Solidification matrix using a polycarboxylic acid polymer

1. A solidification matrix consisting essentially of:

(a) a polycarboxylic acid polymer selected from the group consisting of: a polyacrylic acid polymer having a molecular weight of between about 1,000 and about 100,000, a modified polyacrylic acid polymer having a molecular weight of between about 1,000 and about 100,000, and a polymaleic acid polymer having a molecular weight of between about 500 and about 5,000;

(b) sodium carbonate; and

(c) water;

(d) wherein the solidification matrix is a hydrate solid;

(e) wherein if heated at a temperature of 120 degrees Fahrenheit, the solidification matrix is dimensionally stable and has a growth exponent of less than 2%; and

(f) wherein the solidification matrix is phosphorus-free.

2. The solidification matrix of claim 1 , wherein the polycarboxylic acid polymer constitutes between about 1% and about 15% by weight of the solidification matrix.

3. The solidification matrix of claim 1 , wherein the sodium carbonate constitutes between about 20% and about 70% by weight of the solidification matrix.

4. The solidification matrix of claim 1 , wherein the water constitutes between about 2% and about 50% by weight of the solidification matrix.

5. A solid detergent composition comprising:

(a) between about 1% and about 15% polycarboxylic acid polymer by weight of the solid detergent composition, wherein the polycarboxylic acid polymer is selected from the group consisting of: a polyacrylic acid having a molecular weight of between about 1,000 and about 100,000, a modified polyacrylic acid having a molecular weight of between about 1,000 and about 100,000, and a polymaleic acid having a molecular weight of between about 500 and about 5,000;

(b) between about 2% and about 50% water by weight of the solid detergent composition;

(c) less than about 40% builder by weight of the solid detergent composition;

(d) between about 20% and about 70% sodium carbonate by weight of the solid detergent composition;

(e) between about 0.5% and about 8% surfactant by weight of the solid detergent composition; and

(f) less than about 0.5% phosphorus containing compounds by weight of the solid detergent composition;

(g) wherein if heated at a temperature of 120 degrees Fahrenheit, the solid detergent composition is dimensionally stable and has a growth exponent of less than 2%.

6. The solid detergent composition of claim 5 , wherein the polycarboxylic acid polymer constitutes between about 5% and about 10% by weight of the solid detergent composition.

7. The solid detergent composition of claim 5 , wherein the water constitutes between about 2% and about 35% by weight of the solid detergent composition.

8. The solid detergent composition of claim 5 , wherein the builder constitutes less than about 25% by weight of the solid detergent composition.

9. The solid detergent composition of claim 5 , wherein the sodium carbonate constitutes between about 45% and about 65% by weight of the solid detergent composition.

10. The solid detergent composition of claim 5 , wherein the surfactant constitutes between about 1% and about 5% by weight of the solid detergent composition.

11. A composition consisting essentially of:

(a) a solidification matrix comprising sodium carbonate, water, and a polycarboxylic acid polymer, wherein the polycarboxylic acid polymer is selected from the group consisting of: a polyacrylic acid, a modified polyacrylic acid, and a polymaleic acid; and

(b) at least one functional ingredient;

(c) wherein if heated at a temperature of 120 degrees Fahrenheit, the composition has a growth exponent of less than 2% and is dimensionally stable; and

(d) wherein the solidification matrix is phosphorus-free.

12. The composition of claim 11 , wherein the functional ingredient is selected from the group consisting of: chelating agents, sequestering agents, inorganic detergents, organic detergents, alkaline sources, surfactants, rinse aids, bleaching agents, sanitizers, activators, detergent builders, fillers, defoaming agents, anti-redeposition agents, optical brighteners, dyes, odorants, enzymes, corrosion inhibitors, dispersants, and solubility modifiers.

13. The composition of claim 11 , wherein the polycarboxylic acid polymer constitutes between about 1% and about 15% by weight of the solidification matrix.

14. The composition of claim 11 , wherein the sodium carbonate constitutes between about 20% and about 70% by weight of the solidification matrix.

15. The composition of claim 11 , wherein the polycarboxylic acid polymer is selected from the group consisting of: a polyacrylic acid polymer having a molecular weight of between about 1,000 and about 100,000, a modified polyacrylic acid polymer having a molecular weight of between about 1,000 and about 100,000, and a polymaleic acid polymer having a molecular weight of between about 500 and about 5,000.

16. A method of solidifying a composition, the method comprising:

(a) mixing a solidification matrix consisting essentially of sodium carbonate, water, and polycarboxylic acid polymer, wherein the polycarboxylic acid polymer is selected from the group consisting of: a polyacrylic acid polymer having a molecular weight of between about 1,000 and about 100,000, a modified polyacrylic acid polymer having a molecular weight of between about 1,000 and about 100,000, and a polymaleic acid polymer having a molecular weight of between about 500 and about 5,000; and

(b) adding the solidification matrix to the composition to form a solidified material;

(c) wherein the solidification matrix is phosphorus-free; and

(d) wherein if subjected to a temperature of 120 degrees Fahrenheit, the composition is dimensionally stable and has a growth exponent of less than 2%.

17. The method of claim 16 , and further comprising casting the material into a packaging container.

18. The method of claim 16 , and further comprising forming the material into a paste.

19. The method of claim 16 , and further comprising forming the material into a block.

20. A method of solidifying a composition, the method comprising:

(a) adding a solidification matrix to the composition, the solidification matrix consisting essentially of sodium carbonate, water, and polycarboxylic acid polymer, wherein the polycarboxylic acid polymer is selected from the group consisting of: a polyacrylic acid polymer having a molecular weight of between about 1,000 and about 100,000, a modified polyacrylic acid polymer having a molecular weight of between about 1,000 and about 100,000, and a polymaleic acid polymer having a molecular weight of between about 500 and about 5,000, and wherein the composition is phosphorus-free; and

(b) solidifying the composition for between about 1 minute and about 3 hours to form a solid composition that, if subjected to a temperature of 120 degrees Fahrenheit, is dimensionally stable and has a growth exponent of less than 2%.

21. The method of claim 20 , wherein the composition solidifies in between about 1 minute and about 2 hours.

22. The method of claim 21 , wherein the composition solidifies in between about 1 minute and about 20 minutes.