Toilet bowl cleaner

Abstract: Solid cake lavatory cleansing block compositions comprise polyethylene glycol distearate having a dissolution time of at least 5.5 hours, a non-ionic surfactant, a water-soluble salt filler and optional ingredients which include a gelling natural gum, fragrances, dyes, solid binders, filler material and mixtures thereof.

Description: The present invention relates to cake compositions which are useful for the treatment of the flush water of toilets. More particularly, the invention is concerned with a long lasting toilet tank dispenser which may be formed by casting and is responsive to the flushing of the toilet. In treating toilet flush water with chemicals in order to produce desirable effects such as bowl aesthetics, cleaning, disinfection, deodorization, aerosol reduction, etc., it is desirable that the chemicals be dispensed into the flush water automatically each time the toilet is flushed. The prior art discloses numerous devices which have been designed for this purpose. Particularly desirable devices are those comprising a solid cake composition. In this type of device, a measured amount of water enters the device during one flush cycle and remains in contact with the cake between flushes, thereby forming a concentrated solution of the composition which is dispensed into the flush water during the next flush. The advantages of such devices are that the chemical composition can be packaged and shipped in more concentrated form than aqueous solutions of the chemicals. Also, the problems of liquid spillage resulting from breakage of the dispensers during shipment or handling is eliminated. Prior art surfactant cake compositions are disclosed in US-A-4,308,625 (Kitko) and US-A-4,043,931 (Jeffrey et al). These patents disclose a lavatory cleansing tablet which is formed with two or more non-ionic surfactants which includes the use of polyalkoxylated alcohols. US-A-4,477,363 (Wong et al) discloses a solid cake comprising free fatty alcohol and a buffered alkali earth metal alkyl sulfate surfactant. JP-A-58-168699 (Japan Synthetic Rubber Co. et al) discloses a cast lavatory cleansing block containing 25 to 90 weight % of a mixture of polyethylene glycol or monoester thereof and polyethylene glycol diester. The preferred monoester and diester are the stearates and the exemplified stearates are polyethylene glycol 4000 and 6000 monostearates and polyethylene glycol 6000 distearate. The block may also contain inter alia a deodorising agent, detergent, colorant, filler, binder, aromatic, and dissolution rate adjuster. JP-A-58-25398 (Lion) discloses a cast lavatory cleansing block containing 40 to 98 weight % of polyethylene glycol diester, preferably distearate. Especially preferred diesters are polyethylene glycol 1500, 3000 and 9000 distearates. The block may also contain inter alia aromatic, colorant, surface-active agent, germicide, and builder. JP-A-59-24797 (Earth I) discloses a cast lavatory cleansing block containing at least 40% of a polyethylene glycol distearate having 91 to 230 moles ethylene oxide adduct groups and 0.1 to 60% of either polyoxyethylene sorbitan monostearate, 6 ethylene oxide or polyethylene sorbitan tristearate, 20 ethylene oxide. Exemplified polyethylene glycol distearates have 91, 160, 230 and 245 moles ethylene oxide. The block may also contain inter alia dye and fragrance. JP-A-61-83300 (Earth II) discloses a cast lavatory cleansing block containing 1-8 volume % 12-hydroxy stearic acid and/or 0.1-5% benzylidene sorbitol; 20-70% perfume; 10-30% coloring matter; and 15-60% surface active agent. The surface active agent can comprise a polyethylene glycol distearate. The block may also contain inter alia deodorant, bactericide and chlorine-remover. US-A-4,269,723 (Barford et al I) discloses a compressed lavatory cleansing block containing one or more organic surface active agents and one or more binders which binder(s) act as dissolution retarding agents and are selected from clays and water-soluble and water-dispersible gel-forming organic polymeric materials. Specified binders include alginates and carragheenates and specified surface active agents include alkylene oxide condensates of fatty acids. GB-A-2061996 (Jeyes) is substantially the same as Barford et al I except that the block is formed by melting lower-melting point components, dispersing higher melting point and/or liquid components in the melt, and then casting into a mould. US-A-4460490 (Barford et al II) discloses a bi-component lavatory cleansing block comprising a shaped body formed of a slow-dissolving cleansing composition containing at least one surface active agent and a tablet comprising a bleaching agent embedded in or adhered to the shaped body. The shaped body preferably comprises one or more readily-soluble surface active agents in admixture with one or more solubility control agents. Specified solubility control agents include low ethoxylates of fatty acids and gel-forming gums, such as xanthan gum, or materials, such as alginates or carragheenates. US-A-4,310,434 (Choy et al) and US-A-4,278,571 (Choy) disclose surfactant cake compositions containing dyes and perfumes which are utilized in the present invention. The surfactants provide cleaning and sudsing in the toilet bowl and also serve to dispense other components of the compositions such as dyes, perfumes and organic resins. Water-soluble inert salts such as alkali metal chlorides and sulfates are used in such compositions to act as a "filler" so that the composition can be formed into cakes of desirable size without using excessive amounts of active ingredients. The predominant ingredients of the cake compositions are usually the surfactant, perfume and the filler salt. A major problem in this art has been short and/or erratic longevity of surfactant cakes because of rapid and uneven dissolution resulting in decreased cake stability and longevity. It has been found that a cast solid cake composition which has a long and uniform block life can be provided where the composition comprises a polyethylene glycol distearate if said distearate has a specific water solubility and molecular weight range. It is an object of the present invention to provide a solid cake which may be formed by casting and comprises a specific kind of polyethylene glycol distearate, which compositions are suitable for use for automatically dispensing cleansing agents into the toilet. It is a further object of the present invention to provide a cast solid cake composition having relatively high melt temperatures and less block surface tackiness for improved processing. It is a still further object of the present invention to provide a lavatory block which has a long and uniform block life that eliminates sluggish toilets. It is a yet still further object of the present invention to provide a lavatory block which resists mounding and major fragmentation. Other objects, advantages and novel features of the present invention will be apparent to those skilled in the art from the following description and appended claims. The objectives of the invention are achieved by providing a solid unsupported cake composition which comprises polyethylene glycol distearate having a drop dissolution time of at least 5.5 hours according to the Distearate Dissolution Test (see Example 1 hereinafter) and a molecular weight from 3,000 to 12,000, preferably 7,000 to 9,000, a non-ionic surfactant selected from the condensation products of a long chain ethylene oxide moiety with an aliphatic alcohol, or an alkyl phenol, a water-soluble salt filler, and optional ingredients selected from the groups consisting of fragrances, dyes, binders, filler materials and mixtures thereof. The cake composition comprises from 8% to 35%, preferably 12% to 29%, by weight of said polyethylene glycol distearate. It is known that polyethylene glycol distearate is extremely hydrophilic. Because of the extreme hydrophilic nature of the compound, it would be expected that the material would be very water-soluble without any prolonged transition from solid to a liquid. It has been surprisingly found that the particular kind of polyethylene glycol distearate of the invention goes through a hydration stage forming a tenacious gel so as to provide the aforementioned extended block life relative to other formulations containing polyethylene glycol distearate of varying molecular weights. It is critical in the present invention that the polyethylene glycol distearate which is utilized in the formulation of the cake composition has a drop dissolution time of at least 5.5 hours according to the Distearate Dissolution Test. It has been found that not all polyethylene glycol distearates having a molecular weight of 3,000 to 12,000 possess such a characteristic. Their method of preparation appears to influence their solubility. Preferably, their preparation is according to the method of condensing a fatty acid with an alcohol as described by W.B. Satkowski et al in "Polyoxyethylene esters of Fatty Acids", Non-ionic Surfactants , M.J. Schick Ed. (Dekker, NY 1967) p. 142-174. For example, stearic acid having a molecular weight of 284.5 is reacted with a polyethylene glycol having a molecular weight range between 5500-8500 to form a polyethylene glycol distearate having a molecular weight range of 6033-9033. Such compound having a dissolution time of at least 5.5 hours is suitable for use in the invention. In order to improve the cake characteristics, it has been found advantageous to utilize in the cake composition a greater portion of polyethylene glycol distearate which has a molecular weight between 7,000 to 12,000. A lesser portion of the polyethylene glycol distearate having a molecular weight between 3,000 to 7,000, preferably 3,000 to 4,000 in combination with the higher molecular weight polyethylene glycol distearate aids in preventing mounding and further acts as a binder. The compositions of the invention also comprise a non-ionic surfactant selected from the condensation products of a long chain ethylene oxide moiety with an aliphatic alcohol, or an alkyl phenol. Preferably, the primary and secondary alcohol contains 8 to 20 carbon atoms and the alkyl phenol-based moiety is one wherein the alkyl chain is straight or branched and contains 6 to 12 carbon atoms, preferably 6 to 9 carbon atoms. Illustrative non-ionic surfactants having the desired characteristics for formulation are available on the market under the Registered Trade Marks "Neodol" (Shell Oil Company); "Tergitol" (by Union Carbide Company); and "Alfol" (Continental Oil Company). Specific examples include "Neodol 25-7" (linear C₁₂-C₁₅ primary alcohol condensed with 7 moles of ethylene oxide per mole of alcohol); "Neodol 45-7" (linear C₁₄-C₁₅ primary alcohol condensed with 7 moles of ethylene oxide per mole of alcohol); "Tergitol 15-S-7" (random secondary C₁₁-C₁₅ alcohol condensed with 7 moles of ethylene oxide per mole of alcohol); and "Alfol 1416-6.5" (primary C₁₄-C₁₆ alcohol condensed with 6.5 moles of ethylene oxide per mole of alcohol). Such non-ionic surfactants act as coupling agents to provide an integration of the cake components and are be used in the amount of 20 to 40%, preferably 20 to 30%, by weight of the cake formulation. Also useful to enhance the life of the cake are ethoxylated nonylphenols. The high ethoxylated nonylphenols, that is, those having over 20 moles of ethylene oxide per mole of phenol, provide slow dissolution of the cake formulation. Up to 10%, preferably up to 5%, by weight of ethoxylated nonylphenols is preferably utilized together with the ethoxylated aliphatic alcohols. Water-soluble inert salts are used in present compositions as "fillers" so that the composition can be formed into cakes of desired size without using excessive amounts of active ingredients. They are used alone or in combination in amounts of 20 to 64% by weight. The inert salts (filler salts) used in the compositions of the present invention can be any water-soluble inorganic or organic salt or mixtures of such salts. For purposes of the present invention, "water-soluble" means having a solubility in water of at least 0.2 grams per hundred grams of water at 20°C. Examples of suitable salts include various alkali metal and/or alkaline earth metal sulfates, chlorides, borates, bromides, citrates, acetates, and lactates. Specific examples of suitable salts include calcium sulfate, sodium chloride, potassium sulfate, sodium carbonate, lithium chloride, tripotassium phosphate, sodium borate, potassium bromide, potassium fluoride, sodium bicarbonate, calcium chloride, magnesium chloride, sodium citrate, sodium acetate, calcium lactate, magnesium sulfate and sodium fluoride. The preferred salts are the inorganic salts, especially the alkali metal sulfates and chlorides. Particularly preferred salts, because of their low cost, are calcium sulfate and sodium chloride. The salts are present in the compositions herein at levels of from 20% to 64% by weight, preferably from 20% to 35%. Most preferably, sodium chloride is utilized together with guar gum (binder) either alone or with other salts since the combination not only provides a synergistic viscosity increase of water and decreases the relative solubility properties of the matrix in water but also aids to prevent mounding. Calcium sulfate is advantageously utilized alone or together with other natural gum binders or together with sodium chloride because it has a low solubility level which is constant over the water temperature range likely to exist within toilet tanks. It has been found that natural gums can advantageously be utilized as binders in the present invention. The natural gums which may be utilized are those which are cold water gelling additives and develop a high viscosity and a high gel strength. Included in the gums which may be utilized are guar, xanthan, tragacanth, carrageenan, karaya, and algin. Usually, the gum is present in an amount of 3 to 35%, preferably 5 to 15%, by weight of the composition. The most preferable is guar which has been found to be the most effective in retarding block dissolution and to reduce the problem of sluggish toilet behaviour. As mentioned above, it has been found to be particularly advantageous to utilize guar gum together with sodium chloride as a filler since there is a synergistic viscosity increase of water that is not found with other fillers such as calcium sulfate. Additionally, there is an increase of the relative insolubility properties of the matrix in water. As a further binding agent, the use of solid emollients have been found to be helpful to prevent the cake of the invention from mounding out. Suitable emollients include glyceryl monostearate, glyceryl monopalmitate, ethylene glycol stearate, and propylene glycol monostearate, most preferably is glyceryl monostearate which provides a matrix to prevent mounding. The emollients may be utilized in amounts of up to 20% by weight, preferably 5% to 12%. Various optional materials may be included in the compositions herein. Dyes may be included at levels of up to 15%, preferably 2.5% to 10% by weight. Examples of suitable dyes are Alizarine Light Blue B (C.I. 63010), Carta Blue VP (C.I. 24401), Acid Green 2G (C.I. 42085), Astragon Green D (C.I. 42040), Supranol Cyanine 7B (C.I. 42675), Maxilon Blue 3RL (C.I. Basic Blue 80), Drimarine Blue Z-RL (C.I. Reactive Blue 18), Alizarine Light Blue H-RL (C.I. Acid Blue 182), FD&C Blue No. 1, FD&C Green No.3 and Acid Blue No. 9 (C.I. 42090). Others are disclosed US-A-4,310,434 and US-A-4,477,363. The cakes of the invention may also contain up to 15% by weight of a cationic quaternary ammonium salt. It is known that the cationic quaternary ammonium salts which include a greater number of short-chain alkyl groups in the structure, incline toward better bacteriostatic properties. Specific examples of bacteriostatic agents that may be used in the compositions of this invention include di-isobutyl cresoxy ethoxy ethyl dimethyl benzyl ammonium chloride, di-isobutyl phenoxy ethoxy ethyl dimethyl benzyl ammonium chloride, myristyl dimethylbenzene ammonium chloride, benzalkonium chloride, cetyl pyridinium chloride, coconut dimethyl benzyl ammonium chloride, stearyl dimethyl benzyl ammonium chloride, alkyl dimethyl benzyl ammonium chloride, alkyl diethyl benzyl ammonium chloride, alkyl dimethyl benzyl ammonium bromide, di-isobutyl phenoxy ethoxy ethyl trimethyl ammonium chloride, di-isobutyl phenoxy ethoxy ethyl dimethyl alkyl ammonium chloride, methyl-dodecylbenzyl trimethyl ammonium chloride, cetyl trimethyl ammonium bromide, octadecyl dimethyl ethyl ammonium bromide, cetyl dimethyl ethyl ammonium bromide, octadecenyl-9-dimethyl ethyl ammonium bromide, dioctyl dimethyl ammonium chloride, dodecyl trimethyl ammonium chloride, octadecyl trimethyl ammonium chloride, octadecyl trimethyl ammonium bromide, hexadecynyl trimethyl ammonium iodide, octyltrimethyl ammonium fluoride, and mixtures thereof. Other water dispersible salts, such as the acetates, sulfates, nitrates, and phosphates, are effective in place of the halides, but the chlorides and bromides are preferred. The cakes may also contain perfumes to impart an acceptable odor to the flushing water. The perfume may be in solid form and is suitably present in an amount up to 15%, preferably up to 10%, by weight. In this connection, it may be noted that the term "perfume" is intended to refer to any material giving an acceptable odor and thus materials giving a "disinfectant" odor such as essential oils, pine extracts, terpinolenes, ortho phenyl phenol or paradichlorobenzene may be employed. The essential oils and pine extracts also contribute as plasticizers and are functional to a degree in extending block life. Certain perfume materials may be added which additionally function to control the solubility of anionic sulfate surfactants. Examples of such perfume materials are isobornyl acetate, myrtenyl acetate and frenchyl acetate. Other suitable perfume or fragrances are disclosed in US-A-4,396,522. The cake formulation may also contain other binding and/or plasticizing ingredients serving to assist in the manufacture thereof, for example, polypropylene glycol having a molecular weight from 3,000 to 10,000 in an amount up to 20% by weight, preferably 4% to 15% by weight of the mixture may be used. The polypropylene glycol reduces the melt viscosity, acts as a demolding agent and also acts to plasticize the block when the composition is prepared by a casting process. Other suitable plasticizers such as pine oil fractions, d-limonene, dipentene and the ethylene oxide-propylene oxide block copolymers may be utilized. The blocks of the present invention can be produced by a variety of processes, eg. casting/moulding process, by tablet compression process or by an extrusion process. The casting process being the preferred process of the invention. The casting process which is well within the skill of those in the art involves the melting of the ingredients and then casting the melt into appropriate shaped moulds and allowing the melt to cool and solidify. The shaped tablets or blocks each suitably have a weight of from 20 to 150 grams, preferably from 30 to 70 grams. In one preferred embodiment, the compositions of the invention comprise from 8 to 35% by weight of the polyethylene glycol distearate; 20 to 40% by weight of the non-ionic surfactant; 20 to 64% by weight of water-soluble salt filler; and at least one of: (a) up to 35% by weight of a gelling natural gum, provided that the gum is not guar when the salt filler is sodium chloride; (b) up to 20% by weight of a solid emollient binding agent; (c) up to 10% by weight of an ethoxylated nonylphenol; (d) up to 15% by weight of a dye; (e) up to 15% by weight of a cationic quaternary ammonium salt; (f) up to 15% by weight of a perfume; and (g) up to 20% by weight of a plasticizer. In one especially preferred embodiment, said preferred compositions comprise 20 to 30% by weight of an ethoxylated C₈-C₂₀ aliphatic alcohol, up to 32% by weight of sodium chloride and/or up to 32% by weight of calcium sulfate, from 4% to 15% by weight of plasticizer, and at least one of: up to 10% by weight of glyceryl monostearate; up to 10% by weight of ethoxylated nonylphenol; up to 35% by weight of guar gum except when the composition comprises sodium chloride; and up to 15% by weight of disinfecting agent, coloring and/or fragrance. In another especially preferred embodiment, said preferred composition comprises: (a) from 12 to 29% by weight of said polyethylene glycol distearate; (b) 5 to 15% by weight of a gelling natural gum provided that the gum is not guar when the salt filler is sodium chloride; (c) 5 to 12% by weight of a solid emollient binding agent; (d) 20 to 30% by weight of the non-ionic surfactant; (e) optionally, up to 10% by weight of an ethoxylated nonylphenol; (f) 20 to 35% by weight of a water-soluble salt filler; (g) 2.5 to 10% by weight of a dye; (h) optionally, up to 5% by weight of a cationic quaternary ammonium salt; (i) optionally, up to 10% by weight of a perfume; and (j) 4 to 15% by weight of a plasticizer. In order that the invention may be better understood the following Examples are given by way of illustration only. In the Examples, all parts and percentages are by weight unless otherwise stated. The following Examples are for compositions suited for forming shaped bodies of blocks by a casting/moulding operation. EXAMPLE I Distearate Dissolution Test To determine the dissolution rate of polyethylene glycol distearate in water the test is performed as follows: A sample of the polyethylene glycol distearate is placed into a beaker and heated so as to form a melt. Using a 7.5 ml capacity polyethylene transfer pipet, one drop of the melt is placed in the centre of a petri dish. The drop is allowed to fully solidify for ten minutes, then 75 ml of deionized water is added to the dish. The dish is monitored to determine the time required for the drop of surfactant to totally dissolve. A dissolution time of at least 5.5 hours indicates that the polyethylene glycol distearate with the desired molecular weight is suitable for use in formulating the composition of the invention. EXAMPLE II A. Procedure for the Selection of Polyethylene Glycol 6000 Distearate (PEG 6000DS) To determine the dissolution rate of polyethylene glycol distearate in water the test is performed as follows: 1. An aliquot of PEG 6000DS is placed in a beaker and melted. 2. Using a 7.5 ml polyethylene transfer pipet, a drop of the melt is transferred to a microscope glass slide, the weight of PEG 6000DS added being 0.02 + or -0.001 g using an analytical balance. The melt is allowed to solidify for ten minutes. 3. The glass slide is carefully placed in a 1000 ml glass beaker containing 800 cc deionized water which is immersed in a 38°C water bath. 4. The beaker is monitored to determine the time necessary for the drop of PEG 6000DS to totally dissolve. A dissolution time of at least 5.5 hours indicated that the polyethylene glycol distearate was suitable for use in formulating the composition of the invention. B. Preparation of Cake Composition Polyethylene glycol 6000 distearate from Part A 21% Ethoxylated C₁₂-C₁₅ Linear, Primary Alcohol with 7EO 29.5% Ethoxylated Nonylphenol with 100 EO 5.5% Ethylene oxide-propylene oxide block copolymer (8500 MW 80% EO) 3.5% Acid Blue No.9 dye 5.5% Dipentene 8.0% Ortho-phenyl phenol 1.0% Guar gum 5.5% Sodium chloride 20.5% Into a first mixture vessel four-fifths of the ethoxylated C₁₂-C₁₅ linear primary alcohol is added and slowly heated with stirring. The polyethylene glycol 6000 distearate, ethoxylated nonylphenol and ethylene oxide-propylene oxide block copolymer are added and the mixture is heated with stirring to 71°C to form a clear melt. In a separate vessel, to the remaining one-fifth of the ethoxylated linear primary alcohol there is added with stirring the dye, the dipentene and the ortho-phenyl phenol. The mixture is then added to the first mixing vessel followed by the guar gum and the sodium chloride. The mixture is cooled to 57°C and poured into molds. After cooling to 5°C, the blocks are removed from the mold. EXAMPLE III Following the procedure of Example II, a shaped lavatory cake composition is prepared with the following ingredients: Polyethylene glycol 6000 distearate 9.0% Glyceryl monostearate 5.5% Ethoxylated C₁₂-C₁₅ Linear, Primary Alcohol with 7EO 20.0% Ethoxylated Ceto Stearyl Alcohol with 50 EO 17.5% Acid Blue No.9 dye 5.5% Terpinolene 8.0% Ortho-phenyl phenol 1.0% Guar gum 9.5% Sodium chloride 24.0% EXAMPLE IV Following the procedure of Example II, a shaped cake composition is prepared with the following ingredients: Polyethylene glycol 6000 distearate 20.0% Glyceryl monostearate - acid stable 10.0% Ethoxylated aliphatic alcohol (Neodol 45-7) 20.0% Guar gum 9.0% Sodium chloride 26.0% Polypropylene glycol (PPGD1000) 5.0% Cetyl trimethyl ammonium bromide 1.0% Acid Blue No. 9 dye 4.0% Terpinolene 5.0% The composition had a melt viscosity of 2000 cps (2 Pa.s) at 49°C and a set point at 46°C. The shaped tablet had an in-tank life of more than 30 days and showed only slight mounding. EXAMPLE V Following the procedure of Example II, a shaped cake composition is prepared with the following ingredients: Polyethylene glycol 6000 distearate 20.0% Glyceryl monostearate - acid stable 10.0% Ethoxylated aliphatic alcohol (Neodol 45-7) 21.0% Guar gum 6.0% Sodium chloride 26.0% Polypropylene glycol (PPGD1000) 6.0% Cetyl trimethyl ammonium bromide 1.0% Acid Blue No. 9 dye 4.0% Terpinolene 6.0% The composition had a melt viscosity of 1120 cps (1.2 Pa.s) at 51°C and a set point at 46°C. The shaped tablet had an in-tank life of 20-40 days in 6 different toilets and mounded out after 30 days. EXAMPLE VI Following the procedure of Example II, a shaped cake composition is prepared with the following ingredients: Polyethylene glycol 6000 distearate 16.5% Glyceryl monostearate - acid stable 5.5% Ethoxylated aliphatic alcohol (Neodol 45-7) 25.0% Guar gum 6.0% Sodium chloride 32.0% Polypropylene glycol (PPGD1000) 5.0% Cetyl trimethyl ammonium bromide 1.0% Acid Blue No. 9 dye 4.0% Terpinolene 5.0% The shaped composition had an in-tank life of about 30 days and showed only slight flattening. EXAMPLE VII Following the procedure of Example II, a shaped cake composition is prepared with the following ingredients: Polyethylene glycol 6000 distearate 12.5% Glyceryl monostearate - acid stable 5.5% Ethoxylated aliphatic alcohol (Neodol 45-7) 23.0% Ethoxylated nonylphenol (NP100) 4.0% Guar gum 8.0% Sodium chloride 32.0% Polypropylene glycol (PPGD1000) 5.0% Cetyl trimethyl ammonium bromide 1.0% Acid Blue No. 9 dye 4.0% Terpinolene 5.0% The shaped composition had an in-tank life of about 25-30 days in 6 different toilets and showed only slight mounding. EXAMPLE VIII Following the procedure of Example II, a shaped cake composition is prepared with the following ingredients: Polyethylene glycol 6000 distearate 16.5% Glyceryl monostearate 5.5% Ethoxylated aliphatic alcohol (Neodol 45-7) 23.0% Calcium sulfate 32.0% Guar gum 8.0% Polypropylene glycol (PPGD1000) 5.0% Cetyl trimethyl ammonium bromide 1.0% Acid Blue No. 9 dye 4.0% Terpinolene 5.0% The shaped tablet mounded out after 30 days in-tank. In lieu of guar gum, an equal amount of any one of the aforementioned natural gums may be utilized. EXAMPLE IX Following the procedure of Example II, a shaped cake composition is prepared with the following ingredients: Polyethylene glycol 6000 distearate 30.0% Glyceryl monostearate 20.0% Ethoxylated ceto stearyl alcohol with 50E0 20.0% Acid Blue No. 9 dye 4.0% Cetyl trimethyl ammonium bromide 1.0% Calcium sulfate 25.0% The resulting block had the following characteristics: Demolding Drop Out Block surface Dry Specific gravity 1.11 EXAMPLE X Following the procedure of Example II, a shaped cake composition is prepared with the following ingredients: Polyethylene glycol 6000 distearate 20.0% Glyceryl monostearate 15.0% Ethoxylated ceto stearyl alcohol with 50E0 20.0% Ethoxylated aliphatic alcohol (Neodol 25-7) 5.0% Acid Blue No. 9 dye 4.0% Cetyl trimethyl ammonium bromide 0.9% Polypropylene glycol 425 10.0% Calcium sulfate 20.1% Terpinolene 5.0% The resulting block had the following characteristics: Demolding Light Tap Block surface Dry In-tank life (days) 30 Mounding Slight Mounding EXAMPLE XI Following the procedure of Example II, a shaped cake composition is prepared with the following ingredients: Polyethylene glycol 6000 distearate 20.0% Glyceryl monostearate 10.0% Ethoxylated ceto stearyl alcohol with 50E0 20.0% Ethoxylated aliphatic alcohol (Neodol 25-7) 5.0% Acid Blue No. 9 dye 4.0% Cetyl trimethyl ammonium bromide 0.9% Polypropylene glycol 425 10.0% Calcium sulfate 25.1% Terpinolene 5.0% The resulting block had the following characteristics: Demolding Drop Out Block surface Dry Specific gravity 1.19 Mounding Slight Mounding EXAMPLE XII Following the procedure of Example II, a shaped cake composition is prepared with the following ingredients: Polyethylene glycol 6000 distearate 20.0% Glyceryl monostearate 12.0% Ethoxylated ceto stearyl alcohol with 50E0 20.0% Ethoxylated aliphatic alcohol (Neodol 25-7) 6.0% Acid Blue No. 9 dye 4.0% Cetyl trimethyl ammonium bromide 0.9% Polypropylene glycol 425 9.0% Calcium sulfate 23.1% Terpinolene 5.0% The resulting block had the following characteristics: Demolding Drop Out Block surface Dry Specific gravity 1.21 In-tank life (days) 27 Mounding None EXAMPLE XIII Following the procedure of Example II, a shaped cake composition is prepared with the following ingredients: Polyethylene glycol 6000 distearate 22.5% Glyceryl monostearate 10.0% Ethoxylated ceto stearyl alcohol with 50E0 17.5% Ethoxylated aliphatic alcohol (Neodol 25-7) 5.0% Acid Blue No. 9 dye 4.0% Cetyl trimethyl ammonium bromide 0.5% Polypropylene glycol 425 10.0% Calcium sulfate 25.5% Terpinolene 5.0% The resulting block had the following characteristics: Demolding Light Tap Block surface Dry Specific gravity 1.24 In-tank life (days) 8 toilets, 20-26 days Mounding None EXAMPLE XIV PROCEDURE FOR PRELIMINARY EVALUATION OF THE MOUNDING AND COUPLING PROPERTIES OF A TOILET BLOCK To determine the potential for a block to (1) mound or spread out from its original shape; and (2) remain an integrated unit once the block has been immersed in water, a test is conducted as follows: 1. Two 2000 ml glass beakers are filled with tap water. One is placed in a refrigerator at about 5°C for at least four hours while the other beaker remains at ambient temperature. 2. One block from the sample lot is placed in each beaker. The blocks remain immersed in water overnight or about sixteen hours. 3. The blocks are then observed after the immersion period. The ambient temperature sample provides an indication of the degree of spreading or enlarging of the block base that may occur during immersion within a toilet tank. The 5°C sample provides an indication of the integration of the block components or tendency to dissolve in unison.

Claims: A solid cake lavatory cleansing block composition comprising 8 to 35% by weight polyethylene glycol distearate having a molecular weight from 3,000 to 12,000 and a drop dissolution time (time for a fully solidified melt phase drop dispensed from a 7.5 ml pipette to completely dissolve in 75 ml deionised water at ambient temperature) of at least 5.5 hours, 20 to 64% by weight water-soluble salt filler, and 20 to 40% by weight non-ionic surfactant selected from the condensation products of a long chain ethylene oxide moiety with an aliphatic alcohol or an alkyl phenol. A cleansing block composition as claimed in Claim 1, containing 12 to 29% by weight of the polyethylene glycol distearate. A cleansing block composition as claimed in Claim 1 or Claim 2, wherein said polyethylene glycol distearate comprises a mixture of a major proportion of polyethylene glycol distearate having a molecular weight between 7,000 and 12,000 and a minor proportion of polyethylene glycol distearate having a molecular weight between 3,000 and 7,000. A cleansing block composition as claimed in any one of the preceding claims, wherein said non-ionic surfactant is selected from ethoxylated primary or secondary aliphatic (C₈-C₂₀) alcohols and ethoxylated C₆-C₁₂ alkyl phenols. A cleansing block composition as claimed in any one of the preceding claims, wherein said non-ionic surfactant is an ethoxylated primary or secondary (C₈-C₂₀) alcohol. A cleansing block composition as claimed in any one of the preceding claims, wherein the amount of said non-ionic surfactant is 20 to 30% by weight. A cleansing block composition as claimed in any one of the preceding claims, including a mixture of ethoxylated nonylphenols having more than 20 moles of ethylene oxide per mole of phenol. A cleansing block composition as claimed in Claim 7, wherein said ethoxylated nonylphenols are present in an amount up to 10% by weight. A cleansing block composition as claimed in any one of the preceding claims, wherein said water-soluble salt filler is an alkali metal or alkaline earth metal chloride or sulfate. A cleansing block composition as claimed in Claim 9, wherein said filler is sodium chloride or calcium sulphate. A cleansing block composition as claimed in any one of the preceding claims, including a gelling natural gum selected from xanthan, tragacanth, carrageenan, karaya, algin and when the composition does not contain sodium chloride, guar. A cleansing block composition as claimed in any one of the preceding claims, including a binding agent selected from glyceryl monostearate, glyceryl monopalmitate, ethylene glycol stearate, and propylene glycol monostearate. A cleansing block composition as claimed in any one of the preceding claims, including a cationic quaternary ammonium salt. A cleansing block composition as claimed in any one of the preceding claims, including a plasticizer selected from polypropylene glycol, dipentene, pine oil fractions, d-limonene and ethylene oxide-propylene oxide copolymers. A cleansing block composition as claimed in any one of the preceding claims, comprising and at least one of: (a) up to 35% by weight of a gelling natural gum, provided that the gum is not guar when the salt filler is sodium chloride; (b) up to 20% by weight of a solid emollient binding agent; (c) up to 10% by weight of an ethoxylated nonylphenol; (d) up to 15% by weight of a dye; (e) up to 15% by weight of a cationic quaternary ammonium salt; (f) up to 15% by weight of a perfume; and (g) up to 20% by weight of a plasticizer. A cleansing block composition as claimed in Claim 15, comprising: (a) from 12 to 29% by weight of said polyethylene glycol distearate; (b) 5 to 15% by weight of a gelling natural gum; (c) 5 to 12% by weight of a solid emollient binding agent; (d) 20 to 30% by weight of the non-ionic surfactant; (e) optionally, up to 10% by weight of an ethoxylated nonylphenol; (f) 20 to 35% by weight of a water-soluble salt filler; (g) 2.5 to 10% by weight of a dye; (h) optionally, up to 5% by weight of a cationic quaternary ammonium salt; (i) optionally, up to 10% by weight of a perfume; and (j) 4 to 15% by weight of a plasticizer. A cleansing block composition as claimed in Claim 1 comprising 20 to 30% by weight of ethoxylated aliphatic (C₈-C₂₀) alcohol; up to 32% by weight of sodium chloride; and/or up to 32% by weight of calcium sulfate; and from 4% to 15% by weight of plasticizer; and at least one of: (i) up to 10% by weight of glyceryl monostearate; (ii) up to 10% by weight of ethoxylated nonylphenol; (iii) up to 35% by weight of guar gum except when the composition comprises sodium chloride; and (iv) up to 15% by weight of disinfecting agent, coloring and/or fragrance.

Inventors: BUNCZK CHARLES J, BURKE PETER A, STRAUCH EDWARD R, BUNCZK, CHARLES J., BURKE, PETER A., STRAUCH, EDWARD R.
Applicants: KIWI BRANDS INC
Application year: 1987
Main classification: C11D17
IPC codes: C11D3, C11D1, C11D17