Abstract:
A method of making aluminum salt compositions using a combination of a basic organic buffer with a source of alkaline earth metal ions. This selection of basic organic buffer provides for a lower alkaline earth metal salt content in the composition made by the method.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Antiperspirant salts, such as aluminum chlorohydrex (also called aluminum chlorohydrex polymeric salts and abbreviated here as “ACH”) and aluminum zirconium glycine salts (abbreviated here as “ZAG”, “ZAG complexes” or “AZG”), are known to contain a variety of polymeric and oligomeric species with molecular weights (MW) of 100-500,000. It has been clinically shown that, in general, the smaller the species, the higher the efficacy for reducing sweat. 
         [0002]    In an attempt to increase the quality and quantity of smaller aluminum and/or zirconium species, a number of efforts have focused on: (1) how to select the components of ACH and ZAG that affect the performance of these materials as antiperspirants; and (2) how to manipulate these components to obtain and/or maintain the presence of smaller types of these components. These attempts have included the development of analytical techniques to identify the components. Size exclusion chromatography (“SEC”) or gel permeation chromatography (“GPC”) are methods frequently used for obtaining information on polymer distribution in antiperspirant salt solutions. With appropriate chromatographic columns, generally five distinctive groups of polymer species can be detected in commercial ACH and ZAG complexes appearing in a chromatogram as peaks 1, 2, 3, 4 and a peak known as “5,6”. Peak 1 is the larger Zr species (greater than 60 Angstroms). Peaks 2 and 3 are larger aluminum species. Peak 4 is smaller aluminum species (aluminum oligomers, or small aluminum cluster) and has been correlated with enhanced efficacy for both Al and Al/Zr salts. Peak 5, 6 is the smallest aluminum species. Various analytical approaches for characterizing the peaks of ACH and various types of ZAG actives are found in “Antiperspirant Actives—Enhanced Efficacy Aluminum-Zirconium-Glycine (AZG) Salts” by Dr. Allan H. Rosenberg (Cosmetics and Toiletries Worldwide, Fondots, D. C. ed., Hartfordshire, UK: Aston Publishing Group, 1993, pages 252, 254-256). 
         [0003]    Previously, the inventor has described an aluminum salts having SEC chromatogram exhibiting high SEC peak 4 intensity in WO2009/075678 and WO2009/076591. As a by-product of making these compositions using an alkaline earth metal base, an alkaline earth metal salt is generated. When the salt is an alkaline earth metal halide, it is difficult to dry the material because the salt is hygroscopic. It would be desirable to have less hygroscopic salt present. Described herein is a method of making the aluminum salt having a lower amount of alkaline earth metal salt by-product. 
       BRIEF SUMMARY OF THE INVENTION 
       [0004]    A method of making an aluminum salt composition comprising
   I) heating an aqueous solution of an aluminum chloride compound having an aluminum to chloride molar ratio of 0.3:1 to 3:1 to a temperature of at least 50° C. to reflux temperature for a period of time of at least 1 hour;   II) providing an aqueous solution containing a source of an alkaline earth metal to obtain a pH adjusted aluminum salt solution having a pH of 2 to 5; and
 
wherein at least one basic organic buffer is included with at least one of I) the aqueous solution of the aluminum and chloride containing salt, and II) the aqueous solution containing the alkaline earth metal, wherein the pH adjusted aluminum salt solution has an aluminum salt with an OH:Al molar ratio of 2:1 to 2.6:1, wherein a basic organic buffer to alkaline earth metal ion molar ratio is 0.22:1 to 18:1.
   
 
         [0007]    A composition made by the method. 
         [0008]    A composition comprising an aluminum chloride compound having an aluminum to chloride molar ratio of 0.3:1 to 3:1 exhibiting a Size Exclusion Chromatography (SEC) chromatogram having a SEC Peak 4 to Peak 3 intensity ratio of at least 2 and a basic organic buffer. 
         [0009]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0010]    The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
         [0011]    The method starts by heating an aqueous solution of an aluminum chloride compound having an aluminum to chloride molar ratio of 0.3:1 to 3:1 to a temperature of at least 50° C. to reflux temperature for a period of time of at least 1 hour. In other embodiments, the temperature can be 50° C. to 120° C., 50° C. to 100° C., 75° C. to 100° C. or 90° C. to 100° C. In another embodiment, the temperature is 95° C. In one embodiment, the aluminum chloride solution is 0.01 to 3M, optionally 1 to 3M, 1.5 to 3 M, or 2 to 3M. In other embodiments, the period of time is 1 to 6 hours, 1 to 5 hours, 1 to 4 hours, 2 to 5 hours, 2 to 4 hours, or 2 to 3 hours. 
         [0012]    An aqueous solution containing a source of an alkaline earth metal ion, such as calcium, is added to the aluminum salt solution during the reaction time to obtain a pH adjusted aluminum salt solution having a pH of 2 to 5. 
         [0013]    A basic organic buffer is initially included with the aluminum and chloride containing salt and/or it is included with the aqueous alkaline earth metal ion source. 
         [0014]    The pH adjusted aluminum salt solution has an OH:Al molar ratio of 2:1 to 2.6:1. 
         [0015]    The basic organic buffer can be any organic buffer that will generate an Off ion when the basic organic buffer is in water. Examples of the basic organic buffer include, but are not limited to arginine, lysine, histidine, cysteine, tyrosine, and urea. In certain embodiments, the basic organic buffer is arginine. 
         [0016]    Optionally, a second buffer can be included, which is not a basic organic buffer. Examples of second buffers include, but are not limited to, amino acids that are not a basic organic buffer, glycine, and trimethylglycine. 
         [0017]    The alkaline earth metal can be any alkaline earth metal, optionally, the alkaline earth metal is chosen from calcium, strontium, and barium. In certain embodiments, the alkaline earth metal is calcium. 
         [0018]    The alkaline earth metal ion, such as calcium, can be provided from a base, such as alkaline earth metal hydroxide, calcium hydroxide, alkaline earth metal oxide, or calcium oxide, or from alkaline earth metal salt, such as alkaline earth metal chloride, calcium chloride, alkaline earth metal carbonate, or calcium carbonate. In one embodiment, calcium hydroxide is the source of alkaline earth metal ions. 
         [0019]    The basic organic buffer to alkaline earth metal ion molar ratio in certain embodiments is 0.22:1 to 18:1. In other embodiments, the basic organic buffer to alkaline earth metal ion molar ratio is 0.3:1 to 18:1, optionally, 0.4:1 to 18:1, 0.5:1 to 18:1, 1:1 to 18:1, 1.5:1 to 18:1, 1.9:1 to 18:1, 2:1 to 18:1, 1:1 to 3:1, 1.5:1 to 3:1, 1.5:1 to 2.5:1, 1.5:1 to 2:1, 1.9:1 to 3:1, 1.9:1 to 2.5:1, or 1.9:1 to 2:1. In certain embodiments, the basic organic buffer is arginine, and the alkaline earth metal is calcium. 
         [0020]    In certain embodiments, the amount of alkaline earth metal salt in the final product can be reduced by at least 10%, optionally, at least 20, at least 30, at least 40, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or 10 to 90% compared to methods of using other buffers that are not basic organic buffers. 
         [0021]    In some embodiments, a zirconium salt may also be added to the pH adjusted aluminum salt solution. In one other such embodiment, the molar ratio of Al:Zr is 2:1 to 10:1, optionally 5:1 to 10:1. In one embodiment, a ZrOCl 2  solution is added to the pH adjusted aluminum salt solution. In one such embodiment, the molar ratio of Al:Zr is 8. In another such embodiment, the molar ratio of Al:Zr is 7. In one other such embodiment, the molar ratio of Al:Zr is 9. 
         [0022]    For the above methods, the aluminum chloride compound may be obtained from a variety of sources. In certain embodiments, examples of the aluminum chloride compound include, but are not limited to, aluminum trichloride, aluminum chlorohydrate and aluminum dichlorohydrate. In one such embodiment, the aluminum chloride compound is aluminum trichloride. 
         [0023]    The method can further include a step of drying the composition. 
         [0024]    The method can be used to make an aluminum salt composition having a high SEC peak 4 in aqueous solution. In some embodiments, the aluminum salt compositions obtained by this stepwise procedure include aluminum salts having an aluminum to chloride molar ratio of 0.3:1 to 3:1, the aluminum salt has a SEC Peak 4 to Peak 3 intensity ratio of at least 7 and a Peak 4 intensity greater than a Peak 5 intensity in aqueous solution. 
         [0025]    The aluminum salt can be at least one aluminum salt chosen from aluminum chlorohydrate, aluminum sesquichlorohydrate, and aluminum dichlorohydrate, or the corresponding aluminum-zirconium salt. 
         [0026]    The method can be used to make aluminum salts and/or aluminum-zirconium salts having high levels of low molecular weight Al and Zr species. The high levels of low molecular weight Al and Zr species is reflected in a SEC trace that has an abundance of Peak 4 low amounts of Peaks 1, 2, 3 and 5. The polymerization of the antiperspirant actives in aqueous solutions and the correspondent gelation process were followed by monitoring the molecular weight profile of the polyaluminumoxohalides in time by SEC. The relative retention time (“Kd”) for each of these peaks varies depending on the experimental conditions, but the peaks remain relative to each other. Data for Tables in the examples was obtained using an SEC chromatogram using the following parameters: Waters®600 analytical pump and controller, Rheodyne® 77251 injector, Protein-Pak® 125 (Waters) column, Waters 2414 Refractive Index Detector. 5.56 mM nitric acid mobile phase, 0.50 ml/min flow rate, 2.0 microliter injection volume. Data was analyzed using Water® Empower software (Waters Corporation, Milford, Mass.). The concentration of the antiperspirant in solution does not affect retention time. 
         [0027]    The design of modern AP salts aims at actives with high levels of low molecular weight Al and Zr species, which is reflected in a SEC trace that has intense Peak 4 and low Peaks 1, 2, and 3. Throughout the present study, the levels of the species corresponding to these peaks are estimated based on the following ratios (or percentages): 
         [0000]    
       
         
           
             
               
                 f 
                 Pi 
               
               = 
               
                 
                   
                     Pi 
                     
                       ∑ 
                       Pj 
                     
                   
                    
                   
                       
                   
                    
                   i 
                 
                 = 
                 1 
               
             
             , 
             2 
             , 
             3 
             , 
             4 
             , 
             
               5 
               ; 
             
           
         
       
       
         
           
             
               j 
               = 
               2 
             
             , 
             3 
             , 
             4 
             , 
             5 
           
         
       
     
         [0028]    where f Pi  is the fraction of peak i, and Pi or Pj are the intensity of peaks Pi or Pj, respectively. The amount of low molecular weight Al species will be correlated with the fraction, f P4 , or percentage, f P4  ×100, of SEC-Peak 4. In brief, a preferred antiperspirant salt would have a very low f P1 , f P2 , f P3 , and/or f P5 , and a high f P4 . 
         [0029]    In certain embodiments, the ratio of Peak 4 to Peak 3 is at least 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, or any number up to infinity. 
         [0030]    In one embodiment, an aluminum salt and/or aluminum-zirconium salt, in aqueous solution, exhibit a SEC profile wherein the SEC Peak 4 to Peak 3 intensity ratio is at least 7. In such embodiments, the percentage of SEC Peak 4 of a total area of Peaks 1, 2, 3, 4, 5, and 6 in the SEC chromatogram is: at least 50%; at least 60%; at least 70%; at least 80%; at least 90%, or 95 to 100%. In another such embodiment, the SEC Peak 4 area is 100%. 
         [0031]    In another embodiment, the aluminum salt and/or the aluminum-zirconium salt, in aqueous solution, exhibits a SEC profile wherein the SEC Peak 4 to Peak 3 intensity ratio is at least 7 and exhibits low percentage of SEC Peak 3. In such embodiments, the composition has the percentage of SEC Peak 3 area of a total area of Peaks 1, 2, 3, 4, 5, and 6 in the SEC chromatogram is: less than 10%; less than 5%; less than 2%; less than 1%; less than 0.9%; less than 0.8%; less than 0.7%; less than 0.6%; of less than 0.5%; less than 0.4%; less than 0.3%; less than 0.2%; or less than 0.1%. In another such embodiment, the composition has no SEC Peak 3 area. 
         [0032]    In another embodiment, the aluminum salt and/or the aluminum-zirconium salt, in aqueous solution, exhibits a SEC profile wherein the SEC Peak 4 to Peak 3 intensity ratio is at least 7 and exhibits low percentages of SEC Peak 5. In such embodiments, the percentage of SEC Peak 5 area of a total area of Peaks 1, 2, 3, 4, 5, and 6 in the SEC chromatogram is: less than 30%; less than 20%; less than 10%; less than 5%; or less than 1%. In another such embodiment, the composition has no SEC Peak 5 area. 
         [0033]    In another embodiment, the aluminum salt and/or the aluminum-zirconium salt, in aqueous solution, exhibits a SEC profile wherein the SEC Peak 4 to Peak 3 ratio is at least 7, and exhibits a low percentage of SEC Peak 1 and a low percentage of SEC Peak 2. In such embodiment, the percentage of SEC Peak 1 area of a total area of Peaks 1, 2, 3, 4, 5, and 6 in the SEC chromatogram is: less than 10%; a SEC Peak 1 area less than 5%; less than 2%; less than 1%; less than 0.9%; less than 0.8%; of less than 0.7%; less than 0.6%; less than 0.5%; less than 0.4%; less than 0.3%; less than 0.2%; or less than 0.1%. In another embodiment, the complex has no SEC Peak 1 area. In another embodiment, the percentage of SEC Peak 2 area of a total area of Peaks 1, 2, 3, 4, 5, and 6 in the SEC chromatogram is: less than 10%; less than 5%; less than 2%; less than 1%; less than 0.9%; less than 0.8%; less than 0.7%; less than 0.6%; less than 0.5%; less than 0.4%; less than 0.3%; less than 0.2%; or less than 0.1%. In another embodiment, the composition has no SEC Peak 2 area. 
         [0034]    The aluminum salt compositions and/or aluminum-zirconium salt compositions may be used in a variety of antiperspirant products. If the product is used as a solid powder, the size of the particles of antiperspirant active of the invention can be any desired size, and may include conventional sizes such as in the range of 2 to 100 microns, with selected grades having an average particle size of 30-40 microns; finer sized grades having an average particle size distribution of 2-10 microns with an average size of 7 microns as made by a suitable dry-grinding method; and micronized grades having an average particle size of less than or equal to 2 microns, or less than or equal to 1.5 microns. 
         [0035]    The compositions of this invention may be used to formulate antiperspirants having improved efficacy. Such antiperspirants include solids such as sticks and creams (creams sometimes being included in the term “soft solid”), gels, liquids (such as are suitable for roll-on products), and aerosols. The forms of these products may be suspensions or emulsions. These antiperspirant actives can be used as the antiperspirant active in any antiperspirant composition. 
         [0036]    Examples of formulations that can be made using the antiperspirant active and used of these compositions can be found in PCT/U.S.2007/087145 (Published as WO2009/075678) and PCT/U.S.2008/086556 (Published as WO2009/076591). 
         [0037]    The aluminum salts can also be used in water treatment, wastewater treatment, and clay pillaring. 
       EXAMPLES 
       [0038]    The invention is further described in the following examples. The examples are merely illustrative and do not in any way limit the scope of the invention as described and claimed. 
       Comparative Example 
       [0039]    18.81 mmol AlCl 3   • 6H 2 O is buffered with 23.136 mmol glycine in 29 ml deionized water, held at 95° C., and stirred vigorously. To this solution, a 9 ml Ca(OH) 2  (23.14 mmol) suspension is added dropwise over a 2 hour period. A molar ratio of (OH) − :(Al) 3+  of 2.46 is employed. The pH after the reaction is 3.5. The final [Al] is 0.495M. 
       Example 1 
       [0040]    18.81 mmol AlCl 3 .6H 2 O is buffered with 23.136 mmol L-arginine in 29 ml deionized water, held at 95° C. in a glass reactor and stirred vigorously. To this solution, 9 ml Ca(OH) 2  (12.08 mmol) suspension is added dropwise over a 2 hour period. The reaction solution is left heated and stirring for an additional 1 hour. A molar ratio of (OH) − :(Al) 3+  of 2.51 is employed. The pH after the reaction is 4.2. The final [Al] is 0.495M. 
       Example 2 
       [0041]    18.82 mmol AlCl 3   • 6H 2 O is buffered with 23.133 mmol L-arginine in 29 ml deionized water, held at 95° C. in a glass reactor and stirred vigorously. To this solution, 9 ml of a Ca(OH) 2  (11.58 mmol) suspension is added dropwise over a 2 hour period. The reaction solution is left heated and stirring for an additional 1 hour. A molar ratio of (OH) − :(Al) 3+  of 2.46 is employed. The pH after the reaction is 3.5. The final [Al] is 0.495M. 
       Example 3 
       [0042]    18.81 mmol AlCl 3 .6H 2 O is buffered with 23.136 mmol L-arginine in 29 ml deionized water, held at 95° C. in a glass reactor and stirred vigorously. To this solution, 9 ml of a Ca(OH) 2  (11.92 mmol) suspension is added dropwise over a 2 hour period. The reaction solution is left heated and stirring for an additional 1 hour. A molar ratio of (OH) − :(Al) 3+  of 2.5 is employed. The pH after the reaction is 4. The final [Al] is 0.495M. 
       Example 4 
       [0043]    The material from Example 1 is aged four days at room temperature (23° C.). 
         [0044]    Example 1 and the Comparative Example are characterized by Size Exclusion Chromatography. Both do not have any Peak 1, Peak 2, or Peak 3 peaks, and both have similar Peak 4 and Peak 5 intensities. Examples 2 to 5 are also characterized by Size Exclusion Chromatography. None of these Examples have any Peak 1, Peak 2, or Peak 3 peaks. A summary is in the table below. 
         [0000]    
       
         
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
                 Al 3+ :Arg:Ca 2+   
                   
                   
                   
                   
                 % Reduction 
               
               
                 Example 
                 Molar Ratio 
                 Ca 2+  ions 
                 OH − /Al 3+   
                 Peak 4 
                 Peak 5 
                 of CaCl 2   
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Comparative 
                 N/A 
                 23.15 
                 2.46 
                 97.56% 
                 2.44% 
                 N/A 
               
               
                 Example 1 
                 1:1.23:0.641 
                 12.08 
                 2.51 
                 96.28% 
                 3.72% 
                 47.8 
               
               
                 Example 2 
                 1:1.23:0.615 
                 11.58 
                 2.46 
                 92.94% 
                 7.06% 
                 50   
               
               
                 Example 3 
                 1:1.23:0.633 
                 11.92 
                 2.5 
                 94.90% 
                 5.10% 
                 48.5 
               
               
                 Example 4 
                 1:1.23:0.641 
                 12.08 
                 2.51 
                 96.59% 
                 3.41% 
                 47.8 
               
               
                   
               
             
          
         
       
     
         [0045]    From above, it can be seen that by using arginine, the amount of calcium hydroxide in the reaction can be reduced. By reducing the amount of calcium hydroxide, there will be less calcium available to form calcium chloride. With a reduction in calcium chloride, the drying of the aluminum salt will be made easier because there is less hygroscopic (calcium chloride) in the composition. 
       Example 5 
       [0046]    18.82 mmol AlCl 3 .6H 2 O in 29 ml deionized water is heated and held at 95° C. in a glass reactor and stirred vigorously. To this solution, a 9 ml suspension of 12.08 mmol Ca(OH) 2  and 23.17 mmol urea is added dropwise over a 2 hour period. A molar ratio of (OH) − :(Al) 3+  of 2.51 is employed. The pH after the reaction is 2.8. The final [Al] is 0.495M. The peak 4 intensity is 19.4%, the peak 3 intensity is 0.5%, and the peak 5 intensity is 80.1%. 
       Example 6 
       [0047]    18.81 mmol AlCl 3 .6H 2 O is dissolved in 9.83 ml deionized water. The solution is held at 95° C. in a glass reactor and stirred vigorously. To this solution, 9 ml of a suspension containing 23.16 mmol L-arginine and 12.09 mmol Ca(OH) 2  is added dropwise over a 2 hour period. The reaction solution is left heated and stirring for an additional 1 hour. A molar ratio of (OH) − :(Al) 3+  of 2.51 is employed. The pH after the reaction is 3.3. The final [Al] is 1M. The Al 3+ :Arg:Ca 2+  molar ratio is 1:1.23:0.642. The peak 4 intensity is 96.94% and the peak 5 intensity is 3.06%. There is no peak 3. The reduction in calcium chloride compared to the comparative example is 47.8%. 
       Example 7 
       [0048]    Ten percent reduction in calcium. 18.81 mmol AlCl 3 .6H 2 O is dissolved in 29 ml deionized water. The solution is held at 95° C. in a glass reactor and stirred vigorously. To this solution, 9 ml of a suspension containing 4.72 mmol L-arginine and 21.25 mmol Ca(OH) 2  is added dropwise over a 2 hour period. The reaction solution is left heated and stirring for an additional 1 hour. A molar ratio of (OH) − :(Al) 3+  of 2.51 is employed. The pH after the reaction is 3.5. The final [Al] is 0.495M. The Al 3+ Arg:Ca 2+  molar ratio is 1:0.251:1.13. The peak 4 intensity is 95.5%, the peak 5 intensity is 3.8%, and the peak 3 intensity is 0.7%. 
       Example 8 
       [0049]    Ninety percent reduction in calcium. 18.80 mmol AlCl 3 .6H 2 O is dissolved in 29 ml deionized water. The solution is held at 95° C. in a glass reactor and stirred vigorously. To this solution, 9 ml of a suspension containing 42.47 mmol L-arginine and 2.36 mmol Ca(OH) 2  is added dropwise over a 2 hour period. The reaction solution is left heated and stirring for an additional 1 hour. A molar ratio of (OH) − :(Al) 3+  of 2.51 is employed. The pH after the reaction is 3.8. The final [Al] is 0.495M. The Al 3+ Arg:Ca 2+  molar ratio is 1:2.259:0.1254. The peak 4 intensity is 93.2%, the peak 5 intensity is 2.9%, and the peak 3 intensity is 3.9%. 
         [0000]    
       
         
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
                 Al 3+ :Arg:Ca 2+   
                   
                   
                   
                   
                   
                 % Reduction 
               
               
                 Example 
                 Molar Ratio 
                 Ca 2+  ions 
                 OH − /Al 3+   
                 Peak 3 
                 Peak 4 
                 Peak 5 
                 of CaCl 2   
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Example 5 
                 Al 3+ :urea:Ca 2+   
                 12.08 
                 2.51 
                 0.5% 
                 19.4% 
                 80.1% 
                 52.2% 
               
               
                   
                 1:1.23:0.642 
               
               
                 Example 6 
                 1:1.23:0.642 
                 12.09 
                 2.51 
                 0 
                 96.94%  
                 3.06% 
                 52.2% 
               
               
                 Example 7 
                 1:0.251:1.13 
                 21.25 
                 2.51 
                 0.7% 
                 95.5% 
                  3.8% 
                     10% 
               
               
                 Example 8 
                 1:2.259:0.1254 
                 2.36 
                 2.51 
                 3.9% 
                 93.2% 
                  2.9% 
                     90% 
               
               
                   
               
             
          
         
       
     
         [0050]    As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls. 
         [0051]    Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight. The amounts given are based on the active weight of the material.