Solid block comprising one or more domains of prismatic or cylindrical shape and production thereof

Patent metadata

Field	Value
Publication number	US-10287535-B2
Application number	US-201415304156-A
Country	US
Kind code	B2
Filing date	Apr 15, 2014
Priority date	Apr 15, 2014
Publication date	May 14, 2019
Grant date	May 14, 2019

Abstract

The present invention relates to a solid block comprising a solidified material, characterized in that the solid block comprises one or more domains of prismatic or cylindrical shape extending between two parallel surfaces of the solid block from one surface to the other, wherein the solidified powder inside the one or more domains and the solidified powder outside the one or more domains each comprises one or more chemical substances, and wherein the chemical composition of the solidified powder inside the one or more domains is different from the chemical composition of the solidified powder outside the one or more domains. The present invention further relates to methods for producing such solid block. The present invention also relates to the use of such solid block as detergent in warewashing applications.

First claim

The invention claimed is:

1. A solid block comprising a solidified material,
characterized in that the solid block comprises one or more domains of prismatic or cylindrical shape extending between two parallel surfaces of the solid block from one surface to the other;
wherein the solidified powder inside the one or more domains and the solidified powder outside the one or more domains each comprises one or more chemical substances;
wherein the chemical composition of the solidified powder inside the one or more domains is different from the chemical composition of the solidified powder outside the one or more domains;
wherein the solidified powder inside the one or more domains comprises a peroxidation catalyst, and the solidified powder outside the one or more domains comprises the one or more peroxides;
wherein the solidified powder outside the one or more domains is free of the peroxidation catalyst, and the solidified powder inside the one or more domains is free of the peroxides; and
wherein the peroxidation catalyst is a compound according to formula (I); or
wherein the solidified powder outside the one or more domains comprises a peroxidation catalyst, and the solidified powder inside the one or more domains comprises the one or more peroxides, wherein the solidified powder inside the one or more domains is free of the peroxidation catalyst, and the solidified powder outside the one or more domains is free of the peroxides; wherein the peroxidation catalyst is a compound according to formula (I);
[(L p M q ) n X r ]Y s   (I)

wherein each L independently is an organic ligand containing at least three nitrogen atoms and/or at least two carboxyl groups that coordinate with the metal M;
M is Mn or Fe;
each X independently is a coordinating or bridging group selected from the group consisting of H 2 O, OH − , SH − , HO 2 − , O 2− , O 2 2− , S 2− , F − , Cl − , Br − , I − , NO 3 − , NO 2 , SO 4 2− , SO 3 2− , PO 4 3- , N 3 − , CN − , NR 3 , NCS − , RCN, RS − , RCO 2 − , RO − , and

with R being hydrogen or a C 1 to C 6 alkyl group;
p is an integer from 1 to 4;
q is an integer from 1 to 2;
r is an integer from 0 to 6;
Y is a counter ion; and
s is the number of counter ions.

2. The solid block according to claim 1 , characterized in that the solubility in water at 25° C. of the solidified powder inside the one or more domains and the solubility in water at 25° C. of the solidified powder outside the one or more domains differ by not more than 10%.

3. The solid block according to claim 1 , characterized in that the solidified powder inside the one and more domains and/or outside the one or more domains is a solidified powder or a congealed melt.

4. The solid block according to claim 1 , characterized in that the solidified powder inside the one and/or more domains and/or the solidified powder outside the one and more domains comprises one or more of peroxides, peroxidation catalysts, surfactants, chelating/sequestering agents, detergent fillers or binding agents, alkalinity sources, enzymes, activating agents, defoaming agents, anti-redeposition agents, dyes, odorants, bleaching agents, and water.

5. The solid block according to claim 1 , characterized in that the solidified powder inside the one and/or more domains and/or the solidified powder outside the one and more domains is free of one or more of peroxides, peroxidation catalysts, surfactants, chelating/sequestering agents, detergent fillers or binding agents, alkalinity sources, enzymes, activating agents, defoaming agents, anti-redeposition agents, dyes, odorants, bleaching agents, and water.

6. The solid block according to claim 1 , characterized in that the one or more domains make up between 10% and 50% of the volume of the solid block.

7. The solid block according to claim 1 , characterized in that the perimeter of the solid block measured between two parallel surfaces is between 0.2 to 0.5 m.

8. The solid block according to claim 1 , characterized in that the weight of the solid block is more than 0.5 kg.

9. The solid block according to claim 1 , characterized in that the solidified powder inside the one or more domains comprises the one or more peroxides, the solidified powder outside the one or more domains comprises the peroxidation catalyst, and the solidified powder outside the one or more domains is free of the peroxides.

10. A method for producing a solid block according to claim 1 , comprising the following steps:
a. providing a first powder comprising one or more chemical substances,
b. filling the first powder in a mold having prismatic or cylindrical shape,
c. solidifying the powder to a solid block of prismatic or cylindrical shape,
d. optionally repeating steps a. to c.,
e. placing one or more solid blocks of prismatic or cylindrical shape in a second mold of larger volume than the volume of the one or more solid blocks of prismatic or cylindrical shape,
f. filling the free volume of the second mold with a second powder comprising one or more chemical substances, the second powder having a different chemical composition from the first powder of step a.,
g. solidifying the powder of step f. to obtain a solid block.

11. A method for producing a solid block according to claim 1 , comprising the following steps:
a. providing a first powder comprising one or more chemical substances,
b. melting the powder,
c. filling the melted powder in a first mold having one or more inserts of prismatic or cylindrical shape,
d. solidifying the melted powder,
e. removing the one or more inserts to leave one or more holes,
f. providing a second powder comprising one or more chemical substances, the second powder having a different chemical composition from the first powder of step a.,
g. melting the second powder,
h. optionally repeating steps f. to g.,
i. filling the melted second powder in the one or more holes,
j. solidifying the melted second powder in the one or more holes to obtain a solid block.

12. A method for producing a solid block according to claim 1 , comprising the following steps:
a. providing a first powder comprising one or more chemical substances,
b. melting the first powder
c. filling the melted first powder in a mold,
d. solidifying the melted first powder,
e. drilling one or more holes of prismatic or cylindrical shape into the melted first powder,
f. providing a second powder comprising one or more chemical substances, the second powder having a different chemical composition from the first powder of step a.,
g. melting the second powder,
h. optionally repeating steps f. to g.,
i. filling the melted second powder in the one or more holes,
j. solidifying the melted second powder in the one or more holes to obtain a solid block.

13. Use of a solid block according to claim 1 as detergent in warewashing applications.

14. The use according to claim 13 , characterized in that the solid block is inserted in industrial warewashing machines.

15. The solid block according to claim 1 , characterized in that the one or more domains make up between about 25% and about 35% of the volume of the solid block.

16. The solid block according to claim 1 , characterized in that the perimeter of the solid block measured between two parallel surfaces is between about 0.2 m to about 0.4 m.

17. The solid block according to claim 1 , characterized in that the perimeter of the solid block measured between two parallel surfaces is about

Assignees

• Ecolab Usa Inc
• Foster Tobias
• Klose Sven
• Kullwitz Dirk
• Zurbey Matthew
• Stolte Roger
• Peterson Mark
• Yunus Irwan
• Gohl David

Inventors

• Foster Tobias
• Klose Sven
• Kullwitz Dirk
• Zurbey Matthew
• Stolte Roger
• Peterson Mark
• Yunus Irwan
• Gohl David

Classifications

• C11D11/0023

  Chemistry & Metallurgy · mapped topic

• C11D17/0052 Primary

  Cast detergent compositions · CPC title

• C11D11/0082

  one or more of the detergent ingredients being in a liquefied state, e.g. slurry, paste or melt, and the process resulting in solid detergent particles such as granules, powders or beads · CPC title

• C11D2111/14

  Hard surfaces · CPC title