Cast detergent-containing article and method of making and using
First Claim
1. A process for forming a three-dimensional, uniform solid cast detergent within a receptacle-shaped mold which comprises:
- (a) heating about 20-75 parts by weight of a 40-75 weight percent aqueous solution of an alkali metal hydroxide to about 55°
to 95°
C.;
(b) distributing an effective amount of a hardness sequestering agent and about 15-40 parts by weight of an alkaline hydratable chemical in said aqueous solution;
(c) thickening said solution, and mixing said solution during said thickening to form a castable uniform dispersion;
(d) pouring said uniform dispersion into said receptacle-shaped mold and at least partly filling said mold; and
(e) allowing said thickened dispersion to solidify in said mold to a uniform, solid cast detergent wherein at least one surface of the cast detergent is exposed by the receptacle-shaped mold.
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Accused Products
Abstract
Solid cast detergent-containing articles are produced for use in automatic washing machines. A liquid detergent composition is cast into a mold where it is allowed to solidify. The solid cast detergent, surrounded on all but its upper surface by the mold, is used in automatic washing machines having a dispensing device designed to dispense a liquid aqueous detergent formed from the solid cast detergent using an impinging liquid spray. The liquid aqueous detergent flows out of the dispensing device generally simultaneously with its formation in the dispenser. The cast detergent composition includes an alkaline hydratable chemical and optionally further includes one or more preformed cores or plugs comprising an available chlorine source, a defoamer, or the like.
108 Citations
36 Claims
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1. A process for forming a three-dimensional, uniform solid cast detergent within a receptacle-shaped mold which comprises:
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(a) heating about 20-75 parts by weight of a 40-75 weight percent aqueous solution of an alkali metal hydroxide to about 55°
to 95°
C.;(b) distributing an effective amount of a hardness sequestering agent and about 15-40 parts by weight of an alkaline hydratable chemical in said aqueous solution; (c) thickening said solution, and mixing said solution during said thickening to form a castable uniform dispersion; (d) pouring said uniform dispersion into said receptacle-shaped mold and at least partly filling said mold; and (e) allowing said thickened dispersion to solidify in said mold to a uniform, solid cast detergent wherein at least one surface of the cast detergent is exposed by the receptacle-shaped mold. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A process for forming a three-dimensional, uniform solid cast detergent within a receptacle-shaped mold which comprises:
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(a) heating about 20-75 parts by weight of a 40-75 weight percent aqueous solution of an alkali metal hydroxide to about 55°
to 95°
C.;(b) distributing an effective amount of a hardness sequestering agent and about 15 to 40 parts by weight of an alkaline hydratable chemical in said aqueous solution; (c) thickening said solution with a polyelectrolyte polymer, to form a castable uniform dispersion; (d) pouring said uniform dispersion into said receptacle-shaped mold and at least partly filling said mold; and (e) allowing the castable thickened dispersion to solidify in said mold to a uniform cast detergent, wherein at least one surface of the cast detergent is exposed by said mold. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 26, 27, 29, 30)
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19. A method of making an article of commerce incorporating a detergent composition which comprises:
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(a) forming a castable liquid detergent composition at a temperature of up to 95°
C. which comprises;(1) at least 30% by weight of an alkaline hydratable chemical consisting essentially of alkali metal hydroxide; (2) an effective amount of a hardness sequestering agent; and (3) more than 15 parts by weight, per 100 parts by weight of said alkaline hydratable chemical, of water of hydration, at least a portion of said water of hydration being associated with said alkali metal hydroxide; (b) cooling and agitating the liquid composition at a rate such that the liquid composition thickens without segregation of components forming a thickened liquid dispersion; (c) pouring the thickened liquid dispersion into a receptacle-shaped mold; and (d) solidifying said liquid dispersion to form a uniform solid detergent composition. - View Dependent Claims (20, 21, 22, 23, 24, 25)
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28. A method for forming an article of commerce incorporating a uniform, cast detergent composition which comprises:
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(a) forming a castable liquid detergent composition at a temperature of up to 95°
C. which comprises;(1) at least 30% by weight of an alkaline hydratable chemical consisting essentially of alkali metal hydroxide; (2) an effective amount of a hardness-sequestering agent; (3) an effective thickening amount of a polyacrylate; and (4) more than 15 parts by weight, per 100 parts by weight of said alkaline hydratable chemical of water of hydration, at least a portion of said water of hydration being associated with said alkali metal hydroxide; (b) cooling the liquid composition to afford a thickened uniform dispersion; and (c) casting the uniform dispersion in a receptacle-shaped mold to yield a solid, uniform detergent composition. - View Dependent Claims (31, 32, 33, 34, 35, 36)
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Specification