Spherical stannous compatible silica particles for reduced RDA

Silica particles having a d50 median particle size from 8 to 20 μm, a sphericity factor (S80) of at least 0.9, a BET surface area from 0.1 to 8 m2/g, a total mercury intrusion pore volume from 0.35 to 0.8 cc/g, and a loss on ignition from 3 to 7 wt. %, are disclosed, as well as methods for making these silica particles, and dentifrice compositions containing the silica particles.

BACKGROUND OF THE INVENTION

Compositions containing stannous, including stannous fluoride, are used in toothpaste and other dentifrice applications, providing improved cavity protection and reduced plaque, gingivitis, and tooth sensitivity. However, the effectiveness of stannous in a dentifrice composition can be diminished due to interactions with other components of the formulation, such as silica materials. Therefore, it would be beneficial to provide silica materials with improved stannous compatibility to improve the overall effectiveness of the stannous in a dentifrice composition.

Relative dentin abrasion (RDA) is a test that is used to set safety limits for toothpaste and other dentifrice compositions. The RDA test involves measuring the loss of dentin after brushing with a test toothpaste formulation relative to the control calcium pyrophosphate (set to 100). Spherical silica particles, as compared to traditional non-spherical and irregularly shaped silica particles, have certain properties (such as low Einlehner abrasion) that are beneficial for their use in toothpaste and other dentifrice applications. However, it would be advantageous for these spherical silica materials also to have improved RDA performance.

Therefore, the present invention is principally directed to spherical silica particles having a beneficial combination of both improved stannous compatibility and improved RDA performance.

SUMMARY OF THE INVENTION

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify required or essential features of the claimed subject matter. Nor is this summary intended to be used to limit the scope of the claimed subject matter.

Silica particles with reduced Relative Dentin Abrasion (RDA) and increased stannous compatibility are disclosed and described herein. In accordance with an aspect of this invention, such silica particles can have (i) a d50 median particle size in a range from about 8 to about 20 μm, from about 8 to about 18 μm in a particular aspect, and from about 9 to about 16 μm in a more particular aspect; (ii) a sphericity factor (S80) of greater than or equal to about 0.9, greater than or equal to about 0.92 in a particular aspect, and greater than or equal to about 0.94 in a more particular aspect; (iii) a BET surface area in a range from about 0.1 to about 8 m2/g, from about 0.1 to about 6 m2/g in a particular aspect, and from about 0.5 to about 5 m2/g in a more particular aspect; (iv) a total mercury intrusion pore volume in a range from about 0.35 to about 0.8 cc/g, from about 0.35 to about 0.7 cc/g in a particular aspect, and from about 0.4 to about 0.65 cc/g in a more particular aspect; and (v) a loss on ignition (LOI) in a range from about 3 to about 7 wt. %, from about 3 to about 6 wt. % in a particular aspect, and from about 3.2 to about 5.5 wt. % in a more particular aspect. These silica particles have a spherical shape or morphology, and can be produced using a continuous loop reactor process.

Processes for producing the silica particles also are provided herein, and one such process can comprise (a) continuously feeding a first mineral acid and a first alkali metal silicate into a loop reaction zone comprising a stream of liquid medium, wherein at least a portion of the first mineral acid and the first alkali metal silicate react to form a base silica product in the liquid medium of the loop reaction zone, (b) continuously recirculating the liquid medium through the loop reaction zone, (c) continuously discharging from the loop reaction zone a portion of the liquid medium comprising the base silica product, (d) adding a second mineral acid and a second alkali metal silicate under surface area reduction conditions to a mixture of water and the base silica product, and (e) ceasing the addition of the second alkali metal silicate and continuing the addition of the second mineral acid to the mixture to adjust the pH of the mixture to within a range from about 5 to about 8.5 to produce the silica particles. Beneficially, steps (a)-(c) can be conducted under low shear or no shear conditions, unexpectedly resulting in rounder and more spherical particle morphology.

DEFINITIONS

Herein, features of the subject matter are described such that, within particular aspects, a combination of different features can be envisioned. For each and every aspect and each and every feature disclosed herein, all combinations that do not detrimentally affect the designs, compositions, processes, or methods described herein are contemplated and can be interchanged, with or without explicit description of the particular combination. Accordingly, unless explicitly recited otherwise, any aspect or feature disclosed herein can be combined to describe inventive designs, compositions, processes, or methods consistent with the present disclosure.

The terms “a,” “an,” and “the” are intended to include plural alternatives, e.g., at least one, unless otherwise specified.

Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the typical methods and materials are herein described.

All publications and patents mentioned herein are incorporated herein by reference for the purpose of describing and disclosing, for example, the constructs and methodologies that are described in the publications, which might be used in connection with the presently described invention.

Several types of ranges are disclosed in the present invention. When a range of any type is disclosed or claimed, the intent is to disclose or claim individually each possible number that such a range could reasonably encompass, including end points of the range as well as any sub-ranges and combinations of sub-ranges encompassed therein. As a representative example, the BET surface area of the silica particles can be in certain ranges in various aspects of this invention. By a disclosure that the BET surface area is in a range from about 0.1 to about 8 m2/g, the intent is to recite that the surface area can be any surface area within the range and, for example, can be equal to about 0.1, about 0.5, about 1, about 2, about 3, about 4, about 5, about 6, about 7, or about 8 m2/g. Additionally, the surface area can be within any range from about 0.1 to about 8 m2/g (for example, from about 0.5 to about 5 m2/g), and this also includes any combination of ranges between about 0.1 and about 8 m2/g (for example, the surface area can be in a range from about 0.1 to about 3, or from about 5 to about 7 m2/g). Likewise, all other ranges disclosed herein should be interpreted in a manner similar to this example.

The term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement errors, and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is “about” or “approximate” whether or not expressly stated to be such. The term “about” also encompasses amounts that differ due to different equilibrium conditions for a composition resulting from a particular initial mixture. Whether or not modified by the term “about,” the claims include equivalents to the quantities. The term “about” can mean within 10% of the reported numerical value, preferably within 5% of the reported numerical value.

DETAILED DESCRIPTION OF THE INVENTION

Disclosed herein are generally spherical silica particles that can be characterized by (i) a d50 median particle size in a range from about 8 to about 20 μm, from about 8 to about 18 μm in a particular aspect, and from about 9 to about 16 μm in a more particular aspect; (ii) a sphericity factor (S80) of greater than or equal to about 0.9, greater than or equal to about 0.92 in a particular aspect, and greater than or equal to about 0.94 in a more particular aspect; (iii) a BET surface area in a range from about 0.1 to about 8 m2/g, from about 0.1 to about 6 m2/g in a particular aspect, and from about 0.5 to about 5 m2/g in a more particular aspect; (iv) a total mercury intrusion pore volume in a range from about 0.35 to about 0.8 cc/g, from about 0.35 to about 0.7 cc/g in a particular aspect, and from about 0.4 to about 0.65 cc/g in a more particular aspect; and (v) a loss on ignition (LOI) in a range from about 3 to about 7 wt. %, from about 3 to about 6 wt. % in a particular aspect, and from about 3.2 to about 5.5 wt. % in a more particular aspect. Methods of making these spherical silica particles, and dentifrice compositions containing the spherical particles, also are disclosed and described herein.

Beneficially, the spherical particles disclosed and described herein have an unexpected combination of low RDA and high stannous compatibility.

Spherical Silica Particles

An illustrative and non-limiting example of silica particles consistent with the present invention can have the following characteristics: (i) a d50 median particle size in a range from about 8 to about 20 μm, (ii) a sphericity factor (S80) of greater than or equal to about 0.9, (iii) a BET surface area in a range from about 0.1 to about 8 m2/g, (iv) a total mercury intrusion pore volume in a range from about 0.35 to about 0.8 cc/g, and (v) a loss on ignition (LOI) in a range from about 3 to about 7 wt. %. Another illustrative and non-limiting example of silica particles consistent with the present invention can have the following characteristics: (i) a d50 median particle size in a range from about 8 to about 18 μm, (ii) a sphericity factor (S80) of greater than or equal to about 0.92, (iii) a BET surface area in a range from about 0.1 to about 6 m2/g, (iv) a total mercury intrusion pore volume in a range from about 0.35 to about 0.7 cc/g, and (v) a loss on ignition (LOI) in a range from about 3 to about 6 wt. %. Yet another illustrative and non-limiting example of silica particles consistent with the present invention can have the following characteristics: (i) a d50 median particle size in a range from about 9 to about 16 μm, (ii) a sphericity factor (S80) of greater than or equal to about 0.94, (iii) a BET surface area in a range from about 0.5 to about 5 m2/g, (iv) a total mercury intrusion pore volume in a range from about 0.4 to about 0.65 cc/g, and (v) a loss on ignition (LOI) in a range from about 3.2 to about 5.5 wt. %. In further aspects, such silica particles consistent with the present invention also can have any of the characteristics or properties provided below, and in any combination.

In an aspect, the spherical silica particles can have a relatively large average particle size. Often, the median particle size (d50) and/or mean particle size (average) can fall within a range from about 8 to about 20, from about 8 to about 18 in a particular aspect, from about 8 to about 16 in a particular aspect, from about 8 to about 15 in a particular aspect, and from about 8 to about 14 μm in a more particular aspect. In another aspect, the median particle size (d50) and/or mean particle size (average) can fall within a range from about 9 to about 20, from about 9 to about 18 in a particular aspect, from about 9 to about 16 in a particular aspect, from about 9 to about 15 in a particular aspect, and from about 9 to about 14 μm in a more particular aspect. Other appropriate ranges for the mean and median particle sizes are readily apparent from this disclosure.

The spherical particles also have a very narrow particle size distribution, which can be quantified by the ratio of (d90-d0)/d50. A lower value for the ratio indicates a narrower particle size distribution, while a larger value for the ratio indicates a broader particle size distribution. Generally, the spherical particles disclosed herein can be characterized by a ratio of (d90-d10)/d50 in a range from about 1.1 to about 2.2. In one aspect, the ratio of (d90-d10)/d50 can be in a range from about 1.1 to about 2.1, while in another aspect, the ratio of (d90-d10)/d50 can be in a range from about 1.1 to about 2, from about 1.1 to about 1.7, or from about 1.3 to about 1.5. Yet, in another aspect, the ratio of (d90-d10)/d50 can be in a range from about 1.2 to about 2.2, while in still another aspect, the ratio of (d90-d10)/d50 can be in a range from about 1.2 to about 2, and from about 1.2 to about 1.7 in a more particular aspect. Other appropriate ranges for the ratio of (d90-d10)/d50 are readily apparent from this disclosure.

Another indicator of the narrow particle size distribution of the spherical silica particles is the weight percentage of 325 mesh residue (amount retained in a 325 mesh sieve), which can be less than or equal to about 1.2 wt. %. In some aspects, the 325 mesh residue can be less than or equal to about 1 wt. %, less than or equal to about 0.75 wt. % in a particular aspect, less than or equal to about 0.6 wt. % in a particular aspect, and less than or equal to about 0.3 wt. % in a more particular aspect. Other appropriate ranges for the 325 mesh residue are readily apparent from this disclosure.

The sphericity of the spherical silica particles can be quantified by a sphericity factor (S80), which is typically greater than or equal to about 0.9, greater than or equal to about 0.91 in a particular aspect, and greater than or equal to about 0.92 in a more particular aspect. The sphericity factor (S80) is determined as follows. An SEM image of the silica particle sample is magnified 20,000 times, which is representative of the silica particle sample, and is imported into photo imaging software, and the outline of each particle (two-dimensionally) is traced. Particles that are close in proximity to one another but not attached to one another should be considered separate particles for this analysis. The outlined particles are then filled in with color, and the image is imported into particle characterization software (e.g., IMAGE-PRO PLUS available from Media Cybernetics, Inc., Bethesda, Md.) capable of determining the perimeter and area of the particles. Sphericity of the particles can then be calculated according to the equation, Sphericity=(perimeter)2divided by (4π×area), wherein perimeter is the software measured perimeter derived from the outlined trace of the particles, and wherein area is the software measured area within the traced perimeter of the particles.

The sphericity calculation is performed for each particle that fits entirely within the SEM image. These values are then sorted by value, and the lowest 20% of these values are discarded. The remaining 80% of these values are averaged to obtain the sphericity factor (S80). Additional information on sphericity can be found in U.S. Pat. Nos. 8,945,517 and 8,609,068, incorporated herein by reference in their entirety.

In one aspect of this invention, the spherical silica particles can have a sphericity factor (S80) greater than or equal to about 0.9, or greater than or equal to about 0.91, while in another aspect, the sphericity factor (S80) can be greater than or equal to about 0.92. Yet, in another aspect, the spherical silica particles can be characterized by a sphericity factor (S80) greater than or equal to about 0.93, and in still another aspect, the silica particles can be characterized by a sphericity factor (S80) greater than or equal to about 0.94. As one of skill in the art would readily recognize, a 3-dimensional sphere (or 2-dimensional circle) will have a sphericity factor (S80) equal to 1.

In an aspect, the silica particles can have a very low surface area, generally a BET surface area ranging from about 0.1 to about 8 m2/g. Often, the BET surface area can fall within a range from about 0.1 to about 7, from about 0.1 to about 6 in a particular aspect, from about 0.1 to about 5 in a particular aspect, and from about 0.1 to about 4 m2/g in a more particular aspect. In further aspects, the BET surface area can be in a range from about 0.25 to about 8, from about 0.25 to about 6 in a particular aspect, from about 0.25 to about 5 in a particular aspect, from about 0.25 to about 4 in a particular aspect, from about 0.25 to about 3 in a particular aspect, from about 0.5 to about 8 in a particular aspect, from about 0.5 to about 5 in a particular aspect, and from about 0.5 to about 2 m2/g in a more particular aspect. Other appropriate ranges for the BET surface area are readily apparent from this disclosure.

Likewise, the total mercury intrusion pore volume of the silica particles is also relatively low, often falling within a range from about 0.35 to about 0.8, from about 0.35 to about 0.75 in a particular aspect, from about 0.35 to about 0.7 in a particular aspect, from about 0.35 to about 0.65 in a particular aspect, from about 0.35 to about 0.62 in a particular aspect, and from about 0.35 to about 0.6 cc/g in a more particular aspect. In another aspect, the total mercury intrusion pore volume of the silica particles can be from about 0.4 to about 0.75 cc/g, from about 0.4 to about 0.65 cc/g in a particular aspect, from about 0.45 to about 0.7 cc/g in a particular aspect, from about 0.45 to about 0.65 cc/g in a particular aspect, and from about 0.49 to about 0.6 cc/g in a more particular aspect. Other appropriate ranges for the total mercury intrusion pore volume are readily apparent from this disclosure.

Additionally, the spherical silica particles can be less abrasive, as reflected by an Einlehner abrasion value ranging from about 7 to about 25 mg lost/100,000 revolutions. For instance, the Einlehner abrasion value can be in a range from about 8 to about 20; alternatively, from about 10 to about 20; or alternatively, from about 15 to about 22 mg lost/100,000 revolutions. The Einlehner abrasion value also can be in a range from about 10 to about 22 mg lost/100,000 revolutions, and from about 11 to about 17 mg lost/100,000 revolutions in a particular aspect. Other appropriate ranges for the Einlehner abrasion value are readily apparent from this disclosure.

These spherical silica particles also have a relatively high pack density. In one aspect, the pack density can be in a range from about 53 to about 75 lb/ft3, and from about 53 to about 73 lb/ft3in a more particular aspect. In another aspect, the pack density can be in a range from about 55 to about 70 lb/ft3, from about 58 to about 70 lb/ft3in a particular aspect, and from about 61 to about 72 lb/ft3in a more particular aspect. In yet another aspect, the pack density can be in the range from about 62 to about 72 lb/ft3, and from about 62 to about 65 lb/ft3in a more particular aspect. Other appropriate ranges for the pack density are readily apparent from this disclosure.

Likewise, these spherical silica particles also have a relatively high pour density. In one aspect, the pour density can be in a range from about 40 to about 65 lb/ft3, and from about 40 to about 62 lb/ft3in a more particular aspect. In another aspect, the pour density can be in a range from about 40 to about 58 lb/ft3, from about 42 to about 60 lb/ft3in a particular aspect, and from about 43 to about 58 lb/ft3in a more particular aspect. In yet another aspect, the pour density can be in the range from about 42 to about 56 lb/ft3, and from about 44 to about 54 lb/ft3in a more particular aspect. Other appropriate ranges for the pour density are readily apparent from this disclosure.

Spherical silica particles in accordance with aspects of this invention can have excellent stannous compatibility and excellent CPC compatibility. Typically, the spherical silica particles described herein have a stannous compatibility from about 70 to about 99%, such as, for instance, from about 75 to about 98%, from about 75 to about 95% in a particular aspect, from about 80 to about 95% in a particular aspect, from about 82 to about 98% in a particular aspect, and from about 86 to about 93% in a more particular aspect. Additionally, the spherical silica particles typically have a CPC compatibility from about 70 to about 99%, such as, for instance, from about 75 to about 95%, from about 78 to about 95% in a particular aspect, and from about 81 to about 91% in a more particular aspect. Other appropriate ranges for the stannous compatibility and CPC compatibility are readily apparent from this disclosure.

In another aspect, the spherical silica particles can have relatively low oil absorption, relatively low water absorption, and very low CTAB surface area. For instance, the oil absorption can be in a range from about 20 to about 75 cc/100 g, from about 25 to about 60 cc/100 g in a particular aspect, from about 25 to about 55 cc/100 g in a particular aspect, and from about 32 to about 50 cc/100 g in a more particular aspect. Additionally or alternatively, the water absorption can be in a range from about 40 to about 75 cc/100 g, from about 42 to about 75 cc/100 g in a particular aspect, from about 50 to about 70 cc/100 g in a particular aspect, from about 50 to about 65 cc/100 g in a particular aspect, and from about 57 to about 66 cc/100 g in a more particular aspect. Representative and non-limiting ranges for the CTAB surface include from 0 to about 10 m2/g, from 0 to about 6 m2/g in a particular aspect, from 0 to about 4 m2/g in a particular aspect, and from 0 to about 2 m2/g in a more particular aspect. Other appropriate ranges for the oil absorption, the water absorption, and the CTAB surface area are readily apparent from this disclosure.

While not limited thereto, the disclosed spherical silica particles can have a loss on drying (LOD) that often falls within a range from about 1 to about 15 wt. %. Illustrative and non-limiting ranges for the LOD include from about 1 to about 12 wt. %, from about 3 to about 12 wt. % in a particular aspect, from about 4 to about 15 wt. % in a particular aspect, from about 4 to about 8 wt. % in a particular aspect, from about 5 to about 15 wt. % in a particular aspect, from about 5 to about 10 wt. % in a particular aspect, and from about 5.3 to about 6.1 wt. % in a more particular aspect. Likewise, while not limited thereto, the disclosed spherical silica particles can have a loss on ignition (LOI) that often falls within a range from about 3 to about 7 wt. %. Illustrative and non-limiting ranges for the LOI include from about 3 to about 6.5 wt. %, from about 3 to about 6 wt. % in a particular aspect, from about 3 to about 5.5 wt. % in a particular aspect, from about 3.2 to about 7 wt. % in a particular aspect, from about 3.2 to about 5.5 wt. % in a particular aspect, and from about 3.2 to about 4.5 wt. % in a more particular aspect. Other appropriate ranges for the LOD and LOI are readily apparent from this disclosure.

Generally, the spherical silica particles can have a substantially neutral pH that encompasses, for instance, a pH range of from about 5.5 to about 9, from about 6.2 to about 8.5 in a particular aspect, and from about 6.8 to about 8.2 in a more particular aspect. Other appropriate ranges for the pH are readily apparent from this disclosure.

The Relative Dentin Abrasion (RDA) test is typically performed to confirm that a dentifrice composition, e.g., toothpaste, is safe for consumer use, with the upper limit of the test set at 250. Unexpectedly, the results provided herein demonstrate that, for the spherical silica particles consistent with this invention, the RDA generally decreases as the median particle size (d50) and/or mean particle size (average) increases. The spherical silica particles can be characterized by a RDA at 20 wt. % loading of less than about 200, and in a range from about 120 to about 200 in one aspect of this invention, and from about 120 to about 190 in another aspect. Other illustrative and non-limiting ranges for the RDA at 20 wt. % loading can include from about 120 to about 185, from about 130 to about 200 in a particular aspect, from about 130 to about 190 in a particular aspect, from about 130 to about 180 in a particular aspect, from about 150 to about 200 in a particular aspect, from about 150 to about 190 in a particular aspect, and from about 168 to about 182 in a more particular aspect. Other appropriate ranges for the RDA are readily apparent from this disclosure.

The spherical silica particles also can be described by their Pellicle Cleaning Ratio (PCR), which is a measure of the cleaning characteristics of a dentifrice composition containing the silica particles. The silica particles can be characterized by a PCR at 20 wt. % loading in a range about 70 to about 130, from about 80 to about 130 in a particular aspect, from about 70 to about 120 in a particular aspect, from about 80 to about 120 in a particular aspect, from about 90 to about 110 in a particular aspect, and from about 96 to about 103 in a more particular aspect. The PCR/RDA ratio (at 20 wt. % loading) often can be from about 0.4:1 to about 0.8:1, from about 0.5:1 to about 0.7:1 in a particular aspect, from about 0.5:1 to about 0.65:1 in a particular aspect, and from about 0.56:1 to about 0.57:1 in a more particular aspect.

In these and other aspects, any of the spherical silica particles can be amorphous, can be synthetic, or can be both amorphous and synthetic. Moreover, the spherical silica particles can comprise (or consist essentially of, or consist of) precipitated silica particles in particular aspects of this invention, although not limited thereto.

Processes for Producing Spherical Silica Particles

The spherical silica particles disclosed herein are not limited to any particular synthesis procedure. However, in order to achieve the desired sphericity, a continuous loop reactor process can be utilized to form the spherical precipitated silica particles. A general process and associated reactor system (which can include a continuous loop of one or more loop reactor pipes) are described in U.S. Pat. Nos. 8,945,517 and 8,609,068, incorporated herein by reference in their entirety. Appropriate modifications, as described herein, are made to the general process and reactor system to improve particle sphericity.

First, a base silica product can be produced via a continuous loop process comprising (a) continuously feeding a first mineral acid and a first alkali metal silicate into a loop reaction zone comprising a stream of liquid medium (water-based), wherein at least a portion of the first mineral acid and the first alkali metal silicate react to form the base silica product in the liquid medium of the loop reaction zone, (b) continuously recirculating the liquid medium through the loop reaction zone, and (c) continuously discharging from the loop reaction zone a portion of the liquid medium comprising the base silica product. In particular aspects of this invention, steps (a)-(c) are performed simultaneously.

Typically, although not required, the feed locations of the first mineral acid and the first alkali metal silicate into the loop reaction zone are different, and the total volumetric feed rate of acid and silicate can be proportional to, and often equal to, the volumetric discharge rate of the liquid medium containing the base silica product. All or substantially all of the contents (greater than 95 wt. %) within the loop reaction zone generally are recirculated. The liquid medium, for instance, can be recirculated through the loop reaction zone at a rate ranging from about 50 vol. % per minute (the recirculation rate, per minute, is one-half of the total volume of the liquid medium in the loop reaction zone) to about 1000 vol. % per minute (the recirculation rate, per minute, is ten times the total volume of the liquid medium in the loop reaction zone), or from about 75 vol. % per minute to about 500 vol. % per minute. Representative and non-limiting ranges for the volumetric recirculation rate of the liquid medium through the loop reaction zone include from about 15 L/min to about 150 L/min in one aspect, and from about 60 L/min to about 100 L/min in another aspect.

The loop reaction zone can comprise a continuous loop of one or more loop reactor pipes. Thus, for example, the process can be conducted—continuously—in a single loop reactor. Any suitable pump can be used to utilized to recirculate the liquid medium through the loop reaction zone. The temperature of the liquid medium in the loop reaction zone can be controlled using any suitable technique or control system.

In one aspect, the first alkali metal silicate can comprise sodium silicate, and the first mineral acid can comprise sulfuric acid, hydrochloric acid, nitric acid, phosphoric acid, or a combination thereof. In another aspect, the first alkali metal silicate can comprise sodium silicate, and the first mineral acid can comprise an acidic solution of aluminum sulfate. In these and other aspects, the resultant base silica product can comprise precipitated silica or precipitated sodium aluminosilicate. The pH of the liquid medium being recirculated through the loop reaction zone can range from about 2.5 to about 10, but more often ranges from about 6 to about 10, from about 6.5 to about 8.5 in a particular aspect, and from about 7 to about 8 in a more particular aspect.

In order to promote increased sphericity, the continuous loop process for producing the base silica product can be performed under low shear or no shear conditions. For instance, the stator screen on the loop reactor mixing device can be removed for low shear or no shear operation. Alternatively, a stator design having large openings (e.g., slots, circular holes, square holes, etc.) can be used, such that the stator screen in the loop reaction zone has openings greater than 3 mm2in cross sectional area (e.g., greater than 10 mm2in one aspect, greater than 50 mm2in another aspect, greater than 100 mm2in yet another aspect, greater than 500 mm2in still another aspect, etc., in cross sectional area), for low shear or no shear operation. Further, the mixer rpm's can be reduced to less than 3000 rpm, less than 2500 rpm in a particular aspect, and less than 2000 rpm in a more particular aspect, to reduce shear in the loop reaction zone. Additionally, the recirculation step of the process—step (b)—can be conducted at a relatively high temperature, often ranging from about 85 to about 100° C., from about 90 to about 100° C. in another aspect, and from about 88 to about 98° C. in yet another aspect. Additionally or alternatively, for low shear or no shear conditions, the shear frequency in the loop reaction zone can be less than 1,000,000 interactions/min in one aspect, less than 750,000 interactions/min in another aspect, less than 500,000 interactions/min in yet another aspect, and less than 250,000 interactions/min in still another aspect. The shear frequency is defined as the number of interactions between the flow from the rotor and the stator: rpm×NR×NS, where rpm is the mixer/rotor revolutions per minute, NRis the number of blades/teeth on the rotor, and NSis the number of holes/slots (openings) on the stator. Thus, at 2700 rpm for a 4-blade rotor, 10 large round holes on the stator would equate to 108,000 interactions/min (low shear), whereas a stator with 400 small holes would equate to 4,320,000 interactions/minute (high shear).

Suitable base silica products can be characterized by d50 median particle sizes, ratios of (d90−d10)/d50, and sphericity factors (S80) that encompass the same ranges disclosed herein for the silica particles (after surface area reduction). The base silica particles often can have BET surface areas ranging from about 20 to about 100 m2/g, and in some aspects, from about 25 to about 60 m2/g, although not limited thereto.

Next, the base silica product is subjected to a surface area reduction step. The base silica product serves as a framework for silica material to be deposited thereupon during the surface area reduction step. Generally, the surface area reduction step is conducted in a vessel separate from the loop reaction zone, such as a stirred batch reactor.

The surface area reduction begins with—step (d)—adding a second mineral acid and a second alkali metal silicate under surface area reduction conditions to a mixture of water and the base silica product, followed by a pH adjustment step—step (e), which comprises ceasing the addition of the second alkali metal silicate and continuing the addition of the second mineral acid to the mixture to adjust the pH of the mixture to within a range from about 5 to about 8.5. The result of this process is the spherical silica particles described herein, with improved stannous compatibility and reduced RDA.

In step (d), the second mineral acid and the second alkali metal silicate are added to the mixture comprising water and the base silica product (i.e., the base silica product discharged from the loop reaction zone) under any suitable surface area reduction conditions or any surface area reduction conditions disclosed herein. Consistent with aspects of this invention, the second alkali metal silicate can be added to the mixture at an average silica addition rate in a range from about 0.2 to about 0.8 wt. % per minute, and/or at a maximum silica addition rate of less than about 1.9 wt. % per minute. The average value is determined by starting with the weight of base silica product added (in kg), dividing by the addition time period (in minutes), and then normalizing by the total amount of silica particles (in kg) that is produced at the end of the surface area reduction step. The maximum silica addition rate is the largest average silica addition rate over any 5-minute period in the surface area reduction step. In some aspects, the second alkali metal silicate can be added to the mixture at an average silica addition rate in a range from about 0.25 to about 0.7 wt. %, from about 0.3 to about 0.55 wt. % in a particular aspect, and from about 0.42 to about 0.44 wt. % in a more particular aspect, per minute. Additionally or alternatively, the maximum silica addition rate can be less than about 1.7 wt. % per minute, less than about 1.5 wt. % per minute in a particular aspect, less than about 1.2 wt. % per minute in a particular aspect, less than about 1 wt. % per minute in a particular aspect, and less than about 0.9 wt. % per minute in a more particular aspect.

The second mineral acid and the second alkali metal silicate can be the same as or different from the first mineral acid and the first alkali metal silicate. Thus, the second alkali metal silicate can comprise sodium silicate, potassium silicate, or a mixture thereof, and the second mineral acid can comprise sulfuric acid, hydrochloric acid, nitric acid, phosphoric acid, or a mixture thereof. In some aspects, the second alkali metal silicate can comprise sodium silicate and the second mineral acid can comprise sulfuric acid. The specific methodology for the addition of the second alkali metal silicate and the second mineral acid to the mixture is not altogether limiting; for example, the second alkali metal silicate and the second mineral acid can be added in any order, whether simultaneously, sequentially, alternating, or combinations of these methodologies.

The surface area reduction conditions under which step (d) can be performed would be readily recognized by one of skill in the art in view of this disclosure and the representative examples provided herein below. Nonetheless, in some aspects of this invention, the surface area reduction conditions of step (d) often can include a time period ranging from about 45 minutes to about 5 hours, from about 45 minutes to about 4 hours in another aspect, from about 45 minutes to about 2 hours in another aspect, from about 1 hour to about 5 hours in yet another aspect, and from about 1 hour to about 4 hours in still another aspect; a pH ranging from about 9.2 to about 10.2, from about 9.3 to about 10 in a particular aspect, and from about 9.5 to about 9.8 in a more particular aspect; and a temperature ranging from about 85 to about 100° C., from about 90 to about 100° C. in a particular aspect, and from about 95 to about 98° C. in a more particular aspect. Further, and while not limited thereto, the surface area reduction conditions can be any operating conditions sufficient to reduce the BET surface area of the silica particles produced by the process to less than or equal to about 10 m2/g, less than or equal to about 8 m2/g in another aspect, less than or equal to about 5 m2/g in yet another aspect, and so forth.

The general purpose of the pH adjustment step in the processes disclosed herein is to adjust the pH of the mixture (containing the silica particles) to within a range from about 5 to about 8.5, by adding only the second mineral acid to the mixture. Since there is a significant percentage of soluble alkali metal silicate present in the mixture at the end of the surface area reduction step, the pH adjustment step typically is carefully controlled to minimize any impact on the distribution of porosity of the silica particles. In some aspects, the average rate of addition of the second mineral acid in step (e) is no more than 75% greater than an average rate of addition of the second mineral acid in step (d), while in other aspects, the average rate of addition of the mineral acid in step (e) is no more than 50% greater, no more than 25% greater in a particular aspect, and no more than 10% greater in a more particular aspect, than the average rate of addition of the second mineral acid in step (d). Often, the average rate of addition of second mineral acid in step (e) is approximately the same, or less than, the average rate of addition of the second mineral acid in step (d).

While not being limited thereto, the pH of the reaction mixture at the end of the batch often is adjusted to within a range from about 5 to about 8.5, and in some cases, from about 5.5 to about 8 in a particular aspect, and from about 6 to about 8 in a more particular aspect, for suitability in end-use dentifrice and other applications.

After the pH adjustment step, and optionally, the processes disclosed herein can further include a filtering step to isolate the silica particles, a washing step to wash the silica particles, a drying step (e.g., spray drying) to dry the silica particles, or any combination of the filtering, washing, and drying steps, and performed in any suitable sequence.

The spherical silica particles can be used in any suitable composition and for any suitable end-use application. Often, the silica particles can be used in oral care applications, such as in a dentifrice composition. The dentifrice composition can contain any suitable amount of the silica particles, such as from about 0.5 to about 50 wt. %, from about 1 to about 50 wt. % in a particular aspect, from about 5 to about 35 wt. % in a particular aspect, from about 10 to about 40 wt. % in a particular aspect, and from about 10 to about 30 wt. % in a more particular aspect, of the spherical silica particles. These weight percentages are based on the total weight of the dentifrice composition.

The dentifrice composition can be in any suitable form, such as a solid, liquid, powder, paste, or combinations thereof. In addition to the silica particles, the dentifrice composition can contain other ingredients or additives, non-limiting examples of which can include a humectant, a solvent, a binder, a therapeutic agent, a chelating agent, a thickener other than the silica particles, a surfactant, an abrasive other than the silica particles, a sweetening agent, a colorant, a flavoring agent, a preservative, and the like, as well as any combination thereof.

Humectants serve to add body or “mouth texture” to a dentifrice as well as preventing the dentifrice from drying out. Suitable humectants include polyethylene glycol (at a variety of different molecular weights), propylene glycol, glycerin (glycerol), erythritol, xylitol, sorbitol, mannitol, lactitol, and hydrogenated starch hydrolyzates, and mixtures thereof. In some formulations, humectants are present in an amount from about 20 to about 50 wt. %, based on the weight of the dentifrice composition.

A solvent can be present in the dentifrice composition, at any suitable loading, and usually the solvent comprises water. When used, water is preferably deionized and free of impurities, can be present in the dentifrice at loadings from 5 to about 70 wt. %, and from about 5 to about 35 wt. % in another aspect, based on the weight of dentifrice composition.

Therapeutic agents also can be used in the compositions of this invention to provide for the prevention and treatment of dental caries, periodontal disease, and temperature sensitivity, for example. Suitable therapeutic agents can include, but are not limited to, fluoride sources, such as sodium fluoride, sodium monofluorophosphate, potassium monofluorophosphate, stannous fluoride, potassium fluoride, sodium fluorosilicate, ammonium fluorosilicate and the like; condensed phosphates such as tetrasodium pyrophosphate, tetrapotassium pyrophosphate, disodium dihydrogen pyrophosphate, trisodium monohydrogen pyrophosphate; tripolyphosphates, hexametaphosphates, trimetaphosphates and pyrophosphates; antimicrobial agents such as triclosan, bisguanides, such as alexidine, chlorhexidine and chlorhexidine gluconate; enzymes such as papain, bromelain, glucoamylase, amylase, dextranase, mutanase, lipases, pectinase, tannase, and proteases; quaternary ammonium compounds, such as benzalkonium chloride (BZK), benzethonium chloride (BZT), cetylpyridinium chloride (CPC), and domiphen bromide; metal salts, such as zinc citrate, zinc chloride, and stannous fluoride; sanguinaria extract and sanguinarine; volatile oils, such as eucalyptol, menthol, thymol, and methyl salicylate; amine fluorides; peroxides and the like. Therapeutic agents can be used in dentifrice formulations singly or in combination, and at any therapeutically safe and effective level or dosage.

Thickening agents are useful in the dentifrice compositions to provide a gelatinous structure that stabilizes the toothpaste against phase separation. Suitable thickening agents include silica thickener; starch; glycerite of starch; gums such as gum karaya (sterculia gum), gum tragacanth, gum arabic, gum ghatti, gum acacia, xanthan gum, guar gum and cellulose gum; magnesium aluminum silicate (Veegum); carrageenan; sodium alginate; agar-agar; pectin; gelatin; cellulose compounds such as cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxymethyl cellulose, hydroxymethyl carboxypropyl cellulose, methyl cellulose, ethyl cellulose, and sulfated cellulose; natural and synthetic clays such as hectorite clays; and mixtures thereof. Typical levels of thickening agents or binders are up to about 15 wt. % of a toothpaste or dentifrice composition.

Useful silica thickeners for utilization within a toothpaste composition, for example, include, as a non-limiting example, an amorphous precipitated silica such as ZEODENT® 165 silica. Other non-limiting silica thickeners include ZEODENT® 153, 163, and 167, and ZEOFREE® 177 and 265 silica products, all available from Evonik Corporation, and AEROSIL® fumed silicas.

Surfactants can be used in the dentifrice compositions of the invention to make the compositions more cosmetically acceptable. The surfactant is preferably a detersive material which imparts to the composition detersive and foaming properties. Suitable surfactants are safe and effective amounts of anionic, cationic, nonionic, zwitterionic, amphoteric and betaine surfactants, such as sodium lauryl sulfate, sodium dodecyl benzene sulfonate, alkali metal or ammonium salts of lauroyl sarcosinate, myristoyl sarcosinate, palmitoyl sarcosinate, stearoyl sarcosinate and oleoyl sarcosinate, polyoxyethylene sorbitan monostearate, isostearate and laurate, sodium lauryl sulfoacetate, N-lauroyl sarcosine, the sodium, potassium, and ethanolamine salts of N-lauroyl, N-myristoyl, or N-palmitoyl sarcosine, polyethylene oxide condensates of alkyl phenols, cocoamidopropyl betaine, lauramidopropyl betaine, palmityl betaine and the like. Sodium lauryl sulfate is a preferred surfactant. The surfactant is typically present in the compositions of the present invention in an amount from about 0.1 to about 15 wt. %, from about 0.3 to about 5 wt. % in a particular aspect, and from about 0.3 to about 2.5 wt. % in a more particular aspect.

The disclosed silica particles can be utilized alone as the abrasive in the dentifrice composition, or as an additive or co-abrasive with other abrasive materials discussed herein or known in the art. Thus, any number of other conventional types of abrasive additives can be present within the dentifrice compositions of the invention. Other such abrasive particles include, for example, precipitated calcium carbonate (PCC), ground calcium carbonate (GCC), chalk, bentonite, dicalcium phosphate or its dihydrate forms, silica gel (by itself, and of any structure), precipitated silica, amorphous precipitated silica (by itself, and of any structure as well), perlite, titanium dioxide, dicalcium phosphate, calcium pyrophosphate, alumina, hydrated alumina, calcined alumina, aluminum silicate, insoluble sodium metaphosphate, insoluble potassium metaphosphate, insoluble magnesium carbonate, zirconium silicate, particulate thermosetting resins and other suitable abrasive materials. Such materials can be introduced into the dentifrice compositions to tailor the polishing characteristics of the target formulation.

Colorants can be added to improve the aesthetic appearance of the product. Suitable colorants include without limitation those colorants approved by appropriate regulatory bodies such as the FDA and those listed in the European Food and Pharmaceutical Directives and include pigments, such as TiO2, and colors such as FD&C and D&C dyes.

Flavoring agents also can be added to dentifrice compositions. Suitable flavoring agents include, but are not limited to, oil of wintergreen, oil of peppermint, oil of spearmint, oil of sassafras, and oil of clove, cinnamon, anethole, menthol, thymol, eugenol, eucalyptol, lemon, orange and other such flavor compounds to add fruit notes, spice notes, etc. These flavoring agents generally comprise mixtures of aldehydes, ketones, esters, phenols, acids, and aliphatic, aromatic and other alcohols.

Preservatives also can be added to the compositions of the present invention to prevent bacterial growth. Suitable preservatives approved for use in oral compositions such as methylparaben, propylparaben and sodium benzoate can be added in safe and effective amounts.

EXAMPLES

The multipoint BET surface areas disclosed herein were determined on a Micromeritics TriStar II 3020 V1.03, using the BET nitrogen adsorption method of Brunaur et al., J. Am. Chem. Soc., 60, 309 (1938).

Mercury total intruded volumes were measured on a Micromeritics AutoPore IV 9520, previously calibrated with a silica-alumina reference material available from Micromeritics. As generally known (see Halsey, G. D., J. Chem. Phys. (1948), 16, 931), the mercury porosimetry technique is based on the intrusion of mercury into a porous structure under stringently controlled pressures. From the pressure versus intrusion data, the instrument generates volume and size distributions using the Washburn equation. Since mercury does not wet most substances and will not spontaneously penetrate pores by capillary action, it must be forced into the pores by the application of external pressure. The required pressure is inversely proportional to the size of the pores, and only slight pressure is required to intrude mercury into large macropores, whereas much greater pressures are required to force mercury into micropores. Higher pressures are required to measure the pore sizes and surface areas of the micropores present on the surfaces of silica products disclosed herein.

The total intruded volume (HgI) was measured by mercury porosimetry using a Micromeritics Autopore IV 9520. Samples were dried at 105° C. for two hours prior to analysis. The pore diameters were calculated by the Washburn equation employing a contact angle Theta (0) equal to 130° and a surface tension gamma equal to 484 dynes/cm. Mercury was forced into the voids of the material (both internal and intraparticle porosity) as a function of pressure, and the volume of the mercury intruded per gram of sample was calculated at each pressure setting. Total mercury intrusion pore volume expressed herein represents the cumulative volume of mercury intruded at pressures from vacuum to 60,000 psi. Increments in volume (cm3/g) at each pressure setting were plotted against the pore radius or diameter corresponding to the pressure setting increments. The peak in the intruded volume versus pore radius or diameter curve corresponds to the mode in the pore size distribution and identifies the most common pore size in the sample. Specifically, sample size was adjusted to achieve a stem volume of 30-50% in a powder penetrometer with a 5 mL bulb and a stem volume of about 1.1 mL. Samples were evacuated to a pressure of 50 μm of Hg and held for 5 minutes. Mercury filled the pores from 4 to 60,000 psi with a 10 second equilibrium time at each of approximately 150 data collection points.

CTAB surface areas disclosed herein were determined by absorption of CTAB (cetyltrimethylammonium bromide) on the silica surface, the excess separated by centrifugation and the quantity determined by titration with sodium lauryl sulfate using a surfactant electrode. Specifically, about 0.5 grams of the silica particles were placed in a 250-mL beaker with 100 mL CTAB solution (5.5 g/L), mixed on an electric stir plate for 1 hour, then centrifuged for 30 min at 10,000 RPM. One mL of 10% Triton X-100 was added to 5 mL of the clear supernatant in a 100-mL beaker. The pH was adjusted to 3-3.5 with 0.1 N HCl and the specimen was titrated with 0.01 M sodium lauryl sulfate using a surfactant electrode (Brinkmann SUR1501-DL) to determine the endpoint.

The median particle size (d50) refers to the particle size for which 50% of the sample has a smaller size and 50% of the sample has a larger size. Median particle size (d50), mean particle size (average), d90, and d10 were determined via the laser diffraction method using a Horiba LA 300 instrument. Samples were de-agglomerated using ultrasonic vibration for 2 minutes.

For pour density and pack density, 20 grams of the sample were placed into a 250 mL graduated cylinder with a flat rubber bottom. The initial volume was recorded and used to calculate the pour density by dividing it into the weight of sample used. The cylinder was then placed onto a tap density machine where it was rotated on a cam at 60 RPM. The cam is designed to raise and drop the cylinder a distance of 5.715 cm once per second, until the sample volume is constant, typically for 15 min. This final volume was recorded and used to calculate the pack density by dividing it into the weight of sample used.

The Einlehner abrasion value is a measure of the hardness/abrasiveness of silica particles, and is described in detail in U.S. Pat. No. 6,616,916, incorporated herein by reference, and involves an Einlehner AT-1000 Abrader generally used as follows: (1) a Fourdrinier brass wire screen is weighed and exposed to the action of a 10% aqueous silica suspension for a fixed length of time; (2) the amount of abrasion is then determined as milligrams of brass lost from the Fourdrinier wire screen per 100,000 revolutions (mg lost/100,000 revolutions).

CPC compatibility (%) was determined as follows. 27 grams of a 0.3% solution of CPC (cetylpyridinium chloride) were added to a 3 g sample of the silica to be tested. The silica was previously dried at 105° C. to 150° C. to a moisture content of 2% or less, and the pH of the sample was measured to ensure the 5% pH was between 5.5 and 7.5. The mixture was shaken for a period of 10 minutes. Accelerated aging testing requires agitation of the test specimen for 1 week at 140° C. After agitation was complete, the sample was centrifuged and 5 mL of the supernatant was passed through a 0.45 μm PTFE milli-pore filter and discarded. An additional 2 g of supernatant was then passed through the same 0.45 m PTFE milli-pore filter and then added to a vial containing 38 g of distilled water. After mixing, an aliquot of the sample was placed in a cuvette (methyl methacrylate) and the U.V. absorbance was measured at 268 nm. Water was used as a blank. The % CPC compatibility was determined by expressing as a percentage the absorbance of the sample to that of a CPC standard solution prepared by this procedure with the exception that no silica was added.

Stannous compatibility (%) was determined as follows. A stock solution containing 431.11 g of 70% sorbitol, 63.62 g of de-oxygenated deionized water, 2.27 g of stannous chloride dihydrate, and 3 g of sodium gluconcate was prepared. 34 g of the stock solution was added to a 50 mL centrifuge tube containing 6 g of the silica sample to be tested. The centrifuge tube was placed on a rotating wheel at 5 RPM and was aged for 1 week at 40° C. After aging, the centrifuge tube was centrifuged at 12,000 RPM for 10 minutes, and the stannous concentration in the supernatant was determined by ICP-OES (inductively coupled plasma optical emission spectrometer). The stannous compatibility was determined by expressing the stannous concentration of the sample as a percentage of the stannous concentration of a solution prepared by the same procedure, but with no silica added.

Oil absorption values were determined in accordance with the rub-out method described in ASTM D281 using linseed oil (cc oil absorbed per 100 g of the particles). Generally, a higher oil absorption level indicates a particle with a higher level of large pore porosity, also described as higher structure.

Water absorption values were determined with an Absorptometer “C” torque rheometer from C. W. Brabender Instruments, Inc. Approximately ⅓ of a cup of the silica sample was transferred to the mixing chamber of the Absorptometer and mixed at 150 RPM. Water then was added at a rate of 6 mL/min, and the torque required to mix the powder was recorded. As water is absorbed by the powder, the torque will reach a maximum as the powder transforms from free-flowing to a paste. The total volume of water added when the maximum torque was reached was then standardized to the quantity of water that can be absorbed by 100 g of powder. Since the powder was used on an as received basis (not previously dried), the free moisture value of the powder was used to calculate a “moisture corrected water AbC value” by the following equation.

The Absorptometer is commonly used to determine the oil number of carbon black in compliance with ASTM D 2414 methods B and C and ASTM D 3493.

The pH values disclosed herein (5% pH) were determined in an aqueous system containing 5 wt. % solids in deionized water using a pH meter.

The 325 mesh residue (wt. %) of the silica sample was measured utilizing a U.S. Standard Sieve No. 325, with 44 micron or 0.0017 inch openings (stainless steel wire cloth), by weighing a 10.0 gram sample to the nearest 0.1 gram into the cup of a 1 quart Hamilton mixer (Model No. 30), adding approximately 170 mL of distilled or deionized water, and stirring the slurry for at least 7 min. The mixture was transferred onto the 325 mesh screen and water was sprayed directly onto the screen at a pressure of 20 psig for two minutes, with the spray head held about four to six inches from the screen. The remaining residue was then transferred to a watch glass, dried in an oven at 150° C. for 15 min, then cooled, and weighed on an analytical balance.

Loss on drying (LOD) was performed by measuring the weight loss (wt. %) of a sample of the silica particles after drying at 105° C. for 2 hours. Loss on ignition (LOI) was performed by measuring the weight loss (wt. %) of a pre-dried sample (after drying at 105° C. for 2 hours) of the silica particles after heating at 1000° C. for 1 hour (USP NF for SiO2method).

The cleaning performance of the silica materials in a dentifrice composition is typically quantified by a Pellicle Cleaning Ratio (“PCR”) value. The PCR test measures the ability of a dentifrice composition to remove pellicle film from a tooth under fixed brushing conditions. The PCR test is described in “In Vitro Removal of Stain with Dentifrice” G. K. Stookey, et al., J. Dental Res., 61, 1236-9, 1982, which is incorporated herein by reference for its teaching of PCR. PCR values are unitless.

The Relative Dentin Abrasion (RDA) values of the dentifrice compositions of the invention were determined according to the method set forth by Hefferen, Journal of Dental Res., July-August 1976, 55 (4), pp. 563-573, and described in Wason U.S. Pat. Nos. 4,340,583, 4,420,312 and 4,421,527, which are each incorporated herein by reference for their teaching of RDA measurements. RDA values are unitless.

Comparative Silica Particles and Spherical Silica Particles

Example 1A was a conventional silica material commercially available from Evonik Corporation, which has an irregular and non-spherical particle morphology.

For Examples 2A-6A, a continuous loop reactor process (see e.g., U.S. Pat. Nos. 8,945,517 and 8,609,068) was used to produce silica particles.FIG.1illustrates the continuous loop reactor apparatus, which was configured in a recycle loop such that reaction slurry was circulated numerous times before it was discharged. The loop was comprised of sections of fixed pipe joined together by sections of flexible hose. The internal diameter of the piping/hose was approximately 1″. On one side of the loop, a pump was placed to circulate the reaction slurry, and on the opposite side a Silverson in-line mixer was installed to provide additional shear to the system and also to feed the acid component. In between the pumps, a static mixer heat exchanger was installed to provide a means to control the temperature during production of the silica material. The discharge pipe, located after the acid addition point, allowed the product to discharge as a function of the rates at which silicate and acid were added. The discharge pipe also was fitted with a back pressure valve to enable the system to operate at temperatures greater than 100° C. The product discharge pipe was oriented to collect product into a tank for additional modification (e.g., pH adjustment), or was discharged directly into a rotary or press type filter. Optionally, acid could be added into the product discharge line to avoid pH adjustment when the silica product was prepared at a pH greater than 7.0.

For certain examples, the Silversion in-line mixer was modified to provide a high level of mixing without providing shear. This was accomplished by removing the stator screen from the Silverson mixer and operating the unit with only the backing plate and the normal mixer head. Particle size thus could be controlled by changing the Silverson output rate and the recirculation rate (e.g., a reduction in both rates can increase the average particle size).

Prior to the introduction of acid and silicate into the system for Examples 2A-6A, precipitated silica, sodium sulfate, sodium silicate and water were added and recirculated at 80 L/min. This step was performed to fill the recycle loop with the approximate contents and concentrations of a typical batch to minimize the purging time before the desired product could be collected.

For Example 2A, 1.5 kg of Example 1A, 1.34 kg of sodium sulfate, 11.1 L of sodium silicate (3.32 MR, 19.5%) and 20 L of water were added to the recirculation loop, followed by heating to 95° C. with recirculation at 80 L/min with the Silverson operating at 60 Hz (3485 RPM) with the normal rotor/stator configuration. Sodium silicate (3.32 MR, 19.5%) and sulfuric acid (17.1%) were added simultaneously to the loop at a silicate rate of 1.7 L/min and an acid rate sufficient to maintain a pH of 7.5. If necessary, the acid rate was adjusted accordingly to maintain the pH. Acid and silicate were added under these conditions for 40 minutes to purge unwanted silica out of the system before the desired material was collected. After 40 minutes had passed, the collection vessel was emptied and its contents discarded. The silica product was then collected in a vessel with stirring at 40 RPM while maintaining the temperature at approximately 80° C. After the desired quantity of product was collected, addition of acid and silicate were stopped and the contents of the loop were allowed to circulate. The silica product in the collection vessel was adjusted to pH 6.0 with the manual addition of sulfuric acid and was then filtered, and washed to a conductivity of ˜1500 μS. The pH of the slurry was then readjusted to pH 6.0 with sulfuric acid and spray dried.

For Example 3A, 1.5 kg of Example 1A, 1.34 kg of sodium sulfate, 11.1 L of sodium silicate (2.65 MR, 26.6%) and 20 L of water were added to the recirculation loop, followed by heating to 95° C. with recirculation at 80 L/min with the Silverson operating at 30 Hz (1742 RPM) with the stator screen removed. Sodium silicate (2.65 MR, 26.6%) and sulfuric acid (22.8%) were added simultaneously to the loop at a silicate rate of 1.7 L/min and an acid rate sufficient to maintain a pH of 7.5. If necessary, the acid rate was adjusted accordingly to maintain the pH. Acid and silicate were added under these conditions for 40 minutes to purge unwanted silica out of the system before the desired material was collected. After 40 minutes had passed, the collection vessel was emptied and its contents discarded. The silica product was then collected in a vessel with stirring at 40 RPM while maintaining the temperature at approximately 80° C. After the desired quantity of product was collected (500 L), addition of acid and silicate were stopped and the contents of the loop were allowed to circulate.

Then, for surface area reduction, the silica product in the collection vessel was transferred to a batch reactor and heated to 95° C. with stirring at 80 RPM and recirculation at 80 L/min. Sodium silicate (2.65 MR, 26.6%) was added to the reactor until a pH of 9.5 (+/−0.2) was reached. Once the pH was reached, sodium silicate (2.65 MR, 26.6%) and sulfuric acid (22.8%) were added at rates of 1.66 L/min and 0.80 L/min, respectively. If needed, the acid rate was adjusted to maintain the pH of 9.5 (+/−0.2). After a total time of 60 minutes, the flow of sodium silicate was stopped and the pH was adjusted to 7.0 with continued addition of sulfuric acid (22.8%) at 0.80 L/min. The batch was digested for 15 minutes at pH 7.0, and then filtered and washed to a conductivity of <1500 μS. Prior to drying, the pH of the silica slurry was adjusted to 5.0 with sulfuric acid and spray dried to a target moisture of 5%.

For Example 4A, 1.5 kg of Example 1A, 1.34 kg of sodium sulfate, 11.1 L of sodium silicate (3.3 MR, 19.5%) and 20 L of water were added to the recirculation loop, followed by heating to 90° C. with recirculation at 60 L/min with the Silverson operating at 30 Hz (1742 RPM) with the stator screen removed. Sodium silicate (3.3 MR, 19.5%) and sulfuric acid (17.1%) were added simultaneously to the loop at a silicate rate of 1.7 L/min and an acid rate sufficient to maintain a pH of 7.5. If necessary, the acid rate was adjusted accordingly to maintain the pH. Acid and silicate were added under these conditions for 40 minutes to purge unwanted silica out of the system before the desired material was collected. After 40 minutes had passed, the collection vessel was emptied and its contents discarded. The silica product was then collected in a vessel with stirring at 40 RPM while maintaining the temperature at approximately 80° C. After the desired quantity of product was collected (700 L), addition of acid and silicate were stopped and the contents of the loop were allowed to circulate.

Then, for surface area reduction, the silica product in the collection vessel was transferred to a batch reactor and heated to 95° C. with stirring at 80 RPM. Sodium silicate (3.3 MR, 19.5%) was added to the reactor until a pH of 9.5 (+/−0.2) was reached. Once the pH was reached, sodium silicate (3.32 MR, 19.5%) and sulfuric acid (17.1%) were added at rates of 2.4 L/min and 0.98 L/min, respectively. If needed, the acid rate was adjusted to maintain the pH of 9.5 (+/−0.2). After a total time of 60 minutes, the flow of sodium silicate was stopped and the pH was adjusted to 7.0 with continued addition of sulfuric acid (17.1%) at 0.81 L/min. The batch was digested for 15 minutes at pH 7.0, and then filtered and washed to a conductivity of <1500 μS. Prior to drying, the pH of the silica slurry was adjusted to 5.0 with sulfuric acid and spray dried to a target moisture of 5%.

For Example 5A, 1.5 kg of Example 1A, 1.34 kg of sodium sulfate, 11.1 L of sodium silicate (2.65 MR, 26.6%) and 20 L of water were added to the recirculation loop, followed by heating to 95° C. with recirculation at 80 L/min with the Silverson operating at 30 Hz (1742 RPM) with the stator screen removed. Sodium silicate (2.65 MR, 26.6%) and sulfuric acid (22.8%) were added simultaneously to the loop at a silicate rate of 1.7 L/min and an acid rate sufficient to maintain a pH of 7.5. If necessary, the acid rate was adjusted accordingly to maintain the pH. Acid and silicate were added under these conditions for 40 minutes to purge unwanted silica out of the system before the desired material was collected. After 40 minutes had passed, the collection vessel was emptied and its contents discarded. The silica product was then collected in a vessel with stirring at 40 RPM while maintaining the temperature at approximately 80° C. After the desired quantity of product was collected (500 L), addition of acid and silicate were stopped and the contents of the loop were allowed to circulate.

Then, for surface area reduction, the silica product in the collection vessel was transferred to a batch reactor and was heated to 95° C. with stirring at 80 RPM and recirculation at 80 L/min. Sodium silicate (2.65 MR, 26.6%) was added to the reactor until a pH of 9.5 (+/−0.2) was reached. Once the pH was reached, sodium silicate (2.65 MR, 26.6%) and sulfuric acid (22.8%) were added at rates of 1.66 L/min and 0.80 L/min, respectively. If needed, the acid rate was adjusted to maintain the pH of 9.5 (+/−0.2). After a total time of 60 minutes, the flow of sodium silicate was stopped and the pH was adjusted to 7.0 with continued addition of sulfuric acid (22.8%) at 0.80 L/min. The batch was digested for 15 minutes at pH 7.0, and then filtered and washed to a conductivity of <1500 μS. Prior to drying, the pH of the silica slurry was adjusted to 5.0 with sulfuric acid and spray dried to a target moisture of 5%.

For Comparative Example 6A, 1.5 kg of Example 1A, 1.34 kg of sodium sulfate, 11.1 L of sodium silicate (3.32 MR, 13.0%) and 20 L of water were added to the recirculation loop, followed by heating to 65° C. with recirculation at 80 L/min with the Silverson operating at 60 Hz (1742 RPM) with the normal rotor/stator configuration. Sodium silicate (3.32 MR, 13.0%) and sulfuric acid (11.4%) were added simultaneously to the loop at a silicate rate of 2.5 L/min and an acid rate sufficient to maintain a pH of 7.4. If necessary, the acid rate was adjusted accordingly to maintain the pH. Acid and silicate were added under these conditions for 40 minutes to purge unwanted silica out of the system before the desired material was collected. After 40 minutes had passed, the collection vessel was emptied and its contents discarded. The silica product was then collected in a vessel with stirring at 40 RPM while maintaining the temperature at approximately 80° C. After the desired quantity of product was collected (500 L), addition of acid and silicate were stopped and the contents of the loop were allowed to circulate.

Then, for surface area reduction, the silica product in the collection vessel was transferred to a batch reactor and was heated to 95° C. with stirring at 80 RPM and recirculation at 80 L/min. Sodium silicate (3.32 MR, 13.0%) was added to the reactor until a pH of 9.5 (+/−0.2) was reached. Once the pH was reached, sodium silicate (3.32 MR, 13.0%) and sulfuric acid (11.4%) were added at rates of 2.30 L/min and 0.83 L/min, respectively. If needed, the acid rate was adjusted to maintain the pH of 9.5 (+/−0.2). After a total time of 175 minutes, the flow of sodium silicate was stopped and the pH was adjusted to 7.0 with continued addition of sulfuric acid (11.4%) at 0.80 L/min. The batch was digested for 10 minutes at pH 7.0, and then filtered and washed to a conductivity of <1500 μS. Prior to drying, the pH of the silica slurry was adjusted to 5.0 with sulfuric acid and spray dried to a target moisture of 5%.

Table I summarizes certain properties of spherical silica particles 3A-5A and comparative silica materials 1A-2A and 6A. As compared to Examples 1A-2A, the silica materials of Examples 3A-5A had excellent stannous compatibility and CPC compatibility, significantly lower BET surface area, CTAB surface area, and pore volume, and higher pour density and pack density. Representative SEM images for Examples 2A-5A are provided asFIGS.2-5, respectively. Examination of the SEM images demonstrated a narrow particle size distribution and spherical particle morphology for the silica particles of Examples 3A-5A. The respective sphericity factor (S80) for each of Examples 3A-5A is greater than 0.9.

SEM images for the comparative silica of Example 6A are provided inFIG.6. While the silica product of Example 6A was generally spherical (sphericity is less than 0.9), it is not as spherical as the silica materials of Examples 3A-5A. Further, as compared to Example 6A, the larger particle size silica materials of Examples 3A-5A had significantly lower pore volume and higher pour density and pack density (see Table I).

Toothpaste Formulations and PCR and RDA Testing

Samples of silicas 1A-5A were used in toothpaste formulations 1B-5B at a 20 wt. % loading of the respective silica, and in toothpaste formulation 5C at a 10 wt. % loading of the respective silica, as summarized in Table II.

PCR and RDA testing (at the Indiana University School of Dentistry) were conducted on the toothpaste formulations to determine the impact of the silica properties on the PCR and RDA performance. Table III summarizes the PCR and RDA data for the toothpaste formulations. Unexpectedly, as the particle size of the highly spherical particles increased, the PCR and the RDA both decreased. These results are unexpected and contrary to that typically observed with traditional precipitated silica materials (which are irregularly shaped, and not spherical). While not wishing to be bound by theory, it is believed that since RDA testing is performed on an irregular surface comprised of dentin and hollow dentin tubules that are approximately 2-3 μm in size, that the spherical silica particles fall partway into the tubules, and then gouge the opposite wall as they are pushed out of the tubule by the toothbrush as they move across the dentin surface.

Irregular Silica Particles

Table IV summarizes certain properties of comparative silica materials 7A-11A, which have an irregular and non-spherical particle morphology. Example 7A was a conventional silica material commercially available from Evonik Corporation, and Examples 8A-11A were produced by air milling an unmilled sample of Example 7A to a d50 particle size of 3.5 μm (Example 8A), 6.2 μm (Example 9A), 9.4 μm (Example 10A, broad particle size distribution), and 9.3 μm (Example 11A, narrow particle size distribution).

Toothpaste Formulations and PCR and RDA Testing

Samples of silicas 7A-11A were used in toothpaste formulations 7B-11B at a 20 wt. % loading of the respective silica, using the same formulations shown in Table II for Examples 1B-5B.

PCR and RDA testing (at the Indiana University School of Dentistry) were conducted on the toothpaste formulations to determine the impact of the silica properties on the PCR and RDA performance. Table V summarizes the PCR and RDA data for the toothpaste formulations. As shown in Table V, as the particle size of the silica increased from 3.5 μm to 9.5 μm, there was no change in either the RDA or the PCR values. Thus, for irregular and non-spherical silica particles, there is no correlation between particle size and RDA and no correlation between particle size and PCR.

Discussion of Examples

By comparing the data in Table III with that of Table V, the behavior of the spherical silica materials is fundamentally (and surprisingly) different from that of traditional dental silicas, which are non-spherical and irregularly shaped. Particle size and particle size distribution can be used to control RDA and PCR with highly spherical materials, whereas for traditional irregularly-shaped silicas, particle size and particle size distribution have no significant effect.

While not wishing to be bound by the following theory, it is believed that the spherical particles initially gouge into the substrate, before they begin rolling across the surface (initially there is a lot of wear, but as the particles begin to roll, the wear is essentially eliminated), whereas a traditional non-spherical and irregularly shaped product would scratch the entire way across the substrate.

As shown in Table III, the RDA values for spherical products with particle sizes of greater than 8 μm are less than 190. It is postulated that since the dentin surface is essentially non-homogeneous, comprised of both porous mineral and organic content, the spherical particles partially enter tubules and scrape the opposite side as they exit. With very spherical particles, as the particle size is increased, the depth that they can enter a tubule is reduced. This reduction in penetration in the tubule (and increase in particle size) is thought to be the driving factor for reducing RDA. A model for the spherical particle (at a small particle size) interacting with a dentin tubule is illustrated inFIG.7.

A simple analogy would be driving over a pothole with a car tire. If the pothole is large relative to the car tire, a large bump is felt as the car passes over the pothole. As the pothole is decreased in size, the intensity of the bump that is felt decreases, until the pothole is small enough that the car tire does not fall very far into the hole. If the pothole was a fixed size, the same effect would be observed as the tires on the car were increased in size. In like manner, a model of spherical particles of increasing particle size (4 μm, 5 μm, 6 μm, 10 μm) interacting with dentin tubules of approximately 2.5 μm in size in shown inFIG.8. The penetration depth of the particles into the tubules is reduced as particle size increases.

Using geometric calculations, the depth of penetration for a spherical particle can be calculated based upon its diameter, as described by J. M. Fildes et al., Wear 274-275 (2012) 414-422, incorporated herein by reference in its entirety. As it pertains to silica particle sizes and the 2.5 μm width dentin tubules relevant to RDA, a plot of the depth of penetration versus particle diameter for a sphere can be generated (seeFIG.9). There is a reduction in the depth of penetration of highly spherical particles of roughly 80% as the particle size increases from 3.5 μm to 12 μm.

The force required for a circular wheel (analogous to a spherical particle) to pass over a step of different heights (analogous to a depth of penetration) also can be calculated using formulas in “Physics for Scientists and Engineers” Eighth Edition (2010); Serway|Jewett, incorporated herein by reference in its entirety. Using the assumption that the spherical particle only contacts one part of the tubule as it passes through (with the exception of when it is at the bottom, then the point of contact is a step), a rough estimate of the force required for the particle to exit the tubule can be calculated. Because dentifrice compositions are loaded by weight and numerically there are more small particles than large particles, it is believed that the calculated force in Newtons should be on a weight basis (per gram basis).FIG.10graphically represents the decrease in force required for 1 gram of spherical particles to exit a 2.5 μm tubule as a function of increasing particle size. The force is reduced by over 50% as the particle size increases from 6 μm to 12 μm.

In sum, the figures, tables, and discussion above demonstrate that the behavior of the spherical silica materials is fundamentally (and unexpectedly) different from that of traditional dental silicas, which are non-spherical and irregularly shaped, particularly as it pertains to RDA performance. Particle size is a key factor to control RDA and PCR with highly spherical materials, unlike traditional irregularly-shaped silicas, where particle size has no significant effect.

Examples 3D-6D AND 12D-13D

Toothpaste Formulations and PCR and RDA Testing

Samples of silicas 3A-6A and 12A-13A were used in tartar-control toothpaste formulations 3D-6D and 12D-13D at a 22 wt. % loading of the respective silica, as summarized in Table VI. Silicas 12A-13A were conventional (irregularly shaped) silicas available from Evonik Corporation, with a nominal d50 particle size in the 8-10 μm range, a BET surface area greater than 20 m2/g, and generally poor stannous compatibility (<50%).

PCR and RDA testing (at the Indiana University School of Dentistry) were conducted on the toothpaste formulations to determine the impact of the silica properties on the PCR and RDA performance. Table VI summarizes the PCR and RDA data for the toothpaste formulations. Toothpaste formulations 3D-5D (containing 22 wt. % of the respective spherical silicas of Examples 3A-5A) had equivalent PCR values to those of Examples 12D-13D; however, the RDA values for the spherical silica formulations were approximately 10% lower than for formulations using irregularly shaped silicas. This benefit is also demonstrated by the higher PCR/RDA ratios for spherical silica Examples 3D-5D.

Toothpaste formulation 6D (containing comparative silica 6A) exhibited a PCR value approximately 10% greater than for Examples 3A-5A, but the RDA value for Example 6D was 260, which would not be acceptable for use due to the RDA value being greater than the upper limit of 250. Example 6D demonstrates that properties of the silica (other than sphericity), as shown in Table I for silica 6A, can lead to unacceptable RDA properties.

TABLE IIIExamples 1B-5B and Example 5C-PCR and RDA dataExample1B2B3B4B5B5CBET Surface Area (m2/g)5689120.50.5Median Particle Size (μm)9.73.59.111.813.913.9Mean Particle Size (μm)12.53.89.311.513.713.7Example Silica (wt. %)202020202010PCR106118103969686RDA180270182169168140Ratio of PCR/RDA0.590.430.560.570.570.61

The invention is described above with reference to numerous aspects and specific examples. Many variations will suggest themselves to those skilled in the art in light of the above detailed description. All such obvious variations are within the full intended scope of the appended claims. Other aspects of the invention can include, but are not limited to, the following (aspects are described as “comprising” but, alternatively, can “consist essentially of” or “consist of”):

Aspect 1. Silica particles characterized by:(i) a d50 median particle size in a range from about 8 to about 20 μm;(ii) a sphericity factor (S80) of greater than or equal to about 0.9;(iii) a BET surface area in a range from about 0.1 to about 8 m2/g;(iv) a total mercury intrusion pore volume in a range from about 0.35 to about 0.8 cc/g; and(v) a loss on ignition (LOI) in a range from about 3 to about 7 wt. %.

Aspect 2. The silica particles defined in aspect 1, wherein the silica particles are further characterized by any suitable BET surface area, or a BET surface area in any range disclosed herein, e.g., from about 0.1 to about 6 m2/g, from about 0.5 to about 5 m2/g, or from about 0.5 to about 2 m2/g.

Aspect 3. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable pack density, or a pack density in any range disclosed herein, e.g., from about 53 to about 75 lb/ft3, from about 58 to about 70 lb/ft3, from about 61 to about 72 lb/ft3, or from about 62 to about 65 lb/ft3.

Aspect 4. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable pour density, or a pour density in any range disclosed herein, e.g., from about 40 to about 65 lb/ft3, from about 42 to about 60 lb/ft3, from about 43 to about 58 lb/ft3, or from about 44 to about 54 lb/ft3.

Aspect 5. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable Einlehner abrasion value, or an Einlehner abrasion value in any range disclosed herein, e.g., from about 7 to about 25, from about 8 to about 20, from about 10 to about 22, or from about 11 to about 17 mg lost/100,000 revolutions.

Aspect 6. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable total mercury intrusion pore volume, or a total mercury intrusion pore volume in any range disclosed herein, e.g., from about 0.35 to about 0.7, from about 0.35 to about 0.65, from about 0.4 to about 0.65 cc/g, or from about 0.49 to about 0.6 cc/g.

Aspect 7. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable Stannous compatibility, or a Stannous compatibility in any range disclosed herein, e.g., from about 70 to about 99%, from about 75 to about 95%, from about 80 to about 95%, or from about 86 to about 93%.

Aspect 8. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable CPC compatibility, or a CPC compatibility in any range disclosed herein, e.g., from about 70 to about 99%, from about 75 to about 95%, from about 78 to about 95%, or from about 81 to about 91%.

Aspect 9. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable median particle size (d50) and/or mean particle size (average), or a median particle size (d50) and/or mean particle size (average) in any range disclosed herein, e.g., from about 8 to about 18 μm, from about 9 to about 16 μm, or from about 9 to about 14 μm.

Aspect 10. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable ratio of (d90-d10)/d50, or a ratio of (d90-d10)/d50 in any range disclosed herein, e.g., from about 1.1 to about 2.2, from about 1.2 to about 2, or from about 1.3 to about 1.5.

Aspect 11. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable water absorption, or a water absorption in any range disclosed herein, e.g., from about 40 to about 75 cc/100 g, from about 42 to about 75 cc/100 g, from about 50 to about 65 cc/100 g, or from about 57 to about 66 cc/100 g.

Aspect 12. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable oil absorption, or an oil absorption in any range disclosed herein, e.g., from about 20 to about 75 cc/100 g, from about 25 to about 60 cc/100 g, from about 25 to about 55 cc/100 g, or from about 32 to about 50 cc/100 g.

Aspect 13. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable CTAB surface area, or a CTAB surface area in any range disclosed herein, e.g., from 0 to about 10 m2/g, from 0 to about 6 m2/g, from 0 to about 4 m2/g, or from 0 to about 2 m2/g.

Aspect 14. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable pH, or a pH in any range disclosed herein, e.g., from about 5.5 to about 9, from about 6.2 to about 8.5, from about 6.8 to about 8.2, or from about 7.5 to about 7.9.

Aspect 15. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable 325 mesh residue, or a 325 mesh residue in any range disclosed herein, e.g., less than or equal to about 1.2 wt. %, less than or equal to about 0.6 wt. %, or less than or equal to about 0.3 wt. %.

Aspect 16. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable sphericity factor (S80), or a sphericity factor (S80) in any range disclosed herein, e.g., greater than or equal to about 0.91, greater than or equal to about 0.92, or greater than or equal to about 0.94.

Aspect 17. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable RDA at 20 wt. % loading, or a RDA at 20 wt. % loading in any range disclosed herein, e.g., from about 120 to about 200, from about 130 to about 180, or from about 168 to about 182.

Aspect 18. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable ratio of PCR/RDA, or a ratio of PCR/RDA in any range disclosed herein, e.g., from about 0.4:1 to about 0.8:1, from about 0.5:1 to about 0.7:1, or from about 0.56:1 to about 0.57:1.

Aspect 19. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable loss on drying (LOD), or a LOD in any range disclosed herein, e.g., from about 1 to about 15 wt. %, from about 3 to about 12 wt. %, from about 4 to about 8 wt. %, or from about 5.3 to about 6.1 wt. %.

Aspect 20. The silica particles defined in any one of the preceding aspects, wherein the silica particles are further characterized by any suitable loss on ignition (LOI), or a LOI in any range disclosed herein, e.g., from about 3 to about 6 wt. %, from about 3.2 to about 5.5 wt. %, or from about 3.2 to about 4.5 wt. %.

Aspect 21. The silica particles of Aspect 1, wherein: (i) the d50 median particle size is in a range from about 8 to about 18 μm; (ii) the sphericity factor (S80) is greater than or equal to about 0.92; (iii) the BET surface area is in a range from about 0.1 to about 6 m2/g; (iv) the total mercury intrusion pore volume is in a range from about 0.35 to about 0.7 cc/g; (v) the loss on ignition (LOI) is in a range from about 3 to about 6 wt. %; or any combination thereof.

Aspect 22. The silica particles defined in any one of Aspect 1 or 21, wherein: (i) the d50 median particle size is in a range from about 9 to about 16 μm; (ii) the sphericity factor (S80) is greater than or equal to about 0.94; (iii) the BET surface area is in a range from about 0.5 to about 5 m2/g; (iv) the total mercury intrusion pore volume is in a range from about 0.4 to about 0.65 cc/g; (v) the loss on ignition (LOI) is in a range from about 3.2 to about 5.5 wt. %; or any combination thereof.

Aspect 23. The silica particles of any one of Aspects 1 or 21-22, wherein the silica particles are further characterized by: a pack density in a range from about 53 to about 75 lb/ft3; a pour density in a range from about 40 to about 65 lb/ft3; an Einlehner abrasion value in a range from about 7 to about 25 mg lost/100,000 revolutions; or any combination thereof.

Aspect 24. The silica particles of any one of Aspects 1 or 21-23, wherein the silica particles are further characterized by: a pack density in a range from about 61 to about 72 lb/ft3; a pour density in a range from about 42 to about 60 lb/ft3; an Einlehner abrasion value in a range from about 10 to about 22 mg lost/100,000 revolutions; or any combination thereof.

Aspect 25. The silica particles of any one of Aspects 1 or 21-24, wherein the silica particles are further characterized by: a Stannous compatibility in a range from about 70 to about 99%; a CPC compatibility in a range from about 70 to about 99%; a ratio of (d90-d10)/d50 in a range from about 1.1 to about 2.2; a 325 mesh residue of less than or equal to about 1.2 wt. %; or any combination thereof.

Aspect 26. The silica particles of any one of Aspects 1 or 21-25, wherein the silica particles are further characterized by: a Stannous compatibility in a range from about 80 to about 95%; a CPC compatibility in a range from about 78 to about 95%; a ratio of (d90-d10)/d50 in a range from about 1.2 to about 2; a 325 mesh residue of less than or equal to about 0.6 wt. %; or any combination thereof.

Aspect 27. The silica particles of any one of Aspects 1 or 21-26, wherein the silica particles are further characterized by: a water absorption in a range from about 40 to about 75 cc/100 g; an oil absorption in a range from about 20 to about 75 cc/100 g; a CTAB surface area in a range from 0 to about 10 m2/g; a loss on drying (LOD) in a range from about 1 to about 15 wt. %; or any combination thereof.

Aspect 28. The silica particles of any one of Aspects 1 or 21-27, wherein the silica particles are further characterized by: a water absorption in a range from about 42 to about 75 cc/100 g; an oil absorption in a range from about 25 to about 55 cc/100 g; a CTAB surface area in a range from 0 to about 4 m2/g; a loss on drying (LOD) in a range from about 3 to about 12 wt. %; or any combination thereof.

Aspect 29 The silica particles of any one of Aspects 1 or 21-28, wherein the silica particles are further characterized by: a RDA at 20 wt. % loading in a range from about 120 to about 200; and/or a ratio of PCR/RDA, at 20 wt. % loading, in a range from about 0.4:1 to about 0.8:1.

Aspect 30. The silica particles of any one of Aspects 1 or 21-29, wherein the silica particles are further characterized by: a RDA at 20 wt. % loading in a range from about 130 to about 180; and/or a ratio of PCR/RDA, at 20 wt. % loading, in a range from about 0.5:1 to about 0.7:1.

Aspect 31. The silica particles defined in any one of the preceding aspects, wherein the silica particles are amorphous, or the silica particles are synthetic, or the silica particles are both amorphous and synthetic.

Aspect 32. The silica particles defined in any one of the preceding aspects, wherein the silica particles are precipitated silica particles.

Aspect 33. A process for producing silica particles, the process comprising:(a) continuously feeding a first mineral acid and a first alkali metal silicate into a loop reaction zone comprising a stream of liquid medium, wherein at least a portion of the first mineral acid and the first alkali metal silicate react to form a base silica product in the liquid medium of the loop reaction zone;(b) continuously recirculating the liquid medium through the loop reaction zone;(c) continuously discharging from the loop reaction zone a portion of the liquid medium comprising the base silica product;(d) adding a second mineral acid and a second alkali metal silicate under surface area reduction conditions to a mixture of water and the base silica product; and(e) ceasing the addition of the second alkali metal silicate and continuing the addition of the second mineral acid to the mixture to adjust the pH of the mixture to within a range from about 5 to about 8.5 to produce the silica particles.

Aspect 34. The process defined in aspect 33, wherein steps (a)-(c) are performed simultaneously.

Aspect 35. The process defined in aspect 33 or 34, wherein the loop reaction zone comprises a continuous loop of one or more loop reactor pipes.

Aspect 36. The process defined in any one of aspects 33-35, wherein the first mineral acid and the first alkali metal silicate are fed into the loop reaction zone at different points along the loop reaction zone.

Aspect 37. The process defined in any one of aspects 33-36, wherein the portion of the liquid medium discharged from the loop reaction zone is discharged in a volumetric rate proportional to the amount of the first mineral acid and the first alkali metal silicate fed into the loop reaction zone.

Aspect 38. The process defined in any one of aspects 33-37, wherein steps (a)-(c) are performed in a continuous single loop reactor.

Aspect 39. The process defined in any one of aspects 33-38, wherein the liquid medium is recirculated through the loop reaction zone at a rate in a range from about 15 L/min to about 150 L/min, from about 60 L/min to about 100 L/min, or from about 60 L/min to about 80 L/min.

Aspect 40. The process defined in any one of aspects 33-39, wherein the liquid medium is recirculated through the loop reaction zone at a rate ranging from about 50 vol. % per minute (the recirculation rate, per minute, is one-half of the total volume of the liquid medium in the loop reaction zone) to about 1000 vol. % per minute (the recirculation rate, per minute, is ten times the total volume of the liquid medium in the loop reaction zone), or from about 75 vol. % per minute to about 500 vol. % per minute.

Aspect 41. The process defined in any one of aspects 33-40, wherein the liquid medium is recirculated through the loop reaction zone at a pH in a range from about 2.5 to about 10, from about 6 to about 10, from about 6.5 to about 8.5, or from about 7 to about 8.

Aspect 42. The process defined in any one of aspects 33-41, wherein the first mineral acid comprises sulfuric acid, hydrochloric acid, nitric acid, phosphoric acid, or a combination thereof, and the first alkali metal silicate comprises sodium silicate.

Aspect 43. The process defined in any one of aspects 33-42, wherein all (or substantially all, such as greater than 95 wt. %) of the liquid medium is recirculated in step (b).

Aspect 44. The process defined in any one of aspects 33-43, wherein a pump is utilized to recirculate the liquid medium through the loop reaction zone.

Aspect 45. The process defined in any one of aspects 33-44, wherein step (b) is performed at low shear or no shear conditions, e.g., the loop reaction zone does not comprise a stator screen or the loop reaction zone comprises a stator screen with openings greater than 3 mm2in cross sectional area (or greater than 10 mm2, greater than 50 mm2, greater than 100 mm2, greater than 500 mm2, etc., in cross sectional area), and/or a shear frequency in the loop reaction zone is less than 1,000,000 interactions/min (or less than 750,000 interactions/min, less than 500,000 interactions/min, less than 250,000 interactions/min, etc.).

Aspect 46. The process defined in any one of aspects 33-45, wherein steps (d)-(e) are performed in a vessel separate from the loop reaction zone, such as a stirred batch reactor.

Aspect 47. The process defined in any one of aspects 33-46, wherein the surface area reduction conditions comprises an addition rate of the second alkali metal silicate to the mixture of an average silica addition rate in a range from about 0.2 to about 0.8 wt. % (or from about 0.25 to about 0.7 wt. %, from about 0.3 to about 0.55 wt. %, or from about 0.42 to about 0.44 wt. %) per minute, and/or at a maximum silica addition rate of less than about 1.9 wt. % (or less than about 1.5 wt. %, or less than about 1 wt. %) per minute.

Aspect 48. The process defined in any one of aspects 33-47, wherein the second mineral acid comprises sulfuric acid, hydrochloric acid, nitric acid, phosphoric acid, or a combination thereof, and the second alkali metal silicate comprises sodium silicate.

Aspect 49. The process defined in any one of aspects 33-48, wherein the surface area reduction conditions of step (d) comprise a time period in a range from about 45 minutes to about 5 hours, or from about 1 hour to about 4 hours.

Aspect 50. The process defined in any one of aspects 33-49, wherein the surface area reduction conditions of step (d) comprise a pH in a range from about 9.2 to about 10.2, from about 9.3 to about 10, or from about 9.3 to about 9.7.

Aspect 51. The process defined in any one of aspects 33-50, wherein the surface area reduction conditions of step (d) comprise a temperature in a range from about 90 to about 100° C., or from about 90 to about 95° C.

Aspect 52. The process defined in any one of aspects 33-51, wherein, in step (d), the second alkali metal silicate and the second mineral acid are added to the mixture in any order, e.g., simultaneously, sequentially, alternating, as well as combinations thereof.

Aspect 53. The process defined in any one of aspects 33-52, wherein, in step (e), the addition rate of the second mineral acid to the mixture is at an average rate of addition of no more than 75% greater (no more than 50% greater, or no more than 10% greater) than the average rate of addition of the second mineral acid in step (d).

Aspect 54. The process defined in any one of aspects 33-53, further comprising a step of filtering after step (e) to isolate the silica particles.

Aspect 55. The process defined in any one of aspects 33-54, further comprising a step of washing the silica particles after step (e).

Aspect 56. The process defined in any one of aspects 33-55, further comprising a step of drying (e.g., spray drying) the silica particles after step (e).

Aspect 57. The process defined in any one of aspects 33-56, wherein the silica particles produced are defined in any one of aspects 1-32.

Aspect 58. Silica particles produced by the process defined in any one of aspects 33-56.

Aspect 59. Silica particles defined in any one of aspects 1-32 produced by the process defined in any one of aspects 33-56.

Aspect 60. A composition comprising the silica particles defined in any one of aspects 1-32 or 58-59.

Aspect 61. A dentifrice composition comprising the silica particles defined in any one of aspects 1-32 or 58-59.

Aspect 62. A dentifrice composition comprising from about 0.5 to about 50 wt. % of the silica particles defined in any one of aspects 1-32 or 58-59.

Aspect 63. A dentifrice composition comprising from about 5 to about 35 wt. % of the silica particles defined in any one of aspects 1-32 or 58-59.

Aspect 64. The dentifrice composition defined in any one of aspects 61-63, wherein the composition further comprises at least one of a humectant, a solvent, a binder, a therapeutic agent, a chelating agent, a thickener other than the silica particles, a surfactant, an abrasive other than the silica particles, a sweetening agent, a colorant, a flavoring agent, and a preservative, or any combination thereof.