FIELD OF THE INVENTION
[0001] The present invention relates to compositions and containers therefor. Specifically,
the present invention relates to high viscosity compositions, especially high viscosity
cleaning compositions, and containers therefor. The present invention also generally
relates to foam-generating dispensers.
BACKGROUND OF THE INVENTION
[0002] High viscosity compositions, such as dish washing compositions, hand soap compositions,
hair conditioner compositions, fabric conditioner compositions, scrubbing compositions,
etc. are well known and have typically provided in a liquid, a gel or a paste. While
liquids and pastes may be useful in a variety of situations, such physical forms are
no longer considered new and exciting. Also, while it is desirable to provide new
and interesting physical forms, the use of the above compositions has typically been
limited to application or pre-application of such liquids, gels and pastes into a
substrate, and then the additional step of direct application to the desired surface.
[0003] While it is known to employ a foam-generating dispenser to make low-viscosity compositions
foam, this approach has not to date succeeded for high viscosity compositions. Specifically,
the rheology of high viscosity compositions makes it difficult to achieve an acceptable
foam without extremely turbulent and violent flow characteristics. As such turbulent
flow characteristics often require excessive physical exertion or a highly-pressurized
container, the practical result is that formulators are often required to lower the
viscosity of their products so as to match the limitations of the foam-generating
dispensers currently on the market. Therefore, this approach imparts an artificial,
physical constraint upon formulators' freedom to achieve the best performing and/or
lowest cost composition.
[0004] Accordingly, the need exists for a foam-generating dispenser which is able to produce
foam from a high viscosity composition. The need further exists for a foam-generating
dispenser which may produce such a foam, without the need for excessive physical exertion,
and/or the need to use an aerosol propellant.
SUMMARY OF THE INVENTION
[0005] The present invention relates to foam-generating kit containing a non-aerosol container
with a foam-generating dispenser and a high viscosity dishwashing microemulsion composition,
preferably within the container. The high viscosity composition has a viscosity from
0.3 Pa·s to 4.0 Pa·s. When the foam-generating dispenser is employed with the high
viscosity composition, the foam-generating dispenser generates a foam having a foam
(i.e., volume) to weight ratio of greater than about 2 mL/g. The foam-generating dispenser
employs at least three meshes.
[0006] It has now been found that the combination of a foam-generating dispenser and a high
viscosity composition can simultaneously provide acceptable foaming without excessive
physical exertion and without employing an aerosol propellant. Without intending to
be limited by theory, it is believed that when an increasingly turbulent flow path
is produced, even a high viscosity composition having a viscosity from 0.3 Pa·s to
4.0 Pa·s can be made to produce an acceptable foam.
[0007] These and other features, aspects, advantages, and variations of the present invention,
and the embodiments described herein, will become evident to those skilled in the
art from a reading of the present disclosure with the appended claims, and are covered
within the scope of these claims.
BRIEF DESCRIPTION OF THE FIGURES
[0008] While the specification concludes with claims particularly pointing out and distinctly
claiming the invention, it is believed that the invention will be better understood
from the following description of the accompanying figures in which like reference
numerals identify like elements, and wherein:
Fig. 1 is a cut-away view of a preferred embodiment of the foam-generating dispenser;
Fig. 2 is a top perspective, cut-away view of a preferred embodiment of the shaped
applicator; and
Fig. 3 is a perspective, cut-away view of a preferred embodiment of the shaped applicator.
[0009] The figures herein are not necessarily drawn to scale.
DETAILED DESCRIPTION OF THE INVENTION
[0010] All percentages, ratios and proportions herein are by weight of the final high viscosity
composition, unless otherwise specified. All temperatures are in degrees Celsius (°C)
unless otherwise specified.
[0011] As used herein, the term "comprising" means that other steps, ingredients, elements,
etc. which do not affect the end result can be added. This term encompasses the terms
"consisting of" and "consisting essentially of".
[0012] As used herein, the term "dish" means any dishware, tableware, cookware, glassware,
cutlery, cutting board, food preparation equipment, etc. which is washed prior to
or after contacting food, being used in a food preparation process and/or in the serving
of food.
[0013] As used herein, the terms "foam" and "suds" are used interchangeably and indicate
discrete bubbles of gas bounded by and suspended in a liquid phase.
[0014] As used herein, the term "microemulsion" means a oil-in-water emulsion which has
the ability to emulsify oil into non-visible droplets. Such non-visible droplets typically
have maximum diameter of less than about 100 angstroms (Å), preferably less than 50
Å as measured by methods known in the art, such as ISO 7027 which measures turbidity
at a wavelength of 880 nm. Turbidity measuring equipment is easily available from,
for example, Omega Engineering, Inc., Stamford, Connecticut, U.S.A.
CONTAINER
[0015] The container useful herein is a non-aerosol container and typically has a hollow
body for holding a high viscosity dishwashing composition, and is typically a bottle
or canister formed of plastic, glass, and/or metal, preferably a polymer or resin
such as polyethylene, polypropylene, polyethylene terephthalate, polycarbonate, polystyrene,
ethyl vinyl alcohol, polyvinyl alcohol, thermoplastic elastomer, and combinations
thereof, although other materials known in the art may also be used. Such containers
will typically hold from about 100 mL to about 2 L of liquid, preferably from about
150 mL to about 1.2 L of liquid, and more preferably from about 200 mL to about 1
L of liquid, and are well known for holding liquid consumer products. Such containers
are widely available from many packaging suppliers.
[0016] Operatively attached to the container either directly or indirectly is a foam-generating
dispenser for generating a foam. When activated, the foam-generating dispenser generates
foam and concurrently dispenses the foamed composition from the container. The foam-generating
dispenser may be formed as either integral with, or separate from the container. If
formed separately, the foam-generating dispenser may attach to the container via methods
known in the art such as by employing a transition piece, corresponding threaded male
and female members, pressurized and non-pressurized seals, locking and snap-on parts,
and/or other methods known in the art. Preferably, the foam-generating dispenser is
attached to the container via a transition piece and/or with corresponding threaded
male and female members which allow easy refilling.
[0017] The foam-generating dispenser may interact with the high viscosity composition via
any method so as to generate a foam, such as a chemical reaction, an enzymatic reaction,
and/or a mechanical action. However, a mechanical action is preferred herein, and
typically involves a mechanism which imparts or mixes a gas, such as air, nitrogen,
carbon dioxide, etc., directly into the dishwashing composition in a turbulent manner
as it dispenses, so as to physically form the foam. Preferably, the foam-generating
dispenser includes a gas imparting mechanism to form the foam from air via an air
injection piston, foam-generating aperture, an impinging surface, a mesh or net, a
pump, and/or a sprayer, more preferably, an air injection piston, a pump, an impinging
surface, a plurality of meshes or nets, and/or a sprayer which injects or imparts
air from the atmosphere into the dishwashing composition. In a highly preferred embodiment,
the foam-generating dispenser employs, preferably from three to five, meshes wherein
the high viscosity composition flows through these meshes in series so as to generate
the foam. Without intending to be limited by theory, it is believed that by flowing
through the above meshes in series, the high viscosity composition is repeatedly turbulently
mixed with air, thereby multiplying the foam-generating effect beyond that of any
single mesh. As the viscosity of the high viscosity composition increases, additional
meshes may be added to provide the desired level of foaming and/or quality of foam.
[0018] The foam-generating dispenser also typically includes an activator, preferably a
manual activator such as, for example, a trigger, a pressure-activated pumping mechanism,
a button, and/or a slider, more preferably a button and/or a pressure-activated pumping
mechanism which can be activated with a single finger. It is highly preferred that
the activator be designed such that a consumer may easily activate it when their hands
are wet and/or slippery, such as when in the middle of a manual dishwashing process.
Such an activator should allow the user to easily and conveniently control both the
speed of dispensing and the volume dispensed. For certain applications, such as in
industry or in public facilities, other activators may be useful, such as an electronic
activator, a computer-controlled activator, an electric eye or an infrared detection
activator, a manual lever-assist activator, etc. The foam-generating dispenser useful
herein generates a foam having a foam to weight ratio of greater than about 2 mL/g,
more preferably from about 3 mL/g to about 10 mL/g, and even more preferably from
about 4 mL/g to about 8 mL/g. Furthermore, the foam-generating dispenser useful herein
generates at least about 2 mL foam, preferably from about 3 mL to about 10 mL, and
more preferably from about 4 mL to about 8 mL, per mL of dishwashing composition.
"Creamy" and "smooth" foams having fine bubbles dispersed relatively evenly throughout
may be especially preferred for their aesthetic and/or performance characteristics.
In certain cases, preferred foams are those which do not significantly degrade into
liquid over a period of 3 minutes are especially preferred. Specifically, when the
foam is dispensed onto a clean glass surface (e.g., a PYREX
™ plate) and let sit for 3 minutes at 25°C, less than 1 mm of liquid should be apparent.
Preferably, no liquid is visible at the edge of the foam after 3 minutes. However,
on other cases, it has also been found that a certain amount of liquid (i.e., non-foam)
is also preferable, as this liquid then permeates into the applicator (e.g., a sponge),
and further extends the mileage of the high viscosity composition when it is used
for, example, cleaning dishes.
[0019] Fig. 1 is a cut-away view of a preferred embodiment of the foam-generating dispenser,
10, with a nozzle, 12, from which the foamed dishwashing composition is dispensed.
The dishwashing composition enters the foam-generating dispenser via a dip tube, 14,
and flows past a ball, 16, and into a cylinder, 18. A plug, 20, prevents the ball,
16, from escaping, and also supports a coil spring, 22, and a inner rod, 24. A liquid
piston, 26, creates a suction which draws the dishwashing composition past the ball,
16 and the plug, 20, into a liquid chamber, 28, and thereby primes the foam-generating
dispenser, 10. Meanwhile, an air chamber, 30, and an air piston, 31 are also primed,
and when the activator, 32, is depressed, both the air from the air chamber, 30, and
the dishwashing composition from the liquid chamber, 28, are turbulently forced into
the mixing chamber, 34, and past a first mesh, 36 and a second mesh, 38, which are
both kept in place by a mesh holder, 40. As the turbulent air/dishwashing composition
mixture is forced past the first mesh, 36, a first, rough foam is generated, which
becomes more fine and even after passing through the second mesh, 38, and the third
mesh, 41. These meshes may have the same, or different pore sizes. Also, additional
meshes may also be employed, as desired.
[0020] In a preferred embodiment, the foam-generating dispenser contains a sponge therein
or attached thereto, in addition to three or more meshes. A sponge also produces foam
as the high viscosity composition is turbulently forced through its, open-celled structure.
Such a sponge may be contained within the interior of the foam-generating dispenser
and/or may also be located at the end of the nozzle, as desired. Without intending
to be limited by theory, it has been found that additional meshes and/or a sponge
located slightly within, and/or at the tip of the nozzle are especially useful herein,
as they serve to generate the foam immediately prior to dispensing. Therefore, the
user sees the desired foam as, or immediately after, it passes through the last turbulent
flow area, while the foam quality is at its best and before it noticeably degrades
and/or otherwise changes in quality.
[0021] Fig. 1 also shows a base cap, 42, which secures the foaming dispenser to a container,
44, which holds the high viscosity composition.
[0022] Preferred foam-generating dispensers useful herein include: T8900, OpAd FO, 8203,
and 7512 series foamers from Afa-Polytek, Helmond, The Netherlands; T1, F2, and WR-F3
series foamers from Airspray International, Inc., Alkmaar, The Netherlands or North
Pompano Beach, Florida, U.S.A.; TS-800 and Mixor series foamers from Saint-Gobain
Calmar, Inc., City of Industry, California, U.S.A.; pump foamers and squeeze foamers
from Daiwa Can Company, Tokyo, Japan; TS1 and TS2 series foamers from Guala Dispensing
USA, Inc., Hillsborough, New Jersey, U.S.A.; and YT-87L-FP, YT-87L-FX, and YT-97 series
foamers from Yoshino Kogyosho Co., Ltd., Tokyo, Japan. Also see the foam-generating
dispensers discussed in the
Japanese-language publications Food & Package, (2001) vol. 42, no. 10, pp 609-13;
Food & Package, (2001) vol. 42, no. 11, pp 676-79; and
Food & Package, (2001) vol. 42, no. 12, pp 732-35. Variations and modifications of existing foam-generating dispensers are especially
useful herein, especially by modifying air piston:product piston volume ratio, mesh/net
sizes, impinging angle, etc., as well as optimization of the sizes and dimensions
of the cylinder, rod, dip tube, nozzle, etc.
[0023] While trigger-type foam-generating dispensers may be preferred for certain embodiments
herein, a finger and/or palm-activated type pump (see, e.g., Fig. 1) is often preferred
for aesthetic reasons. This is especially the case where the foam-generating kit is
to be distinguished from the "harsh" image of typical hard-surface cleaners and similar
heavy-duty products.
HIGH VISCOSITY COMPOSITION
[0024] The high viscosity composition herein is ,a dishwashing composition, and preferably
a hand dishwashing composition. Such a high viscosity composition may therefore typically
include a surfactant system, a solvent, and one or more optional ingredients known
in the art of cleaning such as a dye, an enzyme, a perfume, a thickener, a pH controlling
agent, a reducing or oxidizing bleach, an odor control agent, antioxidants and free
radical inhibitors, and a mixture thereof.
[0025] The surfactant system herein typically includes an anionic surfactant, an amphoteric
surfactant, a cationic surfactant, a nonionic surfactant, a zwitterionic surfactant,
or a mixture thereof, preferably an alkyl sulfate, an alkoxy sulfate, an alkyl sulfonate,
an alkoxy sulfonate, an alkyl aryl sulfonate, an amine oxide, a betaine or a derivative
of aliphatic or heterocyclic secondary and ternary amine, a quaternary ammonium surfactant,
an amine, a singly or multiply alkoxylated alcohol, an alkyl polyglycoside, a fatty
acid amide surfactant, a C
8-C
20 ammonia amide, a monoethanolamide, a diethanolamide, an isopropanolamide, a polyhydroxy
fatty acid amide and a mixture thereof. The surfactants useful herein may be further
be branched and/or linear, substituted or unsubstituted, as desired. See also "Surface
Active Agents and Detergents" (Vol. I and II by Schwartz, Perry and Berch).
[0026] The solvent useful herein is typically selected from the group consisting of water,
alcohols, glycols, ether alcohols, and a mixture thereof, more preferably the group
consisting of water, glycol, ethanol, glycol ethers, water, and a mixture thereof,
even more preferably the group consisting of propylene carbonate, propylene glycol,
tripropyleneglycol n-propyl ether, diethylene glycol n-butyl ether, water, and a mixture
thereof. The solvent herein preferably has a solubility in water of at least about
12%, more preferably of at least about 50%, by weight of the solution.
[0027] Solvents which are capable of decreasing the product viscosity and/or imparting a
shear-thinning or non-Newtonian rheology profile to the compositions may be present,
but are not preferred herein, as such solvents are typically expensive, and do not
provide significant non-shear related benefits. Accordingly, in a preferred embodiment,
the high viscosity composition herein acts as a Newtonian Fluid throughout the relevant
shear-range during use in the foam-generating dispenser.
[0028] Preferred solvents useful herein which impart a Newtonian behavior include mono,
di and poly hydroxy alcohols, ethers, and mixtures thereof. Alkyl carbonates such
as propylene carbonate are also preferred.
[0029] The enzyme useful herein includes a cellulase, a hemicellulase, a peroxidase, a protease,
a gluco-amylase, an amylase, a lipase, a cutinase, a pectinase, a xylanase, a reductase,
an oxidase, a phenoloxidase, a lipoxygenase, a ligninase, a pullulanase, a tannase,
a pentosanase, a malanase, a β-glucanase, an arabinosidase and a mixture thereof.
A preferred combination is a detergent composition having a cocktail of conventional
applicable enzymes such as protease, amylase, lipase, cutinase and/or cellulase. An
enzyme is typically present at from about 0.0001% to about 5% of active enzyme, by
weight. Preferred proteolytic enzymes are selected from the group consisting of ALCALASE
® (Novo Industri A/S), BPN', Protease A and Protease B (Genencor), and mixtures thereof.
Protease B is more preferred. Preferred amylase enzymes include TERMAMYL
®, DURAMYL
® and the amylase enzymes described in
WO 94/18314 A1 to Antrim, et al., published on August 18, 1994 (assigned to Genencor International)
and
WO 94/02597 A1 to Svendsen and Bisgard-Frantzen, published on February 3, 1994 (assigned to Novo
Nordisk A/S). Further non-limiting examples of preferred enzymes are disclosed in
WO 99/63034 A1 to Vinson, et al., published on December 9, 1999.
[0030] A microemulsion dishwashing composition typically also contains a low water-soluble
oil having a solubility in water of less than 5,000 ppm, preferably from 0 parts per
million (ppm) to 1,500 ppm, by weight of the low water-soluble oil, and more preferably
from about 1 part per trillion to about 100 ppm. Preferred low water-soluble oils
useful herein include terpenes, isoparaffins, other oils having the above solubility,
and a mixture thereof.
[0031] In the absence of a foam-generating dispenser, the dishwashing composition here typically
has an effective foaming dilution range of less than about 50%, preferably from about
0% to about 40%, and more preferably from about 0% to about 35% of the dilution range.
However, in an embodiment of the invention herein, the dishwashing composition, when
used with the foam-generating dispenser, has an effective foaming dilution range of
at least about 50%, preferably from about 50% to about 100%, more preferably from
about 75% to about 100%, and even more preferably from about 85% to about 100% of
the dilution range. The effective foaming dilution range is calculated as follows:
The suds generation curves of Graph I are generated by testing various dilutions of
a dishwashing composition via the suds cylinder test herein. Such a curve can be generated
either with or without dispensing from a foam-generating dispenser into the cylinders.
"Effective foam" is defmed herein as foam which is at least half (50%) the maximum
volume of foam generated for a given dishwashing composition according to the suds
generation curve. Accordingly, in Graph I for when the foam-generating dispenser is
not employed, effective foam is formed from about 28% to about 2% product concentration,
which translates into an effective foaming dilution range of 26% (i.e., 28% - 2%).
However, when the same dishwashing composition is employed with (i.e., dispensed from)
the foam-generating dispenser, it can be seen that effective foam is generated from
the point of dispensing (100% product concentration) until a product concentration
of about 3% is reached. This is because the dishwashing kit generates foam at a substantially
different dishwashing composition to water dilution than the dilution at which the
maximum volume of foam is formed according to the suds cylinder test. Thus, the effective
foaming dilution range when the dishwashing composition in Graph I is dispensed from
a foaming dispenser is 97% (i.e., 100% - 3%).

[0032] The dishwashing composition useful herein has an oil solubilization curve which is
generated by the oil solubilization test defined herein. "Effective oil solubilization"
is defined herein as oil solubilization which is at least 20% of the maximum amount
of oil solubilized for a given dishwashing composition according to the oil solubilization
curve which is plotted as a function of product concentration (i.e., dilution). Accordingly,
in Graph I, the maximum amount of oil solubilized is about 4.7 at a 70% product concentration,
and thus the effective oil solubilization is an amount of at least about 0.94. The
effective oil solubilization occurs from dilution ranges of about 96% to about 42%,
which translates into an effective oil solubilization dilution range of about 54%.
[0033] As it can be seen in Graph I, there is virtually no overlap between the suds generation
curve without a foam-generating dispenser and the effective oil solubilization dilution
range. Similarly, it can be seen that absent a foam-generating dispenser, there is
no overlap between the effective foaming dilution range (28% to 2%) and the effective
oil solubilization dilution range (from 42% to 96%). In contrast, when a foam-generating
dispenser is employed, the effective foaming dilution range (from 3% to 100%) completely
(100%) overlaps the entire effective oil solubilization dilution range (from 42% to
96%). In a preferred embodiment, the effective foaming dilution range overlaps the
effective oil solubilization dilution range, preferably the effective foaming dilution
range overlaps the effective oil solubilization dilution range by at least about 10%,
more preferably by from about 25% to about 100%, and even more preferably from about
50% to about 100%, especially in the case of a microemulsion or a protomicroemulsion.
Furthermore, it is highly preferred that the effective foaming dilution range overlaps
the point in the oil solubilization curve where the oil solubilization is at a maximum.
Thus, the present invention encourages a user to use the product at a concentration/product
dilution which more effectively solubilizes oil, and thereby optimizes cleaning.
[0034] The present invention has recognized that such microemulsion dishwashing compositions
require the container and foam-generating dispenser herein to achieve consumer-acceptable
foaming at a dilution where the oil solubilization curve is more effective, and preferably
maximized. Accordingly, it is preferred that when the dishwashing composition is employed
with the container and foam-generating dispenser, an effective foam is generated at
a dilution factor significantly different from the suds generation curve when the
container and foam-generating dispenser is not employed.
[0035] Hand dishwashing compositions, cleaning compositions, protomicroemulsion compositions
and microemulsion compositions useful in the present invention are known in the art,
as described in, for example,
WO 96/01305 A1 to Farnworth and Martin, published on January 18, 1996;
US Patent No. 5,854,187 to Blum, et al., issued on Dec. 29, 1998;
U.S. Patent No. 6,147,047 to Robbins, et al., issued on November 14, 2000;
WO 99/58631 A1 to Robbins, et al., published on November 18, 1999;
U.S. Patent No. 4,511,488 to Matta, issued on April 16, 1985;
U.S. Patent No. 5,075,026 to Loth, et al., issued on Dec. 24, 1991;
U.S. Patent No. 5,076,954 to Loth, et al., issued on December 31, 1991;
U.S. Patent No. US05082584 to Loth, et al., issued on January 21, 1992;
U.S. Patent No. 5,108,643 to Loth, et al., issued on April 28, 1992; co-pending
US Patent Application No. 60/451064 (P&G Case # AA614FP), to Ford, et al., entitled "Protomicroemulsion, Cleaning Implement
Containing Same, And Method Of Use Therefor", filed on February 28, 2003; co-pending
US Patent Application No. 60/472941 (P&G Case # AA614P2), to Ford, et al., entitled "Protomicroemulsion, Cleaning Implement
Containing Same, And Method Of Use Therefor", filed on May 23, 2003; co-pending US
Patent Application No.
(P&G Case # AA614P3), to Ford, et al., entitled "Protomicroemulsion, Cleaning Implement
Containing Same, And Method Of Use Therefor", filed on
; and co-pending US Patent Application No.
(P&G Case # AA633FP), to Hutton and Foley, entitled "Protomicroemulsion, Cleaning
Implement Containing Same, And Method Of Use Therefor", filed on
. The dishwashing compositions noted in the above references or variations of the
above compositions, are especially preferred for use in combination with the container
and foam-generating dispenser described herein.
[0036] The high viscosity composition herein typically has a viscosity from 0.3 Pa*s to
4 Pa*s. When the high viscosity composition is dispensed from the foam-generating
dispenser, a foam is produced.
[0037] While the high viscosity composition is preferably sold within the container as a
single item, this is not necessary, as refills, and separate components within the
same kit are contemplated herein.
SHAPED APPLICATOR
[0038] It has further been discovered that a shaped applicator can surprisingly provide
significantly improved results and ease of use as compared to a normal applicator.
The shaped applicator is designed and sized to be easily held in the hand and is used
to apply the foamed dishwashing composition to the surface to be cleaned, i.e., the
dish. It has been found that if the foamed dishwashing composition is applied to a
flat applicator, then the foamed dishwashing composition is quickly wiped onto the
first dish contacted, but that little foamed dishwashing composition will remain on
the flat applicator, for cleaning subsequent dishes. This makes the use of a foamed
dishwashing composition both expensive, as composition mileage is significantly decreased,
and tiresome, as new foamed dishwashing composition constantly needs to be applied
to the flat applicator. In contrast, a shaped applicator which contains a receiving
area, such as a protected indentation and/or a pocket, for the foamed dishwashing
composition will more effectively hold and mete out the foamed dishwashing composition
over time.
[0039] As the shaped applicator will often be used for scrubbing, it is preferred that at
least one surface thereof contain an abrasive surface. The shaped applicator is typically
selected from a porous material such as a natural or artificial sponge, a brush, a
metal scouring device, a woven material, a nonwoven material, an abrasive material,
a plastic material, a cloth material, a microfiber cleaning material, a polymeric
material, a resin material, a rubber material, or a mixture thereof, preferably a
natural or artificial sponge, a brush, a metal scouring device, an abrasive material,
a foam rubber material, a functional absorbent material (FAM), a polyurethane foam,
and a mixture thereof, and more preferably a natural or artificial sponge, a brush,
an abrasive material, a foam rubber material, and a mixture thereof, with all types
of open-celled structures being highly preferred. Such shaped applicators are available
from a variety of commercial sources, such as Minnesota Mining and Manufacturing Company
(3M), St. Paul, Minnesota, U.S.A. If the shaped applicator is formed from a relatively
delicate material, or a material which is easily torn, then it is preferable that
this material be covered, partially or completely, with a water-permeable, more robust
material, such as a nonwoven material. Also useful are surfaces formed from plastic
or polymeric materials such as available from, for example, Minnesota Mining and Manufacturing
Company (3M), St. Paul, Minnesota, U.S.A., and found on, for example, Scotch-Brite™
General Purpose Scrubbing Pads.
[0040] Preferably, the FAM useful herein has an absorbent ability of more than about 20
g H
2O/g, more preferably, 40 g H
2O/g by weight of FAM. Such a preferred FAM is described in
U.S. Pat. No. 5,260,345 to DesMarais, et al., issued on November 9, 1993 or
U.S. Pat. No. 5,889,893 to Dyer, et al., issued on May 4, 1999. Examples of a preferred polyurethane is described
in
U.S. Pat. No. 5,089,534 to Thoen, et al., issued on February 18, 1992;
U.S. Pat. No. 4,789,690 to Milovanovic-Lerik, et al., issued on December 6, 1988;
Japanese Patent Publication No. 10-182780 to Kao Corporation, published on July 7, 1998;
Japanese Patent Publication No. 9-30215 to Yokohama Gum, published on February 4, 1997;
Japanese Patent Publication No. 5-70544 to The Dow Chemical Company, published on March 23, 1993; and
Japanese Patent Publication No. 10-176073 to The Bridgestone Company, published on June 30, 1998.
[0041] Preferably, the shaped applicator is not hard, but instead has at least one resilient
portion, preferably a resilient portion which is covered by an abrasive surface. Such
an optional resilient portion allows the user to vary the amount of contact, pressure,
etc., between the scrubbing surface and the dish. The foamed dishwashing composition
is thus preferably applied into or onto the shaped applicator directly from the foam-generating
dispenser.
[0042] Turning to Fig. 2, which shows a top perspective, cut-away view of a preferred embodiment
of the shaped applicator, 12, herein, a sponge-type shaped applicator, 12, contains
a receiving area, 50, to which the foamed dishwashing composition is applied for use.
The receiving area, 50, is therefore typically bounded by a wall, 52, which protects
the foamed composition from being quickly rubbed off of the shaped applicator, 12.
The receiving area is preferably a concave indentation in the shaped applicator which
may be of any shape and design which keeps the foamed dishwashing composition in contact
with the shaped applicator. In a preferred embodiment, the receiving area contains
a relatively steep concave wall or other structure which effectively keeps the foamed
detergent in the receiving area and dispenses it over time during typical use. Typically
the receiving area holds from about 1 mL to about 200 mL, preferably from about 2
mL to about 150 mL, and more preferably from about 5 mL to about 100 mL of foamed
dishwashing composition.
[0043] In Fig. 2, the shaped applicator, 12, further contains a plurality of abrasive surfaces,
54, for scrubbing a dish. It is highly preferred that at least one abrasive surface
be provided on the shaped applicator.
[0044] Fig. 3 shows a perspective, cut-away view of a preferred embodiment of the shaped
applicator, 12, which is formed as a sponge-type shaped applicator, 12, having a pocket-like
receiving area, 50, whose internal dimensions are indicated by dashed lines. The foamed
dishwashing composition is added to the receiving area, 50, via a mouth, 56, which
may be permanently open, or may be closeable, as desired. An abrasive surface, 54,
substantially covers the entire exterior of the shaped applicator, 12, to assist in
removing stains from a dish.
TEST METHODS
[0045] The viscosity herein is measured on a Brookfield viscometer model # LVDVII+ at 20
°C. The spindle used for these measurements is a S31 spindle with the appropriate
speed to measure products of different viscosities; e.g., 12 rpm to measure products
of viscosity greater than 1 Pa*s; 30 rpm to measure products with viscosities between
0.5 Pa*s - 1 Pa*s; 60 rpm to measure products with viscosities less than 0.5 Pa*s.
[0046] To measure the solubilization capacity, 10.0 g of product (this amount includes water,
if testing at a specific dilution) to be tested is placed in a 25 mL scintillation
vial. To this, 0.1 g food grade canola oil dyed with 0.045% of Pylakrome RED - LX1903
(a mixture of SOLVENT RED 24 CAS# 85-83-6 and SOLVENT RED 26 CAS# 4477-79-6, available
from Pylam Products, Tempe, Arizona, U.S.A.) dye is added, and the vial capped. The
vial is shaken vigorously by hand for 5 seconds, and allowed to stand until it becomes
clear via the ISO 7027 turbidity measuring procedure, or until 5 minutes has passed,
whichever comes first. The ISO 7027 method measures turbidity at a wavelength of 880
nm with turbidity measuring equipment such as that available from Omega Engineering,
Inc., Stamford, Connecticut, U.S.A. If the vial becomes clear, then more oil is added,
in increments of 0.1 g, until the vial fails to become clear within the prescribed
time. The % oil dissolution is recorded as the maximum amount of oil which was successfully
solubilized (i.e., the vial is clear) by 10.0 g of product. Preferably, the dishwashing
composition herein solubilizes at least about 1 g of dyed canola oil, more preferably
at least about 3 g of dyed canola oil, and even more preferably at least about 4 g
of dyed canola oil when tested at a 75% product concentration.
[0047] The sudsing profile can be measured by employing a suds cylinder tester (SCT), and
using the data to plot a suds generation curve. The SCT has a set of 4 cylinders.
Each cylinder is typically 30 cm long, and 10 cm in diameter. The cylinder walls are
0.5 cm thick, and the cylinder bottom is 1 cm thick. The SCT rotates a test solution
in a closed cylinder, typically a plurality of clear plastic cylinders, at a rate
of about 21 revolutions per minute, for 2 minutes, after which the suds height is
measured. Soil may then be added to the test solution, agitated again, and the resulting
suds height measured, again. Such a test may be used to simulate the initial sudsing
profile of a composition, as well as its sudsing profile during use, as more soils
are introduced from the surface being washed.
[0048] The sudsing profile test is as follows:
- 1. Prepare a set of clean, dry, calibrated cylinders, and water having a water hardness
of 136.8 parts per million (2.1 grains per liter), and having a temperature of 25
°C.
- 2. Add the appropriate amount of test composition to each cylinder and add water to
make a total 500 mL of composition + water in each cylinder.
- 3. Seal the cylinders and place them in the SCT.
- 4. Turn on the SCT and rotate the cylinders for 2 minutes.
- 5. Within 1 minute, measure the height of the suds in centimeters.
- 6. The sudsing profile is the average level of suds, in cm, generated by the composition.
[0049] The compositions according to the invention preferably have a sudsing profile maxima
of at least about 2 cm, more preferably at least about 3 cm, and even more preferably
about 4 cm.
[0050] Foam to weight ratio is a measurement of the mL of foam generated per gram of product.
Foam to weight ratio is measured as follows: a volumetric measuring device, such as
a graduated cylinder is weighed to get a tare weight. Then, the product is dispensed,
using the foam-generating dispenser, if appropriate, into a graduated cylinder a set
number of strokes for non-continuous dispensing devices or for a set time period for
continuous dispensing devices. 10 strokes for non-continuous devices (pumps, sprayers)
or 10 seconds for continuous devices is the suggested duration. The dispensing rate
in the test should be consistent with the dispensing rate during normal usage scenarios.
For example, 120 strokes per minute for trigger sprayers, or 45 strokes per minute
for palm pumps.
[0051] The volume of foam generated is measured in mL using the volumetric measuring device.
[0052] The volumetric measuring device containing the dispensed product is weighed in grams.
The tare weight of the volumetric measuring device is subtracted from this weight.
The result is the grams of the product dispensed. Finally, the foam to weight ratio
in mL/g is calculated by dividing the volume of foam generated (in mL) by the weight
product dispensed (in g).
[0053] The foam to weight ratio of mL/g is easily converted to mL foam per mL of product
by multiplying by the density of the high viscosity composition.
[0054] Examples of the invention are set forth hereinafter by way of illustration and are
not intended to be in any way limiting of the invention. The examples are not to be
construed as limitations of the present invention since many variations thereof are
possible without departing from its spirit and scope.
EXAMPLE 1
[0055] A foam-generating kit contains a 300 mL hollow plastic container filled with a microemulsion
dishwashing composition, and an attached T1 series foamer from Airspray, similar to
that shown in Fig. 1. The T1 foamer is modified to include a third mesh, as seen in
Fig. 1, at 41, at the tip of the nozzle. A shaped applicator according to Fig. 3 is
also included. When dispensed, the foamed dishwashing composition has a foam to weight
ratio of about 3 mL/g, and the foam has a creamy, even look and feel. The foamed dishwashing
composition is dispensed from the foaming dispenser into a pocket-type shaped applicator
by sticking the nozzle of the foam-generating dispenser into the mouth of the shaped
applicator, and pressing down on the activator. When used as described above, the
dishwashing kit provides good mileage, and a foam which lasts throughout the normal
use to clean dishes. However, if the foam-generating dispenser is not used (i.e.,
the dishwashing composition is merely poured out of the container), the effective
foaming dilution range does not significantly overlap the effective oil solubilization
dilution range.
EXAMPLE 2
[0056] An ionic-based microemulsion is provided, packaged with the foam-generating dispenser
of Example 1.