Stable solid block metal protecting warewashing detergent composition

• US 6,660,707 B2
• Filed: 06/24/2002
• Issued: 12/09/2003
• Est. Priority Date: 01/13/1997
• Status: Expired due to Term

• Current Assignee: Ecolab USA Incorporated (Ecolab, Inc.)
• Original Assignee: Ecolab, Inc.
• Inventors: Man, Victor F., Olson, Keith E., Lentsch, Steven E.
• Primary Examiner(s): Douyon, Lorna M.
• Application Number:
  US10/178,316
• Publication Number:
  US 20030104961A1
• Time in Patent Office: 533 Days
• Field of Search: 510/224, 510/233, 510/445, 510/451, 510/469, 510/509, 510/510, 510/511, 510/512, 134/25.2
• US Class Current: 510/445
• CPC Class Codes: C11D 17/0047 Detergents in the form of bars or tablets
• CPC Class Codes: C11D 17/0052 Cast detergent compositions
• CPC Class Codes: C11D 17/0065 Solid detergents containing builders C11D17/06 takes precedence
• CPC Class Codes: C11D 3/06 Phosphates, including polyphosphates
• CPC Class Codes: C11D 3/08 Silicates
• CPC Class Codes: C11D 3/10 Carbonates ; Bicarbonates
• CPC Class Codes: C11D 3/361 Phosphonates, phosphinates or phosphonites
• CPC Class Codes: C11D 3/364 containing nitrogen
• CPC Class Codes: C11D 7/12 Carbonates bicarbonates
• CPC Class Codes: C11D 7/36 containing phosphorus

Abstract

The dimensionally stable alkaline solid block warewashing detergent uses an E-form binder forming a solid comprising a sodium carbonate source of alkalinity, a metal corrosion protecting alkali metal silicate composition, a sequestrant, a surfactant package and other optional material. The solid block is dimensionally stable and highly effective in removing soil from the surfaces of dishware in the institutional and industrial environment. The E-form hydrate comprises an organic phosphonate and a hydrated carbonate.

Claims

1. An extruded or cast solid detergent composition comprising:

a solidified mixture comprising;

bleaching agent, enzyme, or bleaching agent and enzyme;

an alkali metal silicate having a M₂O;

SiO₂ ratio of about 1;

1 to 1;

5;

about 10 to 80 wt-% of Na₂CO₃;

an effective amount of an organic phosphonate hardness sequestering agent comprising a potassium salt;

about 5 to 20 wt-% anhydrous sodium carbonate;

a binding agent comprising sufficient amounts of hydrated sodium carbonate and phosphonate comprising a potassium salt, to form the composition; and

no second source of alkalinity or less than a solidification interfering amount of a second source of alkalinity;

wherein the mixture hardens to a solid form within about1 minute to about 20 minutes and the composition provides metal protection.

2. The composition of claim 1, wherein the enzyme comprises lipase, protease, or amylase.

3. The composition of claim 1, wherein the bleaching agent comprises an active oxygen source.

4. The composition of claim 3, wherein the active oxygen source comprises sodium hypochlorite, hydrogen peroxide, perborate, sodium carbonate peroxyhydrate, phosphate peroxyhydrate, potassium permonosulfate, or mixture thereof.

5. The composition of claim 4, wherein the perborate comprises sodium perborate mono and tetrahydrate.

6. The composition of claim 1, further comprising bleach activator.

7. The composition of claim 6, wherein the bleach activator comprises tetraacetylethylene diamine.

8. The composition of claim 1, comprising about 0.1-10 wt-% bleaching agent.

9. The composition of claim 8, comprising about 1-6 wt-% bleaching agent.

10. The composition of claim 1, wherein the organic phosphonate comprises:

aminotri(methylenphosphonic acid);

1-hydroxyethane-1,1-disphosphonic acid;

aminotri(methylenephosphonate), sodium salt;

2-hydroxyethyliminobis(methylenephosphonic acid);

diethylenetriaminepenta(methylenephosphonic acid);

diethylenetriaminepenta(methylenephosphonate), sodium salt;

hexamethylenediamine(tetramethylenephosphonate), potassium salt;

bis(hexamethylene)triamine(pentamethylenephosphonic acid);

or mixtures thereof.

11. The composition of claim 1, further comprising an additional functional ingredient, wherein the additional functional ingredient comprises chelating/sequestering agent, alkaline source, surfactant, hardening agent, solubility modifier, detergent builder, detergent filler, defoamer, anti-redeposition agent, dye, odorant, or mixtures thereof.

12. The composition of claim 1, wherein the composition is provided in the form of a powder, a pellet, a block, or a mixture thereof.

13. The composition of claim 1, wherein the composition is provided in the form of a tablet.

14. The composition of claim 1, wherein the alkali metal silicate has a water content of about 5 to 25 wt-%.

15. The composition of claim 1, wherein the composition comprises about 0.1 to less than about 2.0 moles of water per mole of sodium carbonate.

16. The composition of claim 1, wherein there are less than about 1.7 moles of water per mole of sodium carbonate.

17. The composition of claim 1, wherein the organic phosphonate sequestrant comprises a potassium phosphonate present in an amount of about 0.5 to 20 wt-% of the mixture.

18. The composition of claim 1, further comprising an inorganic condensed phosphate.

19. The composition of claim 18, wherein the condensed phosphate comprises sodium orthophosphate, potassium orthophosphate, sodium pyrophosphate, potassium pyrophosphate, sodium tripolyphosphate, sodium hexametaphosphate, or mixtures thereof.

20. The composition of claim 1, wherein the composition comprises about 3 to 20 wt-% of the organic phosphonate and additionally comprises a tripolyphosphate sequestrant.

21. The composition of claim 1, wherein the composition is substantially free of NaOH.

22. The composition of claim 1, wherein the silicate comprises Na₂O:

SiO₂ in a ratio of about 1;

1.5 to 1;

2.5.

23. The composition of claim 1, wherein the composition comprises about 10 to 30 wt-% of the alkali metal silicate.

24. The composition of claim 1, wherein the composition is cast to form a solid detergent composition.

25. The composition of claim 1, wherein the composition is extruded to form a solid detergent composition.

26. An extruded or cast solid detergent compositin comprising:

a solidified mixture comprising;

bleaching agent, enzyme, or bleaching agent and enzyme;

about 10 to 80 wt-% of Na₂CO₃;

an alkali metal silicate having a M₂O;

SiO₂ ratio of about 1;

1 to 1;

5; and

an effective amount of an organic phosphonate hardness sequestering agent comprising a potassium salt;

wherein the mixture hardens to a solid form within about 1 minute to about 20 minutes, and the composition comprises about 5 to 20 wt-% anhydrous sodium carbonate and a binding agent comprising sufficient amounts of hydrated sodium carbonate and phosphonate comprising a potassium salt, to form the composition, and the composition provides metal protection and comprises either no second source of alkalinity or less than a solidification interfering amount of a second source of alkalinity.

27. The composition of claim 26, wherein the enzyme comprise lipase, protease, or amylase.

28. The composition of claim 26, wherein the bleaching agent comprises an active oxygen source.

29. The composition of claim 28, wherein the active oxygen source comprises sodium hypochlorite, hydrogen peroxide, perborate, sodium carbonate peroxyhydrate, phosphate peroxyhydrate, potassium permonosulfate, or mixture thereof.

30. The composition of claim 29, wherein the perborate comprises sodium perborate mono and tetrahydrate.

31. The composition of claim 26, further comprising bleach activator.

32. The composition of claim 31, wherein the bleach activator comprises tetraacetylethylene diamine.

33. The composition of claim 26, comprising about 0.1-10 wt-% bleaching agent.

34. The composition of claim 33, comprising about 1-6 wt-% bleaching agent.

35. An extruded or cast solid detergent composition comprising:

solidified mixture comprising;

alkali metal silicate having a M₂O;

SiO₂ ratio of about 1;

1 to 1;

5;

about 10 to 80 wt-% of Na₂CO₃, comprising anhydrous sodium carbonate and hydrated sodium carbonate;

organic phosphonate comprising potassium salt; and

effective solidifying amount of binding agent comprising the hydrated sodium carbonate and the organic phosphonate comprising potassium salt;

wherein the mixture hardens to a solid form within about 1 minute to about 20 minutes and the composition provides metal protection.

36. The composition of claim 35, further comprising enzyme.

37. The composition of claim 36, wherein the enzyme comprises lipase, protease, or amylase.

38. The composition of claim 35, further comprising bleaching agent.

39. The composition of claim 38, wherein the bleaching agent comprises sodium hypochlorite, hydrogen peroxide, perborate, sodium carbonate peroxyhydrate, phosphate peroxyhydrate, potassium permonosulfate, or mixture thereof.

40. The composition of claim 35, wherein the organic phosphonate comprises:

aminotri(methylenephosphonic acid);

1-hydroxyethane-1,1-diphosphonic acid;

aminotri(methylenephosphonate), sodium salt;

2-hydroxyethyliminobis(methylenephosphonic acid);

diethylenetriaminepenta(methylenephosphonic acid);

diethylenetriaminepenta(methylenephosphonate), sodium salt;

hexamethylenediamine(tetramethylephosphonate), potassium salt;

bis(hexamethylene)triamine(pentamethylenephosphonic acid);

or

mixtures thereof.

41. The composition of claim 35, further comprising an additional functional ingredient, wherein the additional functional ingredient comprises chelating/sequestering agent, alkaline source, surfactant, hardening agent, solubility modifier, detergent builder, detergent filler, defoamer, anti-redeposition agent, dye, odorant, or mixtures thereof.

42. The composition of claim 35, wherein the composition is provided in the form of a powder, a pellet, a block or a mixture thereof.

43. The composition of claim 35, wherein the composition is provided in the form of a tablet.

44. The composition of claim 35, wherein the alkali metal silicate has a water content of about 5 to 25 wt-%.

45. The composition of claim 35, wherein the composition comprises about 0.1 to less than about 2.0 moles of water per mole of sodium carbonate.

46. The composition of claim 35, wherein there are less than about 1.7 moles of water per mole of sodium carbonate.

47. The composition of claim 35, wherein the organic phosphonate sequestrant comprises a potassium phosphonate present in an amount of about 0.5 to 20 wt-% of the mixture.

48. The composition of claim 35, further comprising an inorganic condensed phosphate.

49. The composition of claim 48, wherein the condensed phosphate comprises sodium orthophosphate, potassium orthophosphate, sodium pyrophosphate, potassium pyrophosphate, sodium tripolyphosphate, sodium hexametaphosphate, or mixtures thereof.

50. The composition of claim 35, wherein the composition comprises about 3 to 20 wt-% of the organic phosphonate and additionally comprises a tripolyphosphate sequestrant.

51. The composition of claim 35, wherein the composition is substantially free of NaOH.

52. The composition of claim 35, wherein the silicate comprises Na₂O:

SiO₂ in a ratio of about 1;

1.5 to 1;

2.5.

53. The composition of claim 35, wherein the composition comprises about 10 to 30 wt-% of the alkali metal silicate.

54. The composition of claim 35, wherein the composition is cast to form a solid detergent composition.

55. The composition of claim 35, wherein the composition is extruded to form a solid detergent composition.

56. An extruded or cast solid detergent composition comprising:

a solidified mixture comprising;

about 10 to 80 wt-% alkaline source;

the alkaline source comprising alkali metal hydroxide, alkali metal carbonate, alkali metal silicate or metasilicate, alkali metal borate, ethanolamines, amines, or mixtures therof;

alkali metal silicate having a M₂O;

SiO₂ ratio of about 1;

1 to 1;

5;

an effective amount of an organic phosphonate hardness sequestering agent comprising a potassium salt.

57. The composition of claim 56, wherein the composition comprises about 10 to 70 wt-% alkaline source.

58. The composition of claim 56, wherein the composition comprises about 20 to 70 wt-% alkaline source.

59. The composition of claim 56, wherein the composition comprises about 20 to 55 wt-% alkaline source.

60. The composition of claim 56, wherein the composition comprises about 45 to 70 wt-% alkaline source.

61. The composition of claim 56, wherein the composition comprises about 45 to 55 wt-% alkaline source.

62. The composition of claim 56, wherein the composition comprises about 10 to 60 wt-% alkaline source.

63. The composition of claim 56, wherein the alkaline source comprises sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, sodium borate, potassium borate, or mixtures thereof.

64. The composition of claim 56, further comprising an additional functional ingredient, wherein the additional functional ingredient comprises chelating/sequestering agent, alkaline source, surfactant, hardening agent, solubility modifier, detergent builder, detergent filler, defoamer, anti-redeposition agent, dye, odorant, or mixtures thereof.

65. The composition of claim 56, wherein the composition is provided in the form of a powder, a pellet, a block or a mixture thereof.

66. The composition of claim 56, wherein the composition is provided in the form of a tablet.

67. The composition of claim 56, wherein the alkali metal silicate has a water content of about 5 to 25 wt-%.

68. The composition of claim 56, wherein the silicate comprises Na₂O:

SiO₂ in a ratio of about 1;

1.5 to 1;

2.5.

69. The composition of claim 56, wherein the composition comprises about 10 to 30 wt-% of the alkali metal silicate.

70. The composition of claim 56, wherein the alkali metal silicate comprises sodium silicate, sodium metasilicate, potassium silicate, potassium metasilicate, or mixtures thereof.

71. The composition of claim 56, wherein the composition is cast to form a solid detergent composition.

72. The composition of claim 56, wherein the composition is extruded to form a solid detergent composition.

73. An extruded or cast solid detergent composition comprising:

a solidified mixture comprising;

an alkali metal silicate having a M₂O;

SiO₂ ratio of about 1;

1 to 1;

5;

about 10 to 80 wt-% of Na₂CO₃;

an effective amount of an aminocarboxylate hardness sequestering agent;

about 5 to 20 wt-% anhydrous sodium carbonate; and

a binding agent comprising sufficient amounts of hydrated sodium carbonate and aminocarboxylate to form the composition;

wherein the mixture hardens to a solid form within about 1 minute to about 20 minutes and the composition provides metal protection.

74. The composition of claim 73, comprising about 6-60 wt-% aminocarboxylic acid.

75. The composition of claim 73, wherein the aminocarboxylic acid comprises n-hydroxyethyliminodiacetic acid, nitrilotriacetic acid (NTA), ethylenediaminetetraacetic acid (EDTA), N-hydroxyethyl-ethylenediaminetriacetic acid (HEDTA), diethylenetriaminepentaacetic acid (DPTA), or mixtures thereof.

76. The composition of claim 73, further comprising enzyme.

77. The composition of claim 73, further comprising bleaching agent.

78. The composition of claim 73, further comprising an additional functional ingredient, wherein the additional functional ingredient comprises chelating/sequestering agent, alkaline source, surfactant, hardening agent, solubility modifier, detergent builder, detergent filler, defoamer, anti-redeposition agent, dye, odorant, or mixtures thereof.

79. The composition of claim 73, wherein the composition is provided in the form of a powder, a pellet, a block, or a mixture thereof.

80. The composition of claim 73, wherein the composition is provided in the form of a tablet.

81. A method of cleaning ware with a metal protecting anticorrosion alkaline detergent, the method comprising;

providing a solid composition formed by solidifying a mixture which hardens to a solid form within about 1 minute to about 20 minutes, the mixture comprising;

bleaching agent, enzyme, or bleaching agent and enzyme;

an alkali metal silicate having a M₂O;

SiO₂ ratio of about 1;

1 to 1;

5;

about 10 to 80 wt-% of Na₂CO₃;

an effective amount of an organic phosphonate hardness sequestering agent comprising a potassium salt;

about 5 to 20 wt-% anhydrous sodium carbonate;

a binding agent comprising sufficient amounts of hydrated sodium carbonate and phosphonate comprising a potassium salt, to form the composition; and

no second source of alkalinity or less than a solidification interfering amount of a second source of alkalinity;

dissolving a portion of the solid composition in a solvent to form an alkaline detergent solution; and

contacting ware with the alkaline detergent solution.

82. A method of cleaning ware with a metal protecting anticorrosion alkaline detergent, the method comprising:

providing a solid composition formed by solidifying a mixture which hardens to a solid form within about 1 minute to about 20 minutes, the mixture comprising;

alkali metal silicate having a M₂O;

SiO₂ ratio of about 1;

1 to 1;

5;

about 10 to 80 wt-% of Na₂CO₃, comprising anhydrous sodium carbonate and hydrated sodium carbonate;

organic phosphate comprising potassium salt; and

effective solidifying amount of binding agent comprising the hydrated sodium carbonate and the organic phosphonate comprising potassium salt;

dissolving a portion of the solid composition in a solvent to form an alkaline detergent solution; and

contacting ware with the alkaline detergent solution.

83. A method of cleaning ware with a metal protecting anticorrosion alkaline detergent, the method comprising:

providing a solid composition formed by solidifying a mixture, the mixture comprising;

about 10 to 80 wt-% alkaline source;

the alkaline source comprising alkali metal hydroxide, alkali metal carbonate, alkali metal silicate or metasilicate, alkali metal borate, ethanolamines, amines, or mixtures thereof;

alkali metal silicate having a M₂O;

SiO₂ ratio of about 1;

1 to 1;

5; and

an effective amount of an organic phosphonate hardness sequestering agent comprising a potassium salt;

dissolving a portion of the solid composition in a solvent to form an alkaline detergent solution; and

contacting ware with the alkaline detergent solution.

84. A method of cleaning ware with a metal protecting anticorrosion alkaline detergent, the method comprising:

providing a solid composition formed by solidifying a mixture which hardens to a solid form within about 1 minute to about 20 minutes, the mixture comprising;

an alkali metal silicate having a M₂O;

SiO₂ ratio of about 1;

1 to 1;

5;

about 10 to 80 wt-% of Na₂CO₃;

an effective amount of an aminocarboxylate hardness sequestering agent;

about 5 to 20 wt-% anhydrous sodium carbonate; and

a binding agent comprising sufficient amounts of hydrated sodium carbonate and aminocarboxylate to form the composition;

dissolving a portion of the solid composition in a solvent to form an alkaline detergent solution; and

contacting ware with the alkaline detergent solution.