The present invention relates to a softener composition.

Heretofore, quaternary ammonium salts having long-chain alkyl group, acid salts of tertiary amines, etc. have been used for softeners. Further, compounding of a softener composition with an antimicrobial agent has been attempted for sanitation and deodorization of fiber products. JP-A 10-512015 discloses a softener composition comprising a water-insoluble quaternary ammonium salt as a softener and a water-soluble quaternary ammonium salt as an antimicrobial agent compounded therein. In addition, JP-A 7-3649 discloses a fiber product-softener composition, having pH 2 to 5, comprising a di-long-chain-alkyl amine (C_6-24 alkyl or alkenyl group which may be interrupted by an ether linkage, ester linkage or acid amide linkage) and a mono-long-chain-alkyl quaternary ammonium salt (C_6-24 alkyl or alkenyl group which may be interrupted by an ether linkage, ester linkage or acid amide linkage), at a weight ratio of from 9 : 1 to 5 : 5. WO 98/56886 discloses an antimicrobial fiber softener composition, being suitable for conferring antimicrobial performance on fibers, comprising a conventional fiber softener composition and one or more cationic antimicrobial agents in a larger amount than required for antimicrobial performance. It, however, is a problem that the antimicrobial water-soluble quaternary ammonium salt lowers the softening effect. The softening effect is necessarily sacrificed in order to attain a satisfactory antimicrobial effect. In particular, it is difficult to achieve a composition demonstrating both a high softening effect and antimicrobial performance being capable of suppressing for long nasty smell attributable to microorganisms when clothes are dried in a room and body smell derived from sweat at the time of wearing.

Accordingly, the purpose of the present invention is to provide a softener composition which suppresses for long body smell derived from sweat etc. and is excellent in the softening effect.

The present invention relates to a softener composition comprising:

• (a) 3 to 50 % by weight of a quaternary ammonium compound represented by the formula (1) : wherein R¹ and R² independently represent a C_12-22 alkyl or alkenyl group, X and Y are independently -COO-, -CONR⁷-, -OCO- or - NR⁷CO-, preferably provided that at least one of X and Y is -COO- or -OCO-. R⁷ represents a hydrogen atom or a C_1-3 alkyl or hydroxyalkyl group. R³ and R⁴ independently represent a C_1-5 alkylene group, R⁵ and R⁶ represent a C_1-3 alkyl or hydroxyalkyl group or R¹-X-R³-, and Z^- is an anionic group,
• (b) a quaternary ammonium compound represented by formula (2) : wherein R⁸ represents a C_12-22 alkyl or alkenyl group, W is a group selected from -COO-, -CONR⁷-, -OCO- and -NR⁷CO-, R⁷ represents a hydrogen atom or a C_1-3 alkyl or hydroxyalkyl group, preferably a hydrogen atom, R⁹ represents a C_1-5 alkylene group, R¹⁰ and R¹¹ represent a C_1-3 alkyl or hydroxyalkyl group, R¹² represents a C_1-3 alkyl group or -R²⁶-OH, R²⁶ is a C_1-5 alkylene group and Z^- is an anionic group, and a compound selected from the following component (c) or (d):
• (c) 0.1 to 15 % by weight of a compound represented by formula (3) and/or formula (4): wherein R¹³ and R¹⁸ independently represent a C_5-19 alkyl or alkenyl group, R¹⁴ and R¹⁵ independently represent a C_1-3 alkyl or hydroxyalkyl group, and T is -COO-, -OCO-, -CONH-, -NHCO-, or a linkage; R¹⁶ represents a C_1-3 alkylene group, R¹⁷ represents a C_1-6 alkylene group or -(O-R¹⁹)_n, R¹⁹ is ethylene group or propylene group and n is a number of 1 to 10 and W^- is an anionic group, and
• (d) 0.01 to 15 % by weight, preferably 0.1 to 15 % by weight of a compound represented by formula (5): wherein 2 or 3 groups of R²⁰, R²¹, R²² and R²³ represent a C_8-12 alkyl group while the remainder(s) represents a C_1-3 alky group, C_1-3 hydroxyalkyl group or C_7-15 arylalkyl group, and Z^- is an anionic group, wherein the weight ratio of (c)/(a) is in the range of 1/30 to 1/1.

As used herein, the "linkage" refers to a covalent bond directly linking R¹³ with R¹⁷.

The component (a) of the present invention is a compound having the formula (1) : in which R¹ and R² independently represent a C_12-22, preferably C_14-22 and more preferably C_14-18 alkyl or alkenyl group, X and Y independently represent a group selected from -COO-, -CONR⁷-, -OCO- and -NR⁷CO-, and preferably at least one of X and Y is -COO- or -OCO-; X and Y are preferably -COO- or -OCNR⁷-. R⁷ represents a hydrogen atom or a C_1-3 alkyl or hydroxyalkyl group. R³ and R⁴ independently represent a C_1-5 alkylene group, R⁵ and R⁶ represent a C_1-3 alkyl or hydroxyalkyl group or R¹-X-R³-, and Z^- is an anionic group. Z^- is preferably a halogen ion, sulfate ion, phosphate ion, a C_1-3 alkyl sulfate ion or a C_1-12 fatty acid ion.

The component (a) is particularly preferably the following compound. R' and R'' may be the same as or different from each other and represent a C_12-18 alkyl or alkenyl group; R''' is a C_1-3 alkyl or hydroxyalkyl group; and R'''' is a C_1-3 alkyl group.

The component (b) of the present invention is a compound represented by formula (2): wherein R⁸ represents a C_12-22, preferably C_14-22 and more preferably C_14-18 alkyl or alkenyl group, W is -COO-, -CONR⁷, -OCO- or -NR⁷CO-, preferably -COO- or -OCNR⁷-. R⁷ represents a hydrogen atom or a C_1-3 alkyl or hydroxyalkyl group, preferably a hydrogen atom. R⁹ is a C_1-5 alkylene group and R¹⁰ and R¹¹ independently represent a C_1-3 alkyl or hydroxyalkyl group. R¹² is a C_1-3 alkyl group or -R²⁶-OH. R²⁶ is a C_1-5 alkylene group. Z^- is an anionic group, preferably a halogen ion, a fatty acid ion or a C_1-3 alkyl sulfate ion.

The component (c) of the present invention is a compound of the formula (3) or (4) above shown. As the most preferable component (c), the following compounds can be exemplified. In the formulae, Z^- has the meanings as defined above. (R is a C_12-16 alkyl group.) (R is an optionally branched C_6-10 alkyl group and m is an integer of 1 to 5.) (R is a C_8-18 alkyl group.)

The component (d) of the present invention is a compound of the formula (5) above shown and the anionic group represented by W of the formula (5) is preferably a sulfate ion, a halogen ion, a C_1-12 fatty acid ion or a C_1-3 alkyl sulfate ion.

The softener composition of the present invention comprises the component (a) in an amount of 3 to 50 % by weight, preferably 3 to 40 % by weight and particularly preferably 5 to 35 % by weight. Further, the amount of the component (b) is 0.5 to 10 % by weight, preferably 0.5 to 5 % by weight. In addition, it is preferable to the softening effect and the deodorizing effect that a weight ratio of the component (a)/the component (b) is from 80/20 to 99/1, particularly from 85/15 to 95/1.

When the component (c) is used in the present invention, the component (c) is contained in an amount of 0.1 to 15 % by weight, preferably 1 to 15 % by weight and particularly preferably 3 to 10 % by weight. Further, it is desirable to the feeling in touch of clothes and the deodorizing effect that the ratio of (c) / (a) by weight is from 1/30 to 1/1, preferably from 1/10 to 1/1. Further, when the component (d) is used in the present invention, it is desirable to the feeling in touch of clothes and the deodorizing effect that the amount of the component (d) is preferably 0.1 to 15 % by weight, more preferably 0.2 to 10 % by weight, and a weight ratio of (a) /(d) is from 50/1 to 2/1, preferably from 30/1 to 2/1, and more preferably from 20/1 to 2/1.

The softener composition of the present invention is preferably in the form of an aqueous solution comprising at least the component (a) and the component (b) and the component (c) or (d), diluted in water. The water used is preferably distilled water or deionized water. It is desirable for storage stability that water is incorporated in an amount of 40 to 90 % by weight, more preferably 50 to 85 % by weight and particularly preferably 60 to 85 % by weight into the composition.

Further, it is preferable to the deodorizing effect and for storage stability that the composition of the present invention is adjusted to a pH value of 1 to 6, further 2 to 5, and particularly 2.5 to 4 at 20 °C.

In the present invention, incorporation of a nonionic surfactant (e) in addition to the above components (a), (b), (c) and (d) is preferable for storage stability. The nonionic surfactant is preferably a polyoxyethylene alkyl ether containing one or more C_8-20 alkyl or alkenyl group, particularly preferably a nonionic surfactant of the formula (6):

        R²⁴-U-[(R²⁵O)_p-H]_q     (6)

wherein R²⁴ is a C_10-18, preferably C_12-18, alkyl or alkenyl group, R²⁵ is a C₂ or C₃ alkylene group, preferably an ethylene group; p is an integer of 2 to 100, preferably 5 to 80, more preferably 10 to 80 and particularly preferably 20 to 60; and U is -O-, -CON- or -N-, and when U is -O-, q is 1, and when U is -CON- or -N-, q is 2.

The compound of the formula (6) includes for example the following compounds:

        R²⁴-O- (C₂H₄O) r-H

wherein R²⁴ has the same meanings as defined above; and when the component (c) is contained, r is an integer of 8 to 100, and when the component (d) is contained, r is an integer of 5 to 100, preferably 10 to 80 and more preferably 20 to 80.

        R²⁴-O- (C₂H₄O) S(C₃H₆O) t-H

wherein R²⁴ has the same meanings as defined above; s and t are independently an integer of 2 to 40, preferably 5 to 40, and the sum of s and t is preferably an integer of 10 to 80, and the ethylene oxide and propylene oxide units may be a random- or block-addition product. wherein R²⁴ has the same meanings as defined above; and when the component (c) is contained, the sum in total of u and v is an integer of 5 to 100 and when the component (d) is contained, the sum in total thereof is an integer of 10 to 80, preferably 5 to 80.

From the viewpoint of stability, the amount of the nonionic surfactant incorporated is 0.5 to 10 % by weight, preferably 1 to 8 % by weight.

For the purpose of improving the feeling in touch of fiber products, in the present invention, (f) a C_8-22 fatty acid or a salt thereof is preferably added in an amount of 0.1 to 5 % by weight, particularly 0.5 to 3 % by weight.

The fatty acid or a salt thereof includes caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, oleic acid or a mixture thereof. One or more members selected from lauric acid, stearic acid and oleic acid are particularly preferable. Further, fatty acids having an alkyl composition derived from coconut oil, palm oil, palm seed oil or tallow are also preferable.

In the present invention, it is preferable for storage stability that an ester compound of a C_8-22 saturated or unsaturated fatty acid and a polyvalent alcohol is incorporated in an amount of 0.1 to 10 % by weight, particularly 0.5 to 5 % by weight into the composition. The ester compound is preferably triglycerides, diglycerides, monoglyceride, a mono-, di- or tri-ester of pentaerythritol and sorbitan ester.

In the present invention, it is desirable for storage stability that inorganic salts such as calcium chloride are added in an amount of 0 to 1000 ppm, preferably 1 to 1000 ppm, and more preferably 10 to 500 ppm. Sodium salts and potassium salts are contained in surfactants such as fatty acid salts and the inorganic salts mixed in the composition by using such surfactants are not subject to the above limitation.

In the present invention, a solvent component selected from ethanol, isopropanol, glycerin, ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol and polyoxyethylene phenyl ether is further preferably incorporated for storage stability. These solvent components are incorporated in an amount of preferably 0 to 20 % by weight, more preferably 0.1 to 20 % by weight and particularly preferably 0.5 to 10 % by weight into the composition. If ethanol is used, it is desirable to use a polyoxyethylene alkyl ether sulfate-modified ethanol or an 8-acetylated sucrose-modified ethanol.

Ingredients such as silicone being ordinarily incorporated into a fiber-treating agent, a perfume (particularly preferably a combination of aroma components shown as the components (c) and (d) described in JP-A 8-113871 and a coloring matter may be incorporated into the softener composition of the present invention.

The ingredients used in the present invention are shown below.

• (a-1) R: a mixed C₁₈ and C₁₆ saturated alkyl group (ratio by weight of C₁₈ group/C₁₆ group = 60/40)
• (a-2) R: a mixed C₁₈ and C₁₆ saturated alkyl group (ratio by weight of C₁₈ group/C₁₆ group = 60/40)
• (a-3) R: a mixed C₁₇ and C₁₅ saturated alkyl group (ratio by weight of C₁₇ group/C₁₅ group = 60/40)
• (a-4) R: a mixted C₁₇ and C₁₅ saturated alkyl group (ratio by weight of C₁₇ group/C₁₅ group = 60/40)
• (a-5) Di(oleoyl xyethyl) dimethyl ammonium methyl sulfate.
• (a-6) R: a mixed C₁₇ and C₁₅ saturated alkyl group (ratio by weight of C₁₇ group/C₁₅ group = 60/40)
• (a'-1) Dioleyl dimethyl ammonium chloride.
• (b-1) R: a mixed C₁₈ and C₁₆ saturated alkyl group (ratio by weight of C₁₈ group/C₁₆ group = 60/40)
• (b-2) R: a mixed C₁₇ and C₁₅ saturated alkyl group (ratio by weight of C₁₇ group/C₁₅ group = 60/40)
• (c-1)
• (c-2)
• (c-3)
• (d-1) Didecyl dimethyl ammonium chloride.
• (e-1) An addition product of a saturated alcohol containing 12 carbon atoms to which 21 moles on the average of ethylene oxide have been added.
• (e-2) An addition product of lauric acid diethanolamide to which 20 moles on the average of ethylene oxide have been added.
• (f-1) Lunack™ S-50 (stearic acid produced by Kao Corporation).
• (f-2) Lauric acid.
• (f-3) Myristic acid.
• (f-4) Palmitic acid.
• (g-1) Excel™ 150 [a mixture of stearic mono-, di- and triglycerides (mono : di : tri = 60 : 35 : 5) produced by Kao Corporation].
• (g-2) Calcium chloride.
• (g-3) Ethylene glycol.
• (h-1) Coloring matter (Acid blue 9).
• (h-2) Perfume [a mixture of hexyl cinnamic aldehyde (18), nerolin yarayara (4), tricyclodecenyl acetate (4), benzyl acetate (10), musk ketone (5), anisyl acetone (2), sandal mysolcore (2), aldehyde C14 peach (1), linalool (18), dihydroxy myrcenol (8), borneol (4), cedrol (4), mugoal (5), benzyl alcohol (5) and dipropylene glycol (10), the figures shown in the parentheses meaning a percent by weight in the perfume mixture.].
• (h-3) Silicone (TSA730 produced by Toshiba Silicone Co., Ltd.).

Using the above compounds, the softener compositions shown in Table 1 were prepared (invention products 1 to 6 and comparative products 1 to 3). Two sweaters (100% cotton) were washed using a commercial weakly alkaline detergent (Attack™, Kao Corporation) in a laundering machine (two-tank system laundering machine VH-360S1 manufactured by Toshiba Corp.; detergent concentration, 0.0667 % by weight; 30 L tap water used; water temperature of 20 °C; 10 minutes). Thereafter, the washing water was discharged and the clothes were dehydrated for 1 minute. After 30 L tap water was poured into the tank, the clothes were rinsed for 5 minutes, the water was discharged, and the clothes were dehydrated for 1 minute. Then, 30 L tap water was again poured into the tank, and 5 g of each softener composition of Table 1 was added thereto. It was stirred for 5 minutes. Thereafter, the clothes were dehydrated and dried for 12 hours in a thermostatic chamber at 70 % RH at 25 °C. (Evaluation of softening performance)

The softener compositions of Table 1 and the corresponding compositions to them, except that the antimicrobial component, the component (c) or (d), was not added, were used in the softening treatment described above. They were evaluated in a paired comparison test using the following criteria by a panel of 10 persons to determine a mean value. +1: Finished to be the softer in the presence of component (c) or (d)
0: No difference in finish regardless of the presence or absence of the component (c) or (d).
-1: Finished to be the softer in the absence of the component (c) or (d).

The smell of the clothes dried in a thermostatic chamber and the smell of the same clothes worn for 12 hours by 5 males, aged twenties, were judged using the following criteria by a panel of 10 persons (10 males aged thirties), to determine a mean value.
0: Hardly smelled.
1: Slightly smelled but not annoying.
2: Smelled.
3: Significantly smelled.

The softener compositions (invention products 7 to 11) shown in Table 2 were prepared in the same manner as in Example 1. As the perfume, a mixture of 100 parts by weight of a composition of Table 3 and 10 parts by weight of dipropylene glycol was used. These softener compositions were evaluated in the same manner as in Example 1. As results they were all recognized to exhibit an excellent smell-preventing effect and softening performance. Perfume Ingredient (wt%) Perfume 1 Perfume 2 Perfume 3 Perfume 4 Perfume 5 hexyl cinnamic aldehyde 0 0 13 0 0 Nerolin yarayara 0 0 3 0 0 tricyclodecenyl acetate 0 0 3 0 0 benzyl acetate 0 0 7 0 0 musk ketone 0 0 3 0 0 anisyl acetone 0 0 1 0 0 Sandalmysore core 0 0 1 0 0 Aldehyde C14 peach 0 0 1 0 0 Metyl ionone- γ 7 0 0 3 0 Iso E Super 7 0 0 3 0 Tentarome 14 0 0 7 0 4-t-butylcyclohexylacetate 14 0 0 7 0 Lilial 20 0 0 10 0 Herional 3 0 0 2 0 coumarin 3 0 0 1 0 Ambroxan 1 0 0 0 0 α-Terpinyl acetate 0 12 0 0 20 cedryl acetate 0 8 0 0 13 Lyral 0 8 0 0 13 Pearlide 0 4 0 0 7 Sandal synth 0 4 0 0 7 phenylacetoaldehyde 50% PEA 0 0 0 0 1 aldehyde C12MNA 0 0 0 0 1 cinnamyl cinnamate 0 2 0 0 3 benzyl isoeugenol 0 2 0 0 3 linalool 0 0 0 0 13 dihydromyrcenol 0 0 0 0 7 borneol 0 0 0 0 3 cedrol 0 0 0 0 3 Muguol 0 0 0 0 3 benzyl alcohol 0 0 0 0 3 phenylethyl alcohol 12 0 29 0 0 citronellol 6 0 13 0 0 terpineol 6 0 13 0 0 phenylethyldimethyl carbinol 3 0 7 0 0 styrallyl alcohol 2 0 3 0 0 cinnamic alcohol 2 0 3 0 0 1-menthol 0 24 0 27 0 geraniol 0 12 0 13 0 dihydromyrcenol 0 12 0 13 0 Phenyl hexanol 0 6 0 7 0 dimethylbenzyl carbinol 0 6 0 7 0 Total (wt%) 100 100 100 100 100

Using the above compounds, the softener compositions shown in Table 4 were prepared. Five shirts (100 % cotton) and 5 towels (100 % cotton) (total weight of the clothes: 1.5 kg) were washed using a commercial weakly alkaline detergent (Attack™, Kao Corporation) in a laundry machine (two-tank system laundering machine VH-360S1 manufactured by Toshiba Corp.; detergent concentration, 0.0667 % by weight; 30 L tap water used; water temperature of 20 °C; 10 minutes). Thereafter, the washing water was discharged and the clothes were dehydrated for 1 minute. After 30 L tap water was poured into the tank, the clothes were rinsed for 5 minutes, the water was discharged, and the clothes were dehydrated for 1 minute. Then, 30 L tap water was again poured into the tank and 7 ml of each composition of Table 1 was added thereto. It was stirred with the clothes for 5 minutes. Thereafter the clothes were dehydrated and air-dried.

The clothes treated as above were worn for 12 hours by 5 males aged twenties, and the smell generated from the shirts worn were judged using the following criteria by a panel of 10 persons (10 males aged thirties), to determine a mean value. ○ was assigned to a mean value of less than 0.8, □ to a mean value of 0.8 to less than 1.2, Δ to a mean value of 1.2 to less than 1.7, and X to a mean value of 1.7 or more. Results are shown in Table 1.
0: Hardly smelled.
1: Slightly smelled but not annoying.
2: Smelled.
3: Significantly smelled.

The towels treated as above and towels (control) treated in the same way, except for using no composition of Table 4, were judged using the following criteria by a panel of 10 persons (10 males aged thirties), to determine a mean value. ○ was assigned to a mean value of 2 or more, □ to a mean value of 1 to less than 1.5, Δ to a mean value of 0.5 to less than 1, and X to a mean value of less than 0.5. Results are shown in Table 1.
+3: much softer than the control.
+2: Softer than the control.
+1: Slightly softer than the control.
0: Equal to the control.