"SOLUTIONS AND CRYSTAL GELS THAT PRODUCE SOAP OR INSTANTLY FOAM"BACKGROUND 1. TECHNICAL FIELDThe present disclosure relates to post-foam-forming detergent compositions. More specifically, the present disclosure relates to compositions containing unique combinations of surfactants and coupling agents that solubilize the volatile hydrocarbons to provide instant foam forming products, such as, for example, instant foam-forming cleaners, shaving creams and hair care products.2. ANTECENT OF THE RELATED TECHNIQUEThe importance and consumer applications of the post-foaming detergent compositions are well established. For example, U.S. Patent No. 4,726,944 discloses crystalline shampoo formulations which are aqueous solutions of water soluble salts of lauryl sulfate, volatile hydrocarbon, a tertiary amine oxide and water soluble gums. In US Pat. No. 4,744,979 a crystalline formulation is provided using an aqueous soap solution and a surfactant such as amine oxide or alkanolamides and the volatile water soluble organic liquid. U.S. Patent Number 4,772,427 achieves a crystalline solubilized volatile hydrocarbon formulation using 10 to 16 carbon atoms of water-soluble anionic alkaline metal, ether sulfate, ethoxylated fatty alcohol dispersible in water or fatty ester, isopropyl myristate, mono- or di-saccharide and a mixture of volatile hydrocarbons such as n-pentane and isobutane. However, US Pat. No. 4,772,427 states in column 6, lines 20 to 27 that "the omission of a single component detrimentally affects the unique properties of the total composition.Therefore, the criticality of the essential ingredients and the specificity of each One of the ingredients is necessary in the formulation of the present novel foam-forming shower gel products. " In U.S. Patent No. 5,186,857, a water-in-oil emulsion is shown with foaming surfactants which are used to increase the solubility of a volatile hydrocarbon. It would be desirable to provide an instant foam-forming crystalline solution or gel, which has an application for cleaning hair or skin or any of the substrates such as fabrics or hard surfaces that may require cleaning.
COMPENDIUMIt has now been discovered that it is possible to solubilize the volatile hydrocarbons in a surfactant system containing a primary surfactant such as alkyl ether sulfate, amine oxide or combinations thereof, using a polyethylene glycol ether solubilizer of propylene glycol oleate, generally identified as PEG 55, propylene glycol oleate. In another aspect, it has been found that polyoxyethylene sorbitol hexaoleate or sorbitan laurate PEG-80 can be used with some alkyl ether sulfates or amine oxide surfactants to solubilize volatile hydrocarbon solvents in order to achieve a solution or crystal gel.
Another important discovery of this disclosure is that the amphoteric surfactants themselves do not solubilize the volatile hydrocarbon solvents. However, in combination with the alkyl ether sulfates or the amine oxide in the presence of PEG-55, propylene glycol oleate or polyoxyethylene sorbitol hexaoleate or PEG-80, the crystalline solutions or gels of sorbitan laurate can be formulated . The resulting crystalline instant foam-forming liquid or gel will form foams on a surface with or without the aid of water. The solution or crystalline gel is not self-foaming type when it is enclosed in a bottle and exposed to high temperatures such as 38 ° C to 49 ° C. Therefore, the products manufactured from present compositions are consumer friendly and can resist transport and a storage condition sends to the market site. The instant foam-forming crystalline solutions or gels described herein can be packaged in non-pressurized containers such as bottles and pump bottles or pressurized barrier packages. Approximate surfactant mixtures are selected depending on the application of the products such as "mousse" shampoos (foam), handwashing, facial cleansers, shower gels, shaving cream or hard surface / fabric cleaners.
DETAILED DESCRIPTION OF THE PREFERRED MODALITIESThe compositions and products in accordance with this disclosure contain a primary surfactant or combination of primary surfactants optionally a secondary surfactant, water, a volatile hydrocarbon and a coupling agent to solubilize the volatile hydrocarbon. The surfactant and combination of surfactants must be soluble in water to produce a crystalline solution or gel. Suitable primary surfactants include alkyl ether sulfates, such as, for example, alkyl ether sulfates of 10 to 16 carbon atoms containing between 2 and 10 moles of ethoxylation. Ammonium, as well as metal alkyl ether sulfates are useful. A surfactant, particularly useful in this class, is sodium lauryl ether sulfate having two moles of ethoxylation. Also useful as the primary surfactant are amine oxides, a nonionic nitrogen containing surfactant. Particularly useful are tertiary amine oxides with a long hydrocarbon chain containing from 12 to 14 carbon atoms. Within this class of nonionic surfactants, lauryl dimethyl amine oxide is particularly useful. Lauryldimethyl amine oxide can be obtained commercially under the name Ammonyx LO from Stepan Co., of Northfield, Illinois. The alkyl ether sulfates of the formula (CH2CH2O) -ROSO3M, wherein M is a monovalent cation and R is a hydrocarbon of 8 to 18 carbon atoms, are also suitable for use as the primary surfactant. A particularly useful alkyl ether sulfate is sodium trideceth sulfate. Sodium trideceth sulfate can be obtained under the name Standapol ES-13 from Henkel Corp., Special Chemical Division, Gulph Mills, PA. The amount of the primary surfactant that is employed in the composition will depend on a number of factors, including the final use of the composition, the desired foaming characteristics, and other ingredients present in the composition. A combination of primary surfactants can also be employed to formulate a desired product having specific characteristics. Typically, the primary surfactant or combination of surfactants will be present in an amount of about 3 percent to about 50 percent active ingredients by weight of the final composition, preferably, from about 5 percent to about 30 percent of active ingredients by weight of the final composition. Optionally, one or more secondary surfactants may be included in the present compositions. For example, an amphoteric surfactant may be added as a foam booster. Suitable amphoteric surfactants include imidazolines, sultaines and betaines. An amphoteric surfactant, particularly useful is cocoamidopropyl betaine such as Monateric CAB-LC which is commercially available from Mona Industry. When used, the secondary surfactant may be present in amounts up to about 25 weight percent of the final composition based on the active ingredients. Preferably, the secondary surfactant is present in an amount from about 0.1 percent to about 20 percent active ingredients by weight. A volatile hydrocarbon is included in the present compositions to provide foam during use or as an impeller. The volatile hydrocarbon is used to improve the foam produced by the primary surfactant and is a gas producing agent, which when exposed to air and temperature will provide instant copious sudsing. The volatile organic liquid foam enhancing agent preferably boils within the range of 25 ° C to 50 ° C at atmospheric pressure. These volatile organic liquids include saturated hydrocarbons such as n-pentane, iso-pentane, n-butane, isobutane / and alkyl ethers of 1 to 6 carbon atoms, such as dimethyl ether, diethyl ether, methylethyl ether and diisopropyl ether. The amount of the volatile hydrocarbon in the compositions will depend on the type of product being formulated and the function that will be performed by the volatile hydrocarbon. Normally, however, the volatile hydrocarbon will be present in an amount of about 1 percent to about 7 percent of the final composition, preferably from about 3 percent to about 4 percent by weight. The present compositions also contain an amount of effective solubilization of a coupling agent. An amount of effective solubilization is an amount sufficient to prevent any significant separation of the volatile hydrocarbon from the surfactant. Thus, for example, an effective amount will prevent the formation of a separate layer of the volatile hydrocarbon. Typically, an effective solubilization amount will be from about 0.5 percent to about 7 percent by weight of the final composition, preferably from about 2 percent to about 4 percent by weight. A coupling agent that was found to effectively solubilize the volatile hydrocarbons is a polyethylene glycol ether of propylene glycol oleate PEG-55, propylene glycol oleate. At concentrations of 1 percent to 7 percent, this coupling agent will solubilize the volatile hydrocarbons such as n-pentane, iso-pentane, iso-butane and dimethyl ether in the presence of the above-mentioned primary surfactants and water, resulting in result a crystalline solution or gel that is stable under high normal temperature stored in regular bottles or pressurized aerosol bottles. Other agents that solubilize the volatile organic solvents in certain primary surfactants include sorbitol polyoxyethylene hexaoleate and PEG-80, sorbitan laurate. Although it is less universal in its ability to solubilize the volatile hydrocarbon solvents, these compounds are quite useful in certain applications such as those formulations that will be exemplified below. Water (preferably deionized) in an amount of about 10 percent to about 65 percent by weight of the final composition is also present in the novel compositions described herein. In addition to the aforementioned ingredients, the instant instant foaming crystalline aqueous solution or gel may also contain a variety of non-essential ingredients. For example, water-soluble gums may be added, such as cellulosic polymers or natural gum which impart the desired aesthetic properties to the product. The gels and crystalline solutions may contain a humectant such as glycerin, sorbitol, propylene glycol, etc. which provides a moisturizing or moisturizing benefit to the skin or hair. The fragrance and color can be added to improve the cosmetic appearance of the product. Active ingredients such as triclosan, chlorhexidene gluconate or salicylic acid can also be dissolved in the surfactant system to provide an antibacterial functional product. In addition, small amounts of water-soluble soap such as palmitate or sodium / potassium or ammonium stearate can be used in order to improve the stability of the foam for shaving application. The alkanolamide can be added in a similar manner to improve the stability of the foam. The crystalline solution or gel compositions which are achieved by means of PEG-55, propylene glycol oleate or polyoxyethylene sorbitol or PEG-80-sorbitan laurate, can be packaged in any conventional non-pressured glass or plastic bottle. In cases where isobutane or dimethyl ether is used as a post-foaming solvent, a pressurized spray bottle or a pressurized barrier pack must be used of course.
EXAMPLESThe following examples are presented to illustrate the specific embodiments of the present compositions and methods. These examples should not be construed as limitations on the scope of the invention. Comparison Examples are also presented to show the novel effects produced by the present compositions. Comparative Examples A-E Compositions are prepared which contain the primary surfactant (or a mixture of primary and secondary surfactants), the volatile hydrocarbon and the water, but no coupling agent. The compositions are prepared, the formulations of the compositions are disclosed in Table I. All the ingredients except the n-pentane are mixed to produce a crystalline solution. Heat is used when necessary to achieve a crystalline solution. This concentrated material is then transferred to a narrow neck glass bottle and the measured amount of n-pentane is added. A screw cap is used to secure the product in a bottle. The product is then stirred gently. TABLE -IABCDE Ether Sulfate Sodium Lauryl (ES-2) (aqueous 28% solution) 50.00 lauryl -oxide (30% solution) - 60-40 Trideceth ether sulfate sodium (30%) - 40 Cocoamidopropyl Betaine - - - 20 10Water 47 37 57 37 57 n-pentane 3 3 3 3 3 All the aforementioned compositions showed the separation of the n-pentane in the upper part of the bottle within 24 hours. These Comparison Examples clearly indicate that n-pentane is insoluble in a primary surfactant or a mixture of the primary surfactant and an amphoteric surfactant.
EXAMPLES 1 to 5The formulations shown inTable II in the manner described in Comparative Examples A and E to show the effects of a coupling agent on the surfactant compositions present. TABLE - IIEj.l Ex.2 Ej.3 Ex. 4 Ex. 5 Sulfate Sodium lauryl ether (28% solution) 50.00 -oxide Laurildimetil- amine (30% solution) - 60-40 - Sodium Trideceth Sulfate (30%) - - 40 cocoamidopropyl betaine (solution 30%) - - - 20 10PEG-55 Propylene glycol Oleate 3 3 3 3 3Water 44 34 54 34 54 n-pentane 3 3 3 3 3Each of the aforementioned compositions produces a liquid or a crystalline gel without any separation of layers. When maintained at higher ambient temperature or temperatures such as 43 ° C to 49 ° C, these compositions remain clear without any separation, indicating that it has achieved complete solubilization of the volatile hydrocarbon in the primary surfactant, with the help of coupling agent. Resting overnight at room temperature or in an oven at a temperature of 38 ° C to 49 ° C, will clear any of the bubbles in the compositions that could have formed during the mixing of the product. The final product is a crystalline solution in which a coupling agent is used. This is a rather surprising result when compared to the separate layer other than n-pentane that is formed when a coupling agent is not used as in the formulation of Comparative Examples A-E shown in Table I.
EXAMPLES 6 to 9To exemplify the use of other coupling agents, the formulations described in Table III are prepared.
TABLE - IIIEx.6 Ex.7 Ex.8 Ex.9 Sodium Trideceth Sulfate (30%) 40 - 40 - Lauryl Dimethylamine Oxide (30%) - 60 - 60Polyoxyethylene Sorbitol Hexaoleate 3 «3 PEG-80 Sorbitol Laurate - - 3 3 Water 54 54 54 54 n-pentane 3 3 3 3All of the aforementioned compositions prepared in a manner similar to that described above produce a crystalline solution without separation of n-pentane.
Examples F-H Comparison and Examples 10-12Isobutane-containing compositions such as volatile hydrocarbon are prepared with or without a coupling agent to show the newly discovered effects of the coupling agent. The formulations are described in Table IV. F G H Ex. 10 Ex. l l Ex. 12Sodium Alkyl Ether Sulfate (28%) 50 - - 50 - - Sodium Trideceth Sulfate (30%) - - 50 - - 5Lauryldimethyl amine oxide (30%) - 60 - - 60 - PEG-55 Propylene glycol oleate - - - 3 3 3Iso-butane 4 4 4 4 4 4Water 46 36 46 43 33 43Compositions F, G and H have two separate layers with an iso-butane top cap indicating the insolubility of isobutane in the system. In Examples 10, 11 and 12 where a coupling agent is used, a crystalline solution or gel is provided indicating total solubilization of the volatile hydrocarbon.
EXAMPLES I-L COMPARISONThe following formulations I-L containing isobutane I J K L Trideceth Sodium Sulfate (30%) 40 40 - Lauryl Dimethylamine Oxide (30%) - 60 60Sorbitol Hexaoleate of Polyoxyethylene 3 - 3 -PEG-80 Sorbitan Laurate - 3 - 3Iso-butane 4 4 4 4Water 53 53 33 33None of the aforementioned systems are crystalline, but rather cloudy and upon standing, a white precipitated material is separated. These formulations show that the specific coupling agent employed, which solubilizes n-pentane or iso-pentane, is unsuitable for the formulations mentioned above for solubilizing isobutane.
Example 13An antibacterial surgical scrubber is prepared having the following composition:Surgical Scrubber Antibacterial Ingredient% by weightLauryldimethylamine Oxide (30%) 40 Cocoamidopropyl Hydroxysultaine (30%) 20 Chlorhexidine Gluconate (20% solution) 20 PEG-55 Propylene Glycol Oleate 5 Water 12 n-pentane 3The surgical scrubber is a crystalline solution that provides good foaming during use. It will be understood that different modifications can be made to the modalities disclosed herein. Therefore, the above description should not be construed as limiting, but only as exemplifications of the preferred modalities. Those skilled in the art will be able to visualize other modifications within the scope and spirit of the appended claims to the present.