ce qu'
au moins la moitié de la masse du matériau brut est constituée des espèces chimiques
qui sont sous forme solides à 25°C et sont solubles ou dispersibles de manière homogène
dans l'eau à 25°C pour former des solutions contenant au moins 10 grammes par litre
de l'espèce chimique sous forme solide dissoute ou dispersée de manière homogène ;
le rapport de la plus petite dimension du macrosolide effectué par le procédé à la
plus petite dimension des particules dans le lit des particules est au moins 10 :1
; au moins 60 % en poids du volume du lit des particules sont sous forme solide à
la température du lit des particules avant de commencer l'irradiation par SER ; et
le volume de pore de chaque lit des particules et du macrosolide se trouve dans la
gamme allant de 1 à 50 % en poids des volumes apparents respectifs.
16. Procédé selon la revendication 15,
caractérisé en ce que
le SER a des fréquences dans la gamme allant de 300 à 300.000 MHz.
17. Procédé selon la revendication 15,
caractérisé en ce que
le SER a des fréquences dans la gamme allant de 3 à 300 MHz.
18. Procédé selon la revendication 2,
caractérisé en ce que
au moins 50 % en poids de la masse du lit des particules du matériau brut est constitué
du matériau choisi parmi le groupe constitué du sodium, potassium, et sulfates de
magnésium, sulfates d'hydrogène, carbonates, carbonates d'hydrogène, silicates, phosphates,
hydroxydes, borates, et citrates ; au moins 70 % en poids du volume du lit des particules
est sous forme solide à la température du lit des particules avant de commencer l'irradiation
par SER ; et le volume de pore de chaque lit des particules et du macrosolide se trouve
dans la gamme allant de 3 à 45 % en poids des volumes apparents respectifs.
19. Procédé selon la revendication 2,
caractérisé en ce que
le produit de macrosolide produit par le procédé a la propriété que lors de l'immersion
à 55°C dans un volume d'eau qui est au moins dix fois le volume apparent du macrosolide,
le macrosolide se dissout, se désagrège, ou se dissout et se désagrège, de sorte qu'aucune
partie du macrosolide ne demeure dans n'importe quelle particule non dissoute isolée
ayant une plus grande dimension supérieure à 2,2 millimètres, en une durée après immersion
qui n'est pas supérieure à 0,036 minutes par centimètre cube de volume apparent du
macrosolide.
20. Procédé selon la revendication 2,
caractérisé en ce que
le lit des particules contient au moins un matériau choisi parmi le groupe constitué
de sources enduites à base de chlore, de sources non-enduites à base de chlore, des
matériaux enduits contenant du chlore, des matériaux non-enduits contenant du chlore,
des sources enduites à base d'oxygène actif, et des sources non-enduites à base d'oxygène
actif.
21. Procédé selon la revendication 2,
caractérisé en ce que
le lit des particules contient au moins 1 % en poids du matériau choisi parmi le groupe
constitué des silicates sous forme de couche cristalline.
22. Produit de nettoyage de macrosolide, ayant pour caractéristiques :
(A) au moins une des deux conditions suivantes est satisfaite :
(i) au moins 30 % en poids de la masse de l'article de macrosolide est constitué du
matériau choisi parmi le groupe constitué des sulfates alcalins, carbonates, silicates
éventuellement hydraté, zéolites, phosphates, hydroxydes, borates, et citrates ;
(ii) au moins 5 % en poids, mais pas plus de 98 % en poids est constitué de matériau
choisi parmi le groupe constitué des matériaux satisfaisant les deux conditions suivantes
:
(ii. 1) le matériau est sous forme solide à 25°C et (ii.2) une solution de 10 % en
poids du matériau dans l'eau, ou une solution saturée du matériau dans l'eau si sa
solubilité est moins de 10 % en poids, a un pH à 25°C de pas plus de 4, et si pas
moins de 10 % en poids de la masse du macrosolide se compose de matériaux fortement
alcalins, pas plus de 10 % en poids de la masse du macrosolide se compose de matériaux
fortement acides ; et si pas moins de 10 % en poids de la masse du macrosolide se
compose de matériaux fortement acides, pas plus de 10 % en poids de la masse du macrosolide
se compose de matériaux fortement alcalins, un matériau étant défini à cette fin comme
"fortement alcalin" si une solution à 0,1 N du matériau dans l'eau à 25°C a une valeur
de pH d'au moins 12,0, et étant défini comme "fortement acide" à cette fin si une
solution à 0,1 N du matériau dans l'eau à 25°C a une valeur de pH pas supérieure à
2,0 ;
(B) au moins 50 % en poids de la masse du macrosolide est constitué des espèces chimiques
qui sont sous forme solide à 25°C et sont solubles dans l'eau à 25°C pour former des
solutions contenant au moins 10 grammes par litre de l'espèce chimique sous forme
solide dissoute ; et
(C) lors de l'immersion à 55°C dans un volume d'eau qui est au moins dix fois le volume
apparent du macrosolide, le macrosolide se dissout, se désagrège, ou se dissout et
se désagrège, de sorte qu'aucune partie du macrosolide ne demeure dans n'importe quelle
particule non dissoute isolée ayant une plus grande dimension supérieure à 2,2 millimètres,
en une durée après immersion qui n'est pas supérieure à 0,050 minutes par centimètre
cube de volume apparent du macrosolide.
23. Produit de nettoyage selon la revendication 22 ayant un volume de pore dans la gamme
allant de 1 à 60 % en poids du volume apparent du produit de nettoyage et ayant au
moins 60 % en poids de sa masse constituée de matériau choisi parmi le groupe constitué
du sodium, potassium, et sulfates de magnésium, carbonates, silicates, phosphates,
hydroxydes, borates, et citrates.
24. Produit de nettoyage selon la revendication 22 contenant au moins un des types suivants
de quantités de tensioactifs : (i) de 1 à 25 % en poids de tensioactifs non ioniques
; (ii) de 0,5 à 25 % en poids de tensioactifs anioniques ; et (iii) de 1 à 15 % en
poids du total de tensioactifs cationiques et d'ions hybrides, les tensioactifs étant
choisis sous réserve de la contrainte que le montant total de tensioactif ne soit
pas supérieur à 60 % en poids.
25. Produit de nettoyage selon la revendication 22 contenant de 80 à 90 % en poids du
matériau choisi parmi le groupe de citrates de métaux alcalins.
26. Produit de nettoyage selon la revendication 22 contenant au moins un de ce qui suit
:
(1) de 1 à 90 % en poids de silicates ;
(2) de 5 à 80 % en poids de phosphates ;
(3) de 2 à 40 % en poids de bicarbonates ;
(4) de 2 à 70 % en poids d'hydroxydes de métaux alcalins ;
(5) de 1 à 30 % en poids de sulfates choisis parmi le groupe constitué de sodium et
de sulfates de magnésium ;
(6) de 1 à 95 % en poids de citrates ; et
(7) de 1 à 100 % en poids de carbonates.
27. Produit de nettoyage selon la revendication 22 ayant un volume de pore dans la gamme
allant de 5 à 40 % en poids de son volume apparent.
28. Procédé pour nettoyer une surface dure ou un textile à l'aide d'une composition de
nettoyage,
caractérisé en ce que
l'amélioration comprend l'utilisation d'un produit de nettoyage sous forme solide
selon la revendication 22 comme la source du soluté efficace pour le nettoyage dans
une composition de nettoyage qui est une solution aqueuse, cette solution comprenant
éventuellement des particules sous forme solide en suspension non dissoutes pas supérieure
à 2,2 millimètres dans leur plus petite dimension.
29. Article de nettoyage à deux constituants ayant les caractéristiques suivantes :
A) un premier constituant sous forme solide, dans lequel ce premier constituant consiste
en un bloc de macrosolide préparé selon un procédé selon la revendication 1 ; et
B) un deuxième constituant liquide, dans lequel ce deuxième constituant consiste en
au moins un constituant liquide, et qui peut de plus éventuellement contenir des substances
sous forme solide dissoutes.
30. Procédé selon la revendication 28 comportant les étapes suivantes :
(A) placer le produit de nettoyage dans un dispositif de distribution ayant un moyen
de pulvérisation, dans une position correspondant à l'horizontal et correspondant
à ce moyen de pulvérisation, pour distribuer le nettoyant de haut en bas à partir
de ce produit de nettoyage, ce produit de nettoyage sous forme solide étant orienté
pour fournir au moins une de ses surfaces qui soit exposée et drainable ;
(B) injecter une pulvérisation de liquide aqueux provenant du moyen de pulvérisation
sur la surface exposée et drainable du produit de nettoyage sous forme solide pour
dissoudre ou dissoudre et désagréger le produit de nettoyage sous forme solide et
former de ce fait une solution liquide aqueuse du nettoyant qui s'écoule de haut en
bas simultanément avec cette injection.
31. Procédé selon la revendication 30,
caractérisé en ce que
le produit de nettoyage produit dans l'étape (A) comprend en plus un constituant liquide
d'un produit à double emballage séparé selon la revendication 29.
32. Procédé selon la revendication 30,
caractérisé en ce que
dans l'étape (A) le nettoyant est distribué vers une zone de lavage d'une machine
à laver, une zone de lavage de textile d'une machine de lavage de textile, ou un réservoir
pour distribuer plus tard vers une zone de lavage d'une machine à laver ou vers une
zone de lavage de textile d'une machine à laver de textile.
33. Procédé selon la revendication 28,
caractérisé en ce que
la composition de nettoyage est distribuée dans une zone de lavage d'une machine à
laver, une zone de lavage de textile d'une machine à laver de textile, ou un réservoir
pour distribuer plus tard vers une zone de lavage d'une machine à laver ou vers une
zone de lavage de textile d'une machine à laver de textile.