QUATERNARY AMMONIUM SALT COMPOSITION

Abstract: A quaternary ammonium salt composition comprises 15-85 wt.% monoester quaternary salt of formula (I), 0-44 wt.% diester quaternary salt of formula (II) and 15-85 wt.% of triester quaternary salt of formula (III). A process for producing the composition and a softener product comprising the quaternary ammonium salt composition are also claimed. In said formulae R represents a C5-35 alkyl or alkenyl group, R<1> represents a C1-4 alkyl or hydroxyalkyl group, n is a number selected from 2 to 4 and X<-> is an anionic group.

Description: DESCRIPTION QUATERNARY AMMONIUM SALT COMPOSITION Technical Field The present invention relates to a quaternary ammonium salr composition, a process for producing the same and a softener composition containing the same Background Art Most, of the commercially available merchandise as a softener composition for fibers are compositions comprising a quaternary ammonium salt containing two long-chain alkyl groups m one molecule and being typified by a di (long-chain alkyl) dimethyl ammonium chloride. However, the quaternary ammonium salt suffers from the problem that, when residues thereof after treatment is discharged into the environment such as a river, most of them are accumulated without biodegradation . As improved products against this problem, N-methyl- N, N-bis (long-cnam alkanoyl oxyethyl ) -N- (2-hydroxyethyl ) ammonium methyl sulfate etc. are commercially available The product is proαuced by esterification of triethanolamme witn a long-chain fatty acid and then quaternizmg with dimetnv sulfate. The reaction molar ratio of the fatty acid to triethanolamme is usually from 1.8 to 2.1, and, at the same time, the ratio of the amount of the diester quaternary salt to the total amounts of the monoester, diester and triester quaternary salts is from 43 to 47 % by weight. It has been considered that the reaction molar ratio was made in the range of 1.8 to 2.1 because the proportion of the diester quaternary salt is maximized in this range, while the proportion of the diester quaternary salt is reduced when the reaction molar ratio is less than 1.8 or more than 2.1, so that a softening performance is reduced. However, even if the reaction molar ratio is m the range of 1.8 to 2.1, a softening effect cannot be sufficiently satisfied. As means to solve this problem, W097/42279 discloses a quaternary ammonium salt wherein the amount of diester quaternary salt is greater than 55 % by weight, as well as it also discloses a process for producing the same. This material has improved a softening performance but is still not satisfactory. Then, W097/42279, US-A 5916863, US-A 6004913 and US-A 6037315 disclose a textile softening composition which comprises a quaternary ammonium salt which comprises a mixture of mono-, di- and tπ- ester components, wherein the amount of the diester quaternary is greater than about 55 % by weight. The textile softening composition may have a solvent such as water . EP-A 675941 discloses dispersions containing a quaternary ammonium compounds which are derived from triethanolamme and whicn contain one, two or three fatty acyloxyethyl groups, characterized that the percentage content of compounds containing two fatty acid acyloxyethyl groups is greater than 50 mole-%, based on the total quantity of quaternary ammonium compounds . Disclosure of Invention The object of the present invention is to provide a softening base and a softener which are further excellent a softening effect and biodegradability . The present invention relates to a quaternary ammonium salt composition which comprises the following components (M) , (D) and (T) , wherein the amount of (M) is 15 to 85 % by weight, the amount of (D) is 0 to 44 % by weight and the amount of (T) is 15 to 85 % by weight based on the total amounts of (M) , (D) and (T) . The present invention also relates to a process for producing the same and a softener composition comprising the quaternary ammonium salt composition. (M) a monoester quaternary salt represented by the formula (I) : wherein R represents a C D „ alkyl or alkenyl group, R 1 represents a C λ 4 alkyl or hydroxyalkyl group, n is a number selected from 2 to 4 and X ~ is an anionic group; (D) a diester quaternary salt represented by the formula (II) : C n H 2n OCOR ι + / R—N C n H 2n OCOR (H) - C n H 2n OH wherein each of R, R 1 , n and X has the same meaning as defined above; and (T) a triester quaternary salt represented by the formula (III): C n H 2n OCOR R-N—C n H 2n OCOR (in) χ _ C n H 2n OCOR wherein each of R, R 1 , n and X ~ has the same meaning as defined above . Further, the present invention provides use of the above-mentioned composition as a softener for fibers and a method of softening fibers witn the above-mentioned composition . Modes for Carrying Out the Invention From the viewpoint of obtaining a sufficient softening effect, the amounts of components (M) , (D) ana (T) the composition of the present invention are selected such that the amount of (M) is 15 to 85 % by weight, preferaoly 20 to 84 % by weight, more preferably 20 to 79 % by weight, the amount of (D) is 0 to 44 % by weight, preferably 1 to 44 % by weight, more preferably 1 to 40 % by weight, and the amount of (T) is 15 to 85 % by weight, preferably 15 to 80 % by weight, more preferably 20 to 60 % by weight, based on the total amounts of (M) , (D) and (T) . In the formulae (I) , (II) and (III) , the number of carbons R is preferably from 11 to 23. R" is preferably a methyl or ethyl group, n is preferably 2. X is preferably a halogen ion such as chloride ion or an alkyl sulfate ion such as methyl sulfate ion and ethyl sulfate ion. In the process for producing the quaternary compound by reacting a trialkanolam e with a fatty acid to obtain a trialkanolam e ester and then quaternizing the trialkanolamme ester, the ratio of the monoesterifled product is reduced while the ratio of the tπesteπfled product is increased m proportion as the reaction molar ratio of the fatty acid to the trialkanolamme is increased, in general. When triethanolamme and a tallow fatty acid are used, the monoester quaternary salt as a major component is 40 % by weight or more while the triester quaternary salt is less than 15 % by weight m quaternary salts of the esteπfied products, if the molar ratio of the fatty acid to the triethanolamme is less than 1.3. Further, if the molar ratio is from 1.3 to 2.0, the diester quaternary salt in an amount of 45 to 48 % by weight is produced as a mam component. Furthermore, if the molar ratio is more than 2.0, the triester quaternary salt m an amount of 40 % by weight or more is produced as a mam component, while the monoester quaternary salt is less than 15 % by weight. That is, the quaternary ammonium salt composition of the present invention is hardly obtained m a usual method by merely reaction of triethanolamme and a fatty acid and then quaternization. Although the method of obtaining the quaternary ammonium salt composition of the present invention is not limited m particular, there is a method which two or more alkanolamme-esterifled products having different degrees of esterification are mixed and then quaternized or which two or more quaternary salts of alkanolamme-esterifled products having different degrees of esterification are mixed. Specifically, it is more than enough to mix a quaternary ammonium salt produced under such a condition that a reaction molar ratio of a fatty acid to trialkanolamme is low and anothrer quaternary ammonium salt produced under such a condition that another reaction molar ratio thereof is high. The reaction molar ratio and tne mixing (or blending) ratio thereof may be selected such that the ratios of the components (M) , (D) and (T) are the above-mentioned range, and three or more quaternary ammonium salts may be mixed. The alkanolamme-esterifled products may be first mixed and then quaternized . According to the present invention, the quaternary ammonium salt produced under such a condition that the reaction molar ratio of the fatty acid to trialkanolamme is low and the quaternary ammonium salt produced under such a condition that the reaction molar ratio thereof is high are produced the same manner as for N-methyl-N,N-bιs (long-chain alkanoyloxyethyl) -N- (2- hydroxyethyl) ammonium, methyl sulfate etc. That is, the salt can be produced by esterifymg a trialkanolamme such as triethanolamme with a long-chain fatty acid such as a tallow fatty acid, a hydrogenated tallow fatty acid, stearic acid from a palm and hydrogenated (or hardened) stearic acid from a palm and a mixture of two or more members selected therefrom, with a lower alkyl ester thereof or with a fat and/or oil and then quaternizmg the resultant ester with a quaternizmg agent such as dimethyl sulfate, diethyl sulfate and methyl chloride. In this case, a quaternized product of an unreacteα trialkanolamme is formed when the reaction molar ratio of the fatty acid to the trialkanolamme is lower, but it is no matter that the quaternized product of the amme unreacted m the esterification reaction is present. Further, the unreacted fatty acid remains when the reaction molar ratio is high, but it is no matter that the fatty acid is present. If two or more alkanolamme-esterifled products having different degrees of esterification are mixed or if two or more quaternized products thereof having different degrees of esterification are mixed, the fatty acid residues thereof may be the same or different. From the viewpoint of a softening performance, the fatty acid residue of a compound having high degree of esterification is preferably a residue derived from a tallow fatty acid or stearic acid from a palm. On the other hand, the fatty acid residue of a compound having low degrees of esterification is preferably a hydrogenated tallow fatty acid residue from the viewpoint of a softening performance. The quaternary ammonium salt composition of the present invention can be formed into a liquid softener by dispersing 3 to 50 % by weight of the said composition water. A nonionic surfactant is preferably blended with the softener composition of the present invention order to improve a dispersibility and softening effect. The nonionic surfactant for use is preferably an alkylene oxide adduct of a higher alcohol, more preferably an adduct of ethylene oxide with 5 to 100 moles, particularly 10 to 60 moles, to a higher alcohol having 8 to 22 carbon atoms. A higher alcohol or higher fatty acid can be added in order to further improve a softening performance. A lower alcohol such as ethanol and lsopropanol, glycol or polyol as well as an ethylene oxide or propylene oxide adduct thereof can be added as a storage stabilizer. Furthermore, an inorganic salt, a pH adjuster, a hydrotropic agent, a perfume, a defoammg agent, a pigment and the like can be added if necessary. [Method of analyzing the ester quaternary salt] The composition of the monoester, diester and triester quaternary salt according to the present invention is determined the following manner. An ester amme obtained from triethanolamme with a fatty acid is dissolved in CDC1 3 and analyzed with a nuclear magnetic resonance spectrum (NMR, with an internal standard TMS) . The ratio by weight of the quaternary salts was calculated on the basis of the other ratio determined by integration concerning a peak of a methylene group (-CH-.-OH-) adjacent to a hydroxyl group observed at about 3.5 to 3.7 ppm and another peak of another methylene group (-OCO-Cϋ,-) adjacent to an ester group observed at about 4.0 to 4.2 ppm, m order to prepare the ratio by composition . Examples Examples 1 to 17 and Comparative Examples 1 to 10 Triethanolamme was reacted with a hydrogenated tallow fatty acid or tallow fatty acid m each of the molar ratio shown Table 1 and then quaternized with dimethyl sulfate to obtain Compounds A-l to A-7 and B-l to B-2 having the compositions shown in Table 1. The composition (% by weight) m Table 1 is calculated as a weight value the quaternary salt based on the other composition obtained by measuring with a nuclear magnetic resonance spectrum (NMR, CDC1 3 solvent, with an internal standard TMS) of the ester amine. The compounds A-l to A-7 and B-l to B-2 were used respectively or mixed the weight ratios shown m Tables 2 and 3 to obtain the quaternary ammonium salt composition havinc the compositions shown m Tables 2 and 3. Next, 5 % by weight of composition were added dropwise to water at 60 °C which 5 % by weight of an adduct of ethylene oxide with 20 moles to lauryl alcohol were dissolved in ordei to prepare each of softeners. The softener was evaluated for a softening effect in the following manner. The results are shown m Table 4. <Method of evaluating a softening effect> ® Softening treatment 1 kg of commercial cotton towels or jersey cloths made of acrylate fibers was laundered repeatedly 5 times with a commercial detergent "Attack" (a registered trade mark, manufactured by Kao Corporation) m hard water of 3.5° DH a laundering machine having its capacity of 15 L. Then, 25 ml of the softener was introduced tneremto and the resultant was treated at 25 °C for 1 minute under stirring. (2) Evaluation for a softening effect The cloth thus subjected to softening treatment was air-dried at room temperature and then left in a constant 1C temperature and humidity chamber at 25 °C under 65 %RH for 24 hours. The cloth with the softener of Comparative Example 8 was used as the control and 10 skilled testers evaluated by the paireα comparison test with the following criteria. The average value of the evaluations by 10 tester was rounded off as follows, namely, the fraction thereof of .5 or more was counted as a unit and the rest was cut away. The rounded value was made as the evaluation value. +2: Softer than the control. +1: Somewhat softer than the control. 0: Equal m softening effect to the control. -1 : Somewhat harder than the control. -2: Harder than the control. Tabl e 1 *1: Molar ratio of fatty acid to triethanolamine . *2 : Produced by esterifying triethanolamine with tallow fatty acid, then subjecting it to thin-film distillation, distilling the unreacted triethanolamine and monoesterified product off, and moreover quaternizing the resultant product. *3: % by weight including also the quaternary salt of triethanolamine . Table 2 Table 3 *: % by weight to the total of monoester, diester and triester quaternary salts, and % by weight in the bracket including also the quaternary salt of triethanolamine. Table 4

Claims: CLAIMS 1, quaternary ammonium salt composition which comprises the following components (M) , (D) and (T), wherein the amount of (M) is 15 to 85 % by weight, the amount of (D) is 0 to 4 & % bv weight and the amount of (T) is 15 to 85 % by weight based on the total amounts of (M) , (D) and (T) : (M) a monoester quaternary salt represented by the formula (I) : wherein R represents a C 5 _ 35 alkyl or alkenyl group, R" represents a C x _ 4 alkyl or hydroxyalkyl group, n is a number selected from 2 to 4 and X ~ is an aniomc group; (D) a diester quaternary salt represented by the formula (II) : C n H 2n OCOR R 1 —N C n H 2n OCOR (II) - C n H 2n OH wherein each of R, R 1 , n and X ~ has the same meaning as defined above; and (T) a triester quaternary salt represented by the formula ι,III): C n H 2n OCOR l + / R—N—C„nH- n ,2 n nO' COR ( in ) C n H 2n OCOR X " wherein each of R, R , n and X has the same meaning as defined above . 2, A process for producing the quaternary ammonium salt composition as defined in Claim 1, wherein two or more alkanolamme-esterifled products having different degrees of esterification are mixed and then quaternized or wherein two or more quaternary salts of alkanolamme-esterifled products having different degrees of esterification are mixed. 3, A softener composition comprising the quaternary ammonium salt composition as defined Claim 1. 4, The composition as claimed in Claim 1, wherein the amount of (D) is 1 to 44 % by weight. 5, The composition as claimed m Claim 1, wherein the amount of (M) is 20 to 79 % by weight, the amount of (D) is 1 to 40 % b\ weight and the amount of (T) is 20 to 60 % by weight.

Inventors: KATOH TOHRU, OHTAWA YASUKI, TOMIFUJI TAKESHI, KATOH, TOHRU, OHTAWA, YASUKI, TOMIFUJI, TAKESHI
Applicants: KAO CORP, KATOH TOHRU, OHTAWA YASUKI, TOMIFUJI TAKESHI, KAO CORPORATION, KATOH, TOHRU, OHTAWA, YASUKI, TOMIFUJI, TAKESHI
Application year: 2000
Main classification: C11D1
IPC codes: C11D1, C11D3, D06M13