VISCOSITY-MODIFIERS FOR AQUEOUS-BASED FUNCTIONAL PRODUCTS

Abstract: Aqueous-based functional products such as household or commercial cleansers, household products, commercial products, and personal care products are thickened or viscosity-modified by the addition of at least one crystalline mixed metal hydroxide of the formula LimDdT(OH)(m+2d+3+n.a)Aa<n>.xH2O, where m is zero to one, D is a divalent metal, d is from zero to 4, T is a trivalent metal, A is at least one anion or negative-valence radical of valence n, where n is 1 or more, (m+2d+3+n.a) is equal to or greater than 3, (m+d) is greater than zero, and xH2O is waters of hydration.

Description: VISCOSITY-MODIFIERS FOR AQUEOUS-BASED FUNCTIONAL PRODUCTS The invention relates to thickeners or viscosity-modifiers for aqueous-based functional commercial or household products, such as cleansers, or personal care products. Thickeners or other viscosity-modifiers are often used in aqueous-based functional, commercial or household products, such as cleansers, disinfectants, bleaches, and the like and in personal care products, such as soaps, lotions, face creams, hand creams, toothpaste, and the like. Thickeners that have been used in these applications include natural and synthetic water-sensitive organic polymers, or other water-sensitive organic substances. Also, inorganic substances, such as natural clays, refined clays, synthetic clay-like materials, silicates, and aluminates have been used. As used herein, a "functional" product is one which is applied to, or mixed with, or added to a substance which is desirably and beneficially affected by the thickener, such as cleaning solutions, bleaches, lotions, creams, corrosive fluids, oxidizing agents, reducing agents, alkali solutions, amine solutions, phenolic solutions, and chemical solutions not lower than about pH 4.5 preferably not lower than about pH 5. s - Natural clays and refined natural clays may vary from one mining location to another and the performance attained with one batch may not exactly match the performance of another batch. For example, the colors of different batches may not match or, when 10 employed as an additive to a product, the effect of each batch on viscosity of the product may not be identical. The natural clays, and even refined natural clays, may contain impurities which can produce such non-uniformities among batches and may create side- 15 reactions with other ingredients in a formulation to which the clay is added. Clays are normally anionic and can react with ingredients which are cationic, such as cationic surfactants used in hair conditioners or in 20 cleansers and the like. Polymers or other organic thickeners are often subject to microbial attack and may lose their effectiveness if not protected with a preservative. 2 c Polymerlcs often have a gooey, tacky, and/or slippery feel on the skin which is unpleasant. Some polymers do not typically have a true yield point which is required to indefinitely suspend solids. Many of the polymeric thickeners also contain functional groups which are 30 adversely attacked by the chemicals in bleaches or other formulations, and this can cause a loss or diminishment of either the desired viscosity control or the effectiveness of the chemical. 35 The invention is certain mixed metal hydroxides, which are of layered crystalline structures exhibiting cationic surface charges, that are beneficially employed as thickeners or viscosity- modifiers in various aqueous-based functional products such as various formulations used in cleansers, household products, commercial products, and personal care products. For purposes of conciseness, the expression "MMOH" will be used in this disclosure to refer to the mixed metal hydroxides which are described in detail below. The inorganic MMOH compounds are resistant to microbial attack, are cationic (which prevents interaction with cationic ingredients used in many of the formulations), and, since they are synthetic, can be made substantially of consistent quality and purity. The crystalline mixed metal hydroxides (MMOH) used in the present invention conform substantially to the empirical formula Li m D T(0H)(m + 2d + 3 + n-a)A a n -xH2θ where m is zero to one, where D represents at least one divalent metal cation and d is zero to , where T represents at least one trivalent metal cation, where A represents at least one monovalent or polyvalent anion or negative-valence radical, a is an amount of A ions of valence n, with n«a being an amount of zero to -3, where (m+2d+3+n-a) is equal to or greater than 3, where m+d is greater than zero, and where xH2θ represents excess waters of hydration, with x being zero or more. (By "excess waters of hydration" it is meant that there is more water associated with the compound than is needed to supply the amount of hydroxyl ions required in the crystal formula.) In the above formula, it should be noted that n, being the valence of the anion, is a negative number; thus n-a is a negative number. In one aspect, the present invention is a 10 formulation of the type described having incorporated therein the MMOH compounds, as a means for providing viscosity-modifiers or thickeners to the described formulations. - t - A further aspect is that MMOH compounds provide a thickened product which thins readily under even very slight shear, but which rethickens rapidly when the shear is stopped. The gelation rate is observed as being immediate. 0 The MMOH compounds useful in the present invention are preferably those of the monodispersed, monolayer variety such as described in U.S. Patent 4,664,843, but can also be of the varieties disclosed 25 in U.S. Patents 4,477,367; 4,446,201; 4,392,979; and 4,461,714. The MMOH compounds may be prepared by forming a solution of compounds of the subject metals under certain conditions whereby a soluble alkaline material, e.g. ammonia or caustic, reacts with the 30 soluble metal compounds to produce the layered crystals of mixed metal hydroxides. In the present invention, it is preferred to avoid having ammonia in the product, in which case another alkaline material, especially 35 NaOH or KOH is used. The MMOH may be used as a slurry of varied solids content, or dry. The process of using MMOH compounds to thicken aqueous-based functional products can be achieved in at least two general ways. One method, in general, involves the activation of the MMOH particles by an electrolyte. In this process, the MMOH is first dispersed by using high shear, sonic waves or other methods known in the art to produce a high degree of dispersion of agglomerated particles. Once the material is dispersed in aqueous or partially aqueous media, a salt (electrolyte) is added either predissolved or dry and mixing/or shearing is continued until a smooth, thickened system is obtained. Other ingredients may be blended into the prethickened material. Often, one or more of the ingredients is a salt and a separate activator is not needed. The salt used for activation can be almost any ionic substance but components containing organic anions or multivalent anions such as CO3-2, PO -3, P3θιo~5 and the like are usually more effective. The other general method involves interaction with other colloidal particles in such a manner that they are linked together through bridges or bonds formed by the MMOH. In these cases, it can be interpreted as forming an adduct with the other particles. This can produce an "extension" effect, for example, when fumed silica or a clay is also an ingredient with the result that less material is needed for thickening. This can also occur when a normally soluble material is included in the formulation beyond the point of saturation such that very small or colloidal particles are present as crystals or agglomerates. In this case, the thickening occurs when the MMOH and other particles are sheared together a.id agglomerates are broken, exposing fresh faces which react. "Thickener", when used in reference to the c effect of the MMOH additives, means that the apparent viscosity at ambient conditions and at little or no applied shear has been increased by the addition of the MMOH. The expression "viscosity-modifier" is used herein to refer to the effect attained by the addition 10 of the MMOH whether the effect on viscosity is evident at ambient or at non-ambient conditions and whether the effect is a thickening effect apparent under no-stress or under shear conditions. For example, changing of a Newtonian liquid to a non-Newtonian liquid, or vice- 15 versa, is one form of a viscosity modification. Changing the degree or extent of thixotropicity or dilatancy of a liquid is a form of viscosity modification. 0 The expression "mixed metal hydroxide" implies that there are at least two different metals in the hydrous oxide crystals. In the present invention, it is preferred that at least one of the metals is a 2c trivalent metal, along with at least one other metal which can be either, or both, divalent or monovalent (Li). The amount of the A anion (or negative-valence radical) present is that which substantially satisfies the valence requirements of the cations in the 30 crystalline material. In the above described formula, the trivalent metal cation is preferably Al, Fe, or Ga, and can be mixtures of any of these; Al is most preferred as the 35 trivalent metal. The divalent metal cation is preferably Mg, Ca, Mn, Fe, Co, Ni, Cu, or Zn and can be mixtures of any of these. Ca or Mg, especially Mg, is most preferred as the divalent metal. The anion, A, can be monovalent, divalent, trivalent, or polyvalent, and is preferably hydroxyl, halide, sulfate, nitrate, phosphate, carbonate, glycolate, lignosulfate, and polycarboxylic or 0 negative-valence radicals. Thus, the A anion can be inorganic or a hydrophilic organic group. Preferably the A anion is inorganic. The formulations that can be thickened or 5 modified by the addition of MMOH compounds can be varied widely. Generally, the ingredients and amounts thereof in a given formulation are chosen for a desired effect other than that of thickening or viscosity- modification. The MMOH compounds are particularly 0 beneficial in that they can be added to so many formulations for viscosity purposes without interfering with the other ingredients. Substitutions, replacements, and/or eliminations of one or more of the r components (other than the MMOH compound) usually has little effect on thickening or viscosity-modification. The amount of the MMOH added to the aqueous- based functional product formulation, cleanser, 0 household product, commercial product, or personal care product and the like will usually be 0.03 percent to 10 percent or more depending somewhat on the temperature, the product into which it is added, which of the MMOH varieties is being used, and the extent of thickening or viscosity-modification desired. Preferably, 0.5 percent to 5 percent, and most preferably, 1 percent to 2 percent may be used. Generally, one would not expect amounts of MMOH of much less than 0.03 percent to give a desired effect on thickening or viscosity- modification. Thus, an overall ' concentration range for the MMOH of 0.03 percent to 10 percent is anticipated as being sufficient for most applications. The functional products into which the MMOH compounds are incorporated are, for the most part, aqueous base to provide fluidity to the formulation. It will be understood, of course, that some products, such as facial cleansing creams, also involve hydrocarbons or other organic compounds emulsified in water, or water emulsified in an organic compound, as a part of the formulation. Among the cleansers, household products, and personal care products contemplated for use with the MMOH compounds of the present invention are liquid soaps, bar soaps, shampoos, dishwashing detergents, laundry detergents, bleaches, stain removers, tile cleaners, porcelain cleaners, masonry cleaners, floor cleaners, carpet cleansers, toothpaste, denture cleansers, lotions, face creams, grime removers, grease removers, disinfectants, mildew removers, toilet bowl cleansers, grease removers for cook-stoves, mechanic's grease remover, and the like. The MMOH compounds can be used with highly corrosive fluids which are alkaline or have a pH above about 4.5. The MMOH compounds may in some instances, stabilize emulsions, cause gelling of a formulation and/or suspend particles in a fluid formulation. In many cleansers or other products that are applied to vertical or inclined surfaces the composition of the invention will prevent, or at least retard, the product from flowing too rapidly off the surface to which it is applied. Thus, the composition of the invention is useful, for example, when a disinfectant, mildewcide, fungicide, bleach, grime-remover, or the like is sprayed on the walls of a shower bath stall, or sprayed under the inside edge of a toilet bowl, or when a grease-remover is sprayed onto a piece of machinery, or when a mildewcide is sprayed on the wall of a building. 10 The thickener or viscosity-modifier effect of the present invention causes the product to remain in place long enough to do a more thorough job of alleviating the problem for which it was applied. The thickened -j- product can be easily washed off or hosed off with water after it has been allowed to stand for the desired period of time. The thickening effect can normally be "diluted out" using copious amounts of water. 0 In the following examples "MAH" refers to certain compounds within the generic formula shown above that conform substantially to the formula MgAl(OH)5_yClyxH2θ. Those compounds wherein y is zero 5 to one are prepared from an aqueous solution of MgCl2 and AICI3 as taught, for example, in U.S. Patent 4,664,843. The amount y of Cl~ anion present is a small residual from the starting materials. 0 The following examples illustrate applications of the MMOH in various kinds of products. However, the invention is not limited to only the ones illustrated. Example 1 5 A "dry touch" lotion is prepared by admixing the following: O 89/08693 -10- Part A 0.5 parts MAH (dry basis) 85.5 parts water Part B 0.1 parts triethanolamine 3.5 parts glycerine Part C 3.6 parts white mineral oil 1.6 parts stearic acid 0.8 parts cetyl alcohol 1.4 parts glycerol monostearate 2.0 parts lanolin The above totals about 99 parts by weight. Mix A until smooth, add B to A and heat to 70 to 75°C with gentle stirring. Heat C to 75 to 80°C and add C to A/B and mix while cooling. The elevated temperature aids in the blending operation. An emulsion is formed which is thickened and stabilized by the MAH as observed for several weeks. The so-formed lotion is thixotropic, applies smoothly, and has no greasy feel. Variations in the above formulation can be made and still obtain the beneficial effect of the MAH. Example 2 A mineral oil emulsion is prepared as follows, all amounts being parts by weight: Admix 4.5 parts of flash-dried MAH into 50 parts of water, add 41 parts mineral oil and 3 parts of oleic acid, and stir to produce a thin oil in water emulsion. Add 1 part of a2Cθ3. The product is a thick, stable, creamy emulsion. Exampl e 3 An antiperspirant is prepared by admixing the following, all amounts being parts by weight. Part A 1.0 parts of MAH 51.0 parts of water 0.25 parts of NaCl salt* Part B 8.0 parts glycerol monostearate Part C 40.0 parts aluminum chlorohydrate (50 percent aqueous solution) Mix MAH, salt, and water until smooth. Heat A to 70°C, and heat B to 75°C. Add B To A and mix while cooling to 50°C. Heat C to 50°C and add C to A/B and mix until cool. A slightly thickened, thixotropic lotion-like stable mixture is obtained which flows easily under shear, such as by rolling or smearing onto the skin. *The salt can also be KC1, Na2S04, MgCl2, or AICI3; but Na2C03, Na2HP0 , and NaH2P04 should not be used as these can cause flocculation when aluminum chlorohydrate is in the formulation. Example 4 An after-shave lotion is prepared as follows, all amounts being parts by weight. Mix 2.04 parts of dry MAH, 18 parts of ethanol, and 20 parts of deionized water in a sonic blender and add 0.07 parts of Na2C03« Then the mixture is mixed in a high-shear mixer and a thick, shear-thinning (thixotropic), creamy lotion is produced. Viscosity, O 89/08693 - 12- measured at various RPM's on a Brookfield viscometer, is as follows: RPM 50 1.0 0.5 Viscosity 392 7,600 20,000 centipoise Example 5 A liquid automatic dishwater detergent that dispenses from a container well and substantially remains in the closed cup of a domestic dishwasher is made from the following formulas: *(the surfactant is disodium 4-decylated oxydibenzenesulfonate.) The difference between Formulas A and B is that in A the MAH comprises 1.25 percent, whereas B contains 1.5 percent MAH. This gives a comparison between two different concentrations of the MAH. The blending of ingredients is done in an apparatus capable of high shear in viscous blends and has variable speeds, such as a blender manufactured by Waring or Cowles companies. The MAH slurry and the water are mixed at moderate shear until smooth and uniform. The Na2Cθ3 is added while stirring. An immediate thickening is observed. Stirring is continued at moderate to high speed until substantially all the a2Cθ3 is dissolved and the thickened slurry is again smooth and uniform. The NaOH is stirred in until dissolved and some thinning is observed. The sodium silicate is added with stirring and more thinning is observed. Stirring is continued until all thickened portions are evenly distributed throughout the system. The bleach is added with stirring and the Na5P3θio (TPP) is added in two portions (200 gm, then 100 gm) taking care to keep the exotherm under control by using a cool bath. The mixture is stirred at high shear until smooth, taking adequate time to assure good distribution of undissolved TPP which is present in an amount greater than saturation. This brings the viscosity to near the final point. The stirring is reduced to a level at which there is no vortex and the surfactant is added while stirring slowly (to avoid foaming and entrainment of air) until all the surfactant has been added and well distributed. Tests are made of (1) container dispensability (ease of getting the product out of a bottle) and (2) hot dishwasher closed cup retention. The following data illustrate the findings: - 14- (1) (2) Formula A 5.18 63.5 Formula B 5.38 86.7 ' (1) weight percent remaining in dispensing bottle (795 cc bottle with 6.35 mm orifice); reproducibility approximately ±10 percent. (2) weight percent retained in detergent cup of Kenmore Model 587.1744580 at 118 to 122°F (47.8 to 50°C) ; 0 reproducibility approximately ±10 percent. The dispensing bottle test is done at about ambient temperature. The dishwasher closed cup test is measured before the controls automatically dump the cup into the wash water. The tests indicate the ease with which the liquid dishwasher detergent can be dispensed from a bottle, yet can effectively remain in the closed dishwasher cup until it is ready to be dumped into the water. By having a liquid detergent which can be thickened enough to remain in the closed cup (which is normally designed to hold powders, thus is not water¬ tight), yet which will flow out effectively when the 5 cup is opened during the washing cycles, one may avoid having to use powders. The thickened detergent can, of course, also be used in the initial open cup cycle of the dishwasher. 0 Furthermore, such thickened or gelled liquid detergents can also be used where one wishes to coat a heavily soiled vessel or article (such as a skillet or pan with scorched food in it) with a detergent which c does not evaporate very quickly. The thickened detergent can be used to put a thick layer of the detergent on a soiled surface. Example 6 A consumer product sold for use as a cleanser solution, known as TOUGH ACT* (*trademark of DowBrands Inc.), is thickened in accordance with the following recipe: Ingredient Grams Approx % of Total MAH slurry (12 MAH cone.) 185 20.9 Na2Cθ3 6 0.7 TOUGH ACT solution 693 78.4 Totals: 884 100 (In the above recipe, the MAH comprises about 2.5 percent of the total) The Na2Cθ3 is added to the MAH slurry and stirred using a Cowles blender until well mixed (about 5 minutes). The TOUGH ACT solution is added and the mixture is stirred at high speed (but not so fast as to mix in much air and create much foam) until the mixture is smooth (about 5 more minutes). The following rheological data are obtained using a Brookfield Model RV* viscosimeter (*a trademark) : RPM: 0.5 1.0 2.5 5.0 10 20 50 100 Vise.** 11.4 6.7 5.0 5.2 5.0 3.0 1.4 0.76 (**viscosity, cps X1000) The data show that a small percent of the MAH thickens the cleaning solution, but it thins easily when sheared. Thus the thickened cleaning solution can be applied to a vertical surface where it does not run off rapidly, or it can be applied as a thick coat on a horizontal surface where it does not rapidly evaporate to dryness. This gives the cleaning solution an extended period of contact with the surface, a feature which is helpful if "soaking" of the grime is wanted. Example 7 Commercially available Kandu* laundry bleach (*a trademark) is thickened in accordance with the following recipe: Ingredient Grams Approx. % of Total MAH slurry (12% MAH cone.) 418 20.9 N Cθ3 90 4.5 Bleach (5.25% NaOCl) 1229 61.45 Water 263 13.15 Totals: 2000 100 In the above recipe, the MAH comprises about 2.5 percent of the total and the NaOCl comprises about 3.23 percent of the total. The MAH, a2C03 and water are mixed until the Na2Cθ3 is dissolved and a smooth paste is obtained. The thickened paste is allowed to set for several minutes and the NaOCl solution is added slowly with blending until the mixture is smooth. The following rheological data are obtained using a Brookfield Model RV viscosimeter: RPM: 0.5 1.0 2.5 5.0 10 20 . 50 . 100 Vise.** 26.7 19.7 12.5 7.1 3.9 2.2 1.0 0.5 (**viscosity, cps X1000) The data show that a small percent of the MAH thickens the bleach solution, but it thins easily when shear. The thickened bleach solution can be applied to a vertical surface where it quickly re-gels and does not run off rapidly, or as a thick coat on a horizontal surface where it does not rapidly evaporate to dryness. This gives the bleach solution an extended period of contact with the surface, a feature which is helpful when longer periods are needed, such as when killing mildew or fungus in a shower bath or on a wall, and the like. Example 8 A small amount of MgAl(0H)5, when added to Easy Off* oven cleaner (*a trademark) thickens it sufficiently such that the cleaner remains on a vertical surface for an extended period of time. Example 9 A small amount (about 2 percent by weight) of MgAl(0H)5, when added to TOUGH ACT cleaning solution in a bottle equipped with a hand (or finger) pump for spraying the cleaning solution, thickens the solution sufficiently that it remains in place on a vertical surface when sprayed from the bottle by using the pump, yet the shear acting on the thickened solution by the action of the pump is sufficient to thin it so that it is easily sprayed from the bottle. Example 10 A small amount of MAH (e.g. about 1 to 3 percent by weight), when added to an AFFF* foam preparation (*a tradename of 3M Corporation) used as a foam for fighting fires, has very good stabilizing effect on the foam. The foam lasts longer and clings to vertical surfaces better. Even if the AFFF* foam preparation Is made using sea water instead of plain water, the MAH is effective in its improvement of the foam. Example 11 In similar manner to the above laundry bleach example, thickened bleaches are prepared by using more MAH. Furthermore, other oxidizing or reducing agents are similarly thickened, such as KMnθ4, NaClθ3, or Na2S03 and the like, using MAH or other MMOH compounds

Claims: 1. A method for providing thickening or modifying the viscosity of an aqueous-based functional product formulation, comprising adding to said formulation an effective amount of a mixed metal hydroxide, said mixed metal hydroxide being at least one compound of the formula LimDciT(OH)(m+2d+3+n-a)A a n -xH2θ wherein m is zero to one, D is at least one divalent metal cation and d is zero to 4, T is at least one trivalent metal cation, A is at least one monovalent or polyvalent anion or negative-valence radical, a is the number of A ions of valence n, with n-a being zero to -3, (m+2d+3+n.a) is equal to or greater than 3» (m+d) is greater than zero, and xH2θ is waters of hydration, with x being zero or more. 2. The method of Claim 1 wherein said functional formulation is a household or commercial cleanser, bleach, personal care product, corrosive product, disinfectant, fungicide, mildewicide, oxidizing agent, reducing agent, dishwasher detergent, or stain remover. 3. The method of Claim 1 wherein the D metal is at least one of Mg, Ca, Mn, Fe, Co, Ni, Cu, or Zn. 4. The method of Claim 1 wherein the T metal is at least one of Al, Fe, or Ga. 5. The method of Claim 1 wherein the A anion is at least one of hydroxyl, halide, sulfate, nitrate, phosphate, carbonate, glycolate, lignosulfate, or polycarboxylic radicals. 6. The method of Claim 1, wherein the mixed metal hydroxide is MgAl(OH)(5 + n-a)Aa n- xH2θ) , where n-a is zero to one, and A is an anion other than OH-. 7. The method of Claim 1 wherein the mixed metal hydroxide is of crystalline, monodispersed and monolayer variety. 8. An aqueous-based product formulation characterized by a thickener or viscosity-modifier that is an effective amount of at least one crystalline mixed metal hydroxide compound of the formula Li m DdT(0H)(m + 2d + 3 + n.a)A a n -xH2θ where m is zero to one, D is a divalent metal and d is zero to 4, T is at least one trivalent metal, A is at least one monovalent or polyvalent anion or negative-valence radical, a is an amount of A ions of valence n, with n-a being zero to -3, (m+2d+3+n-a) is equal to or greater than 3, (m+d) is greater than zero, and xH2θ represents waters of hydration, with x being zero or more. 9. The composition of Claim 8 wherein the aqueous-based formulation is a household or commercial cleanser, bleach, personal care product, disinfectant, fungicide, mildewcide, oxidizing agent, reducing agent, dishwasher detergent, or stain remover. 10. The product of Claim 8 wherein the mixed metal hydroxide compound conforms essentially to the formula MgAl(OH)(5_ n .a)Aa n -xH2θ where A is chloride and na is zero to one and x is zero or more.

Inventors: BURBA JOHN L, CRABB CLARENCE R, DOTY PETER A, READ ARTHUR E JR, BURBA, JOHN, L., CRABB, CLARENCE, R., DOTY, PETER, A., READ, ARTHUR, E., JR.
Applicants: DOW CHEMICAL CO, THE DOW CHEMICAL COMPANY
Application year: 1989
Main classification: C11D3
IPC codes: A01N25, A01N59, A61K8, A61Q15, A61Q19, C09K3, C11D3, C11D17