Patent Description:
According to some embodiments, the present invention is directed to a powder soap as defined in the claims.

A powdered soap can be comprising a plurality of particles, each of the particles comprising: a cationic polymer; a clay; and a fatty component; wherein the plurality of particles has d77 value of <NUM> microns.

Other embodiments of the present invention include a method of forming a hand-soap/body soap/hair soap as defined in the claims.

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention as defined in the claims.

According to the present application, the term "substantially free" less than about <NUM> wt.

The present invention is directed to a powder soap as defined in the claims.

The shape of each of the plurality of discrete particles may be spherical. In other embodiments, the discrete particles may be ellipsoid, conical, cylindrical, cubical, cuboid, and the like. In some embodiments, the discrete particles may have a non-geometric shape.

The plurality of discrete particles may have a particle size distribution. The size distribution may include about <NUM>% to about <NUM>% of the plurality of particles having a particle size that is greater than <NUM>,<NUM> microns. The size distribution may include about <NUM>% to about <NUM>% of the plurality of particles having a particle size that is greater than about <NUM> microns and less than about <NUM>,<NUM> microns. The size distribution may include about <NUM>% to about <NUM>% of the plurality of particles having a particle size that is greater than about <NUM> microns and less than about <NUM> microns. The size distribution may include about <NUM>% to about <NUM>% of the plurality of particles having a particle size that is greater than about <NUM> microns and less than about <NUM> microns. The size distribution may include about <NUM>% to about <NUM>% of the plurality of particles having a particle size that is less than about <NUM> microns.

Each particle may comprise a soap composition comprising a cationic polymer, a clay, and a fatty component. In some embodiments, the soap composition may further comprise a pigment. In some embodiments, the soap composition may further comprise a fragrance.

The polyquat is present in an amount ranging from <NUM>% wt. % to <NUM>% wt. % as defined in the claims - including all percentages and sub-ranges-there-between - based on the total weight of the soap composition. Each particle may be formed entirely of the soap composition - therefore, the weight percentages referred to here may also be in reference to the total weight of the respective particle or active material. In a preferred embodiment, the cationic polymer (i.e. polyquat as defined in the claims) may be present in an amount ranging from <NUM>% wt. % to about <NUM>% wt. % - including all percentages and sub-ranges-there-between - based on the total weight of the soap composition.

The cationic polymer is a polyquaternary ammonium as defined in the claims - as referred to herein as a "polyquat. " The polyquat of the present invention may comprise a compound having formula (I) - which may also be referred to as a "diquat":
<CHM>
wherein R<NUM>, R<NUM>, R<NUM>, R<NUM>', R<NUM>', R<NUM>', R<NUM>, R<NUM>, in the above formula may be identical or different, and are independently selected from hydrogen, an C<NUM>-C<NUM> alkyl group, an aryl group, a benzyl group, an aralkyl group, or an alkylaryl group. Each C<NUM>-C<NUM>alkyl group may be substituted or un-substituted, linear or branched. R<NUM>, and R<NUM> in the above formula may be identical or different, and are independently selected from (CH<NUM>)m, or (CH<NUM>)m-(CH=CH)m'-(CH<NUM>)m, wherein <NUM>=>m>=<NUM>, <NUM>=>m'>=<NUM> and <NUM>>=n=><NUM>; and Z is anionic moiety including without limitation, F, Cl, Br, I and COOH.

The polyquat of the present invention may have a weight average molecular weight Mw most preferably about <NUM> to <NUM>,<NUM>. Non-limiting polyquats of the present invention include each of polyquaternium <NUM>-<NUM> compounds.

In a non-limiting example, the polyquat of the present invention may comprise polyquaternium-<NUM>: α-<NUM>-[<NUM>-tris(<NUM>-hydroxyethyl) ammonium-<NUM>-butenyl] poly[<NUM>-dimethylammonium-<NUM>-butenyl]-ω-tris(<NUM>-hydroxyethyl)ammonium chloride, having the chemical structure described in formula (II):
<CHM>.

Other non-limiting examples of such polyquaterniums include, but are not limited to (<NUM>) the polymeric quaternary ammonium salt of hydroxyethyl cellulose reacted with a trimethyl ammonium substituted epoxide, referred to as Polyquaternium-<NUM>; (<NUM>) the quaternary ammonium derivative of hydroxypropyl guar, referred to as guar hydroxypropyltrimonium chloride; (<NUM>) the copolymer of hydroxyethylcellulose and DADMAC, referred to as Polyquaternium-<NUM>; (<NUM>) the copolymer of acrylamide and METAMS, referred to as Polyquaternium-<NUM>; (<NUM>) the homopolymer of DADMAC, referred to as Polyquaternium-<NUM>; (<NUM>) The copolymer of acrylamide and DADMAC, referred to as Polyquaternium-<NUM>; (<NUM>) the copolymer of vinyl pyrrolidone and METAMS, referred to as Polyquaternium-<NUM>; (<NUM>) the homopolymer of METAMS, referred to as Polyquaternium-<NUM>; (<NUM>) the copolymer of methacrylamide and METAMS, referred to as Polyquaternium-<NUM>; (<NUM>) the polymeric quatemary ammonium salt of hydroxyethyl cellulose reacted with a lauryl dimethyl ammonium substituted epoxide, referred to as Polyquaternium-<NUM>; (<NUM>) the copolymer of vinyl pyrrolidone and MAPTAC, referred to as Polyquaternium-<NUM>; (<NUM>) the copolymer of acrylamide and METAC, referred to as Polyquaternium-<NUM>; (<NUM>) the copolymer of acrylamide and AETAC, referred to as Polyquaternium-<NUM>; (<NUM>) the copolymer of butylmethacrylate, dimethylaminoethylmethacrylate, and METAMS, referred to as Polyquaternium-<NUM>; (<NUM>) the homopolymer of METAC, referred to as Polyquaternium-<NUM>; (<NUM>) the copolymer of METAMS, methyl methacrylate, and hydroxyethylmethacrylate, referred to as Polyquaternium-<NUM>; (<NUM>) the homopolymer of MAPTAC, referred to as polymethacrylamidopropyltrimonium chloride; (<NUM>) Hydroxypropyl trimethyl ammonium chloride ether derivatives of starch, as generally described by the CAS Registry Number <NUM>-<NUM>-<NUM>, the starch of which can be derived from a variety of natural sources such as corn, potato, rice, tapioca, wheat, or other sources; (<NUM>) the copolymer of DADMAC and acrylic acid, referred to as Polyquaternium-<NUM>; (<NUM>) the copolymer of DADMAC, acrylic acid, and acrylamide, referred to as Polyquaternium-<NUM>; and (<NUM>) the copolymer of MAPTAC, acrylic acid, and methyl(meth)acrylate, referred to at Polyquaternium-<NUM>.

In a preferred embodiment, the cationic polymer is the homopolymer of DADMAC, referred to as Polyquaternium-<NUM>.

The clay is present in an amount of about <NUM> wt. % based on the total weight of each particle, and wherein the term "about" means +/- <NUM>% of the reference value <NUM> wt%. as defined in the claims. Generally, clay may be present in an amount ranging from about <NUM> wt. % to about <NUM> wt. % - including all percentages and sub-ranges-there-between - based on the total weight of the soap composition. Each particle may be formed entirely of the soap composition - therefore, the weight percentages referred to here may also be in reference to the total weight of the respective particle.

The clay may comprise a one or more of kaolin, kaolinite, dickite, halloysite, nacrite, smectite, montmorillonite, nontronite, illite, bentonite, attapulgite, palygorskite, sepiolite, hormite, pyrophyllite, chlorite, aluminosilicates, and mixtures thereof. In a preferred embodiment, the clay comprises calcined kaolin.

According to the present invention, it has been surprisingly discovered that the addition of the cationic polymer with the clay to the soap composition results in a powder soap that exhibits not only desirable feel when washing skin but also superior dissolution rates. Specifically, when added at an amount below <NUM> wt. % (preferably less than <NUM> wt. %, preferably less than <NUM> wt. %, preferably less than <NUM> wt. %, preferably less than <NUM> wt. %) based on the total weight of the soap composition - the clay no longer functions as a filler but rather causes each discrete particle of the powder soap to quickly disintegrate and dissolve without interfering with the superior feel provided by the addition of the polyquat.

In some embodiments, the compositions of the present invention further comprise an antibacterial agent or antifungal agent selected from: phenoxyethanol, triclocarban (TCC), chloroxylenol (PCMX), silver oxide, climbazole, zinc pyrithione, piroctone olamine, and the like.

The fatty component of the present invention may be present in an amount ranging from about <NUM>% wt. % to about <NUM>% wt. % - including all percentages and sub-ranges-there-between - based on the total weight of the soap composition. Each particle may be formed entirely of the soap composition - therefore, the weight percentages referred to here may also be in reference to the total weight of the respective particle. In a preferred embodiment, the fatty component may be present in an amount ranging from about <NUM>% wt. % to about <NUM>% wt. % - including all percentages and sub-ranges-there-between - based on the total weight of the soap composition.

The fatty component may be an ionic compound that is a salt of a fatty acid. Non-limiting fatty acids include saturated and unsaturated C<NUM> to C<NUM> fatty acids. Exemplary fatty acids include, but are not limited to, caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, palmitoleic acid, stearic acid, oleic acid, ricinoleic acid, vaccenic acid, linoleic acid, α-linolenic acid, γ-linolenic acid, arachidic acid, gadoleic acid, arachidonic acid, behenic acid, erucic acid, lignoceric acid, and mixtures thereof.

In a non-limiting embodiment, the ionic fatty component may comprise a solubilizing cation such as sodium, potassium, ammonium or substituted ammonium.

The fatty component may be present in an amount ranging from about <NUM> wt. % to about <NUM> wt. % - based on the total weight of the soap composition - including all percentages and sub-ranges there-between. Each particle may be formed entirely of the soap composition - therefore, the weight percentages referred to here may also be in reference to the total weight of the respective particle. In some embodiments, the fatty component may be present in an amount ranging from about <NUM>% wt. % to about <NUM>% wt. % - based on the total weight of the soap composition - including all percentages and sub-ranges there-between.

The soap composition may further comprise one or more fragrances. The fragrance may be present in an amount ranging from about <NUM>% wt. % to about <NUM>% wt. % - based on the total weight of the soap composition - including all percentages and sub-ranges there-between. Each particle may be formed entirely of the soap composition - therefore, the weight percentages referred to here may also be in reference to the total weight of the respective particle. In some embodiments, the fragrance may be present in an amount ranging from about <NUM>% wt. % to about <NUM>% wt. % - based on the total weight of the soap composition - including all percentages and sub-ranges there-between.

Non-limiting examples of fragrances and perfumes include odor compounds selected from: <NUM>-acetyl-<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>-octahydro-<NUM>,<NUM>,<NUM>,<NUM>-tetramethylnaphthalene, α-ionone, β-ionone, γ-ionone α-isomethylionone, methylcedrylone, methyl dihydrojasmonate, methyl <NUM>,<NUM>,<NUM>-trimethyl-<NUM>,<NUM>,<NUM>-cyclododecatrien-<NUM>-yl ketone, <NUM>-acetyl-<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>-hexamethyltetralin, <NUM>-acetyl-<NUM>-tert-butyl-<NUM>,<NUM>-dimethylindane, hydroxyphenylbutanone, benzophenone, methyl β-naphthyl ketone, <NUM>-acetyl-<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>-hexamethylindane, <NUM>-acetyl-<NUM>-isopropyl-<NUM>,<NUM>,<NUM>,<NUM>-tetramethylindane, <NUM>-dodecanal, <NUM>-(<NUM>-hydroxy-<NUM>-methylpentyl)-<NUM>-cyclohexene-<NUM>-carboxaldehyde, <NUM>-hydroxy-<NUM>,<NUM>-dimethyloctanal, <NUM>-undecen-<NUM>-al, isohexenylcyclohexylcarboxaldehyde, formyltricyclodecane, condensation products of hydroxycitronellal and methyl anthranilate, condensation products of hydroxycitronellal and indole, condensation products of phenylacetaldehyde and indole, <NUM>-methyl-<NUM>-(para-tert-butylphenyl)propionaldehyde, ethylvanillin, heliotropin, hexylcinnamaldehyde, amylcinnamaldehyde, <NUM>-methyl-<NUM>-(isopropylphenyl)propionaldehyde, coumarin, γ-decalactone, cyclopentadecanolide, <NUM>-hydroxy-<NUM>-hexadecenoic acid lactone, <NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>-hexahydro-<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>-hexamethylcyclopenta-γ-<NUM>-benzopyran, β-naphthol methyl ether, ambroxane, dodecahydro-<NUM>α,<NUM>,<NUM>,<NUM>α-tetramethylnaphtho[<NUM>,<NUM>b]furan, cedrol, <NUM>-(<NUM>,<NUM>,<NUM>-trimethylcyclopent-<NUM>-enyl)-<NUM>-methylpentan-<NUM>-ol, <NUM>-ethyl-<NUM>-(<NUM>,<NUM>,<NUM>-trimethyl-<NUM>-cyclopenten-<NUM>-yl)-<NUM>-buten-<NUM>-ol, caryophyllene alcohol, tricyclodecenyl propionate, tricyclodecenyl acetate, benzyl salicylate, cedryl acetate, and tert-butylcyclohexyl acetate.

Other fragrances may include odor compounds selected from essential oils, resinoids and resins from a large number of sources, such as, for example, Peru balsam, olibanum resinoid, styrax, labdanum resin, nutmeg, cassia oil, benzoin resin, coriander, and lavandin.

Further suitable fragrances include odor compounds selected from phenylethyl alcohol, terpineol, linalool, linalyl acetate, geraniol, nerol, <NUM>-(<NUM>,<NUM>-dimethylethyl)cyclo-hexanol acetate, benzyl acetate, and eugenol. The fragrances or perfumes can be used as single substances or in a mixture with one another.

The soap composition may further comprise one or more colorants. The colorants may be a pigment, a dye, or mixtures thereof. Non-limiting examples of pigments include titanium dioxide, Zinc Oxide, Kaolin, Mica etc. Non-limiting examples of dyes include food dyes suitable for food, drug and cosmetic applications, and mixtures thereof. Some color agents (colorants) are known as FD&C dyes.

The colorants may be present in an amount ranging from about <NUM>% wt. % to about <NUM>% wt. % - based on the total weight of the soap composition - including all percentages and sub-ranges there-between. Each particle may be formed entirely of the soap composition - therefore, the weight percentages referred to here may also be in reference to the total weight of the respective particle. In some embodiments, the colorants may be present in an amount ranging from about <NUM>% wt. % to about <NUM>% wt. % - based on the total weight of the soap composition - including all percentages and sub-ranges there-between.

The discrete particles that form the powder soap of the present invention are provided as solid discrete particles. In particular, the discrete particles may have a solids content of at least about <NUM>% based on the total weight of each discrete particle. Preferably, the discrete particles may have a solids content of at least about <NUM>% based on the total weight of each discrete particle. Preferably, the discrete particles may have a solids content of at least about <NUM>% based on the total weight of each discrete particle.

The discrete particles that form the powder soap of the present invention may have a content of liquid carrier - such as water or organic solvents - that is less than about <NUM> wt. % based on the total weight of each discrete particle. In some embodiments, the discrete particles that form the powder soap of the present invention may have a content of liquid carrier - such as water or organic solvents - that is less than about <NUM> wt. % based on the total weight of each discrete particle. In some embodiments, the discrete particles that form the powder soap of the present invention may have a content of liquid carrier - such as water or organic solvents - that is less than about <NUM> wt. % based on the total weight of each discrete particle.

In some embodiments, the discrete particles that form the powder soap of the present invention may be substantially free of liquid carrier - such as water or organic solvents.

The soap composition present in the powder soap of the present invention may have a solids content of at least about <NUM>% based on the total weight of the soap composition. Preferably, the soap composition present in the powder soap may have a solids content of at least about <NUM>% based on the total weight of the soap composition. Preferably, the soap composition present in the powder soap may have a solids content of at least about <NUM>% based on the total weight of the soap composition.

The soap composition present in the powder soap may have a content of liquid carrier - such as water or organic solvents - that is less than about <NUM> wt. % based on the total weight of the soap composition. In some embodiments, the soap composition present in the powder soap of the present invention may have a content of liquid carrier - such as water or organic solvents - that is less than about <NUM> wt. % based on the total weight of the soap composition. In some embodiments, the soap composition present in the powder soap may have a content of liquid carrier - such as water or organic solvents - that is less than about <NUM> wt. % based on the total weight of each soap composition.

In some embodiments, the soap composition that forms the powder soap of the present invention may be substantially free of liquid carrier - such as water or organic solvents.

The powder soap of the present invention may be manufactured by forming a blend of the cationic polymer, the clay, and the fatty component. According to the embodiments containing colorant, fragrances, and other additives, the additional components may also be added to the blend. The blend may be lightly agitated until the various components are uniformly distributed throughout the blend. According to some embodiments, the blend may further comprise one or more liquid carriers (e.g., water, non-aqueous solvent) to help the agitation of the various components.

Once agitated, the blend may be dried to remove the liquid carrier. The resulting dry blend may then be subjected to mechanical stress (e.g., grinding), thereby breaking apart the blend into smaller particles that form the plurality of discrete particles of the powder soap. Non-limiting examples of grinding may be subjecting the dry blend to a high-speed mixer, a Henschel mixer, or a Loedige mixer.

After grinding, the plurality of discrete particles may be collected. In some embodiments, the plurality of particles may be subjected to a screening to remove small or large particles not suitable for the powder soap. In other embodiments, the plurality of particles are not subjected to a screening process.

The resulting powder soap may then be distributed into the reservoir of a soap dispensing device. In non-limiting examples, the soap dispensing device may be a hermetically sealable bag, box, or another container.

In some embodiments, the soaps and personal care compositions described herein are in a form selected from: a hand soap; a gel; a shampoo; a conditioner; a cleanser; and a scrub (e.g. an exfoliating scrub or a facial scrub).

In some embodiments, the personal care compositions described herein are substantially anhydrous. In some embodiments, the personal care compositions described herein provide a skin-feel substantially similar to a comparative product having an aqueous carrier.

A first experiment was performed to test the dissolution performance of the soap granules. The first experiment included soap granules of four different formulations - as set forth below in Table <NUM>.

Each formulation was then processed into particles having a size distribution set forth as in Table <NUM>.

The particles of each of Comp. <NUM> and Ex. <NUM>-<NUM> were then subjected to a dissolution test, whereby equal amounts of each example were agitated by hand while being exposed to constant amounts of tap water, thereby simulating a hand-washing exercise. Each example included a total of ten (<NUM>) samples - whereby samples for each example were averaged to give a final rank of how each formulation performed in the dissolution test. The rankings for each example are tabulated below in Table <NUM>.

Claim 1:
A powder soap in the form of a plurality of discrete particles, each of the particles comprising:
a polyquat;
a clay; and
a fatty component,
wherein the polyquat is present in an amount ranging from <NUM> wt. % to <NUM> wt. % based on the total weight of each particle,
wherein the clay is present in an amount of about <NUM> wt. % based on the total weight of each particle, and
wherein the term "about" means +/- <NUM>% of the reference value <NUM> wt%.