Augmenting Cleaning Chemicals

Abstract

Device, system and method for electrochemical generation of a liquid soap by electrolyzing a surfactant in an aqueous carrier in a cathode compartment of an electrolytic cell and electrolyzing an antimicrobial agent in an aqueous carrier in an anode compartment of the electrolytic cell with the compartments separated by a semipermeable membrane. Portions of the electrolyzed surfactant solution and portions of the electrolyzed antimicrobial solution are withdrawn from the cathode compartment and the anode compartment and combined to form the liquid soap. Skin benefiting agents such as vitamins may be added to the liquid soap with the surfactant and/or antimicrobial agent.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a dispensing device, system and method for electrochemically altering the properties of cleaning chemicals such as liquid soap in a carrier fluid such as water by application of an electric field or current.

2. Brief Description of the Prior Art

Water, surfactant and antimicrobial agents are usually the major components of cleaning chemicals such as liquid soap and electrolytically activated water is known to have good cleaning and disinfecting properties. As described below it is difficult to reach a balance between mildness and antimicrobial function because some of the ingredients prefer an acid environment and others a basic environment. If mixed together the ingredients may become unstable and/or lose their potency or ability to function in the product. How to deliver a liquid soap with a good balance of mildness and functionality at the time of desired use has been elusive.

BRIEF SUMMARY OF THE INVENTION

In accordance with the invention, a device for dispensing a liquid soap comprises:

a flow through electrolytic cell comprising an anode compartment containing an anode and a cathode compartment containing a cathode, said anode and cathode compartments separated by a semipermeable membrane;

a first container for a surfactant in an fluid carrier and a second container for an antimicrobial agent in a fluid carrier, said first container flowably connected to the cathode compartment and said second container flowably connected to the anode compartment;

a drain in the electrolytic cell for withdrawing at least a portion of a solution formed in the anode compartment and at least a portion of a solution formed in the cathode compartment after electrolysis, said solutions forming a liquid soap with a high level of functionality when brought together immediately prior to use.

A system for dispensing a liquid soap comprises:

a flow through electrolytic cell comprising an anode compartment containing an anode and a cathode compartment containing a cathode, said anode and cathode compartments separated by a semipermeable membrane;

a first container for a surfactant in a fluid carrier and a second container for an antimicrobial agent in a fluid carrier, said first container flowably connected to the cathode compartment and said second container flowably connected to the anode compartment;

a drain in the electrolytic cell for withdrawing at least a portion of a solution formed in the anode compartment and at least a portion of a solution formed in the cathode compartment after electrolysis, said solutions forming a liquid soap with a high level of functionality when brought together immediately prior to use.

A method for disinfecting a user's hands comprises:

providing a flow through electrolytic cell comprising an anode compartment containing an anode and a cathode compartment containing a cathode, said anode and cathode compartments separated by a semipermeable membrane;

providing a first container for a surfactant in a fluid carrier and a second container for an antimicrobial agent in a fluid carrier, said first container flowably connected to the cathode compartment and said second container flowably connected to the anode compartment;

withdrawing at least a portion of a solution formed in the anode compartment and at least a portion of a solution formed in the cathode compartment after electrolysis, said solutions forming a liquid soap with a high level of functionality when brought together;

immediately applying the liquid soap to the user's hands.

The invention summarized above comprises the devices, systems and methods hereinafter described, the scope of the invention being indicated by the subjoined claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, in which one of various possible embodiments of the invention is illustrated, FIG. 1 is a schematic representation of a device for dispensing liquid soap in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1 more particularly by reference character, reference numeral 10 refers to a device for dispensing a liquid soap. For convenience throughout the discussion that follows and the patent claims, the term “liquid soap” is used generally to include cleaning chemicals such as detergents, santizers, disinfectants and sterilizers unless the context dictates otherwise. In each case, the “liquid soap” contains a surfactant and an antimicrobial agent.

As shown in FIG. 1, device 10 includes a flow through electrolytic cell 12 with a cathode compartment 14 containing a cathode 16 and a anode compartment 18 containing an anode 20 separated by a semipermeable membrane 22. A first container or cartridge 24 for a surfactant in a fluid carrier is flowably connected to cathode compartment 14 and a second container or cartridge 26 containing an antimicrobial agent in a fluid carrier is flowably connected to anode compartment 18. During electrolysis, conditions in the vicinity of the cathode are alkaline which favor stability for detergents (i.e., surfactants and or a mixture of surfactants) and in the vicinity of the anode are acidic which favor stability of antimicrobial agents.

After electrolysis, the chemicals in cathode compartment 14 are combined with the chemicals in the anode compartment 18 to form a liquid soap that might not be stable if the chemicals were combined and stored for an extended period of time. As shown in FIG. 1, a drain 28 is provided in the electrolytic cell 12 for withdrawing at least a portion of the solution formed in the cathode compartment 14 and at least a portion of the solution formed in the anode compartment 18 which when brought together form the liquid soap. As discussed below when the surfactant and/or the antimicrobial agent is in a fluid carrier such as water with an electrolyte such as sodium chloride, additional antimicrobial agents may be formed during electrolysis to further augment the cleaning capacity of the liquid soap.

Operation of device 10 may be activated by a user 30 moving a lever or placing at least one hand 32 under a nozzle 34 connected to drain 28. Solutions from first container 24 and second container 26 to electrolytic cell 12 may be gravity fed or transferred with pumps (not shown). Similarly, solution from first cathode compartment 14 and second anode compartment 18 through drain 28 to nozzle 34 may be gravity fed or assisted with pumps (not shown). Any electric power needed to operate device 10 may be provided by power-over-ethernet (PoE), battery power or AC current.

Device 10 may include operational and control features and a user interface. Practical operation of electrolytic cell 12 will vary depending on a number of factors, such as the chemical nature of the surfactants, antimicrobial agents, fluid carriers, etc. Other factors include chemical concentrations. Cell operational parameters that may be varied include, but are not limited to, cell voltage, electrode spacing, cell current, solution flow rates, cell operating temperature and/or the nature of the electrodes and coatings on the anode or cathode surfaces.

How a soap or disinfectant dispenser type system may contain two cartridges, each containing a different chemical and such that when dispensing occurs, the two chemicals are combined to form a superior hand cleaning agent (soap or disinfectant), which may not be stable if the combined agent were stored for an extended period of time in a cartridge.

1.1 Background of the Invention

Water, surfactant and antimicrobial agents usually are the major components of liquid soap. There are basically four types of surfactants 1) anionic surfactants 2) cationic surfactants 3) non-ionic surfactants and 4) amphoteric. However, it is hard to improve the skin conditions as a result of exposure to liquid soaps and reach the effect of mildness and strong antimicrobial functions at the same time. For instance, alcohol and/or harsh surfactants will dry out and irritate skin tissues. Thereby, developing soap products with strong cleansing efficiencies, extra mildness without irritation or dryness and antimicrobial functions is a challenging topic. There are two ways of reaching mildness of the soap: using extra mildness surfactant or adding moisturizing compounds such as vitamins.

1.2 Chemistry of Surfactant and Antimicrobial Agent

Nowadays, in order to maintain cleaning effectiveness and reduce harshness, synthetic surfactants have replaced fatty acid soaps. However, anionic surfactants are still harsh, so the mild nonionic or amphoteric surfactants have been used. But nonionic surfactants generally do not generate creamy thick lather and are sticky and difficult to process. Large amounts of particular nonionic surfactants have been found to be very defatting to the skin. Besides, due to the low-foaming character of nonionic surfactants, amphoteric surfactant, e.g., phospholipids, have been added to provide enhanced foaming and skin care characteristics and can enhance the antibacterial activity of the chlorhexidine or substituted phenol. Thereby, a number of applications have focused on combining anionic surfactant with nonionic surfactant in soap production. For instance, it has been found that use of small amounts of hydrophobically modified polyethylene glycol nonionic polymer surfactants in anionic surfactant can significantly enhance the mildness of the soap without sacrificing the processibility and lather of anionic surfactant. Moreover, certain ionic additive substances, such as anti-bacterial agents, ultraviolet light absorbers, are more compatible with a nonionic surfactant than anionic surfactant. Nonionic surfactants include ethoxylated alkylphenols, ethoxylated aliphatic alcohols, ethoxylated amines, ethoxylated ether amines, carboxylic esters, carboxylic amides, and polyoxyalkylene oxide block copolymers.

Most anionic surfactant is incompatible with cationic quaternary antimicrobial surfactant. For example, most fatty acid soaps are alkaline, and thus incompatible with antimicrobial agents which requires acidic environment. Thereby, it is difficult to achieve the goal of combining anionic surfactant and antimicrobial agents in one soap cartridge. There are several active antimicrobial agents currently available for use in cleansing compositions. For example, many antimicrobial cleansing compositions contain a bisbiguanide bacterial substance such as chlorhexidine digluconate. Other cleansing compositions use phenolic compounds. Due to the different chemical structures of the antimicrobial substances, their effects are often dependent upon the type(s) of surfactants or other ingredients employed in the soap composition. For instance, the antimicrobial activity of p-chloro-m-xylol (PCMX) is enhanced against Pseudomonas aeruginosa by the addition of the chelating agent ethylenediaminetetraacetic acid (EDTA) and/or the sequestering agent sodium hexametaphosphate, most likely due to bonding of the agents to metal ions in the cell wall. The antimicrobial activity of PCMX can be reduced in the presence of organic material, and may be inhibited by moderate concentrations of anionic surfactants. Previous research indicated that conventional anionic surfactants are also detrimental to the antimicrobial activity of the substituted phenol. Examples of conventional anionic surfactants include fatty acid soaps, sulfates, carboxylates, sulfonates, sulfosuccinates, phosphonates, phosphates, sarcosinates, and isethionates of hydrophobic moieties. Moreover, many nonionic surfactants also inhibit the antibacterial activity of substituted phenols.

Sometimes, the antimicrobial agent has a limited solubility in water, the antimicrobial agent is added to the soap solution as part of an ‘active premix’, which is a solution of the antimicrobial agent dissolved in a hydric solvent. The hydric solvent should be chosen from either monohydric solvents, such as alcohols, or polyhydric solvents such as glycols.

Moreover, chlorhexidine or its salt can also be used as an antimicrobial cleansing component, but combining surfactant and chlorhexidine can be a very complicated process. For instance, chlorhexidine digluconate is low in toxicity and mild, but some nonionic surfactant such as alkyl polyglucoside can reduce its antibacterial activity. Anionic surfactants are also very likely to destroy the antimicrobial activity of chlorhexidine solutions by complexing with the cationic chlorhexidine. Cationic surfactants are also not desirable because of their irritancy, and in combination with a soluble chlorhexidine salt, double decomposition can occur with the formation of insoluble chlorhexidine salts and consequent loss of antibacterial activity. Amphoteric surfactants may also be incompatible due to disadvantages of both anionic and cationic surfactants.

1.3 Chemistry of Surfactant and Skin Care Agent

Healthy human skin is covered by a layer of fatty substances as a barrier against aggressions from the environment. During washing, in contact with soap or detergent substances, this layer is partly removed, thus evaporation increases, and skin begins drying up. Therefore, a lot of cosmetic agent or chemicals that can bring moisture to the skin have been added into soaps, for instance, glycerin and gelatin.

Skin benefit agents include: lipids such as cholesterol, ceramides, and pseudoceramides, sunscreens such as cinnamates, other types of ex-foliant particles such as polyethylene beads, walnut shells, apricot seeds, flower petals and seeds, and inorganics such as silica, and pumice. Additional emollients (skin softening agents) such as long chain alcohols and waxes like lanolin; additional moisturizers, skin-toning agents, skin nutrients such as vitamins like Vitamin C, D and E and essential oils like bergamot, citrus unshiu, calamus, water soluble or insoluble extracts of avocado, grape, grape seed, myrrh, cucumber, watercress, calendula, elder flower, geranium, linden blossom, amaranth, seaweed, gingko, ginseng, carrot, impatiens balsamina, camu camu, alpine leaf and other plant extracts such as witch-hazel.

The composition can also include a variety of other active ingredients that provide additional skin benefits. Examples include anti-acne agents such as salicylic and resorcinol, anti-wrinkle, anti-skin atrophy and skin-repair actives such as vitamins, vitamin alkyl esters, minerals, magnesium, calcium, copper, zinc and other metallic components, retinoic acid and esters and derivatives such as retinal and retinol, vitamin B3 compounds, alpha hydroxyl acids, beta hydroxyl acids, e.g. salicylic acid and derivatives, skin soothing agents such as aloe vera, jojoba oil, propionic and acetic acid derivatives, fenamic acid derivatives, artificial tanning agents such as dihydroxyacetone, tyrosine, tyrosine esters such as ethyl tyrosinate and glucose tyrosinate, skin lightening agents such as aloe extract and niacinamide, alpha-glyceryl-L-ascorbic acid, aminotyroxine, ammonium lactate, glycolic acid, hydroquinone, sebum stimulation agents such as bryonolic acid, dehydroepiandrosterone and orizano, sebum inhibitors such as aluminum hydroxyl chloride, corticosteroids, dehydroacetic acid and its salts, dichlorophenyl imidazoldioxolan, antioxidants, protease inhibition, skin tightening agents such as terpolymers of vinylpyrrolidone, (meth)acrylic acid and a hydrophobic monomer comprised of long chain alkyl (meth)acrylates.

The cosmetic agent is used to diminish, reduce, or prevent skin conditions including: aging, wrinkles, acne, age spots, scar broken capillaries. Antioxidants (e.g., CoQIO), vitamins such as C, B5, B6, Bg, E, energy enhancing agents (for example creatine, chelated minerals, pyruvate, nicotinamide) osmolytes and skin softeners are used to slow the process of aging. The skin benefit agent is preferably 0.1 to 15 wt %.

Vitamin-containing liquid soaps usually have a gel-like rheology, different from normal liquid soap, to prevent settling or other physical instability of vitamins. Moreover, the microcapsules containing vitamins (suspended with xanthan gum) have to withstand the chemical actions of the surfactant system and physical manipulation and mechanical breakage.

Moreover, dimethicones or silicones can be added to soap as skin protectant constituents, and various cationic polyquaternium-type polymers can work as skin conditioning agents. Moisturizer and fatty acid have been proven effective in anionic surfactant to reduce its harshness. However, there are still problems with added moisturizer, since it could leave the skin with a greasy filmy feeling as the skin dries. For fatty acids there will be the problem of rancidity of the soap composition over time.

1.4 All Natural Compositions

Essential oils (EO), or aromatic plant essences, are also widely known for their antibacterial, antifungal, antiviral, insecticidal and antioxidant properties. Their antimicrobial properties might result from the complex interaction between the different classes of compounds such as phenols, aldehydes, ketones, alcohols, esters, ethers or hydrocarbons in EO. Natural EO, such as thyme oil and origanum oil, have many advantages over conventionally available antimicrobial compounds, for instance, non-toxicity to individuals, moisturizing skin, few adverse side effects and increased efficacy.

Essential oil of thyme has been reported to be used in the making of soap as the sole of principle antimicrobial component. The combination of essential oil actives thymol and terpineol can interact synergistically to provide anti-microbial activity in 15 seconds or so. The structure of thymol is C₆H₃(CH₃)(OH)(CH(CH₃)₂). The structure of a terpineol compound is

The carrier of antimicrobial composition is selected from the group consisting of water, oil, solvent, inorganic particulate material, starch and mixture. The inorganic particulate materials include clay, talc, calcite, dolomite, silica, and aluminosilicate. The examples of oils include mineral oils, vegetable oils, and petroleum-derived oils and waxes.

In addition to terpineol, more antimicrobial actives can be added: hexachlorophene, chlorohexidine, 3,4′,5-tribromosalicylanilide, 4,4′-dichloro-3′-(trifluoromethyl)carbanilide, or 2,4,4′-trichloro-2′-hydroxy diphenyl ether. The preferred antibacterial active is thymol.

One or more surfactants e.g., an alkyl polyglucoside can be mixed with the EO and water in the composition of liquid soap. Co-surfactants, such as sodium laurel ether sulphate, sodium laurel sulphate, sodium lauryl sulfate, sarcosinates, yucca, naturally-derived sulfosuccinate, betaine, sultaine, propionate, acetate, amine oxide, naturally-derived ammonium chloride, geminis, carboxylate, and alcohol ethoxylate should be added to solubilize and disperse the EO in water.

Essential oils include mentha, jasmine, camphor, white cedar, bitter orange peel, ryu, turpentine, cinnamon, bergamot, citrus unshiu, calamus, pine, lavender, bay, clove, hiba, eucalyptus, lemon, starflower, peppermint, rose, sage, menthol, cineole, eugenol, citral, citronelle, borneol, linalool, geraniol, evening primrose, camphor, thymol, spirantol, penene, limonene and terpenoid oil.

The surfactant may be an anionic surfactant, a cationic surfactant, an ampholytic surfactant, or a nonionic surfactant. For instance, polyethoxylates, fatty alcohols as nonionic surfactants, and anionic surfactants include ammonium lauryl sulfate, lauryl ether sulfosuccinate. A preferred surfactant is lauroyl ethylenediamine triacetic acid sodium salt at a concentration of 0.5-2.0%.

It has been reported that EO, in combination with fruit acid may be used as non-toxic alternatives to conventional disinfectants. Fruit acids include citric acid, glycolic acid, lactic acid, malic acid, tartaric acid and acetic acid.

Bifunctional alcohols may include alkanediols, such as dodecanediol, decanediol, nonanediol, octanediol, heptanediol, hexanediol and pentanediol. Non-alkanediol alcohols for solubilisation of both essential oils and citric acid are aliphatic alcohols having carbon atoms about 1 to 8 such as methanol, ethanol, n-propanol, isopropyl alcohol, 2-methyl-2-propanol, hexanol, or combination at a concentration of between about 5 and 20 percent. Aromatic alcohols include phenoxy ethanol, benzyl alcohol, 1-phenoxy-2-propanol, or phenethyl alcohol at a concentration of 0.5 to 5% wt.

Preferably, the pH of personal care products is between 3.5-5.0. Further emollient may be added to reduce irritation, such as a fatty alcohol, behentrimonium methosulfate-cetyl alcohol, or a polyol like glycerol, propylene glycol, diglycerol, ethylene glycol, diethylene glycol, methylene glycol, dipropylene glycol, tripropylene glycol, hexylene glycol or butylene glycol.

Antioxidants include white tea extract, green tea extract, GHK copper peptides (e.g., copper PCA), vitamin C (L-asorbic acid), grape seed extract, marine algae (e.g., Haematococcus algae), vitamin E, lycopene, bioflavonoids, blueberry extract, blackberry extract, pomegranate extract, beta carotene, idebenone, and coenzyme QIO.

1.5 Conclusions

Mild personal cleansers are used to minimize skin irritation and dryness by antimicrobial agents or surfactants. A personal cleaning product having all three of these preferred characteristics (mildness, super cleansing effectiveness, and antimicrobial abilities) would be very desirable.

The antimicrobial agents can be selected from a variety of classes, including bisguanidine (e.g., chlorhexidine digluconate), diphenyl compounds, benzyl alcohols, trihalocarbanilides, quaternary ammonium compounds, ethoxylated phenols, and phenolic compounds, such as halo-substituted phenolic compounds, like p-chloro-m-xylenol (PCMX) and 2,4,4′-trichloro-2′hydroxy-diphenylether (triclosan). The antibacterial agent can be present at a level of from about 0.001% to about 5% by weight of the composition. However, the antibacterial liquid cleaning products are also harsh. Mildness is often obtained at the expense of effectiveness or product stability.

Another example of antibacterial agents and surfactant incompatibility are as follows: antibacterial agents are compatible with cosurfactant, e.g., alkyl sulfates, but are not compatible with mild ethoxylate surfactants. The ethoxylated surfactant was used widely in liquid soaps since it has high wetting ability and low aqueous surface tension. An essential ingredient is an ethoxylated (or propoxylated) surfactant which is mild to the skin, but the ethoxylated mild surfactant diminishes antibacterial effectiveness of the composition. The level of water in the compositions is typically from about 60% to 93% by weight. The pH is kept in the acidic range to maintain the stability of the antibacterial TCS.

In conclusion, a liquid soap in accordance with the present invention is formed by the combination of two separate cartridges which flow into electrolytic cell 12. Anionic surfactant and nonionic surfactant could be stored in one cartridge and flowed into the anode compartment 14, while antimicrobial agent could be stored in the other and flowed into the cathode compartment 18. Skin benefiting agents, such as vitamins could be added into either of the cartridges, depending on the exact selected chemicals.

How a soap or disinfectant dispenser type system may apply an electrical charge or current to a soap described above to cause an electrochemical reaction that creates a superior hand cleaning agent (soap or disinfectant), which may not be stable if it were stored for an extended period of time in a cartridge.

2.1 Background of the Invention

Water and chemical surfactants are the major components of conventional cleaning liquid. The surfactant cleans the skin by 1) reducing the surface tension of water to get wetting properties and releasing soil from surfaces, and 2) dispersing solid particles and pigment.

It has been reported that electrochemically activated (EA) water and EA liquids can be used with conventional cleaning systems in addition to chemical surfactant-based liquids, for example in washing machines, medical industries and cleaning floors. The electrolysis cells have different configurations depending on specific needs. EA water has strong cleaning and sanitation capabilities and it has elevated reactivity that contains 1) reactive species, and/or 2) meta-stable (activated) ions and free radicals formed after exposure to electrochemical energy.

2.2 EA Water

Pure water consists almost entirely of H₂O molecules loosely bound in a network-like structure in which individual molecules exhibit a very slight tendency to dissociate (“ionize”) into hydrogen ions and hydroxide but the extent of this reaction is severely limited because the reverse reaction is much more rapid, so that on average, only about two out of every billion H₂O molecules are dissociated.

Because water does not conduct electricity, a salt such as sodium chloride which readily dissociates into Na⁺ and Cl⁻ is added to make the water more conductive and subject to electrolysis. Positive ions that find themselves close to the negative electrode (cathode) will acquire electrons, and negative ions near the positive electrode (anode) will lose electrons. The consumption of H⁺ ions at the negative electrode leaves an excess of OH⁻ ions in the vicinity of this electrode, making the water in this region alkaline. Similarly, the consumption of OH⁻ ions at the positive electrode makes the water near this electrode acidic. If the anode and cathode are surrounded by a semipermeable membrane that inhibits ion diffusion, local excesses can build up.

When sodium chloride is added to water as the electrolyte, for example, hydrogen gas and hydroxide ions are liberated at the cathode, producing an alkaline solution that consists essentially of NaOH which can be drawn off as “alkaline water.” At the anode, chloride ions are oxidized to elemental chlorine. If some of the chlorine is allowed to combine with some of the hydroxide ions produced at the cathode, it disproportionates into hypochlorous acid (HOCl), a weak acid and an oxidizing acid. Some ionizer devices allow the user to draw off this solution for use as a disinfecting agent. Other suitable electrolytes include other chloride salts such as potassium chloride, magnesium chloride and calcium chloride, nitrate salts, carbonate salts or any other salt that is soluble in water.

EA water also differs from regular or untreated water at the molecular level and electron level. During electrochemical activation of water, many meta-stable ionic and reactive free radical molecules can include: O₃, O₂, H₂O₂, Cl₂, ClO₂, HClO, HCl, HClO₃, O₂, H₂O₂, O₃, H⁺, H₃O⁺, OH⁻, ClO⁻, HO⁺, H₂O, O₂, O., ClO., and Cl. The chlorine-based reagents may be used to kill microorganisms. The oxygen gas bubbles can improve the wetting properties of the liquid by reducing the surface tension of the liquid and can be reactive to further enhance the cleaning and/or sanitizing properties.

Molecules such as oxygen (O₂) and hydrogen (H₂) produced at the surfaces may enter small cavities in the liquid phase of the water as gases and/or may become solvated by the liquid phase of the water. These gas-phase bubbles are thereby dispersed or otherwise suspended throughout the liquid phase of the water.

Therefore, the charged EA water can act as a cleaning agent owing to tiny electrically-charged bubbles. These bubbles can attach to dirt particles/microorganisms to transferring their charge. The charged particles are easily separated due to the repulsion between their similar charges and enter the solution as a suspension.

The electrolysis products near the cathode and anode are listed in following table. The anolyte solution has mild oxidative power and can kill microorganisms. The catholyte can work as a detergent and a surfactant.

Molecules near the cathode and anode
		Reactive molecules	Reactive ions
	Anolyte	O3
		O2
		H2O2	OH−
		ClO2	ClO−
		HClO
		Cl2
		HCl
		HClO3
	Catholyte	H2O2	H3O+
		NaOH	Na+
		H2

Also, it was previously thought that the disinfect activity strongly depends on the hypochlorite content (at least 50 ppm). But activated Cl and O₂ also can produce a redox potential to render water disinfectant activity. The EA water with a chlorine content of 8 ppm is not harmful to skin and thereby can be utilized in combination with liquid soap products to enhance disinfectant capabilities.

2.3 Applications of EA Water in Soap Products

As discussed above, electrolysis could enhance both the cleansing and antimicrobial effectiveness of water or liquid soap. Anolyte EA liquids have good sanitizing properties, while the catholyte EA liquids have known cleaning properties.

The electrolysis process should be run at a voltage and/or power density which is higher than that at which O₂ and Cl₂ could be produced. At voltages (6-15 V) the total amount of chlorine Cl generated depends on the voltage and chloride concentration.

The chloride ion concentration is proportional to the chlorine concentration in the electrolysis. Thereby, in the liquid soap described herein, by varying the concentration of Cl⁻, which is most likely from NaCl, the concentration of chlorine could be controlled to below 8 ppm. However, since it is a much more complicated situation in the soap development, a number of parameters, such as the chemical composition of the soap and the concentrations of the chemicals could significantly influence the configuration of the dispenser.

Moreover, since the favorite conditions for the antimicrobial agents are acidic and favorite pH for the detergents is alkaline, it is preferable to separate these chemicals in first container or cartridge 24 and second container or cartridge 26 as shown in FIG. 1. After electrolysis device 10 combines the anolyte solution from anode compartment 18 with the catholyte solution from cathode compartment 14 to produce a liquid soap with a high level of functionality at the time of desired use.

The following examples illustrate the invention wherein an anionic surfactant and a nonionic surfactant are stored in first container 24 as shown in FIG. 1 and wherein an antimicrobial agent is stored in second container 26. Skin benefiting agents, such as vitamins can be added into either container, depending on the exact selected chemicals.

EXAMPLE 1

Proposed Soap Composition—Recipe One

Compositions	Chemicals	Amount	Note
Anionic	Sodium alcohol	10% to 70% wt	Cartridge one
surfactant	ethoxy glyceryl
	sulfonate, sodium
	cocoate, sodium
	palm kernelate
Nonionic	HMPEG, ethoxylate	1% to 20% wt	Cartridge one
surfactant
Antimicrobial	CHG, PCMX with	0.001% to 5%	Cartridge two
agent	glycol as solvent
Skin benefit	Vitamin E with		Cartridge one,
agent	xanthan gum,		when vitamins are
	silicone,		added, particular
	fatty acid, glycerin		formula needs
			to be followed
Others	Fragrance,	0.1% to 15%	Cartridge one,
	amphoteric	of electrolyte	amphoteric
	surfactant,		surfactant
	electrolyte,		can adjust pH
	amine salt		of the soap

Detailed Explanations:

Chemical Structure of Sodium Salt of Alcohol Ethoxy Glyceryl Sulfonate

Chemical Structure of HMPEG

Where n is 2 to 1200, R4 and R5 are linear or branched, saturated or unsaturated, aliphatic or aromatic hydrocarbon radicals having from 2 to 100 carbon atoms, or mixtures thereof; x is 1 to 10; y is 0 to 10; the sum of x and y is greater than or equal to 2.
CHG is chlorhexidine digluconate. Chlorhexidine is N,N-bis(4-chlorophenyl)-3,12-diimino-2,4,11,13-tetraazatetradecanediimidamide (also known as 1,6-di(4′-chlorophenyldiguanido)hexane), C₂₂H₃₀Cl₂N₁₀. Its chemical structure is listed:

Cl—C₆H₄—NH—C(NH)—NH—C(NH)—NH—CH₂—CH₂—CH₂—CH₂—CH₂—CH₂—NH—C(NH)—NH—C(NH)—NH—C₆H₄—Cl

PCMX is p-chloro-m-xylenol and being phenolic in nature with acidic hydrogen and insoluble in water, reacts with bases to form salts:

C₆H₂(OH)(CH₃)(Cl)(CH₃)+NaOH→C₆H₂(ONa)(CH₃)(Cl)(CH₃)+H₂O

PCMX exists in the salt form in solutions at higher pH and in the phenolic state at lower pH. Thereby its efficiency is dependent upon pH (pH 4.0 to 6.0 is commonly used) and other factors such as solubility and reactions with other chemicals.

Vitamins, such as Vitamin E and/or Vitamin A, can be added into the soap to enhance its skin care properties. The microcapsules usually comprise a natural polysaccharide matrix such as agar/alginate/chitosan, which contains active ingredients such as tocopheryl acetate and retinyl palmitate. The microcapsules with vitamins need to be custom designed to have the same density as that of the particular liquid soap so that the microcapsules will not settle down for an extended time¹⁷. Also, a cross-lined acrylic polymer should be added to the liquid soap to suspend the vitamin-containing microcapsules.

Silicone compounds can be selected from polyalkyl siloxanes, polyaryl siloxanes, polyalkylaryl siloxanes, polysiloxanes with amino functional substitutions, or polyether siloxane copolymers.

EXAMPLE 2

Proposed Soap Composition—Recipe Two

Compositions	Chemicals	Amount	Note
Anionic	Alkyl ether sulfates,	10% to 70% wt	Cartridge one
surfactant	Acyl isethionate, or
	alkyl ether sulfonates,
	sarcosinates,
	sulfosuccinates,
	taurates
Nonionic	Ethoxylated surfactant	1% to 10% wt	Cartridge one
surfactant
Antimicrobial	Essential oils with	EO 0.001% to 5%,	Cartridge two
agent	fruit acid	Fruit acid 0.125% to
		1%
Skin benefit	Emollient, silicone,		Cartridge two
agent	fatty acid, glycerol
Others	Non-alkanediol	0.5% to 20%	Cartridge two
	alcohol solvent and
	alkanediol solvent

Note: The purpose of this recipe is to develop a super soap with good mildness and skin care properties by adding an essential oil as the antimicrobial agents. Moreover, a mild anionic surfactant which has the following molecular formula could be used in this soap:

R1C(═O)OCH₂(CH₂)nCH(R₂)OR₃

R1 is CH₃(CH₂)m and may be interrupted with at least one heteroatom selected from the group consisting of amine, ether, ester, amide, sulfur, sulfur monoxide, sulfur dioxide, sulfamate, hydroxyl, or mixtures. M=6-16 n=0 or 1 R2=H or CH₃ R₃═H, SO₃X, CO(CH₂)COOH, or COCH(SO₃X)CH₂COOX1, X and X1 are the same or different, and each is selected from NH₄⁺ or alkali metal.

In view of the above, it will be seen that the several objects of the invention which may be inferred from the disclosure are achieved and other advantageous results attained. As various changes could be made in the above devices, systems and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and examples or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Claims

1. A device for dispensing a liquid soap, the device comprising:

a flow through electrolytic cell comprising an anode compartment containing an anode and a cathode compartment containing a cathode, said anode and cathode compartments separated by a semipermeable membrane;

a first container for a surfactant in an aqueous carrier and a second container for an antimicrobial agent in an aqueous carrier, said first container flowably connected to the cathode compartment and said second container flowably connected to the anode compartment;

a drain in the electrolytic cell for withdrawing at least a portion of an aqueous solution formed in the anode compartment and at least a portion of an aqueous solution formed in the cathode compartment after electrolysis, said aqueous solutions forming a liquid soap when brought together.

2. The device of claim 1 that is powered by power-over-ethernet (PoE), a battery or an AC current.

3. The device of claim 1 wherein the surfactant or the antimicrobial agent or both undergo ionization in the electrolytic cell.

4. The device of claim 1 wherein the surfactant or the antimicrobial agent or both undergo de-ionization in the electrolytic cell.

5. The device of claim 1 wherein the surfactant or the antimicrobial agent or both are molecularly broken apart in the electrolytic cell.

6. The device of claim 1 wherein a skin benefiting agent is included in the first container or the second container or both depending on the selection of the surfactant and the selection of the antimicrobial agent.

7. The device of claim 6 wherein the skin benefiting agent comprises between about 0.1 to about 15 weight percent of the surfactant in the aqueous carrier in the first container or between about 0.1 to about 15 weight percent of the antimicrobial agent in an aqueous carrier in the second container.

8. The device of claim 7 wherein the skin benefitting agent is a cosmetic agent used to diminish, reduce or prevent aging, wrinkles, age spots or scar broken capillaries.

9. The device of claim 1 further comprising operational controls and a user interface.

10. A system for dispensing a liquid soap comprising:

a flow through electrolytic cell comprising an anode compartment containing an anode and a cathode compartment containing a cathode, said anode and cathode compartments separated by a semipermeable membrane;

a first container for a surfactant in an aqueous carrier and a second container for an antimicrobial agent in an aqueous carrier, said first container flowably connected to the cathode compartment and said second container flowably connected to the anode compartment;

a drain in the electrolytic cell for withdrawing at least a portion of an aqueous solution formed in the anode compartment and at least a portion of an aqueous solution formed in the cathode compartment after electrolysis, said aqueous solutions forming a liquid soap when brought together.

11. The device of claim 10 that is powered by power-over-ethernet (PoE), a battery or an AC current and having operational controls and a user interface.

12. The device of claim 10 wherein the surfactant or the antimicrobial agent or both undergo ionization in the electrolytic cell.

13. The device of claim 10 wherein the surfactant or the antimicrobial agent or both undergo de-ionization in the electrolytic cell.

14. The device of claim 10 wherein the surfactant or the antimicrobial agent or both are molecularly broken apart in the electrolytic cell.

15. The device of claim 10 wherein a skin benefiting agent is included in the first container or the second container or both depending on the selection of the surfactant and the selection of the antimicrobial agent.

16. The device of claim 15 wherein the skin benefiting agent comprises between about 0.1 to about 15 weight percent of the surfactant in the aqueous carrier in the first container or between about 0.1 to about 15 weight percent of the antimicrobial agent in an aqueous carrier in the second container.

17. The device of claim 16 wherein the skin benefitting agent is a cosmetic agent used to diminish, reduce or prevent aging, wrinkles, age spots or scar broken capillaries.

18. A method for applying liquid soap to a surface comprising:

providing a flow through electrolytic cell comprising an anode compartment containing an anode and a cathode compartment containing a cathode, said anode and cathode compartments separated by a semipermeable membrane;

providing a first container for a surfactant in an aqueous carrier and a second container for an antimicrobial agent in an aqueous carrier, said first container flowably connected to the cathode compartment and said second container flowably connected to the anode compartment;

withdrawing at least a portion of an aqueous solution formed in the anode compartment and at least a portion of an aqueous solution formed in the cathode compartment after electrolysis, said aqueous solutions forming a liquid soap when brought together;

applying the liquid soap to the surface.

19. The method of claim 18 wherein the liquid soap is applied to a user's hands.

20. The method of claim 19 wherein the liquid soap is dispensed through a nozzle which is activated by a user moving a lever or placing at least one hand under the nozzle.