JP2003511485A - Manufacturing method for foam components - Google Patents

Abstract

  (57) [Summary] The present invention relates to a method for producing a foam component, comprising the step of extruding a viscous mixture from a rotary extrusion plate onto a surface. The method provides a convenient, efficient, and simple means for producing foam components, particularly those used in cleaning compositions. The invention also provides a foam component obtained from the method.

Description

Detailed Description of the Invention

[0001]

【Technical field】

The present invention relates to a method for producing a foam component and a foam component obtained by the method, which method is particularly applicable to the production of foam components useful in cleaning compositions, such as laundry cleaning compositions.

[0002]

[Background technology]

Compositions such as cleaning and personal care products, cosmetics and pharmaceuticals often comprise active ingredients that are required to be supplied in water or active in an aqueous environment. Many of these active ingredients are sensitive to moisture, temperature changes, light and / or air during storage.

Another problem associated with many of these active ingredients, particularly enzymes, is that they tend to form dust due to the physical forces exerted on them during handling.
This not only wastes material, but dust can cause hygiene and health problems.

Attempts to solve these problems have developed methods of protecting these active ingredients with coatings or encapsulants. Typically, these active ingredients are prepared by spraying the coating material onto core particles which comprise the active ingredient to be protected. This process is extremely expensive, time consuming and technically difficult to carry out.

We now provide a method of making a foam component that is impact resistant to the physical forces typically applied during handling and that does not form dust. Since the process of the present invention produces foam components in a single step, it does not require many processing steps, such as spheronisation.

The process provides a quick, simple, convenient and cost-effective means for providing foam components, especially spherical foam components.

The foam components obtained by the process of the present invention are impact resistant to the physical forces typically applied during handling and do not form dust.

[0008]

DISCLOSURE OF THE INVENTION

The present invention extrudes a viscous mixture through an opening in a rotary extrusion plate and onto a surface,
A method of making a foam component comprising the steps of introducing a gas into the viscous mixture before, simultaneously with, or after extruding the viscous mixture through the opening.

Preferably, the shortest distance between the extruded plate and the receiving surface is 50 μm to 3000 μm.
And preferably the size of the opening is 50 μm to 3000 μm.

[0010]   The invention also provides the foam component resulting from this process.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION

Method for Producing Foam Component The production method of the present invention (herein referred to as “production method”) is a simple, quick, effective, and easy method for producing a foam component, particularly a foam component used for a cleaning composition. Providing cost effective means. The foam component will be described in more detail below.

The present method receives the viscous mixture through the opening of the rotary extrusion plate and extrudes it onto the surface,
Introducing a gas into the viscous mixture prior to, simultaneously with, or after extruding the viscous mixture through the opening.

Preferably, the shortest distance between the extruded plate and the receiving surface is 50 μm to 3000 μm.
And preferably the size of the opening is 50 μm to 3000 μm.

The present production method, particularly the step of extruding the viscous mixture through the opening, has a temperature of −20 ° C.
100 ° C, preferably -10 ° C or higher, or 0 ° C or higher, or 10 ° C or higher, preferably 90 ° C or lower, or 80 ° C or lower, or 70 ° C or lower, or 60 ° C or lower,
Alternatively, it is performed at a temperature of 50 ° C. or lower, or 40 ° C. or lower. If the foam component comprises a component, such as a temperature-sensitive active component, it is preferred to carry out the process at a temperature that is compatible with the temperature-sensitive component. For foam components containing enzymes, this temperature is typically 0 ° C to 50 ° C, preferably 10 ° C to 30 ° C.

Viscous Mixtures Viscous mixtures (referred to herein as "mixtures") typically have viscosities of 1 mPas and above.
It is 200,000 mPas. The mixture is preferably a fluid or liquid. The viscosity of the mixture depends on the chemical and physical properties of the ingredients in the mixture, which depends on the ingredients required for the foam component. However, if the viscosity is too low, the mixture will flow through the openings too quickly onto the receiving surface and will not form extruded particles. On the contrary, if the viscosity of the mixture is too high, the mixture cannot pass through the openings or
Alternatively, additional cutting and optionally spheronization steps are required before forming extruded noodles, rather than extruded particles, to produce a usable foam component.

Typically the viscosity of the mixture is 2 mPas or higher, or 5 mPas or higher, or 7 mPas or higher, or 10 mPas or higher, or 12 mPas or higher, or 1.
5 mPas or more, or 17 mPas or more, or 20 mPas or more, or 2
2 mPas or more, or 25 mPas or more, or 50 mPas or more, or 1
00 mPas or more, or 150 mPas or more, or 200 mPas or more,
Typically 150,000 mPas or less, or 100,000 mPas or less, or 50,000 mPas or less, or 25,000 mPas or less, or 12000
mPas or less, or 10,000 mPas or less, or 8000 mPas or less,
Alternatively, it is 5000 mPas or less.

The mixture typically comprises all or most of the components present in the foam component. Typically, the mixture comprises polymeric material, a plasticizer and an active ingredient, preferably also stabilizers, solubilizers. The polymeric material, plasticizer, active ingredient, stabilizer, solubilizer will be described in more detail below.

The water content of the mixture influences the physical and chemical properties of the mixture. Typically, the water content of the mixture is 0.1% to 80% by weight, preferably 60% to 80%.
% By weight. If the mixture comprises active ingredients that are particularly sensitive to water, for example components that decompose in the presence of water, the water content of the mixture is as low as possible, less than 5% by weight,
Alternatively, it is preferably less than 3% by weight, or less than 1% by weight, or less than 0.1% by weight, and more preferably water-free. The term "water" means a water molecule that is typically not bound to other compounds, for example the term "water" typically includes the water content of hydrated molecules such as aluminosilicates. However, it does include water added to the mixture, such as processing aids.

Alternatively, it may be preferred that the mixture comprises water. For example, if the mixture comprises polymeric material, water is preferably also present in the mixture and acts as a plasticizer when forming the foam component from the polymeric material. When water is present in the mixture, it is preferably at least 3% by weight, or at least 5% by weight, or at least 10% by weight, or at least 20% by weight, or even at least 40% by weight.

The presence of solid material in the mixture affects the extrusion process and subsequent extruded particle structure. Extrusion of the liquid is generally more difficult when undissolved solid material is present in the mixture. Moreover, extruded particles formed by extruding a mixture comprising undissolved solid material typically require additional processing steps, such as spheronization. Therefore, the undissolved solid material contained in the mixture is preferably 3
Less than 0% by weight, preferably less than 15% by weight, preferably less than 12% by weight, preferably less than 10% by weight, preferably less than 7% by weight, preferably less than 5% by weight, preferably less than 3% by weight. It is less than wt%, preferably less than 0.1 wt%. Most preferably, the mixture is free of undissolved solid material. Typically, the amount of undissolved solid material referred to above refers to the amount of solid material in the process of receiving the mixture through an opening in a rotary extrusion plate and extruding it onto a surface. During processing of the present invention other than the extrusion step, it may be preferred that the mixture comprises a solid material.

When undissolved solid material is present during the extrusion process, the solid material has a particle size of 50 μm.
It is preferably in the form of undissolved particles that are smaller than the size of the openings of m to 3000 μm, or other preferred sizes of the openings described in more detail below, and that can pass through the openings.

Rotary Extrusion Plate The rotary extrusion plate is preferably 1 rpm to 1000 rpm, preferably 2 rpm or more, or 3 rpm or more, or 4 rpm or more, or 5 rpm or more, or 6
rpm or more, or 7 rpm or more, or 8 rpm or more, or 9 rpm or more,
Or 10 rpm or higher, preferably 900 rpm or lower, 800 rpm or lower, 700 rpm or lower, or 600 rpm or lower, or 500 rpm or lower, or 400 rpm or lower, or 300 rpm or lower, or 200 rpm or lower, or 100 rpm or lower, or 50 rpm or lower. The rotary extrusion plate can rotate clockwise or counterclockwise.

[0023]   Rotary extrusion plates typically have a tip speed of 0.1 ms^-1~ 1600 ms^-1,
Or typically 10 ms^-1Or more, or 50 ms^-1Or more, or 100 ms ^-1 Or more, or 150 ms^-1Or more, or 200 ms^-1That's it, typical
900 ms^-1Below, or 800ms^-1Below, or 700ms^-1 Below, or 600ms^-1Below, or 500ms^-1Below or 400m
s^-1It is the following. For purposes of the present invention, the tip speed of a rotary extrusion plate is typically
It is defined as the angular velocity of the outer surface or edge of the rotary extrusion plate.

The direction of rotation, or typically the angular direction of rotation, of the rotary extrusion plate is perpendicular to the direction of flow of the viscous liquid through the openings of the rotary extrusion plate.

The rotary extrusion plate typically surrounds a volume that can hold a liquid prior to the extrusion process,
Or a housing that at least partially surrounds. The housing rotates clockwise or counterclockwise around the volume. The housing may be a single layer housing or may be a housing of two or more layers, eg outer phase and inner layer. For the purposes of the present invention, if the rotary extrusion plate is in the form of a housing for a volume and the housing comprises more than one layer, only one layer needs to rotate, but two It is preferred that the above layers rotate, or that all layers of the housing rotate. If the housing consists of an outer layer and an inner layer, the outer layer is preferably rotated, but the inner layer can also be rotated, or both the inner and outer layers can be rotated.

[0026] Preferably, the rotary extrusion plate has a cylindrical shape, an oblong shape, or a cubic shape. The rotary extrusion plate may be a polyhedron, for example, a tetrahedron, a pentahedron, a hexahedron, a rhombohedron, a heptahedron, an octahedron, a hexahedron, a decahedron. Most preferably the rotary extrusion plate is cylindrical, for example barrel-shaped.

The rotary extrusion plate has a thickness of 50 μm to 3000 μm, preferably 100 μm to 1000 μm.
It comprises an opening of size m. These openings are typically formed by laser cutting an extruded plate. Typically, the rotary extrusion plate comprises two or more openings, preferably multiple openings. If the rotary extrusion plate comprises more than one opening, the openings may differ in size. By changing the size of the openings and the number of openings having the same size, the size distribution of the particles to be extruded can be adjusted, and the particles having a desired particle size distribution can be extruded by the present production method.

[0028]   Typically, the density of the openings present on the rotary extrusion plate is 0.001 mm.^-2 ~ 400 mm^-2, Or 0.01 mm^-2Or more, or 0.1 mm^-2that's all,
Or 1 mm^-2Or more, or 5 mm^-2Or more, or 10 mm^-2Or more
Is 25 mm^-2Or more, or 50 mm^-2Or more, or 100 mm^-2Above,
Preferably 300 mm^-2Below, or 275 mm^-2Below or 250 mm ^-2 Below, or 225 mm^-2Below or 200 mm^-2Or less, or 17
5 mm^-2Below, or 150mm^-2It is the following. The rotary extrusion plate may be
And have openings of different densities. For example, a section of a rotary extrusion plate
Has small sized openings in high density, and different areas of the rotary extrusion plate
Large size openings can be present at low densities.

If it is preferred to produce a spherical foam component with the process according to the invention, the openings are preferably square, rectangular, rhombic, triangular, oval, circular or diamond,
It preferably has a diamond shape or a shape close thereto. When two or more openings are used in the present invention, two or more types of openings can be used.

The rotary extrusion plate is at least partially coated, preferably completely coated with a release agent. The release agent reduces the adhesion between the surface of the rotary extrusion plate and the liquid, and particularly acts to separate the liquid from the rotary extrusion plate during the extrusion process. Typical release agents are hydrophobic materials,
For example waxes, oils, greases, combinations thereof, preferably silicone oils. The rotary extrusion plate can also be coated with an agent that reduces the interaction between the rotary extrusion plate and the liquid or a portion thereof. Preferred coatings are plasma coating, abrasive finish,
Or a combination thereof. These coatings can be added to the coating comprising the release agent or combined with the release agent coating. A preferred plasma coating comprises polyethylene, polypropylene, or a combination thereof. A typical plasma coating comprises the components known under the trade name Teflon.

If the rotary extrusion plate is a housing with a liquid-holding volume, both the inner surface or the outer surface are coated or partially coated with a release agent and / or another coating, for example a plasma coating. Is preferred. Where the rotary extrusion plate is a housing comprising two or more layers, all layers or parts thereof are coated or partially coated with a release agent and / or another coating, eg plasma coating. Is preferred.

Although two or more rotary extrusion plates can be used in the production method of the present invention, it is preferable to use only one rotary extrusion plate here.

A preferred rotary extrusion plate for use herein is from Sandvik Conveyor GMBH to Rotof.
Orm, and a rotary extrusion plate known by Gausche Machinefabriek under the trade name of Disk Pastillator.

The extruded mixture of the viscous mixture is extruded from the rotating extrusion plate through the opening and onto the receiving surface. The temperature of this step is preferably as described above.

[0035] Typically, the mixture is extruded by means of an extrusion through the opening. The force required to push the mixture through the opening depends on the size of the opening, the temperature of the extrusion process,
And on the physical and chemical properties of the mixture, such as viscosity. The squeezing means may comprise pushing, scraping, aspirating the liquid through the opening. The squeezing means may be in the form of a solid object such as a rod, wedge, scraper, or a combination thereof that scrapes or squeezes the mixture through the opening. The compression means may be a pump that pumps the mixture through the opening. rod,
Combinations of pumps with one or more means selected from wedges or scrapers can also be used here.

The mixture is typically extruded through the openings in the form of drops of extrudate. The drops are pressed onto the receiving surface by the pressing means. The rotation of the extrusion plate causes the droplets to separate, leaving some of the droplets on the receiving surface to form the extruded particle size. The force required to pull the extruded drop apart must be greater than the yield strength of the drop.

Receiving Surface The receiving surface typically receives the extrudate from a rotating extrusion plate on which the extruded liquid forms extruded particles.

The receiving surface may be similar or identical in shape to a belt, drum, disc, platen, or rotary extrusion plate. Preferably, the receiving surface is a belt or disc. More preferably, the receiving surface is a conveyor belt or spinning disc.

The shortest distance between the receiving surface and the rotary extrusion plate is 50 μm to 3000 μm. For purposes of the present invention, the shortest distance means the distance measured at the closest point. Preferably, this distance is the height or cross-sectional distance of the foam component produced by this method. For example, if a spherical foam component having an average diameter of 200 μm is required, the preferred minimum distance between the rotary extrusion plate and the receiving surface is 200 μm.

The receiving surface can rotate, which rotation can be clockwise or counterclockwise.
Preferably, the receiving surface rotates counterclockwise with respect to the rotary extrusion plate. For example,
When the rotary extrusion plate rotates clockwise, the receiving surface preferably rotates counterclockwise. This prevents extruded particles and / or liquids from being smeared or damaged by the rotary extrusion plate when positioned on the receiving surface.

The receiving surface can be maintained at any temperature as desired and the receiving surface can be heated or cooled. Preferably, the receiving surface is -20 ° C to 200 ° C
Temperature, preferably -10 ° C or higher, or 0 ° C or higher, or 10 ° C or higher,
Or 20 ° C or higher, preferably 150 ° C or lower, or 100 ° C or lower, or 99
℃ or less, or 75 ℃ or less, or 60 ℃ or less, or 50 ℃ or less, or 40
C. or lower, or 30.degree. C. or lower. If desired, the receiving surface can have different temperatures depending on the area. For example, the first area of the receiving surface may be at a higher temperature than the second area.

The receiving surface is preferably coated, or at least partially coated, with a release agent or other coating, such as a plasma coating or an abrasive finish. The coating and release agent are as described above. When the receiving surface is coated with a release agent or partially coated, the adhesion between the receiving surface and the extruded particles is reduced, and the extruded particles are easily separated from the receiving surface. No, in addition to this,
The surface tension between the extruded particles and the receiving surface increases and the contact area between the extruded particles and the receiving surface decreases, so that the extruded particles become more spherical in shape.

Introducing the Gas The gas can be introduced into the liquid by any suitable means. Gas is
It is introduced into the mixture before, simultaneously with, or after it is extruded through the opening. Preferably, gas is introduced into the mixture prior to extruding the mixture through the opening.

[0044]   By introducing gas into the mixture, the mixture foams.

Typically, the gas is physically and / or chemically introduced into the mixture.
Preferred routes are: (a) gas injection (dry or aqueous route), high shear mixing (dry or aqueous route), gas dissolution and relaxation (critical or dry route) including critical gas diffusion, compressed gas, optionally with agitation. In situ gas formation, including the formation of CO ₂ by an effervescent system, for example by injection of a supercritical fluid, and / or (b) a chemical reaction of one or more components, and / or (C) Vapor injection and UV light radiation curing.

The gas preferably comprises CO ₂ , N ₂ , or a combination thereof, such as air. The gas may be a compressed gas, eg a supercritical fluid.

If the gas is introduced into the mixture before it is extruded through the openings and the gas forms bubbles in the mixture, these bubbles are smaller than the openings through which the mixture is extruded. Is preferred.

Foam Component The foam component is formed by extruding the mixture onto the surface through an opening in a rotary extrusion plate. It is typically formed on the receiving surface as foam component extruded particles.

The extruded particles may be liquid, eg as drops, or may be solid particles, eg beads or tablets. Preferably, the extruded particles are solid, typically formed from an extruded liquid, and dried on the receiving surface.

The foam component can be further processed. For example, the foam component can be received from the surface into a fluidized bed and dried. The temperature of this fluidized bed drying step is typically 40 ° C to 80 ° C, preferably 40 ° C to 60 ° C.

The foam component is preferably spherical or spheroidal. This is especially true when the receiving surface is coated or partially coated with a release agent, such as silicone oil.

The gas injected into the mixture returns to the gaseous state in the extruded particles, leaving pores or voids in the structure of the extruded particles, especially when in the compressed state, eg in a supercritical fluid. You can This is an important part of the foaming process. The mixture is preferably at elevated temperature or pressure before being extruded. At these conditions, the gas is in compressed form or is a supercritical fluid. Following the extrusion process, the extruded particles formed from the extruded mixture are at a low temperature and / or pressure, eg, normal, and the gas returns to the gaseous state, causing the extrudate to foam. This foaming step can be performed on the receiving surface.

The foam component (referred to herein as the “component”) typically comprises the active ingredient, a matrix and a solubilizing agent. The active ingredient, matrix and stabilizer are described in more detail below.

The constituents are preferably dispersible in water, disintegratable in water or water-soluble. Preferred water dispersible products herein have a dispersity of at least 50%, preferably at least 75%, and even at least 95% as measured by the method described below using a glass filter with a maximum pore size of 50 μm. And more preferably,
This product is water-soluble or water-disintegrable and has a maximum pore size of 20 as described below.
The solubility or disintegration is at least 50%, preferably at least 75%, and even at least 95, measured by the method using a glass filter which is μm.
%.

A gravimetric method for determining water solubility, disintegration in water or dispersibility in water of a component is as follows: 50 g ± 0.1 g of product is placed in a 400 ml beaker whose weight is measured, and 245 ml ± 1 ml of distilled water is used. Add. This is vigorously stirred for 30 minutes with a magnetic stirrer set at 600 rpm. The product mixture is then filtered through a folded qualitative sintered glass filter with the pore size defined above (maximum 20 or 50 μm). Water is removed by evaporation from the collected filtrate by any conventional method and the residual product fraction is weighed (this is the dissolved, disintegrated or dispersed fraction). The solubility, disintegration or% dispersity can then be calculated.

The present components are typically used to deliver the active ingredient to the aqueous environment. In that case, the component, and preferably the matrix, becomes unstable when contacted with water. This occurs so that the active ingredient or part thereof present in the component is supplied to a liquid, preferably an aqueous environment, such as water. Preferably, the component or part of it is modified, disintegrated in a liquid, preferably an aqueous environment, more preferably water,
It is preferably dispersed or dissolved. It is preferred that the active ingredient be rapidly fed to the water and that the component disperse or dissolve rapidly, preferably within 30 minutes after contact of the component with water, preferably at least 10% by weight of the product, more preferably At least 30% by weight, even at least 50% by weight, even at least 70% by weight, even at least 90% by weight are dissolved or dispersed (introduced in water at a concentration of 1% by weight). It is even more preferred that this occurs within 20 minutes, even within 10 minutes, and even within 5 minutes of the contact of the component with water. The dissolution or dispersion can be measured by the method described below for the measurement of dissolution, disintegration and dispersion of the present constituent material.

Preferably, the composition is such that when 1 cm ³ of the composition is added to 100 ml of deionized water and stirred at a temperature of 25 ° C. and a speed of 200 rpm for 5 minutes, the total volume of the composition is compared with the initial total volume. By at least 10%, preferably reduced. This total volume change, preferably reduction, is at least 20%, even at least 40%, even at least 60%, since substantially the entire constituent preferably disintegrates, disperses or preferably dissolves in water. Even at least 90%, and even about 1
It is preferably 00%.

This can be measured by any method known in the art, in particular by the following method (double dipping technique). Obtain 1 cm ³ of elastic product, 50 m
1. Place in a 100 ml micro graduated cylinder containing 0.1 ml of organic inert solvent. The polymeric material in the matrix of the elastic product (eg, this is PVA
If) is found to be unmodified and / or does not interact with the polymeric material, acetone is used, for example. Although other neutral organic media can be used, depending on the nature of the product being tested, the inert solvent is a solvent that does not substantially dissolve, disperse, disintegrate or modify the constituents with the solvent.

The cylinder is sealed and left for 1 minute so that the solvent permeates the entire constituent material. The change in volume is measured and is taken as the original volume of the foam sample, V _i . Then, the constituent material is taken out of the solvent and left in the air to evaporate the solvent and dry it.

The constituents were then maintained at 25 ° C., containing 100 ml of deionized water.
Place in a 0 ml beaker and stir at 200 rpm for 5 minutes using a magnetic stirrer. If a constituent material sample remains, it is filtered through a 60 mm mesh copper filter and placed in a heating furnace at a temperature and for a time such that residual moisture is removed. The dried residual constituents are re-introduced into a graduated cylinder with the acetone amount readjusted to 50 ml. The increase in total volume is monitored and is the final volume of the component, V _f . The total volume decrease ΔV of the constituent material sample is as follows.

[Equation 1]

The constituent material has a relative density ρ ^* of 0.01 to 0.95, more preferably 0.05 to 0.
． 9, further 0.1 to 0.8, further 0.3 to 0.7. The relative density is
It is the ratio of the density (ρ ^* ) of the constituent material to the partial density (ρ _s ) of the entire raw material used to form the constituent material.

A preferred foamed component for use herein is stable in air, ie stable on contact with air, ie the bulk volume of the component or its matrix is exposed to air. Sometimes practically unchanged. This is especially the case when the components are stored for 24 hours in an incubator in an open beaker (9 cm diameter, without protective barrier) under controlled ambient conditions (humidity = RH 60%, temperature = 25 ° C). To
75% to 125%, even 90% to 110%, and even 95% of its bulk volume
Means to maintain ~ 100%. Preferably, the component is 75% to 125%, or even 90% to 11% of its bulk volume under the above storage conditions at a humidity of 80%.
Maintain 0%, and even 95% to 100%.

The change in bulk volume can be measured by any conventional method. In particular, a digital image recorder mechanism that includes a digital camera connected to a personal computer with calibrated image analysis software is useful. A 1 cm ³ sample of the product is obtained, placed in an open beaker with a diameter of 9 cm and stored under the above conditions for 24 hours. After 24 hours, the image analysis recorder mechanism is used to measure all sizes in length, width, and height. The measurement of each sample is repeated 3 times and the average bulk volume change is calculated in%.

Preferably, when the constituent material is in the form of particles having an average particle size of 2000 μm or less, these particles also have 75% to 125%, and even 90% to 110% of their bulk volume.
%, And even 95% to 100%. This can be measured, for example, by placing 20 grams of such particles, or a weight comprising more than 500 particles in a 9 cm diameter female beaker. Tap the beaker at the bottom to align the elastic particles in a stable position and level the surface. Measure the volume. The open beaker containing the particles is then carefully placed in an incubator set to the desired% RH and temperature for 24 hours. The bulk volume is measured after 24 hours and the change in bulk volume is calculated in%.

The constituents (by weight) are preferably at least 1%, more preferably 5% to 70%.
%, More preferably at least 10% by weight of the product, more preferably 15% by weight or more, even 20% by weight or more, even 25% by weight or more, up to 50% by weight of the active ingredient.

The constituent material (by weight) is preferably 10% or more and up to 99%, more preferably at least 20% by weight, or 30% or more and up to 99% by weight, more preferably 20%.
% Or more than 30%, up to 90% to 80% matrix.

The constituent material is at least 1% (by weight), more preferably 5% or more, or 10
% Or more, or 15% or more, or 20% or more, up to 50%, or up to 40%, or up to 30%, or up to 25% of a stabilizer.

The matrix of the matrix component (hereinafter referred to as the "matrix") is typically formed from a polymeric material and preferably a plasticizer. The polymeric material and the plasticizer are described in more detail below.

The ratio of plasticizer to polymeric material in the matrix is preferably 1: 100, more preferably 1:70, or 1:50, depending on the type of plasticizer and polymeric material used. More preferably, it is 1:30 or 1:20. For example, if the polymeric material comprises PVA and the plasticizer comprises glycerin or a glycerol derivative and optionally water, this ratio is preferably about 1:15 to 1: 8, with a preferred ratio of about It is 10: 1.

The matrix may further comprise active ingredients of the component and / or solubilizers of the component. The active ingredient and the solubilizer are described in more detail below. Crosslinking agents can be added to improve the properties of the matrix and the resulting components as appropriate. Borate is useful in this matrix.

The matrix has a glass transition temperature (Tg) of less than 50 ° C., preferably 40 ° C.
Less, preferably less than 20 ° C, even less than 10 ° C, even less than 0 ° C.
The Tg of the matrix is preferably higher than -20 ° C, more preferably higher than -10 ° C.

As used herein, the Tg of the matrix is the Tg of the matrix as it is present in the component, which may be a mixture of polymeric material and plasticizer only,
Or a mixture of polymeric materials, plasticizers, active ingredients and / or stabilizers,
In any case, other optional ingredients may be present, such as stabilizers, densification aids, fillers, lubricants, etc. as described herein.

The Tg used here is the textbook “Dynamic Mechanical Analysis” (page 53,
A material (matrix) that changes from vitreous to rubber-like, i.e. obtains sufficient mobility for the chains to slide on each other, as defined in Figure 3.11c) on page 57. Is the temperature of.

The Tg of the matrix of the constituent material of the present invention is a Perkin-Elmer DMA 7e device, and according to the operation manual of this device, this Dynamic Mechanical Analysis, page 57, FIGS.
It can be measured by drawing a curve as illustrated in 11c.
Tg is the temperature or log frequency, as measured by this instrument, between the glass and "leather zone" as defined in that textbook.

The matrix, and preferably the entire component, has a particular elasticity and flexibility due to its particular glass transition temperature. In particular, this is because the matrix and the constituents are reversibly deformed and absorb the energy of impact or force, so that the constituent or matrix is essentially its original material after physical forces are no longer applied to its constituents. Means to stay in the bulk volume.

[0076]   Elasticity can be defined by the modulus of elasticity of the matrix or constituents,
It can be specified by Young's modulus. This can be extended as is known in the art.
Or stress mechanical testing, for example with a Perkin-Elmer DMA 7e device
According to test procedure, over a certain% static extension range, ie 10-40% static
It can be calculated by extension. This can work during normal manufacturing or handling
Represents the maximum elongation. Therefore, the elastic modulus specified here is 10 with this device.
Maximum modulus measured within the range of 40% to 40% static elongation. For example, 1 cm ^Three Matrix (or component) pieces of can be used for testing with this device.

The matrices of the present invention typically have a modulus or Young's modulus of 4 GN.s, as measured on a Perkin-Elmer DMA 7e instrument. m ⁻² , typically 2GN. less than m ^-2 ,
More preferably 1 GN. m ⁻² but typically 0.5 GN.
m ⁻² , further 0.1 GN. m ^{−2 or} less, further 0.01 GN. It is less than m ^-2 . In particular, for example, the matrix of the present invention containing bubbles formed by a manufacturing method in which air is introduced into the matrix has a modulus of elasticity of 0.1 GN. m ^{−2 or} less, further 0.01 GN. m ⁻² , further 0.005 GN. m ⁻² , further 0.0001 GN. It is less than m ^-2 .

Preferably the matrix is flexible and has a relative yield elongation of greater than 2%, preferably greater than 15% and even 50% as measured on a Perkin-Elmer DMA 7e apparatus.
(Yield elongation is the deformation limit at which the matrix piece is irreversibly deformed in this measurement).

In particular, this compresses a matrix sample having a cross section of a certain length, for example 1 cm, with a static force applied along the axis of the cross section, the static force being variable,
At least equal to twice atmospheric pressure means that this change in length after removal of the force is at least 90% to 110% of the original length. This is for example Pe
It can be measured with the rkin-Elmer DMA 7e instrument.

Similarly, the matrix preferably extends a matrix sample having a cross section of a particular length, eg 1 cm, with a static force applied along the axis of the cross section, the static force being variable, At least equal to twice atmospheric pressure, this change in length after removal of the force is flexible to the extent that it is at least 90% to 110% of its original length. This can be measured, for example, on a Perkin-Elmer DMA 7e instrument.

In particular, when using this device, the static force applied along the axis of the cross section of the 1 cm ³ matrix sample is gradually increased until the deformation of the components in the direction of the cross section is 70%. The force is then removed and the final deformation of the matrix sample in the cross-sectional direction is measured. Preferably, this length of the cross section after this experiment is preferably 90% to 110%, preferably 95% to 105%, or even 98% to 100% of the original length of the cross section.

[0082]   Modulus of elasticity or Young's modulus is a function of relative density, ie

[Equation 2] Where ρ ^* is the relative density of the matrix or even of the constituent, ρ _s is the relative density of the components described herein of the matrix or of the constituent and E ^* is the Young's modulus of the matrix or of the constituent itself. And E _s is the Young's modulus of the matrix or even the constituents. This is because even rigid polymeric materials with high E _s
Elasticity by adjusting the amount and / or type of plasticizer, and optionally by varying the density (or, for example, by introducing gas as described below in the process of making the foam component). It means that a flexible matrix can be formed.

The matrix, or even the entire component, is in the form of a foam, preferably an interconnected network of open cells (cells) and / or closed cells, in particular edges and faces of open cells and / or closed cells. Forming a mesh structure of solid struts or plates that form the. The inner space of the cell contains the active ingredient and / or gas, eg air,
Can include a part of

[0084]   Preferably, the matrix of components or continuous cells with independent cells throughout the component
The cell ratio is greater than 1: 1 and preferably greater than 3: 2, even greater than 2: 1.
More than 3: 1. This ratio is the total volume of the matrix or constituent sample V _T Calculate (assuming a sphere) and then the continuous cell volume (
V_O) Is measured and the continuous cell volume is subtracted from the total volume to obtain the independent cell volume.
Can be obtained (V_C, V_T= V_O+ V_C).

[0085] the formation of a matrix of polymeric material present invention can be used in any kind of polymeric material, preferably, the polymer itself has a Tg that defined above, or, more typically ,
Appropriate amounts of plasticizer can be used to form a matrix with a Tg as defined above.

Preferably, the polymeric material comprises or consists of an amorphous polymer.

The polymeric material may consist of a single type of homologous polymer or may be a mixture of polymers. Mixtures of polymers are particularly advantageous for controlling their mechanical and / or dissolution properties depending on the application and requirements of the component.

The polymeric material preferably comprises a water-dispersible, or more preferably water-soluble polymer. Water dispersibility and water solubility are typically determined by the methods described above for determining water solubility and dispersibility of the present components. The preferred water-dispersible polymer herein has a dispersity of at least 50%, preferably at least 75%, and even at least 95, as measured by the method described above using a glass filter having a maximum pore size of 50 μm. %, More preferably the polymer has a solubility of at least 50%, preferably at least 75% as measured by the method described above using a glass filter with a maximum pore size of 20 μm.
%, Or even at least 95%.

The polymer may have any average molecular weight, but is preferably about 1000-1,000,
000, further 4000-250,000, further 10,000-200,
000, and further 20,000 to 75,000. Weight average molecular weight 30,0
Highly preferred are polymeric materials having an amount of from 00 to 70,000.

The polymeric material can be tailored according to the required properties of the constituent materials. For example, to reduce solubility, typically greater than 50,000, or even 100,
The material can include polymers having a high molecular weight greater than 000, and vice versa. For example, polymers of varying degrees of hydrolysis can be used to alter solubility. For example, to improve (decrease) the modulus, one can increase the crosslinking of the polymer and / or increase the molecular weight.

The polymer used in the constituent material of the present invention preferably has a secondary function, for example, a function in a composition in which the constituent material is blended. For example, for cleaning products, it is advantageous that the polymer in the polymeric material is a dye transfer inhibiting polymer, dispersant, and the like.

Polyvinyl alcohol and derivatives thereof, polyethylene glycol and derivatives thereof, polyvinylpyrrolidone and derivatives thereof, cellulose ethers and derivatives thereof, and polymers thereof, or between these polymers and other monomers or oligomers. Polymers selected from copolymers with are preferred. Most preferred polymers are PVP (and their derivatives) and / or PE
G (and their derivatives) and most preferably PVA (and their derivatives) or a mixture of PVA with PEG and / or PVP (or a mixture thereof). Most preferred is a polymeric material comprising only PVA. Preferably, such polymers have a degree of hydrolysis of at least 50%, more preferably at least 70%, even 85-95%.

[0093] able to use all of the plasticizer suitable for easily forming a matrix defined herein plasticizer. Mixtures of plasticizers can also be used. If water is used, it is preferred that an additional plasticizer is present.

The plasticizer or at least one of the plasticizers has a boiling point above 40 ° C., preferably 6
Over 0 ° C, over 95 ° C, over 120 ° C, and over 150 ° C
It is preferably above ° C.

Preferred plasticizers include glycerol or glycerin, glycol derivatives including ethylene glycol, digomeric polyethylene glycol,
For example, diethylene glycol, triethylene glycol and tetraethylene glycol, polyethylene glycol having an average molecular weight of less than 1000, wax and carbowax, ethanolacetamide, ethanolformamide, triethanolamine or its acetate, and ethanolamine salt, sodium thiocyanate, ammonium thiocyanate. , Polyols such as 1,3-butanediol, sugars, sugar alcohols, ureas, dibutyl or dimethyl phthalate, oxamonoacids, oxadic acids, diglycolic acids and other at least one ether group distributed along the chain. A linear carboxylic acid, water or a mixture thereof.

The plasticizer is preferably present in an amount of at least 0.5% by weight, based on the weight of the product, preferably of the matrix, provided that water is the only plasticizer, water is the constituent. It is preferably present in an amount of at least 3% by weight of the weight of the matrix.

Preferably, the plasticizer is 1-35% by weight of the product or matrix, more preferably 2-25% by weight, even 15% by weight of the product or matrix, even 10% by weight, even 8%. It is present in amounts up to wt%. The exact amount is
Depending on the polymeric material and plasticizer used, the product matrix should have the desired Tg. For example, when urea is used, its amount is preferably from 1 to 10% by weight of the matrix, but when glycerin or ethylene glycol or other glycol derivatives are used, higher levels, such as 2 to 2% of the constituent or matrix. 15% by weight is preferred.

Active Ingredient The active ingredient may be any material supplied to a liquid environment, or preferably an aqueous environment, preferably an active ingredient in an aqueous environment. For example, when used in a cleaning composition, the component can include all active cleaning ingredients. The component can also comprise a composition such as a cleaning composition or a personal care composition.

In particular, active ingredients that are sensitive to water or react when contacted with water, or solid ingredients that have a limited impact resistance and tend to form dust during handling are incorporated into the constituent materials. Is advantageous. In particular, enzymes, fragrances, bleaches, bleach activators, fabric softening agents, fabric conditioners, surfactants, such as liquid nonionic surfactants, regulators, bactericides, brighteners, photobleaches and them. Active ingredients such as a mixture of

Another active ingredient is a perhydrate bleach, such as a metal perborate, a metal percarbonate, especially the sodium salt. Organic peracid bleach precursors or activator compounds are also preferred active ingredients, and preferred imide-type alkyl percarboxylic acid precursor compounds include N-, N, N containing alkylene groups containing from 1 to 6 carbon atoms. ¹ , N ¹ tetraacetylated alkylenediamines, especially compounds in which the alkylene group contains 1, 2 and 6 carbon atoms, for example tetraacetylethylenediamine (TAED), sodium 3,5,5-tri-methylhexanoyloxybenzenesulfonate. (Iso-
NOBS), sodium nonanoyloxybenzene sulfonate (NOBS),
Examples include sodium acetoxybenzene sulfonate (ABS) and pentaacetyl glucose, but amide-substituted alkyl peracid precursor compounds are also preferred.

Highly preferred components for the components of the present invention are one or more enzymes. Preferred enzymes include commercially available lipases, cutinases, which have been conventionally blended in detergent compositions.
Amylases, neutral and alkaline proteases, cellulases, endolases,
Mention may be made of esterases, pectinases, lactases and peroxidases. Suitable enzymes are described in US Pat. Nos. 3,519,570 and 3,533,139. Preferred commercial protease enzymes include Novo Industries A /
Alcalase, Savinase, Primase, Durazym, and Esperase from S (Denmark)
From Gist-Brocades under the trade names Maxatase, Maxacal and Maxapem under the trade names, Genencor International from the enzyme, and Solvay Enzymes under the trade names
Enzymes marketed under the trade names Opticlean and Optimase are mentioned. Preferred amylases include α-amylases obtained from specialized strains of B. licheniformis, which are described in more detail, for example, in British Patent 1,269,839 (Novo). Preferred commercial amylases include, for example, the amylases sold under the trade name Rapidase by Gist-Brocades, and Termamyl, Dur from Novo Industries A / S.
Examples include amylase sold under the brand names amyl and BAN. Highly preferred amylase enzymes are PCT / US9703635 and International Patent No. WO
The enzymes may be those described in 95/26397 and WO 96/23873. Lipases are derived from fungi or bacteria, for example Humicola sp., Thermomyces
sp., or derived from Pseudomonas sp. lipase-producing strain, including Pseudomonas pseudoalcaligenes or Pseudomonas fluorescens. Also useful herein are lipases obtained from chemically or genetically modified mutants of these strains. A preferred lipase is the assigned European patent EP-B-021827.
Obtained from Pseudomonas pseudoalcaligenes described in No. 2. Another preferred lipase is obtained by cloning a gene obtained from Humicola lanuginosa as described in European patent application EP-A-0258068 and expressing this gene in Aspergillus oryza as a host, Novo Indust
It is marketed under the trade name Lipolase from ries A / S, Bagsvaerd, Denmark. This lipase is described in US Pat. No. 4,810,414, Huge-Jensen et al., 1989.
It was also announced on March 7, 2013.

Preferred Additional Ingredients The ingredients of the present invention preferably comprise additional ingredients that can improve the dissolution characteristics of the product.

Preferred additional components which improve the solubility of the product are sulphonated compounds such as C ₁ -C ₄ alk (en) yl sulphonates, C ₁ -C ₄ aryl sulphonates, diisobutylbenzene sulphonates, toluene sulphonates, Cumene sulfonate, xylene sulfonate, their salts, such as their sodium salts, their derivatives, or combinations thereof, preferably diisobutylbenzene sulfonate, sodium toluene sulfonate, sodium cumene sulfonate, sodium xylene sulfonate, and combinations thereof, and / or Or C ₁ ~
C ₄ alcohols such as methanol, ethanol, propanol, for example iso -
Propanol, and derivatives thereof, and combinations thereof, preferably ethanol and / or iso - propanol, and / or C ₄ -C ₁₀ diol such as hexane diol and / or cyclohexanediol, preferably 1,6-hexanediol and And / or 1,4-cyclohexanedimethanol, and / or components that can act as whipping agents, such as cellulosic components, especially modified cellulose, and / or swelling agents, such as clay (preferred clays being smectite clays, especially dioctahedral or Tri-octahedral smectite clays, highly preferred clays are montmorillonite clays and hectorites, or other clays found in bentonite clay structures), and / or foam systems (preferred foam systems are Reacting with an alkali source in the presence of water comprising an acid source capable of generating a gas) comprising.

The components of the present invention preferably comprise additional ingredients that can improve the stability of the active ingredients of the product.

These additional ingredients can typically stabilize the active ingredient of the component, which means that the active ingredient can be oxidizable or sensitive to moisture, such as 1%. It is particularly preferred if it comprises more than one enzyme. These additional ingredients are
It is also possible to stabilize the matrix of the component, and thus indirectly stabilize the active ingredient. These stabilizing components are defined herein as "stabilizers".

Stabilizers are compounds which stabilize the active ingredient or matrix against oxidation and / or deterioration due to moisture during storage. The stabilizer may be, or may comprise, a foam matrix stabilizer. The stabilizer may be or comprise an active ingredient stabilizer, especially an enzyme stabilizer. Stabilizers that can indirectly stabilize the active ingredient by maintaining the foam matrix of the product in a stable state are referred to herein as "foam stabilizers".

The foam stabilizer is preferably a surfactant, such as a fatty alcohol, a fatty acid,
It comprises an alkanolamide, an amine oxide, or a derivative thereof, or a combination thereof. The foam stabilizer can comprise betaine, sulfobetaine, phosphine oxide, alkyl sulfoxides, their derivatives, or combinations thereof.

Other preferred foam stabilizers comprise one or more anions or cations, for example 1, 2, 3 or other polyvalent metal ions, preferably sodium, calcium, magnesium, Salts of potassium, aluminum, zinc, copper, nickel, cobalt, iron, manganese, and silver, preferably anionic counterions, i.e. sulfates, carbonates, oxides, chlorides, bromides, iodides, phosphates, borates, acetates, Having citrate, and nitrate, and combinations thereof.

Foam stabilizers are finely divided particles, preferably having an average particle size of less than 10 μm, more preferably less than 1 μm, even more preferably less than 0.5 μm, or less than 0.1 μm.
It can comprise finely divided particles that are less than 1 μm. Preferred finely divided particles are aluminosilicates, such as zeolites, silicas, or the above electrolytes in the form of finely divided particles.

Foam stabilizers include agar, sodium alginate, sodium dodecyl sulfate,
It can comprise polyethylene oxide, guar gum, polyacrylates, or their derivatives, or combinations thereof.

The foam stabilizer may be a coating separate from the matrix of the product. The foam stabilizer typically partially surrounds, preferably completely surrounds, the product of the invention or its active ingredients.

The coating typically contacts the active ingredient so as to preferably form an overcoat on the active ingredient, after which the active ingredient contacts the polymeric material or plasticizer of the matrix, It is preferably incorporated into the product.

[0113] Typically, after the polymeric material and the plasticizer have formed a matrix, and preferably the active ingredient is in contact with the matrix or incorporated into the product, the coating is applied to the product. The product is preferably contacted so as to form a jacket.

Preferred coatings are polymers, typically polyvinyl alcohol and their derivatives, polyethylene glycol and their derivatives, polyvinylpyrrolidone and their derivatives, cellulose ethers and their derivatives, and between these polymers, Alternatively, it comprises a polymer selected from copolymers of these polymers and other monomers or oligomers. The most preferred polymers are PVP (and their derivatives) and / or PEG (and their derivatives), most preferably PVA (and their derivatives) or PVA and PEG and / or PVP (and their derivatives). Is a mixture of. These polymers do not form the matrix of this product. Therefore, these polymers differ from the foam matrix polymeric materials.

Preferred coatings are glycerol or glycerin, glycol derivatives including ethylene glycol, digomeric polyethylene glycols such as diethylene glycol, triethylene glycol and tetraethylene glycol, polyethylene glycols with a weight average molecular weight of less than 1000, waxes and carbowaxes. Ethanolacetamide, ethanolformamide, triethanolamine or its acetate, and ethanolamine salts, sodium thiocyanate, ammonium thiocyanate, polyols such as 1,3-butanediol, sugars, sugar alcohols, urea, dibutyl or dimethyl phthalate, oxamono. Acids, oxazic acids, diglycolic acids, and other linear, at least one ether group in the chain It comprises a compound such as a carboxylic acid, water or a mixture thereof distributed along. These compounds do not form the foam matrix of the product.
Therefore, these compounds are different from the foam matrix plasticizers.

Preferred stabilizers capable of directly stabilizing the active ingredient are defined as "active stabilizers" or "enzyme stabilizers", especially when the active ingredient comprises one or more enzymes. Typically, the active stabilizer interacts directly with and stabilizes the active ingredient.

Typical active stabilizers used herein preferably comprise surfactants.
Suitable surfactants for use herein are the surfactants previously described as suitable surfactants for matrix stabilizers. In addition to these surfactants, other surfactants suitable for use herein comprise surfactants such as sodium alk (en) yl sulfonate, sodium alkoxy sulfonate, preferred alkoxy sulfonates , Any structure, preferably linear, in
It comprises 18 carbon atoms and has an average degree of ethoxylation of 1 to 7, preferably 2 to
It is 5.

Other preferred active stabilizers comprise boric acid, formic acid, acetic acid, and salts thereof. These acid salts preferably comprise counterions such as calcium and / or sodium.

A preferred active stabilizer comprises cations such as calcium and or sodium. Preferably calcium chloride and / or sodium chloride.

Other preferred activity stabilizers comprise small peptide chains containing an average of 3 to 20, preferably 3 to 10 amino acids which interact with and stabilize the active ingredient, especially the enzyme.

Other activity stabilizers comprise small nucleic acid molecules, which typically comprise 3 to 300, preferably 10 to 100 nucleotides. Typically, nucleic acid molecules are deoxyribonucleic acid and ribonucleic acid. The nucleic acid molecule can be complexed with other molecules, such as proteins, or can be complexed with the active ingredients of the product, especially the enzyme.

Suitable active stabilizers for use herein are antioxidants and / or reducing agents such as thiosulfates, methionine, especially if the product comprises a bleaching agent.
Urea, thiourea dioxide, guanidine hydrochloride, guanidine carbonate, guanidine sulfamate, monoethanolamine, diethanolamine, triethanolamine,
Amino acids such as glycine, sodium glutamate, proteins such as bovine serum albumin and casein, tert-butylhydroxytoluene, 4-4
, -Butylidene bis (6-tert-butyl-3-methyl-phenol), 2,
2'-butylidene bis (6-tert-butyl-4-methyl-phenol), (
It comprises monostyrenated cresol, distyrenated cresol, monostyrenated phenol, distyrenated phenol 1,1-bis (4-hydroxy-phenyl) cyclohexane, or derivatives thereof, or combinations thereof.

Other activity stabilizers may comprise reversible inhibitors of the active ingredient. Without wishing to be bound by theory, reversible inhibitors of the active ingredient, particularly when the active ingredient comprises one or more enzymes, form a complex with the active ingredient and improve the stability of the active ingredient, It is believed to stabilize the active ingredient during storage. When the active ingredient is released, typically in a liquid environment, the reversible inhibitor dissociates from the active ingredient, allowing the active ingredient to perform its designed or intended desired action.

Active stabilizers suitable for use herein include sugars, typical sugars used herein include sucrose, glucose, fructose, raffinose, trehalose, lactose, maltose, their derivatives, And a sugar selected from the group consisting of combinations thereof.

The active stabilizer may also comprise sugar alcohols such as sorbitol, mannitol, inositol, their derivatives, and combinations thereof.

The active stabilizer is preferably in the form of a coating or barrier at least partially surrounding the product or its active ingredients, preferably completely surrounding the product or its active ingredients, especially the enzyme.

[0127]

【Example】

Example 1 Method for Producing Foam Constituent Polyvinyl alcohol (weight average molecular weight 30,000 to 70,000) 33
4700 g of a weight% solution, 159.3 g of glycerol and 019.8 citric acid
g in a high shear mixer until a smooth foam is formed. This mixture is placed in a feed tank and, using a gear pump, pumped into the drum known as Rotoform, supplied by Sandvik Conveyor GMBH. The drum has 1000 μm size holes spaced 2500 μm apart. This perforated drum is placed on a drum having a smooth surface, and the shortest distance (distance at the closest point) is 1000 μm. The perforated drum was rotated at 15 rpm and the mixture was pumped through the opening of the perforated drum onto a smooth surfaced drum coated with silicone oil and heated to 30 ° C. A pastel is formed on top. When a quarter of the drum is covered with pastel, the extrusion process is stopped and the pastel is dried with hot air at a temperature of 70 ° C. so that the surface of the pastel is barely touchable. The resulting dry pastel is scraped from the smooth surface drum and collected.

Example 2 Method for Producing Foam Components 33 of polyvinyl alcohol (weight average molecular weight 30,000 to 70,000)
4700 g of a weight% solution was added to an enzyme solution (5% by weight of active enzyme and 85% by weight of water).
360 g, glycerol 159.3 g and cyclohexanedimethanol 155
g in a high shear mixer until a smooth foam is formed. This mixture is placed in a feed tank and, using a gear pump, pumped into the drum known as Rotoform, supplied by Sandvik Conveyor GMBH. The drum has 1000 μm size holes spaced 2500 μm apart. This perforated drum is placed on a drum having a smooth surface, and the shortest distance (distance at the closest point) is 1000 μm. The perforated drum was rotated at 15 rpm and the mixture was pumped through the opening of the perforated drum onto a drum having a smooth surface coated with silicone oil and heated to 30 ° C. Form a pastel on top. When a quarter of the drum is covered with pastel, the extrusion process is stopped and the pastel is dried with hot air at a temperature of 70 ° C. so that the surface of the pastel is barely touchable. The resulting dry pastel is scraped from the smooth surface drum and collected.

Example 3 Method for Producing Foam Component Polyvinyl alcohol (weight average molecular weight 30,000 to 70,000) 146
4.0 g, enzyme solution (5 wt% active enzyme and 85 wt% water) 2282.0 g,
150.4 g of glycerol and 103.6 of sodium thiosulfate are mixed in a high shear mixer until a smooth foam is formed, producing 4000 g of solution. Put this mixture in the feed tank, use a gear pump, Sandvik Conveyor GMB
Pump into a drum known as the Rotoform trade name, supplied by H. The drum has 300 μm size holes arranged at 100 μm intervals. The perforated drum is placed on a steel belt conveyor with a smooth surface. The perforated drum was rotated at 100 rpm and the mixture was pumped through the opening of the perforated drum onto a steel belt conveyor coated with silicone oil and heated to 30 ° C. that had a smooth surface. Form a pastel on the surface belt. When the entire length of the smooth surface belt is covered with pastel, the extrusion process is stopped and the pastel is heated to 70 ° C.
Dry the pastel surface with hot air so that it doesn't stick to the surface. The resulting dry pastel is scraped off the smooth surface belt and collected.

Example 4 Method for Producing Foam Components Solution 4000 as described in Example 3 except that CO ₂ gas was dissolved in the solution.
g is produced. Dissolution of CO ₂ is achieved by placing the above solution in a 10 L pressure vessel and charging the pressure vessel with CO ₂ gas until the pressure is 1.0 bar. At this point the CO ₂ feed is stopped and the pressure vessel and its contents are left to reach dissolution equilibrium. Using a gear pump, this mixture is directly from the pressure vessel, Sandvik Conveyor
Pump into a drum known by the name Rotoform, supplied by GMBH. The drum has 300 μm size holes arranged at 100 μm intervals.
The perforated drum is placed on a steel belt conveyor with a smooth surface. The perforated drum was rotated at 100 rpm and the mixture was pumped through the opening of the perforated drum onto a steel belt conveyor with a smooth surface coated with silicone oil, pasting onto the smooth surface belt. To form. Spray the cooling medium onto the side of the steel belt conveyor opposite the side where the pastel is formed. The cooling medium spray brings the belt temperature to −10 ° C. and immediately solidifies the pastel. If desired, use a scraper blade to remove the pastel from the smooth surface steel belt. When the pastel leaves the belt, it falls by gravity or, in a similar fashion, Fl
It is sent to the uid Bed Dryer / Coater, where water is removed. In addition, Fluid Bed
Additional coating can be applied with Dryer / Coater. The resulting dried, coated pastel is removed from the Fluid Bed Dryer / Coater.

─────────────────────────────────────────────────── ─── Continued front page    (31) Priority claim number 0010599.9 (32) Priority date May 3, 2000 (May 2000) (33) Priority claim country United Kingdom (GB) (31) Priority claim number 0022499.8 (32) Priority date September 13, 2000 (September 13, 2000) (33) Priority claim country United Kingdom (GB) (81) Designated countries EP (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE, I T, LU, MC, NL, PT, SE), OA (BF, BJ , CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG), AP (GH, GM, K E, LS, MW, MZ, SD, SL, SZ, TZ, UG , ZW), EA (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), AE, AG, AL, AM, AT, AU, AZ, BA, BB, BG, BR, BY, BZ, C A, CH, CN, CR, CU, CZ, DE, DK, DM , DZ, EE, ES, FI, GB, GD, GE, GH, GM, HR, HU, ID, IL, IN, IS, JP, K E, KG, KP, KR, KZ, LC, LK, LR, LS , LT, LU, LV, MA, MD, MG, MK, MN, MW, MX, MZ, NO, NZ, PL, PT, RO, R U, SD, SE, SG, SI, SK, SL, TJ, TM , TR, TT, TZ, UA, UG, US, UZ, VN, YU, ZA, ZW (72) Inventor Matthew, Grady, Magoff             United Kingdom Newcastle, Upon, Ta             Inn, Jesmond, Park, West,             Jesmond, Park, Muse, 3 (72) Inventor Scott, Edward, Stevens             United Kingdom Newcastle, Upon, Ta             Inn, Deanside, Court, 25 (72) Inventor Hotham, Hassan, Tantawee             Morpeth, Hulbeck, The, Chi             Chimes Lodge (72) Inventor Christopher, Charles, Driphy             Ludo             United Kingdom Newcastle, Upon, Ta             Inn, High, Heaton, Westlands,             12 F-term (reference) 4F074 AA42 AD04 AD09 BA32 BA33                       CB52 CB53 CC22X DA34                 4J002 AE032 BE021 CH022 EC046                       EP016 FD022 FD026 FD207                       GG01

Claims (15)

[Claims] 1. A gas is extruded into the viscous mixture prior to, at the same time as, or after extruding the viscous mixture through an opening in a rotary extrusion plate to receive the viscous mixture through the opening. A method for producing a foam component, which comprises the step of introducing. 2. The viscosity of the viscous mixture is 25 mPas to 20000 mPas, preferably 5 mPas.
The method according to claim 1, which is 0 mPas to 10000 mPas. 3. The method according to claim 1, wherein the shortest distance between the extruded plate and the receiving surface is 50 μm to 3000 μm. 4. The method according to claim 1, wherein the size of the opening is 50 μm to 3000 μm. 5. The water content of the viscous mixture is 0.1% to 80% by weight, preferably 60% by weight.
The method according to any one of claims 1 to 4, wherein the method is -80% by weight. 6. The method according to claim 1, wherein the rotation direction of the rotary extrusion plate is perpendicular to the flow direction of the viscous liquid passing through the opening of the rotary extrusion plate. 7. The viscous mixture comprises a material selected from the group consisting of polymeric materials, plasticizers, active ingredients, combinations thereof, preferably solubilizers, stabilizers or combinations thereof. 7. The method of any one of claims 1-6, comprising a material selected from the group consisting of: 8. The method according to claim 1, wherein the viscous mixture is extruded through the opening at a temperature of 0 ° C. to 50 ° C. 9. The method according to claim 1, wherein the opening has the shape of a diamond, a square or a circle, or a triangle, preferably a diamond. 10. The method of any one of claims 1-9, wherein the gas comprises carbon dioxide, nitrogen, or a combination thereof, such as air. 11. The rotary extrusion plate is 1 rpm to 1000 rpm, preferably 10 rpm to 20.
Rotating at 0 rpm, the tip speed of the rotary extrusion plate is 0.1 ms ^{-1 to} 1600 m.
The method according to claim 1, wherein the method is s ⁻¹ . 12. The method according to claim 1, wherein the receiving surface and / or the rotary extrusion plate are partially coated with a release agent. 13. The method according to claim 1, wherein the foam component is water-soluble or water-dispersible. 14. A foam component suitable for use in a cleaning composition, a fabric protection composition, a personal care composition, a cosmetic composition, a pharmaceutical composition, or a foam composition according to any one of claims 1 to 13. Use of the method according to the paragraph, preferably enzymes, perfumes, surfactants, brighteners, dyes, foam inhibitors, bleaches, bleach activators, fabric softening agents, bactericides, foaming systems and Use, wherein the composition is formulated with an active ingredient selected from the group consisting of mixtures thereof. 15.   A foam component obtained by the method according to any one of claims 1 to 13.