Low Energy, Cold Process Formulation Aid

Abstract

Provided are cold process formulation aids (CPFAs), methods for their manufacture, and personal care products made using them. CPFAs include (i) a polymer having an aliphatic backbone and a plurality of pendant groups thereon that are pendant ionic or ionizable groups, or pendant groups having at least one permanent dipole that includes an acid, alcohol, thiol, ester, amine, amide, imide, imine, or nitrile moiety, and (ii) a wax selected from natural waxes and synthetic waxes, wherein if the wax is not micronized and is not self-emulsifying, the ratio, by weight, of the non-micronized wax to the polymer having an aliphatic backbone is from about 60:40 to 80:20, and if the wax is a micronized wax or a self-emulsifying wax, the ratio, by weight, of wax to polymer backbone is 70:30 to 98:2.

1 . An anhydrous cold process formulation aid in the form of a flake, slab, powder, a paste, a semi-solid, or a slurry consisting essentially of
 (i) a polymer having polysaccharide backbone and a plurality of pendant groups thereon that are pendant ionic or ionizable groups, and   (ii) a wax selected from the group consisting of natural waxes and synthetic waxes, wherein if the wax is not micronized and is not self-emulsifying, the ratio, by weight, of the non-micronized wax to the polymer having an aliphatic backbone is from about 60:40 to 80:20, and if the wax is a micronized wax or a self-emulsifying wax, the ratio, by weight, of wax to polymer backbone is 70:30 to 98:2,
 wherein when the anhydrous cold process formulation aid is mixed with an aqueous medium at a temperature not exceeding the melt point of the wax or the melt point of the anhydrous cold process formulation aid, the anhydrous cold process formulation aid forms a hydrogel or an emulsion. 
   
     
     
         2 . The anhydrous cold process formulation aid of  claim 1  wherein the pendant ionic or ionizable groups on the polysaccharide backbone are selected from carboxyl groups, carboxylate groups, sulfate groups, and salts thereof, and/or poly(aspartate). 
     
     
         3 . The anhydrous cold process formulation aid of  claim 1  wherein the polymer having a polysaccharide backbone and a plurality of pendant groups thereon that are pendant ionic or ionizable groups is selected from the group consisting of sodium alginate, carrageenan, carboxymethyl cellulose, xanthan, starches, and cationic guar. 
     
     
         4 . An anhydrous cold process formulation aid of  claim 1  that is in the form of a powder. 
     
     
         5 . The anhydrous cold process formulation aid of  claim 4  that is prepared by spray drying, jet milling, prilling or dry blending. 
     
     
         6 . The anhydrous cold process formulation aid of  claim 5  wherein the wax is micronized and has an average particle size not exceeding about 50 microns, and the ratio, by weight, of wax to polymer backbone is from about 85:15 to about 98:2. 
     
     
         7 - 25 . (canceled) 
     
     
         26 . A method for producing an anhydrous cold-process formulation aid comprising the sequential steps of:
 (i) adding at least one wax to a vessel, heating the at least one wax to a temperature that is at least about 5° C. above the melt point of the at least one wax, mixing the at least one wax until a homogenous batch of molten wax is achieved;   (ii) adding a polymer having polysaccharide backbone with a plurality of pendant ionic or ionizable groups thereon to the batch of molten wax from step (i), mixing the batch of molten wax and the polymer together, while heating to a temperature of at least about 5° C. above the higher of (a) the melt point of the at least one wax or (b) the softening point of the polymer, until a homogenous mixture is produced;   (iii) cooling the mixture from step (ii) to a temperature of about 5° C. above the congealing point of the mixture;   (iv) pouring the mixture from step (iii) into a container, producing an anhydrous cold-process formulation aid in the form of a solid wax, or wax-like substance;   wherein if the at least one wax is not micronized and is not emulsifying, the ratio, by weight, of the non-micronized/non-emulsifying wax to the polymer having a polysaccharide backbone is from about 60:40 to 80:20, and if the at least one wax is a micronized wax or an emulsifying wax, the ratio, by weight, of at least one wax to polymer backbone is 70:30 to 98:2; and   wherein when mixed with an aqueous medium, the anhydrous cold-process formulation aid forms a hydrogel or an emulsion.   
     
     
         27 . The method for producing an anhydrous cold-process formulation aid according to  claim 26  wherein
 (a) in step (i), two waxes, a first wax and a second wax, are combined and the two waxes are heated to a temperature that is at least about 5° C. above the higher of (x) the melt point of the first wax and (y) the melt point of the second wax, and 
 (b) in step (ii), after addition of the polymer having a polysaccharide backbone with a plurality of pendant ionic or ionizable groups thereon, the two waxes and the polymer are mixed together, while heating to a temperature of at least about 5° C. above the higher of (x) the melt point of the first wax, (y) the melt point of the second wax, or (z) the softening point of the polymer. 
 
     
     
         28 . The method for producing an anhydrous cold-process formulation aid according to  claim 26  wherein in step (ii), two polymers having a polysaccharide backbone with a plurality of pendant ionic or ionizable groups thereon, a first ionic/ionizable polymer and a second ionic/ionizable polymer, are mixed with the wax, while heating to a temperature of at least about 5° C. above the higher of (xx) the melt point of the wax, (yy) the softening point of the first ionic/ionizable polymer, or (zz) the softening point of the second ionic/ionizable polymer. 
     
     
         29 . The method for producing an anhydrous cold-process formulation aid according to  claim 27  wherein in step (ii), two polymers having a polysaccharide backbone with a plurality of pendant ionic or ionizable groups thereon, a first ionic/ionizable polymer and a second ionic/ionizable polymer, are mixed with the two waxes, while heating to a temperature of at least about 5° C. above the higher of (aa) the melt point of the first wax, (bb) the melt point of the second wax, (cc) the softening point of the first ionic/ionizable polymer, or (dd) the softening point of the second ionic/ionizable polymer. 
     
     
         30 - 41 . (canceled)