JPS594480B2 - Solid casting detergent-containing products and their manufacturing and usage methods - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION This invention relates to solid cast detergent-containing products particularly useful in standardized dishwashers and industrial washing machines, and methods of making and using the same.

Normal standardized or industrial spray cleaning machines use liquid or powder detergents;
Generally, it is added to the wash tank by an automatic dispenser.

All forms of detergents of this type, whether liquid or solid, have stability problems and other problems associated with their manufacture, distribution, and use. These issues are discussed in publications and patent literature. In the early days of solid detergents, when performance was relatively low compared to today's products, the above problems were less pronounced. However, the emergence of high-performance products, spurred in part by increasing aesthetic and hygienic standards and demands for shorter cleaning times, generally have complex detergent formulations, are hazardous to the user, and are less stable. , and are difficult to dissolve to a satisfactory degree. For example, the higher the performance of a solid detergent, the more alkaline it is (for example, the higher the sodium hydroxide concentration).

In some cases, the alkalinity is so high that it is dangerous to the user.
Historically, dishwashing detergents have been relatively low in alkalinity. The large number of aluminum dishes and utensils in use, the presence of soft metals in wash pump impellers, and other factors generally preclude the use of highly alkaline detergents. It is. However, in recent years there has been a trend to use highly alkaline and high performance products. This is partly a result of the increased use of stainless steel and corrosion-resistant plastics in the manufacture of instruments. In addition, the above-mentioned standards required by the increase in the number of cafeteria businesses and the desire for short cleaning times (usually 10 seconds or less) have increased the demand for high-performance products. In addition to alkali metal hydroxides (e.g., sodium hydroxide), chemicals used in high-performance products include cleaning of particularly hard surfaces (
Examples include phosphates, silicates, chlorine-containing compounds, defoamers, and organic electrolyte polymers (for example, for cleaning utensils).

Regarding this point, U.S. Patent Nos. 3,166,513 and 3
No. 535285, No. 3579455, No. 3700
No. 599, and No. 3,899,436. In these compositions, the alkali metal hydroxides are effective in removing most stubborn stains from food and drink;
An available chlorine source is usually included to control food and drink stains, such as tea and coffee stains. Defoamers are commonly included to suppress foam caused by proteinaceous soils and saponified fats. Examples of the use of chlorinated cyanurates as a source of available chlorine in cleaning agents used to clean hard surfaces are described in US Pat. These patent documents also describe various means for obtaining chlorine-containing detergents with good storage stability. Examples of using defoamers in detergent compositions are U.S. Pat. Nos. 3,048,548 and 333,414.
No. 7 and No. 3442242. One problem with detergents that contain both a source of available chlorine and an organic defoamer is that most of the available chlorine is lost in a relatively short period of time. This problem has been addressed in many of the above-mentioned patent documents as well. Hooks, J. Polkowski and Kafagno, ``Agormered Automation and Data Transfer'' (
Chemical Times and Trends, 1977)
It is described on pages 37-42 of . One solution to this problem is to encapsulate the organic defoamer by absorbing it into inorganic carrier particles. (U.S. Patent No. 33
(See No. 06858). The problem of chlorine stability is present even in low alkaline detergents containing defoamers, but becomes more acute in high alkaline detergents. This is because many defoamers and chlorine-containing compounds are not stable in the presence of highly alkaline chemicals such as sodium hydroxide. In addition to chlorine stability issues, several problems still exist with high performance powder detergents used in standardized or industrial washers.

One of these is caused by the different solubility of detergent components. Not all standard detergent ingredients dissolve at the same rate or have the same equilibrium solubility.
For example, soluble fine particles such as sodium dichloroisocyanurate, a common source of available chlorine, dissolve much faster than sodium tripolyphosphate, a common detergent ingredient. Therefore, when a powder detergent containing these two components is charged to a dispenser, the initial effluent will be excessively rich in available chlorine, whereas the final effluent before being reloaded to the dispenser will be rich in available chlorine. become scarce. Another type of solubility problem exists for many defoamers.

Many defoamers have an oily viscosity and are poorly soluble in water. When detergents containing such defoamers are dispensed from a conventional Water-in-Reservoir type dispenser, the oil-based defoamers float to the surface and are not accidentally deposited into the wash tank. It can only be prepared.
Another problem arises when the components of powdered detergents differ in particle size and density. Differences in particle size and density between the components result in segregation during manufacturing, shipping, and handling. Even if uniformly dispersed during manufacturing, handling and shipping can cause deviations. Segregation creates non-uniformity in the composition of the detergent when it is removed from the container. Aggregation of each component has been used to minimize this segregation. However, with agglomeration, it is necessary to recycle any particles that are too large or too small, which make up a significant proportion of the product. Returning again to the issue of safety, one commonly used method is to dispense powdered or liquid detergents directly from the transport container.

In any case, for reasons of safety and convenience, it is desirable to minimize contact between the user and the high-performance detergent;
Also, one of the benefits of automatic distribution is that there is less contact.

In the case of liquid detergents, it is relatively simple to provide automatic dispensing systems and methods. For example, liquid detergent can be pumped directly from the transport container to the wash tank. However, things do not go so easily with solid detergents (in packet form or most typically in powder form). Several methods have been developed for using solid detergents without losing the benefits of automatic dispensing. One method is to apply detergents used in large conveyor type machines to US Pat. No. 35,954.
Direct dispensing from the transport container by means of a dispensing machine similar to that described in No. 38. The transport container is inverted and placed over the detergent dispenser reservoir and water spray is used to dissolve the detergent dispensed from the reservoir as needed. Systems are also known for dissolving powdered detergent from transport bins of 5 to 10 gallon capacity (
(See U.S. Pat. No. 4,020,865). Simply put, the solid powder detergent in the transport container is not in such a form that it can normally be introduced directly into the wash tank of a washing machine. It is generally preferred to make the powder detergent into a liquid, for example by dissolving it with water in special equipment to accomplish the dissolution. The dissolving device need not be physically separated from the washer. In fact, the solution /
It is common practice to install a distribution machine. This type of dispenser is the so-called water-in-reservoir type (when it is referred to as water-in-reservoir type,
Although this is not limited to the above-mentioned dispenser, in such a case, a water-in-reservoir dispenser is generally used in single-tub warewashing machines. Typically, water-in-reservoir type dispensers produce a concentrated cleaning solution from a detergent powder in a reservoir by the swirling or stirring action of the introduced water. This concentrated solution is delivered by gravity or directly through piping to the wash tank. The concentration of detergent in the wash tank can be maintained by a conductivity sensing control device similar to that described in US Pat. No. 3,680,070. Various other devices can dissolve and dispense powdered detergent and can be installed directly on the washer.

For example, US Pat. No. 4,063,663 describes a dispenser in which powdered detergent is placed on a conical or hemispherical screen and water is sprayed from below the screen to dissolve the detergent. The concentrated solution produced by the water spray is collected and introduced into a wash tank. This dispenser has no water retention inside the dispenser.
It differs from the water-in-reservoir type in that the powder detergent mass remains dry, but otherwise operates similarly to the water-in-reservoir type. Other powdered detergent dispensers include small dispensers that hold 4 to 6 pounds of detergent.

The hopper of the dispenser can be refilled with washing from a drum containing detergent by using single or small individual (eg, 2 pound) loads of detergent. Dispensers for cleaning machines are also known which consist of a plurality of hoppers filled with different chemicals or mixtures thereof. Dispensing devices for dispensing prickets of detergent are also known.

In this regard, US Pat.
No. 382164, No. 2382165 and No. 24
See No. 12819 (all McMahon patents). In this case, the detergent pricket is dispensed from a round pot-shaped dispenser of the modified water-in-reservoir type. The prickets (usually three) are held in a mesh basket that forms an approximately 1-inch wide slot across the diameter of the dispenser. The dissolving action is obtained by the flow of water directed towards the lowermost pricket and from the swirling action of the water around the immersed portion of the lowermost pricket. Similar to the water-in-reservoir type, water remains in the storage tank. This type of device has the advantage that it is possible to visually determine when the reservoir of the detergent dispenser needs to be refilled. The McMahon patent also discloses detergent pricket compositions and methods of making the same.

This composition and process requires silicates and trisodium polyphosphate or sodium carbonate. Detergent bars or cakes are also known which are highly encapsulated with organic detergents and tripolyphosphates. (U.S. Patent No. 39
39286). Compressed tablets containing detergents are also known (U.S. Pat. Nos. 2,738,323 and 3).
417024).

In the field of dispensing solid detergents into conventional standardized or industrial washing machines for spray cleaning of hard surfaces (eg, ware washing), prickly detergents are inferior to powdered detergents.

The present invention has been made in view of the above circumstances, and its purpose is to provide a detergent-containing product that can minimize the problems of chlorine stability, solubility difference, segregation, and safety issues, as well as its manufacturing method and use. The purpose is to provide a method.

This objective is achieved by molding a solid casting detergent into a disposable mold and dispensing or using the product directly from the mold and detergent combination. That is, the combination of a cast detergent and a disposable mold provides a product in which the dissolved solid detergent can be dispensed from substantially one surface (the surface not supported in the mold). This detergent product further reduces chlorine stability and differential solubility problems by including the chlorine source and/or defoamer as a plug or wick encapsulated in the cast detergent. Accordingly, this invention provides three-dimensional solid cast detergent compositions containing an alkaline hydratable solid component and at least one other solid component, and which surrounds the detergent composition on all but one surface. The present invention relates to a product made of a container-shaped mold, and a method for manufacturing and using the same.

The above-mentioned detergent composition is usually prepared by mixing each component in the form of an aqueous solution, heating the solution, cooling the solution to thicken it, and hydrating the hydratable components, and then pouring the solution into a mold. It is obtained by injecting it and solidifying it. The plug or core can be preformed and inserted after pouring the aqueous solution into the mold and before solidifying. The casting detergent remains in the disposable mold and is placed in a detergent dispensing device where it is eluted from the mold through an opening in the mold by a liquid spray.

This invention will be explained in more detail below by dividing it into each item.
Raw Materials One ingredient necessary to make the cast detergent compositions of this invention is a hydratable chemical.

This "hydratable chemical" includes chemicals that can form both discrete and continuous states of hydration, absorbing or binding water (e.g., 0.2 to
20 moles) means a chemical capable of producing hydration in any of the above states. This hydrating chemical is usually alkaline. In other words, is this one weight? Aqueous solution is 23℃
So…the value exceeds 7.0. Since the detergent composition used in this invention is highly alkaline, it is preferred that the hydrating chemicals (components) are themselves alkaline. Hydrable chemicals useful in this invention include alkali metal hydroxides such as sodium hydroxide and potassium hydroxide; silicates such as sodium metasilicate; phosphates, particularly those of the formula MO-(-PO3M+; or PO3M-(-PO3
Phosphates represented by MCHNPO3M (where M is an alkali metal and n is 1 to about 60), such as sodium orthophosphate or potassium orthophosphate, and alkaline salts such as sodium pyrophosphate, potassium pyrophosphate, and sodium tripolyphosphate. Condensed phosphates and the like; carbonates such as sodium carbonate and potassium carbonate; borates such as sodium borate; zeolites and the like. An example of a combination of two hydrating chemicals is sodium hydroxide and sodium tripolyphosphate. The second necessary component of the detergent compositions of this invention is water.

Water is used to create a solution containing detergent ingredients. This solution is poured into a mold and solidifies as the hydratable chemicals form hydrates with water. Water is added separately or in combination with other ingredients (eg, as a 50% aqueous solution of sodium hydroxide). This invention requires at least two solid components.

With only one solid component, problems of solubility differences and segregation would not exist, and there would be little advantage in molding the casting composition. The advantages of cast detergent compositions over conventional powder detergent compositions are discussed in more detail below. In addition to the ingredients already mentioned, other customary detergent ingredients and fillers may be added.

For example, it is common to add an available chlorine source and a defoaming agent. Many sources of chlorine can be used, including chlorinated isocyanurates such as sodium dichloroisocyanurate dihydrate and hypochlorites such as sodium hypochlorite and lithium hypochlorite. be. As will be described in more detail below, when the detergent composition of the present invention contains an available chlorine-containing component, it is preferably included as a preformed plug or wick. Defoamers are also commonly used in detergent compositions. Typically, a "defoamer" is a compound with a suitable hydrophobic/hydrophilic balance to reduce foam stability. Hydrophobicity is provided by the lipophilic portion of the molecule (eg, aromatic alkyl or aralkyl groups; oxypropylene units or chains, or oxyalkylene groups other than oxyethylene, such as tetramethylene oxide). Hydrophilicity is provided by oxyethylene units, chains or blocks and/or ester groups such as organophosphates, salt-type groups or salt-forming groups. Typically defoamers are hydrophobic. It is a nonionic organic surface-active polymer having a hydrophilic ester group, block, unit or chain, but anionic, cationic and zwitterionic defoamers are also known. Examples of ionic defoamers are U.S. Pat. No. 3,048,548 and U.S. Pat.
No. 334147 and No. 3442242. Phosphoric esters are likewise suitable. For example,
Formula RO+PO3M+NR (where n is as described above,
There are also esters in which R is an organic group or M (as described above) and at least one R is an organic group such as an oxyalkylene chain. If a defoamer is included, it can be included as a preformed plug or core, as described below. When included as a preformed plug or wick, it is solid at room temperature or becomes solid when combined with other ingredients. Further wax-like substances may be added to separate the chlorine source or defoamer in the core from the surrounding casting. Detergent Composition The above hydratable chemicals or mixtures thereof usually make up at least 30% by weight of the cast detergent composition. , preferably 60 weight? Configure.

The water of hydration typically comprises at least 15% by weight of the cast detergent composition.
Preferably 25 weight? Configure. Performance-improving additives such as active chlorine-generating components and defoamers constitute a minor amount, ie, up to 5% by weight, of the casting detergent composition. A typical three-component composition of this invention is (1) a phosphate or other sequestering agent, (2) an alkali metal hydroxide, and (3)
It is made of water.

A typical four-component or five-component composition includes a defoamer and/or a neutral inorganic salt (alkali metal halide, alkali metal sulfate, etc.) and/or a chlorine source and/or
It further contains thickening agents, thixotropic agents, suspending agents, etc. Typical detergent compositions of this invention include metal ions (Mg
+8 and Ca+8 ions) A condensed alkali metal phosphate is used as a sequestering agent.

However, there are substitutes for this condensed phosphate, such as U.S. Pat.
No. 700599 and No. 3869436.

One embodiment of a solid cast detergent-containing product according to the invention is shown at 1 in the accompanying Figures 1-3.

The product 1 consists of a disposable container or mold 3 and a detergent 2 cast or solidified within the mold 3. During transportation, the product 1 is typically provided with a lid or cover 5. The lid or cover 5 can be made of the same or similar material to that of the mold 3. As discussed below, this material is alkali resistant, indestructible, and inexpensive. Although more expensive corrosion-resistant metals or plastics can be used for reuse, "disposable" materials are usually preferred for most industrial applications. As shown in FIG. 2, all surfaces of the casting detergent composition except the upper surface are surrounded by and in contact with the mold 3. In a preferred embodiment of the invention, the casting detergent includes one or more pre-shaped plugs or wicks 6, as shown in FIGS. 2 and 3.

At least one plug typically comprises a chlorine source. When multiple plugs are used, they usually consist of different and incompatible components. For example, one plug may consist of a chlorine source, another a defoamer, etc. By introducing the chlorine source in one plug and the defoamer in a separate plug, the deterioration of the chlorine source that often occurs due to contact between the chlorine source and the defoamer and the resulting effectiveness can be avoided. Disappearance of chlorine is suppressed. That is, by introducing incompatible components as plugs, stability problems associated with conventional powder detergents are minimized. To suppress the reaction between the detergent and the material added as a core, the core material may be encapsulated with a film or material that does not react with the core material or with the detergent. This encapsulation can be accomplished using natural waxes, synthetic waxes, phosphate esters, and the like. Some available chlorine sources, such as calcium hypochlorite, react very slowly at the interface between the plug and the detergent, so it is not necessary to encapsulate them in a film, etc.
Usually not.

However, other chlorine sources, such as sodium dichloroisocyanurate dihydrate, are more reactive and in this case it is advantageous to use the film described above. The mold or container 3 is at a slightly higher temperature, for example 150'F (65.
It may be made of any alkali-resistant material that can withstand temperatures (6°C) and can be molded into the desired shape.

Since molds are generally intended to be "disposable" (ie, not intended to be reused as molds), inexpensive materials such as thermoplastics, resin-impregnated cardboard, etc. are preferred. Cheap but brittle materials such as glass and ceramics are not ideal for handling and transportation. Relatively flexible materials are preferred. Molds made of plastic (eg, inexpensive thermoplastics) are particularly useful. MANUFACTURE METHOD Although the manufacturing method is described below with respect to specific ingredients, other or similar methods may be used to prepare a detergent solution, inject it into a mold, and solidify by hydration of its hydratable components. method can also be used.

Particularly useful detergent compositions of this invention include 50-75% by weight of an alkali metal hydroxide (e.g., sodium hydroxide).
It is produced by heating 50-75 parts by weight of an aqueous solution to about 55-65°C. Although other alkali metal hydroxides may be used, sodium hydroxide is particularly useful, and hence the process of the present invention will be described with reference to sodium hydroxide. 50 weight of sodium hydroxide? Aqueous solutions are commercially available. Aqueous solutions containing higher concentrations of sodium hydroxide are also commercially available (e.g. 73%) and
0? It can be prepared by adding the desired amount of anhydrous sodium hydroxide to an aqueous solution. Aqueous solutions of sodium hydroxide can also be prepared by mixing water and anhydrous sodium hydroxide in the desired proportions. After the aqueous sodium hydroxide solution reaches a temperature of about 55 to 65°C, 30 to 40 parts by weight of anhydrous sodium tripolyphosphate is added thereto. This sodium tripolyphosphate usually does not dissolve completely, so it is kept suspended by continuous mixing. Other fillers and ingredients may then be added as desired. The solution is then allowed to cool while stirring. After about 10 to 15 minutes, the mixture begins to thicken. Once it begins to thicken, the mixture is poured into the container-shaped mold to such an extent that it rises at least partially up the side wall surface of the mold. As the mixture cools, it solidifies to form a casting composition. The solidification is partly due to solidification, but is thought to be mainly due to hydration of sodium tripolyphosphate and partly due to hydration of sodium hydroxide. After solidification, the casting detergent is surrounded by and in contact with the mold on all sides except the top surface. A preformed core or plug, such as plug 6 shown in FIGS. 2 and 3, may be added after the detergent is poured into the mold and before it solidifies.

When a plug is added, the detergent solidifies around it and holds it together. Although any size and shape plug can be used, it is preferred that the plug span the entire depth of the detergent, as shown in Figure 2. The plug extends through the depth of the solidified detergent so that a constant component ratio is achieved while the detergent and plug are dissolved for use. Another method of containing separately molded plugs is to use a mold comprising one or more smaller molds within a larger mold.

The larger mold contains the casting detergent, and the smaller mold contains another composition such as an available chlorine source or defoamer. This composition is poured into small molds and pressed. Method of Use The solid cast detergent-containing product of this invention is generally used as shown in FIG.

A detergent dispensing device 10 is shown in FIG. This device may form part of a conventional standardized or industrial cleaning machine (not shown). A product 1 consisting of a detergent 2, a preformed plug 6 and a container 3 is connected to a water source 1
4 is installed in an inverted state on a spraying mechanism 12 connected to 4. When the water source 14 is activated, water is sprayed by the sprayer 12 onto the exposed surfaces of the detergent 2 and the plug 6. The detergent and plug dissolve and flow through pipe 13 to the wash tank of the washer (not shown). Detergent 2 and plug 6 can be prepared to dissolve at substantially the same rate, so that the wash tank is filled with a fixed ratio of the components. By controlling the spray time, the amount of detergent in the wash tank and hence the detergent concentration can be controlled. Examples of this invention will be described below.

All "parts" and "%" in the examples are based on weight.
Example 1 An 8.8 pound batch (approximately 40
00 grams) was prepared by the following steps.

55 parts of a 50% aqueous solution of sodium hydroxide was charged to a laboratory mixer equipped with a stirrer and a heater.

The aqueous sodium hydroxide solution was heated to about 55-60°C. To this was added 9 parts of anhydrous sodium hydroxide. This solution was stirred until the anhydrous sodium hydroxide was completely dissolved. By adding anhydrous sodium hydroxide, an approximately 57% aqueous solution of sodium hydroxide was obtained. 36 parts of anhydrous sodium tripolyphosphate was added to the above aqueous solution and mixed.

The tripolyphosphate salt was not completely dissolved, but was suspended by mixing. Mixing was continued without heating until the solution began to thicken. This was approximately 10-15 minutes after the addition of tripolyphosphate. After the mixture has thickened and is still in the fluid stage, 6 lbs.
1 end) Approximately 6Σ inch (approximately 16.5C1T
L), a container-shaped mold consisting of a slightly tapered cylindrical plastic container with a small diameter of about 5Σ inches (about 14CTfL) and a depth of about 4 inches (about 11.5C!!L) (
For example, it was poured into a mold 3) shown in FIGS. 1 to 3.

This mixture was allowed to solidify in a mold. This took approximately 5 minutes. The composition of the final cast product was approximately as follows.
Example 2 A product with the same composition as Example 1 was prepared, except that 1 part of the defoaming agent replaced 1 part of the 50% aqueous sodium hydroxide solution.

The defoamer was added following the addition of the sodium tripolyphosphate and was uniformly dispersed by mixing until the mixture was poured into the mold. Upon injection, the mixture was sufficiently viscous to maintain a homogeneous dispersion. The composition of the final cast product was approximately as follows.

Example 3 A mixture was prepared according to the steps of Example 1.

53.57 parts of a 50% aqueous sodium hydroxide solution, 8.77 parts of anhydrous sodium hydroxide, and 35.06 parts of anhydrous sodium tripolyphosphate were used.

This mixture was poured into the mold of Example 1. Before this mixture completely solidifies, it will be approximately 1 inch in diameter (approximately 2.5 Cfr.
A preformed circular plug of a source of available chlorine, 3-inch long, was embedded approximately in the center of the mold. The length of the plug was such that it reached from the bottom of the mold to the surface of the mixture. The mixture was then allowed to solidify around the plug. The composition of the final casting detergent was as follows.

The available chlorine containing plug was prepared by forming the following composition. 1υυ●υ After the above three components were mixed, they were filled into a cylindrical die of an appropriate size, and this was pressed at about 2000 psi in a hydraulic press.

Available chlorine-containing plugs were manufactured from the following two compositions according to the same process as above.

The two types of plugs mentioned above were also useful. EXAMPLE 4 This example shows how to further separate the plug 6 of FIGS. 2 and 3 from detergent.

Plugs were obtained by compression molding the following two compositions at a mold pressure of about 2000 psi. The above two plugs were immersed in paraffin wax maintained at a temperature slightly higher than the melting point of 56.5°C to form a film of paraffin wax on the peripheral wall and one end of the plugs. This wax was cooled and solidified. Example 3 of each of these plugs
It was inserted into the casting detergent of Example 2 according to the steps of . No reaction at the interface with the detergent was observed for any of these plugs. Example 5 A mixture was prepared according to the steps of Example 2.

50, sodium hydroxide 52.57 parts, anhydrous sodium hydroxide 8.77 parts, anhydrous sodium tripolyphosphate 35
．． 06 parts and 1 part of defoamer were used.

This mixture was then poured into the mold of Example 1. Before the mixture completely solidified, 2.6 parts of a chlorine-containing plug similar to that of Example 3 was added as in Example 3. The composition of the final casting detergent was as follows. Example 6 A solid cast detergent having the same composition as in Example 5 was produced.

However, the defoamer was not mixed with the detergent and was added as a plug. That is, two plugs were used, one consisting of a defoaming agent and the other consisting of an available chlorine source. Two plugs were inserted approximately in the center of the mold after the detergent was injected and before it solidified. The composition of the final solid casting detergent was as follows.

The above defoamer plug is prepared by heating a mixture of 60 parts of a viscous polyoxyalkylene glycol at room temperature and 40 parts of a solid mixture of a monoalkyl phosphate and a dialkyl ester of phosphate until the phosphoric acid ester melts; was prepared by mixing until homogeneous.

This mixture was then poured into a cylindrical mold and cooled to produce a solid plug at room temperature. Following substantially the same process as above, 50 parts of polyethylene glycol, 25 parts of polyoxyalkylene glycol, and 25 parts of a mixture of phosphoric acid monoalkyl ester and phosphoric acid dialkyl ester were prepared.
A similar plug was manufactured using

Example 7 A solid casting detergent was manufactured using the same composition and process as in Example 2, except that 1 part of a defoaming agent was added as a plug similar to Example 6.

Example 8 Approximately 6 pounds of solid cast detergent was made according to the following process.

A laboratory mixing apparatus equipped with a stirrer and a heater was charged with 40 parts of anhydrous sodium metasilicate and 39 parts of a 10% aqueous solution of sodium hypochlorite.

The solution was heated to approximately 55-60°C. To this was added 20 parts of anhydrous sodium tripolyphosphate, and the solution was mixed without heating until it began to thicken. After the mixture thickened, it was poured into the same mold as in Example 1 while it was still fluid. Before the mixture completely solidified, 1 part defoamer plug similar to Example 6 was added according to the previous steps.
The composition of the final solid casting detergent was approximately as follows.

40% Sodium metasilicate 35% Water 20% Sodium tripolyphosphate Example 9 This example shows that the sodium tripolyphosphate of each of the above Examples was reacted with sodium trimetaphosphate and sodium hydroxide according to the following reaction steps. This shows that it can be generated on the spot.

Approximately 2200 Tnl of 50% aqueous sodium hydroxide solution was added to a jacketed stainless steel beaker equipped with a Lightning stirrer.

The temperature was 70'F (21°C). Then, 1440 grams of sodium trimetaphosphate powder was slowly added. The mixture reached a temperature of 100'F (38°C) and was then cooled. The remainder of the sodium trimetaphosphate was added gradually until all 1440 grams were added. A maximum temperature of 200°F (93°C) was reached during this addition. After standing for a few minutes, the mixture became a solid that could be poured into molds and used as a solid casting detergent.

Example 10 This example demonstrates that chlorinated trisodium phosphate can be used as a chlorine source.

A solid cast detergent having the following composition was manufactured. The above mixture was prepared according to the steps of Example 2.

Approximately 2360 grams of this mixture was poured into a mold with a removable 2 inch diameter cylinder in the center. After the mixture solidified, the cylinder was pulled out to form a hollow cylindrical cavity.
Approximately 34 kg of chlorinated trisodium phosphate is added to this hollow cavity.
I put in 0 grams. This chlorinated trisodium phosphate solidified when cooled below its melting point. Some reaction occurred at the interface of this plug. This reaction can be accomplished by completely cooling the casting detergent before injecting the chlorinated trisodium phosphate and/or by covering the cavity surface with an inert barrier such as paraffin wax or mono- and dialkyl esters of polyphosphoric acid. It can be greatly reduced by coating. Example 11 This example shows the production of a non-phosphate solid cast detergent.

1500 parts of 5-0% aqueous sodium hydroxide solution in a jacketed stainless steel beaker equipped with a stirrer.
Heat to F (65.5°C). To this was added 20 parts of anhydrous sodium hydroxide and the mixture was stirred until a molten solution formed. To this was added 25 parts of a liquid silicate (RU Silicate manufactured by Philadelphia Tautz) with an S102/Na20 ratio of 2.54, and the temperature of the mixture was approximately 200'F.
(93°C). Heat this mixture to about 150°F (7
1°C) and 15 parts of sodium polyacrylate.
Add slowly while stirring. The above mixture was poured into a plastic container and allowed to cool and solidify. Example 12 This example compares the available chlorine concentration in the effluent from a cast detergent containing product of the present invention and a conventional powder detergent.

The above conventional detergent was a mixture consisting of sodium tripolyphosphate, sodium dichloroisocyanurate (chlorine source), sodium metasilicate and sodium hydroxide. Sodium dichloroisocyanurate makes up about 2.0% of the mixture.
It comprised 8%. The cast detergent-containing product used was manufactured using the composition and method shown in Example 5. The chlorine source was added as a plug located approximately in the center of the casting detergent.
This cast detergent-containing product was dispensed from a device similar to that shown in FIG. The conventional detergent is disclosed in US Pat. No. 3,680,007.
It was dispensed from a water-in-reservoir type dispenser as shown in Figure 1 of No. 0. Effluent samples from each of the above dispensers were collected periodically and titrated for alkalinity with hydrochloric acid to the phenol phthalein end point, and available chlorine was determined by conventional iodometric titration with sodium thiosulfate.

The temperature of the outflow water supplied to each dispenser above is approximately 7
It was 1℃. The amount of detergent in each effluent was determined by the alkalinity of the effluent. The theoretical chlorine recovery rate (CRPT) was calculated using the following formula. The results are shown in Figure 5.

In FIG. 5, curve a relates to the present invention, and curve b relates to the conventional method. As can be seen in FIG. 5, the solid cast detergent of the present invention provides an effluent with a much more uniform chlorine concentration than conventional powder detergents. The reason why the chlorine concentration in the effluent of conventional detergents varies is thought to be due to the difference in solubility of each component. COMPARATIVE EXAMPLE This comparative example was designed to investigate the effects of segregation that occurs during the manufacture of conventional conventional O powder detergents.

Since there is no segregation in the solid cast detergents of this invention (as all components are physically combined), segregation for powdered detergents represents a disadvantage of powdered detergents. The conventional powder detergent used was the same as in Example 12. This powdered detergent is commonly packaged in two pound packages. Seven 2 pound packages from the same production batch were randomly selected for analysis. Ideally, each package should contain the four components in equal proportions. The contents of each package were weighed and dissolved in the appropriate amount of water in a 30 gallon drum to form a 1% (w/v) solution.

This eliminated any variation due to different amounts of detergent present in each package. A 100 ml sample was collected from each drum and the percent available chlorine was determined using standard iodometric titration with sodium thiosulfate.
was titrated. The results were as follows. As shown in the above results, the effective chlorine concentration ranges from 1.53 to 2.
It fluctuated up to 00.

This variation is due in part to deviations that occur during mixing and packaging of the detergent powder. This deviation is probably one of the factors causing the variation in chlorine recovery shown in FIG.
Example 13 This example is intended to compare the solid cast detergents of this invention where the chlorine source is added directly to the detergent and when the chlorine source is added as a plug as shown in Example 3. be.

Three types of chlorine sources were used. namely, sodium dichloroisocyanurate dihydrate (NaDCC-2H20), lithium hypochlorite (LiOCt) and calcium hypochlorite (Ca(0Ct)2). All compositions were prepared according to the process of Example 1, in the first case the chlorine source was added directly (up to the addition of sodium tripolyphosphate), in the second the chlorine source was added as a plug. In the third case, the chlorine source plug is replaced with paraffin wax (melting point 52.5
In the fourth case, the chlorine source plug is immersed in mono- and dialkyl esters of polyphosphoric acid (waxy solid,
(melting point approximately 65.6-71°C). Table 1 shows the composition used and the available chlorine (%) remaining after each time period. As can be seen from Table 1, when the chlorine source is added directly to the detergent, most of the chlorine disappears within 24 hours.

However, excellent chlorine stability is obtained for Ca(0Ct)2 and LiOCt when the chlorine source is added as a preformed plug. The best chlorine stability is obtained when the chlorine source is coated with paraffin wax or a film of mono- and dialkyl esters of polyphosphoric acid. Example 14 This example uses a conventional powder detergent (ScOre: a commercial product manufactured by Economics Laboratories), (B) a casting detergent (
To compare the uniformity of the distribution of the defoamer from (C) a casting detergent containing the defoamer as a plug (product of Example 6) (product of Example 5).

Each of these compositions contained 1% defoamer. The conventional detergent (4) and the product of Example 6 (B) contained the same defoamer. The product of Example 6 (0 contained a blend of the two defoamers shown in Example 6, which blend was used to obtain a solid product that could be formed into plugs). All The test was conducted in a Hobart C-44 single tank dishwasher.

A water-in-reservoir type C-11 dispenser (manufactured by Economics Laboratories) was used to dispense the detergent. A dispenser similar to that shown in FIG. 4 was installed in a Hobart C-44 dishwasher for dispensing detergent (B) and (0). Both dispensers were electrically conductive of the type described in U.S. Pat. The detergent concentration in the wash tank was controlled by a rate sensing controller that was set to 0.2% detergent concentration in the wash tank.
). Defoamers are included in spray cleaner detergents to control foam caused by food and beverage soiling.

Foam in the wash tank causes air to be entrained in the wash fluid circulating through the washer, reducing mass and kinetic energy and resulting in poor soil removal. Excess foam in the wash tank will cause a loss of water pressure. This water pressure can be measured with a manometer connected to the wash branch pipe upstream of the water pump. Eggs are a common foaming contaminant and were used in this study. The above C-11 dispenser dispenses approximately 4 ml of powdered detergent.
4 pounds of conventional detergent was used.

Approximately 6 pounds each of detergents (B) and (O) were used and were in the form described in Example 1 and shown in Figures 1-4.The water pressure (in inches of water) was
Recordings were made when approximately 1/2 of the detergent was dispensed and when approximately 4/5 of the detergent was dispensed.

The manometer records the detergent prepared: (1) in the case of water only, (2) after the addition of the detergent, (3) after 5 minutes after adding 115 grams of eggs, and (4) after 5 minutes after adding another 100 grams of eggs. It happened later. Between the loading test and the 1/2 detergent consumption test, the fill valve was opened to pump in 2 gallons of water per minute, allowing the rinse water to be supplied to the wash tank to refresh the wash water. Approximately normal dilution of the wash tank.

The conductivity detection control device detects that the detergent concentration in the cleaning tank is 0.2.
It was set to be %. When about 1/2 of the detergent charged in the dispenser remained, a record was made using a manometer, and the two egg additions were completed. Recordings were made 5 minutes after each egg addition. Also, 1/5 of the detergent charged in dispenser 1 remained in dispenser 1 (4
/5 was consumed), the same thing was done. The test at the time of 1/2 consumption of detergent is more severe than the test at the time of preparation.
Furthermore, since the washing tank was not drained between each test, the egg contamination concentration was accumulated, so the test when 4/5 of the detergent was consumed was more severe than the test when 1/2 of the detergent was consumed.

The results are shown in the table.

As can be seen from the table, detergent (Q) showed the highest and most stable water pressure, and detergent (B) showed higher and more stable water pressure than detergent (4).

High and stable water pressure indicates that the defoaming agent is being supplied evenly. The defoaming agent in the powder detergent (4) floated to the surface and formed an oily film throughout the dispenser.

As a result, it is thought that the defoaming agent was not distributed uniformly but instead was distributed as a slag. In contrast, for the solid cast detergent of the present invention, the detergent and defoamer are dispensed simultaneously, resulting in an even distribution of the defoamer.

[Brief explanation of the drawing]

FIG. 1 is a partially cutaway side view of a cast-molded detergent-containing product of the present invention, and FIG. 2 is a sectional view of another cast-molded detergent-containing product of the present invention.
3 is a top view of the product shown in FIG. 2, FIG. 4 is a view of the product shown in FIG. 2 installed in a dispenser, and FIG. 5 is a top view of the product shown in FIG. A graph showing the chlorine distribution of mold detergents as well as that of conventional powder detergents. 2... Casting detergent, 3... Disposable mold, 5... Lid, 6... Additive plug, 10... Dispenser 1 12...
spray machine.

Claims (1)

[Scope of Claims] 1 Consisting of at least two solid components, at least one of the solid components being an alkaline hydrating chemical containing an alkali metal hydroxide, and a second solid component containing sequestering metal ions. a three-dimensional solid cast hydrated detergent composition containing at least 30% by weight of the hydratable chemical, in which each component is uniformly blended; and excluding one surface of the detergent composition. A solid cast detergent-containing product consisting of a receiver-shaped mold that encloses it in contact with all surfaces. 2. The product according to claim 1, wherein the mold is a mold in which a detergent composition is cast and solidified. 3. The product of claim 1, wherein the detergent composition contains at least 15% by weight of water of hydration. 4. The product according to claim 2, characterized in that a lid is attached to the mold. 5 Patent characterized in that it comprises at least one preformed core, enclosed on at least one side in contact with a detergent composition, consisting of an available chlorine source or a defoaming agent. The product according to claim 2. 6. The product according to claim 5, wherein the wick is made of an available chlorine source. 7. The product according to claim 5, wherein the core is made of a defoaming agent. 8 comprising at least two wicks, at least one of which consists of an available chlorine source and at least another one of which consists of a defoamer. product. 9. Product according to claim 5, characterized in that the core is separated from the detergent composition by an inert film. 10 consisting of at least two solid components, at least one of which comprises an alkaline hydratable chemical containing an alkali metal hydroxide, a second solid component comprising a sequestering agent; At least 3 drugs
A three-dimensional solid casting detergent composition containing 0% by weight, in which each component is uniformly blended, and a receptor shape surrounding the detergent composition so as to be in contact with all surfaces except one surface. A solid cast detergent-containing product comprising a mold is placed in a dispensing device for dispensing detergent to a cleaning area so that the exposed surface of the detergent composition is exposed within the interior of the dispensing device, and the exposed surface of the detergent composition is A method of using a solid cast detergent-containing product comprising contacting an aqueous liquid with an aqueous liquid to form a cleaning liquid containing the detergent composition, and then dispensing the cleaning liquid to the cleaning area. 11 (a) About 50 to 75 parts by weight of a 50 to 75% aqueous solution of alkali metal hydroxide at about 55 to 65°C.
(b) add about 30 to 40 parts by weight of a sequestering agent to the aqueous solution, (c) cool and thicken the resulting solution while mixing, and (d) receive the thickened solution. (e) pouring into a body-shaped mold so as to reach at least the sides thereof and such that the top surface is not supported by said mold;
A method for manufacturing a solid cast detergent-containing product, comprising solidifying the thickened solution in the mold. 12. The manufacturing method according to claim 11, wherein the alkali metal hydroxide is sodium hydroxide. 13. The manufacturing method according to claim 12, wherein the sequestering agent is sodium tripolyphosphate. 14. Process according to claim 11, characterized in that after step (d) and before step (e) at least one preformed additive core is inserted into the thickened solution. 15. The manufacturing method according to claim 14, wherein at least one of the additive cores comprises an available chlorine source. 16. The manufacturing method according to claim 14, wherein at least one of the additive cores comprises a defoaming agent. 17. The production method according to claim 11, wherein the sequestering agent is sodium phosphate or potassium phosphate. 18. The manufacturing method according to claim 11, wherein the metal ion sequestering agent is sodium polyphosphate. 19 Claim 1 in which the sequestering agent is sodium trimetasilicate or potassium trimetasilicate
The manufacturing method according to item 1. 20. The manufacturing method according to claim 11, characterized in that at least one kind of polymer electrolyte water quality regulator is added.