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Shaped Toilet Bars

Abstract: Intricately shaped toilet bars with specific compositions and plasticity properties can be advantageously manufactured via three dimensional cutting. Such cut bars are characterized by specific surface profiles and topographic features. Intricately shaped toilet bars with a wide range of formulations for enhanced skin treatment can be thus economically and reliably manufactured.

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Patent Information

Application #
Filing Date
08 March 2011
Publication Number
48/2011
Publication Type
INA
Invention Field
CHEMICAL
Status
Email
Parent Application

Applicants

HINDUSTAN UNILEVER LIMITED
HINDUSTAN LEVER HOUSE, 165-166 BACKBAY RECLAMATION, MUMBAI, 400 020, INDIA

Inventors

1. MCFANN GREGORY JAY
CONOPCO, INC., D/B/A/ UNILEVER, 40 MERRITT BOULEVARD, TRUMBULL, CONNECTICUT, 06611, UNITED STATES OF AMERICA
2. MISRA MANOJ
CONOPCO, INC., D/B/A/ UNILEVER, 40 MERRITT BOULEVARD, TRUMBULL, CONNECTICUT 06611, UNITED STATES OF AMERICA
3. KAPLAN PETER DANIEL
188 WATCHUNG AVENUE, MONTCLAIR, NEW JERSEY, 07043, UNITED STATES OF AMERICA
4. GIUGNO GEORGE
CONOPCO, INC., D/B/A/ UNILEVER, 75 MERRITT BOULEVARD, TRUMBULL, CONNECTICUT, 06611, UNITED STATES OF AMERICA
5. VELTHUIZEN ROBERT PAUL
CONOPCO, INC., D/B/A/ UNILEVER, 40 MERRITT BOULEVARD, TRUMBULL, CONNECTICUT, 06611, UNITED STATES OF AMERICA

Specification

FORM - 2 THE PATENTS ACT, 1970 (39 of 1970) & The Patents Rules, 2003 COMPLETE SPECIFICATION (See Section 10 and Rule 13) SHAPED TOILET BARS HINDUSTAN UNILEVER LIMITED, a company incorporated under the Indian Companies Act, 1913 and having its registered office at 165/166, Backbay Reclamation, Mumbai -400 020, Maharashtra, India The following specification particularly describes the invention and the manner in which it is to be performed Shaped Toilet Bars The present invention relates to a toilet bar suitable for cleansing. In particular, it relates to a toilet bar that has a specific formulation and plasticity or surface properties. Toilet bars are well known for providing a wide range of skin care and cleansing benefits and are frequently made available to consumers in aesthetically pleasing shapes. Toilet bars that contain high levels of soap and synthetic surfactants are excellent for cleaning and usually have sufficient hardness to be economically extruded into a billet and stamped into a final attractive shape. Stamping, however, does not provide for creating intricate three dimensional shapes. Toilet bars that are transparent or translucent and/or contain high levels of components that are liquid at room temperature are usually too soft to be stamped and must usually be cast in a shaped mould or frame from a flowable feedstock. Casting also has limitations regarding the creation of intricate shapes. The cast bar will often have at least one fiat surface upon hardening and will thus limit the choice of shape of the finished bar unless further process steps are employed to shape the flat surface(s). Additional steps will add to the complexity and cost of making such bars. Manufacturers have sought to provide to the consumer aesthetically pleasing shaped toilet bars that are shaped on their entire surface while attempting to meet a wide range of skin conditioning qualities, manufacturing and formulation constraints. A brief representation of the prior art is set forth below. U.S. Patent No. 3,856,449 issued to Fisher on Dec. 24, 1974 discloses a wire trimmer for trimming soap extrusions to obtain improved surface finish for soap. The cut lines will all be parallel to the direction of motion of the extruded soap. U.S. Patent No. 5,083,486 issued to Allison et al. on Jan. 28, 1992 discloses a method and apparatus for trimming non-soap solid stick deodorants to provide for a protruding rounded deodorant stick in the container. U.S, Patent No. 6,024,967 issued to Fattori et al. on Feb. 15, 2000 discloses a method and apparatus for shaping a top surface of a non-soap antiperspirant or deodorant product to have a compound-curved shape using a plurality of cutting blades. It has been discovered that three-dimensional shaping via cutting can be usefully employed to produce aesthetically pleasing bar shapes for specifically formulated toilet bars that unexpectedly possess a defined range of plasticity in order to produce a bar with an acceptable appearance (i.e. having minimal or no visually detectable surface defects such as cracks and gouges). Such plasticity can be quantified by the fracture initiation energy (Gic) and the fracture energy parameter (Gc) from a three-point bending test described below. Moreover, a specific range of yield stress (σy) was also unexpectedly found to be an important property for preparing a bar with an acceptable appearance after cutting i.e. avoiding surface defects, as well as for generally efficient processing of the inventive bar. The inventive bar was discovered to have a distinctive striated topographic pattern compared to bars shaped by stamping or casting, and this striated pattern can be quantified using microscopic analysis techniques described below. In one aspect of the invention there is provided a shaped toilet bar including but not limited to: a. about 10 % to 60 % by wt. of total non-soap anionic surfactant(s); b. 0 % to about 30 % by wt. of fatty acid soap(s); c. wherein the bar has a fracture initiation energy (Gic) greater than 2 J/m2.; d. wherein the bar has a length extending along an x axis, a width extending along a y axis, and a thickness extending along a z axis, and the x, y and z axis are orthogonal to each other; and e. wherein the bar has an exterior surface, wherein the exterior surface includes: i. a top surface, a bottom surface and a middle portion extending from the top to the bottom surface; ii. wherein the top surface has a first profile extending along the x axis, the bottom surface has a second profile extending along the y axis, and the middle portion has a third profile normal to the z axis; iii. each of said first, second and third profiles independently being either linear, curvilinear or having both linear and curvilinear elements; iv. wherein at least two of the first, second and third profiles are different; and v. wherein the maximum value of the standard deviations of a Directional Variation Array of surface striations of each of the top surface, bottom surface and middle portion of the bar is each greater than 0.64 calculated via the DVA surface imaging method. In a second aspect of the invention there is provided a shaped toilet bar including but not limited to: a. about 5 % to 40 % by wt. of total non-soap anionic surfactant(s); b. about 30 % to 80 % by wt. of fatty acid soap(s); c. wherein the bar has a fracture initiation energy (Gic) greater than 2 J/m2.; d. wherein the bar has a length extending along an x axis, a width extending along a y axis, and a thickness extending along a z axis, and the x, y and z axis are orthogonal to each other; and e. wherein the bar has an exterior surface, wherein the exterior surface includes: i. a top surface, a bottom surface and a middle portion extending continuously from the top to the bottom surface,; ii. wherein the top surface has a first profile extending along the x axis, the bottom surface has a second profile extending along the y axis, and the middle portion has a third profile normal to the z axis; iii. each of said first, second and third profiles independently being either linear, curvilinear or having both linear and curvilinear elements; iv. wherein at least two of the first, second and third profiles are different; and v. wherein the maximum value of the standard deviations of a Directional Variation Array of surface striations of each of the top surface, bottom surface and middle portion of the bar is each greater than 0.64 calculated via the DVA surface imaging method. In a third aspect of the invention there is provided a shaped toilet bar including but not limited to: a. 0 % to about 10 % by wt. of total non-soap anionic surfactant(s); b. about 40 % to 90 % by wt. of fatty acid soap(s); c. wherein the composition has a 1racture initiation energy (GIC) greater than 2 J/m2; d. wherein the bar has a length extending along an x axis, a width extending along a y axis, and a thickness extending along a z axis, and the x, y and z axis are orthogonal to each other; and e. wherein the bar has an exterior surface, wherein the exterior surface includes: i. a top surface, a bottom surface and a middle portion extending continuously from the top to the bottom surface,; ii. wherein the top surface has a first profile extending along the x axis, the bottom surface has a second profile extending along the y axis, and the middle portion has a third profile normal to the z axis; iii. each of said first, second and third profiles independently being either linear, curvilinear or having both linear and curvilinear elements; iv. wherein at least two of the first, second and third profiles are different; and v. wherein the maximum value of the standard deviations of a Directional Variation Array of surface striations of each of the top surface, bottom surface and middle portion of the bar is each greater than 0.64 calculated via the DVA surface imaging method. In a fourth aspect of the invention there is provided a shaped toilet bar including but not limited to: a. 0 to about 40 % by wt. of total non-soap anionic surfactant(s); b. 0 to about 60 % by wt. of fatty acid soap(s), provided that the sum of total non-soap anionic surfactants and fatty acid soaps is not 0; c. about 10 % to 50 % by wt. of total mono and polyhydric alcohols; d. wherein the composition has a fracture initiation energy (Gic) greater than 2 J/m2; e. wherein the bar has a length extending along an x axis, a width extending along a y axis, and a thickness extending along a z axis, and the x, y and z axis are orthogonal to each other; and f. wherein the bar has an exterior surface, wherein the exterior surface includes: i. a top surface, a bottom surface and a middle portion extending from the top to the bottom surface; ii. wherein the top surface has a first profile extending along the x axis, the bottom surface has a second profile extending along the y axis, and the middle portion has a third profile normal to the z axis; iii. each of said first, second and third profiles independently being either linear, curvilinear or having both linear and curvilinear elements; iv. wherein at least two of the first, second and third profiles are different; and v. wherein the maximum value of the standard deviations of a Directional Variation Array of surface striations of each of the top surface, bottom surface and middle portion of the bar is each greater than 0.64 calculated via the DVA surface imaging method. The invention will now be described by way of example only with reference to the accompanying drawings, in which: - Figure 1A is a side efevationaf view of an embodiment of an inventive bar. - Figure 1B is a side eJevational view of the embodiment of the inventive bar depicted in Fig. 1A oriented at 90 degrees. - Figure 1C is a bottom plan view of the embodiment of the inventive bar depicted in Fig. 1A. - Figure 2A is a side perspective photographic view of inventive bar sample 545. - Figure 2B is a top plan photographic view of comparative bar sample 553. - Figure 2C is a side, perspective photographic view of inventive bar sample 555 displaying a cut section. - Figure 2D is a detailed side, perspective photographic view of inventive bar sample 555 shown in Fig. 2C. - Figure 3A is a graph depicting the relationship of Force (Newtons) vs. Displacement (mm) of the three point bending test of comparative sample 553 - Figure 3B is a graph depicting the relationship of Force (Newtons) vs. Displacement (mm) of the three point bending test of inventive sample 547 - Figure 3C is a graph depicting the relationship of Force (Newtons) vs. Displacement (mm) of the three point bending test of inventive sample 545 - Figure 3D is a graph depicting the relationship of Force (Newtons) vs. Displacement (mm) of the three point bending test of inventive sample 549 - Figure 3E is a graph depicting the relationship of Force (Newtons) vs. Displacement (mm) of the three point bending test of inventive sample 551 - Figure 3F is a graph depicting the relationship of Force (Newtons) vs. Displacement (mm) of the three point bending test of comparative sample 543 - Figure 3G is a graph depicting the relationship of Force (Newtons) vs. Displacement (mm) of the wire cutting test of comparative sample 555 - Figure 4A is a graph depicting the relationship of fracture energy to temperature for inventive sample 551. - Figure 4B is a graph depicting the relationship of yield stress to temperature for inventive sample 551. - Figure 4C is a graph depicting the relationship of fracture energy to temperature for inventive sample 549. - Figure 4D is a graph depicting the relationship of yield stress to temperature for inventive sample 549. - Figure 4E is a graph depicting the relationship of fracture energy to temperature for inventive sample 555 - Figure 4F is a graph depicting the relationship of yield stress to temperature for inventive sample 555 - Figure 5A is an image of the surface of inventive bar 551. - Figure 5B is an image of the surface of a comparative version of bar 551 shaped via stamping. - Figure 5C is an image of the surface of inventive bar 547. - Figure 5D is an image of the surface of a comparative version of bar 547 shaped via stamping. - Figure 6A is a micrographic PRIMOS input image of a representative inventive cut bar. - Figure 6B is a micrographic PRIMOS image of a representative comparative stamped bar after preprocessing. - Figure 7 shows in schematic form the steps to compute one element in the DVA from a rotated image of the same sample depicted in Figures 6 A and B. - Figure 8 shows in schematic form the steps to create a Feature Vector from one DVA of the same sample depicted in Figures 6A, 6B and 7. - Figure 9A is a perspective photographic view of the wire test fixture used in Example 1. - Figure 9B is a perspective photographic view of the blade test fixture used in Example 2 All publications and patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. Referring now to the drawings in which like figures represent like elements, Figures 1A to C depict different views defined by x, y, z coordinates of one embodiment of an inventive shaped bar 14 having a middle portion 15, a bottom surface 16 and a top surface 17. A first profile, i.e., perimeter, of the bar 14 extends along the length or x axis of the bar and is parallel with the xz plane, A second profile of the bar extends along the width or y axis of the bar and is parallel with yz plane. A third profile of the bar is normal to the z axis of the bar and is parallel with the xy plane. Shaped profiles or surfaces are herein defined as curvilinear profiles or surfaces as opposed to flat profiles or surfaces. In a first embodiment of the invention there is provided a shaped toilet bar including but not limited to: a. about 10 % to 60 % by wt. of total non-soap anionic surfactant(s) (preferably the minimum concentration is about 15, 20 or 25 and the maximum concentration is about 50 or 55 % by wt. of total non-soap anionic surfactant(s)); b. 0 % to about 30 % by wt. of fatty acid soap(s) (preferably the maximum concentration is about 20 or 25 % by wt. of a fatty acid soap); c. wherein the bar has a fracture initiation energy (Gic) greater than 2 Jim2. (preferably the minimum fracture initiation energy has a lower limit of about 8, 12 or 16 and the maximum fracture initiation energy has an upper limit of about 24 or 20 J/m2); d. wherein the bar has a length extending along an x axis, a width extending along a y axis, and a thickness extending along a z axis, and the x, y and z axis are orthogonal to each other; and e. wherein the bar has an exterior surface, wherein the exterior surface includes: i. a top surface, a bottom surface and a middle portion extending from the top to the bottom surface, (preferably wherein the each of the top surface, the middle portion and the bottom surface has the same composition); ii. wherein the top surface has a first profile extending along the x axis, the bottom surface has a second profile extending along the y axis, and the middle portion has a third profile normal to the z axis; iii. each of said first, second and third profiles independently being either linear, curvilinear or having both linear and curvilinear elements; iv. wherein at least two of the first, second and third profiles are different (preferably the first, second and third profiles are all different); and v. wherein the maximum value of the standard deviations of a Directional Variation Array of surface striations of each of the top surface, bottom surface and middle portion of the bar is each greater than 0.64 calculated via the DVA surface imaging method. Optionally the first embodiment bar composition may contain 0 to about 10 % by wt. of total amphoteric surfactant(s), 0 to about 10 % by wt. of total nonionic surfactant(s), 0 to about 5 % by wt. of total cationic surfactant(s), 0 to about 10 % by wt. of total cationic polymer(s)-, about 5 to 30 % by wt. of total hydrophobic structurant(s), about 5 to 40 % by wt. of hydrophilic structurant(s), 0 to about 10 % by wt. of total solvent(s), 0 to about 7 % by wt. of total hydrophobic emollient(s) and 0 to about 7 % by wt. of total humectant(s). Preferably the first embodiment of the bar has a fracture energy (Gc) greater than about 25 J/m2. More preferably the minimum fracture energy has a lower limit of about 100, 150 or 200 and the maximum fracture energy has an upper limit of about 300 or 250. Advantageously the bar has a yield stress greater than about 100 kPa. Preferably the maximum yield stress has an upper limit of about 600 kPa. Advantageously at least two of the first, second or third profiles of the bar have curvilinear profiles. Preferably the first, second and third profiles are all curvilinear. In a second embodiment of the invention is a shaped toilet bar including but limited to: a. about 5 % to 40 % by wt. of total non-soap anionic surfactant(s) (preferably the minimum concentration is about 7 or 10 and the maximum concentration is about 20 or 30 % by wt. of total non-soap anionic surfactant(s)); b. about 30 % to 80 % by wt. of fatty acid soap(s) (preferably the minimum concentration is about 35 or 40 and the maximum concentration is about 60 or 70 % by wt. of fatty acid soap(s)); c. wherein the bar has a fracture initiation energy (Gic) greater than 2 J/m2. (Preferably the minimum fracture initiation energy has a lower limit of about 8,12 or 16 and the maximum fracture initiation energy has an upper limit of about 24 or 20) J/m2; d. wherein the bar has a length extending along an x axis, a width extending along a y axis, and a thickness extending along a z axis, and the x, y and z axis are orthogonal to each other; and e. wherein the bar has an exterior surface, wherein the exterior surface includes: i. a top surface, a bottom surface and a middle portion extending continuously from the top to the bottom surface, (preferably wherein the each of the top surface, the middle portion and the bottom surface has the same composition); ii. wherein the top surface has a first profile extending along the x axis, the bottom surface has a second profile extending along the y axis, and the middle portion has a third profile normal to the z axis; iii. each of said first, second and third profiles independently being either linear, curvilinear or having both linear and curvilinear elements; iv. wherein at least two of the first, second and third profiles are different (preferably the first, second and third profiles are all different); and v. wherein the maximum value of the standard deviations of a Directional Variation Array of surface striations of each of the top surface, bottom surface and middle portion of the bar is each greater than 0.64 calculated via the DVA surface imaging method. Optionally the second embodiment of the bar composition may contain 0 to about 10 % by wt. of total amphoteric surfactant(s), 0 to about 7 % by wt. of total nonionic surfactant(s), 0 to about 5 % by wt. of total cationic surfactant(s), 0 to about 10 % by wt. of total cationic polymer(s), 0 to about 10 % by wt. of total hydrophobic structurant(s), 0 to 10 % by wt. of hydrophilic structurant(s), 0 to about 10 % by wt. of total solvent(s), 0 to about 7 % by wt. of total hydrophobic emollient(s) and 0 to about 10 % by wt. of total humectant(s). Preferably the second embodiment toilet bar has a fracture energy (Gc) greater than about 25 J/m2. Preferably the minimum fracture energy has a lower limit of about 100, 150 or 200 and the maximum fracture energy has an upper limit of about 300 or 250. Preferably the toilet bar has a yield stress at greater than about 100 kPa. Preferably the maximum yield stress has an upper limit of about 600. Advantageously at least two of the first, second or 'third profiles of the bar have curvilinear profiles. Preferably the first, second and third profiles are all curvilinear. In a third embodiment of the invention there is provided a shaped toilet bar including but not limited to: a. 0 % to about 10 % by wt. of total non-soap anionic surfactant(s) (preferably the maximum concentration is about 5 or 7 % by wt. of total non-soap anionic surfactant(s)); b. about 40 % to 90 % by wt. of fatty acid soap(s) (preferably the minimum concentration is about 50 or 60 and the maximum concentration is about 85 or 80 % by wt. of fatty acid soap{s)); c. wherein the composition has a fracture initiation energy (Gic) greater than 2 J/m2. (Preferably the minimum fracture initiation energy has a lower limit of about 8, 12 or 16 and the maximum fracture initiation energy has an upper limit of about 24 or 20) J/m2; d. wherein the bar has a length extending along an x axis, a width extending along a y axis, and a thickness extending along a z axis, and the x, y and z axis are orthogonal to each other; and e. wherein the bar has an exterior surface, wherein the exterior surface includes: i. a top surface, a bottom surface and a middle portion extending continuously from the top to the bottom surface, (preferably wherein the each of the top surface, the middle portion and the bottom surface has the same composition); ii. wherein the top surface has a first profile extending along the x axis, the bottom surface has a second profile extending along the y axis, and the middle portion has a third profile normal to the z axis; iii. each of said first, second and third profiles independently being either linear, curvilinear or having both linear and curvilinear elements; iv. wherein at least two of the first, second and third profiles are different (preferably the first, second and third profiles are all different); and v. wherein the maximum value of the standard deviations of a Directional Variation Array of surface striations of each of the top surface, bottom surface and middle portion of the bar is each greater than 0.64 calculated via the DVA surface imaging method. Optionally the third embodiment of the bar composition may contain 0 to about 10 % by wt. of total amphoteric surfactant(s), 0 to about 7 % by wt. of total nonionic surfactant(s), 0 to about 5 % by wt. of total cationic surfactant(s), 0 to about 10 % by wt. of total cationic polymer(s), 0 to about 10 % by wt. of total hydrophobic structurant(s), 0 to about 10 % by wt. of hydrophilic structurant(s), 0 to about 15 % by wt. of total solvent(s), 0 to about 7 % by wt. of total hydrophobic emollient(s) and 0 to about 15 % by wt. of total humectant(s). Advantageously the third embodiment bar has a fracture energy (Gc) greater than about 25 J/m2. Preferably the minimum fracture energy has a lower limit of about 100, 150 or 200 and the maximum fracture energy has an upper limit of about 300 or 250. Preferably the bar has a yield stress greater than about 100 kPa. Preferably the maximum yield stress has an upper limit of about 600. Preferably at least two of the first, second or third profiles of the bar have curvilinear profiles. Preferably the first, second and third profiles are all curvilinear. In a fourth embodiment of the invention there is provided a shaped toilet bar including but not limited to: a. 0 to about 40 % by wt. of total non-soap anionic surfactant(s); (preferably the minimum concentration is about 5, 10 or 20% by wt. and the maximum concentration is about 35, 30 or 25% by wt.) b. 0 to about 60 % by wt. of fatty acid soap(s), provided that the sum of total non-soap anionic surfactants and fatty acid soaps is not 0; (preferably the minimum concentration is about 10, 20 or 30 % by wt. and the maximum concentration is about 55, 45 or 40 % by wt.) c. about 10 % to 50 % by wt. of total mono and polyhydric alcohols (preferably the minimum concentration is about 15 or 20 % by wt. and the maximum concentration is about 30 or 25 % by wt.) (preferably at least one alcohol is selected from the following compounds: glycerol, sorbitol, triethanolamine, or an alkylene glycol); d. wherein the composition has a fracture initiation energy (Gic) greater than 2 J/m2. (Preferably the minimum fracture initiation energy has a lower limit of about 8, 12 or 16 and the maximum fracture initiation energy has an upper limit of about 24 or 20) J/m2; e. wherein the bar has a length extending along an x axis, a width extending along a y axis, and a thickness extending along a z axis, and the x, y and z axis are orthogonal to each other; and f. wherein the bar has an exterior surface, wherein the exterior surface includes: i. a top surface, a bottom surface and a middle portion extending from the top to the bottom surface, (preferably wherein the each of the top surface, the middle portion and the bottom surface has the same composition); ii. wherein the top surface has a first profile extending along the x axis, the bottom surface has a second profile extending along the y axis, and the middle portion has a third profile normal to the z axis; iii. each of said first, second and third profiles independently being either linear, curvilinear or having both linear and curvifinear elements; iv. wherein at least two of the first, second and third profiles are different (preferably the first, second and third profiles are all different); and v. wherein the maximum value of the standard deviations of a Directional Variation Array of surface striations of each of the top surface, bottom surface and middle portion of the bar is each greater than 0.64 calculated via the DVA surface imaging method. Optionally the fourth embodiment of the bar composition may contain 0 to about 30 % by wt. of total amphoteric surfactant(s), 0 to about 20 % by wt. of total nonionic surfactant(s), 0 to about 10 % by wt. of total cationic surfactant(s), 0 to about 10 % by wt. of total cationic polymer(s), 0 to about 20 % by wt. of total hydrophobic structurant(s), 0 to about 30 % by wt. of hydrophilic structurant(s), about 10 to 50 % by wt. of total solvent(s), 0 to about 20 % by wt. of total hydrophobic emollient(s) and 0 to about 25 % by wt. of total humectant(s). Preferably the fourth embodiment toilet bar has a fracture energy (Gc) greater than about 25 J/m2. Preferably the minimum fracture energy has a lower limit of about 100,150 or 200 and the maximum fracture energy has an upper limit of about 300 or 250. Advantageously the bar has a yield stress greater than about 100 kPa. Preferably the minimum yield stress has a lower limit of about 200, 250 or 300 and the maximum yield stress has an upper limit of about 600, 450 or 400. Preferably at least two of the first, second or third profiles of the bar have curvilinear profiles. Preferably the first, second and third profiles are all curvilinear. Surfactants Surfactants, also known as detergents, are an essentia! component of the inventive toilet bar composition. They are compounds that have hydrophobic and hydrophilic portions that act to reduce the surface tension of the aqueous solutions they are dissolved in, Useful surfactants include soap(s), and non-soap anionic, nonionic, amphoteric, and cationic surfactant(s), and blends thereof. Anionic Surfactants The inventive toilet bar composition optionally contains one or more non-soap anionic detergent(s) (syndets) as discussed above. The anionic detergent active which may be used may be aliphatic sulfonate(s), such as a primary alkane (e.g., C8-C22) sulfonate(s), primary aJkane (e.g., C8-C22) disulfonate(s), C8-C22 alkene sulfonate(s), C8-C22 hydroxyalkane sulfonate(s) or alkyl glyceryl ether sulfonate(s) (AGS); or aromatic sulfonate(s) such as alkyl benzene sulfonate. The anionic may also be alkyl sulfate(s) (e.g., C12-C18 alkyl sulfate) or alkyl ether sulfate (including alkyl glyceryl ether sulfates). Among the alkyl ether sulfate(s) are those having the formula: RO(CH2CH20)nSO3M wherein R is an alkyl or alkenyl having 8 to 18 carbons, preferably 12 to 18 carbons, n has an average value of greater than 1.0, preferably greater than 3; and M is a solubilizing cation such as sodium, potassium, ammonium or substituted ammonium. Ammonium and sodium lauryl ether sulfates are preferred. The anionic may also be alkyl sulfosuccinate(s) (including mono- and dialkyl, e.g., C6-C22 sulfosuccf'nate(s)); alkyl and acyl taurate(s), alkyl and acyl sarcosinate(s), sulfoacetate(s), C8-C22 alkyl phosphate(s) and phosphate(s), alkyl phosphate ester(s) and alkoxyl alkyl phosphate ester(s), acyl lactate(s), C8-C22 monoalkyl succinate(s) and maleate(s), sulphoacetate(s), and alkyl glucoside(s) and the like, Sulfosuccinates may be monoalkyi sulfosuccinates having the formula: R4O2CCH2CH 6, and has a magnitude of approx. 2 for the formulations tested. Kic indicates the magnitude of the stresses around a crack tip. The higher the value of Kic, the greater the stresses. Units: Pa. Kic values are reported as kPa for convenience. Fracture initiation energy: where v is Poisson's ratio. Poisson's ratio is assumed to be 0.5, meaning that there is no change in the total billet volume during the fracture process. The fracture initiation energy is the energy required to initiate cracking. Units: J/m2 Plastic zone radius: The pfastic zone radius is a measurement of the size of the plastic region around the crack tip resulting from Kic. Materials with higher r values are more ductile (plastic) than those with lower r values. Units: m. Plastic zone radius values are reported as mm for convenience. Measurement of Gc by wire cutting: A simplified analysis of wire cutting yields the following equation: Where F is force exerted on wire as it cuts through the sample B is length of cut µ is coefficient of friction σy is yield stress d is wire diameter Therefore a plot of normalized cutting force vs. wire diameter should be a straight line having a slope of (1+µ)σy and an intercept of Gc. See: Kamyab I., Chakrabarti S., Williams J.G.; Cutting Cheese With Wire; J. Materials Sci.; 33, 2763-2770 (1998) incorporated herein by reference in its entirety. The fixture used for the wire test is illustrated in Figure 9A. The yoke assembly for securing and tensioning the wire fits into the crosshead of the Instron 5567 test machine. Stainless steel wires of various diameters were obtained from Malin Company (location Brook Park, OH). Wire diameters below about 0.03 cm were found to be impractical for use on soap billets/bars because of the tendency of the thin wire to break during the test. The upper limit of wire diameter is dependent on the particular test rig design used. The wire test was carried out by first equilibrating billets overnight at the desired test temperature in an oven, in the same way as was done for the 3-point bending test. Billets were then taken out one at a time and attached to the base of the test rig. The wire was positioned just above the billet; then the Instron crosshead was set in motion at 10 mm/min, with data logging to a computer. The Instron was stopped when the "plateau" region in the force vs. displacement curve was reached, which was usually when the wire had penetrated halfway through the billet. Five replicate tests were run on each billet. Three wire diameters were used: 0.020" (0.508 mm), 0.032" (0.813 mm), and 0.051" (1.295 mm)" Tests were run on three wire diameters for each of four temperatures (23.5, 30, 40, and 50°C) for a total of 60 individual tests. The width of the billet was checked at the midpoint of the depth for each test to get the F/B value (see above equation). The data were normalized to set the point of first contact between wire and billet at 0 force and 0 displacement. The normalized data were then pfotted to locate the "plateau value" of the cutting force. Surface analysis: A method was developed for quantitatively analyzing the surface topography of inventive and comparative skin cleansing bars, using both instrumental and image processing protocols described below. The instrument used comprises a stripe projector, micro-mirrors, and digital camera. Three dimensional scans of the bar to be tested are obtained by placement of the bar or bar segment on a stage. Visible stripe patterns are rapidly projected on the surface (<1 sec). Surface coordinates in all three dimensions are computed from the distortion of the stripe patterns and inputted to a computer for further analysis. A MATLAB algorithm (MathWorks, Natick, MA) was used to convert the surface patterns into feature vectors that were then inputted into a classifier routine. Images of each bar were obtained from three different areas, each 13 mm by 18 mm. The images were loaded into a database. An ~11 mm square was placed over each image, and the area outside the square was cropped away to remove artefacts and noise that occurs at the edges. A 5th order polynomial filter was applied to remove the waviness of the image. All image processing was done using MATLAB software. The texture of the images was enhanced by convoluting images with a Prewitt filter fit = [11 1; 0 0 0;-1 -1 -1]. The filtered images were used for calculating the directional variation array (DVA). The DVA in turn forms the input for a feature vector. The three feature vectors for the three areas scanned in each bar make up the feature matrix. The procedure is as follows: 1. Pre-processing 1.1. Input: Micrographic images (1024x768 pixels) as shown in Fig 6(a) were processed as described in section 1.3 below to yield an output image as shown in Fig. 6(b), an image of size 565x764 pixels with the horizontal texture enhanced. 1.2. Output: an image with size 565x764 pixels with the horizontal texture enhanced 1.3. Procedure 1.3.1. Cut the rectangular area of 567x766 pixels from the input image 1.3.2. Use Prewitt filter flt = [1 1 1; 0 0 0; -1 -1 -1] 1.3.3. Convolve the result of 1.3.1 with the filter in 1.3.2, take the valid range of the result with size 565x764 pixels as the output of pre-processing. Use the Matlab function conv2, the Matlab command to perform this function is outimg=conv2(inimg,f!t, 'valid'); where fit is the filter defined as above, and inimg and outimg are the input and output images, respectively. 2. Compute a Directional Variation Array (DVA) 2.1 Input: output from step 1.3.3. 2.2 Output; a DVA vector with length of 21 2.3 Procedure 2.3.1 Do the following steps 2.3.2 to 2.3.6 with ang ~ -10° to 10° 2.3.2. Rotate the pre-processed image to the angle ang, output is an image of varied size holding the rotated image with four triangle blank areas in its corners. 2.3.3 Calculate the mean along each of the line, parallel to the long axis, to get a mean array. Note: Do not take the blank area (caused by the rotation) into the mean computation. 2.3.4 Cut off the two ends and leave the center part (of length 561 pixels) of the mean array 2.3.5 Compute the SD (standard deviation) of the mean array 2.3.6 Take the output value of 2.3.5 as the N-th element in the DVA, where N=ang+11 Steps to compute one element in the DVA array from a rotated image are shown in Fig. 7 3. Compute feature vector based on the DVA 3.1 Input: output from step 2.3. 3.2 Output: a feature vector with length of 6 3.3 Procedure 3.3.1 Feature 1 = angO where DVA takes its maximum 3.3.2 Feature 2 = maximum of the DVA 3.3.3 Feature 3 = minimum of the DVA 3.3.4 Feature 4 = SD of the DVA 3.3.5 Feature 5 = frequency of the mean array at angle angO computed as follows ( 3.3.5.1 With angle equals angO, re-do the steps 2.3.2, 2.3.3, and 2.3.4. 3.3.5.2 Count the number of peaks in the resulting array as the frequency. The Matlab command codes to perform this function are mary(dsff(mary)~=0) = Q; peakjnum - sum(diff(diff(mary)>0)==1); where mary is the mary obtained from 3.3.5.1. 3.3.6 Feature 6 = frequency of the smoothed mean array at angle angO as follows 3.3.6.1 Same as 3.3.5.1. 3.3.6.2 Smooth the obtained mean array by (1D) convolution with filter [111]. The Matlab command codes to perform this function are Smoothed_mary=conv(mary,ones(3,1)); where mary is the mary obtained from 3.3.6.1. 3.3.6.3 Same as 3.3.5.2. Steps to create a Feature Vector, FV=(F1, F2, F3, F4, F5, F6), from one DVA are shown in Fig. 8 4. Classification 1.4. Input: a feature matrix FM, and associated truth value array t 1.4.1. For each sample image of the soap bars, get the output from step 3.3, a row vector of length 6 1.4.2. The collection of all such feature vectors form a vector matrix, with size Nx6, where N is the number of the samples. This is the input feature matrix FM. 1.4.3. t is a list (must be with length N) of 0 and 1 's telling whether a sample belongs to class 0 or class 1 4.2 Output: A classifier—a rule to discriminate different sample toilet bar images 4.3 Procedure 4.3.1 Create a classification tree T for predicting response t as a function of the feature matrix FM. The Matlab function treefit, the Matlab command code to perform this function is: T=treefit(FM, t, 'method', 'classification', 'splitmin' ,3); where FM and t are defined as above, and T is the output tree. 4.3.2. Analyze the tree, and decide the classifier. 4.3.2.1. View the tree with the help of the Matlab tools, the Matlab command codes to perform this function are FNAMES={'peak_angle', "sgm', 'max', 'min', 'freq 1', 'freq2'}; treedisp(t, 'names',FNAMES); 4.3.2.2. Examine the tree from the graphic display, each branch in the tree is labelled with its decision rule, and each terminal node is labelled with the predicted value for that node. A computer pointing device click on any node reveals more information about that node. 4.3.2.3. Ignore the lower levels of the tree if it has more than 3 levels, with the pop-up menu 'click to display' set to be 'class membership', right click the left and right nodes of the second level, to find out how much error would be caused if only the first level decision rule is used. 4.3.2.4. If the error rate is satisfied, output the rule, in the form of feature_name [> or <] critical value 5. Classifier 5.1. To determine if a soap sample was prepared by cutting or a non-cutting process such as casting or stamping the following procedure is used: 5.2. Do steps 1, 2, and 5.3. Do 3.3.4 (generally, do the step 3.3.x to compute the feature_name, as found in 4.3.2.3), and obtain a single value. If the resultant value is larger than 0.6493(generally, critical value), the sample will be classified as class 0 (inventive cut bar), otherwise it will befong to the comparative non-cut bar class. The foregoing description and examples illustrate selected embodiments of the present invention. In light thereof variations and modifications will be suggested to one skilled in the art, all of which are within the scope and spirit of this invention. CLAIMS 1. A shaped toilet bar comprising: a a composition selected from the group consisting of: i. 10% to 60% by wt. of total non-soap anionic surfactant(s) and 0% to 30% by wt. of fatty acid soap(s); ii. 5% to 40% by wt. of total non-soap anionic surfactant(s) and 30% to 80% by wt. of fatty acid soap(s); iii. 0% to 10% by wt. of total non-soap anionic surfactants) and 40% to 90% by wt. of fatty acid soap(s); and iv. 0% to 40% by wt. of total non-soap anionic surfactant(s), 0% to 60% by wt. of fatty acid soap(s) and 10% to 50% by wt. of total mono and polyhydric alcohols, provided that the sum of non-soap anionic surfactants and fatty acid soaps is not 0; b. wherein the bar has a fracture initiation energy (Gic) greater than 2 J/m2.; c. wherein the bar has a length extending along an x axis, a width extending along a y axis, and a thickness extending along a z axis, and the x, y and z axis are orthogonal to each other; and d. wherein the bar has an exterior surface, wherein the exterior surface includes: i. a top surface, a bottom surface and a middle portion extending from the top to the bottom surface; ii. wherein the top surface has a first profile extending along the x axis, the bottom surface has a second profile extending along the y axis, and the middle portion has a third profile normal to the z axis; iii. each of said first, second and third profiles independently being either linear, curvilinear or having both linear and curvilinear elements; iv. wherein at least two of the first, second and third profiles are different; and v. wherein the maximum value of the standard deviations of a Directional Variation Array of surface striations of each of the top surface, bottom surface and middle portion of the bar is each greater than 0.64 calculated via the DVA surface imaging method. 2. A toilet bar according to claim 1 wherein the bar has a fracture energy (Gc) greater than 25 J/m2. 3. A toilet bar according to claim 1 or claim 2 wherein the bar has a yield stress greater than 100 kPa. 4. The toilet bar according to any one of the preceding claims, wherein at least two of the first, second or third profiles have curvilinear profiles. 5. The toilet bar according to claim 4, wherein the at least two curvilinear profiles are different.

Documents

Orders

Section Controller Decision Date

Application Documents

# Name Date
1 441-MUMNP-2011-ANNEXURE TO FORM 3(20-6-2011).pdf 2018-08-10
1 441-MUMNP-2011-FORM 3(12-08-2011).pdf 2011-08-12
2 441-mumnp-2011-claims.pdf 2018-08-10
2 441-MUMNP-2011-FORM 3(10-12-2013).pdf 2013-12-10
3 441-MUMNP-2011-FORM 3(10-11-2014).pdf 2014-11-10
3 441-MUMNP-2011-CORRESPONDENCE(15-4-2011).pdf 2018-08-10
4 441-MUMNP-2011-FORM-3-(25-04-2015).pdf 2015-04-25
4 441-MUMNP-2011-CORRESPONDENCE(19-6-2012).pdf 2018-08-10
5 Examination Report Reply Recieved [13-08-2016(online)].pdf 2016-08-13
5 441-MUMNP-2011-CORRESPONDENCE(20-6-2011).pdf 2018-08-10
6 Description(Complete) [13-08-2016(online)].pdf 2016-08-13
6 441-MUMNP-2011-Correspondence-131015.pdf 2018-08-10
7 Claims [13-08-2016(online)].pdf 2016-08-13
7 441-mumnp-2011-correspondence.pdf 2018-08-10
8 Other Patent Document [14-12-2016(online)].pdf 2016-12-14
8 441-mumnp-2011-description(complete).pdf 2018-08-10
9 441-mumnp-2011-drawing.pdf 2018-08-10
9 Form 26 [14-12-2016(online)].pdf 2016-12-14
10 441-mumnp-2011-form 1.pdf 2018-08-10
10 441-MUMNP-2011_EXAMREPORT.pdf 2018-08-10
11 441-MUMNP-2011-FORM 13(13-2-2012).pdf 2018-08-10
11 441-mumnp-2011-wo international publication report a3.pdf 2018-08-10
12 441-MUMNP-2011-FORM 18(19-6-2012).pdf 2018-08-10
12 441-mumnp-2011-wo international publication report a2.pdf 2018-08-10
13 441-mumnp-2011-form 2(title page).pdf 2018-08-10
13 441-MUMNP-2011-US DOCUMENT(20-6-2011).pdf 2018-08-10
14 441-mumnp-2011-form 2.pdf 2018-08-10
14 441-MUMNP-2011-OTHERS-131015.pdf 2018-08-10
15 441-MUMNP-2011-FORM 3(15-2-2012).pdf 2018-08-10
15 441-mumnp-2011-other documents.pdf 2018-08-10
16 441-MUMNP-2011-FORM 3(21-5-2014).pdf 2018-08-10
16 441-MUMNP-2011-GENERAL POWER OF ATTORNEY(15-4-2011).pdf 2018-08-10
17 441-mumnp-2011-form pct-isa-210.pdf 2018-08-10
17 441-MUMNP-2011-FORM 3(22-6-2013).pdf 2018-08-10
18 441-MUMNP-2011-FORM 3(23-1-2013).pdf 2018-08-10
18 441-mumnp-2011-form pct-ipea-416.pdf 2018-08-10
19 441-MUMNP-2011-Form 3-081015.pdf 2018-08-10
19 441-mumnp-2011-form pct-ipea-409.pdf 2018-08-10
20 441-MUMNP-2011-Form 3-120816.pdf 2018-08-10
20 441-mumnp-2011-form 5.pdf 2018-08-10
21 441-MUMNP-2011-Form 3-190316.pdf 2018-08-10
21 441-mumnp-2011-form 3.pdf 2018-08-10
22 441-MUMNP-2011-Form 3-190316.pdf 2018-08-10
22 441-mumnp-2011-form 3.pdf 2018-08-10
23 441-MUMNP-2011-Form 3-120816.pdf 2018-08-10
23 441-mumnp-2011-form 5.pdf 2018-08-10
24 441-mumnp-2011-form pct-ipea-409.pdf 2018-08-10
24 441-MUMNP-2011-Form 3-081015.pdf 2018-08-10
25 441-MUMNP-2011-FORM 3(23-1-2013).pdf 2018-08-10
25 441-mumnp-2011-form pct-ipea-416.pdf 2018-08-10
26 441-MUMNP-2011-FORM 3(22-6-2013).pdf 2018-08-10
26 441-mumnp-2011-form pct-isa-210.pdf 2018-08-10
27 441-MUMNP-2011-FORM 3(21-5-2014).pdf 2018-08-10
27 441-MUMNP-2011-GENERAL POWER OF ATTORNEY(15-4-2011).pdf 2018-08-10
28 441-MUMNP-2011-FORM 3(15-2-2012).pdf 2018-08-10
28 441-mumnp-2011-other documents.pdf 2018-08-10
29 441-mumnp-2011-form 2.pdf 2018-08-10
29 441-MUMNP-2011-OTHERS-131015.pdf 2018-08-10
30 441-mumnp-2011-form 2(title page).pdf 2018-08-10
30 441-MUMNP-2011-US DOCUMENT(20-6-2011).pdf 2018-08-10
31 441-MUMNP-2011-FORM 18(19-6-2012).pdf 2018-08-10
31 441-mumnp-2011-wo international publication report a2.pdf 2018-08-10
32 441-MUMNP-2011-FORM 13(13-2-2012).pdf 2018-08-10
32 441-mumnp-2011-wo international publication report a3.pdf 2018-08-10
33 441-mumnp-2011-form 1.pdf 2018-08-10
33 441-MUMNP-2011_EXAMREPORT.pdf 2018-08-10
34 441-mumnp-2011-drawing.pdf 2018-08-10
34 Form 26 [14-12-2016(online)].pdf 2016-12-14
35 441-mumnp-2011-description(complete).pdf 2018-08-10
35 Other Patent Document [14-12-2016(online)].pdf 2016-12-14
36 Claims [13-08-2016(online)].pdf 2016-08-13
36 441-mumnp-2011-correspondence.pdf 2018-08-10
37 Description(Complete) [13-08-2016(online)].pdf 2016-08-13
37 441-MUMNP-2011-Correspondence-131015.pdf 2018-08-10
38 Examination Report Reply Recieved [13-08-2016(online)].pdf 2016-08-13
38 441-MUMNP-2011-CORRESPONDENCE(20-6-2011).pdf 2018-08-10
39 441-MUMNP-2011-FORM-3-(25-04-2015).pdf 2015-04-25
39 441-MUMNP-2011-CORRESPONDENCE(19-6-2012).pdf 2018-08-10
40 441-MUMNP-2011-FORM 3(10-11-2014).pdf 2014-11-10
40 441-MUMNP-2011-CORRESPONDENCE(15-4-2011).pdf 2018-08-10
41 441-MUMNP-2011-FORM 3(10-12-2013).pdf 2013-12-10
41 441-mumnp-2011-claims.pdf 2018-08-10
42 441-MUMNP-2011-ANNEXURE TO FORM 3(20-6-2011).pdf 2018-08-10
42 441-MUMNP-2011-FORM 3(12-08-2011).pdf 2011-08-12