Cast detergent-containing article and method of using

Abstract

Solid cast detergent-containing articles are produced for use in automatic washing machines. A liquid detergent composition is cast into a mold where it is allowed to solidify. The solid cast detergent, surrounded on all but its upper surface by the mold, is used in automatic washing machines having a dispensing device designed to dispense a liquid aqueous detergent formed from the solid cast detergent using an impinging liquid spray. The liquid aqueous detergent flows out of the dispensing device generally simultaneously with its formation in the dispenser. The cast detergent composition includes an alkaline hydratable chemical and optionally further includes one or more preformed cores or plugs comprising an available chlorine source, a defoamer, or the like.

What is claimed is: 
     
       1. A detergent-containing article of commerce comprising: (a) a three-dimensional, solid.Iadd., .Iaddend.cast, hydrated, substantially uniform alkaline detergent .Iadd.for ware and hard surface washing .Iaddend.comprising: (1) at least .Iadd.about .Iaddend.30% by weight of an alkaline hydratable chemical consisting essentially of alkali metal hydroxide:   (2) .Iadd.an effective amount of .Iaddend.a hardness-sequestering agent;   (3) .[.more than 15 parts by weight, per 100 parts by weight of said alkaline hydratable chemical, of.]. water of hydration, at least a portion of said water of hydration being associated with said alkali metal hydroxide.Iadd., wherein the alkali metal hydroxide and the hardness sequestering agent are present in an amount sufficient to render the cast detergent a solid at room temperature by virtue of the water of hydration.Iaddend.; and     (b) a receptacle-shaped disposble container surrounding and in contact with said solid, cast, hydrated alkaline detergent composition on all but one surface thereof.   
     
     
       2. An article according to claim 1 wherein said container is the mold in which said composition .[.was.]. .Iadd.is .Iaddend.cast and solidified. 
     
     
       3. An article according to claim 2 wherein said article further comprises a cover attached to the said receptacle-shaped container. 
     
     
       4. An article according to claim 1 wherein said article comprises at least one preformed core.[., said core being surrounded by and in contact with said detergent on at least one side of said core.].. 
     
     
       5. An article according to claim 4 wherein said preformed core comprises a material selected from the group consisting of a defoamer and a solid, available chlorine-containing component. 
     
     
       6. An article according to claim 5 comprising a plurality of preformed cores, at least one of which comprises a solid, available chlorine-containing component. 
     
     
       7. An article according to claim 5 wherein .[.a.]. said preformed core has been coated with .[.an inert barrier.]. .Iadd.a .Iaddend.film. 
     
     
       8. An article according to claim 1 wherein said solid, cast, hydrated, alkaline detergent composition comprises: (a) at least about 30% by weight of a first alkaline hydratable chemical consisting essentially of an alkali metal hydroxide;   (b) a second alkaline hydratable chemical comprising a hardness-sequestering amount of an alkali metal condensed phosphate;   (c) .[.more than 5% by weight of.]. water of hydration in both discrete and continuous states of hydration, at least a portion of said water of hydration being associated with said alkali metal hydroxide;   (d) .[.up to about 15% by weight of a.]. .Iadd.an effective hardness sequestering amount of an organic .Iaddend.polyelectrolyte; and   (e) up to 5% by weight of an additive selected from the group consisting of a defoamer and a solid, available chlorine-containing compound.   
     
     
       9. An article according to claim 8 wherein said solid, cast, hydrated alkaline detergent composition further comprises a sodium silicate. .[.10. The detergent containing article of claim 1 wherein there is about 10 to 35 wt %, based on the hydrated alkaline detergent composition, of water of 
     
     
        hydration..]. 11. A method for dispensing warewashing detergent into a warewashing zone for washing alkaline detergent-resistant ware, using the cast, hydrated.Iadd., .Iaddend.alkaline detergent composition of the detergent-containing article of claim 1, comprising the following steps: (a) placing said cast, hydrated, alkaline detergent composition in a detergent dispensing device having a spray means, in a position with respect to the horizontal and with respect to said spray means, for dispensing detergent downwardly from said detergent composition to the warewashing zone of a warewashing machine, whereby the side of the cast, hydrated alkaline detergent composition not surrounded by said receptacle-shaped container is contained within the interior of said detergent dispensing device and is oriented to provide the interior of said detergent dispensing device with essentially one unsurrounded, exposed, drainable surface of cast, hydrated, alkaline detergent composition;   (b) impinging a spray of aqueous liquid from said spray means upon said unsurrounded, exposed, drainable surface to dissolve detergent composition at a generally consistent rate and thereby form an aqueous liquid detergent containing said detergent composition in the aqueous liquid, which aqueous liquid detergent .[.rains.]. .Iadd.drains .Iaddend.downwardly from said unsurrounded, exposed, drainable surface generally simultaneously with said impinging;   (c) generally simultaneously permitting the downwardly-draining aqueous liquid detergent to flow out of said detergent dispensing device and into said warewashing zone for the purpose of washing alkaline detergent-resistant ware .[.wherein.]. .Iadd.therein.Iaddend.; and   (d) controlling the duration of said step (b), thereby controlling the amount of said aqueous liquid detergent composition flowing into said warewashing zone, thereby controlling the concentration of said detergent   
     
     
        composition in said warewashing zone. 12. A method according to claim 11 wherein said unsurrounded, exposed, drainable surface generally faces 
     
     
        toward said spray means. 13. A method according to claim 12 wherein said cast, hydrated alkaline detergent composition is placed in accordance with said step (a) in an inverted position above said spray means, such that said unsurrounded, exposed, drainable surface faces downwardly toward said 
     
     
        spray means. 14. A method according to claim 11 wherein, in said step (a), said cast, hydrated, alkaline detergent composition is placed in an inverted position over said spray means, and said impinging is provided by a spray oriented generally perpendicularly to said unsurrounded, exposed, 
     
     
        drainable surface. .Iadd.15.  A detergent-containing article of commerce comprising: (a) a three-dimensional, uniform solid cast, hydrated, alkaline warewashing detergent comprsing: (1) at least 30% by weight of an alkaline hydratable chemical consisting essentially of alkali metal hydroxide;   (2) an effective amount of a condensed phosphate hardness-sequestering agent; and   (3) water of hydration, at least a portion of said water of hydration being associated with said alkali metal hydroxide wherein the alkali metal hydroxide and the condensed phosphate hardness sequestering agent are present in amounts sufficient to render the cast detergent solid at room temperature by virtue of said water of hydration; and     (b) a receptacle-shaped disposable container surrounding and in contact with said solid, cast, hydrated alkaline warewashing detergent composition on all but one surface thereof. .Iaddend. .Iadd.16. An article according to claim 15 wherein the container is made of a thermoplastic material and wherein the container is a mold in which said alkaline detergent was cast and solidified. .Iaddend. .Iadd.17. An article according to claim 15 wherein said article further comprises a cover attached to the said   
     
     
        receptacle-shaped container mold. .Iaddend. .Iadd.18.  The article of claim 15 wherein the weight of the alkali detergent is at least 6 lbs. .Iaddend. .Iadd.19. The article of claim 15 wherein the hardness sequestering agent is a sodium tripolyphosphate compound. .Iaddend. .Iadd.20. An article according to claim 15 wherein said solid, cast, hydrated, alkaline detergent composition comprises: (a) at least about 30% by weight of the alkaline hydratable chemical consisting essentially of sodium hydroxide;   (b) an effective hardness-sequestering amount of a sodium tripolyphosphate compound;   (c) an effective hardness sequestering amount of a polyelectrolyte; and   (d) up to 5% by weight of an additive selected from the group consisting of a defoamer and a solid, available chlorine-containing component; wherein the alkaline detergent is cast within the disposable container. .Iaddend.   
     
     
        .Iadd.21.  The article of claim 20 wherein the polyelectrolyte is an organic polyelectrolyte composition. .Iaddend. .Iadd.22. A detergent-containing article of comprising a three-dimensional, uniform, solid cast, hydrated alkaline warewashing detergent comprising: (a) at least about 30% by weight of sodium hydroxide;   (b) a second alkaline hydratable chemical comprising an effective hardness-sequestering amount of sodium tripolyphosphate;   (c) water of hydration in both discrete and continuous states of hydration;   (d) an effective hardness sequestering amount of a polyacrylate; and   (e) up to 5% by weight of an additive selected from the group consisting of a defoamer and a solid, available chlorine-containing component; wherein the alkali metal hydroxide and the hardness sequestering agent are present in amounts sufficient to render the cast detergent a solid at room temperature by virtue of the water of hydration and the alkaline warewashing detergent is surrounded by and held in contact with a receptacle-shaped disposable thermoplastic container, on all but one     
     
     
        surface thereof. .Iaddend. .Iadd.23.  An article according to claim 22 wherein said article further comprises a cover attached to said receptacle-shaped container. .Iaddend.