Background
1. Field of the Invention
[0001] The present invention relates to compositions of matter which are useful for water
softening or as detergent builders.
2. Description of the Art
[0002] Aluminosilicates which have high calcium and magnesium exchange. rates and capacity
have been added to water softening and detergent products to remove water hardness.
Effective removal of calcium and magnesium ions from water when considered in the
context of detergent products is important in that those ions can precipitate anionic
surfactants rendering the former less effective in fabric cleaning. Moreover, if the
calcium and magnesium ions are not removed from water used for washing, these ions
will interact with soils on the fabrics thus interfering with soil removal.
[0003] U.S. Patent 3,985,669, issued October 12, 1976, Krummel et al, describes the formulation
of a detergent composition containing aluminosilicates and alkali metal silicates.
In Krummel et al the silicates are present at a very low level to avoid the interaction
with the aluminosilicate. This product is formed by spray drying all of the components
in the composition including the aluminosilicate and the alkali metal silicate. Said
patent is incorporated herein by reference.
[0004] It has been found that the incorporation of the aluminosilicate materials into detergent
and water softening compositions described above presents great difficulties. For
instance, if aluminosilicates are to be admixed into the composition as a dry material,
a considerable quantity of dust can be generated by improper handling of the finely
divided aluminosilicate. Moreover, the aluminosilicates per se are not free flowing.
It is also noted that if the aluminosilicate materials with which the present invention
is concerned are admixed dry with the remainder of a composition, that segregation
of the fine aluminosilicate materials will occur during packing and transportation
of tne finished product. The segregation is extremely undesirable in that when the
consumer uses the product the lack of uniformity may result in over-usage or under-usage.
[0005] The present invention is an improvement on U.S. Patent 4,096,081, Phenicie et al,
issued June 20, 1978'and incorporated herein by reference. This patent teaches agglomeration
of the aluminosilicate particles using an organic agglomerating agent and an inorganic
salt. This agglomerate can be admixed with conventional spray-dried detergent granules.
[0006] Throughout the specification and claims, percentages and ratios are by weight and
temperatures are in degrees centigrade unless otherwise indicated.
Summary of the Invention
[0007] A free-flowing particulate water softening composition comprising an intimate mixture
of:
(a) from about 60% to about 95% of an aluminosilicate detergency builder, preferably
(i) an amorphous aluminosilicate;
(ii) a hydrated crystalline zeolite selected from the group consisting of Zeolite
A, X, and P having a particle size of from about 0.1 to about 25 microns; and
(iii)mixtures thereof having a calcium ion exchange capacity of at least about 200
mg eq./g (four milliequiva- lents/g.); and a calcium ion exchange rate of at least
about 2 grains/gallon/minute gram;
(b) from about 1% to about 4% of synthetic anionic detergent surfactants which are
relatively hardness insensitive;
(c) from about 1% to about 10% of an inorganic salt and being essentially free of
silicates; and
(d) balance water.
Detailed Description of the Invention
[0008] The aluminosilicate detergency builder of this invention comprise both amorphous
and crystalline aluminosilicates as is well known in the art. U.S. Patent 4,096,081'
contains a description of such builders. Zeolites A, X and P are preferred, with Zeolite
A being most preferred.
[0009] An essential feature of the ion exchange builder materials herein is that they be
in a hydrated form, i.e., contain at least about 10% by weight of water. Highly preferred
Zeolite A aluminosilicates herein contain the theoretical maximum of from about 18%
to about 22% (wt.) water in their crystal matrix. It has been found, for example,
that less highly hydrated Zeolite A aluminosilicates, e.g., those with about 6% water,
do not function effectively as ion exchange builders when employed in the context
of a laundry detergent composition.
[0010] A second essential feature of the ion exchange builder materials herein is their
particle size range. Of course, the amorphous aluminosilicates inherently have a small
particle size (ca. 0.01 micron - 5 micron diameter). However, the crystalline aluminosilicates
must have a small particle size in the range disclosed herein. Proper selection of
small particle sizes results in fast, highly efficient builder materials. Moreover,
the small particle size of the preferred aluminosilicates herein (≤10 microns) presumably
accounts for the fact that they are not noticeably deposited on fabrics from an aqueous
laundering liquor. This nondeposition is, of course, desirable when the aluminosilicates
are employed as detergent builders.
[0011] The amorphous aluminosilicate ion exchange builder/water softening materials herein
can be prepared according to the following procedure:
(a) Admix sodium aluminate (NaAlO2) and sodium hydroxide in water to form a mixture having the following (preferred)
weight ratios of the components:
H2O/NaA102 = 2.9:1
H2O/NaOH = 5.2:1
NaAlO2/NaOH = 1.8:1.
The temperature of the mixture is adjusted to about 20°C-70°C, preferably about 50°C.
If prepared at lower temperatures, the mixture of aluminate and sodium hydroxide is
not a true solution and may contain a small quantity of finely dispersed particulate
materials.
(b) Add a sodium silicate solution (ca. 37% wt. solid; 3.2:1 SiO2/Na2O ratio) rapidly to the mixture of step (a). This rapid mixing step can be carried
out using a vessel employed with an efficient agitator; alternatively, the two mixtures
at the desired temperature can be metered into an inline mixer which can be part of
a dominant bath system to provide a continuous process. The ratio of NaAlO2 to sodium silicate (anhydrous basis) is about 1.6:1.
(c) Heat the mixture of step (b) rapidly to 75°C to 95°C (preferably 80°C - 85°C)
and maintain at this temperature for 10 minutes to 60 minutes (preferably 10 minutes
- 20 minutes).
(d) Cool the slurry from step (c) to about 50°C- and filter. Recover the resulting
filter cake and wash in water using a sufficient quantity of water to yield a wash
water/solids (anhydrous basis) weight ratio of about 2.0:1 (preferred). Repeat the
filtration and washing operations.
[0012] The filter cake prepared by the foregoing process comprises a mixture of crystalline
aluminosilicate and amorphous aluminosilicate in approximately a 1:1 (wt.) ratio.
The material from the filter cake exhibits a rapid and efficient uptake of both Ca
++ and Mg
++ ions. The filter cake is useful per se as an ion exchange material. For use in powdered
or granular detergent compositions, it is preferred to dry the filter cake only .
the minimum amount to eliminate free moisture, using a drying temperature below about
175°C to avoid excessive dehydration. Preferably, the drying is performed at 100°C
to 105°C.
[0013] The amorphous aluminosilicate of this invention can, if desired, be separated from
the amorphous-crystalline mixture prepared in the foregoing manner by simply suspending
the filter cake- mixture in water. When thus suspended, the crystalline portion of
the mix settles out (over a period of about 1-6 hours), whereas the amorphous material
remains suspended in the aqueous medium. The amorphous material can be separated by
decantation or other physical means. Of course, low speed centrifugation can be employed
to more rapidly separate the amorphous component from the crystalline component of
the mixtures herein.
[0014] Both the crystalline and amorphous aluminosilicate ion exchangers herein are further
characterized by their calcium ion exchange capacity which is preferably at least
about 200 mg. equivalent of CaCO
3 hardness/gram of aluminosilicate, calculated on an anhydrous basis, and which preferably
lies within the range of about 300 mg. eq./g. to about 352 mg. eq./g.
[0015] The ion exchange materials herein are further characterized by their calcium ion
exchange rate which is at least about 2 grains (Ca
++)/gal./min./g. of aluminosilicate (anhydrous basis). Optimum aluminosilicates for
builder purposes exhibit a Ca
++ exchange rate of at least about 4 gr./gal./min./g.
[0016] The amorphous aluminosilicate ion exchanges herein are further characterized by their
magnesium exchange capacity, which is at least about 50 mg. eq. of CaCO
3, hardness/gram of aluminosilicate, calculated on an anhydrous basis, and which generally
lies within the range of about 50 mg. eq./g. to 150 mg. eq./g. or greater.
[0017] The amorphous ion exchange materials herein are still further characterized by their
magnesium ion exchange rate which is at least about 1 grain (Mg
++)/gal./min./g. of aluminosilicate (anhydrous basis). Optimum aluminosilicates for
builder purposes exhibit a magnesium exchange rate of at least about 2 gr./gal./min./g.
[0018] The ion exchange properties of the aluminosilicates herein can conveniently be determined
by means of a calcium ion electrode and a divalent ion electrode. In this technique
the rate and capacity of Ca
++ and Mg
++ uptake from an aqueous solution containing a known quantity of Ca
++ and Mg
++ ions are determined as a function of the amount of aluminosilicate ion exchange material
added to the solution. More specifically, the ion exchange rates of the amorphous
and mixed amorphous-crystalline aluminosilicates herein are determined as follows.
The aluminosilicate prepared in the foregoing manner is added in the sodium form to
150 ml. of aqueous solution containing 4.7 gr./gal. Ca
++ and 2.4 gr./gal. Mg
++ (measured as CaC0
3) at a concentration of 0.06% (wt.), pH of 10.0, and with gentle stirring of the solution.
The rate of calcium depletion is measured using the calcium electrode (commercially
available; Orion) and the rate of total calcium and magnesium depletion is determined
using the general divalent cation electrode. Magnesium ion removal is thereafter determined
by the difference in readings. The rate of depletion is determined for each cation
by taking measurements at appropriate time intervals. Total depletion from the solution
is calculated after ten minutes, which corresponds to the normal wash time in an aqueous
laundering process. Rate curves for calcium depletion, magnesium depletion and mixed
calcium and magnesium depletion can be plotted as gr./gal. v. time.
[0019] Calcium exchange capacity of the aluminosilicates herein can be determined by a simple
titration method. In practice the aluminosilicate sample is equilibrated with a known
excess of Ca
++. After equilibration and uptake of the calcium ion, the excess calcium ion remaining
in solution is determined by a standard titration with EOTA, using a standard Eriochrome
Black T Indicator. Magnesium ion capacity is determined titrimetrically, in similar
fashion.
[0020] As noted hereinabove, both the crystalline and amorphous aluminosilicates herein
exhibit excellent rates of exchange and capacities for calcium ions. Moreover, the
amorphous material herein addition--ally provides rapid and efficient uptake of magnesium
ions. Accordingly, a mixture of crystalline and amorphous material can provide mixed
Ca
++/Mg
++ hardness control.
[0021] Preferably, the compositions of this invention are essentially free of the organic
agglomerating agents of U.S. Patent 4,096,081.
[0022] The surfactant agglomerating agents of this invention include the following.
[0023] Preferably the detergent component of the present invention is a water-soluble salt
of: an ethoxylated sulfated alcohol with an
' average degree of ethoxylation of about 1 to about 10 and an alkyl chain length of
from about 8 to about 20; an alkyl benzene sulfonate with an average alkyl chain length
between about 9 and about 15, preferably from about 11 to about 13, and most preferably
about 11.8 carbon atoms; a C
6-C
20 alpha-sulfocarboxylic acid or ester thereof having 1 to 14 carbon atoms in the alcohol
radical; a C
8-C
18 secondary paraffin sulfonate; a C
10-C
18 olefin sulfonate or mixtures thereof; or other hardness insensitive anionic surfactant.
Such preferred detergents are discussed below. Blends of surfactants which exhibit
hardness resistance (insensitivity) can be used as well.
[0024] An especially preferred alkyl ether sulfate detergent component of the present invention
is a mixture of alkyl ether sulfates, said mixture having an average (arithmetic mean)
carbon chain length within the range of about 12 to 16 carbon atoms, preferably from
about 14 to 15 carbon atoms, and an average (arithmetic mean) degree of ethoxylation
of from about 1 to 4 moles of ethylene oxide, preferably from about 2 to 3 moles of
ethylene oxide.
[0025] Specifically, such preferred mixtures comprise from about 0 to 10% by weight of mixture
of C
12-13 compounds, from about 50 to 100% by weight of mixture of C
14-15 compounds, and from about 0 to 45% by weight of mixture of C16-17 compounds, and
from about 0 to 10% by weight of a mixture of C18-19 compounds. Further, such preferred
alkyl ether sulfate mixtures comprise from about 0 to 30% by weight of mixture of
compounds having
'a degree of ethoxylation of 0, from about 45 to 95% by weight of mixture of compounds
having a degree of ethoxylation from 1 to 4, from about 5 to 25% by weight of mixture
of compounds having a degree of ethoxylation from 5 to 8, and from about 0 .to 15%
by weight of mixture of compounds having a degree of ethoxylation greater than 8.
The sulfated condensation products of ethoxylated alcohols of 8 to 24 alkyl carbons
and with from 1 to 30, preferably 1 to 4 moles of ethylene oxide may be used in place
of the preferred alkyl ether sulfates discussed abova.
[0026] Preferred water-soluble organic detergent compounds herein also include alkyl benzene
sulfonates (preferably essentially linear, although "hard" ABS may be used) containing
from about 9 to 15 carbon atoms in the alkyl group. Examples of the above are sodium
and potassium alkyl benzene sulfonates in which the alkyl group contains from about
11 to about 13 carbon atoms, in straight chain or branched chain configuration, e.g.,
those of the type described in U.S. Pat.
Nos. 2,220,099 and 2,477,383. Especially valuable are straight chain alkyl benzene
sulfonates in which the average of the alkyl groups is about 11.8 carbon atoms, abbreviated
as C
11.2LAS.
[0027] Another useful detergent compound herein includes the water-soluble salts of esters
of alpha-sulfonated fatty acids containing from about 6 to 20 carbon atoms in the
fatty acid group and their esters with alcohols containing from about 1 to 14, preferably
1 to 2, carbon atoms.
[0028] Preferred "olefin sulfonate" detergent mixtures utilizable herein comprise olefin
sulfonates containing from 10 to about 18 carbon atoms. Such materials can be produced
by sulfonation of olefins by means of uncomplexed sulfur trioxide followed by neutralization
under conditions such that any sultones present are hydrolyzed to the corresponding
hydroxy-alkane sulfonates. The alpha-olefin starting materials preferably have from
14 to 16 carbon atoms. Said preferred alpha-olefin sulfonates are described in U.S.
Pat. No. 3,332,880, incorporated herein by reference.
[0029] The secondary paraffin sulfonates embraced in the present invention are essentially
linear and contain from about 8 to about 18 carbon atoms, preferably from about 12
to about 16 and more preferably from about 14 to about 15 carbon atoms in the alkyl
radical.
[0030] Other anionic detergent 'compounds herein include the sodium alkyl glyceryl ether
sulfates, especially those ethers of higher alcohols derived from tallow and coconut
oil; sodium coconut oil fatty acid monoglyceride sulfonates and sulfates; and sodium
or potassium salts -of alkyl phenol ethylene oxide ether sulfate containing about
1 to about 10 units of ethylene oxide per molecule and wherein the alkyl groups contain
about 8 to about 12 carbon atoms.
[0031] Other useful detergents include water-soluble salts of 2-acyl- oxy-alkane-l-sulfonic
acids containing from about 2 to 9 carbon atoms in the acyl group and from about 9
to about 18 carbon atoms in the alkane moiety; beta-alkyloxy
'alkane sulfonates containing from about 1 to 3 carbon atoms in the alkyl group and
from about 8 to 18 carbon atoms in the alkane moiety; alkylmethylammoniopropane sulfonates
and- alkylmethylammoniohydroxypropane sulfonates wherein the alkyl group in both types
contains from about 14 to 18 carbon atoms; and alkyl glycerol ether sulfates with
from 10 to 18 carbon atoms in the alkyl radical.
[0032] A typical listing of the classes and species of detergent compounds useful herein
appear in U.S. Pat. No. 3,852,211, to Ohren issued Dec. 3, 1974, incorporated herein
by reference. The foregoing list of detergent compounds and mixtures which can be
used in the instant compositions is representative of such materials, but is not intended
to be limiting.
[0033] The compositions comprise from about 1 to about 4%, preferably from about 2% to about
3% of hardness insensitive anionic surfactant. Higher levels of surfactant simply
dilute the zeolite without any benefit and can give undesirable physical properties
to the agglomerate.
[0034] The surfactant improves dispersion of the zeolite as shown hereinafter thus minimizing
unacceptable deposits, e.g. on fabrics, and increasing the rate of ion exchange.
[0035] The inorganic salts are water soluble and form ions. They promote dispersion of the
aluminosilicate as shown to rapidly control the water hardness. Examples of such inorganic
salts include those having alkali metal cations such as sodium, or potassium, and
having as anions thereof sulfates, chlorides, carbonates, bicarbonates, aluminates
and phosphates, and mixtures thereof.
[0036] Preferred inorganic salts include sodium sulfate, sodium carbonate, sodium orthophosphate,
sodium pyrophosphate, sodium tripolyphosphate, and sodium hexametaphosphate. Especially
preferred are sodium sulfate and sodium carbonate. Alkali metal silicates should not
be present because of their ability to polymerize the aluminosilicate leading to deposits
upon washed fabrics.
[0037] When the aluminosilicate, the inorganic salt and the organic surfactant are to be
incorporated into a detergent composition, additional surface active agent (detergent
surfactant) will be included as a portion of the overall detergent composition since
the level of surfactant herein is insufficient to form a complete detergent product.
[0038] Exemplary of detergent components which may be used in the present invention are
those described in U.S. Patent 3,852,211 to Ohren, - issued December 3, 1974, which
is herein incorporated by reference.
Composition Preparation
[0039] The preparation of the particulate containing the aluminosilicate, the inorganic
salt and the detergent surfactant is described as follows:
(a) dispersing the detergent surfactant;
(b) dispersing the inorganic salt into the detergent surfactant;
(c) admixing into the dispersed detergent surfactant the aluminosilicate of the present
invention, thereby forming an intimate mixture; and,
(d) solidifying the resultant mass to form the particulate. Alternatively, the detergent
surfactant can be sprayed onto a bed of the aluminosilicate and the inorganic salt.
Water may be added to the mixture of the detergent surfactant, the inorganic salt,
and the aluminosilicate to facilitate mixing. The excess water is then driven off
by heating on forming the particulate.
[0040] In a preferred method, sulfuric acid is added to the synthesis liquor of the aluminosilicate
to neutralize excess caustic (while staying above pH 9) and form Na
2S0
4. The surfactant is then dispersed in the slurry and the product is spray or flash
dried.
[0041] Another preferred method of preparing the particulate of the present invention is
to spray the mixture of the aluminosilicate, the inorganic salt and the detergent
surfactant to
'form granules of the size compatible with normal detergent particles. It is to be
understood, however, that the product can take several forms, e.g. cakes, flakes,
prills, or granules which are reduced by conventional methods to the appropriate size.
[0042] The preferred method of preparing the particulate of the present invention is by
spray-drying or spray cooling the mass to form the particulate. It is essential when
spray-drying is employed that the aluminosilicate should not be dehydrated beyond
the point where its ion exchange capacity is adversely affected. Also, certain of
the surfactants which are- heat sensitive should not be heated to the extent at which
they begin to decompose.
[0043] when a spray-drying operation is used to prepare the agglomerate the apparatus for
conducting the drying operating may be a multilevel spray-drying tower such as that
described in U.S. Patent 3,629,950 and 3,629,955 issued to Davis et al, both of which
are herein incorporated by reference.
[0044] In preparing the particulate of the present invention the detergent surfactant will
be present at from about 1/2% to about 4%, preferably from about 1-1/2% to about 2-1/2%
by weight while the aluminosilicate will be present at from about 60% to about 95%,
preferably from about 70% to about 80% by weight.
[0045] The inorganic salts which promote lessened friability are used at a level of from
about 1/2% to about 10%, preferably from about 2% to about 4%. Larger amounts of the
inorganic salts may be utilized in the particulate, however, the benefit reaches a
maximum at about 5% and additional amounts merely take up more formula room.
Composition Utilization
[0046] When the particulate of the present invention is utilized as a water softener for
laundering purposes, it is simply added to the wash tub or washing machine, preferably
before the fabrics and the detergent composition are introduced and after the water
has been introduced into the container.
[0047] When the particulate of the present invention is used as part of a
. complete detergent product admixed with a separate granule containing additional
detergent surfactant, the overall product is desirably added to the wash tub or the
washing machine before the fabrics and after the water has been added.
[0048] The amount of the particulate utilized as a water softening pretreatment is simply
an amount sufficient to remove most of the calcium and magnesium ions present in the
wash water. As the product of the present invention normally has a density of from
about 0.45 gram per cc to about 0.65 gram per cc, sufficient usage of the product
will, under most United States conditions, be satisfied by the use of from about 1/4
cup to about 1 cup. Under continental European washing conditions where the water
hardness is somewhat greater, the product will normally be used at a level of from
about 1/2 cup to about 3 cups.
[0049] Laundry detergent products of'the present invention as used under U.S. washing conditions
at from about 1/2 to about 1-1/2 cups and from about 1 cup to about 3 cups under European
washing conditions.
[0050] The agglomerate of this invention, when added to a spray-dried detergent granule
containing a surfactant to give an agglomerate level of from about 5% to about 80%,
preferably from about 10% to about 60% by weight of the total composition, provides
a complete detergent composition with little or no apparent formation of insolubles.
This is especially important when the spray-dried detergent granule contains large
amounts of silicates. In order to avoid segregation, the agglomerate should have a
size that is compatible with the detergent granule, e.g., not less than about 100
microns in diameter, preferably not less than about 150 microns in diameter. The agglomerates
of this invention do not break down unacceptably under ordinary handling and shipping.
[0051] Particle size can be adjusted by sieving and recycling or by adjusting spray drying
pressure and nozzle size.
[0052] Preferably the agglomerates of this invention are completely free of the agglomerating
compounds of U.S. Patent 4,096,081, and especially free of the polyethylene glycol
of said patent.
[0053] The following are Examples of the present invention:
EXAMPLE I
[0054] Detergent compositions were made with the intent of increasing the thoroughness of
zeolite builder dispersion in wash water. The expected benefits of increased dispersion
are (1) reduced incidence of insoluble aggregates on washed fabrics, and (2) increased
rate of zeolite availability for complexation of water hardness.
[0055] The method used for evaluating degree of dispersion involved Nephelometer Turbidity
Unit (NTU) measurements of wash water concentrations (0.3 g. active zeolite/1. city
water at about 9 grains/gallon hardness). A water sample was graobed after four minutes
of normal wash agitation with the zeolite-containing composition present. A higher
turbidity reading indicates greater exposed particle surface and thus more effective
dispersion. A more sustained turbidity reading after 30 minutes of static observation
indicates a slower settling rate and thus a smaller average zeolite aggregate size.
Zeolite A, Arogen 2000 from Huber Co., was used in these experiments.
[0056] It is known that electrolytes alone aid in dispersion of aluminosilicates in an aqueous
medium, and this is seen in comparing A and C. The addition of a binding and wetting
agent, polyethylene glycol (PEG 8000), in D (ref. Patent 4,096,081) improves dispersibility
to the level seen with a typical full detergent composition (non-phosphate), as in
B. Addition of a relatively hardness-insensitive synthetic surfactant in E and G improves
the dispersion, though removal of the PEG (F and H) now shows further benefit in fineness
and stability of the zeolite dispersion.
[0057] Both of the surfactants in E-H are acceptably hardness insensitive. A tallow alkyl
sulfate, for example, would be precipitated by free hardness and rendered ineffective
as a zeolite dispersant. It is noted that the higher sustained dispersion at 30 minutes
with samples E and F reflect the greater degree of hardness insensitivity of the alkyl
polyethoxy sulfate vs. the alkylbenzene sulfonate of G and H.
[0058] In all cases, the zeolite was dried from an aqueous slurry of about 50-60% total
water. to which the other ingredients had been added.
[0059] The slurry was heated to about 140°F and mixed thoroughly. This mixture was then
dried in a thin film in a 70°C oven until only about 18-20% H
20 remained. The water of hydration in the Zeolite A is generally not removed under
these conditions. The dried cake was granulated and screened through a 14 mesh Tyler
screen. The resultant density was about 0.58 g./cc.. The particle size was mostly
greater than about 150 microns. Zeolite delivered to the wash water was controlled
at 0.3 g/l. and other components (except in B) were used as: sodium sulfate at 0.01
to 0.03 g./l., PEG 8000 at 0.01 to 0.015 g./l., and synthetic surfactants at 0.008
g./l.
EXAMPLE II
[0060] A base granule was spray dried containing:
27.6% of the following admix, formed by spray drying a slurry according to Example
1H, heated to about 175.F and pressure atomized into a pilot scale (10' diameter)
spray-drying tower with 500°F inlet air, was mixed with the above base granule and
the mixture was sprayed with .9% polyethyleneglycol (M.W. 8000) and 0.14% perfume
The . admix density was about 0.55-0.58 g./cc. and the particle size was about 90%
greater than 150 micron diameter. Admix composition:
EXAMPLE III (comparison)
[0061] Composition of Example II was made using powdered zeolite (as received) admixed to
the base granule composition. The resulting detergent product was excessively dusty
and free flow was unacceptable due to bridging and surging. Segregation is a further
potential problem with this approach.
EXAMPLE IV
[0062] The zeolite composition of Example II is metered into a fluidized bed along with
other dry ingredients and nonionic surfactant, minors, and perfume are sprayed on.
1. A stable, rapidly-dispersible zeolite detergent builder agglomerate comprising
an intimate mixture of:
(a) from about 60% to about 95% of an aluminosilicate detergency builder, selected
from the group consisting of:
(i) an amorphous aluminosilicate;
(ii) a hydrated crystalline zeolite selected from the group consisting of Zeolite
A, X, and P having a particle size of from about 0.1 to about 25 microns; and (iii)mixtures
thereof having a calcium ion exchange capacity of at least about 200 mg eq./g (four
milliequiva- lents/g.); and a calcium ion exchange rate of at least about 2 grains/gallon/minute
gram;
(b) from about 1% to about 4% of synthetic anionic detergent surfactant which is relatively
hardness insensitive;
(c) from about 1% to about 10% of an inorganic salt and being essentially free of
silicates; and
(d) balance water.
2. The agglomerate of Claim 1 wherein the aluminosilicate is from about 70% to about
80% by weight, the surfactant is from about 1-1/2% to about 2-1/2% by weight, and
the inorganic salt is from about 2% to about 4% by weight.
3. The agglomerate of Claim 2 wherein the surfactant is selected from the group consisting
of water-soluble salts of:
(a) alcohol polyethxylate sulfates wherein the alcohol contains from about 8 to about
20 carbon atoms and the average degree of ethoxylation is from about 1 to about 10;
(b) alkylbenzene sulfonates with alkyl groups containing from about 9 to about 15
carbon atoms;
(c) alpha-sulfocarboxylic acids containing from about 6 to about 20 carbon atoms;
(d) the esters of (s) with alcohols containing up to about 14 carbon atoms;
(e) secondary paraffin sulfonates containing from about 8 to about 18 carbon atoms;
(f) olefin sulfonates containing from about 8 to about 18 carbon atoms; and
(g) mixtures thereof.
4. The agglomerate of Claim 1 wherein the zeolite is selected from the group consisting
of zeolites A, X, P and mixtures thereof.
5. The agglomerate of Claim 1 wherein the zeolite is Zeolite A.
6. The agglomerate of Claims 1, 3, 4, or 5 wherein the inorganic salt is selected
from the group consisting of sodium and potassium sulfates, chlorides, carbonates,
bicarbonates, aluminates, phosphates, and mixtures thereof.
7. The agglomerate of Claims 1, 3, 4 or 5 wherein the inorganic salt is sodium carbonate
or sodium sulfate.
8.. The agglomerate of Claim 3 wherein the zeolite is selected from the group consisting
of Zeolites A, X, P and mixtures thereof.
9. A detergent composition comprising from about 5% to about 80% of the agglomerate
of Claim 1 and from about 20% to about 95% of a spray-dried granule containing a surfactant.