SOFTENING LAUNDRY DETERGENT

FIELD OF THE INVENTION

This invention relates to laundry conditioning compositions. More particularly, the invention is directed to laundry detergent compositions which also deliver a softening benefit .

BACKGROUND OF THE INVENTION

Traditionally, textile fabrics, including clothes, have been cleaned with laundry detergents, which provide excellent soil removal, but can often make garments feel harsh after washing. To combat this problem, a number of fabric conditioning technologies, including rinse-added softeners, dryer sheets, and 2-in-l detergent softeners, have been developed. 2-in-l detergent softeners have normally been the most convenient of these technologies for consumers, but many of these existing technologies still have disadvantages.

Softening laundry detergent compositions have been disclosed in WO 2004/0152616; EP 786,517; Binder et al . (US 7,012,054), Murphy et al . (US 6,949,498), Kischkel et al . (US Patent No. 6,616,705); Kischkel et al . (US Patent No.

6,620,209); Mermelstein et al . (US Patent No. 4,844,821); Wang et al. (US Patent No. 6,833,347); Weber et al . (US Patent No. 4,289,642); WO 0/309511; Erazo-Majewicz et al . (US 2003/0211952) . Washer added fabric softening compositions have been disclosed in Caswell et al . (US Patent No. 4,913,828) and Caswell (US Patent No. 5,073,274). Fabric softener compositions have been disclosed in WO 00/70005; Cooper et al .

(US Patent No. 6,492,322); Christiansen (US Patent No. 4,157,388). US 6,855,680 discloses liquid detergent compositions containing a hydroxyl-containing stabilizing agent and a fabric-substantive agent (e.g. dye fixative agent, such as cationic polymer) .

A need remains for softening laundry detergent compositions including cationic polymers for improved softening achieved through adding the compositions in the wash cycle of automatic washing machines, without compromising cleaning performance .

SUMMARY OF THE INVENTION

The present invention includes in part a liquid laundry composition comprising:

(a) a solubilized cationic polymer having a weight average molecular weight of less than about 850,000 daltons; (b) from about 0.5% to about 15% of a solubilized fatty acid soap blend comprising from about 5% to about 60%, by weight of the soap blend, of a saturated hydroxy carboxylic acid salt R ² CH ₂ CH ₂ OOM, wherein R ² is a saturated hydroxyalkyl group comprising from 7 to 21 carbons and one hydroxy group;

(c) at least about 5% of a surfactant.

The invention also includes methods of cleaning and conditioning laundry.

DETAILED DESCRIPTION OF THE INVENTION

The cationic polymers of this invention can be any cationic polyelectrolyte; examples of preferred suitable materials include cationically-modified polysaccharides such as Polyquaternium-10 , fully synthetic cationic polymers such as polyquaternium-7.

Surprisingly, it has been discovered that by virtue of using a specific soap blend which comprises a long chain saturated hydroxy acid, improved softening results are attained.

In addition, these compositions should contain less than about 10% phosphate, in order to minimize their environmental impact .

The compositions according to the invention are liquid. "Liquid" as used herein means that a continuous phase or predominant part of the composition is liquid and that a composition is flowable at 15°C and above (i.e., suspended solids may be included) . Gels and concentrates are included in the definition of liquid compositions as used herein.

Preferably the compositions are isotropic liquid compositions, which may also include concentrated compositions.

As used herein, the term "comprising" means including, made up of, composed of, consisting and/or consisting essentially of. Furthermore, in the ordinary meaning of

"comprising, " the term is defined as not being exhaustive of the steps, components, ingredients, or features to which it refers .

All amounts are by weight of the final detergent composition, unless otherwise specified.

It should be noted that in specifying any range of concentration, any particular upper concentration can be associated with any particular lower concentration.

Except in the operating and comparative examples, or where otherwise explicitly indicated, all numbers in this description indicating amounts or ratios of material or conditions of reaction, physical properties of materials and/or use are to be understood as modified by the word "about".

SURFACTANT

In order to attain the desired level of softening and cleaning the inventive softening laundry compositions contain greater than about 5% surfactant by weight of the composition, generally from 8 to 45%, preferably from 10 to 40%, more preferably from 15 to 40%.

The compositions of this invention comprise at least about 5%, and preferably at least about 10% of one or more surfactants with a hydrophilic/ lipophilic balance (HLB, defined in U.S. Pat. No. 6,461,387) of more than about 4.

Anionic Surfactant

The anionic surfactants used in this invention can be any anionic surfactant that is water soluble. "Water soluble" surfactants are, unless otherwise noted, here defined to include surfactants which are soluble or dispersible to at

least the extent of 0.01% by weight in distilled water at 25°C. "Anionic surfactants" are defined herein as amphiphilic molecules with an average molecular weight of less than about 10,000, comprising one or more functional groups that exhibit a net anionic charge when in aqueous solution at the normal wash pH of between 6 and 11.

Primary Alkyl Sulfates

R ² OSO ₃ M

where R is a primary alkyl group of 8 to 18 carbon atoms and M is a solubilizing cation. The alkyl group R may have a mixture of chain lengths. It is preferred that at least two-thirds of the R alkyl groups have a chain length of 8 to 14 carbon atoms. This will be the case if R ² is coconut alkyl, for example. The solubilizing cation may be a range of cations which are in general monovalent and confer water solubility. An alkali metal, notably sodium, is especially envisaged. Other possibilities are ammonium and substituted ammonium ions, such as trialkanolammonium or trialkylammonium.

Alkyl Ether Sulfates

R ³ O (CH ₂ CH ₂ O) _n SO ₃ M

where R ³ is a primary alkyl group of 8 to 18 carbon atoms, n has an average value in the range from 1 to 6 and M is a solubilizing cation. The alkyl group R ³ may have a mixture of chain lengths. It is preferred that at least two-thirds of the R ³ alkyl groups have a chain length of 8 to 14 carbon atoms. This will be the case if R ³ is coconut alkyl, for example. Preferably n has an average value of 2 to 5. Ether sulfates have been found to provide viscosity build in certain of the

formulations of this invention, and thus are considered a preferred ingredient.

Fatty Acid Ester Sulfonates R ⁴ CH(SO ₃ M)CO ₂ R ⁵

where R ⁴ is an alkyl group of 6 to 16 atoms, R ⁵ is an alkyl group of 1 to 4 carbon atoms and M is a solubilizing cation. The group R ⁴ may have a mixture of chain lengths. Preferably at least two-thirds of these groups have 6 to 12 carbon atoms.

This will be the case when the moiety R ⁸ CH (-) CO ₂ (-) is derived from a coconut source, for instance. It is preferred that R ⁵ is a straight chain alkyl, notably methyl or ethyl.

Alkyl Benzene Sulfonates

R ⁶ ArSO ₃ M

where R ⁶ is an alkyl group of 8 to 18 carbon atoms, Ar is a benzene ring (CeH ₄ ) and M is a solubilizing cation. The group R ⁶ may be a mixture of chain lengths. A mixture of isomers is typically used, and a number of different grades, such as "high 2-phenyl" and "low 2-phenyl" are commercially available for use depending on formulation needs. A plentitude of commercial suppliers exist for these materials, including Stepan (Northfield, 111.) and Witco (Greenwich, Conn.) Typically they are produced by the sulfonation of alkylbenzenes, which can be produced by either the HF-catalyzed alkylation of benzene with olefins or an AlCl3-catalyzed process that alkylates benzene with chloroparaffins, and are sold by, for example, Petresa (Chicago, 111.) and Sasol (Austin, Tex.). Straight chains of 11 to 14 carbon atoms are usually preferred.

Paraffin sulfonates having 8 to 22 carbon atoms, preferably 12 to 16 carbon atoms, in the alkyl moiety. They are usually produced by the sulfoxidation of petrochemically-derived normal paraffins. These surfactants are commercially available as, for example, Hostapur SAS from Clariant (Charlotte, N. C.) .

Olefin sulfonates having 8 to 22 carbon atoms, preferably 12 to 16 carbon atoms. U.S. Patent No. 3,332,880 contains a description of suitable olefin sulfonates. Such materials are sold as, for example, Bio-Terge AS-40, which can be purchased from Stepan (Northfield, 111.)

Sulfosuccinate esters

R ⁷ OOCCH ₂ CH (SO ₃ ^~ M ⁺ ) COOR ⁸

are also useful in the context of this invention. R ⁷ and R ⁸ are alkyl groups with chain lengths of between 2 and 16 carbons, and may be linear or branched, saturated or unsaturated. A preferred sulfosuccinate is sodium bis (2-ethylhexyl) sulfosuccinate, which is commercially available under the tradename Aerosol OT from Cytec Industries (West Paterson, N. J. ) .

Organic phosphate based anionic surfactants include organic phosphate esters such as complex mono- or diester phosphates of hydroxyl- terminated alkoxide condensates, or salts thereof. Included in the organic phosphate esters are phosphate ester derivatives of polyoxyalkylated alkylaryl phosphate esters, of ethoxylated linear alcohols and ethoxylates of phenol. Also included are nonionic alkoxylates having a sodium alkylenecarboxylate moiety linked to a terminal hydroxyl group of the nonionic through an ether bond. Counterions to the salts

of all the foregoing may be those of alkali metal, alkaline earth metal, ammonium, alkanolammonium and alkylammonium types.

Other preferred anionic surfactants include the fatty acid ester sulfonates with formula:

R ⁹ CH (SO ₃ M) CO ₂ R ¹⁰

where the moiety R ⁹ CH (-) CO ₂ (-) i s derived from a coconut source and R ¹⁰ i s either methyl or ethyl ; primary al kyl sul fates with the formula :

R ¹¹ OSO ₃ M

wherein R ¹¹ is a primary alkyl group of 10 to 18 carbon atoms and M is a sodium cation; and paraffin sulfonates, preferably with 12 to 16 carbon atoms to the alkyl moiety.

Other anionic surfactants preferred for use with this formulation include isethionates, sulfated triglycerides, alcohol sulfates, ligninsulfonates, naphthelene sulfonates and alkyl naphthelene sulfonates and the like.

Nonionic Surfactants

Nonionic surfactants are useful in the context of this invention to both improve the cleaning properties of the compositions, when used as a detergent, and to contribute to product stability. For the purposes of this disclosure, "nonionic surfactant" shall be defined as amphiphilic molecules with a molecular weight of less than about 10,000, unless otherwise noted, which are substantially free of any functional groups that exhibit a net charge at the normal wash

pH of 6-11. Any type of nonionic surfactant may be used, although preferred materials are further discussed below.

Fatty Alcohol Ethoxylates: R ¹⁸ O(EO) _n

Wherein R represents an alkyl chain of between 4 and 30 carbon atoms, (EO) represents one unit of ethylene oxide monomer and n has an average value between 0.5 and 20. R may be linear or branched. Such chemicals are generally produced by oligomerizing fatty alcohols with ethylene oxide in the presence of an effective amount catalyst, and are sold in the market as, for example, Neodols from Shell (Houston, Tex.) and Alfonics from Sasol (Austin, Tex.) . The fatty alcohol starting materials, which are marketed under trademarks such as Alfol, Lial and Isofol from Sasol (Austin, Tex.) and Neodol, from Shell, may be manufactured by any of a number of processes known to those skilled in the art, and can be derived from natural or synthetic sources or a combination thereof. Commercial alcohol ethoxylates are typically mixtures, comprising varying chain lengths of R and levels of ethoxylation . Often, especially at low levels of ethoxylation, a substantial amount of unethoxylated fatty alcohol remains in the final product, as well.

Because of their excellent cleaning, environmental and stability profiles, fatty alcohol ethoxylates wherein R ¹⁸ represents an alkyl chain from 10-18 carbons and n is an average number between 5 and 12 are highly preferred.

Alkylphenol Ethoxylates:

R ¹⁹ ArO (EO) _.

Where R ¹⁹ represents a linear or branched alkyl chain ranging from 4 to 30 carbons, Ar is a phenyl (C ₆ H ₄ ) ring and (EO) _n is an oligomer chain comprised of an average of n moles of ethylene oxide. Preferably, R ¹⁹ is comprised of between 8 and 12 carbons, and n is between 4 and 12. Such materials are somewhat interchangeable with alcohol ethoxylates, and serve much the same function. A commercial example of an alkylphenol ethoxylate suitable for use in this invention is Triton X-IOO, available from Dow Chemical (Midland, Mich.)

Ethylene Oxide / Propylene Oxide Block Polymers:

(EO) _x (PO) _y (EO) _x or (PO) _x (EO) _y (PO) _x

wherein EO represents an ethylene oxide unit, PO represents a propylene oxide unit, and x and y are numbers detailing the average number of moles ethylene oxide and propylene oxide in each mole of product. Such materials tend to have higher molecular weights than most nonionic surfactants, and as such can range between 1,000 and 30,000 daltons. BASF (Mount Olive, N.J.) manufactures a suitable set of derivatives and markets them under the Pluronic and Pluronic-R trademarks.

Other nonionic surfactants should also be considered within the scope of this invention. These include condensates of alkanolamines with fatty acids, such as cocamide DEA, polyol-fatty acid esters, such as the Span series available from Uniqema (Wlimington, Del.), ethoxylated polyol-fatty acid esters, such as the Tween series available from Uniqema

(Wilmington, Del.), Alkylpolyglucosides, such as the APG line available from Cognis (Gulph Mills, Pa.) and n- alkylpyrrolidones, such as the Surfadone series of products marketed by ISP (Wayne, N.J) . Furthermore, nonionic surfactants not specifically mentioned above, but within the definition, may also be used.

Soap Blend

Inventive compositions include a soap of fatty acid of Formula (1):

R ¹ COOM

where R ¹ is a primary or secondary alkyl group of 4 to 30 carbon atoms and M is a solubilizing cation. The alkyl group represented by R ¹ may represent a mixture of chain lengths and may be saturated or unsaturated, although it is preferred that at least two thirds of the R ¹ groups have a chain length of between 8 and 18 carbon atoms. Nonlimiting examples of suitable alkyl group sources include the fatty acids derived from coconut oil, tallow, tall oil and palm kernel oil.

For the purposes of minimizing odor, however, it is often desirable to use primarily saturated carboxylic acids. Such materials are available from many commercial sources, such as Uniqema (Wilmington, Del.) and Twin Rivers Technologies (Quincy, Mass . ) .

According to the invention, the soap blend includes a long chain saturated hydroxy acid of Formula (2)

R ² CH ₂ CH ₂ OOM

wherein R ² is a saturated hydroxyalkyl group comprising from 7 to 21 carbons and 1 hydroxy group. Preferably R comprises from 9 to 17 carbon atoms, most preferably from 13 to 16 carbon atoms. 12-hydroxy stearic acid is most preferred due to its improved performance and commercial availability.

While not wishing to be bound to theory, it is thought that the hydroxyl group associated with the fatty acid modifies the solution behavior of the soap blend to promote smaller flocculates along with a different morphology -- these hydroxysoap containing flocculates interact with the cationic polymer to form a complex to deposit more uniformly on the fabric surface, thereby promoting an enhancement in perceived softening.

The solubilizing cation, M, may be any cation that confers water solubility to the product, although monovalent moieties are generally preferred. Examples of acceptable solubilizing cations for use with this invention include alkali metals such as sodium and potassium, which are particularly preferred, and amines such as monoethanolammonium, triethanolammonium, ammonium and morpholinium. Although, when used, the majority of the fatty acid should be incorporated into the formulation in neutralized salt form, it is often preferable to leave a small amount of free fatty acid in the formulation, as this can aid in the maintenance of product viscosity.

According to the present invention, both the cationic polymer and the soap blend are present in solubilized form, in order to facilitate polymer/soap complex formation.

For purposes of this invention, the soap blend is not considered an anionic surfactant, and its amounts are not

included within the amounts discussed above for the anionic surfactant. Typically, from 0.5 tol5% of the soap blend is included. Lower amounts, however, may be used according to the invention, by virtue of incorporating a long chain saturated hydroxy acid soap; thus, preferably from 1 to 12% of the soap is employed, more preferably from 3 to 10%. The amount of the long chain hydroxy acid that is included depends on the concrete formulation, subject to maintaining the solubility of the soap blend. Typically, the long chain saturated hydroxy acid is included in an amount of from 5 to 60%, more preferably from 5 to 40%, most preferably from 10 to 30%, by weight of the soap blend. The amounts of the soap blend and the long chain hydroxy acid are calculated as acid.

Cationic Polymer

A cationic polymer is here defined to include polymers which, because of their molecular weight or monomer composition, are soluble or dispersible to at least the extent of 0.01% by weight in distilled water at 25°C. Water soluble cationic polymers include polymers in which one or more of the constituent monomers are selected from the list of copolymerizable cationic or amphoteric monomers. These monomer units contain a positive charge over at least a portion of the pH range 6-11. A partial listing of monomers can be found in the "International Cosmetic Ingredient Dictionary," 5th Edition, edited by J. A. Wenninger and G.N. McEwen, The Cosmetic, Toiletry, and Fragrance Association, 1993. Another source of such monomers can be found in "Encyclopedia of Polymers and Thickeners for Cosmetics", by R. Y. Lochhead and W. R. Fron, Cosmetics & Toiletries, vol. 108, May 1993, pp 95- 135.

The cationic polymers of this invention are effective at surprisingly low levels. As such, the weight ratio of the cationic polymer to the soap blend in the composition should preferably be in the range of from 1:10 to 1:50, preferably in the range of from 1:20 to 1:35.

Specifically, monomers useful in this invention may be represented structurally as etiologically unsaturated compounds as in formula I .

¥ R ¹²

wherein R ¹² is hydrogen, hydroxyl, methoxy, or a Ci to C30 straight or branched alkyl radical; R ¹³ is hydrogen, or a Ci-30 straight or branched alkyl, a Ci-30 straight or branched alkyl substituted aryl, aryl substituted Ci-30 straight or branched alkyl radical, or a poly oxyalkene condensate of an aliphatic radical; and R ¹⁴ is a heteroatomic alkyl or aromatic radical containing either one or more quaternerized nitrogen atoms or one or more amine groups which possess a positive charge over a portion of the pH interval pH 6 to 11. Such amine groups can be further delineated as having a pK _a of about 6 or greater.

Examples of cationic monomers of formula I include, but are not limited to, co-poly 2-vinyl pyridine and its co-poly 2-vinyl N-alkyl quaternary pyridinium salt derivatives; co-poly 4-vinyl pyridine and its co-poly 4-vinyl N-alkyl quaternary pyridinium salt derivatives; co-poly 4- vinylbenzyltrialkylammonium salts such as co-poly 4- vinylbenzyltrimethylammonium salt; co-poly 2-vinyl piperidine and co-poly 2-vinyl piperidinium salt; co-poly 4- vinylpiperidine and co-poly 4-vinyl piperidinium salt; co-poly

3-alkyl 1-vinyl imidazolium salts such as co-poly 3-methyl 1- vinyl imidazolium salt; acrylamido and methacrylamido derivatives such as co-poly dimethyl aminopropylmethacrylamide, co-poly acrylamidopropyl trimethylammonium salt and co-poly methacrylamidopropyl trimethylammonium salt; acrylate and methacrylate derivatives such as co-poly dimethyl aminoethyl (meth) acrylate, co-poly ethanaminium N, N, N trimethyl 2-[(l-oxo- 2 propenyl) oxy] -salt , co-poly ethanaminium N, N, N trimethyl 2- [ (2 methyl-l-oxo-2 propenyl) oxy] - salt , and co-poly ethanaminium N, N, N ethyl dimethyl 2- [ (2 methyl-l-oxo-2 propenyl) oxy] - salt.

Also included among the cationic monomers suitable for this invention are co-poly vinyl amine and co-polyvinylammonium salt; co-poly diallylamine, co-poly methyldiallylamine, and co- poly diallydimethylammonium salt; and the ionene class of internal cationic monomers. This class includes co-poly ethylene imine , co-poly ethoxylated ethylene imine and co-poly quaternized ethoxylated ethylene imine; co-poly [ (dimethylimino) trimethylene (dimethylimino) hexamethylene disalt], co-poly [ (diethylimino) trimethylene (dimethylimino) trimethylene disalt] ; co-poly [ (dimethylimino) 2-hydroxypropyl salt]; co-polyquarternium-2, co-polyquarternium-17, and co- polyquarternium 18, as defined in the "International Cosmetic Ingredient Dictionary" edited by Wenninger and McEwen.

An additional, and highly preferred class of cationic monomers suitable for this invention are those arising from natural sources and include, but are not limited to, cocodimethylammonium hydroxypropyl oxyethyl cellulose, lauryldimethylammonium hydroxypropyl oxyethyl cellulose, stearyldimethylammonium hydroxypropyl oxyethyl cellulose, and stearyldimethylammonium hydroxyethyl cellulose; guar 2-hydroxy-

3- (trimethylammonium) propyl ether salt; cellulose 2- hydroxyethyl 2-hydroxy 3- (trimethyl ammonio) propyl ether salt.

It is likewise envisioned that monomers containing cationic sulfonium salts such as co-poly 1- [3-methyl-4- (vinyl- benzyloxy) phenyl ] tetrahydrothiophenium chloride would also be applicable to the present invention.

The counterion of the comprising cationic co-monomer is freely chosen from the halides: chloride, bromide, and iodide; or from hydroxide, phosphate, sulfate, hydrosulfate, ethyl sulfate, methyl sulfate, formate, and acetate.

The weight fraction of the cationic polymer which is composed of the above-described cationic monomer units can range from 1 to 100%, preferably from 10 to 100%, and most preferably from 15 to 80% of the entire polymer. The remaining monomer units comprising the cationic polymer are chosen from the class of anionic monomers and the class of nonionic monomers or solely from the class of nonionic monomers. In the former case, the polymer is an amphoteric polymer while in the latter case it can be a cationic polymer, provided that no amphoteric co-monomers are present. The nonionic monomers comprise a class of monounsaturated compounds which are uncharged over the pH range from pH 6 to 11 in which the cationic monomers possess a positive charge. It is expected that the wash pH at which this invention would be employed would either naturally fall within the above mentioned portion of the pH range 6-11 or, optionally, would be buffered in that range. A highly preferred class of nonionic monomers includes naturally derived materials such as hydroxyethylcellulose and guar gum.

The concentration of cationic polymer will generally be less than about 3% of the total product mass.

Many of the aforementioned cationic polymers can be synthesized in, and are commercially available in, a number of different molecular weights. In order to achieve optimal cleaning and softening performance from the product, it is desirable that the water-soluble cationic or amphoteric polymer used in this invention be of an appropriate molecular weight. Without wishing to be bound by theory, it is believed that polymers that are too high in mass can entrap soils and prevent them from being removed. The use of cationic polymers with an average molecular weight of less than about 850,000 daltons, and especially those with an average molecular weight of less than 500,000 daltons can help to minimize this effect without significantly reducing the softening performance of properly formulated products. On the other hand, polymers with a molecular weight of about 10,000 daltons or less are believed to be too small to give an effective softening benefit.

Conditioning Benefits

The compositions of this invention are intended to confer conditioning benefits to garments, home textiles, carpets and other fibrous or fiber-derived articles. These formulations are not to be limited to conditioning benefits, however, and will often be multi-functional.

The primary conditioning benefit afforded by these products is softening. Softening includes, but is not limited to, an improvement in the handling of a garment treated with the compositions of this invention relative to that of an article laundered under identical conditions but without the

use of this invention. Consumers will often describe an article that is softened as "silky" or "fluffy", and generally prefer the feel of treated garments to those that are unsoftened.

The conditioning benefits of these compositions are not limited to softening, however. They may, depending on the particular embodiment of the invention selected, also provide an antistatic benefit. The cationic polymers of this invention are also believed to inhibit the transfer, bleeding and loss of vagrant dyes from fabrics during the wash, further improving color brightness over time.

Form of the Invention

The present invention can take any of a number of forms, including a dilutable fabric conditioner that may be an isotropic liquid, a surfactant-structured liquid or any other laundry detergent form known to those skilled in the art. A "dilutable fabric conditioning" composition is defined, for the purposes of this disclosure, as a product intended to be used by being diluted with water or a non-aqueous solvent by a ratio of more than 100:1, to produce a liquor suitable for treating textiles and conferring to them one or more conditioning benefits. As such, compositions intended to be used as combination detergent / softeners, along with fabric softeners sold for application in the final rinse of a wash cycle and fabric softeners sold for application at the beginning of a wash cycle are all considered within the scope of this invention. For all cases, however, these compositions are intended to be used by being diluted by a ratio of more than 100:1 with water or a non-aqueous solvent, to form a liquor suitable for treating fabrics.

Particularly preferred forms of this invention include combination detergent/softener products, preferably isotropic liquid products intended for application as a fabric softener during the wash cycle or the final rinse. For the purposes of this disclosure, the term "fabric softener" shall be understood to mean a consumer or industrial product added to the wash, rinse or dry cycle of a laundry process for the express or primary purpose of conferring one or more conditioning benefits.

The pH range of the composition is about 2 to about 12. As many cationic polymers can decompose at high pH, especially when they contain amine or phosphine moieties, it is desirable to keep the pH of the composition below the pK _a of the amine or phosphine group that is used to quaternize the selected polymer, below which the propensity for this to occur is greatly decreased. This reaction can cause the product to lose effectiveness over time and create an undesirable product odor. As such, a reasonable margin of safety, of 1-2 units of pH below the pK _a should ideally be used in order to drive the equilibrium of this reaction to strongly favor polymer stability. Although the preferred pH of the product will depend on the particular cationic polymer selected for formulation, typically these values should be below about 8.5 to about 10. Wash liquor pH, especially in the case of combination detergent / softener products, can often be less important, as the kinetics of polymer decomposition are often slow, and the time of one wash cycle is typically not sufficient to allow for this reaction to have a significant impact on the performance or odor of the product. A lower pH can also aid in the formulation of higher-viscosity products.

Conversely, a product with a pH that is too low will not saponify fatty materials and often will not effectively remove particulate soil. As such, in the most preferred embodiment of this invention, the pH of the product will be greater than about 5.

The formulation may be buffered at the target pH of the composition .

Method of Use

The following details a method for conditioning textiles comprising the steps, in no particular order of: a. providing a laundry detergent or fabric softener composition comprising anionic surfactant, a soap blend comprising a long chain saturated 12-hydroxy acid and cationic polymer, in ratios and concentrations to effectively soften and condition fabrics under predetermined laundering conditions; b. contacting one or more articles with the composition at one or more points during a laundering process; and c. allowing the articles to dry or mechanically tumble-drying them.

Amounts of composition used will generally range between about 1Og and about 30Og total product per 3 kg of conditioned fibrous articles, depending on the particular embodiment chosen and other factors, such as consumer preferences, that influence product use behavior.

A consumer that would use the present invention could also be specifically instructed to contact the fabrics with the

inventive composition with the purpose of simultaneously cleaning and softening the said fabrics. This approach would be recommended when the composition takes the form of a softening detergent to be dosed at the beginning of the wash cycle.

Insoluble Matter

It is preferred that the inventive compositions be formulated with low levels, if any at all, of any matter that is substantially insoluble in the solvent intended to be used to dilute the product. For the purposes of this disclosure, "substantially insoluble" shall mean that the material in question can individually be dissolved at a level of less than 0.001% in the specified solvent. Examples of substantially insoluble matter in aqueous systems include, but are not limited to aluminosilicates, pigments, clays and the like. Without wishing to be bound by theory, it is believed that solvent-insoluble inorganic matter can be attracted and coordinated to the cationic polymers of this invention, which are believed to attach themselves to the articles being washed.

When this occurs, it is thought that these particles can create a rough effect on the fabric surface, which in turn reduces the perception of softness.

Preferably, insoluble and substantially insoluble matter will be limited to less than 10% of the composition, more preferably to about 5%, most preferably to less than about l%of substantially insoluble matter or precipitation.

Optional Ingredients

In addition to the above-mentioned essential elements, the formulator may include one or more optional ingredients, which are often very helpful in rendering the formulation more acceptable for consumer use.

Examples of optional components include, but are not limited to: anionic polymers, uncharged polymers, nonionic surfactants, amphoteric and zwitterionic surfactants, cationic surfactants, hydrotropes, fluorescent whitening agents, photobleaches, fiber lubricants, reducing agents, enzymes, enzyme stabilizing agents, powder finishing agents, defoamers, builders, bleaches, bleach catalysts, soil release agents, dye transfer inhibitors, buffers, colorants, fragrances, pro- fragrances, rheology modifiers, anti-ashing polymers, preservatives, insect repellents, soil repellents, water- resistance agents, suspending agents, aesthetic agents, structuring agents, sanitizers, solvents, fabric finishing agents, dye fixatives, wrinkle-reducing agents, fabric conditioning agents and deodorizers.

Preservatives

Optionally, a soluble preservative may be added to this invention. The use of a preservative is especially preferred when the composition of this invention is a liquid, as these products tend to be especially susceptible to microbial growth,

The use of a broad-spectrum preservative, which controls the growth of bacteria and fungi is preferred. Limited-

spectrum preservatives, which are only effective on a single group of microorganisms may also be used, either in combination with a broad-spectrum material or in a "package" of limited- spectrum preservatives with additive activities. Depending on the circumstances of manufacturing and consumer use, it may also be desirable to use more than one broad-spectrum preservative to minimize the effects of any potential contamination .

The use of both biocidal materials, i.e. substances that kill or destroy bacteria and fungi, and biostatic preservatives, i.e. substances that regulate or retard the growth of microorganisms, may be indicated for this invention.

In order to minimize environmental waste and allow for the maximum window of formulation stability, it is preferred that preservatives that are effective at low levels be used. Typically, they will be used only at an effective amount. For the purposes of this disclosure, the term "effective amount" means a level sufficient to control microbial growth in the product for a specified period of time, i.e., two weeks, such that the stability and physical properties of it are not negatively affected. For most preservatives, an effective amount will be between about 0.00001% and about 0.5% of the total formula, based on weight. Obviously, however, the effective level will vary based on the material used, and one skilled in the art should be able to select an appropriate preservative and use level.

Preferred preservatives for the compositions of this invention include organic sulfur compounds, halogenated materials, cyclic organic nitrogen compounds, low molecular

weight aldehydes, quaternary ammonium materials, dehydroacetic acid, phenyl and phenoxy compounds and mixtures thereof.

Examples of preferred preservatives for use in the compositions of the present invention include: a mixture of about 77% 5-chloro-2-methyl-4-isothiazolin-3-one and about 23% 2-methyl-4-isothiazolin-3-one, which is sold commercially as a 1.5% aqueous solution by Rohm & Haas (Philadelphia, Pa.) under the trade name Kathon; 1, 2-benzisothiazolin-3-one, which is sold commercially by Avecia (Wilmington, Del.) as, for example, a 20% solution in dipropylene glycol sold under the trade name Proxel GXL; and a 95:5 mixture of 1,3 bis (hydroxymethyl) -5, 5-dimethyl-2, 4 imidazolidinedione and 3- butyl-2-iodopropynyl carbamate, which can be obtained, for example, as Glydant Plus from Lonza (Fair Lawn, N.J.) .

Fluorescent Whitening Agents

Many fabrics, and cottons in particular, tend to lose their whiteness and adopt a yellowish tone after repeated washing. As such, it is customary and preferred to add a small amount of fluorescent whitening agent, which absorbs light in the ultraviolet region of the spectrum and re-emits it in the visible blue range, to the compositions of this invention, especially if they are combination detergent / fabric conditioner preparations.

Suitable fluorescent whitening agents include derivatives of diaminostilbenedisulfonic acid and their alkali metal salts. Particularly, the salts of 4, 4' -bis (2-anilino4-morpholino- 1 , 3, 5-triazinyl-6-amino) stilbene-2 , 2 ' -disulfonic acid, and related compounds where the morpholino group is replaced by

another nitrogen-comprising moiety, are preferred. Also preferred are brighteners of the 4, 4' -bis (2-sulfostyryl) biphenyl type, which may optionally be blended with other fluorescent whitening agents at the option of the formulator. Typical fluorescent whitening agent levels in the preparations of this invention range between 0.001% and 1%, although a level between 0.1% and 0,3%, by mass, is normally used. Commercial supplies of acceptable fluorescent whitening agents can be sourced from, for example, Ciba Specialty Chemicals (High Point, N. C.) and Bayer (Pittsburgh, Pa.).

Builders

Builders are often added to fabric cleaning compositions to complex and remove alkaline earth metal ions, which can interfere with the cleaning performance of a detergent by combining with anionic surfactants and removing them from the wash liquor. The preferred compositions of this invention contain low levels, if any at all, of builder. Generally, these will comprise less than 10%, preferably less than 7% and most preferably less than 5% by weight of total phosphate and zeolite .

Soluble builders, such as alkali metal carbonates and alkali metal citrates, are particularly preferred, especially for the liquid embodiment of this invention. Other builders, as further detailed below, may also be used, however. Often a mixture of builders, chosen from those described below and others known to those skilled in the art, will be used.

Alkali and Alkaline Earth Metal Carbonates:

Alkali and alkaline earth metal carbonates, such as those detailed in German patent application 2,321,001, published Nov. 15, 1973, are suitable for use as builders in the compositions of this invention. They may be supplied and used either in anhydrous form, or including bound water. Particularly useful is sodium carbonate, or soda ash, which both is readily available on the commercial market and has an excellent environmental profile.

The sodium carbonate used in this invention may either be natural or synthetic, and, depending on the needs of the formula, may be used in either dense or light form. Natural soda ash is generally mined as trona and further refined to a degree specified by the needs of the product it is used in. Synthetic ash, on the other hand, is usually produced via the Solvay process or as a coproduct of other manufacturing operations, such as the synthesis of caprolactam. It is sometimes further useful to include a small amount of calcium carbonate in the builder formulation, to seed crystal formation and increase building efficacy.

Organic Builders:

Organic detergent builders can also be used as nonphosphate builders in the present invention. Examples of organic builders include alkali metal citrates, succinates, malonates, fatty acid sulfonates, fatty acid carboxylates, nitrilotriacetates, oxydisuccinates, alkyl and alkenyl disuccinates, oxydiacetates, carboxymethyloxy succinates, ethylenediamine tetraacetates, tartrate monosuccinates, tartrate disuccinates, tartrate monoacetates, tartrate

diacetates, oxidized starches, oxidized heteropolymeric polysaccharides, polyhydroxysulfonates, polycarboxylates such as polyacrylates, polymaleates, polyacetates, polyhydroxyacrylates, polyacrylate/polymaleate and polyacrylate/ polymethacrylate copolymers, acrylate/maleate/vinyl alcohol terpolymers, aminopolycarboxylates and polyacetal carboxylates, and polyaspartates and mixtures thereof. Such carboxylates are described in U.S. Patent Nos. 4,144,226, 4,146,495 and 4,686,062. Alkali metal citrates, nitrilotriacetates, oxydisuccinates, acrylate/maleate copolymers and acrylate/maleate/vinyl alcohol terpolymers are especially preferred nonphosphate builders.

Phosphates:

The compositions of the present invention which utilize a water-soluble phosphate builder typically contain this builder at a level of from 1 to 90% by weight of the composition. Specific examples of water-soluble phosphate builders are the alkali metal tripolyphosphates, sodium, potassium and ammonium pyrophosphate, sodium and potassium orthophosphate, sodium polymeta/phosphate in which the degree of polymerization ranges from about 6 to 21, and salts of phytic acid. Sodium or potassium tripolyphosphate is most preferred.

Phosphates are, however, often difficult to formulate, especially into liquid products, and have been identified as potential agents that may contribute to the eutrophication of lakes and other waterways. As such, the preferred compositions of this invention comprise phosphates at a level of less than about 10% by weight, more preferably less than about 5% by

weight. The most preferred compositions of this invention are formulated to be substantially free of phosphate builders.

Zeolites :

Zeolites may also be used as builders in the present invention. A number of zeolites suitable for incorporation into the products of this disclosure are available to the formulator, including the common zeolite 4A. In addition, zeolites of the MAP variety, such as those taught in European Patent Application EP 384,07OB, which are sold commercially by, for example, Ineos Silicas (UK), as Doucil A24, are also acceptable for incorporation. MAP is defined as an alkali metal aluminosilicate of zeolite P type having a silicone to aluminum ratio not exceeding 1.33, preferably within the range of from 0.90 to 1.33, more preferably within the range of from 0.90 to 1.20.

Especially preferred is zeolite MAP having a silicone to aluminum ratio not exceeding 1.07, more preferably about 1.00. The particle size of the zeolite is not critical. Zeolite A or zeolite MAP of any suitable particle size may be used. In any event, as zeolites are insoluble matter, it is advantageous to minimize their level in the compositions of this invention. As such, the preferred formulations contain less than about 10% of zeolite builder, while especially preferred compositions comprise less than about 5% zeolite.

Enzyme Stabilizers

When enzymes, and especially proteases are used in liquid detergent formulations, it is often necessary to include a

suitable quantity of enzyme stabilizer to temporarily deactivate it until it is used in the wash. Examples of suitable enzyme stabilizers are well-known to those skilled in the art, and include, for example, borates and polyols such as propylene glycol. Borates are especially suitable for use as enzyme stablizers because in addition to this benefit, they can further buffer the pH of the detergent product over a wide range, thus providing excellent flexibility.

If a borate-based enzyme stabilization system is chosen, along with one or more cationic polymers that are at least partially comprised of carbohydrate moeities, stability problems can result if suitable co-stablizers are not used. It is believed that this is the result of borates' natural affinity for hydroxyl groups, which can create an insoluble borate-polymer complex that precipitates from solution either over time or at cold temperatures. Incorporating into the formulation a co-stabilizer, which is normally a diol or polyol, sugar or other molecule with a large number of hydroxyl groups, can ordinarily prevent this. Especially preferred for use as a co-stabilizer is sorbitol, used at a level that is at least about 0.8 times the level of borate in the system, more preferably 1.0 times the level of borate in the system and most preferably more than 1.43 times the level of borate in the system, is sorbitol, which is effective, inexpensive, biodegradable and readily available on the market. Similar materials including sugars such as glucose and sucrose, and other poyols such as propylene glycol, glycerol, mannitol, maltitol and xylitol, should also be considered within the scope of this invention.

Fiber Lubricants

In order to enhance the conditioning, softening, wrinkle- reduction and protective effects of the compositions of this invention, it is often desirable to include one or more fiber lubricants in the formulation. Such ingredients are well known to those skilled in the art, and are intended to reduce the coefficient of friction between the fibers and yarns in articles being treated, both during and after the wash process. This effect can in turn improve the consumer's perception of softness, minimize the formation of wrinkles and prevent damage to textiles during the wash. For the purposes of this disclosure, "fiber lubricants" shall be considered non-cationic materials intended to lubricate fibers for the purpose of reducing the friction between fibers or yarns in an article comprising textiles which provide one or more wrinkle- reduction, fabric conditioning or protective benefit.

Examples of suitable fiber lubricants include, functionalized plant and animal-derived oils, natural and synthetic waxes and the like. Such ingredients often have low HLB values, less than about 10, although exceeding this level is not outside of the scope of this invention. Various levels of derivatization may be used provided that the derivatization level is sufficient for the oil or wax derivatives to become soluble or dispersible in the solvent it is used in so as to exert a fiber lubrication effect during laundering of fabrics with a detergent containing the oil or wax derivative.

When the use of a fiber lubricant is elected, it will generally be present as between 0.1% and 15% of the total composition weight.

Bleach Catalyst

An effective amount of a bleach catalyst can also be present in the invention. A number of organic catalysts are available such as the sulfonimines as described in U.S. Patents 5,041,232; 5,047,163 and 5,463,115.

Transition metal bleach catalysts are also useful, especially those based on manganese, iron, cobalt, titanium, molybdenum, nickel, chromium, copper, ruthenium, tungsten and mixtures thereof. These include simple water-soluble salts such as those of iron, manganese and cobalt as well as catalysts containing complex ligands.

Suitable examples of manganese catalysts containing organic ligands are described in U.S. Pat. 4,728,455, U.S. Pat. 5,114,606, U.S. Pat 5,153,161, U.S. Pat. 5,194,416, U.S. Pat. 5,227,084, U.S. Pat. 5,244,594, U.S. Pat .5, 246, 612, U.S. Pat. 5,246,621, U.S. Pat. 5,256,779, U.S. Pat. 5,274,147, U.S. Pat. 5,280,117 and European Pat. App . Pub. Nos. 544,440, 544,490, 549,271 and 549,272. Preferred examples of these catalysts include Mn ^IV ₂ (u-O) ₂ (1, 4, 7-trimethyl-l, 4, 7- triazacyclononane) ₂ (PF ₆ ) ₂ , Mn ^IJI ₂ (u-O) 1 (u-OAc) ₂ (1, 4, 7- trimethyl- 1, 4, 7-triazacyclononane) ₂ (CIO ₄ ) 2 Mn ^IV ₄ (u-O) ₆ (1, 4, 7- triazacyclononane) 4 (CIO ₄ ) ₄ , Mn ^IJI Mn ^IV ₄ (u-O) 1 (u-OAc) ₂ (1, 4, 7- trimethyl-1 , 4 , 7-triazacyclononane) ₂ (ClO ₄ ) ₃ , Mn ^IV (1,4, 7-trimethyl- 1, 4, 7-triazacyclononane) - (OCH ₃ ) ₃ (PF ₆ ) , and mixtures thereof. Other metal-based bleach catalysts include those disclosed in U.S. Pat. 4,430,243 and U.S. Pat. 5,114,611. Other examples of complexes of transition metals include Mn gluconate, Mn(CF ₃ SOs) ₂ , and binuclear Mn complexed with tetra-N-dentate and

bi -N-dentate l igands , including [ bipy ₂ Mn ^{I I i:} ( u-O ) ₂ Mn ^Iv bipy ₂ ] - ( C I O ₄ ) ₃ .

Iron and manganese salts of aminocarboxylic acids in general are useful herein including iron and manganese aminocarboxylate salts disclosed for bleaching in the photographic color processing arts. A particularly useful transition metal salt is derived from ethylenediaminedisuccinate and any complex of this ligand with iron or manganese.

Another type of bleach catalyst, as disclosed in U.S. Pat. 5,114,606, is a water soluble complex of manganese (II), (III), and/or (IV) with a ligand which is a non-carboxylate polyhydroxy compound having at least three consecutive C-OH groups. Preferred ligands include sorbitol, iditol, dulsitol, mannitol, xylithol, arabitol, adonitol, meso-erythritol, meso- inositol, lactose and mixtures thereof. Especially preferred is sorbitol.

Other bleach catalysts are described, for example, in European Pat. App . Pub. Nos. 408,131 (cobalt complexes), 384,503 and 306,089 (metallo-porphyrins) , U.S. Pat. 4,728,455 (manganese/multidenate ligand), U.S. Pat. 4,711,748 (absorbed manganese on aluminosilicate) , U.S. Pat. 4,601,845

(aluminosilicate support with manganese, zinc or magnesium salt), U.S. Pat. 4,626,373 (manganese/ligand) , U.S. Pat. 4,119,557 (ferric complex), U.S. Pat. 4,430.243 (Chelants with manganese cations and non-catalytic metal cations), and U.S. Pat. 4,728,455 (manganese gluconates).

Useful catalysts based on cobalt are described in WO 96/23859, WO 96/23860 and WO 96/23861 and U.S. Pat. 5,559,261.

WO 96/23860 describe cobalt catalysts of the type [Co _n L _m X _p ] ^Z Y _Z , where L is an organic ligand molecule containing more than one heteroatom selected from N, P, O and S; X is a co-ordinating species; n is preferably 1 or 2; m is preferably 1 to 5; p is preferably 0 to 4 and Y is a counterion. One example of such a catalyst is N, N ' -Bis (salicylidene) ethylenediaminecobalt (II). Other cobalt catalysts described in these applications are based on Co(III) complexes with ammonia and mono-, bi-, tri- and tetradentate ligands such as [Co (NH ₃ ) ₅ 0Ac] ²⁺ with Cl ^" , OAc ^" , PF ₆ ^" , S0 ₄ ⁼ , and BF ₄ ^" anions.

Certain transition-metal containing bleach catalysts can be prepared in the situ by the reaction of a transition-metal salt with a suitable chelating agent, for example, a mixture of manganese sulfate and ethylenediaminedisuccinate . Highly colored transition metal-containing bleach catalysts may be co- processed with zeolites to reduce the color impact.

When present, the bleach catalyst is typically incorporated at a level of about 0.0001 to about 10% by wt . , preferably about 0.001 to about 5% by weight.

Hydrotropes

In many liquid and powdered detergent compositions, it is customary to add a hydrotrope to modify product viscosity and prevent phase separation in liquids, and ease dissolution in powders .

Two types of hydrotropes are typically used in detergent formulations and are applicable to this invention. The first of these are short-chain functionalized amphiphiles. Examples

of short-chain amphiphiles include the alkali metal salts of xylenesulfonic acid, cumenesulfonic acid and octyl sulfonic acid, and the like. In addition, organic solvents and monohydric and polyhydric alcohols with a molecular weight of less than about 500, such as, for example, ethanol, isoporopanol, acetone, propylene glycol and glycerol, may also be used as hydrotropes.

The following examples will more fully illustrate the embodiments of this invention. All parts, percentages and proportions referred to herein and in the appended claims are by weight unless otherwise illustrated. Physical test methods are described below.

TEST METHOD AND EXAMPLES

Procedure for Evaluating Softening Panel

Fabric was washed with a variety of product, the formulations for which are set forth herein below. For each example formulation, the dosage to the wash was 37 grams. The washed fabric was then evaluated by expert panelists for perceived softening. For each of the washes, product was added to a top loading Kenmore washing machine that contained 64.4 L of water and 2.5 kg of fabric. There were four 100% cotton towels in each machine along with 100% cotton sheets to bring the total weight of the fabric to 2.5 kg. A maximum of four formulations were tested.

The temperature of the water for the washes was 32 deg. C and the fabrics were washed for 12 minutes. The hardness of the water for both the wash and rinse cycle was maintained at

130 ppm. Four washes were done for each product. Each formula tested is benchmarked against two controls- one using a leading marketplace liquid detergent (dosed at 98 gms . ) and one using a leading marketplace liquid detergent plus a leading marketplace liquid ultra-concentrated fabric softener. For the latter control, 29.5 gms of the softening formula is added to the beginning of the rinse cycle. After the rinse cycle, the fabrics were tumble dried in a Kenmore dryer for 60 minutes at the normal cycle. After the drying cycle, the fabrics were folded and placed in a room temperature environment.

The following day, five expert panelists scored the softness of each towel on a 0-10 scale with 0 being "not soft at all" and 10 being "extremely soft." Once 5 expert panelists have felt the towel, it will get replaced by the replicate and evaluated again for softening. The softening scores of each product, as correlated by the towel, are averaged and analyzed by utilizing the Tukey-Kramer HSD statistical comparison method.

TABLE 1. Experimental Formulations

tionic polymer ex. Amerchol Corp.

Table 2 Softening Results

As seen from the results in Table 2, Formula 1 containing hydroxystearic acid delivered directionally higher perceived softening at the constant overall soap level. Composition 4, which was a typical cleaning-only (no intended softening) delivered substantially lower perceived softening.

The cleaning of these compositions was tested in a consumer test and was found to be on par with the current commercial cleaning compositions.

While the present invention has been described herein with some specificity, and with reference to certain preferred embodiments thereof, those of ordinary skill in the art will recognize numerous variations, modifications and substitutions of that which has been described which can be made, and which are within the scope and spirit of the invention. It is intended that all of these modifications and variations be within the scope of the present invention as described and claimed herein, and that the inventions be limited only by the scope of the claims which follow, and that such claims be interpreted as broadly as is reasonable. Throughout this application, various publications have been cited. The

entireties of each of these publications are hereby incorporated by reference herein.