Structured multi-phased personal care composition comprising branched anionic surfactants

Abstract

A multi-phase personal care composition is described that comprises a first visually distinct phase including a structured surfactant component and a second visually distinct phase. The structured surfactant component comprises at least one branched anionic surfactant and from 0 to 10% by weight of the first visually distinct phase, of sodium trideceth sulfate.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional application Ser. No. 60/670,785 filed on Apr. 13, 2005 and U.S. Provisional application Ser. No. 60/680,114 filed on May 12, 2005 and U.S. Provisional application Ser. No. 60/680,149 filed on May 12, 2005.

FIELD OF THE INVENTION

The present invention relates to a structured multi-phase personal care composition that comprises at least one branched anionic surfactant and from 0% to 10%, by weight of the first visually distinct phase, of sodium trideceth sulfate.

BACKGROUND OF THE INVENTION

Personal cleansing compositions that attempt to provide skin-conditioning benefits are known. Desirable personal cleansing compositions must meet a number of criteria. For example, in order to be acceptable to consumers, a multi-phase personal cleansing composition must exhibit good cleaning properties, must exhibit good lathering characteristics, must be mild to the skin (not cause drying or irritation) and preferably should even provide a conditioning benefit to the skin.

Many personal cleansing compositions are aqueous systems comprising emulsified conditioning oil or other similar materials in combination with a lathering surfactant. Although these products provide both conditioning and cleansing benefits, it is often difficult to formulate a product that deposits sufficient amount of skin conditioning agents on skin during use. In order to combat emulsification of the skin conditioning agents by the cleansing surfactant, large amounts of the skin conditioning agent are added to the compositions. However, this introduces another problem associated with these cleansing and conditioning products. Raising the level of skin conditioning agent in order to achieve increased deposition negatively affects the compositions speed of lather generation, total lather volume, performance and stability.

Some surfactants used in personal cleansing compositions, such as, sodium trideceth sulfate and similarly homologous chemicals based on tridecanol, also may depress the speed of lather production, although such compositions provide relatively mild cleansing. It is believed that the high level of branching in tridecanol-based surfactants and compositions that comprise them, exhibits less flash lather as a result of their water solubility. Moreover, sodium trideceth sulfate and similar homologues based on tridecanol, are relatively costly materials, as such, the compositions do not enjoy broad commercial use.

Accordingly, the need still remains for body wash composition that provides cleansing with increased lather longevity and improved lathering characteristics, and skin benefits such as silky skin feel, improved soft skin feel, and improved smooth skin feel. It is desirable to formulate compositions comprising lower levels, or even no sodium trideceth sulfate, which have the same beneficial properties as high sodium trideceth sulfate compositions.

SUMMARY OF THE INVENTION

The present invention relates to a multi-phase personal care composition that comprises a first visually distinct phase comprising a structured surfactant component; and a second visually distinct phase. The structured surfactant component comprises at least one branched anionic surfactant and from 0% to 10%, by weight of the first visually distinct phase, of sodium trideceth sulfate.

The inventors believe that mixtures of branched and linear anionic surfactants can provide good mildness, structure, and higher flash lather volume than compositions that comprise sodium trideceth sulfate, as the only anionic surfactant. Sufficient mildness can be provided by the highly branched tridecanol-based anionic surfactant complemented by high flash lather volume from linear structured surfactant components. These properties can be accomplished in the same composition by blending sodium trideceth sulfate with surfactants having a higher proportion of linear surfactants than sodium trideceth sulfate or by selecting surfactant which naturally have less branching than sodium trideceth sulfate. A preferred surfactant component comprises a substantial level of mono-methyl branched surfactants leading to structure and stability of structure.

DETAILED DESCRIPTION OF THE INVENTION

The term “ambient conditions” as used herein, refers to surrounding conditions at one (1) atmosphere of pressure, 50% relative humidity, and 25° C.

By the term “multi-phase” as used herein, is meant that the phases of the present compositions occupy separate but distinct physical spaces inside the package in which they are stored, but are in direct contact with one another (i.e., they are not separated by a barrier and they are not emulsified or mixed to any significant degree). In one preferred embodiment of the present invention, the “multi-phase” personal care compositions comprise at least two visually distinct phases which are present within the container as a visually distinct pattern. The pattern results from the combination of the “multi-phase” composition by a process herein described. The “patterns” or “patterned” include but are not limited to the following examples: striped, marbled, rectilinear, interrupted striped, check, mottled, veined, clustered, speckled, geometric, spotted, ribbons, helical, swirl, arrayed, variegated, textured, grooved, ridged, waved, sinusoidal, spiral, twisted, curved, cycle, streaks, striated, contoured, anisotropic, laced, weave or woven, basket weave, spotted, and tessellated. Preferably the pattern is selected from the group consisting of striped, geometric, marbled, and combinations thereof.

In a preferred embodiment, the striped pattern may be relatively uniform across the dimension of the package. Alternatively, the striped pattern may be uneven, i.e. wavy, or may be non-uniform in dimension. The striped pattern does not need to necessarily extend across the entire dimension of the package. The size of the stripes can be at least about 0.1 mm in width and 10 mm in length, preferably at least about 1 mm in width and at least 20 mm in length as measured from the package exterior. The phases may be various different colors, and/or include particles, glitter or pearlescent agents in at least one of the phases in order to offset its appearance from the other phase(s) present.

The term “multi-phase personal care composition” as used herein, refers to compositions intended for topical application to the skin or hair.

The term “visually distinct phase” as used herein, refers to a region of the multi-phase personal care composition having one average composition, as distinct from another region having a different average composition, wherein the regions are visible to the unaided naked eye. This would not preclude the distinct regions from comprising two similar phases where one phase could comprise pigments, dyes, particles, and various optional ingredients, hence a region of a different average composition. A phase generally occupies a space or spaces having dimensions larger than the colloidal or sub-colloidal components it comprises. A phase may also be constituted or re-constituted, collected, or separated into a bulk phase in order to observe its properties, e.g., by centrifugation, filtration or the like.

The term “stable” as used herein, unless otherwise specified, refers to compositions that maintain at least two “separate” phases when sitting in undisturbed physical contact at ambient conditions for a period of at least about 180 days wherein the distribution of the two phases in different locations in the package does not significantly change over time. Compositions of the present invention, preferably exhibit enhanced stability, in that the first visually distinct phase has greater than 50% Viscosity Retention measured according to the T-Bar method disclosed herein.

The term “structured surfactant component” as used herein means the total of all anionic, nonionic, amphoteric, zwitterionic and cationic surfactants in a phase. When calculations are based on the structured surfactant component, water and electrolyte are excluded from the calculations involving the structured surfactant component, since surfactants as manufactured typically are diluted and neutralized.

The term “structured,” as used herein means having a rheology that confers stability on the multi-phase composition. The degree of structure is determined by characteristics determined by one or more of the following methods the Yield Stress Method, or the Zero Shear Viscosity Method or by the Ultracentrifugation Method, all in the Test Methods below. Accordingly, a surfactant phase of the multiphase composition of the present invention is considered “structured,” if the surfactant phase has one or more of the following properties described below according to the Yield Stress Method, or the Zero Shear Viscosity Method or by the Ultracentrifugation Method. A surfactant phase is considered to be structured, if the phase has one or more of the following characteristics:

• • A. a Yield Stress of greater than about 0.1 Pascal (Pa), more preferably greater than about 0.5 Pa, even more preferably greater than about 1.0 Pa, still more preferably greater than about 2.0 Pa, still even more preferably greater than about 3 Pa, and even still even more preferably greater than about 5 Pa as measured by the Yield Stress and Zero Shear Viscosity Method described hereafter; or
  • B. a Zero Shear Viscosity of at least about 500 Pascal-seconds (Pa-s), preferably at least about 1,000 Pa-s, more preferably at least about 1,500 Pa-s, even more preferably at least about 2,000 Pa-s; or
  • C. a Structured Domain Volume Ratio as measured by the Ultracentrifugation Method described hereafter, of greater than about 40%, preferably at least about 45%, more preferably at least about 50%, more preferably at least about 55%, more preferably at least about 60%, more preferably at least about 65%, more preferably at least about 70%, more preferably at least about 75%, more preferably at least about 80%, even more preferably at least about 85%.

Product Form:

The multi-phase personal care composition of the present invention is typically extrudable or dispensable from a package. The multi-phase personal care compositions typically exhibit a viscosity of from about 1,500 centipoise (cP) to about 1,000,000 cP, as measured by the Viscosity Method as described in copending application Ser. No. 10/841174 filed on May 7, 2004 titled “Multi-phase Personal Care Compositions.”

When evaluating a structured multi-phase personal care composition, by the methods described herein, preferably each individual phase is evaluated prior to combining, unless otherwise indicated in the individual methodology. However, if the phases are combined, each phase can be separated by centrifugation, ultracentrifugation, pipetting, filtering, washing, dilution, concentration, or combination thereof, and then the separate components or phases can be evaluated. Preferably, the separation means is chosen so that the resulting separated components being evaluated is not destroyed, but is representative of the component as it exists in the structured multi-phase personal care composition, i.e., its composition and distribution of components therein is not substantially altered by the separation means. Generally, multi-phase compositions comprise domains significantly larger than colloidal dimensions so that separation of the phases into the bulk is relatively easy to accomplish while retaining the colloidal or microscopic distribution of components therein. Preferably, the compositions of the present invention are rinse-off formulations, by which is meant the product is applied topically to the skin or hair and then subsequently (i.e., within minutes) the skin or hair is rinsed with water, or otherwise wiped off using a substrate or other suitable removal means with deposition of a portion of the composition.

In a preferred embodiment of the present invention the structured multi-phase personal care composition comprises at least two visually distinct phases wherein a first phase is visually distinct from a second phase. Preferably, the visually distinct phases are packaged in physical contact with one another and are stable. Preferably, the visually distinct phases form a pattern.

Phases:

The multi-phase personal care compositions of the present invention comprise at least two visually distinct phases, wherein the composition can have a first phase, a second phase, a third phase, a fourth phase, and so on. The ratio of a first phase to a second phase is typically from about 1:99 to about 99:1, preferably from 90:10 to about 10:90, more preferably from about 80:20 to about 20:80, even more preferably about from 70:30 to about 30:70, still even more preferably about 60:40 to about 40:60, even still even more preferably about 50:50.

First Visually Distinct Phase:

The first visually distinct phase of a multi-phase personal care composition of the present invention can comprises a structured surfactant component. The structured surfactant component comprises at least of branched anionic surfactant and from 0 to 10% by weight of the first visually distinct phase, of sodium trideceth sulfate. Preferably, the structured surfactant component comprises a mixture of surfactants. The structured multi-phased personal care composition comprises from about 1% to about 99%, by weight of the composition, of said first visually distinct phase.

Structured surfactant component:

The structured surfactant component comprises at least one branched anionic surfactant. The structured surfactant component preferably comprises a lathering surfactant or a mixture of lathering surfactants. The structured surfactant component comprises surfactants suitable for application to the skin or hair. Suitable surfactants for use herein include any known or otherwise effective cleansing surfactant suitable for application to the skin, and which are otherwise compatible with the other essential ingredients in the structured multi-phase personal care composition including water. These surfactants include anionic, nonionic, cationic, zwitterionic, amphoteric surfactants, soap, or combinations thereof. Preferably, anionic surfactant comprises at least 40% of the structured surfactant component, more preferably from about 45% to about 95% of the structured surfactant component, even more preferably from about 50% to about 90%, still more preferably from about 55% to about 85%, and even still most preferably at least about 60% of the structured surfactant component comprises anionic surfactant.

The multi-phase personal care composition preferably comprises a structured surfactant component at concentrations ranging from about 2% to about 23.5%, more preferably from about 3% to about 21%, even more preferably from about 4% to about 20.4%, still more preferably from about 5% to about 20%, still even more preferably from about 13% to about 18.5%, and even still even more preferably from about 14% to about 18%, by weight of the first visually distinct phase.

The first visually distinct phase comprising the structured surfactant component is preferably a structured domain comprising surfactants. The structured domain enables the incorporation of high levels of benefit components in a separate phase that are not emulsified in the composition. In a preferred embodiment the structured domain is an opaque structured domain. The opaque structured domain is preferably a lamellar phase. The lamellar phase produces a lamellar gel network. The lamellar phase can provide resistance to shear, adequate yield to suspend particles and droplets and at the same time provides long term stability, since it is thermodynamically stable. The lamellar phase tends to have a higher viscosity thus minimizing the need for viscosity modifiers.

The first visually distinct phase typically provides a Total Lather Volume of at least about 600 ml, preferably greater than about 800 ml, more preferably greater than about 1000 ml, even more preferably greater than about 1200 ml, and still more preferably greater than about 1500 ml, as measured by the Lather Volume Test described hereafter. The first visually distinct phase preferably has a Flash Lather Volume of at least about 300 ml, preferably greater than about 400 ml, even more preferably greater than about 500 ml, as measured by the Lather Volume Test described hereafter.

Suitable surfactants are described in McCutcheon's, Detergents and Emulsifiers, North American edition (1986), published by allured Publishing Corporation; and McCutcheon's, Functional Materials, North American Edition (1992); and in U.S. Pat. No. 3,929,678 issued to Laughlin, et al on Dec. 30, 1975.

Preferred linear anionic surfactants for use in the structured surfactant phase of the multiphase, personal care composition include ammonium lauryl sulfate, ammonium laureth sulfate, sodium lauryl sulfate, sodium laureth sulfate, potassium laureth sulfate, sodium lauryl sarcosinate, sodium lauroyl sarcosinate, lauryl sarcosine, cocoyl sarcosine, ammonium cocoyl sulfate, potassium lauryl sulfate, and combinations thereof.

Amphoteric surfactants are suitable for use in the multiphase composition of the present invention. The amphoteric surfactants include those that are broadly described as derivatives of aliphatic secondary and tertiary amines in which the aliphatic radical can be straight or branched chain and wherein one of the aliphatic substituents contains from about 8 to about 18 carbon atoms and one contains an anionic water solubilizing group, e.g., carboxy, sulfonate, sulfate, phosphate, or phosphonate. Examples of compounds falling within this definition are sodium 3-dodecyl-aminopropionate, sodium 3-dodecylaminopropane sulfonate, sodium lauryl sarcosinate, and N-alkyltaurines. Zwitterionic surfactants suitable for use include those that are broadly described as derivatives of aliphatic quaternary ammonium, phosphonium, and sulfonium compounds, in which the aliphatic radicals can be straight or branched chain, and wherein one of the aliphatic substituents contains from about 8 to about 18 carbon atoms and one contains an anionic group, e.g., carboxy, sulfonate, sulfate, phosphate, or phosphonate. Zwitterionic surfactants suitable for use in the multiphase, personal care composition include betaines, including cocoamidopropyl betaine.

Non-limiting examples of preferred nonionic surfactants for use herein are those selected form the group consisting of glucose amides, alkyl polyglucosides, sucrose cocoate, sucrose laurate, alkanolamides, ethoxylated alcohols and mixtures thereof. In a preferred embodiment the nonionic surfactant is selected from the group consisting of glyceryl monohydroxystearate, isosteareth-2, trideceth-3, hydroxystearic acid, propylene glycol stearate, PEG-2 stearate, sorbitan monostearate, glyceryl laurate, laureth-2, cocamide monoethanolamine, lauramide monoethanolamine, and mixtures thereof.

Mixtures of anionic surfactants can be used in some embodiments, including mixtures of linear and branched surfactants, and anionic surfactants combined with nonionic, amphoteric, and/or zwitterionic surfactants.

An electrolyte, if used, can be added per se to the multiphase personal care composition or it can be formed in situ via the counterions included in one of the raw materials. The electrolyte preferably includes an anion comprising phosphate, chloride, sulfate or citrate and a cation comprising sodium, ammonium, potassium, magnesium or mixtures thereof. Some preferred electrolytes are sodium chloride, ammonium chloride, sodium or ammonium sulfate. The electrolyte is preferably added to the structured surfactant phase of the composition in the amount of from about 0.1% to about 15% by weight, preferably from about 1% to about 6% by weight, more preferably from about 3% to about 6%, by weight of the structured surfactant composition.

In one embodiment of the present invention, the multiphase, personal care composition comprises a structured surfactant phase comprising a mixture of at least one nonionic surfactant, and an electrolyte. In another embodiment, the surfactant phase can comprise a mixture of surfactants, water, at least one anionic surfactant, an electrolyte, and at least one alkanolamide.

Branched Anionic Surfactants:

At least one anionic surfactant comprising anionic surfactant molecules of the present invention is preferably branched. A surfactant molecule is branched when the hydrocarbon tail of the surfactant molecule comprises at least one ternary or quaternary carbon atom, such that a methyl, ethyl, propyl, butyl, pentyl or hexyl side chain extends from the hydrocarbon backbone. The hydrocarbon backbone is described by the longest hydrocarbon length in the hydrocarbon tail. A side chain in the branched hydrocarbon of a surfactant molecule can be described by its position on the backbone, counting from the first carbon attached to a hydrophilic atom, enumerated as carbon number 1, the adjacent carbon on the backbone being carbon number 2, and so on. Side chains are also described by their length, a single carbon side chain denoted methyl; a 2-carbon length denoted ethyl, and so on. Side chains that have their own branching are denoted by conventional nomenclature techniques, e.g., isopropyl, but are less common. Anionic surfactant molecules which do not have branching are linear anionic surfactant molecules, and surfactants comprising a preponderance of linear anioinic surfactant molecules as indicated hereafter are linear anionic surfactants. Most anionic surfactants derived from common natural sources such as coconut and palm, are linear anionic surfactants, such as ammonium lauryl sulfate, sodium lauryl ether sulfate. Linear anionic surfactants can also be derived from other sources including synthetic.

Because an anionic surfactant typically comprises a mixture of different types of surfactant molecules, anionic surfactants can be called linear or branched depending on the relative amounts of individual surfactant molecules of different types that comprise the anionic surfactant. For example, sodium tridecyl sulfate and sodium trideceth sulfate can be called branched surfactants because they typically comprise nearly all (>95%) branched surfactant molecules. For the purposes of the present invention, an anionic surfactant is considered branched surfactant when at least 10% of its hydrocarbon chains are branched molecules.

Branched anionic surfactants comprise surfactant molecules having different kinds of branching. Some branched anionic surfactants, such as tridecanol based sulfates such as sodium trideceth sulfate, comprise a high level of branching, with over 80% of surfactant molecules comprising at least 2 branches and having an average of about 2.7 branches per molecule in some sodium trideceth sulfates. Other branched anionic surfactants, such as C_12-13 alkyl sulfate derived from Safol ™ 23 alcohol (Sasol, Inc, Houston, Tex., USA) comprise a mixture of about 50-55% linear anionic surfactant molecules, with about 15-30% branched surfactant molecules. For the purposes of the present invention, anionic surfactants comprising more than 10% branched surfactant molecules, but having an average of less than 2.0 branches per molecule, are considered monomethyl branched anionic surfactants.

Branching information for many surfactants is typically known or obtainable from suppliers of branched alcohol feedstocks. For example, Sasol publishes the following information related to Safol ™ 23 primary alcohol:

Linear Alcohol Isomers        50%
Mono-Methyl Alcohol Isomers   30%
Other Primary Alcohol Isomers <20%
Total                         100%

Safol ™ 23 alcohol can be sulfated, for example in an SO₃/air stream falling film reactor followed by rapid neutralization with sodium hydroxide to produce sodium C_12-13 alkyl sulfate, a process known in the art. Since the sulfation process involves no rearrangement of the hydrocarbon backbone, the backbone of the C_12-13 alkyl sulfate has the same structure as the Safol ™ 23 alcohol, and is a branched anionic surfactant, and is also a monomethyl branched anionic surfactant. Other suppliers of alcohols provide similar information on their primary alcohols, e.g., Shell Chemical for the Neodol ™ primary alcohols. In the absence of published analytical information by established methods from material suppliers on branching of a surfactant or its feedstock alcohol, analytical techniques known to those skilled in the art can be used to determine branching. For example, when the structure of the hydrocarbon tail is not very complex (i.e., less than about a dozen major components), a gas chromatography-mass spectrometry (GC-MS) technique can be used, involving oxidation of the alcohol in acetone (cosolvent) by a 3.3 M H₂CRO₄ Jones Reagent to a fatty acid followed by oxazoline derivatization using 2-amino, 2-methyl, 1-propanol at 200 C for 2 hours, dilution with CHCl₃ and subsequent washing with distilled water, drying with sodium sulfate prior to injection into a split injection (280 C) or on-column injection. A typical GC program is 80-320 C at 5 C/min rate on a 30 m×0.25 mm DB-1 (0.25 uM film) column, and can give specific information on branching location for a majority of a hydrocarbon tail of an anionic surfactant. When co-elution of species and/or elution of unknown components occur, GC-MS is able to obtain the amount of branched components, which is taken as 100% minus the sum of n-C12 and n-C13 eluted. Typically, n-C₁₁, n-C₁₂ and n-C₁₃ elution times are known for a column and/or can be obtained by simple running of standards which are available. By convention for our invention, inventors sum all oxazoline peaks in the GC window between n-C₁₁ and n-C₁₂, said peaks are the branched C₁₂ peaks; sum all oxazoline peaks in the GC window between n-C₁₂ and n-C₁₃, said peaks are the branched C₁₃ peaks; dividing the peak areas obtained by the total area obtained, including linear C₁₂ and linear C₁₃, to obtain the fractional amount of each component. By our convention, the sum of the peak fractions in the branched C₁₂ and branched C₁₃ windows, added together, is the fraction of branched molecules, which can be expressed as a percentage. The integrated area under each GC peak is the peak information used in the calculations. If necessary, the surfactant can even be obtained by extraction from a composition first, e.g. by filtration such as cross flow filtration. From the GC data, the number of branch points per hydrocarbon chain is summed, multiplying number of branches per molecule by mole fraction for each species identified to obtain an average degree of branching per molecule for the surfactant. For example, 50% of molecules having 1 branch point with 50% linear molecules is an average degree of branching of 0.5. For highly branched molecules (>1.25 average degree of branching), such as sodium trideceth sulfate, determining degree of branching from the GC spectra can be difficult and require specialized equipment, so instead is determined from conventional NMR techniques, using the ratio of ternary to secondary carbon-carbon bonds in the hydrocarbon tail to determine average degree of branching.

Branched anionic surfactants include but are not limited to the following surfactants: sodium trideceth sulfate, sodium tridecyl sulfate, sodium C_12-13 alkyl sulfate, sodium C_12-15 alkyl sulfate, sodium C_11-15 alkyl sulfate, sodium C_12-18 alkyl sulfate, sodium C_10-16 alkyl sulfate, sodium C_12-13 pareth sulfate, sodium C_12-13 pareth-n sulfate, and sodium C_12-14 pareth-n sulfate. Other salts of all the aforementioned surfactants are useful, such as TEA, DEA, ammonia, potassium salts. Useful alkoxylates include the ethylene oxide, propylene oxide and EO/PO mixed alkoxylates. Phosphates, carboxylates and sulfonates prepared from branched alcohols are also useful anionic branched surfactants. Branched surfactants can be derived from synthetic alcohols such as the primary alcohols from the liquid hydrocarbons produced by Fischer-Tropsch condensed syngas, for example Safol ™ 23 Alcohol available from Sasol North America, Houston, Tex.; from synthetic alcohols such as Neodol ™ 23 Alcohol available from Shell Chemicals, USA; from synthetically made alcohols such as those described in U.S. Pat. No. 6,335,312 issued to Coffindaffer, et al on Jan. 1, 2002. Preferred alcohols are Safol ™ 23 and Neodol ™ 23. Preferred alkoxylated alcohols are Safol ™ 23-3 and Neodol ™ 23-3. Sulfates can be prepared by conventional processes to high purity from a sulfur based SO₃ air stream process, chlorosulfonic acid process, sulfuric acid process, or Oleum process. Preparation via SO₃ air stream in a falling film reactor is a preferred sulfation process.

Monomethyl branched anionic surfactants include but are not limited to the branched anionic sulfates derived from Safol ™ 23-n and Neodol ™ 23-n as previously described, where n is an integer between 1 and about 20. Fractional alkloxylation is also useful, for example by stoichiometrically adding only about 0.3 moles EO, or 1.5 moles EO, or 2.2 moles EO, based on the moles of alcohol present, since the molecular combinations that result are in fact always distributions of alkoxylates so that representation of n as an integer is merely an average representation. Preferred monomethyl branched anionic surfactants include a C_12-13 alkyl sulfate derived from the sulfation of Safol ™ 23, which has about 28% branched anionic surfactant molecules; and a C12-13 pareth sulfate derived from Neodol ™ 23-3, which has about 10-18% branched anionic surfactant molecules.

When the anionic surfactant is a branched anionic primary sulfate, it may contain some of the following branched anionic surfactant molecules: 4-methyl undecyl sulfate, 5-methyl undecyl sulfate, 7-methyl undecyl sulfate, 8-methyl undecyl sulfate, 7-methyl dodecyl sulfate, 8-methyl-dodecyl sulfate, 9-methyl dodecyl sulfate, 4,5-dimethyl decyl sulfate, 6,9-dimethyl decyl sulfate, 6,9-dimethyl undecyl sulfate, 5-methyl-8-ethyl undecyl sulfate, 9-methyl undecyl sulfate, 5,6,8-trimethyl decyl sulfate, 2-methyl dodecyl sulfate, and 2-methyl undecyl sulfate,. When the anionic surfactant is a primary alkoxylated sulfate, these same molecules may be present as the n=0 unreacted alcohol sulfates, in addition to the typical alkoxylated adducts that result from alkoxylation (e.g., Neodol ™ 23-3 mol EO retains typically 16% unreacted Neodol ™ 23 with 57% of molecules having 1 to 5 EO molecules reacted, according to Shell Chemicals technical literature, ‘Typical Distributions of NEODOL Ethoxylate Adducts”).

Second Visually Distinct Phase:

The second visually distinct phase is distinguishable from the first visually distinct phase by having a different color, opacity may comprise a structured surfactant or a non-lathering structured Aqueous Phase.

The second visually distinct phase may comprise a structured surfactant identical to the structured surfactant in the first visually distinct phase; described in detail above.

The second visually distinct phase of the multi-phase personal care compositions of the present invention can comprise a structured aqueous phase that comprises a water structurant and water. The structured aqueous phase can be hydrophilic and in a preferred embodiment the structured aqueous phase is a hydrophilic, non-lathering gelled water phase. In addition, the structured aqueous phase typically comprises less than about 5%, preferably less than about 3%, and more preferably less than about 1%, by weight of the structured aqueous phase, of a surfactant. In one embodiment of the present invention, the structured aqueous phase is free of lathering surfactant in the formulation. A preferred structured aqueous phase is a non-lathering structured aqueous phase as described in published U.S. Patent Application No. 2005/0143269A1 entitled “Multi-phase Personal Cleansing Compositions Containing A Lathering Cleansing Phase And A Non-Lathering Structured Aqueous Phase.”

The structured aqueous phase of the present invention can comprise from about 30% to about 99%, by weight of the structured aqueous phase, of water. The structured aqueous phase generally comprises more than about 50%, preferably more than about 60%, even more preferably more than about 70%, and still more preferably more than about 80%, by weight of the structured aqueous phase, of water.

The structured aqueous phase will typically have a pH of from about 5 to about 9.5, more preferably about 7. A water structurant for the structured aqueous phase can have a net cationic charge, net anionic charge, or neutral charge. The structured aqueous phase of the present compositions can further comprise optional ingredients such as, pigments, pH regulators (e.g. triethanolamine), and preservatives.

The structured aqueous phase can comprise from about 0.1% to about 30%, preferably from about 0.5% to about 20%, more preferably from about 0.5% to about 10%, and even more preferably from about 0.5% to about 5%, by weight of the structured aqueous phase, of a water structurant.

The water structurant is typically selected from the group consisting of inorganic water structurants, charged polymeric water structurants, water soluble polymeric structurants, associative water structurants, and mixtures thereof. Non-limiting examples of inorganic water structurants include silicas, polymeric gellants such as polyacrylates, polyacrylamides, starches, modified starches, crosslinked polymeric gellants, copolymers, and mixtures thereof. Non-limiting examples of charged polymeric water structurants for use in the multi-phase personal care composition include Acrylates/Vinyl Isodecanoate Crosspolymer (Stabylen 30 from 3V), Acrylates/C10-30 Alkyl Acrylate Crosspolymer (Pemulen TR1 and TR2), Carbomers, Ammonium Acryloyldimethyltaurate/VP Copolymer (Aristoflex AVC from Clariant), Ammonium Acryloyldimethyltaurate/Beheneth-25 Methacrylate Crosspolymer (Aristoflex HMB from Clariant), Acrylates/Ceteth-20 Itaconate Copolymer (Structure 3001 from National Starch), Polyacrylamide (Sepigel 305 from SEPPIC), and mixtures thereof. Non-limiting examples of water soluble polymeric structurants for use in the multi-phase personal care composition include cellulose gums and gel, and starches. Non-limiting examples of associative water structurants for use in the multi-phase personal care composition include xanthum gum, gellum gum, pectins, alginates such as propylene glycol alginate, and mixtures thereof.

Additional Ingredients:

The phases of the multi-phase personal care composition, preferably the first visually distinct phase, can further comprise a polymeric phase structurant. The compositions of the present invention typically can comprise from about 0.05% to about 10%, preferably from about 0.1% to about 4%, of a polymeric phase structurant. Non-limiting examples of polymeric phase structurant include but are not limited to the following examples: naturally derived polymers, synthetic polymers, crosslinked polymers, block copolymers, copolymers, hydrophilic polymers, nonionic polymers, anionic polymers, hydrophobic polymers, hydrophobically modified polymers, associative polymers, and oligomers.

Preferably the polymeric phase structurant can be crosslinked and further comprise a crosslinking. These polymeric phase structurant useful in the present invention are more fully described in U.S. Pat. No. 5,087,445, to Haffey et al., issued Feb. 11, 1992; U.S. Pat. No. 4,509,949, to Huang et al., issued Apr. 5, 1985, U.S. Pat. No. 2,798,053, to Brown, issued Jul. 2, 1957. See also, CTFA International Cosmetic Ingredient Dictionary, fourth edition, 1991, pp. 12 and 80.

The phase of the present compositions, preferably the first visually distinct phase, optionally can further comprise a liquid crystalline phase inducing structurant, which when present is at concentrations ranging from about 0.3% to about 15%, by weight of the phase, more preferably at from about 0.5% to about 5% by weight of the phase. Suitable liquid crystalline phase inducing structurants include fatty acids (e.g. lauric acid, oleic acid, isostearic acid, linoleic acid) ester derivatives of fatty acids (e.g. propylene glycol isostearate, propylene glycol oleate, glyceryl isostearate) fatty alcohols, trihydroxystearin (available from Rheox, Inc. under the trade name THIXCIN™ R). Preferably, the liquid crystalline phase inducing structurant is selected from lauric acid, trihydroxystearin, lauryl pyrrolidone, and tridecanol.

The structured multi-phase personal care compositions of the present invention can additionally comprise an organic cationic deposition polymer in the one or more phases as a deposition aid for the benefit agents described herein. Suitable cationic deposition polymers for use in the structured multi-phase personal care compositions of the present invention contain cationic nitrogen-containing moieties such as quaternary ammonium or cationic protonated amino moieties. The cationic protonated amines can be primary, secondary, or tertiary amines (preferably secondary or tertiary), depending upon the particular species and the selected pH of the structured multi-phase personal care composition. Suitable cationic deposition polymers that would be useful in the compositions of the present invention are disclosed in the co-pending and commonly assigned U.S. Patent Application No. 60/628,036 filed on Nov. 15, 2003 by Wagner, et al titled “Depositable Solids.”

One or more of the phases of the multiphase personal care composition can comprise a variety of additional optional ingredients such as shiny particles, beads, exfoliating beads. Such optional ingredients are most typically those materials approved for use in cosmetics and that are described in reference books such as the CTFA Cosmetic Ingredient Handbook, Second Edition, The Cosmetic, Toiletries, and Fragrance Association, Inc. 1988, 1992.

Other non limiting examples of these optional ingredients include vitamins and derivatives thereof (e.g., ascorbic acid, vitamin E, tocopheryl acetate, and the like), sunscreens; thickening agents, preservatives for maintaining the anti microbial integrity of the cleansing compositions, anti-acne medicaments, antioxidants, skin soothing and healing agents such as aloe vera extract, allantoin and the like, chelators and sequestrants, skin lightening agents, and agents suitable for aesthetic purposes such as fragrances, essential oils, skin sensates, pigments, pearlescent agents and essential oils and fragrance.

The preferred pH range of the structured multi-phase personal care composition is from about 5 to about 8.

Test Methods:

Yield Stress and Zero Shear Viscosity Method:

The Yield Stress and Zero Shear Viscosity of a phase of the present composition, can be measured either prior to combining in the composition, or after combining in the composition by separating the phase by suitable physical separation means, such as centrifugation, pipetting, cutting away mechanically, rinsing, filtering, or other separation means.

A controlled stress rheometer such as a TA Instruments AR2000 Rheometer is used to determine the Yield Stress and Zero Shear Viscosity. The determination is performed at 25° C. with the 4 cm diameter parallel plate measuring system and a 1 mm gap. The geometry has a shear stress factor of 79580 m⁻³ to convert torque obtained to stress.

First a sample of the phase is obtained and placed in position on the rheometer base plate, the measurement geometry (upper plate) moving into position 1 mm above the base plate. Excess phase at the geometry edge is removed by scraping after locking the geometry. If the phase comprises particles discernible to the eye or by feel (beads, e.g.) which are larger than about 150 microns in number average diameter, the gap setting between the base plate and upper plate is increased to the smaller of 4 mm or 8-fold the diameter of the 95^th volume percentile particle diameter. If a phase has any particle larger than 5 mm in any dimension, the particles are removed prior to the measurement.

The determination is performed via the programmed application of a continuous shear stress ramp from 0.1 Pa to 1,000 Pa over a time interval of 5 minutes using a logarithmic progression, i.e., measurement points evenly spaced on a logarithmic scale. Thirty (30) measurement points per decade of stress increase are obtained. Stress, strain and viscosity are recorded. If the measurement result is incomplete, for example if material flows from the gap, results obtained are evaluated and incomplete data points excluded. The Yield Stress is determined as follows. Stress (Pa) and strain (unitless) data are transformed by taking their logarithms (base 10). Log(stress) is graphed vs. log(strain) for only the data obtained between a stress of 0.2 Pa and 2.0 Pa, about 30 points. If the viscosity at a stress of 1 Pa is less than 500 Pa-sec but greater than 75 Pa-sec, then log(stress) is graphed vs. log(strain) for only the data between 0.2 Pa and 1.0 Pa, and the following mathematical procedure is followed. If the viscosity at a stress of 1 Pa is less than 75 Pa-sec, the zero shear viscosity is the median of the 4 highest viscosity values (i.e., individual points) obtained in the test, the yield stress is zero, and the following mathematical procedure is not used. The mathematical procedure is as follows. A straight line least squares regression is performed oh the results using the logarithmically transformed data in the indicated stress region, an equation being obtained of the form:
(1) Log(strain)=m*Log(stress)+b

Using the regression obtained, for each stress value (i.e., individual point) in the determination between 0.1 and 1,000 Pa, a predicted value of log(strain) is obtained using the coefficients m and b obtained, and the actual stress, using Equation (1). From the predicted log(strain), a predicted strain at each stress is obtained by taking the antilog (i.e., 10^x for each x). The predicted strain is compared to the actual strain at each measurement point to obtain a % variation at each point, using Equation (2).
(2) % variation=100*(measured strain−predicted strain)/measured strain

The Yield Stress is the first stress (Pa) at which % variation exceeds 10% and subsequent (higher) stresses result in even greater variation than 10% due to the onset of flow or deformation of the structure. The Zero Shear Viscosity is obtained by taking a first median value of viscosity in Pascal-seconds (Pa-sec) for viscosity data obtained between and including 0.1 Pa and the Yield Stress. After taking the first median viscosity, all viscosity values greater than 5-fold the first median value and less than 0.2×the median value are excluded, and a second median viscosity value is obtained of the same viscosity data, excluding the indicated data points. The second median viscosity so obtained is the Zero Shear Viscosity.

Lather Volume Test:

Lather volume of a first visually distinct phase, a structured surfactant component or a structured domain of a structured multi-phase personal care composition, is measured using a graduated cylinder and a rotating apparatus. A 1,000 ml graduated cylinder is used which is marked in 10 ml increments and has a height of 14.5 inches at the 1,000 ml mark from the inside of its base (for example, Pyrex No. 2982). Distilled water (100 grams at 25° C.) is added to the graduated cylinder. The cylinder is clamped in a rotating device, which clamps the cylinder with an axis of rotation that transects the center of the graduated cylinder. Inject 0.50 grams of a structured surfactant component or first visually distinct phase from a syringe (weigh to ensure proper dosing) into the graduated cylinder onto the side of the cylinder, above the water line, and cap the cylinder. When the sample is evaluated, use only 0.25 cc, keeping everything else the same. The cylinder is rotated for 20 complete revolutions at a rate of about 10 revolutions per 18 seconds, and stopped in a vertical position to complete the first rotation sequence. A timer is set to allow 15 seconds for lather generated to drain. After 15 seconds of such drainage, the first lather volume is measured to the nearest 10 ml mark by recording the lather height in ml up from the base (including any water that has drained to the bottom on top of which the lather is floating).

If the top surface of the lather is uneven, the lowest height at which it is possible to see halfway across the graduated cylinder is the first lather volume (ml). If the lather is so coarse that a single or only a few foam cells which comprise the lather (“bubbles”) reach across the entire cylinder, the height at which at least 10 foam cells are required to fill the space is the first lather volume, also in ml up from the base. Foam cells larger than one inch in any dimension, no matter where they occur, are designated as unfilled air instead of lather. Foam that collects on the top of the graduated cylinder but does not drain is also incorporated in the measurement if the foam on the top is in its own continuous layer, by adding the ml of foam collected there using a ruler to measure thickness of the layer, to the ml of foam measured up from the base. The maximum lather height is 1,000 ml (even if the total lather height exceeds the 1,000 ml mark on the graduated cylinder). 30 seconds after the first rotation is completed, a second rotation sequence is commenced which is identical in speed and duration to the first rotation sequence. The second lather volume is recorded in the same manner as the first, after the same 15 seconds of drainage time. A third sequence is completed and the third lather volume is measured in the same manner, with the same pause between each for drainage and taking the measurement.

The lather results after each sequence are added together and the Total Lather Volume determined as the sum of the three measurements, in milliters (“ml”). The Flash Lather Volume is the result after the first rotation sequence only, in ml, i.e., the first lather volume. Compositions according to the present invention perform significantly better in this test than similar compositions in conventional emulsion form.

Ultracentrifugation Method:

The Ultracentrifugation Method is used to determine the percent of a structured domain or an opaque structured domain that is present in a structured multi-phase personal care composition that comprises a first visually distinct phase comprising a structured surfactant component. The method involves the separation of the composition by ultracentrifugation into separate but distinguishable layers. The structured multi-phase personal care composition of the present invention can have multiple distinguishable layers, for example a non-structured surfactant layer, a structured surfactant layer, and a benefit layer.

First, dispense about 4 grams of multi-phase personal care composition into Beckman Centrifuge Tube (11×60 mm). Next, place the centrifuge tubes in an Ultracentrifuge (Beckman Model L8-M or equivalent) and ultracentrifuge using the following conditions: 50,000 rpm, 18 hours, and 25° C.

After ultracentrifuging for 18 hours, determine the relative phase volume by measuring the height of each layer visually using an Electronic Digital Caliper (within 0.01 mm). First, the total height is measured as H_a which includes all materials in the ultracentrifuge tube. Second, the height of the benefit layer is measured as H_b. Third, the structured surfactant layer is measured as H_c. The benefit layer is determined by its low moisture content (less than 10% water as measured by Karl Fischer Titration). It generally presents at the top of the centrifuge tube. The total surfactant layer height (H_s) can be calculated by this equation:
H_s=H_a−H_b

The structured surfactant layer components may comprise several layers or a single layer. Upon ultracentrifugation, there is generally an isotropic layer at the bottom or next to the bottom of the ultracentrifuge tube. This clear isotropic layer typically represents the non-structured micellar surfactant layer. The layers above the isotropic phase generally comprise higher surfactant concentration with higher ordered structures (such as liquid crystals). These structured layers are sometimes opaque to naked eyes, or translucent, or clear. There is generally a distinct phase boundary between the structured layer and the non-structured isotropic layer. The physical nature of the structured surfactant layers can be determined through microscopy under polarized light. The structured surfactant layers typically exhibit distinctive texture under polarized light. Another method for characterizing the structured surfactant layer is to use X-ray diffraction technique. Structured surfactant layer display multiple lines that are often associated primarily with the long spacings of the liquid crystal structure. There may be several structured layers present, so that H_c is the sum of the individual structured layers. If a coacervate phase or any type of polymer-surfactant phase is present, it is considered a structured phase.

Finally, the structured domain volume ratio is calculated as follows:
Structured Domain Volume Ratio=H_c/H_s*100%

If there is no benefit phase present, use the total height as the surfactant layer height, H_s=H_a.

T- Bar Method for Assessing Structured Surfactant Stability In Presence of Lipid

The stability of a surfactant-containing phase (“cleansing phase” or “first visually distinct phase”) in the presence of lipid can be assessed using a T-Bar Viscosity Method. The apparatus for T-Bar measurement includes a Brookfield DV-II+ Pro Viscometer with Helipath Accessory; chuck, weight and closer assembly for T-bar attachment; a T-bar Spindle D, a personal computer with Rheocalc software from Brookfield, and a cable connecting the Brookfield Viscometer to the computer. First, weigh 40 grams of the cleansing phase in a 4-oz glass jar. Centrifuge the jar at 2,000 rpm for 20 min to de-aerate the cleansing phase, which may also remove large particles by sedimentation or flotation. Measure the height of the cleansing phase “H_surf” using an Electronic Caliper with a precision of 0.01 mm. Measure the initial T-bar viscosity by carefully dropping the T-Bar Spindle to the interior bottom of the jar and set the Helipath stand to travel in an upward direction. Open the Rheocalc software and set the following data acquisition parameters: set Speed to 5 rpm, set Time Wait for Torque to 00:01 (1 second), set Loop Start Count at 40. Start data acquisition and turn on the Helipath stand to travel upward at a speed of 22 mm/min. The initial T-Bar viscosity “T_ini,” is the average T-Bar viscosity reading between the 6^th reading and the 35^th reading (the first five and the last five readings are not used for the average T-Bar viscosity calculation). Cap the jar and store at ambient temperature. Prepare a separate lipid blend by heating a vessel to 180° F. (82.2° C.) and add together 70 parts of Petrolatum (G2218 from WITCO) and 30 parts of Hydrobrite 1000 White Mineral Oil. Cool the vessel to 110° F. (43.3° C.) with slow agitation (200 rpm). Stop agitation and cool the vessel to ambient temperature overnight. Add 40 grams of the lipid blend (70/30 Pet/MO) to the jar containing the first visually distinct phase. Stir the first visually distinct phase and lipid together using a spatula for 5 min. Place the jar at 113° F. (45° C.) for 5 days. After 5 days, centrifuge the jar at 2000 rpm for 20 min (do not cool the jar first).

After centrifugation, cool down the jar and contents to ambient conditions, overnight. Observe the contents of the jar. A stable cleansing phase exhibits a uniform layer at the bottom of the jar, below the less dense petrolatum/oil phase. An unstable cleansing phase can form layers not present in the originally centrifuged cleansing phase (i.e., an isotropic phase) either at the bottom or between the cleansing phase-lipid interface. If more than one layer is present in the cleansing phase, measure the height of each newly formed layer, “H_new” using an Electronic Caliper. Add together the heights of all the newly formed layers. The new phase volume ratio is calculated as H_new/H_surf*100% , using the height of all new layers added together as H_new. Preferably, a stable structured cleansing phase forms less than 10% of new phase volume. More preferably, a stable structured cleansing phase forms less than 5% of new phase volume. Most preferably, a stable structured cleansing phase forms 0% of new phase volume.

The T-Bar viscosity of the centrifuged contents of the jar is then measured using the T-Bar method above. Open the Rheocalc software and set the following data acquisition parameters: set Speed to 5 rpm, set Time Wait for Torque to 00:01 (1 second), set Loop Start Count at 80. Start the data acquisition and turn on the Helipath stand to travel upward at a speed of 22 mm/min. There is usually a distinctive viscosity jump between the first visually distinct phase layer and the lipid layer. The average cleansing phase T-Bar viscosity after lipid exposure, “T_aft” is the average reading between the 6^th T-Bar viscosity and the last T-Bar viscosity reading before the jump in viscosity due to the lipid layer. In the case where there is no distinctive T-Bar viscosity jump between cleansing phase and lipid phase, only use the average reading between the 6^th T-Bar viscosity reading and the 15^th reading as the average cleansing phase T-bar viscosity, T_aft. Preferably, a stable structured cleansing phase has T_aft higher than 10,000 cP. More preferably, a stable structured cleansing phase has T_aft higher than 15,000 cP. Most preferably, a stable structured first visually distinct phase has T_aft higher than 20,000 cP Viscosity Retention is calculated as T_aft/T_ini*100%. Preferably, a stable structured cleansing phase has >50% Viscosity Retention. More preferably, a stable structured cleansing phase has >70% Viscosity Retention. Most preferably, a stable structured cleansing phase has >80% Viscosity Retention.

Method of Use:

The multi-phase personal care compositions of the present invention are preferably applied topically to the desired area of the skin or hair in an amount sufficient to provide effective delivery of the skin cleansing agent, hydrophobic material, and particles to the applied surface. The compositions can be applied directly to the skin or indirectly via the use of a cleansing puff, washcloth, sponge or other implement. The compositions are preferably diluted with water prior to, during, or after topical application, and then subsequently the skin or hair rinsed or wiped off, preferably rinsed off of the applied surface using water or a water-insoluble substrate in combination with water.

The present invention is therefore also directed to methods of cleansing the skin through the above-described application of the compositions of the present invention. The methods of the present invention are also directed to a method of providing effective delivery of the desired skin active agent, and the resulting benefits from such effective delivery as described herein, to the applied surface through the above-described application of the compositions of the present invention.

Method of Manufacture:

The multi-phase personal care compositions of the present invention may be prepared by any known or otherwise effective technique, suitable for making and formulating the desired multi-phase product form. It is effective to combine toothpaste-tube filling technology with a spinning stage design. Additionally, the present invention can be prepared by the method and apparatus as disclosed in U.S. Pat. No. 6,213,166 issued to Thibiant, et al on Apr. 10, 2001. The method and apparatus allows two or more compositions to be filled with a spiral configuration into a single container. The method requires that at least two nozzles be employed to fill the container. The container is placed on a static mixer and spun as the composition is introduced into the container.

Alternatively, it is effective to combine at least two phases by first placing the separate compositions in separate storage tanks having a pump and a hose attached. The phases are then pumped in predetermined amounts into a single combining section. Next, the phases are moved from the combining sections into the blending sections and the phases are mixed in the blending section such that the single resulting product exhibits a distinct pattern of the phases. The pattern is selected from the group consisting of striped, marbled, geometric, and mixtures thereof. The next step involves pumping the product that was mixed in the blending section via a hose into a single nozzle, then placing the nozzle into a container and filing the container with the resulting product. Specific non-limiting examples of such methods as they are applied to specific embodiments of the present invention are described in the following examples.

If the multi-phase personal care compositions are patterned, it can be desirable to be packaged as a personal care article. The personal care article would comprise these compositions in a transparent or translucent package such that the consumer can view the pattern through the package. Because of the viscosity of the subject compositions it may also be desirable to include instructions to the consumer to store the package upside down, on its cap to facilitate dispensing.

It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification includes every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification includes every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.

All parts, ratios, and percentages herein, in the Specification, Examples, and Claims, are by weight and all numerical limits are used with the normal degree of accuracy afforded by the art, unless otherwise specified.

EXAMPLES

The following first visually distinct phases are prepared as non-limiting examples (chemical content is shown). Examples 1 and 2 are Comparative Examples of the first visually distinct phase of the present invention. Examples 3-7 are examples of the first visually distinct phase of the present invention. Examples 8, 9 and 10 are Comparative Examples. Examples 11 and 12 are examples of structured aqueous phase of the present invention.

Examples 1 and 2 are comparative examples of the first visually distinct phase of the present invention which comprise all linear anionic surfactants. Examples 3-5 are examples of the present invention comprising a mix of linear and branched anionic surfactants. Of the mixed anionic surfactant compositions Examples 3-5, compositions with lower sodium trideceth sulfate exhibited higher flash and total lather volumes. However, mixtures of branched and linear anionic surfactant (Examples 3-5) exhibited higher flash and total lather volume than all linear anionic compositions (Comparative Examples 1 and 2), and improved stability.

		First visually distinct
	Comparative Example	phase example:
	1	2	3	4	5
Water, distilled	QS	QS	QS	QS	QS
Skin Benefit Components and Thickeners
Water, distilled	QS	QS	QS	QS	QS
Glycerin	0.3	0.3	1.93	—	—
Guar hydroxypropropyl-trimonium chloride(N-	0.4	0.4	0.2	0.6	0.6
Hance 3196 - Aqualon or Jaguar C-17, Rhodia)
PEG 90M (Polyox WSR 301, Amerchol Corp)	0.10	0.10	0.15	0.15	0.15
Citric acid	—	—	0.25	0.25	0.25
Structured surfactant components
Sodium trideceth sulfate (Cedepal TD403,	—	—	6.17	7.9	7.9
Stepan)
Ammonium Lauryl Sulfate (P&G)	13.4	9.40	9.26	7.9	7.9
Sodium Lauroamphoacetate (Miranol L-32,	—	—	4.57	4.7	4.7
Rhodia)
Polyoxyethylene 2.5 lauryl alcohol (Arylpon F,	3.0	2.1	—	—	—
Cognis Corp, Cincinnati, OH)
Cocamidopropyl betaine (Tegobetaine F,	3.7	2.6	—	—	—
DeGussa)
Isosteareth-2 (Hetoxol IS-2, Global Seven,	—	—	1.0	1.0	1.0
USA)
Preservative and Minors
Fragrance/perfume	1.4	1.4	1.54	1.54	1.44
Sodium chloride	3.5	3.5	3.5	3.5	3.5
Disodium EDTA	0.06	0.06	0.12	0.12	0.12
DMDM Hydantoin (Glydant)	0.73	0.73	0.37	0.37	0.37
Sodium benzoate	—	—	0.2	0.2	0.2
Expancel 091 DE d30 microspheres (Akzo	0.3	0.3	0.3	0.3	0.3
Nobel; Expancel, Inc.)
Polymeric Phase Structurants
Xanthan gum (Keltrol CGT, Kelco)	0.13	0.26	0.4	0.2	0.2
Acrylates/Vinyl Isodecanoate Crosspolymer	0.27	0.54	—	—	—
(Stabylen 30 from 3V)
Final pH (adjust using NaOH or citric acid)	5.9	5.9	6.0	6.0	6.0
Total surfactant, % of first visually distinct	20.1	14.1	21.0	21.5	21.5
phase
Anionic surfactant, % of structured surfactant	67	67	74	74	74
component
Mono methyl branched anionic surfactant, % of	0	0	0	0	0
anionic surfactant
Branched anionic surfactant, % of anionic	0	0	40	50	50
surfactant
Zero shear viscosity, Pa-sec	6800	7600	8100	4900	5700
Yield stress, Pa	14
Lather Volume of first visually distinct phase:	490/1810	500/1930	650/2340	540/2150	510/2020
Flash/Total (ml/ml)
Structured Domain Volume Ratio	64	52	91	86	88
Stability: % Third Phase	0	6	0	0	0
T-bar % viscosity change	−23	−37	−18	−15	−7

Examples 8-10 are Comparative Examples. Example 8 does not comprise branched anionic surfactants. Comparative Examples 9 and 10 comprise higher sodium trideceth sulfate than in the claimed range. Examples 6 and 7, having lower sodium trideceth sulfate than Comparative Examples 9 and 10, which have greater than 10% sodium trideceth sulfate, have higher flash and total lather volumes. Comparative Example 8, which does not have any branched surfactants, is not stable, and also does not have lather volumes as high as Examples 6 and 7, which have both branched and linear anionic surfactants.

	First visually distinct
	phase Example:	Comparative Example
	6	7	8	9	10
Water, distilled	QS	QS	QS	QS	QS
Skin Benefit Components and Thickeners
Water, distilled	QS	QS	QS	QS	QS
Glycerin		0.21	0.3	0.5	0.5
Guar hydroxypropropyl-trimonium chloride(N-	0.45	0.47	0.4	0.45	0.45
Hance 3196 - Aqualon or Jaguar C-17, Rhodia)
PEG 90M (Polyox WSR 301)	0.15	0.07	0.1	0.08	0.08
Citric acid	0.25	0.25	0.2	0.2	0.2
Structured surfactant components
Sodium trideceth sulfate (Cedepal TD-403)	5.6	5.56	—	10.3	10.3
Safol 23 sulfate, sodium salt		5.56	—	—	—
Ammonium Lauryl Sulfate (P&G)	8.4	—	—	—	—
Ammonium Laureth Sulfate (P&G, 3 mol EO)	—	—	9.4	—	—
Cocamide monoethanolamine	—	—	—	2.1	2.1
Sodium Lauroamphoacetate (Miranol L-32)	3.0	—	—	3.3	3.3
Polyoxyethylene 2.5 lauryl alcohol (Arylpon F)	0.75	2.35	2.1	—	—
Cocamidopropyl betaine (Tegobetaine F)		3.35	2.58	—	—
Isosteareth-2 (Hetoxol IS-2)	1.0	1.0	—	—	—
Preservative and Minors
Fragrance/perfume	1.44	1.54	1.4	1.25	1.25
Sodium chloride	3.5	3.5	3.5	2.8	2.8
Disodium EDTA	0.12	0.12	0.06	—	—
DMDM Hydantoin (Glydant)	0.37	0.37	0.7	0.25	0.25
Sodium benzoate	0.2	0.2	—	—	—
Expancel 091 DE d30 microspheres	0.3	0.3	0.3	—	—
Polymeric Phase Structurants
Xanthan gum (Keltrol CGT, Kelco)	0.4	0.66	0.26	—	—
Acrylates/Vinyl Isodecanoate Crosspolymer	—	—	0.54	0.5	0.8
(Stabylen 30 from 3V)
Final pH (adjust to)	6.0	6.2	5.9	6.7	5.8
Total surfactant, % of surfactant phase	18.8	17.8	14.1	15.7	15.7
Anionic surfactant, % of structured surfactant	75	62	67	56	56
component
Mono methyl branched anionic surfactant, % of	0	50	0	0	0
anionic surfactant
Branched anionic surfactant, % of anionic	40	100	0	100	100
surfactant
Zero shear viscosity, Pa-sec	4600	4500	900	3300	8700
Lather Volume of first visually distinct phase:	590/2250	520/1910	470/1920	490/1840	460/1800
Flash/Total (ml/ml)
Structured Domain Volume Ratio	87
Stability: % Third Phase	0	0	5%		0
T-bar % viscosity change	−20	−29	−79		−30

The first visually distinct phase can be prepared by conventional mixing techniques. Prepare the first visually distinct phase by first adding the water, skin benefit components and thickeners into a vessel, agitating until a dispersion is formed. Then add in the following sequence: surfactants, Disodium EDTA, preservative, half the sodium chloride and all other minors except fragrance and the withheld sodium chloride. Heat to 65-70° C. if Cocamide monoethanolamine is used, otherwise maintain at ambient temperature while agitating the mixing vessel. Cool to 45 C if heating was used. For additional stability, gas filled microspheres having a density of about 30 kg/m³ such as Expancel 091 DE 40 d30 (from Expancel, Inc.) can optionally be used at about 0.1-0.5% of the batch. In a separate vessel, prewet the structuring polymers with fragrance and add to the mix vessel at the same time as the remaining sodium chloride while agitating. Agitate until homogeneous, then pump through a static mixing element to disperse any lumps to complete the batch.

Structured Aqueous Phase

The Structured Aqueous Phase of Examples 11-12 can be prepared by dispersing polymers in water with high shear, adding salt and remaining ingredients except petrolatum and mineral oil, neutralizing to pH 7.0 with triethanolamine (approximate TEA level is shown), heating to 50° C., adding the petrolatum and mineral oil as a liquid at 80° C., and agitating until homogeneous without high shear. Pigments having no water soluble components are preferably used. A particle size of about 5-100 microns for the petrolatum component is obtained for most of the particles.

	Structured Aqueous Phase
	(non-lathering) Example:
	11	12
Water, distilled	QS	QS
Acrylates/Vinyl Isodecanoate Crosspolymer	1.0	0.8
(Stabylen 30 from 3V)
Xanthan gum (Keltrol CGT or Keltrol 1000	1.0	0.8
from Kelco)
DMDM Hydantoin, preservative	0.4	0.4
EDTA	0.05	0.04
Mineral oil (Hydrobrite 1000, Witco)	0.03	4.82
Petrolatum (Super White Protopet, Witco)	20.0	18.78
Triethanolamine	0.80	0.80
Sodium chloride	3.0	2.4
Pigment	0.35	0.35

Visually Distinct Compositions

Visually distinct compositions are prepared by first preparing two compositions that differ in appearance. A first visually distinct phases of Examples 3-7 is selected (any can be selected) and pigmented using a hydrophobic pigment, which keeps color from leaching. A second first visually distinct phase of Examples 3-7 and 11-12 can be selected and either pigmented to a different color, pigmented white, or not pigmented, such that the phase visually differs from the first phase chosen, including by being, e.g., a transparent gel. The phases are added to separate hoppers and gravity fed to a package (e.g., bottle, tube, etc.) filling operation. The phases are maintained at ambient temperature and are simultaneously pumped in a specified volumetric ratio through ¾ in. diameter pipes containing a single element static mixer (Koch/SMX type), the single pipe exits into a 10 oz. bottle on a spinning platform. The platform is set to 200 rpm spin speed, the composition filling 315 ml in about 2 seconds, the spinning platform being lowered during filling so that filling proceeds in a layering fashion from bottom to top. A relatively horizontal striped pattern is obtained. By adjusting temperature and viscosity of the phases, static mixer element types and number of elements (including no elements), pipe diameters, spin rates, etc., a wide variety of patterns is obtained. One or both of the phases can be a benefit phase, or a combined benefit phase, by preparing an emulsion or a dispersion with the phase using conventional techniques to prepare an emulsion or dispersion with a dispersed phase such as petrolatum, mineral oil, other synthetic and natural oils such as jojoba, shea butter, triglyceride, lanolin, ethers, esters including emollient sucrose esters, ethers, waxes, silicone fluids, polymers including polymeric esters such as polyglyceryl esters, mixtures and combinations of these and other hydrophobic materials having a Vaughn Solubility Parameter less than about 13 (cal/cm³)^1/2. When mixtures of such hydrophobic materials are used, they can be prepared by combining the hydrophobic materials first at an elevated temperature, such as is done in traditional emulsion preparation, or they can be added separately, either with heat or without, in a batch, semi-batch, or continuous process to the hydrophilic phase. Colorant, pigment or whitener can be added to the dispersed phase or to either of the hydrophilic continuous phases. To optimize benefit phase efficacy and/or appearance, any of the Examples 3-7 can be diluted to a lower surfactant concentration, e.g. to 10%, or 6%, or 4% or even less than 1% surfactant so long as the phase remains continuously hydrophilic and the rheology of the phase sufficient so the visually distinct composition remains stable. The hydrophobic material can also be dispersed in a non-lathering structured aqueous phase, for example the non-lathering structured aqueous phase of Examples 1 or 12, as shown. The benefit phase can thus be lathering, or non-lathering. If the surfactant level is reduced in one of the phases, rheology can be adjusted using traditional thickeners, for example water soluble polymers, cross-linked water swellable polymers, clays, gel networks, etc., as is known to one with ordinary skill in the art. Additionally, surfactant can be concentrated in one of the phases by reducing water content, so that the surfactant concentration is 24%, 30%, 40%, 50% or even as high as 75% of one or more of the phases in order to deliver efficient cleansing from a low level of a concentrated surfactant phase. Typically, levels of electrolyte (e.g., salt), thickeners and cationic polymer would be adjusted for viscosity control. In some cases, it may be preferred to increase viscosity, for example so that the Zero Shear Viscosity is greater than 15,000 Pa-sec, even greater than 25,000 Pa-sec, or even greater than 35,000 Pa-sec in order to provide phases which are visually distinct and paste-like, such as for example visually distinct concentrates packaged in tubes, filled by apparati such as multi-phase toothpaste filling equipment.

Additionally, the present invention can be prepared by the method and apparatus as disclosed in U.S. Pat. No. 6,213,166 issued to Thibiant et, al. on Apr. 10, 2001 which method and apparatus allows compositions to be filled with a spiral configuration into a single container using at least 2 nozzles.

All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this written document conflicts with any meaning or definition of the term in a document incorporated by reference, the meaning or definition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. A multi-phase personal care composition comprising: a first visually distinct phase comprising a structured surfactant component; and

a second visually distinct phase;

wherein said structured surfactant component comprises at least one branched anionic surfactant and from 0 to 10%, by weight of said first visually distinct phase, of sodium trideceth sulfate.

2. The multi-phase personal care composition of claim 1, wherein said structured surfactant component comprises 0.1% to 10%, by weight of said first visually distinct phase, of sodium trideceth sulfate.

3. The multi-phase personal care composition of claim 1, wherein said structured surfactant component comprises 9.5%, by weight of said first visually distinct phase, of sodium trideceth sulfate.

4. The multi-phase personal care composition of claim 1, wherein said composition comprises from about 2% to about 23.5%, by weight of said first visually distinct phase, of said structured surfactant component.

5. The multi-phase personal care composition of claim 1, wherein said composition comprises from about 3% to about 21%, by weight of said first visually distinct phase, of said structured surfactant component.

6. The multi-phase personal care composition of claim 1, wherein said branched anionic surfactant is selected from the group consisting of sodium trideceth sulfate, sodium tridecyl sulfate, ammonium trideceth sulfate, ammonium tridecyl sulfate, monomethyl branched sulfated derivatives of branched hydrocarbons, and mixtures thereof.

7. The multi-phase personal care composition of claim 6, wherein said branched anionic surfactant comprises monomethyl branched sulfated derivatives of hydrocarbons.

8. The multi-phase personal care composition of claim 1, wherein said first visually distinct phase provides a Yield Stress of greater than about 1.5 Pascal.

9. The multi-phase personal care composition of claim 1, wherein said composition further comprises a polymeric phase structurant.

10. The multi-phase personal care composition of claim 9, wherein said polymeric phase structurant is selected from the group consisting of deflocculating polymers, naturally derived polymers, synthetic polymers, crosslinked polymers, block polymers, block copolymers, copolymers, hydrophilic polymers, nonionic polymers, anionic polymers, hydrophobic polymers, hydrophobically modified polymers, associative polymers, oligomers, and mixtures thereof.

11. The multi-phase personal care composition of claim 9, wherein said multi-phase personal care composition comprises from about 0.05% to about 10%, by weight of said first visually distinct phase, of said polymeric phase structurant.

12. The multi-phase personal care composition of claim 1, wherein said first visually distinct phase and said second visually distinct phase form a pattern.

13. The multi-phase personal care composition of claim 12 wherein the pattern is selected from the group consisting of striped, geometric, marbled, and combinations thereof.

14. The multi-phase personal care composition of claim 12, wherein said composition is packaged in a container such that said pattern is visible.

15. The multi-phase personal care composition of claim 1, wherein said first visually distinct phase further comprises:

(i) at least one electrolyte;

(ii) at least one alkanolamide; and

(iii) water;

wherein said first visually distinct phase is non-Newtonian shear thinning; and

wherein

16. The multi-phase personal care composition of claim 1, wherein said first visually distinct phase comprises:

(a) said structured surfactant component further comprising: (i) at least one nonionic surfactant having an HLB from about 3.4 to about 15.0; (ii) at least one amphoteric surfactant; and

(b) an electrolyte.

17. The multi-phase personal care composition of claim 1, wherein said first visually distinct phase further comprises a liquid crystalline phase inducing structurant.

18. The multi-phase personal care composition of claim 17, wherein said liquid crystalline phase inducing structurant is selected from the group consisting of fatty acids, fatty alcohols, fatty esters, trihydroxystrearin, and mixtures thereof.

19. The structured, multi-phase personal cleansing composition of claim 1, wherein said composition additionally comprises a benefit component, wherein said benefit component is selected from the group consisting of emollients, particles, beads, skin whitening agents, fragrances, colorants, vitamins and derivatives thereof, sunscreens, preservatives, anti-acne medicaments, antioxidants, chelators, essential oils, skin sensates, antimicrobial, and mixtures thereof.