US4722802A — Process for the manufacture of surfactant cleansi…

Claim 1

Independent Claim 47 words

A process for the manufacture of a formed cleansing block adapted for slow dissolution in aqueous media the process comprising the steps of forming an uncured block from a homogeneous blend comprising a hydrated cellulosic material and a surfactant, and permitting the uncured formed block to cure.

Claim 2

Dependent Claim 47 words

A process for the manufacture of a formed cleansing block adapted for slow dissolution in aqueous media the process comprising the steps of forming an uncured block from a homogeneous blend comprising a hydrated cellulosic material and a surfactant, and permitting the uncured formed block to cure.

Claim 3

Dependent Claim 58 words

The process of claim 1 wherein the cellulosic material is selected from the group consisting of hydroxyalkyl cellulose having from 1 to about 6 carbons in the alkyl group, carboxyalkyl cellulose having from 1 to about 6 carbons in the alkyl group, hydroxycellulose, cellulose, and alkyl cellulose having from 1 to about 6 carbons in the alkyl group.

Claim 4

Dependent Claim 22 words

The process of claim 1 wherein the cellulosic material is hydroxyalkyl cellulose having from 1 to 6 carbons in the alkyl group.

Claim 5

Dependent Claim 20 words

The process of claim 3 wherein the alkyl group of the hydroxyalkyl cellulose contains from 1 to 4 carbon atoms.

Claim 6

Dependent Claim 175 words

The process of claim 1 wherein the homogeneous blend further comprises one or more of the following optional constituents: an organic oil, a diluent, and an adjuvant selected from the group consisting of dyes, fragrances other than organic oils, and bacteriocides, the process further comprising the step of first hydrating a cellulosic material with a compound containing hydroxy groups available for sorption by said cellulosic material, the weight ratio of the cellulosic material to the hydroxy-containing compound in the hydrated cellulosic material being from about 30:1 to about 2:1, said hydrxy-containing compound being available as a vehicle for the incorporation of the surfactant and the optional constituents into the homogeneous blend, the surfactant and the optional constituents being of a nature and of an amount compatible with the proper hydration of the cellulosic material, said homogeneous blend being formed by mixing the cellulosic material and the hydroxy-containing compound and thereafter admixing with the hydrated cellulosic material that portion of the surfactant and of the one or more optional constituents not incorporated with said hydroxycontaining compound.

Claim 7

Dependent Claim 17 words

The process of claim 5 wherein the hydroxy-containing compound is about 30% by weight hydroxy or greater.

Claim 8

Dependent Claim 23 words

The process of claim 6 wherein the hydroxy-containing compound is selected from the group consisting of water, alcohols, and glycols including polyethylene glycols.

Claim 9

Dependent Claim 11 words

The process of claim 5 wherein the hydroxy-containing compound is water.

Claim 10

Dependent Claim 23 words

The process of claim 7 wherein the cellulosic material is hydroxyalkyl cellulose having from 1 to about 6 carbons in the alkyl group.

Claim 11

Dependent Claim 20 words

The process of claim 9 wherein the alkyl group of the hydroxyalkyl cellulose has from 1 to 4 carbon atoms.

Claim 12

Dependent Claim 21 words

The process of claim 10 wherein the weight ratio of hydroxyalkyl cellulose to hydroxy-containing compound is about 10:1 to about 3:1.

Claim 13

Dependent Claim 11 words

The process of claim 11 wherein the hydroxy-containing. compound is water.

Claim 14

Dependent Claim 65 words

The process of claim 12 wherein the homogeneous blend comprises on a weight basis from about 10 to about 50% hydroxyalkyl cellulose; from about 20 to about 60% of a surfactant selected from the group of anionic and nonionic surfactants; from about 0 to about 15% organic oil; from about 0 to 30% diluent, and less than about 5% each of one or more adjuvants.

Claim 15

Dependent Claim 22 words

The process of claim 13 wherein the weight ratio of surfactant to hydrated hydroxyalkyl cellulose is from about 1:1 to about 4:1.

Claim 16

Dependent Claim 46 words

The process of claim 13 wherein in the formation of the homogeneous blend the organic oil is introduced in advance of the surfactant, the homogeneous blend having a doughlike consistency, and wherein the block is formed by dispensing a predetermined amount thereof onto a suitable surface.

Claim 17

Dependent Claim 57 words

A process for the manufacture of a formed cleansing block adapted for slow dissolution in aqueous media, the process comprising the steps of extruding a homogeneous blend comprising a hydrated cellulosic material and a surfactant to obtain a continuous, uncured extrudate; cutting the continuous extrudate into blocks of predetermined size, and permitting the cut blocks to cure.

Claim 18

Dependent Claim 57 words

A process for the manufacture of a formed cleansing block adapted for slow dissolution in aqueous media, the process comprising the steps of extruding a homogeneous blend comprising a hydrated cellulosic material and a surfactant to obtain a continuous, uncured extrudate; cutting the continuous extrudate into blocks of predetermined size, and permitting the cut blocks to cure.

Claim 19

Dependent Claim 58 words

The process of claim 16 wherein the cellulosic material is selected from the group consisting of hydroxyalkyl cellulose having from 1 to about 6 carbons in the alkyl group, carboxyalkyl cellulose having from 1 to about 6 carbons in the alkyl group, hydroxycellulose, cellulose, and alkyl cellulose having from 1 to about 6 carbons in the alkyl group.

Claim 20

Dependent Claim 22 words

The process of claim 16 wherein the cellulosic material is hydroxyalkyl cellulose having from 1 to 6 carbons in the alkyl group.

Claim 21

Dependent Claim 20 words

The process of claim 18 wherein the alkyl group of the hydroxyalkyl cellulose contains from 1 to 4 carbon atoms.

Claim 22

Dependent Claim 175 words

The process of claim 16 wherein the homogeneous blend further omprises one or more of the following optional constituents: an organic oil, a diluent, and an adjuvant selected from the group consisting of dyes, fragrances other than organic oils, and bacteriocides, the process further comprising the step of first hydrating a cellulosic material with a compound containing hydroxy groups available for sorption by said celllosic material, the weight ratio of the cellulosic material to the hydroxy-containing material in the hydrated cellulosic material being from about 30:1 to about 2:1, said hydroxy-containing compound being available as a vehicle for the incorporaion of the surfactant and the optional constituents into the homogeneous blend, the surfactant and the optional constituents being of a nature and of an amount compatible with the proper hydration of the cellulosic material, said homogeneous blend being formed by mixing the cellulosic material and the hydroxy-containing compound and thereafter admixing with the hydrated cellulosic material that portion of the surfactant and of the one or more optional constituents not incorporated with said hydroxy-containing compound.

Claim 23

Dependent Claim 17 words

The process of claim 20 wherein the hydroxy-containing compound is about 30% by weight hydroxy or greater

Claim 24

Dependent Claim 23 words

The process of claim 21 wherein the hydroxy-containing compound is selected from the group consisting of water, alcohols, and glycols including polyethylene glycols.

Claim 25

Dependent Claim 11 words

The process of claim 20 wherein the hydroxy-containing compound is water.

Claim 26

Dependent Claim 23 words

The process of claim 22 wherein the cellulosic material is hydroxyalkyl cellulose having from 1 to about 6 carbons in the alkyl group.

Claim 27

Dependent Claim 20 words

The process of claim 24 wherein the alkyl group of the hydroxyalkyl cellulose has from 1 to 4 carbon atoms.

Claim 28

Dependent Claim 20 words

The process of claim 25 wherein the ratio of hydroxyalkyl cellulose to hydroxy-containing compound is about 10:1 to about 3:1.

Claim 29

Dependent Claim 11 words

The process of claim 26 wherein the hydroxy-containing compound is water.

Claim 30

Dependent Claim 66 words

The process of claim 27 wherein the homogeneous blend comprises on a weight basis from about 10 to about 50% hydrated hydroxyalkyl cellulose; from about 20 to about 60% of a surfactant selected from the group of anionic and nonionic surfactants; from about 0 to about 15% organic oil; from about 0 to 30% diluent, and less than about 5% each of one or more adjuvants.

Claim 31

Dependent Claim 27 words

The process of claim 28 wherein the homogeneous blend is passed through an extruder having a barrel, the barrel being maintained at less than about 110° F.

Claim 32

Dependent Claim 27 words

The process of claim 29 wherein the barrel temperature is less than about 95° F., and wherein the extruder die temperature is less than about 120° F.

Claim 33

Dependent Claim 22 words

The process of claim 29 wherein the weight ratio of surfactant to hydrated hydroxyalkyl cellulose is from about 1:1 to about 4:1.

Claim 34

Dependent Claim 40 words

The process of claim 31 wherein the surfactant is selected from the group consisting of alkyl aryl sulfonates, alpha-olefin sulfonates, fatty alcohol sulfonates, decyl- and tridecyloxypoly(ethyleneoxy) ethanol, and condensation products of ethylene and propylene glycol with ethylene and propylene oxide.

Claim 35

Dependent Claim 23 words

The process of claim 29 wherein in the formation of the homogeneous blend the organic oil is introduced in advance of the surfactant.

Claim 36

Dependent Claim 20 words

The process of claim 33 wherein the homogeneous blend contains from about 2 to about 10% of an organic oil.

Claim 37

Dependent Claim 35 words

The process of claim 34 wherein the organic oil is selected from the group consisting of glycerin, paraffinic and naphthenic hydrocarbons, low molecular weight polyethylene glycols, eugenol, limonene, methyl salicylate, ethyl salicylate and ethyl succinate.

Claim 38

Dependent Claim 11 words

The process of claim 34 wherein the organic oil is methylsalicylate.

Claim 39

Dependent Claim 11 words

The process of claim 31 wherein the cellulose is hydroxyethyl cellulose.

Claim 40

Dependent Claim 27 words

The process of claim 16 wherein the homogeneous blend is passed through an extruder having a barrel, the barrel being maintained at less than about 110° F.

Claim 41

Dependent Claim 90 words

A formed cleansing block adapted for slow dissolution in aqueous media comprising on a weight basis from about 10 to about 50% of a hydrated cellulosic material comprising a cellulosic material and a compound containing hydroxy groups available for sorption by the cellulosic material; from about 20 to about 60% of a surfactant selected from the group consisting of anionic and nonionic surfactants; from 0 to about 15% of an organic oil; from 0 to 30% of a diluent and less than about 5% each of one or more adjuvants.

Claim 42

Dependent Claim 90 words

A formed cleansing block adapted for slow dissolution in aqueous media comprising on a weight basis from about 10 to about 50% of a hydrated cellulosic material comprising a cellulosic material and a compound containing hydroxy groups available for sorption by the cellulosic material; from about 20 to about 60% of a surfactant selected from the group consisting of anionic and nonionic surfactants; from 0 to about 15% of an organic oil; from 0 to 30% of a diluent and less than about 5% each of one or more adjuvants.

Claim 43

Dependent Claim 59 words

The cleaning block of claim 39 wherein the cellulosic material is selected from the group consisting of hydroxyalkyl cellulose having from 1 to about 6 carbons in the alkyl group, carboxyalkyl cellulose having form 1 to about 6 carbons in the alkyl group, hydroxycellulose, cellulose, and alkyl cellulose having from 1 to about 6 carbons in the alkyl group.

Claim 44

Dependent Claim 23 words

The cleaning block of claim 40 wherein the cellulosic material is hydroxyalkyl cellulose having from 1 to 6 carbons in the alkyl group.

Claim 45

Dependent Claim 18 words

The cleaning block of claim 40 wherein the cellulosic material is an alkali metal salt of carboxymethyl cellulose.

Claim 46

Dependent Claim 21 words

The cleansing block of claim 41 wherein the alkyl group of the hydroxalkyl cellulose has from 1 to 4 carbon atoms.

Claim 47

Dependent Claim 17 words

The cleansing block of claim 41 wherein the hydroxy-containing compound is at least 30% by weight hydroxy.

Claim 48

Dependent Claim 24 words

The cleansing block of claim 44 wherein the hydroxy-containing compound is selected from the group consisting of water, alcohols, and glycols including polyalkylene glycols.

Claim 49

Dependent Claim 12 words

The cleansing block of claim 44 wherein the hydroxy-containing compound is water.

Claim 50

Dependent Claim 28 words

The cleansing block of claim 45 wherein the weight ratio of hydroxyalkyl cellulose to hydroxy-containing compound in the prehydrated hydroxyalkyl cellulose is from about 30:1 to about 2:1.

Claim 51

Dependent Claim 23 words

The cleansing block of claim 46 wherein the ratio of hydroxyalkyl cellulose to the hydroxy-containing compound is from about 10:1 to about 3:1.

Claim 52

Dependent Claim 13 words

The cleansing block of claim 39 wherein the block is an extruded article.

Claim 53

Dependent Claim 39 words

The cleansing block of claim 49 wherein the surfactant is selected from the group consisting of alkyl aryl sulfonates, alpha-olefin sulfonates, fatty alcohol sulfonates, alcohol ethoxylates, and condensation products of ethylene and propylene glycols with ethylene and propylene oxides.

Claim 54

Dependent Claim 17 words

The cleansing block of claim 50 wherein the surfactant concentration is from about 35 to about 50%.

Claim 55

Dependent Claim 20 words

The cleansing block of claim 51 wherein the organic oil is present in an amount of from 1 to 10%.

Claim 56

Dependent Claim 23 words

The cleansing block of claim 52 wherein the organic oil is selected from the group consisting of glycerin, limonene, methylsalicylate, and ethyl succinate.

Claim 57

Dependent Claim 13 words

The cleansing block of claim 52 wherein the organic oil is methyl salicylate.

Claim 58

Dependent Claim 19 words

The cleansing block of claim 39 wherein the diluent is present in an amount of from 5 to 20%.

Claim 59

Dependent Claim 15 words

The cleansing block of claim 55 wherein the diluent is a soluble alkali metal salt.

Claim 60

Dependent Claim 27 words

The cleansing block of claim 55 wherein the diluent is selected from the group consisting of sodium sulfate, magnesium sulfate, sodium borate, sodium chloride and magnesium chloride.

Claim 61

Dependent Claim 22 words

The cleansing block of claim 52 wherein the hydrated hydroxyalkyl cellulose is present in an amount of from about 20 to 35%.

Claim 62

Dependent Claim 19 words

The cleansing block of claim 56 wherein the cellulose is hydroxyethyl cellulose and wherein the hydroxy-containing compound is water.

Claim 63

Dependent Claim 13 words

A surfactant cleansing block made in accordance with the process of claim 1.

Claim 64

Dependent Claim 13 words

A surfactant cleansing block made in accordance with the process of claim 16.

Claim 65

Dependent Claim 13 words

A surfactant cleansing block made in accordance with the process of claim 33.

Claim 66

Dependent Claim 26 words

The process of claim 5 wherein the homogeneous blend is formed by admixing the surfactant, the organic oil, and the diluent to the hydrated cellulosic material.

Claim 67

Dependent Claim 26 words

The process of claim 13 wherein the homogeneous blend is formed by admixing the surfactant, the organic oil, and the diluent to the hydrated hydroxyalkyl cellulose.

Claim 68

Dependent Claim 26 words

The process of claim 20 wherein the homogeneous blend is formed by admixing the surfactant, the organic oil, and the diluent to the hydrated cellulosic material.

Claim 69

Dependent Claim 26 words

The process of claim 28 wherein the homogeneous blend is formed by admixing the surfactant, the organic oil, and the diluent to the hydrated hydroxyalkyl cellulose.

Claim 70

Dependent Claim 13 words

The cleansing block of claim 59 wherein the block is an extruded article.

Claim 71

Dependent Claim 150 words

An extruded cleansing block adapted for slow dissolution in aqueous media comprising on a weight basis from about 10 to about 40% of a hydrated cellulosic material, the hydrated hydroxyalkyl cellulosic material comprising a hydroxyalkyl cellulose of from 1 to about 4 carbon atoms and a hydroxy-containing compound selected from the group consisting of water, alcohols, and glycols, the weight ratio of the hydroxyalkyl cellulose to the hydroxy-containing compound being from about 10:1 to about 3:1; from about 30 to about 50% of a surfactant selected from the group consisting of alkyl aryl sulfonates, alpha-olefin sulfonates, fatty alcohol sulfonates, alcohol ethoxylates, and the condensation products of ethylene and propylene glycols with ethylene and propylene oxides; from about 2 to 10% of an organic oil selected from limonene, methylsalicylate, ethyl succinate, and glycerin; and from about 5 to about 20% of a water-soluble inorganic alkali or alkaline earth metal salt diluent.

Claim 72

Dependent Claim 150 words

An extruded cleansing block adapted for slow dissolution in aqueous media comprising on a weight basis from about 10 to about 40% of a hydrated cellulosic material, the hydrated hydroxyalkyl cellulosic material comprising a hydroxyalkyl cellulose of from 1 to about 4 carbon atoms and a hydroxy-containing compound selected from the group consisting of water, alcohols, and glycols, the weight ratio of the hydroxyalkyl cellulose to the hydroxy-containing compound being from about 10:1 to about 3:1; from about 30 to about 50% of a surfactant selected from the group consisting of alkyl aryl sulfonates, alpha-olefin sulfonates, fatty alcohol sulfonates, alcohol ethoxylates, and the condensation products of ethylene and propylene glycols with ethylene and propylene oxides; from about 2 to 10% of an organic oil selected from limonene, methylsalicylate, ethyl succinate, and glycerin; and from about 5 to about 20% of a water-soluble inorganic alkali or alkaline earth metal salt diluent.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1991-02-01	1991-08-03	1992-02-02	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1995-02-01	1995-08-03	1996-02-02	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1999-02-01	1999-08-03	2000-02-02	$7700.00	Window Closed / Lapsed

Process for the manufacture of surfactant cleansing blocks and compositions thereof

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