Process for manufacturing solid cast silicate-based detergent compositions and resultant product

• US 6,365,568 B1
• Filed: 04/07/1994
• Issued: 04/02/2002
• Est. Priority Date: 01/29/1991
• Status: Expired due to Term

• Current Assignee: Ecolab, Inc.
• Original Assignee: Ecolab, Inc.
• Inventors: Tallman, Dan N., Mizuno, Bill George, Oakes, Tom R., Olson, Keith Edward
• Primary Examiner(s): Gupta, Yogendra N.
• Assistant Examiner(s): MRUK, BRIAN P
• Application Number:
  US08/224,063
• Time in Patent Office: 2,917 Days
• Field of Search: 252/135, 252/174, 252/156, 252/160, 252/90, 252/99, 510/445, 510/460, 510/466, 510/486, 510/511
• US Class Current: 510/511
• CPC Class Codes: C11D 17/0052 Cast detergent compositions
• CPC Class Codes: C11D 3/08 Silicates
• CPC Class Codes: C11D 3/361 Phosphonates, phosphinates or phosphonites
• CPC Class Codes: C11D 3/3761 in solid compositions

Abstract

The invention includes a process for manufacturing an improved solid cast alkaline composition, that includes (a) reacting an alkali metal silicate with an alkali metal hydroxide of the formula MOH, where M is an alkali metal, in an aqueous environment to form a reaction product; and (b) solidifying the reaction product in a mold where the reaction product is formed and solidified at room temperature without the addition of externally supplied heat and the reaction product solidifies without the use of external cooling; and where the relative amount of alkali metal silicate, alkali metal hydroxide and water incorporated into the composition are effective for producing a reaction product having about 20 to 50 parts water per 100 parts of a combination of the alkali metal silicate, the alkali metal hydroxide and water in the cast solid composition and an M₂O:SiO₂ ratio of about 2.5:1 to 4.0:1 and M is an alkali metal; and where the process does not result in the deactivation of desirable operative cleaning components.

Claims

1. A process for manufacturing an improved solid cast alkaline composition, said process comprising the steps of:

(i) reacting an alkali metal silicate with an alkali metal hydroxide of the formula MOH, wherein M is an alkali metal, in an aqueous environment to form a reaction product; and

(ii) solidifying the reaction product in a mold wherein the reaction product is formed and solidified at room temperature without the addition of externally supplied heat and the reaction product solidifies without the use of external cooling; and

wherein the relative amount of alkali metal silicate, alkali metal hydroxide and water incorporated into the composition are effective for producing a reaction product having about 20 to 50 parts water per 100 parts of a combination of the alkali metal silicate, the alkali metal hydroxide and water in the cast solid composition and an M₂O;

SiO₂ ratio of about 2.5;

1 to 4.0;

1 and M is an alkali metal;

and wherein said process does not result in the deactivation of desirable operative cleaning components.

2. A process for manufacturing an improved solid cast alkaline composition, said process comprising the steps of:

(i) reacting an alkali metal silicate with an alkali metal hydroxide of the formula MOH, wherein M is an alkali metal, in an aqueous environment to form a reaction product; and

(ii) solidifying the reaction product in a mold wherein the reaction product is formed and solidified at room temperature without the addition of externally supplied heat and the reaction product solidifies without the use of external cooling; and

wherein the relative amount of alkali metal silicate, alkali metal hydroxide and water incorporated into the composition are effective for producing a reaction product having about 20 to 40 parts water per 100 parts of a combination of the alkali metal silicate, the alkali metal hydroxide and water in the cast solid composition and an M₂O;

SiO₂ ratio of about 1.5;

1 to 2.5;

1 and M is an alkali metal;

and wherein said process does not result in the deactivation of desirable operative cleaning components.

3. A process for manufacturing an improved solid cast alkaline composition, said process comprising the steps of:

(i) reacting an alkali metal silicate with an alkali metal hydroxide of the formula MOH, wherein M is an alkali metal, in an aqueous environment to form a reaction product; and

(ii) solidifying the reaction product in a mold wherein the reaction product is formed and solidified at room temperature without the addition of externally supplied heat and the reaction product solidifies without the use of external cooling; and

wherein the relative amount of alkali metal silicate, alkali metal hydroxide and water incorporated into the composition are effective for producing a reaction product having about 20 to 45 parts water per 100 parts of a combination of the alkali metal silicate, the alkali metal hydroxide and water in the cast solid composition and an M₂O;

SiO₂ ratio of about 2.5;

1 to 3.5;

1 and M is an alkali metal;

and wherein said process does not result in the deactivation of desirable operative cleaning components.

4. A process for manufacturing an improved solid cast alkaline composition, said process comprising the steps of:

(i) reacting an alkali metal silicate with an alkali metal hydroxide of the formula MOH, wherein M is an alkali metal, in an aqueous environment to form a reaction product; and

(ii) solidifying the reaction product in a mold wherein the reaction product is formed and solidified at room temperature without the addition of externally supplied heat and the reaction product solidifies without the use of external cooling; and

wherein the alkali metal silicate comprises a first alkali metal silicate having a M₂O;

SiO₂ ratio between about 1;

1.5 and 1;

3.8 and a second alkali metal silicate having a M₂O;

SiO₂ ratio between about 1;

1.5 and 1;

2.5 and M is an alkali metal,

and wherein said process does not result in the deactivation of desirable operative cleaning components.

5. A process for manufacturing an improved solid cast alkaline composition, said process comprising t steps of:

(i) reacting an alkali metal silicate with an alkali metal hydroxide of the formula MOH, wherein M is an alkali metal, in an aqueous environment to form a reaction product; and

(ii) solidifying the reaction product in a mold wherein the reaction product is formed and solidified at room temperature without the addition of externally supplied heat and the reaction product solidifies without the use of external cooling; and

wherein the alkali metal silicate comprises a sodium silicate having a Na₂O;

SiO₂ ratio of about 0.1;

1and 0.8;

1 and a sodium metasilicate,

and wherein said process does not result in the deactivation of desirable operative cleaning components.