Polymers and detergent compositions containing them

Abstract: Certain polymeric polycarboxylic acids and salts containing hydroxyl or hydroxymethyl groups in close proximity to carboxyl groups, especially poly(2-hydroxymethylacrylic) acid and its salts, are effective sequestrants of divalent and polyvalent metal ions and are useful as builders in detergent compositions.

Description: TECHNICAL FIELD The present invention relates to polymeric polycarboxylic acids and salts, and their use as metal ion sequestrants and as builders in detergent compositions. BACKGROUND AND PRIOR ART Polycarboxylate polymers are well-known ingredients of detergent compositions and provide various benefits. They are used, for example, as antiredeposition and antiincrustation agents, and for supplementary detergency building, especially in conjunction with water-insoluble aluminosilicate builders. Acrylic and maleic polymers have been especially widely used. For example, GB 1 596 756 (Procter & Gamble) is concerned with maleic polymers, especially methyl vinyl ether/maleic anhydride copolymers, and their use as auxiliary detergent builders in phosphate-built compositions. GB 1 460 893 (Unilever) discloses the use of polyacrylates as antiincrustation agents in detergent compositions containing ortho- and pyrophosphate builders. EP 25 551B (BASF) discloses the use of acrylic/maleic copolymers as antiincrustation agents. EP 124 913B (Procter & Gamble) discloses detergent compositions containing a combination of polyacrylate and acrylic/maleic copolymer. Although various polymers have been disclosed in the literature, only polyacrylates and acrylate/maleate copolymers have found widespread use in commercial detergent products. The present invention is based on the observation that certain carbon backbone polycarboxylate polymers having hydroxyl and or hydroxymethyl groups in close proximity to the carboxyl groups exhibit efficient improved detergency building (calcium binding). GB 1 328 749 (Solvay) discloses the use as metal ion sequestrants of water-soluble salts of poly (alpha-hydroxyacrylic acid) of the formula : wherein the R groups are hydrogen atoms or C 1 -C 3 alkyl groups, and M is an alkali metal or ammonium cation. The salts may be used as replacements for sodium tripolyphosphate as builders in detergent compositions. 2-(1-hydroxymethyl)acrylate monomer of the formula Ia : wherein R is a lower alkyl group, is disclosed in EP 184 731A (BASF), and the polymerisation of methyl ester derivatives has been reported by L J Mathias, S J Kusefoglu and A O Kress, Macromolecules 1987 20 2326. Polymers in free acid or salt form, that is to say, containing units of the formula Ib : wherein M represents a hydrogen atom or a solubilising cation, are not disclosed. US 3 743 669 (Hillman & Co/Celanese Corp) discloses the preparation of 2-(1-hydroxymethyl)acrylic esters and their polymerisation to produce adhesives. US 3 066 165 (Rosenthal et al/Koppers Co Inc) discloses the preparation of alkyl α-(hydroxymethyl) acrylates, and their use as copolymers in latices. AU 450 758A (Degussa) discloses acrylic copolymers which are used as complex forming substances. These polymers contain units of acrylic acid (or homologues) plus units of non-carboxylic monomers containing hydroxyl groups. If prepared by a particular process, not preferred, the polymers may optionally contain small numbers of units derived from 2-hydroxymethyl acrylic acid. DEFINITION OF THE INVENTION In its first aspect, the present invention provides a polymeric polycarboxylic acid or salt suitable for use as a binder of divalent or polyvalent metal ions, consisting of units of the formula I and, optionally, units of the formula II and/or units of the formula III wherein each of the R groups, which may be the same or different, represents a hydrogen atom, a methyl group or an ethyl group; and M represents a hydrogen atom or a solubilising cation; the polymer having a number average molecular weight within the range of from 1000 to 100 000 and a weight average molecular weight within the range of from 1000 to 1 000 000. The R groups preferably represent hydrogen atoms, and M preferably represents an alkali metal or ammonium ion, more preferably a sodium ion. In its second aspect, the present invention provides the use of the polymers defined above to bind divalent and polyvalent metals, especially calcium; more especially, their use as builders in detergent compositions. In its third aspect, the present invention provides a detergent composition comprising at least one detergent-active compound, suitably in an amount of from 0.5 to 60 wt%, and at least one detergency builder, suitably in an amount of from 15 to 80 wt%, the detergency builder consisting wholly or partially of a polymer as defined above. DETAILED DESCRIPTION OF THE INVENTION The polymers The polymers of the invention are characterised by containing monomer units (formula I) derived from 2-(1-hydroxymethyl)acrylic acid or homologues thereof in acid or salt form. The polymers therefore have a main chain or backbone of carbon atoms and a plurality of carboxyl groups bonded to the main chain, wherein there are also present hydroxymethyl groups separated from at least some of the carboxyl groups by not more than one carbon atom; that is to say, hydroxymethyl groups are present in the α-position to at least some of the carboxyl groups. The polymers of the invention may also contain other monomer units containing further carboxyl groups, which contribute to calcium binding. These units are derived from itaconic acid (formula II) or α-hydroxy acrylic acid (formula III), or homologues thereof, in acid or salt form. Molecular weights The molecular weights of the polymers may vary over a wide range. The number-average molecular weight is from 1000 to 100 000, and preferably from 3 000 to 40 000. The weight-average molecular weight is from 1000 to 1 000 000, and preferably from 5 000 to 800 000. Preferred polymers A first preferred class of polymers according to the invention consist of units of the formula I derived from 2-(1-hydroxymethyl)acrylic acid, or a salt thereof. Polymers within this class include the following: poly(2-hydroxymethylacrylic) acid and salts thereof (units of the formula I only); copolymers of 2-(1-hydroxymethyl)acrylic acid and itaconic acid, and salts thereof (units of the formula I and units of the formula II); copolymers of 2-(1-hydroxymethyl)acrylic acid and α-hydroxyacrylic acid, and salts thereof (units of the formula I and units of the formula III). Preparation of the polymers The polymers of the invention may be prepared by conventional radical bulk or solution (aqueous or organic) polymerisation techniques. Homopolymers and copolymers of 2-(1-hydroxymethyl)acrylic acid may be prepared by polymerising or copolymerising a lower alkyl 2-(1-hydroxymethyl)acrylate ester, then hydrolysing the resulting polymer. As mentioned previously, the ester monomer and its preparation are disclosed in EP-A-184 731 (BASF), and polymerisation of the methyl ester is described by L J Mathias, S J Kusefoglu and A O Kress, Macromolecules 1987 20 2326. An alternative method of introducing hydroxymethyl groups into the polymer chain is by means of allyl acetate: the acetate groups in the resulting polymer may be hydrolysed to give hydroxymethyl groups. To introduce further hydroxyl groups into the main chain, halogenated precursors such as α-chloroacrylic acid, bromo- or chloromaleic anhydride and dichloromaleic anhydride, or esterified precursors such as vinyl acetate, may be used. After appropriate homo- or copolymerisation, the resulting halogenated or esterified materials may be hydrolysed to give the hydroxylated polymers. Polymerisations will generally be carried out in the presence of a radical initiator, for example, sodium or potassium persulphate, 2,2-azobis(amidinopropane) hydrochloride, dibenzoyl peroxide (Lucidol), cyclohexanone peroxide, di-tert-butyl peroxide, 2,2-azobis-isobutyronitrile (AIBN), cyclohexylsulphonyl peroxide (Percadox ACS), diisopropylperdicarbonate (Percadox JPP), and cumene hydroperoxide. Preferred initiators are sodium or potassium persulphate, and 2,2-azobis(amidinopropane) hydrochloride. The initiator is preferably added gradually to the reaction mixture. The preferred polymerisation temperature range is between 40 and 120°C. If higher molecular weight branched materials are desired, there may be included in the monomer mixture a small amount of a branching agent, for example, butanedioldiacrylate, divinyl benzene, glycoldivinyl ether, adipic acid divinyl ether, bisphenol A dimethacrylate, divinyl 2,4,8,10-tetraoxospiro [5.5] undecane, pentaerythritol triacrylate, acrylamidomethyl dextrin (DP6 3108 ex Allied Colloids), divinyl ether, or vinyl allyl ether. Detergent compositions The novel detergency builders of the present invention may be incorporated in detergent compositions of all physical types, for example, powders, liquids, gels, and solid bars. They may if desired be used in conjunction with other detergency builders. The total amount of detergency builder in the compositions will suitably range from 15 to 80 wt%, and this may be constituted wholly or partially by the polymeric materials of the invention. Inorganic builders that may be present include sodium carbonate, if desired in combination with a crystallisation seed for calcium carbonate, as disclosed in GB 1 437 950 (Unilever); crystalline and amorphous aluminosilicates, for example, zeolites as disclosed in GB 1 473 201 (Henkel), amorphous aluminosilicates as disclosed in GB 1 473 202 (Henkel) and mixed crystalline/amorphous aluminosilicates as disclosed in GB 1 470 250 (Henkel); and layered silicates as disclosed in EP 164 514B (Hoechst). Inorganic phosphate builders, for example, sodium orthophosphate, pyrophosphate and tripolyphosphate, may also be present, but the invention is of particular applicability to compositions containing reduced or zero levels of inorganic phosphate. Organic builders that may be present include other polycarboxylate polymers such as polyacrylates, acrylic/maleic copolymers, and acrylic phosphinates; monomeric polycarboxylates such as citrates, gluconates, oxydisuccinates, tartrate monosuccinates and disuccinates, glycerol mono-, di- and trisuccinates, carboxymethyloxysuccinates, carboxymethyloxymalonates, dipicolinates, hydroxyethyliminodiacetates, nitrilotriacetates, ethylenediaminetetraacetates, alkyl-and alkenyl malonates and succinates, and sulphonated fatty acid salts. Detergent compositions of the invention will also contain, as essential ingredients, one or more detergent-active compounds which may be chosen from soap and non-soap anionic, cationic, nonionic, amphoteric and zwitterionic detergent-active compounds, and mixtures thereof. Many suitable detergent-active compounds are available and are fully described in the literature, for example, in "Surface-Active Agents and Detergents", Volumes I and II, by Schwartz, Perry and Berch. The preferred detergent-active compounds that can be used are soaps and synthetic non-soap anionic and nonionic compounds. Anionic surfactants are well known to those skilled in the art. Examples include alkylbenzene sulphonates, particularly sodium linear alkylbenzene sulphonates having an alkyl chain length of C 8 -C 15 ; primary and secondary alkyl sulphates, particularly sodium C 12 -C 15 primary alcohol sulphates; alkyl ether sulphates; olefin sulphonates; alkane sulphonates; alkyl xylene sulphonates; dialkyl sulphosuccinates; and fatty acid ester sulphonates. Nonionic surfactants that may be used include the primary and secondary alcohol ethoxylates, especially the C 12 -C 15 primary and secondary alcohols ethoxylated with an average of from 3 to 20 moles of ethylene oxide per mole of alcohol; and alkylpolyglycosides. The choice of surfactant, and the amount present, will depend on the intended use of the detergent composition. For example, for machine dishwashing a relatively low level of a low-foaming nonionic surfactant is generally preferred. In fabric washing compositions, different surfactant systems may be chosen, as is well known by the skilled detergent formulator, for handwashing products and for machine washing products. The total amount of surfactant present will of course depend on the intended end use and may be as low as 0.5% by weight, for example in a machine dishwashing composition, or as high as 60% by weight, for example in a composition for washing fabrics by hand. For fabric washing compositions in general, an amount of from 5 to 40% by weight is generally appropriate. Detergent compositions suitable for use in most automatic fabric washing machines generally contain anionic non-soap surfactant, or nonionic surfactant, or combinations of the two in any ratio, optionally together with soap. Detergent compositions according to the invention may also suitably contain a bleach system. Machine dishwashing compositions may suitably contain a chlorine bleach, while fabric washing compositions may contain peroxy bleach compounds, for example, inorganic persalts or organic peroxyacids, which may be employed in conjunction with activators to improve bleaching action at low wash temperatures. Preferred inorganic persalts for inclusion in fabric washing compositions are sodium perborate monohydrate and tetrahydrate, and sodium percarbonate, advantageously employed together with an activator. Bleach activators, also referred to as bleach precursors, have been widely disclosed in the art. Preferred examples include peracetic acid precursors, for example, tetraacetylethylene diamine, now in widespread commercial use in conjunction with sodium perborate; and perbenzoic acid precursors. The novel quaternary ammonium and phosphonium bleach activators disclosed in US 4 751 015 and US 4 818 426 (Lever Brothers Company) are also of great interest. Other materials that may be present in detergent compositions of the invention include sodium silicate, fluorescers, antiredeposition agents, inorganic salts such as sodium sulphate, enzymes, lather control agents or lather boosters as appropriate, pigments, and perfumes. This list is not intended to be exhaustive. Detergent compositions of the invention may be prepared by any suitable method. Detergent powders are suitably prepared by spray-drying a slurry of compatible heat-insensitive components, and then spraying on or postdosing those ingredients unsuitable for processing via the slurry. The skilled detergent formulator will have no difficulty in deciding which components should be included in the slurry and which should be postdosed or sprayed on. The polymeric builder material of the invention may generally be included in the slurry if desired, although other methods of incorporation may of course be used if desired. EXAMPLES The invention will now be further illustrated by the following non-limiting Examples. Characterisation of the polymers The polymers were characterised by infrared spectrometry and in some cases by nuclear magnetic resonance spectroscopy. The infrared instrumentation used included the Nicolet (Trade Mark) 1705X Fourier Transform infrared spectrometer with MCT detector using the Nicolet 1280 processor, and the Nicolet SDXC Fourier Transform infrared spectrometer with DGS detector using the Nicolet 62 processor. 13 C NMR spectra were run on a Brucker (Trade Mark) WM 360 MHz Fourier Transform spectrometer. Number-average and weight-average molecular weights of polymeric materials were determined by gel permeation chromatography. This was carried out using a Hewlett Packard (Trade Mark) HP 1090 liquid chromatograph fitted with a 30 cm x 7.5 cm TSK gel linear GMPW column. Organic-solvent-soluble polymers were measured against polystyrene standards, and water-soluble polymers against polyethylene glycol. Calcium binding The calcium binding properties of the polymers were measured by titration of the samples with a calcium chloride solution using a calcium-ion-selective electrode of the type Radiometer (Trade Mark) F2112Ca. The calcium binding constant pK Ca 2+ was calculated by the method of C Tanford in Chapter 8, Multiple Equilibria, Physical Chemistry of Macromolecules, John Wiley, New York, 1961. Values of pK Ca 2+ of 4.0 or above represent materials likely to be useful as detergency builders, either alone or in conjunction with other builder materials. Example 1: poly (2-hydroxymethylacrylic acid) This example describes a polymer of the formula IV shown below, in which n represents an integer, consisting of units within the formula I as defined previously. The methyl ester of 2-hydroxymethylacrylic acid was first prepared as follows. Methyl acrylate (25.8 g, 0.3 mole), 37% aqueous formaldehyde (22.5 g), 1,4-diazabicyclo[2-2.2]octane (DABCO) (2 g) and methanol (25 ml) were stirred in a flask equipped with a magnetic stirrer for 48 hours at room temperature, while the pH was maintained at about 9. The turbid mixture was acidified to pH 5.5 with concentrated hydrochloric acid. Organic material was extracted with ether (3 x 100 ml), the combined ether extracts were washed with saturated brine (1 x 100 ml, 2 x 50 ml), then dried over magnesium sulphate and filtered, and the ether removed by rotary evaporation. The resulting clear oil was purified by vacuum distillation without appreciable loss. The product, which was shown by gas chromatography to be of >98% purity, was identified by infrared spectrometry as being identical to that described in the literature. The polymer was prepared as follows. The monomer (10 g) was dissolved in deionised water (180 ml) in a 500 ml reaction flask fitted with a mechanical stirrer, condenser, oxygen-free nitrogen sparge tube, and gas outlet. The solution was heated under nitrogen in a water-bath held at 60°C. Sodium persulphate initiator (0.2 g) dissolved in degassed water (10 ml) was added to the stirred solution. After approximately 0.5 hour a white precipitate of polymer appeared. A second addition of initiator (0.1 g in 10 ml water) was made after several hours and the polymerisation continued to give a total reaction time of 24 hours. After cooling, the polymer was filtered off, washed with water, then with methanol and hexane to de-swell it; finally it was vacuum-dried at 60°C. This product was the polymeric ester. It was hydrolysed to the sodium salt by stirring at 60°C with a 10% aqueous sodium hydroxide solution. Initially, a less than stoichiometric amount of base was present; further incremental additions of base were made until a stable pH of 8-9 was achieved. The solution was diluted and centrifuged to remove a small amount of gel, then freeze dried to isolate the salt. The yield was 5.2 g. The infrared spectrum (KBr wafer) showed characteristic strong absorptions at 3500 cm -1 (H-bonded OH str), 1580 and 1400 cm -1 (-COO str). Molecular weight and calcium binding results were as follows: Example Molecular weight pK Ca 2+ M n M w D 1 4 800 18 400 3.80 4.5 Example 2: poly(2-hydroxymethylacrylic acid) A second polymer of the formula IV, given in Example 1 was prepared by a similar method. Molecular weight and calcium binding results were as follows: Example Molecular weight pK Ca 2+ M n M w D 11 200 732 000 65.36 6.0 Example 3: poly(2-hydroxymethylacrylic acid) A third polymer of the formula IV given in Example 1 was prepared, by a different procedure. The monomer (10 g), azoisobutyronitrile (200 mg) and dioxan (10 ml) were charged to an evacuable sealed tube reactor. On evacuation, the tube was placed in a thermostatted bath at 60°C for 72 hours. The solid mass obtained was dissolved in the minimum amount of acetone and the polymer purified by triple precipitation into petroleum ether. The white solid obtained (the polymeric ester) was then hydrolysed with aqueous sodium hydroxide solution to form the corresponding sodium salt, and the resulting solution was freeze dried. The yield was 6.70 g. The infrared spectrum (KBr wafer) showed characteristic strong absorptions at 3500 cm -1 (H-bonded OH str), 1580 and 1400 cm -1 (-COO str). Molecular weight and calcium binding results were as follows: Example Molecular weight pK Ca 2+ M n M w D 10 880 41 300 3.90 5.1 Example 4: 2-hydroxymethylacrylic acid/itaconic acid copolymer A polymer was prepared by copolymerisation of α-hydroxymethylacrylic acid methyl ester, prepared as described in Example 1, and itaconic acid. The polymer had the formula I shown below, wherein n and m are integers, and consisted of units within the formulae I and II as defined previously. 2-hydroxymethylacrylic acid methyl ester (7.0 g, 60 mmole), itaconic acid (7.0 g), 54 mmole) and water (90 ml) were placed in a flange flask fitted with a condenser, electric stirrer and nitrogen inlet. The reaction mixture was degassed with nitrogen for 30 minutes. Potassium persulphate solution (1.5 g, 6 mmole, in 10 ml water) was added, and the reaction mixture was heated to 60°C and maintained at that temperature for 24 hours under nitrogen. The resulting polymer (ester) was coagulated and washned by pouring the reaction mixture into excess methanol. It was then hydrolysed to the sodium salt by heating with sodium hydroxide solution (13.68 g NaOH in 40 ml water). Once hydrolysis was complete, the polymer was coagulated and washed with methanol. After two more precipitations from water into methanol, the polymer was freeze dried. The yield was 8.7 g. Infrared data (KBr wafer) were as follows: Short chain polycarboxylate (C=O str) 1600 cm -1 (OH str) 3500 cm -1 (C-O str) 1100 cm -1 Molecular weights and calcium binding results were as follows: Example Molecular weight pK Ca 2+ M n M w D 5 3 200 5 950 1.86 5.5 Example 5: 2-hydroxymethylacrylic acid/α-hydroxyacrylic acid copolymer This example describes the preparation of a polymer of the formula VI shown below, wherein n and m are integers, consisting of units within the formulae I and III as defined previously. The polymer was prepared by copolymerisation of 2-(1-hydroxymethyl)acrylate methyl ester prepared as described in Example 1 (3 g) and 2-chloroacrylic acid (8.3 g). The polymerisation was carried out by the procedure described in Example 1; the alkaline hydrolysis step also caused replacement of the chlorine atoms introduced by the 2-chloroacrylic acid to hydroxyl groups. The yield was 11.8 g. Molecular weights and calcium binding results were as follows: Example Molecular weight pK Ca 2+ M n M w D 8 16 800 92 950 5.53 5.3

Claims: A polymeric polycarboxylic acid or salt suitable for use as a binder of divalent or polyvalent metal ions, consisting of units of the formula I and, optionally, units of the formula II and/or units of the formula III wherein each of the R groups, which may be the same or different, represents a hydrogen atom, a methyl group or an ethyl group, and M represents a hydrogen atom or a solubilising cation, the polymer having a number average molecular weight within the range of from 1000 to 100 000 and a weight average molecular weight within the range of from 1000 to 1 000 000. A polymer as claimed in claim 1, wherein the R groups represent hydrogen atoms. A polymer as claimed in claim 2, which is a homopolymer of 2-(1-hydroxymethyl)acrylic acid, or a salt thereof. A polymer as claimed in claim 2, which is a copolymer of 2-(1-hydroxymethyl)acrylic acid or a salt thereof, and 2-hydroxyacrylic acid or a salt thereof. A polymer as claimed in claim 2, which is a copolymer of 2-(1-hydroxymethyl)acrylic acid or a salt thereof, and itaconic acid or a salt thereof. A polymer as claimed in any preceding claim, characterised in that it has a number-average molecular weight within the range of from 3000 to 40 000. A polymer as claimed in any preceding claim, characterised in that it has a weight-average molecular weight within the range of from 5000 to 800 000. A polymer as claimed in any preceding claim, characterised that it is in sodium salt form. Use of a polymer as claimed in any preceding claim to bind divalent and polyvalent metals. A detergent composition comprising at least one detergent-active compound, and at least one detergency builder, characterised in that the detergency builder consists wholly or partially of a polymer as claimed in any one of claims 1 to 8. A detergent composition as claimed in claim 10, characterised in that it comprises from 0.5 to 60 wt% of detergent-active compound and from 15 to 80 wt% of detergency builder.

Inventors: KHOSHDEL EZAT, VAN KRALINGEN CORNELIS GERHARD, KHOSHDEL, EZAT, VAN KRALINGEN, CORNELIS GERHARD
Applicants: UNILEVER NV, UNILEVER PLC, UNILEVER N.V.
Application year: 1990
Main classification: C08F8
IPC codes: C11D3, C08F8, C08L33, C08F222, C08L35, C08F220