KR20240019086A - Water-soluble unit dose article comprising a water-soluble core component - Google Patents

Abstract

The single unit dose article includes a water-soluble core substrate comprising a water-soluble resin. The water-soluble core substrate includes a carrier solvent with an active cleaning formulation, wherein upon contact of the carrier solvent with the water-soluble core substrate, the water-soluble core substrate exhibits shrinkage or swelling. Additionally, a method of making a single unit dose article is disclosed.

Description

Water-soluble unit dose article comprising a water-soluble core component

Cross-reference to related applications

This application claims the benefit of U.S. Provisional Patent Application No. 63/185,592, filed May 7, 2021, which is expressly incorporated herein by reference in its entirety.

Technology field

The present disclosure generally relates to water-soluble unit dose articles comprising a water-soluble core component. More specifically, the disclosure relates to water-soluble unit dose articles configured to include cleaning formulations.

Water-soluble packaging materials are commonly used to simplify dispersion, injection, dissolution, and administration of the delivered substance. Conventional packaging materials include water-soluble films and pouches made from water-soluble films, which are commonly used to package formulations such as laundry detergents, dish detergents, or personal care formulations. Consumers can add the pouched formulation directly to water. Advantageously, this provides for accurate dosing, eliminating the need for the consumer to measure the formulation. However, some currently commercially available pouches made from water-soluble polymer films have an unpleasant rubbery or plastic-like feel, for example when handled by the consumer. Additionally, bulk or concentrated detergents are not always stable and may contain relatively incompatible ingredients that become unstable when in contact with other ingredients. For example, enzymes may become unstable in various solvents, which may affect the properties of the film, for example, the mechanical properties of the film may deteriorate over time. As a result, conventional pouches, such as detergent pouches, contain a limited number of cavities or compartments. Additionally, conventional water-soluble film-based unit dose components are complex and expensive, requiring separate production of film, detergent, and pods.

Therefore, it is easily manufacturable, provides chemical stability during transportation and storage, but is easy to handle and leaves no unwanted residue during intended use, for example, when the unit dose article is placed in a washing machine. There is a need in the art for a unit dose article with components that dissolve quickly without leaving behind water.

1-14 are cross-sectional schematics of exemplary single unit dose (SUD) articles comprising active cleaning formulations according to exemplary embodiments;
Figure 15 shows an example method for making a SUD article according to an example embodiment;
16 shows a first type of fiber (“F1”) comprising a polyvinyl alcohol copolymer with a degree of hydrolysis of 88% and a second type of fiber comprising a polyvinyl alcohol copolymer with a degree of hydrolysis of 96% (“F1”). Shows shrinkage results (in a detergent formulation with 20% water at 45°C) for an example sample comprising a core substrate comprising at least one nonwoven layer or sheet having a plurality of fibers comprising "F2") ;
17 shows a first type of fiber comprising a polyvinyl alcohol copolymer with a degree of hydrolysis of 88% (“F1”) and a second type of fiber comprising a polyvinyl alcohol copolymer with a degree of hydrolysis of 96% (“F1”) (in a detergent formulation with 35% water at 20°C, 35°C, 45°C) for example samples comprising a core substrate comprising at least one nonwoven layer or sheet having a plurality of fibers comprising "F2") ) represents the shrinkage results;
Figure 18 shows shrinkage results (in detergent formulations with 50% water at 20°C, 35°C, 45°C) for example samples as shown in Figure 17;
Figure 19 shows shrinkage results (in detergent formulation with 65% water at 20°C, 35°C, 45°C) for the example samples as shown in Figure 17;
Figure 20 shows shrinkage results (in a detergent formulation with 35% water at 20°C) of an example sample comprising at least one nonwoven layer with a plurality of fibers (fibers F1) having different basis weights;
21 shows a plurality of fibers having a basis weight of 50 gsm with different bonding patterns including a point bonding pattern and a daisy bonding pattern with bonding points that are more dense than the point bonding pattern. Shows the shrinkage results (in a detergent formulation with 35% water at 20°C) of an example sample comprising at least one nonwoven layer with (fiber F1);
22 shows a first type of fiber comprising a polyvinyl alcohol copolymer with a degree of hydrolysis of 88% (“F1”) and a second type of fiber comprising a polyvinyl alcohol copolymer with a degree of hydrolysis of 96% (“F1”) (at 20°C, 35°C, 45°C) for example samples comprising a core substrate comprising at least one nonwoven layer or sheet (50 gsm, partially bonded) having a plurality of fibers comprising "F2") ) represents the decomposition time results;
Figure 23 shows the rupture time results (at 20°C, 35°C, 45°C) for the example samples as shown in Figure 22;
24 shows at least one nonwoven layer or sheet (daisy-bonded, different Shows the decomposition time results (at 20°C, 35°C, 45°C) for example samples comprising a core substrate comprising (with basis weight);
Figure 25 shows time to rupture results (at 20°C, 35°C, 45°C) for example samples as shown in Figure 24;
26 shows a plurality of fibers having a basis weight of 50 gsm (fiber F1) with one of two different bonding patterns, including a partial bonding pattern and a daisy bonding pattern with tighter bonding points than the partial bonding pattern. Shows time to rupture results (in water at 20°C, 35°C, 45°C) for example samples comprising at least one nonwoven layer;
Figure 27 shows disintegration time results (in water at 20°C, 35°C, 45°C) for example samples as shown in Figure 26.

In exemplary embodiments described herein, a single unit dose (SUD) article comprises one or more core substrates, e.g., one or more open or closed foam core substrates (e.g., one or more open or closed foam core substrates) that are precisely dosed to deliver a detergent for laundry laundry. foam core substrate) or one or more nonwoven web core substrates. In exemplary embodiments, the substrate is a water-soluble polymer, such as a polyvinyl alcohol (PVOH) based polymer and/or a starch derivative, for example, or is otherwise water-dispersible or has a high degree of biodegradability or can be composted or recycled. and blends thereof with polymers. In exemplary embodiments, the core substrate(s) are comprised within a water-soluble material, such as a water-soluble nonwoven material, a water-soluble foam material, and/or a water-soluble film material. As a result, consumers simply place SUD articles that are pre-loaded with one or more active cleaning formulations for chemical and mechanical cleaning action that will disperse, dissolve, and/or biodegrade during the cleaning cycle without leaving unwanted residues. Includes an activated substrate to be administered.

The SUD article and, more specifically, in exemplary embodiments, the water-soluble core substrate is configured to include a carrier solvent with one or more active cleaning formulations, such as laundry detergent formulations. In exemplary embodiments, the carrier solvent with the active cleaning formulation is disposed on or coated on one or more surfaces of the water-soluble core substrate or embedded within and/or attached to the water-soluble core substrate. The water-soluble core substrate may comprise a single layer, e.g., a single-layer nonwoven core substrate or a foam core substrate, or may comprise a plurality of layers, e.g., a carrier with the active cleaning formulation disposed between adjacent layers of the water-soluble nonwoven core substrate. It may comprise sheets of a non-woven core substrate or a foam core substrate folded or overlapped, for example in a serpentine arrangement, to form layers with a solvent. As an example, an active cleaning formulation may include, without limitation, laundry detergent, soap, fabric softener, bleach, laundry accelerator, stain remover, optical brightener, or water softener. Other examples include dish detergent, soap or cleaner, shampoo, conditioner, body wash, face wash, skin lotion, skin treatment, body oil, fragrance, hair treatment, bath salt, essential oil, and bath bomb. ), or enzymes. In certain exemplary embodiments, the water-soluble core substrate is surrounded by a water-soluble nonwoven material, a water-soluble foam material, and/or a water-soluble film material. Additionally, the carrier solvent may include, without limitation, any suitable polar solvent, water, polyol such as glycerol, DPG, or any combination thereof. In an exemplary embodiment, the water-soluble core substrate includes a plurality of fibers comprising a water-soluble resin. Upon contact of at least one fiber of the plurality of fibers with a suitable amount, for example a saturating amount, of the carrier solvent, the at least one fiber exhibits a shrinkage of 0.5% to 65%. Exemplary processes as disclosed herein for incorporating active cleaning formulations into water-soluble core substrates facilitate the preservation of active agents, such as enzymes, and improve the overall performance of SUD articles.

As used herein and unless otherwise specified, the term “water dispersible” means any material that physically separates a nonwoven substrate, foam substrate, film, or laminate into smaller component pieces upon immersion in water at a specified temperature. relates to a nonwoven substrate (or nonwoven web), foam substrate, film, or laminate. Smaller pieces may or may not be visible to the naked eye, may or may not remain suspended in water, and ultimately may or may not dissolve. In exemplary embodiments where the dispersion temperature is not specified, the nonwoven substrate, foam substrate, film, or laminate will decompose in 300 seconds or less at a temperature of about 100° C. or less according to MSTM-205. For example, the decomposition time may optionally be 200 seconds or less at a temperature of about 80°C, about 70°C, about 60°C, about 50°C, about 40°C, about 20°C, or about 10°C according to MSTM-205; It may be 100 seconds or less, 60 seconds or less, or 30 seconds or less. For example, this dispersion parameter may be characteristic of a nonwoven substrate, foam substrate, film, or laminate structure having a thickness of 6 mil (about 152 μm).

As used herein and unless otherwise specified, the term "water-soluble" refers to any nonwoven web, foam, having a dissolution time of 300 seconds or less at a specified temperature, as determined in accordance with MSTM-205 as set forth herein. , film, or laminate. For example, the dissolution time of the nonwoven web, foam, film, or laminate can optionally be about 80°C, about 70°C, about 60°C, about 50°C, about 40°C, about 20°C, or about 10°C according to MSTM-205. It may be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less at a temperature of °C. In embodiments where the dissolution temperature is not specified, the water-soluble nonwoven web, foam, film, or laminate has a dissolution time of 300 seconds or less at a temperature of about 80° C. or less. In an exemplary embodiment, “water-soluble film” means that the film, at a thickness of 1.5 mil, dissolves in 300 seconds or less at a temperature of about 80° C. or less according to MSTM-205. For example, a 1.5 mil (about 38 μm) thick water-soluble film may have a temperature of about 70°C, about 60°C, about 50°C, about 40°C, about 30°C, about 20°C, or about 10°C according to MSTM-205. It may have a dissolution time at a temperature of 300 seconds or less, 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less.

As used herein and unless otherwise specified, the term "cold water-soluble" means 300 seconds or less at a temperature ranging from about 10°C to about 20°C, as determined in accordance with MSTM-205. It relates to any water-soluble nonwoven web, foam, film, or laminate having a dissolution time of For example, the dissolution time of the nonwoven web, foam, film, or laminate can optionally be 200 seconds or less, 100 seconds or less, 60 seconds or less at a temperature ranging from about 10° C. to about 20° C. according to MSTM-205. It may be less than that, or 30 seconds. In an embodiment, “cold water soluble film” means that, at a thickness of 1.5 mil (about 38 μm), the film dissolves in 300 seconds or less at a temperature of 20° C. or less according to MSTM-205. For example, a 1.5 mil (about 38 μm) thick water-soluble film can be heated for 300 seconds or less, 200 seconds or less, 100 seconds or less, 60 seconds at a temperature of about 20°C or about 10°C according to MSTM-205. It may have a dissolution time of seconds or less, or 30 seconds or less.

As used herein and unless otherwise specified, the term "hot water-soluble" means greater than about 20°C, e.g., from about 21°C to about 80°C, as determined according to MSTM-205. It relates to any water-soluble nonwoven web, foam, film, or laminate having a dissolution time of 300 seconds or less at a temperature in the range of For example, the dissolution time of the nonwoven web, foam, film, or laminate may optionally be greater than about 20°C according to MSTM-205, such as about 21°C to about 80°C, about 25°C to about 80°C, about 25°C. to about 60°C, about 30°C to about 60°C, about 25°C to about 45°C, about 30°C to about 45°C, or about 25°C to about 43°C, about 30°C to about 43°C, about 25°C to It may be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds at a temperature of about 40°C, or in the range of about 30°C to about 40°C. In an exemplary embodiment, “hot water soluble film” means that, at a thickness of 1.5 mil (about 38 μm), the film dissolves in 300 seconds or less at a temperature of at least about 21° C. according to MSTM-205. For example, a 1.5 mil (about 38 μm) thick water-soluble film may have a temperature of about 80° C., 70° C., about 60° C., about 50° C., about 40° C., about 30° C., about 25° C., or about It may have a dissolution time of 300 seconds or less, 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less at a temperature of 21°C. In an exemplary embodiment, a hot water soluble substrate, such as a “hot water soluble nonwoven substrate” or a “hot water soluble nonwoven web”, remains stable and dissolves, e.g., when contacted with water having a temperature below its hot water solubility temperature. but is soluble and, for example, dissolves, when contacted with water having a temperature equal to its hot water solubility temperature, for example for a suitable dissolution time, for example a time of 300 seconds or less.

As used herein and unless otherwise specified, the term “nonwoven web” includes, consists of, or consists essentially of fibers arranged and bonded together (e.g., by a carding process). It refers to a web or sheet made of . Accordingly, the term “nonwoven web” may be considered a shorthand term for a nonwoven fiber-based web. Additionally, as used herein, “nonwoven web” includes any component comprising a nonwoven web or sheet, including, for example, a nonwoven web or sheet having a film laminated to its surface. Methods for making nonwoven webs from fibers are described, for example, in Nonwoven Fabrics Handbook , prepared by Ian Butler, edited by Subhash Batra et al., Printing by Design, 1999, which is hereby incorporated by reference in its entirety. It is well known in the art. As used herein and unless otherwise specified, the term “film” refers to a continuous film or sheet made, for example, by casting or extrusion processes.

As used herein, a “plurality of fibers” may consist of a single fiber type or may include two or more different fiber types. In exemplary embodiments where the plurality of fibers comprises two or more different fiber types, each fiber type generally comprises any amount of the total weight of the plurality of fibers, e.g., from about 0.5% to about 99.5% by weight. may be included. In embodiments where the plurality of fibers consists of a single fiber type, the plurality of fibers is substantially free of the second or more fiber type. The plurality of fibers is substantially free of a second or more fiber type when the plurality of fibers includes less than about 0.5 weight percent of the second or more fiber type. Typically, differences between fiber types include fiber length-to-diameter ratio (L/D), toughness, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T _g ), chemical composition, color, or combinations thereof. It could be the difference.

As used herein, the terms “packet(s)” and “pouch(s)” should be considered interchangeable. In certain embodiments, the terms “packet(s)” and “pouch(s)” are each used to refer to a single unit dose article comprising a water-soluble core substrate containing one or more active cleaning formulations. In certain embodiments, the pouch is sealed with an external water-soluble material to surround and contain a water-soluble core substrate containing one or more active cleaning formulations. Sealed pouches may be made using any suitable method including such processes and features as heat sealing, solvent fusion or sealing, and/or adhesive sealing (e.g., using a water-soluble adhesive).

As used herein, the terms “resin(s)” and “polymer(s)” should be considered interchangeable. In certain embodiments, the terms resin(s) and polymer(s) are used to refer to a polymer, optionally in combination with one or more additional polymers, respectively, and to a single type of polymer, e.g., a resin may contain more than one polymer. It can be included.

As used herein and unless otherwise specified, the terms “weight percent (wt.% and wt%)” refer to, for example, the “dry” (anhydrous) weight of the entire water-soluble film, including residual moisture in the water-soluble film. It is intended to refer to the composition of components identified in parts, or as the context requires, parts by weight of the total composition.

As used herein and unless otherwise specified, the term "PHR" ("phr") refers to a water-soluble film, or a PVOH or other polymer resin (unless otherwise specified) in a solution used to prepare a water-soluble film. is intended to refer to the composition of the identified ingredients in parts per hundred of the water-soluble polymer resin(s).

As used herein and unless otherwise specified, the term “comprising” means that various ingredients, components, or steps can be used together in practicing the present disclosure. Accordingly, the term “comprising” encompasses the more restrictive terms “consisting essentially of” and “consisting of.” The composition may comprise, consist essentially of, or consist of any of the required components disclosed herein. The disclosure illustratively disclosed herein may suitably be practiced without any component or step specifically disclosed herein.

When values are expressed as approximations using the antecedent “about,” it will be understood that the specific values form alternative embodiments. As used herein, “about

SUD articles, water-soluble nonwoven materials, water-soluble foam materials, and water-soluble film materials, and related methods of making and using the SUD articles, water-soluble nonwoven materials, water-soluble foam materials, and water-soluble film materials, are further described below, unless otherwise noted. It is contemplated to include embodiments that include any combination of one or more of the additional optional components, features and steps described.

In an exemplary embodiment, the single unit dose article includes a water-soluble core substrate comprising a water-soluble resin. In exemplary embodiments, the water-soluble core substrate is one of a water-soluble nonwoven core substrate, a water-soluble foam core substrate, or a water-soluble film core substrate, or any suitable combination of a water-soluble nonwoven core substrate, a water-soluble foam core substrate, and/or a water-soluble film core substrate. Contains one or more The water-soluble core substrate includes a carrier solvent with an active cleaning formulation. Upon contact with a suitable amount, e.g., a saturating amount, of the carrier solvent, the water-soluble core substrate exhibits a shrinkage of 0.5% to 65%. In exemplary embodiments where the water-soluble core substrate comprises a water-soluble nonwoven substrate comprising a plurality of fibers, at least one fiber or core substrate exhibits a shrinkage of 0.5% to 65% upon contact with a suitable amount of carrier solvent. In exemplary embodiments where the core substrate is contacted with water having a temperature as low as 5°C to 10°C, the core substrate becomes dispersible, i.e., decomposes, to release the active cleaning formulation. In exemplary embodiments where the core substrate is contacted with water having a temperature greater than 20° C., the water-soluble core substrate is soluble, i.e., dissolves, to release the active cleaning formulation. In exemplary embodiments, the active cleaning formulation is in the form of at least one of a solid, for example, a powder or a plurality of granules or particles, a gel, a liquid, or a slurry, or any suitable combination thereof. In certain embodiments, the water-soluble core substrate is saturated with an active cleaning formulation. In other embodiments, the active cleaning formulation is contained within, coated on, or attached to a water-soluble core substrate, e.g., the active cleaning formulation is disposed on the surface of the water-soluble core substrate. In an exemplary embodiment, the water-soluble core substrate is at least one of coated with an active cleaning formulation or impregnated with an active cleaning formulation. In exemplary embodiments, the active cleaning formulation is present in a water-soluble core substrate, for example, in a fiber-forming composition, foam-forming composition, or film-forming composition.

In an exemplary embodiment, the single unit dose article is a water-soluble composite comprising a water-soluble nonwoven material, a water-soluble foam material, or a water-soluble film material, or a combination thereof, e.g., surrounding a water-soluble core substrate and/or an active cleaning formulation. It includes a water-soluble nonwoven material or a water-soluble film material laminated to a water-soluble foam material. In an exemplary embodiment, a water-soluble external material defines an interior space containing the water-soluble core substrate and the active cleaning formulation. The bonding interface is configured to create a seal surrounding the water-soluble core substrate and the active cleaning formulation within the interior space. In certain embodiments, the water-soluble film is laminated to a water-soluble nonwoven material. For example, the water-soluble film is disposed on a first surface, such as an interior surface of the water-soluble nonwoven material.

Referring to the drawings and initially to FIGS. 1-3, a single unit dose article 20 includes a water-soluble nonwoven substrate 22 comprising a plurality of fibers comprising a water-soluble resin. In an exemplary embodiment, the water-soluble nonwoven substrate 22 includes, without limitation, PVOH fibers or any suitable fiber chemistry, including PVOH fibers blended with up to 90% cellulose-type fibers by weight. In an alternative embodiment, the nonwoven substrate is made from water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven substrate 22 has a basis weight of 15 grams per square meter (gsm) to 150 gsm, more particularly, 30 gsm to 65 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable has a fiber diameter. The fibers of the water-soluble nonwoven substrate 22 may be bonded using any suitable method, including, without limitation, thermal, thermal, chemical, water, or solution bonding or any suitable bonding method known in the art of nonwoven fiber bonding. there is. As described below and in FIGS. 1-3, the water-soluble nonwoven substrate 22 can have any suitable number of layers or plies, for example, from 1 layer or ply to 50 layers or plies, or a specific number of layers or plies. Embodiments may include more. Water-soluble nonwoven substrate 22 may be porous or non-porous and may be cold or hot water soluble. Water-soluble nonwoven substrate 22 may be formed using any suitable manufacturing process known in the art of nonwoven manufacturing, including, but not limited to, carding processes. Components of water-soluble substrate 22 may include, for example, folded layers or plies, laminated layers or plies, or rolled layers or plies.

1-3, in an exemplary embodiment, the water-soluble nonwoven substrate 22 includes a plurality of layers 24. For example, water-soluble nonwoven substrate 22 may include layers 24 _n , 24 _n+1 , 24 _n+2 , 24 _n+3 , etc. In an exemplary embodiment, the water-soluble nonwoven substrate 22 is a continuous sheet of a water-soluble nonwoven web folded into a serpentine structure forming a plurality of layers 24. In an exemplary alternative embodiment, water-soluble nonwoven substrate 22 comprises a plurality of separate water-soluble nonwoven substrate sheets in a lapped, stacked, or layered structure forming a plurality of layers 24. In exemplary embodiments, each layer 24 may include the same active cleaning formulation 26 or each layer 24 may include a different cleaning formulation 26 than one or more other layers 24. You can. For example, in certain embodiments, the first layer (24 _n ) comprises a protease, the second layer (24 _n+1 ) comprises an amylase, and the third layer (24 _n+2 ) comprises a lipase. And, the fourth layer (24 _n+3 ) includes a surfactant, the fifth layer (24 _n+4 ) includes a chelating agent, and the sixth layer (24 _n+5 ) includes a builder. do.

In an exemplary embodiment, the water-soluble nonwoven substrate 22 includes a carrier solvent 25 with an active cleaning formulation 26. In an exemplary embodiment, active cleaning formulation 26 is a liquid formulation. In an exemplary embodiment, a suitable amount, e.g., a saturating amount, of carrier solvent 25 and a water-soluble nonwoven substrate 22, e.g., one or more fibers of a plurality of fibers forming the water-soluble nonwoven substrate 22. Upon contact, the one or more fibers exhibit at least one fibrous or nonwoven substrate, which exhibits a shrinkage of 0.5% to 65%. In an exemplary embodiment, the fibers will have a crystallinity of at least 25%, more particularly between 30% and 35%. In an exemplary embodiment, the carrier solvent 25 includes any suitable polar solvent and may include, without limitation, water, polyols such as glycerol, DPG (dipropylene glycol), or any combination thereof. In another exemplary embodiment, the carrier solvent 25 is first disposed on, for example, coated on, or applied to the water-soluble nonwoven substrate 22 to shrink or swell the fibers of the water-soluble nonwoven substrate 22, and then The active cleaning formulation (26) is applied to the water-soluble nonwoven substrate (22). In an exemplary embodiment, the carrier solvent 25 with the active cleaning formulation 26 facilitates the incorporation of the active cleaning agent into the core substrate, such as a water-soluble nonwoven substrate 22, to form a SUD while maintaining acceptable cleaning power and solubility. Causes product stability.

In an exemplary embodiment in which the water-soluble nonwoven substrate 22 is contacted with water having a temperature of at least 10° C., the water-soluble nonwoven substrate 22 is soluble to release the active cleaning formulation 26 from the water-soluble nonwoven substrate 22. Additionally, when the water-soluble nonwoven substrate 22 is contacted with water having a temperature of at least 10° C. for 300 seconds or less, the active cleaning formulation 26 is substantially released from the water-soluble nonwoven substrate 22. In an alternative embodiment, the water dispersible nonwoven substrate is dispersible such that when the water dispersible nonwoven substrate is contacted with water having a temperature of less than 10° C., the water dispersible nonwoven substrate releases the active cleaning formulation from the water dispersible nonwoven substrate. When the water-dispersible nonwoven substrate is contacted with water having a temperature of less than 10° C. for 300 seconds or less, the active cleaning formulation is substantially released from the water-dispersible nonwoven substrate.

The active cleaning formulation 26 may be a solid, e.g., a powder or a plurality of granules or particles, a gel, liquid, or slurry formulation, or any suitable combination of, e.g., a powder, solid, gel, liquid, or slurry formulation. It may be in the form. In an exemplary embodiment, the active cleaning formulation 26 exists in any suitable phase, including, for example, a solid phase, a liquid phase, a slurry phase (liquid and multiple phases including solids), and any suitable combination of phases. do. For example, the active cleaning formulation 26 may include fine powders or granules, a gel, one or more liquids, or a slurry (e.g., a liquid and multiple phases containing solids), or multiple phases. Active cleaning formulations include, without limitation, detergents, surfactants, emulsifiers, chelating agents, dirt suspenders, stain removers, enzymes, pH adjusters, builders, stain removal polymers, structurants, free fragrance, The encapsulation may include fragrances, preservatives, solvents, minerals, and/or any ingredients suitable for personal hygiene, laundry detergents, dish detergents, and/or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article 20 comprises an active cleaning formulation having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In embodiments where the active cleaning formulation 26 is solid, the particles or granules may have a size from 1 micron to 100 microns, or may be in tablet form.

In an exemplary embodiment, for example, by saturating the water-soluble nonwoven substrate 22 as shown in Figures 1 and 2 with a carrier solvent 25 with an active cleaning formulation 26, as shown in Figure 3, the water-soluble By embedding the carrier solvent 25 with the active cleaning formulation 26 in the matrix of the nonwoven substrate 22, for example in one or more layers 24 of the water soluble nonwoven substrate 22, and/or ) by disposing the carrier solvent 25 with the active cleaning formulation 26 between adjacent layers 24 of, for example, one or more surfaces of layer 24 _n , one or more surfaces of layer 24 _n+1. surface, and/or one or more surfaces of the layer 24 _n+2 , for example by coating the carrier solvent 25 with the active cleaning formulation 26, 25) is comprised by the water-soluble nonwoven substrate 22. Carrier solvent 25 with active cleaning formulation 26 may be adsorbed to and/or adhered to or bound to, for example, the surface of water-soluble nonwoven substrate 22 . In the exemplary embodiment as shown in FIG. 1 , the single unit dose article 20 comprises a multilayered water-soluble nonwoven substrate 22, a carrier solvent having a liquid active cleaning formulation 26 surrounding the water-soluble nonwoven substrate 22. (25), and a water-soluble nonwoven material (28) surrounding and comprising a water-soluble nonwoven substrate (22), a carrier solvent (25), and an active cleaning formulation (26). In an exemplary embodiment as shown in FIG. 2 , the single unit dose article 20 comprises a multilayered water-soluble nonwoven substrate 22 comprising a carrier solvent 25 with a liquid active cleaning formulation 26, and a water-soluble nonwoven fabric. and a water-soluble nonwoven material 28 surrounding and comprising a substrate 22 and a carrier solvent 25 with an active cleaning formulation 26. In an exemplary embodiment as shown in FIG. 3 , the single unit dose article 20 comprises a multilayer water-soluble nonwoven substrate 22 comprising a solid active cleaning formulation 26, and a water-soluble nonwoven substrate 22 and an active cleaning agent. and a water-soluble nonwoven material (28) surrounding and comprising a carrier solvent (25) with a formulation (26).

Referring further to Figures 1-3, in an exemplary embodiment, the water-soluble nonwoven substrate 22 includes a plurality of fibers (detailed structure of the fibers not shown in Figures 1-3). In an exemplary embodiment, one or more fibers of the plurality of fibers are saturated with a carrier solvent (25) with an active cleaning formulation (26). The carrier solvent 25 with the active cleaning formulation 26 may be embedded within one or more fibers of the plurality of fibers or the carrier solvent 25 with the active cleaning formulation 26 may be a surface on one or more fibers of the plurality of fibers. It can be placed on and, for example, coated thereon.

In exemplary embodiments, the water-soluble nonwoven material 28, e.g., as shown in FIGS. 1-3, and/or the water-soluble film (e.g., see FIGS. 13 and 14) is at least partially formed of a water-soluble nonwoven substrate 22 ) and defines an interior space 32 containing, for example, a water-soluble nonwoven substrate 22 and a carrier solvent 25 with an active cleaning formulation 26. For example, in certain embodiments, a water-soluble film (e.g., as described in FIGS. 13 and 14) is laminated to a first surface, e.g., an interior surface of water-soluble nonwoven material 28. In an exemplary embodiment, the water-soluble nonwoven material 28 includes, without limitation, PVOH fibers or any suitable fiber chemistry, including PVOH fibers blended with up to 90% cellulose-type fibers by weight. In an alternative embodiment, the nonwoven material is made from water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material 28 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of water-soluble nonwoven material 28 may be bonded using any suitable method, including, without limitation, thermal, thermal, chemical, water, or solution bonding, or any suitable bonding method known in the art of nonwoven fiber bonding. there is. Water-soluble nonwoven material 28 may include any suitable number of layers or plies, for example, from 1 layer or ply to 50 layers or plies, or in certain embodiments, more. The water-soluble nonwoven material 28 may be porous or non-porous and may be cold or hot water soluble. Water-soluble nonwoven material 28 may be formed using any suitable manufacturing process known in the art of nonwoven manufacturing, including, but not limited to, carding processes. Components of water-soluble material 28 may include, for example, folded layers or plies, stacked layers or plies, or rolled layers or plies. In exemplary embodiments, the first side or surface may have a fibrous appearance, for example, and the second side or surface opposite the first side or surface may be smooth or may be formed in successive layers using heat and/or water. Can be coated with water to create The first surface is an internal surface and the second surface is, in certain embodiments, an external surface.

1-3, the bonding interface 34 forms a seal 36 surrounding the water-soluble nonwoven substrate 22 and the carrier solvent 25 with the active cleaning formulation 26 within the interior space 32. Formed or composed to create. Suitable bonding interfaces or seals 36 may be formed using liquid, solvent, thermal, chemical, pneumatic, or mechanical entanglement (needle punch) bonding or sealing 36. For example, as shown in Figure 1, carrier solvent 25 with liquid active cleaning formulation 26 is contained within interior space 32.

4 and 5 below, single unit dose article 120 includes a water-soluble nonwoven substrate 122 comprising a water-soluble resin. In an exemplary embodiment, the water-soluble nonwoven substrate 122 includes, without limitation, PVOH fibers or any suitable fiber chemistry, including PVOH fibers blended with up to 90% cellulose-type fibers by weight. In an alternative embodiment, the nonwoven substrate is made from water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven substrate 122 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of water-soluble nonwoven substrate 122 may be bonded using any suitable method, including, without limitation, thermal, thermal, chemical, water, or solution bonding or any suitable bonding method known in the art of nonwoven fiber bonding. there is. In exemplary embodiments, the water-soluble nonwoven substrate 122 may include any suitable number of layers or plies, for example, from 1 layer or ply to 50 layers or plies, or in certain embodiments, more. . Water-soluble nonwoven substrate 122 may be porous or non-porous and may be cold or hot water soluble. Water-soluble nonwoven substrate 122 may be formed using any suitable manufacturing process known in the art of nonwoven fabrication, including, but not limited to, carding processes. Components of water-soluble nonwoven substrate 122 may include, for example, a folded layer or ply, a laminated layer or ply, or a rolled layer or ply, or a high loft nonwoven substrate.

In an exemplary embodiment, the water-soluble nonwoven substrate 122 includes a carrier solvent 125 with an active cleaning formulation 126. In an exemplary embodiment, when the water-soluble nonwoven substrate 122 is contacted with water having a temperature greater than 20° C., the water-soluble nonwoven substrate 122 is soluble to release the active cleaning formulation 126. The active cleaning formulation 126 may be in the form of a solid, gel, liquid, or slurry formulation, or any suitable combination of solid, gel, liquid, or slurry formulations, for example. In exemplary embodiments as shown in Figures 4 and 5, the active cleaning formulation 126 is in a solid state, such as tablets, solid particles, granules, or fine powder. Active cleaning formulations 126 include, without limitation, activators, detergents, surfactants, emulsifiers, chelating agents, dirt suspenders, stain removers, enzymes, pH adjusters, builders, stain removal polymers, structurants, glass fragrances, encapsulating fragrances, It may include preservatives, solvents, minerals, and/or any ingredients suitable for personal hygiene, laundry detergents, dish detergents, and/or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article 120 has an active agent having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml, and a particle or granule size of 1.0 microns to 100 microns. Includes cleaning formulation. In an exemplary embodiment, the carrier solvent 125 with the active cleaning formulation 126 is embedded by the water-soluble nonwoven substrate 122, e.g., on the surface of the water-soluble nonwoven substrate 122, as shown in Figure 4. Activities that are adsorbed or bound to solid particles or granules of the cleaning formulation 126 and/or, as shown in FIG. 5, are contained, adsorbed, or bound to the matrix of the water-soluble nonwoven substrate 122. Included by solid particles or granules in the cleaning formulation 126. An exemplary single unit dose article 120 is shown in FIGS. 4 and 5 for illustrative purposes only. The water-soluble nonwoven substrate 122, the carrier solvent 125, and the active cleaning formulation 126 are, respectively, as depicted in Figures 1-3. It may be an example of or the same as this. Single unit dose article 120 as shown in Figures 4 and 5 may be part of single unit dose article 20 as shown in Figures 1-3.

Referring now to Figures 6-9, in an exemplary embodiment, the single unit dose article 220 includes a water-soluble foam substrate 222 comprising a water-soluble resin. In an exemplary embodiment, the water-soluble foam substrate 222 can be selected from any suitable resin chemistry, such as PVOH homopolymer; PVOH copolymer; Modified PVOH copolymers such as PVOH copolymers modified with maleic anhydride (MA), PVOH copolymers modified with monomethyl maleate (MMM), PVOH copolymers modified with 2-acrylamido-2-methylpropanesulfonic acid (AMPS) PVOH copolymers, cellulose and cellulose derivatives, polyvinylpyrrolidone (PVP), proteins, casein, soy, or any water-dispersible or water-soluble resin. In certain embodiments, the water-soluble foam substrate 222 has a thickness of 3 microns to 3000 microns and can be cast, extruded, melt processed, coated, chemically blown, mechanically aerated, air injected, or turbulent extrusion. It may be formed using any suitable manufacturing process known in the art of foam manufacturing, including processes. Water-soluble foam substrate 222 may be porous or non-porous and may be cold or hot water soluble. Components of water-soluble foam substrate 222 may include, for example, folded layers or plies, laminated layers or plies, or rolled layers or plies.

The water-soluble foam substrate 222 is configured to include a carrier solvent 225 with an active cleaning formulation 226. In an exemplary embodiment, upon contact of the carrier solvent 25 with the water-soluble foam substrate 222, the water-soluble foam substrate 222 exhibits a carrier solvent absorption capacity of 1% to 1300%. Additionally, when the water-soluble foam substrate 222 is contacted with water having a temperature greater than 20° C., the water-soluble foam substrate 222 is soluble to release the active cleaning formulation 226. 6-8, water-soluble nonwoven material 228 at least partially surrounds and includes a water-soluble foam substrate 222 and a carrier solvent 225 with active cleaning formulation 226. The active cleaning formulation 226 may be in the form of a solid, liquid, gel, or slurry formulation, or any suitable combination of solid, liquid, gel, or slurry formulations, for example. 6-9, the active cleaning formulation 226 exists in a solid phase, but in certain embodiments, for example, a liquid phase, a slurry phase (liquid containing solids and multiple phases). , and any suitable combination of phases. Active cleaning formulations include, without limitation, activators, detergents, surfactants, emulsifiers, chelating agents, dirt suspenders, stain removers, enzymes, pH adjusters, builders, decontamination polymers, structurants, free flavors, encapsulated flavors, preservatives, and solvents. , minerals, and/or any ingredient suitable for personal hygiene, laundry detergents, dish detergents, and/or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article 220 includes a structuring agent or adhesive material to secure the solid, liquid, or gel active cleaning formulation 226, which is bonded to the water-soluble foam substrate 222 to be used by the consumer. Provides a barrier to the hands of In an exemplary embodiment, the single unit dose article 220 includes the active cleaning formulation 226 having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In an exemplary embodiment as shown in Figures 7-9, the active cleaning formulation 226 comprises a solid active cleaning formulation 226 in the form of a fine powder or granules, or tablets, having a particle size of 1 micron to 100 microns. do.

In an exemplary embodiment, for example, by saturating the water-soluble foam substrate 222 with a carrier solvent 225 with an active cleaning formulation 226 as shown in Figure 6, or by saturating the water-soluble foam substrate 222 with a carrier solvent 225 as shown in Figures 7-9. By attaching, adsorbing, or otherwise binding a solid, e.g., powder or granule, carrier solvent 225 with the active cleaning formulation 226 to the surface of the foam substrate 222, or by ), for example, by disposing or embedding the carrier solvent 225 with the active cleaning formulation 226 in one or more layers or surfaces, or a matrix, of the carrier solvent 225 with the solid active cleaning formulation 226. ), the carrier solvent 225 with the active cleaning formulation 226 is incorporated by the water-soluble foam substrate 222. In an exemplary embodiment as shown in FIG. 6 , the single unit dose article 20 comprises a carrier solvent 225 having a water-soluble foam substrate 222 and an active cleaning formulation 226 included in the water-soluble foam substrate 222; and a water-soluble nonwoven material (228) surrounding and comprising a water-soluble foam substrate (222) and a carrier solvent (225) with an active cleaning formulation (226). 7 and 8, the single unit dose article 220 is a solid phase, e.g., a water-soluble foam comprising a carrier solvent 225 with the active cleaning formulation 226 in powder or granular form. A substrate 222 and a water-soluble nonwoven material 228 at least partially surrounding and comprising a water-soluble foam substrate 222 and a carrier solvent 225 with an active cleaning formulation 226. In the example shown in FIG. 7 , bonding interface 234 surrounds carrier solvent 225 with water-soluble foam substrate 222 and active cleaning formulation 226 within interior space 232 of water-soluble nonwoven material 228. It is formed or configured to create a seal (236). In an exemplary embodiment as shown in FIG. 9 , the single unit dose article 220 is without a water-soluble nonwoven material 228 surrounding a water-soluble foam substrate 222 and a carrier solvent 225 with an active cleaning formulation 226. , comprising a water-soluble foam substrate 222 comprising a carrier solvent 225 with an active cleaning formulation 226 in the form of a solid, for example, powder or granule, attached or bonded to the surface of the water-soluble foam substrate 222. . An exemplary single unit dose article 220 is shown in Figures 6-9 for illustration purposes only. The water-soluble nonwoven substrate 222, the carrier solvent 225, the active cleaning formulation 226, and the water-soluble nonwoven material 228 are, respectively, water-soluble nonwoven substrate 22, carrier solvent 25, and It can be made from the same materials as the active cleaning formulation (26) and the water-soluble nonwoven material (28). Mating interface 234 and seal 236 may be identical to mating interface 34 and seal 36, respectively, as shown in Figures 1-3.

In an exemplary embodiment, the water-soluble nonwoven material 228, e.g., as shown in FIGS. 6-8, and/or the water-soluble film (e.g., see FIGS. 13 and 14) is at least partially formed by the water-soluble foam substrate 222. surrounds and defines an interior space 232 containing a water-soluble foam substrate 222 and a carrier solvent 225 with an active cleaning formulation 226. For example, in certain embodiments, a water-soluble film is laminated to a first surface, such as the interior surface of water-soluble nonwoven material 228. In an exemplary embodiment, the water-soluble nonwoven material 228 comprises any suitable fiber chemistry, such as PVOH fibers or PVOH fibers blended with up to 90% cellulose-type fibers by weight. In an alternative embodiment, the nonwoven material is made from water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material 28 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of water-soluble nonwoven material 28 may be bonded using any suitable method, including, without limitation, thermal, thermal, chemical, water, or solution bonding, or any suitable bonding method known in the art of nonwoven fiber bonding. there is. Water-soluble nonwoven material 228 may include any suitable number of layers or plies, for example, from 1 layer or ply to 50 layers or plies, or in certain embodiments, more. Water-soluble nonwoven material 228 may be porous or non-porous and may be cold or hot water soluble. Water-soluble nonwoven material 228 may be formed using any suitable manufacturing process known in the art of nonwoven manufacturing, including, but not limited to, carding processes. Components of water-soluble material 228 may include, for example, folded layers or plies, stacked layers or plies, or rolled layers or plies. In exemplary embodiments, the first side or surface may have a fibrous appearance, for example, and the second side or surface opposite the first side or surface may be smooth or may be formed in successive layers using heat and/or water. Can be coated with water to create

For example, in exemplary embodiments, as shown in Figures 8 and 9, disposable laundry bags or hamper liners contain a water-soluble foam substrate alone or with a suitable amount of one or more active cleaning formulations for washing multiple loads of laundry. It is included in combination with a water-soluble film base and/or a water-soluble non-woven fabric base. The active cleaning formulation can be embedded within or comprised within a polymer matrix of the water-soluble foam substrate and/or disposed on one or more surfaces of the water-soluble foam substrate. Consumers can simply place the laundry bag or hamper liner containing the dirty laundry into the washing machine and start the wash cycle. In an exemplary embodiment, the water-soluble disposable laundry bag or hamper liner completely dissolves or otherwise disperses to release the active cleaning formulation to clean dirty laundry. In other exemplary embodiments, a single unit dose article, for example in the form of a tag or sticker, may be sewn or otherwise attached to the article of clothing to be cleaned. Consumers may benefit from high-performance cleaning power, natural or more sustainable appearance, and convenience for separating otherwise incompatible cleaners or activators.

Referring now to FIG. 10 , in an exemplary embodiment, a single unit dose article 320 includes a carrier solvent 325 with an active cleaning formulation 326. The active cleaning formulation 326 may be in the form of a solid, powder or granule, gel, liquid, or slurry formulation, or any suitable combination of powder, solid, liquid, or slurry formulations, for example. 10, the active cleaning formulation 326 exists in a solid phase comprising a plurality of solid particles or granules; however, in certain embodiments, the active cleaning formulation 326 is, for example, It may exist in any suitable phase, including a liquid phase, a slurry phase (liquid and multiple phases including solids), or a combination of any suitable phases. Active cleaning formulations include, without limitation, activators, detergents, surfactants, emulsifiers, chelating agents, dirt suspenders, stain removers, enzymes, pH adjusters, builders, decontamination polymers, structurants, free flavors, encapsulated flavors, preservatives, and solvents. , minerals, and/or any ingredient suitable for personal hygiene, laundry detergents, dish detergents, and/or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article 20 comprises an active cleaning formulation having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In an exemplary embodiment, the active cleaning formulation 326 includes a plurality of fine powder particles or granules having a particle size of 1 micron to 100 microns or in tablet form. The particles, granules, or tablets in active cleaning formulation 326 may have different particle sizes, for example, single or dual particle size distributions.

In an exemplary embodiment, the water-soluble nonwoven material 328, e.g., as shown in FIG. 10, and/or the water-soluble film (e.g., see FIGS. 13 and 14) is a carrier solvent with an active cleaning formulation 326. An internal space 332 including 325 is defined. In an exemplary embodiment, the water-soluble nonwoven material 328 comprises any suitable fiber chemistry, such as PVOH fibers or PVOH fibers blended with up to 90% cellulose-type fibers by weight. In an alternative embodiment, the nonwoven material is made from water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material 328 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of water-soluble nonwoven material 328 may be bonded using any suitable method, including, without limitation, thermal, thermal, chemical, water, or solution bonding or any suitable bonding method known in the art of nonwoven fiber bonding. there is. Water-soluble nonwoven material 328 may include any suitable number of layers or plies, for example, from 1 layer or ply to 50 layers or plies, or in certain embodiments, more. Water-soluble nonwoven material 328 may be porous or non-porous and may be cold or hot water soluble. Water-soluble nonwoven material 328 may be formed using any suitable manufacturing process known in the art of nonwoven manufacturing, including, but not limited to, carding processes. Components of water-soluble material 328 may include, for example, folded layers or plies, stacked layers or plies, or rolled layers or plies. In exemplary embodiments, the first side or surface may have a fibrous appearance, for example, and the second side or surface opposite the first side or surface may be smooth or may be formed in successive layers using heat and/or water. Can be coated with water to create

As shown in FIG. 10 , bonding interface 334 is formed or configured to create a seal 336 surrounding carrier solvent 325 with active cleaning formulation 326 within interior space 332 . A suitable bonding interface 334 or seal 336 may be formed using liquid, solvent, thermal, chemical, pneumatic, or mechanical entanglement (needle punching) bonding or sealing 336. In an exemplary embodiment, when the water-soluble nonwoven material 328 is contacted with water having a temperature greater than 20° C., the water-soluble nonwoven material 328 is soluble to release the active cleaning formulation 326. An exemplary single unit dose article 320 is shown in FIG. 10 for illustration purposes only. Carrier solvent 325, active cleaning formulation 326, and water-soluble nonwoven material 328 are carrier solvent 25, active cleaning formulation 26, and water-soluble nonwoven material 28, respectively, as depicted in Figures 1-3. It can be manufactured from the same material as. Mating interface 334 and seal 336 may be identical to mating interface 34 and seal 36, respectively, as shown in Figures 1-3. Particles, granules, or tablets from the active cleaning formulation 326 having different particle sizes, for example in one or dual particle size distributions, may also be applied to the single unit dose article 20 shown in FIGS. 1-3.

11 and 12, the single unit dose article 420 includes a first water-soluble nonwoven web 428a comprising a first water-soluble resin and a second water-soluble resin that is the same or different from the first water-soluble nonwoven web 428a. and a water-soluble nonwoven material 428 with an opposing second water-soluble nonwoven web 428b. The active cleaning formulation 426 is disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web, wherein the first water-soluble nonwoven web and/or the second water-soluble nonwoven web are contacted with water having a temperature greater than 20°C. , the first water-soluble nonwoven web and/or the second water-soluble nonwoven web are soluble to release the active cleaning formulation. A water-soluble film substrate 422 is disposed between a first water-soluble nonwoven web 428a and a second water-soluble nonwoven web 428b, and a carrier solvent 425 with an active cleaning formulation 426 is disposed between the water-soluble film substrate 422. disposed on the surface of, for example, embedded within or coupled thereto.

In an exemplary embodiment, water-soluble film substrate 422 includes a water-soluble resin. In an exemplary embodiment, the water-soluble film substrate 422 can be selected from any suitable chemical, such as PVOH homopolymer, PVOH copolymer, PVOH copolymer modified with MA, PVOH copolymer modified with MMM, PVOH copolymer modified with AMPS. polymers, cellulose and cellulose derivatives, PVP, proteins, casein, soy, or any water-dispersible or water-soluble resin. Water-soluble film substrate 422 has a thickness of 3 microns to 3000 microns and can be formed using any suitable manufacturing process known in the art of foam manufacturing, including, but not limited to, casting, extrusion, melt processing, and coating processes. Water-soluble film substrate 422 may be cold water soluble or hot water soluble. In an exemplary embodiment, the water-soluble film substrate 422 includes a suitable structuring agent or adhesive material to secure or bond the solid, liquid, and/or gel active cleaning formulation 426 to the water-soluble film substrate 422.

In an exemplary embodiment, the water-soluble film substrate 422 includes a carrier solvent 425 with an active cleaning formulation 426. In an exemplary embodiment, when the water-soluble film substrate 422 is contacted with water having a temperature greater than 20° C., the water-soluble film substrate 422 is soluble to release the active cleaning formulation 426. The active cleaning formulation 426 can be any of a solid, e.g., a fine powder or granule, a powder, liquid, or slurry formulation, or, e.g., a solid, e.g., a fine powder or granule, a liquid, or slurry formulation. It may be a suitable combination of . 11 and 12, the active cleaning formulation 426 exists in a solid phase, for example, a liquid phase, a slurry phase (a liquid and a plurality of phases containing solids), and any suitable phase. It may exist in any suitable phase, including combinations of phases. Active cleaning formulations include, without limitation, activators, detergents, surfactants, emulsifiers, chelating agents, dirt suspenders, stain removers, enzymes, pH adjusters, builders, decontamination polymers, structurants, free flavors, encapsulated flavors, preservatives, and solvents. , minerals, and/or any ingredient suitable for personal hygiene, laundry detergents, dish detergents, and/or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article 20 comprises an active cleaning formulation having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In an exemplary embodiment, the active cleaning formulation 426 comprises fine powders or granules having a particle size of 1 micron to 100 microns or in tablet form. The powders or granules may have different sizes with a particle size distribution or, for example, a bimodal particle size distribution.

11 and 12, the single unit dose article 420 comprises a water-soluble film substrate 422 and a solid phase attached to, adsorbed to, or bound to the surface of the water-soluble film substrate 422. a carrier solvent (425) with the active cleaning formulation (426), and a water-soluble nonwoven material (428) at least partially surrounding and comprising the water-soluble film substrate (422) and the carrier solvent (425) with the active cleaning formulation (426). Includes. 11, the single unit dose article 420 comprises a water-soluble film substrate 422 comprising a carrier solvent 425 with a solid active cleaning formulation 426, and an active cleaning formulation ( It includes a water-soluble nonwoven material 428 surrounding and comprising a water-soluble film substrate 422 together with a carrier solvent 425 having 426). 12, the single unit dose article 420 comprises a water-soluble film substrate 422 comprising a carrier solvent 425 with a solid active cleaning formulation 426, and an active cleaning formulation ( and a water-soluble nonwoven material 428 partially surrounding and comprising a water-soluble film substrate 422 together with a carrier solvent 425 having 426). An exemplary single unit dose article 420 is shown in FIG. 10 for illustration purposes only. Carrier solvent 425, active cleaning formulation 426, and water-soluble nonwoven material 428 are carrier solvent 25, active cleaning formulation 26, and water-soluble nonwoven material, respectively, as described with reference to FIGS. 1-3. It can be manufactured from the same material as 28).

In an exemplary embodiment, the water-soluble nonwoven material 428 comprises any suitable fiber chemical, such as PVOH fibers or PVOH fibers blended with up to 90% cellulose-type fibers by weight. In an alternative embodiment, the nonwoven material is made from water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material 428 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of water-soluble nonwoven material 428 may be bonded using any suitable method, including, without limitation, thermal, thermal, chemical, water, or solution bonding, or any suitable bonding method known in the art of nonwoven fiber bonding. there is. Water-soluble nonwoven material 428 may include any suitable number of layers or plies, for example, from 1 layer or ply to 50 layers or plies, or in certain embodiments, more. Water-soluble nonwoven material 428 may be porous or non-porous and may be cold or hot water soluble. Water-soluble nonwoven material 428 may be formed using any suitable manufacturing process known in the art of nonwoven manufacturing, including, but not limited to, carding processes. Components of water-soluble nonwoven material 428 may include, for example, folded layers or plies, laminated layers or plies, or rolled layers or plies. In exemplary embodiments, the first side or surface may have a fibrous appearance, for example, and the second side or surface opposite the first side or surface may be smooth or may be formed in successive layers using heat and/or water. Can be coated with water to create The first surface can be an interior surface and the second surface can be an exterior surface of the single unit dose article 420 in certain embodiments.

As shown in FIG. 11 , the bonding interface 434 is a carrier solvent 425 with a water-soluble film substrate 422 and an active cleaning formulation 426 within an interior space 432 defined by a water-soluble nonwoven material 428. is formed or configured to create a seal 436 surrounding the . Suitable bonding interfaces or seals 436 may be formed using liquid, solvent, thermal, chemical, pneumatic, or mechanical entanglement (needle punching) bonding or sealing 436. Mating interface 434 and seal 436 may be identical to mating interface 34 and seal 36, respectively, as shown in Figures 1-3.

13 and 14, a single unit dose article 520 may be connected or bonded to a water-soluble foam material 529 or a water-soluble nonwoven material 527, for example, made of a water-soluble resin as described herein. and a water-soluble composite 528 comprising a water-soluble film 522 material made of a water-soluble resin as described herein, or laminated thereto. For example, as shown in FIG. 13, the water-soluble composite 528 has a first surface 527a opposite the interior space 532 and an opposing second surface 527b, e.g., on the first surface. and a water-soluble nonwoven web (527) having an exterior surface with a water-soluble film material (522) disposed thereon. The water-soluble composite 528 is bonded at a bonding interface 534 along the edges of the water-soluble material to define the interior space 532 of the single unit dose article 520. A seal 536 is also formed. Active cleaning formulation 526 is disposed within interior space 532. In an exemplary embodiment, when the water-soluble composite 528 is contacted with water having a temperature greater than 20° C., at least a portion of the water-soluble composite 528 is soluble to release the active cleaning formulation 526.

In an exemplary embodiment, as shown, for example, in Figure 13, the water-soluble nonwoven material 527 of the water-soluble composite 528 is blended with any suitable fiber chemistry, such as PVOH fibers or up to 90% cellulose-type fibers by weight. Contains PVOH fibers. In an alternative embodiment, nonwoven material 527 is made from water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material 527 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of water-soluble nonwoven material 527 may be bonded using any suitable method, including, without limitation, thermal, thermal, chemical, water, or solution bonding or any suitable bonding method known in the art of nonwoven fiber bonding. there is. Water-soluble nonwoven material 527 may include any suitable number of layers or plies, for example, from 1 layer or ply to 50 layers or plies, or in certain embodiments, more. Water-soluble nonwoven material 527 may be porous or non-porous and may be cold or hot water soluble. The water-soluble nonwoven material may be formed using any suitable manufacturing process known in the art of nonwoven manufacturing, including, but not limited to, carding processes. Components of water-soluble nonwoven material may include, for example, folded layers or plies, laminated layers or plies, or rolled layers or plies. In exemplary embodiments, the first side or surface may have a fibrous appearance, for example, and the second side or surface opposite the first side or surface may be smooth or may be formed in successive layers using heat and/or water. Can be coated with water to create

In an exemplary embodiment, as shown, for example, in Figure 14, the water-soluble foam substrate 529 of water-soluble composite 528 can be modified with any suitable resin chemistry, such as homopolymer, PVOH copolymer modified with MA, MMM. modified PVOH copolymers, PVOH copolymers modified with AMPS, cellulose and cellulose derivatives, PVP, proteins, casein, soy, or any water-dispersible or water-soluble resin. The water-soluble foam material 529 has a thickness of 3 microns to 3000 microns and can be used in any of the foam manufacturing arts, including, but not limited to, casting, extrusion, melt processing, coating, chemical blown, mechanical aeration, air injection, and turbulent extrusion processes. It may be formed using any suitable manufacturing process. The water-soluble foam material 529 may be porous or non-porous and may be cold or hot water soluble. Components of water-soluble foam material 529 may include, for example, folded layers or plies, laminated layers or plies, or rolled layers or plies.

In an exemplary embodiment, the carrier solvent 525 with the active cleaning formulation 526 is a solid, e.g., a powder or granule, a liquid, or a slurry formulation, or any of the solid, liquid, or slurry formulations, e.g. It may be in the form of a suitable combination. 13 and 14, the active cleaning formulation 526 exists in a liquid phase, but in certain embodiments, for example, a liquid phase, a slurry phase (liquid containing solids, and multiple phases). , a solid phase, and any suitable combination of phases. Active cleaning formulations include, without limitation, activators, detergents, surfactants, emulsifiers, chelating agents, dirt suspenders, stain removers, enzymes, pH adjusters, builders, decontamination polymers, structurants, free flavors, encapsulated flavors, preservatives, and solvents. , minerals, and/or any ingredient suitable for personal hygiene, laundry detergents, dish detergents, and/or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article 520 includes the active cleaning formulation 526 having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In an exemplary embodiment, the active cleaning formulation 526 comprises a fine powder or granules having a particle size of 1 micron to 100 microns or in tablet form.

13, the single unit dose article 520 comprises a water-soluble film material laminated to a water-soluble nonwoven material surrounding and comprising a carrier solvent 525 with an active cleaning formulation 526. and a carrier solvent (525) with a liquid active cleaning formulation (526) contained within the water-soluble composite (528). 14, the single unit dose article 520 comprises a water-soluble film material laminated to a water-soluble foam material surrounding and comprising a carrier solvent 525 with an active cleaning formulation 526. and a carrier solvent (525) with a liquid active cleaning formulation (526) contained within the water-soluble composite (528). Figures 13 and 14 are shown for illustrative purposes. Carrier solvent 525 and active cleaning formulation 526 may be the same as described with reference to Figures 2-12. Carrier solvent 525 and active cleaning formulation 526 may also be adsorbed onto one or more layers of a water-soluble core substrate, such as a nonwoven, foam and/or film, having one of the arrangements described with reference to FIGS. 2-12 within the pouch. , embedded therein, or inserted between them, applied or forming a layer.

In exemplary embodiments, the single unit dose article comprises a water-soluble nonwoven material, e.g., and/or a water-soluble film, which defines an interior space containing the active cleaning formulation. In an exemplary embodiment, the water-soluble nonwoven material includes any suitable fiber chemical, such as PVOH fibers or PVOH fibers blended with up to 90% cellulose-type fibers by weight. In an alternative embodiment, the nonwoven material is made from water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of the water-soluble nonwoven material may be bonded using any suitable method including, without limitation, thermal, thermal, chemical, water, or solution bonding or any suitable bonding method known in the art of nonwoven fiber bonding. The water-soluble nonwoven material may include any suitable number of layers or plies, for example, from 1 layer or ply to 50 layers or plies, or in certain embodiments more. Water-soluble nonwoven materials may be porous or non-porous and may be cold or hot water soluble. The water-soluble nonwoven material may be formed using any suitable manufacturing process known in the art of nonwoven manufacturing, including, but not limited to, carding processes. Components of water-soluble material may include, for example, folded layers or plies, laminated layers or plies, or rolled layers or plies. In exemplary embodiments, the first side or surface may have a fibrous appearance, for example, and the second side or surface opposite the first side or surface may be smooth or may be formed in successive layers using heat and/or water. Can be coated with water to create

In exemplary embodiments, the active cleaning formulation is in the form of a solid, e.g., a powder, but the active cleaning formulation may be in a gel, liquid, or slurry formulation, or any suitable formulation, e.g., a solid, liquid, or slurry formulation. It may be in the form of a combination. Active cleaning formulations include, without limitation, activators, detergents, surfactants, emulsifiers, chelating agents, dirt suspenders, stain removers, enzymes, pH adjusters, builders, decontamination polymers, structurants, free flavors, encapsulated flavors, preservatives, and solvents. , minerals, and/or any ingredient suitable for personal hygiene, laundry detergents, dish detergents, and/or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article comprises an active cleaning formulation having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In an exemplary embodiment, the active cleaning formulation comprises a plurality of fine powder particles or granules having a particle size of 1 micron to 100 microns or in tablet form.

Bonding interface 534 is formed or configured to create a seal 536 surrounding the active cleaning formulation within the interior space. Suitable bonding interfaces or seals can be formed using liquid, solvent, thermal, chemical, pneumatic, or mechanical entanglement (needle punching) bonding or sealing. In an exemplary embodiment, when the water-soluble nonwoven material is contacted with water having a temperature greater than 20° C., the water-soluble nonwoven material is soluble to release the active cleaning formulation from the interior space.

The consumer places one or more single unit dose articles, e.g., single unit dose articles (20, 120, 220, 320, 420, or 520) into a cleaning vessel, e.g., a washing machine or washbasin, to apply the active cleaning formulation; For example, the active cleaning formulation 26, 126, 226, 326, 426, 526 may be delivered or injected into a cleaning vessel for cleaning personal bodies or articles, including, without limitation, clothing, utensils, and/or surfaces. You can. In exemplary embodiments, the materials of the single unit dose article are completely or substantially completely dissolved, or otherwise dispersed, without adversely affecting the clean appearance perceived by the consumer. In certain exemplary embodiments, the single unit dose article is connected or joined to, for example, sewn on or attached to, an article, such as a piece of clothing being cleaned. Other examples include single unit dose articles in the form of tags that are attached to clothing or stickers that are adhesively connected to the surface being cleaned.

Additionally, the single unit dose article 520 can be configured as a bag or container for dirty items for unit cleaning and an overall streamlined cleaning process, for example, a laundry bag containing an active cleaning formulation. A laundry bag containing dirty items can be placed in a washing machine and the dirty items will completely or substantially completely dissolve, or otherwise disperse, as they are washed. Consumer-perceived advantages of single-unit dose articles include, for example, high-performance cleaning, the ability to physically separate otherwise incompatible cleaners, and a natural and more sustainable appearance, convenience, and/or product differentiation and novelty. do.

Referring now to Figure 15, in an exemplary embodiment, a method 600 for making a single unit dose article comprising a carrier solvent with an active cleaning formulation comprises any of steps 602, 604, 606, and 608. Or includes all. In step 602, a water-soluble core substrate comprising a water-soluble resin is formed. In an exemplary embodiment, forming a water-soluble core substrate comprising a water-soluble resin, a carrier solvent with an active cleaning formulation, comprises forming one of a water-soluble nonwoven substrate, a water-soluble foam substrate, or a water-soluble film substrate. do. In an exemplary embodiment, the water-soluble nonwoven substrate is formed of a plurality of layers with a carrier solvent having an active cleaning formulation disposed between adjacent layers of the plurality of layers. The plurality of layers may be formed by folding a continuous sheet of the water-soluble nonwoven web in a serpentine configuration or, for example, by laminating a plurality of separate substrate sheets in an overlapping configuration.

The water-soluble core substrate includes a carrier solvent with an active cleaning formulation as described herein. In an exemplary embodiment, the water-soluble core substrate is saturated with a carrier solvent with the active cleaning formulation, the carrier solvent with the active cleaning formulation is disposed on a surface of the water-soluble core substrate, and the surface of the water-soluble core substrate is with the active cleaning formulation. Coated with a carrier solvent, the carrier solvent with the active cleaning formulation is embedded within a water-soluble core substrate and/or the water-soluble core substrate is impregnated with the carrier solvent with the active cleaning formulation.

In an exemplary embodiment, method 600 comprises applying a carrier solvent comprising glycerol with an active cleaning formulation to the surface of a water-soluble nonwoven sheet, e.g., a 30 gsm water-soluble nonwoven sheet, at a 120° C. applying at a maximum coating weight of gsm, wherein the maximum coating weight limits the amount of active cleaning formulation that can be applied to each water-soluble nonwoven sheet, and the number of plies of water-soluble nonwoven sheets required to make up the water-soluble core substrate. Decide. A carrier solvent comprising the maximum amount of solvent, such as a glycerol solvent, with the active cleaning formulation is applied to the surface of the water-soluble nonwoven substrate until the single unit dose article comprises 55% by weight of the active cleaning formulation. In an exemplary embodiment, the water-soluble nonwoven substrate is formed of multiple layers such that a single unit dose article includes 55% by weight of the active cleaning formulation.

In an exemplary embodiment, method 600 includes forming a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin. The water-soluble core substrate includes a carrier solvent with an active cleaning formulation. Upon contact of at least one fiber of the plurality of fibers with a carrier solvent, the at least one fiber or water-soluble core substrate exhibits a shrinkage of 0.5% to 65%. In an exemplary embodiment, method 600 includes contacting a water-soluble solid substrate with a carrier solvent, wherein upon contact with the carrier solvent, the at least one fiber or substrate exhibits a shrinkage of 0.5% to 65%. . In an exemplary embodiment, when the water-soluble core substrate is contacted with water having a temperature greater than 10° C., the water-soluble core substrate is soluble to release the active cleaning formulation from the water-soluble core substrate. Additionally, when the water-soluble core substrate is contacted with water having a temperature of at least 10° C. for up to 300 seconds, the active cleaning formulation is substantially released from the water-soluble core substrate.

In step 604, the external water-soluble material is formed into an open pouch defining an interior space configured to contain a water-soluble core substrate and a carrier solvent with an active cleaning formulation. The external water-soluble material includes a water-soluble non-woven material, a water-soluble foam material, a water-soluble film material, or a composite comprising a water-soluble non-woven material, a water-soluble foam material, and/or a water-soluble film material. In exemplary embodiments, the outer water-soluble material is formed, for example, as a film layer, or is formed by bonding the inner surface of the outer water-soluble material to form a substantially continuous smooth surface, or the outer water-soluble material has a waxy layer on the inner surface of the outer water-soluble material. and a dispersible barrier coating layer on the inner surface of the outer water-soluble material opposed to the water-soluble core substrate formed by applying a coating or hydrophobic material. Any suitable dispersible barrier coating can be applied to an external water-soluble material to facilitate reducing hand transfer of active cleaning formulations, such as laundry detergents, to the user's hands. In step 606, a carrier solvent with an aqueous core substrate and an active cleaning formulation is injected into the interior space. In an exemplary embodiment, in step 608, the external water-soluble material is sealed to surround the internal space. For example, a seal is formed at the bonding interface to surround the water-soluble core substrate and the active cleaning formulation within an interior space.

In an exemplary embodiment, forming a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin forms a water-soluble nonwoven substrate of a plurality of layers with a carrier solvent and an active cleaning formulation disposed between adjacent ones of the plurality of layers. It includes doing. In an exemplary embodiment, a continuous sheet of water-soluble nonwoven web is folded into a serpentine configuration to form a plurality of layers or a plurality of separate substrate sheets are laminated in an overlapping configuration. A carrier solvent comprising glycerol with an active cleaning formulation can be applied, for example, to a maximum coating weight of 120 gsm over the carrier solvent with an active cleaning formulation, until a single unit dose article comprises 55% by weight of the active cleaning formulation. Applied to the surface of a water-soluble nonwoven substrate. In an exemplary embodiment, the water-soluble nonwoven substrate is formed from 25 layers to 110 layers.

In an exemplary embodiment, a method for making a single unit dose article comprising a carrier solvent with an active cleaning formulation includes forming a water-soluble foam substrate comprising a water-soluble resin. The water-soluble foam substrate comprises a carrier solvent with an active cleaning formulation, wherein upon contact of the carrier solvent with the water-soluble foam substrate, the water-soluble foam substrate exhibits a carrier solvent absorption capacity of 1% to 1300%. For example, the water-soluble foam substrate exhibits a carrier solvent absorption capacity ranging from 10% to 1000%, 10% to 500%, 10% to 200%, or 10% to 100%. In an exemplary embodiment, an external water-soluble material comprising at least one of a water-soluble nonwoven material, a water-soluble foam material, a water-soluble film material, or a composite thereof defines an interior space configured to include a water-soluble foam substrate and a carrier solvent with an active cleaning formulation. It is formed as an open pouch. A carrier solvent with a water-soluble foam substrate and an active cleaning formulation is introduced into the interior space and, in exemplary embodiments, an exterior water-soluble material is sealed to surround the interior space.

Water-soluble films and fiber-forming substances

Water-soluble polymers for use in water-soluble fibers, water-soluble nonwoven webs, water-soluble foams, and water-soluble films include, but are not limited to, polyvinyl alcohol (PVOH) polymers, polyacrylates, water-soluble acrylate copolymers, polyvinyl pyrrolidone, polyethylene. imine, pullulan, water-soluble natural polymers including, but not limited to, guar gum, acacia gum, xanthan gum, carrageenan, and starches, water-soluble including but not limited to modified starches, ethoxylated starches, and hydroxypropylated starches. polymer derivatives, copolymers of the foregoing and combinations of any of the foregoing. Other water-soluble polymers include polyalkylene oxide, polyacrylamide, polyacrylic acid and its salts, cellulose, cellulose ether, cellulose ester, cellulose amide, polyvinyl acetate, polycarboxylic acid and its salts, polyamino acids, polyamides, gelatin, It may include methylcellulose, carboxymethylcellulose and salts thereof, dextrin, ethylcellulose, hydroxyethyl cellulose, hydroxypropyl methylcellulose, maltodextrin, polymethacrylate, and any combination of the above. These water-soluble polymers, whether PVOH polymers or not, are commercially available from a variety of sources.

Generally, fibers, foams, and films as described herein include polyvinyl alcohol. Polyvinyl alcohol is a synthetic polymer generally prepared by alcoholysis, commonly referred to as "hydrolysis" or "saponification", of polyvinyl acetate. Fully hydrolyzed PVOH, in which virtually all of the acetate groups have been converted to alcohol groups, is a strongly hydrogen bonded, highly crystalline polymer that is soluble only in warm water - above about 140°F (about 60°C). If a sufficient number of acetate groups remain after hydrolysis of the polyvinyl acetate, i.e., if the PVOH polymer is partially hydrolyzed, the polymer is more weakly hydrogen bonded, less crystalline, and generally has a temperature of about 50°F (about 10°C). ) is less than - soluble in cold water. As such, the partially hydrolyzed polymer is a PVOH copolymer, but is a vinyl alcohol-vinyl acetate copolymer, commonly referred to as PVOH.

In certain embodiments, suitable examples of such polymers include, without limitation, polyvinyl alcohol homopolymers, polyvinyl alcohol copolymers, modified polyvinyl alcohol copolymers, and combinations thereof. For example, the polyvinyl alcohol copolymer is, in some embodiments, a copolymer of vinyl acetate and vinyl alcohol. For example, in some embodiments, modified polyvinyl alcohol copolymers include anionically modified copolymers, which further include vinyl alcohols that further include additional groups, such as carboxylates, sulfonates, or combinations thereof. It may be a copolymer of acetate and vinyl alcohol. As such, the partially hydrolyzed polymer is a PVOH copolymer, but is a vinyl alcohol-vinyl acetate copolymer, commonly referred to as “polyvinyl alcohol (PVOH)” or “PVOH polymer.” Briefly, as used herein, the term “PVOH polymer” encompasses homopolymers, copolymers, and modified copolymers comprising vinyl alcohol moieties, e.g., 50% or more vinyl alcohol moieties. It is understood that As used herein, the term “PVOH fiber” refers to a fiber comprising PVOH polymer.

The fibers, foams, and/or films described herein may include one or more polyvinyl alcohol (PVOH) homopolymers, one or more polyvinyl alcohol copolymers, one or more modified polyvinyl alcohol copolymers, or combinations thereof. . As used herein, the term “homopolymer” generally includes polymers having a single type of monomeric repeat unit (e.g., a polymeric chain consisting of or consisting essentially of a single monomeric repeat unit). . In the specific case of PVOH, the term "PVOH polymer" refers to a copolymer consisting of a distribution of vinyl alcohol monomer units and vinyl acetate monomer units depending on the degree of hydrolysis (e.g., consisting of or essentially consisting of vinyl alcohol and vinyl acetate monomer units). It further comprises a polymeric chain consisting of). In the limited case of 100% hydrolysis, PVOH homopolymers may comprise true homopolymers with only vinyl alcohol units. In some embodiments, the fibers, foams, and/or films of the present disclosure include polyvinyl alcohol copolymers. In some embodiments, the fibers, foams, and/or films of the present disclosure include cold water soluble or hot water soluble polyvinyl alcohol copolymers.

Unless explicitly indicated otherwise, the term “degree of hydrolysis” is understood as the percentage (e.g., molar percentage) of hydrolyzed moieties out of all hydrolyzable moieties of the initial polymer. For example, for polymers comprising at least one of vinyl acetate moieties or vinyl alcohol moieties, partial replacement of ester groups in the vinyl acetate moiety with hydroxyl groups occurs during hydrolysis, and the vinyl acetate moiety becomes a vinyl alcohol moiety. The degree of hydrolysis of polyvinyl acetate homopolymer can be considered to be zero, while the degree of hydrolysis of polyvinyl alcohol homopolymer can be considered to be 100%. The degree of hydrolysis of the copolymer of vinyl acetate and vinyl alcohol is equal to the percentage of vinyl alcohol moieties in the total vinyl acetate and vinyl alcohol moieties and is from zero to 100%.

In some embodiments, polyvinyl alcohol polymers include modified polyvinyl alcohols, such as copolymers. Modified polyvinyl alcohol may include copolymers or higher polymers (e.g., terpolymers) comprising one or more monomers other than vinyl acetate/vinyl alcohol groups. Optionally, the modification is neutral, for example it is provided by ethylene, propylene, N-vinylpyrrolidone or other uncharged monomer species. Optionally, the modification is a cationic modification, for example it is provided by a positively charged monomeric species. Optionally, the modification is an anionic modification. Accordingly, in some embodiments, the polyvinyl alcohol polymer comprises anionic modified polyvinyl alcohol.

Anionic modified polyvinyl alcohol comprises a partially or fully hydrolyzed PVOH copolymer comprising anionic monomer units, vinyl alcohol monomer units, and optionally vinyl acetate monomer units (i.e., if not completely hydrolyzed). can do. In some embodiments, the modified PVOH copolymer may include two or more types of anionic monomer units. The general series of anionic monomer units that can be used for PVOH copolymers include vinyl sulfonic acid monomers and their esters, monocarboxylic acid vinyl monomers, esters and anhydrides thereof, dicarboxylic acid monomers with polymerizable double bonds, and esters thereof. and anhydrides, and vinyl polymerized units corresponding to alkali metal salts of any of the above. Examples of suitable anionic monomer units include vinyl anionic monomers including vinyl acetic acid, maleic acid, monoalkyl maleates, dialkyl maleates, maleic anhydride, fumaric acid, monoalkyl fumarates, dialkyl fumarates, itaconic acid, Monoalkyl Itaconate, Dialkyl Itaconate, Citraconic Acid, Monoalkyl Citraconate, Dialkyl Citraconate, Citriconic Anhydride, Mesaconic Acid, Monoalkyl Mesaconate, Dialkyl Mesaconate, Glutaconate Conic acid, monoalkyl glutaconate, dialkyl glutaconate, alkyl acrylate, alkyl acrylate, vinyl sulfonic acid, allyl sulfonic acid, ethylene sulfonic acid, 2-acrylamido-1-methyl propane sulfonic acid, 2- Acrylamide-2-methylpropanesulfonic acid, 2-methylacrylamido-2-methylpropanesulfonic acid (AMPS), 2-sulfoethyl acrylate, alkali metal salts of the above (e.g. sodium, potassium, or other alkali metal salts), esters of the foregoing (e.g., methyl, ethyl, or other C ₁ -C ₄ or C ₆ alkyl esters), and combinations of the foregoing (e.g., multiple forms of anionic monomers or equivalent vinyl polymerization units corresponding to the same anionic monomer form. In some embodiments, the modified PVOH copolymer may include two or more types of monomer units selected from neutral, anionic, and cationic monomer units.

The level of incorporation of one or more anionic monomer units in the PVOH copolymer is not particularly limited. In certain embodiments, the one or more anionic monomer units range from about 1 mole % or 2 mole % to about 6 mole % or 10 mole % (e.g., in various embodiments at least 1.0, 1.5, 2.0, 2.5, 3.0 , 3.5, or 4.0 mole percent and/or up to about 3.0, 4.0, 4.5, 5.0, 6.0, 8.0, or 10 mole percent).

Polyvinyl alcohol can undergo changes in solubility properties. Acetate groups in co-poly(vinyl acetate vinyl alcohol) polymers (PVOH copolymers) are known to those skilled in the art to be hydrolyzable by acidic or alkaline hydrolysis. As the degree of hydrolysis increases, polymer compositions made from PVOH copolymers will have increased mechanical strength at lower temperatures, but will have reduced solubility (e.g., hot water temperatures are required for complete dissolution). Accordingly, exposure of a PVOH copolymer to an alkaline environment (e.g., resulting from laundry bleach additives) can change from rapid and complete dissolution in a given aqueous environment (e.g., cold water medium) to gradual and/or dissolution in an aqueous environment. Alternatively, it may convert the polymer to become incompletely soluble, potentially resulting in undissolved polymeric residue.

The degree of hydrolysis (DH) of the PVOH homopolymers and PVOH copolymers (including modified PVOH copolymers) included in the water-soluble fibers, foams, and films of the present disclosure is from about 75% to about 99.9% (e.g., about 79.9%). % to about 92%, about 75% to about 89%, about 80% to about 90%, about 88% to 92%, about 86.5% to about 89%, or about 88%, 90% or 92% such as cold water solubility. For the composition: about 90% to about 99.9%, about 90% to about 99%, about 92% to about 99%, about 95% to about 99%, about 98% to about 99%, about 98% to about 99.9%. %, about 96%, about 98%, about 99%, or greater than 99%). As the degree of hydrolysis is reduced, fibers, foams, or films made from the polymer will have reduced mechanical strength at temperatures below about 20° C., but more rapid solubility. As the degree of hydrolysis increases, fibers, foams, or films made from the polymer will tend to become mechanically stronger and thermoformability will tend to decrease. The degree of hydrolysis of PVOH can be selected such that the water solubility of the polymer is temperature dependent and thus also affects the solubility of films, foams, or fibers made with the polymer and additional components. In certain embodiments, the films, foams, and/or fibers are cold water soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., copolymers that do not copolymerize with anionic monomers), cold water soluble fibers that are soluble in water at temperatures below 10° C.; The foam or film may be PVOH having a degree of hydrolysis ranging from about 75% to about 90%, from about 75% to about 89%, or from about 80% to about 90%, or from about 85% to about 90%. may include. In other embodiments, the fibers, foams, or films are hot water soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., copolymers that do not copolymerize with anionic monomers), hot water soluble fibers that are soluble in water at a temperature of at least about 60° C. , foam, or film may include PVOH having a degree of hydrolysis of at least about 98%. In an embodiment, one or more of the plurality of fibers comprises a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 75% to about 99.9%. In an embodiment, one or more of the plurality of fibers comprises a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 75% to about 98%. In an embodiment, one or more of the plurality of fibers comprises a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 75% to about 89%. In an embodiment, one or more of the plurality of fibers comprises a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 90% to about 99.9%. In an embodiment, the water-soluble film comprises a polyvinyl alcohol copolymer or modified PVOH copolymer having a degree of hydrolysis ranging from about 75% to about 99.9%. In an embodiment, the water-soluble film comprises a polyvinyl alcohol homopolymer or polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 98%.

The degree of hydrolysis of a polymer blend is also determined by the arithmetic weighted average degree of hydrolysis ( ) can be characterized. For example, for a PVOH polymer comprising two or more PVOH polymers is the following expression It is calculated as, where W _i is the mole percentage of each PVOH polymer and H _i is the degree of hydrolysis of each. When a polymer is referred to as having (or not) a specified degree of hydrolysis, the polymer may be a single polyvinyl alcohol polymer with a specified degree of hydrolysis or a blend of polyvinyl alcohol polymers with a specified average degree of hydrolysis.

The viscosity (μ) of the PVOH polymer is measured on freshly prepared solutions using a Brookfield LV type viscometer with UL adapter as described in British Standard EN ISO 15023-2:2006 Annex E Brookfield Test method. It is decided. It is international practice to express the viscosity of a 4% aqueous polyvinyl alcohol solution at 20°C. All viscosities specified herein in centipoise (cP) are to be understood as referring to the viscosity of a 4% aqueous polyvinyl alcohol solution at 20° C., unless otherwise specified. Similarly, when a polymer is described as having (or not having) a specific viscosity, unless otherwise specified, the specified viscosity is intended to be the average viscosity for the polymer, which essentially corresponds to the molecular weight distribution, That is, it has a weighted natural log average viscosity. The viscosity of a PVOH polymer is a function of the weight average molecular weight of the PVOH polymer. , and often the viscosity is It is well known in the art that it is used as an alternative to .

In embodiments, the PVOH resin is between about 1.0 and about 50.0 cP, about 1.0 and about 40.0 cP, or about 1.0 and about 30.0 cP, such as about 4 cP, 8 cP, 15 cP, 18 cP, 23 cP, or It can have a viscosity of 26 cP. In embodiments, the PVOH homopolymers and/or copolymers have a molecular weight of about 1.0 to about 40.0 cP, or about 5 cP to about 23 cP, such as about 1 cP, 1.5 cP, 2 cP, 2.5 cP, 3 cP, 3.5 cP. cP, 4 cP, 4.5 cP, 5 cP, 5.5 cP, 6 cP, 6.5 cP, 7 cP, 7.5 cP, 8 cP, 8.5 cP, 9 cP, 9.5 cP, 10 cP, 11 cP, 12 cP, 13 cP, 14 cP, 15 cP, 17.5 cP, 18 cP, 19 cP, 20 cP, 21 cP, 22 cP, 23 cP, 24 cP, 25 cP, 26 cP, 27 cP, 28 cP, 29 cP, 30 cP, 31 cP , 32 cP, 33 cP, 34 cP, 35 cP, or 40 cP. In embodiments, the PVOH homopolymer and/or copolymer may have a viscosity of about 21 cP to 26 cP. In embodiments, the PVOH homopolymers and/or copolymers may have a viscosity of about 5 cP to about 14 cP. In embodiments, the PVOH homopolymer and/or copolymer may have a viscosity of about 5 cP to about 23 cP.

Water-soluble polymers, whether polyvinyl alcohol polymers or not, can be blended. When the polymer blend comprises a blend of polyvinyl alcohol polymers, the PVOH polymer blend is a PVOH copolymer comprising one or more types of anionic monomer units (e.g., PVOH ter- (or higher co-) polymers). or a first PVOH polymer (“first PVOH polymer”), which may comprise a modified PVOH copolymer and one or more types of anionic monomer units (e.g., PVOH ter- (or higher co-) polymers) and a second PVOH polymer (“second PVOH polymer”), which may include a PVOH copolymer comprising a PVOH copolymer or a modified PVOH copolymer. In some embodiments, the PVOH polymer blend solely includes a first PVOH polymer and a second PVOH polymer (e.g., a binary blend of two polymers). Alternatively, or additionally, the PVOH polymer blend, or fibers, foams, or films made therefrom, may be substantially free or free of other polymers (e.g., other water-soluble polymers in general, other PVOH-based polymers, or both). It can be characterized as being absent. As used herein, “substantially free” means that the first and second PVOH polymers comprise at least 95%, at least 97%, or at least 99% by weight of the total amount of water-soluble polymers in the water-soluble fiber, foam, or film. It means to compose. In other embodiments, the water-soluble fibers, foams, or films may include one or more additional water-soluble polymers. For example, the PVOH polymer blend includes a third PVOH polymer, a fourth PVOH polymer, a fifth PVOH polymer, etc. (e.g., one or more additional PVOH copolymers or modified PVOH copolymers with or without anionic monomer units). can do. For example, the water-soluble film may comprise at least a third (or fourth, fifth, etc.) water-soluble polymer other than the PVOH polymer (e.g., other than a PVOH copolymer or a modified PVOH copolymer with or without anionic monomer units). may include. PVOH homopolymer may also be included in each blend.

biodegradable

Polyvinyl alcohol polymers are generally biodegradable because they decompose in the presence of water and enzymes under aerobic, anaerobic, soil and compost conditions. Generally, as the degree of hydrolysis of the polyvinyl alcohol polymer increases up to about 80%, the biodegradation activity of the polyvinyl alcohol polymer increases. Without intending to be bound by theory, it is believed that increasing the degree of hydrolysis beyond 80% does not significantly affect biodegradability. Additionally, the stereoregularity of the hydroxyl groups of the polyvinyl alcohol polymer has a great influence on the level of biodegradability activity, and the greater the isotacticity of the hydroxyl groups of the polymer sequence, the higher the degradation activity. Without intending to be bound by theory, for soil and/or compost biodegradation, nonwoven webs made from polyvinyl alcohol fibers are superior to similar polyvinyl alcohol polymers due to the increased polymer surface area provided by the nonwoven web relative to the film. It is believed to have a higher level of biodegradation activity compared to the water-soluble films from which it is produced. Additionally, while not intending to be bound by theory, the degree of polymerization of a polyvinyl alcohol polymer will have little or no effect on the biodegradability of the film, foam, or nonwoven web made from the polymer, but the polymerization temperature This can have an impact on the biodegradability of the nonwoven fabric because the polymerization temperature can affect the crystallinity and aggregation state of the polymer. As the degree of crystallinity decreases, the polymer chain hydroxyl groups become less ordered in the polymer structure and the polymer chains become more disordered, causing the chains to accumulate as amorphous aggregates, thereby reducing the availability of ordered polymer structures, The biodegradation activity is thus expected to be reduced for soil and/or compost biodegradation mechanisms, where the polymer is not soluble. Without intending to be bound by theory, since the stereoregularity of the hydroxyl groups of polyvinyl alcohol polymers has a great influence on the level of biodegradable activity, functional groups other than hydroxyl groups (e.g., anionic AMPS functional groups, Substitution of a boxylate group, or lactone group) is expected to reduce the level of biodegradable activity compared to a polyvinyl alcohol copolymer with the same degree of hydrolysis, unless the functional group itself is also biodegradable, in which case the biodegradation of the polymer It is believed that sex can be increased by substitution. Additionally, although the level of biodegradable activity of substituted polyvinyl alcohol may be less than that of the corresponding homopolymer or copolymer, it is believed that substituted polyvinyl alcohol will still be biodegradable.

Methods for determining biodegradation activity are described, for example, in Chiellini et al., Progress in Polymer Science, Volume 28, Issue 6, 2003, pp. 963-1014, which is incorporated herein by reference in its entirety. Additional methods and standards can be found in ECHA's Annex XV Restriction Report - Microplastics, Version number 1, January 11, 2019, which is incorporated by reference in its entirety. Suitable standards include OECD 301B (immediate biodegradation), OECD 301B (enhanced biodegradation), OECD 302B (intrinsic biodegradation), OECD 311 (anaerobic), and ASTM D5988 (soil).

In exemplary embodiments, the fibers described herein may be of readily biodegradable or enhanced biodegradable standards. As used herein, the term "immediate biodegradation" means that a material (e.g. a fiber) undergoes 60% biodegradation (mineralization) within 28 days from the start of the test, according to the OECD 301B test as described in ECHA's Annex XV. ) refers to the standard that is met when it is reached. As used herein, the term "enhanced biodegradation" refers to a standard that is met when 60% biodegradation is reached within 60 days from the start of the test, according to the OECD 301B test as described in ECHA's Annex XV, supra. do. In an exemplary embodiment, the fiber meets standards for immediate biodegradation. In exemplary embodiments, the films herein meet standards for immediate biodegradation or enhanced biodegradation. In exemplary embodiments, laminates (nonwovens and films or foams and films) as used herein meet standards for immediate biodegradation or enhanced biodegradation.

carrier solvent

In an exemplary embodiment, the carrier solvent includes a polar solvent. In exemplary embodiments, the solvent is octanol, heptanol, hexanol, pentanol, butanol, propanol, tetrahydrofuran, dichloromethane, acetone, ethanol, N -methylpyrrolidone, methanol, acetonitrile, ethylene glycol, N,N -dimethylformamide, glycerol, dimethyl sulfoxide, formic acid, water, or combinations thereof. In exemplary embodiments, the carrier solvent is n -octanol, n -heptanol, n -hexanol, n -pentanol, n -butanol, isobutanol, sec -butanol, tert -butanol, n -propanol, isopropanol, Acetone, ethanol, N -methylpyrrolidone, methanol, acetonitrile, N,N -dimethylformamide, dimethyl sulfoxide, formic acid, water, or combinations thereof. In exemplary embodiments, the carrier solvent is n -propanol, acetone, ethanol, N-methylpyrrolidone, methanol, acetonitrile, N,N -dimethylformamide, dimethyl sulfoxide, formic acid, water, or combinations thereof. Includes. In an exemplary embodiment, the carrier solvent comprises an alcohol that is liquid under miscible conditions. In an exemplary embodiment, the carrier solvent includes methanol. In an exemplary embodiment, the carrier solvent includes methanol and at least one additional solvent. In an embodiment, the carrier solvent includes methanol and water. In an exemplary embodiment, the carrier solvent includes at least one of butanol, pentanol, hexanol, heptanol, and octanol in combination with water. In an exemplary embodiment, the carrier solvent includes DMSO and water. In an exemplary embodiment, the carrier solvent comprises DMSO and water, provided in a weight ratio of about 40/60 to 80/20. Without intending to be bound by theory, as the amount of water increases above 60% or the amount of DMSO increases above 60%, the interaction of the polyvinyl alcohol with each solvent increases, resulting in increased swelling of the polymer and It is believed to cause gelation.

In an exemplary embodiment, the carrier solvent includes a non-polar solvent. In exemplary embodiments, the carrier solvent includes hexane, cyclohexane, methylpentane, pentane, cyclopropane, dioxane, benzene, pyridine, xylene, toluene, diethyl ether, chloroform, or combinations thereof.

In an exemplary embodiment, the carrier solvent comprises a mixture of a first carrier solvent and a second carrier solvent. In an exemplary embodiment, the first carrier solvent comprises a polar solvent and the second carrier solvent comprises a non-polar solvent. In an exemplary embodiment, the first carrier solvent has a first dielectric constant, the second carrier solvent has a second dielectric constant, and the dielectric constant of the first carrier solvent is different from the dielectric constant of the second carrier solvent, for example. And, for example, higher than this. In exemplary embodiments, the first dielectric constant is 5 or less, 4 or less, 3 or less, or 2 or less. In exemplary embodiments, the second dielectric constant is greater than 5, greater than 7.5, greater than 10, greater than 15, greater than 18, greater than 20, greater than 25, or greater than 30. In exemplary embodiments, the difference between the first dielectric constant and the second dielectric constant is at least 3, at least 5, at least 8, or at least 10. In exemplary embodiments where the carrier solvent comprises a mixture of a first carrier solvent and a second carrier solvent, the first carrier solvent and the second carrier solvent may be provided in any ratio, provided that the fibers are treated prior to and during processing. , and is not soluble in the mixture after treatment. In exemplary embodiments, the first carrier solvent and the second carrier solvent have a weight of about 99/1 to about 1/99, about 95/5 to about 5/95, about 90/10 to 10/90, about 85/15 to about 85/15. About 15/85, about 80/20 to about 20/80, about 75/25 to about 25/75, about 70/30 to about 30/70, about 65/35 to about 35/65, about 60/40 to It may be provided in a weight ratio of about 40/60, about 55/45 to about 45/55, or about 50/50.

active cleaning formulation

In exemplary embodiments, the SUD article and, more specifically, the water-soluble core substrate are configured to include one or more active cleaning formulations, such as laundry detergent formulations. In exemplary embodiments, the active cleaning formulation is disposed on or coated on one or more surfaces of the water-soluble core substrate or contained within and/or attached to the water-soluble core substrate. The water-soluble core substrate may comprise a single layer, e.g., a single-layer foam core substrate, or may comprise a plurality of layers, e.g., to form a layer with the active cleaning formulation disposed between adjacent layers of the water-soluble nonwoven core substrate. , for example, may include sheets of a non-woven core substrate folded or overlapped in a serpentine arrangement. By way of example, and without limitation, an active cleaning formulation may include an activator, laundry detergent, soap, fabric softener, bleach, laundry accelerator, stain remover, optical brightener, or water softener. Other examples include dish detergent, soap or cleaner, shampoo, conditioner, body wash, face wash, skin lotion, skin treatment, body oil, fragrance, hair treatment, bath salt, essential oil, bath bomb, or enzyme. In certain exemplary embodiments, the water-soluble core substrate is surrounded by a water-soluble nonwoven material, a water-soluble foam material, and/or a water-soluble film material.

supplements

Generally, along with the film-forming, foam-forming, and/or fiber-forming materials, the fibers, nonwoven webs, foams, and/or water-soluble films of the disclosure may be supplemented with adjuvants, such as, but not limited to, plasticizers, plasticizer compatibilizers. , surfactants, lubricants, mold release agents, fillers, extenders, crosslinkers, anti-blocking agents, antioxidants, detackifying agents, anti-foaming agents, nanoparticles such as layered silicate nanoclays (e.g. sodium montmorillonite), bleaches (e.g. For example, sodium metabisulfite, sodium bisulfite or others), aversive agents such as bittering agents (e.g., denatonium salts such as denatonium benzoate, denatonium saccharide and denatonium chloride; sucrose octaacetate; quinine; flavonoids such as Quercetin and naringen; quassinoids such as quassin and brucin) and stimulants (e.g. capsaicin, piperine, allyl isothiocyanate, resinferatoxin) and other functional ingredients for their intended use. It can be included in an amount appropriate for the purpose. As used herein and unless otherwise specified, “adjuvant” includes secondary additives, processing agents, and activators. These specific adjuvants may be selected from those suitable for use in water-soluble fibers, non-water-soluble fibers, nonwoven webs, foams, or those suitable for use in water-soluble films.

In exemplary embodiments, the fibers, foams, and/or films may be free of adjuvants. As used herein and unless otherwise specified, “free of adjuvants” with respect to fibers means that the fibers contain less than about 0.01%, less than about 0.005%, or less than about 0.001% by weight, based on the total weight of the fibers. This means that it contains supplements. As used herein and unless otherwise specified, “free of adjuvants” with respect to a film or nonwoven web means that the nonwoven web contains less than about 0.01 weight percent, and about 0.005%, based on the total weight of the film, foam, or nonwoven web. means containing less than % by weight, or less than about 0.001 % by weight, of adjuvants. In an embodiment, the water-soluble fiber includes a plasticizer. In an embodiment, the water-soluble fiber includes a surfactant. In an embodiment, the non-water soluble fiber includes a plasticizer. In an embodiment, the non-water soluble fiber includes a surfactant. In an embodiment, the nonwoven web includes a plasticizer. In an embodiment, the nonwoven web includes a surfactant.

Plasticizers are liquids, solids, or semi-solids that are added to materials (usually resins or elastomers) to make them softer, more flexible (by reducing the glass-transition temperature of the polymer), and easier to process. Polymers can alternatively be internally plasticized by chemically modifying the polymer or monomers. Additionally, or alternatively, the polymer may be externally plasticized by addition of a suitable plasticizer. Water is recognized as a very effective plasticizer for PVOH polymers and other polymers, including but not limited to water-soluble polymers; However, the volatility of water limits its usefulness because the polymer film needs to have at least some resistance (robustness) to a variety of ambient conditions, including low and high relative humidity.

Plasticizers include, without limitation, glycerin, diglycerin, sorbitol, xylitol, maltitol, ethylene glycol, diethylene glycol, triethylene glycol, dipropylene glycol, tetraethylene glycol, propylene glycol, polyethylene glycol up to 1000 MW, neopentyl glycol, It may include trimethylolpropane, polyether polyol, sorbitol, 2-methyl-1,3-propanediol (MPDiol®), ethanolamine, and mixtures thereof.

Surfactants for use in films are well known in the art and may be suitably used in the fibers, foams, films, and/or compositions of the disclosure. Optionally, a surfactant is included to aid in dispersion of the fibers during carding. Optionally, surfactants are included as cleaning aids. Suitable surfactants may include nonionic, cationic, anionic and zwitterionic series. Suitable surfactants include, but are not limited to, sodium alkyl sulfate (sodium dodecyl sulfate) and other surfactants suitable for laundry applications as cleaning aids, propylene glycol, diethylene glycol, monoethanolamine, polyoxyethylenated polyoxypropylene glycol, Alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylene glycols and alkanolamides (nonionic), polyoxyethylenated amines, quaternary ammonium salts and quaternary polyoxyethylenated amines (cationic), about 8 to 24 Alkali metal salts of high fatty acids containing 2 carbon atoms, alkyl sulfates, alkyl polyethoxylate sulfates and alkylbenzene sulfonates (anionic), and amine oxides, N-alkylbetaines and sulfobetaines (zwitterionic). Includes. Other suitable surfactants are dioctyl sodium sulfosuccinate, lactylated fatty acid esters of glycerin and propylene glycol, lactylic esters of fatty acids, sodium alkyl sulfates, polysorbate 20, polysorbate 60, polysorbate 65, polysorb. Bait 80, lecithin, acetylated fatty acid esters of glycerin and propylene glycol and odium lauryl sulfate, acetylated esters of fatty acids, myristyl dimethylamine oxide, trimethyl tallow alkyl ammonium chloride, quaternary ammonium compound, about 8 to 24 carbons alkali metal salts of high fatty acids containing atoms, alkyl sulfates, alkyl polyethoxylate sulfates, alkylbenzene sulfonates, monoethanolamine, lauryl alcohol ethoxylate, propylene glycol, diethylene glycol, sodium cocoyl isethionate, Sodium lauryl sulfate, glucotain, phoenamid, cola lipid, cocamide, such as cocamide ethanolamine, ethylene oxide surfactants, saponified oils of avocado and palm. , salts thereof, and combinations of any of the above. In an embodiment, the surfactant includes cocamide. Without intending to be bound by theory, it is believed that cocamide may aid in foam formation, which improves the foaming experience of articles containing personal care compositions. In various embodiments, the amount of surfactant in the fiber is from about 0.01% to about 10% by weight, from about 0.1% to about 5% by weight, from about 1.0% to about 2.5% by weight, or from about 0.01% to about 1.5% by weight. %, ranging from about 0.1% to about 1% by weight, from about 0.01% to 0.25% by weight, or from about 0.10% to 0.20% by weight. In various embodiments, the amount of surfactant in the personal care composition contained within the pouch ranges from about 5% to about 50% by weight, from about 10% to about 45% by weight, or from about 10% to about 40% by weight. It can be.

In embodiments, the nonwoven webs, foams, and/or films of the disclosure may further include adjuvants such as one or more of the following groups: exfoliants (chemical exfoliants and mechanical exfoliants), fragrances, and /or perfume microcapsules, repellents, surfactants, colorants, enzymes, skin conditioners, oil removers, and cosmetic agents.

In embodiments, the adjuvant is provided in or on one or more of the nonwoven web, foam, plurality of fibers, and water-soluble film. In embodiments, the active cleaning formulation is provided on or within one or more of the following groups: a nonwoven web, a plurality of fibers, and a water-soluble film. In embodiments, one or more adjuvants may be provided on the surface of the nonwoven web. In embodiments, one or more adjuvants may be dispersed among the fibers of the nonwoven web. In embodiments, one or more adjuvants may be dispersed on the sides of the nonwoven web. In embodiments, one or more adjuvants may be dispersed within the fiber. In embodiments, one or more adjuvants may be dispersed on the fiber. In embodiments, one or more adjuvants may be provided on one side of the water-soluble film. In embodiments, one or more adjuvants may be dispersed within the water-soluble film. In an embodiment, the nonwoven web in the form of a pouch has an outer surface opposite the interior space and the active cleaning formulation is provided on the outer surface. In an embodiment, the nonwoven web in the form of a pouch has an outer surface opposite the interior space and one or more adjuvants are provided on the outer surface.

Chemical exfoliants, mechanical exfoliants, fragrance and/or perfume microcapsules, repellents, surfactants, colorants, proteins, peptides, enzymes, skin conditioners, oil removers, cosmetic agents, or combinations thereof, if present, are polymeric. It may be provided in an amount of at least about 0.1% by weight, or in an amount ranging from about 0.1% to about 99% by weight, based on the weight of the mixture (e.g., fiber-forming material or film-forming material). In embodiments, chemical exfoliants, mechanical exfoliants, fragrance and/or perfume microcapsules, repellents, surfactants, colorants, enzymes, skin conditioners, oil removers, and/or cosmetic agents include fibers and/or fibers such as for exfoliation of human skin. /or may be provided in an amount sufficient to provide additional functionality of the film. Chemical exfoliants, mechanical exfoliants, fragrance and/or perfume microcapsules, repellents, surfactants, colorants, enzymes, skin conditioners, oil removers, cosmetic agents, or combinations thereof may be used as solids (e.g., powders, granules, crystals). , pieces, or ribbons), liquids, mulls, pastes, gases, etc., and can optionally be encapsulated such as microcapsules.

In certain embodiments, nonwoven webs, foams, and/or films may include enzymes. Suitable enzymes fall into the six conventional Enzyme Commission (EC) categories: oxidoreductases of EC 1 (catalyze oxidation/reduction reactions), transferases of EC 2 (catalyze functional groups, e.g. methyl or phosphate groups), transfer), hydrolase of EC 3 (catalyzes the hydrolysis of various bonds), hydrolase of EC 4 (cleaves various bonds by means other than hydrolysis and oxidation), isomerization of EC 5 Includes enzymes that are classified as either enzymes (catalyze isomerization changes within a molecule) and ligases of EC 6 (join two molecules by a covalent bond). Examples of such enzymes include dehydrogenases and oxidase in EC 1, transaminases and kinases in EC 2, lipases, cellulases, amylases, mannanases, and peptidases (i.e., proteases or proteolytic enzymes) in EC 3, and Includes decarboxylase, isomerase and mutase of EC 5 and synthase and synthase of EC 6. Suitable enzymes from each category are described, for example, in U.S. Pat. No. 9,394,092, the entire disclosure of which is incorporated herein by reference. In certain embodiments, the enzymes include bromelain (pineapple extract), papain (papaya), ficin (fig), actinidin (kiwi), hyaluronidase, lipase, peroxidase, and superoxide dismutase. , tyrosinase, alkaline phosphatase, or a combination thereof. In embodiments, enzymes may be encapsulated, for example in the form of nanoemulsions, nanocapsules, granules, or combinations thereof.

Enzymes for use in laundry and dishwashing applications include proteases, amylases, lipases, dehydrogenases, transaminases, kinases, cellulases, mannanases, peptidases, decarboxylases, isomerases, mutases, synthases, synthases and It may comprise one or more of oxido-reductase enzymes, including oxido-reductase enzyme, which catalyzes the formation of bleach.

It is contemplated that enzymes for use herein may be derived from any suitable source or combination of sources, such as bacterial, fungal, plant, or animal sources. In one embodiment, the mixture of two or more enzymes will be derived from at least two different types of sources. For example, mixtures of proteases and lipases can be derived from bacterial (protease) and fungal (lipase) sources.

Enzymes for use herein, optionally but not limited to any enzyme family or member described herein, are those that function at alkaline pH conditions, e.g., a pH ranging from about 8 to about 11. Enzymes for use herein, optionally including but not limited to any enzyme family or member described herein, are those that operate at temperatures ranging from about 5°C to about 45°C.

In embodiments, nonwoven webs, foams, and/or films may include proteins and/or peptides. Suitable proteins and/or peptides include, but are not limited to, collagen and/or collagen peptides, or amino acids such as aspartic acid, glutamic acid, serine, histidine, glycine, threonine, arginine, alanine, tyrosine, cysteine, valine, methionine. , phenylalanine, isoleucine, leucine, lysine, hydroxyproline, or proline.

In embodiments, nonwoven webs, foams, and/or films may include colorants. Suitable colorants are indicator dyes, such as pH indicators (e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), moisture/water indicators (e.g., hydrochromic inks or leuco dyes), or heat. A photochromic ink may be included, wherein the ink changes color as temperature increases and/or decreases. Suitable colorants include, but are not limited to, triphenylmethane dyes, azo dyes, anthraquinone dyes, perylene dyes, indigoid dyes, food, drug and cosmetic (FD&C) colorants, organic pigments, inorganic pigments, or combinations thereof. do. Examples of colorants include, but are not limited to, FD&C Red #40; Red #3; FD&C Black #3; Black #2; Mica-based pearlescent pigments; FD&C Yellow #6; Green #3; Blue #1; Blue #2; Titanium dioxide (food grade); brilliant black; and combinations thereof. Other examples of suitable colorants can be found in U.S. Patent No. 5,002,789, which is hereby incorporated by reference in its entirety.

Other embodiments may include one or more fragrances within the nonwoven webs, foams, and/or films of the disclosure. As used herein, the term “fragrance” refers to any applicable substance that is sufficiently volatile to produce a fragrance. Embodiments comprising fragrances may include fragrances that produce a scent that is pleasant to humans, or alternatively, fragrances that produce a fragrance that is repulsive to humans, animals, and/or insects. Suitable flavors include, but are not limited to, lemon, apple, cherry, grape, pear, pineapple, orange, strawberry, raspberry, fruit, including musk, and lavender-like, rose-like, iris-like, and carnation-like. Including, but not limited to, floral scents containing quicksand. Optionally, the flavoring is also unflavored. Other aromatics include, but are not limited to, herbal scents including rosemary, thyme, and sage; and forest scents derived from pine, spruce, and other forest odors. Fragrances may also be derived from various oils, including but not limited to essential oils, or from plant materials, including but not limited to peppermint, spearmint, etc., or any combination thereof. Suitable perfume oils can be found in U.S. Patent No. 6,458,754, which is incorporated herein by reference in its entirety. Suitable perfume oils include, but are not limited to, 4-(2,2,6-trimethylcyclohex-1-enyl)-2-en-4-one, acetaldehyde phenylethyl propyl acetal, 2,6,10-trimethyl-9-undee. Cenal, hexanoic acid 2-propenyl ester, 1-octen-3-ol, trans-anethole, isobutyl (z)-2-methyl-2-butenoate, anisaldehyde diethyl acetal, 3-methyl-5 -Propyl-cyclohezen-1-one, 2,4-dimethyl-3-cyclohexen-1-carbaldehyde, trans-4-decenal, decanal, 2-pentylcyclopentanone, ethyl anthranilate, eugenol (eugenol), 3-(3-isopropylphenyl)butanoal, methyl 2-octinoate, isoeugenol, cis-3-hexenyl methyl carbonate, linalool, methyl-2-noninonate, Includes benzoic acid 2-hydroxymethyl ester, nonal, octanal, 2-nonennitrile, 4-nonanolide, 9-decen-1-ol, and 10-undecen-1-al. Applicable fragrances also include those disclosed in US Pat. No. 4,534,981; No. 5,112,688; No. 5,145,842; No. 6,844,302; and Perfumes Cosmetics and Soaps, 2nd edition, edited by W. A. Poucher, 1959, all of which are hereby incorporated by reference in their entirety. These spices include acacia, cassie, chypre, cyclamen, fern, gardenia, hawthorn, heliotrope, and honeysuckle. , hyacinth, jasmine, lilac, lily, magnolia, mimosa, narcissus, freshly-cut hay, orange blossom. blossom, orchids, reseda, sweet pea, trefle, tuberose, vanilla, violet, wallflower, etc. or any combination thereof.

Fragrances may include perfume. Fragrances may include pure perfume, encapsulated perfume, or mixtures thereof. In an exemplary embodiment, the perfume comprises pure perfume. A portion of the perfume may be encapsulated in a core-shell capsule. In other embodiments, the perfume will not be encapsulated in a core/shell capsule.

As used herein, the term “perfume” encompasses perfume raw materials (PRMs) and perfume accords. As used herein, the term “perfume raw material” refers to a compound having a molecular weight of at least about 100 g/mol, which is useful alone or in combination with other perfume raw materials for imparting an odor, fragrance, essence or fragrance. As used herein, the terms “perfume ingredient” and “perfume raw material” are interchangeable. As used herein, the term “accord” refers to a mixture of two or more PRMs. In embodiments, either a perfume accord, perfume raw material, or perfume may be included in microcapsules, termed “perfume microcapsules” as used herein.

Common PRMs include alcohols, ketones, aldehydes, esters, ethers, nitrites, and alkenes such as terpenes, among others. Lists of common PRMs can be found in various references, for example, “Perfume and Flavor Chemicals,” Vols. I and II; Steffen Arctander Allured Pub. Co. (1994)] and “Perfumes: Art, Science and Technology,” Miller, P. M. and Lamparsky, D., Blackie Academic and Professional (1994). PRM is characterized by its boiling point (B.P.), measured at normal pressure (760 mm Hg), and its octanol/water partition coefficient (P). Based on these characteristics, PRMs can be classified as Quadrant I, Quadrant II, Quadrant III, or Quadrant IV perfumes.

In embodiments, the nonwoven webs, foams, and/or films may include an exfoliant. In embodiments, the exfoliating agent may include a chemical exfoliating agent or a mechanical exfoliating agent. Suitable mechanical exfoliants for use herein may include, but are not limited to, apricot peel, sugar, oatmeal, salt, silica, diatomaceous earth, clay, aluminum hydrate, PVOH microbeads, pumice, or combinations thereof. Suitable chemical exfoliants for use herein may include, but are not limited to, alpha hydroxyl acids, beta hydroxy acids, enzymes, salicylic acid, glycolic acid, citric acid, malic acid, or combinations thereof.

In certain embodiments, the repellent, surfactant, colorant, enzyme, skin conditioner, oil remover, cosmetic agent, or combinations thereof are encapsulated to allow controlled release. Suitable microcapsules include melamine formaldehyde, polyurethane, urea formaldehyde, chitosan, polymethyl methacrylate, polystyrene, polysulfone, poly tetrahydrofuran, gelatin, gum arabic, starch, polyvinyl pyrrolidone, carboxymethylcellulose, Hydroxyethylcellulose, methylcellulose, arabinogalactan, polyvinyl alcohol, polyacrylic acid, ethylcellulose, polyethylene, polymethacrylate, polyamide, poly(ethylenevinyl acetate), cellulose nitrate, silicone, poly(lactideco) -contains or is prepared from one or more of the following: (glycolide), paraffin, carnauba, spermaceti, beeswax, stearic acid, stearyl alcohol, glyceryl stearate, shellac, cellulose acetate phthalate, zein and combinations thereof It can be. In one type of embodiment, the microcapsules are characterized by an average particle size (e.g., Dv50) of at least about 0.1 micron, or for example in the range of about 0.1 micron to about 200 microns. In alternative embodiments, the microcapsules may form agglomerates of individual particles, for example, wherein the individual particles have an average particle size of at least about 0.1 micron, or in the range of about 0.1 micron to about 200 microns. .

soluble fiber

Water-soluble fibers, when provided as the sole resin of a film or foam, or as the sole fiber-forming material of a nonwoven fabric, will heat the film, foam, or nonwoven to 80° C. or less in 300 seconds or less as determined by MSTM-205. It includes fibers and/or fiber-forming materials made from any material that melts at a temperature of Water-soluble fibers may comprise a single water-soluble polymer or a blend of water-soluble polymers. Suitable water-soluble polymers include, but are not limited to, polyvinyl alcohol homopolymers, polyvinyl alcohol copolymers, modified polyvinyl alcohol copolymers, polyacrylates, water-soluble acrylate copolymers, polyvinyl pyrrolidone, polyethyleneimine, pullulan. , water-soluble natural polymers including, but not limited to, guar gum, acacia gum, xanthan gum, carrageenan, and starch, water-soluble polymer derivatives including, but not limited to, modified starch, ethoxylated starch, and hydroxypropylated starch, the above copolymers of and combinations of any of the above. Other water-soluble fibers include polyalkylene oxide, polyacrylamide, polyacrylic acid and its salts, cellulose, cellulose ethers, cellulose esters, cellulose amide, polyvinyl acetate, polycarboxylic acid and its salts, polyamino acids, polyamides, and gelatin. , methylcellulose, carboxymethylcellulose and salts thereof, dextrin, ethylcellulose, hydroxyethyl cellulose, hydroxypropyl methylcellulose, maltodextrin, polymethacrylate, and combinations of any one of the above. In embodiments, the water-soluble fibers may include PVOH copolymer fiber-forming materials, modified PVOH copolymer fiber-forming materials, or combinations thereof. In embodiments, the water-soluble fibers may comprise a single PVOH homopolymer fiber-forming material or a blend of PVOH copolymer fiber-forming materials. In embodiments, the water-soluble fiber may comprise a hot water soluble PVOH copolymer fiber-forming material. In a further embodiment, the water-soluble fiber may comprise a PVOH copolymer fiber-forming material having a viscosity ranging from 5 cP to 23 cP and a degree of hydrolysis ranging from 86% to 92%.

In embodiments, the water-soluble fiber may include an adjuvant as described above. In embodiments, the water-soluble fiber may be substantially free of adjuvants as described above. In embodiments, the water-soluble fiber may include a plasticizer as described above. The total amount of non-aqueous plasticizer provided to the water-soluble fiber may be from about 1% to about 45% by weight, or from about 5% to about 45% by weight, or from about 10% to about 40% by weight, or about range from 20% to about 30% by weight, from about 1% to about 4% by weight, or from about 1.5% to about 3.5% by weight, or from about 2.0% to about 3.0% by weight, for example about 1% by weight. , about 2.5% by weight, about 5% by weight, about 10% by weight, about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, or about 40% by weight. In embodiments, the water-soluble fiber includes glycerin, sorbitol, or a combination thereof. In an embodiment, the soluble fiber includes glycerin. In an embodiment, the water-soluble fiber includes sorbitol. In certain embodiments, the water-soluble fiber may comprise, for example, about 10% by weight glycerin, based on the total fiber weight, and, for example, about 5% sorbitol, by weight based on the total fiber weight.

In embodiments, the water-soluble fiber may include a surfactant as described above. In various embodiments, the amount of surfactant in the water-soluble fiber is about 0.01% by weight, about 2.5% by weight, about 0.1% by weight to about 2.5% by weight, about 1.0% by weight to about 2.0% by weight, about 0.01% by weight to about 0.25% by weight. % by weight, or in the range of about 0.10% to 0.20% by weight.

In embodiments, any of the adjuvants disclosed above may be added to the fibers of the disclosure. In this improved embodiment, the auxiliary agent may be added to the fiber-forming material prior to formation of the fibers such that the auxiliary agent is dispersed within the fiber. Additionally and/or alternatively, adjuvants may be added to the surface of the fibers (e.g., dispersed onto the fibers) after the fibers are formed.

When included in water-soluble fibers, the colorant may be added from 0.01% to 25% by weight of the polymer mixture, such as 0.02%, 0.05%, 0.1%, 0.5%, 1%, 2%, 3% by weight of the polymer mixture. Weight %, 4 weight %, 5 weight %, 6 weight %, 7 weight %, 8 weight %, 9 weight %, 10 weight %, 11 weight %, 12 weight %, 13 weight %, 14 weight %, 15 weight % , 16% by weight, 17% by weight, 18% by weight, 19% by weight, 20% by weight, 21% by weight, 22% by weight, 23% by weight, and 24% by weight.

non-soluble fiber

The non-soluble fibers, if provided to a film as the sole film-forming material or to a nonwoven web or foam as the sole fiber-forming material, may be removed for 300 seconds or longer when the film, nonwoven web, or foam is provided as the sole film-forming material, as determined by MSTM-205. It includes fibers and/or fiber-forming materials made from any material that does not dissolve at temperatures below 80°C or below. Non-water soluble fibers may comprise a single non-water soluble polymeric fiber-forming material or a blend of non-water soluble polymeric fiber-forming materials. Suitable non-soluble fibers and/or non-soluble fiber-forming materials include, but are not limited to, cotton, polyester, polyethylene (e.g., high-density polyethylene and low-density polyethylene), polypropylene, wood pulp, fluff pulp, Abaca, viscose, polylactic acid, polyester, nylon 6, insoluble cellulose, insoluble starch, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, lacebark. , silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate. fibers, and combinations thereof. In an embodiment, the non-soluble fiber-forming material and/or non-soluble fibers include one or more of the following groups: cotton, hemp, jute, flax, ramie, sisal, bagasse, banana, lacebark, Silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo, modal, diacetate fiber, triacetate fiber, or combinations thereof.

In embodiments, the non-soluble fiber may include an adjuvant as described above. In embodiments, the non-soluble fiber may be substantially free of adjuvants as described above. In embodiments, the non-water soluble fiber may include a plasticizer as described above. The total amount of non-aqueous plasticizer provided to the non-water soluble fiber is from about 1% to about 45% by weight, or from about 5% to about 45% by weight, or from about 10% to about 40% by weight, based on the total fiber weight. , or in a range from about 20% to about 30% by weight, from about 1% to about 4% by weight, or from about 1.5% to about 3.5% by weight, or from about 2.0% to about 3.0% by weight, for example, About 1% by weight, about 2.5% by weight, about 5% by weight, about 10% by weight, about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, or about 40% by weight It can be. In embodiments, the non-soluble fiber includes glycerin, sorbitol, or combinations thereof. In an embodiment, the non-soluble fiber includes glycerin. In an embodiment, the non-soluble fiber includes sorbitol. In certain embodiments, the non-soluble fibers may include a plasticizer, such as, for example, about 10% by weight glycerin, based on the total fiber weight, and sorbitol, for example, about 5% by weight based on the total fiber weight.

In embodiments, the non-water soluble fiber may include a surfactant as described above. In various embodiments, the amount of surfactant in the water-soluble fiber is about 0.01% by weight, about 2.5% by weight, about 0.1% by weight to about 2.5% by weight, about 1.0% by weight to about 2.0% by weight, about 0.01% by weight to about 0.25% by weight. % by weight, or in the range of about 0.10% to 0.20% by weight.

In embodiments, any one of the adjuvants disclosed herein may be added to the fibers of the disclosure. In this improved embodiment, the auxiliary agent can be added to the fiber-forming material prior to fiber formation such that the auxiliary agent can be added to the surface of the fiber after fiber formation. In this improved embodiment, the auxiliary agent may be added to the surface of the fiber after fiber formation.

When included in non-water soluble fibers, the colorant may be present in an amount of from 0.01% to 25% by weight of the polymer mixture, such as 0.02%, 0.05%, 0.1%, 0.5%, 1%, 2% by weight of the polymer mixture. , 3% by weight, 4% by weight, 5% by weight, 6% by weight, 7% by weight, 8% by weight, 9% by weight, 10% by weight, 11% by weight, 12% by weight, 13% by weight, 14% by weight, 15% by weight. It can be provided in amounts of % by weight, 16% by weight, 17% by weight, 18% by weight, 19% by weight, 20% by weight, 21% by weight, 22% by weight, 23% by weight, and 24% by weight.

Nonwoven web or substrate

The nonwoven webs or nonwoven substrates of the disclosure may be water-soluble, non-water-soluble, or at least partially non-water-soluble. A unit dose article of the disclosure may include a nonwoven web, wherein at least a portion of the nonwoven web is soluble in water at a temperature ranging from about 0° C. to about 20° C. according to MSTM 205, or at least a portion of the nonwoven web is soluble in water according to MSTM 205. Not soluble in water at a temperature of 20°C or below according to MSTM 205, or the nonwoven web is not soluble in water at a temperature of 20°C or below according to MSTM 205, or the nonwoven web is not soluble in water at a temperature of 20°C or below according to MSTM 205. It is soluble in water at temperatures ranging from about 20°C. “At least a portion” of the nonwoven web is (or is not) soluble at a given temperature if the nonwoven web is comprised of a plurality of fibers, or if provided in the nonwoven as the sole fiber type, the nonwoven web comprised of this fiber type is MSTM- 205 will be understood as being soluble (or not) at a given temperature.

The nonwoven web of the disclosure includes a plurality of fibers. Nonwoven webs involve arrangements of fibers bonded together, where the fibers are neither woven nor knitted. The plurality of fibers may be arranged in any orientation. In an embodiment, the plurality of fibers are randomly arranged (i.e., have no orientation). In an embodiment, the plurality of fibers are arranged in a unidirectional orientation. In an embodiment, the plurality of fibers are arranged in a bidirectional orientation. In some embodiments, the plurality of fibers are multidirectional and have different arrangements in different regions of the nonwoven web.

The plurality of fibers in any given nonwoven web may include any of the fiber-forming materials disclosed herein. Nonwoven webs can be comprised of (1) a single fiber type comprising a single fiber-forming material, (2) a single fiber type comprising a blend of fiber-forming materials, and (3) fibers where each fiber type includes a single fiber-forming material. A blend of types, (4) a blend of fiber types where each fiber type comprises a blend of fiber-forming substances, or (5) a fiber type where each fiber type comprises a single fiber-forming substance or a blend of fiber-forming substances. It may include a blend of In embodiments comprising blends of fiber types, the different fiber types have length to diameter ratio (L/D), toughness, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T _g ), and fiber-forming material chemistry. , and may have differences in one or more of the groups of colors. In certain embodiments, the plurality of fibers can include two or more types of soluble fibers. In an embodiment, the plurality of fibers may include at least one fiber type comprising at least one type of soluble fiber-forming material, and at least one fiber type comprising at least one type of non-soluble fiber. . In embodiments, the plurality of fibers may comprise two or more fiber types comprising at least one type of non-soluble fiber-forming material.

In embodiments, the nonwoven web may further include any adjuvant as disclosed herein for fibers and/or films. In embodiments, the adjuvant may be added to the fibers themselves, to the nonwoven web during carding of the nonwoven web, to the nonwoven web before bonding (e.g., after carding), to the nonwoven web after bonding, or a combination thereof. Auxiliaries added to the fibers during carding may be dispersed throughout the nonwoven web. Auxiliaries added to the nonwoven web after carding but before bonding may be selectively added to one or both sides of the nonwoven web.

The adjuvant may be applied to one or more sides of the nonwoven web or article comprising it, such as a packet, by any suitable means. In an embodiment, the adjuvant is in powder form. In this improved embodiment, one or more stationary powder spray guns are used to direct a powder stream from one or more directions toward the web or packets, while the webs or packets are conveyed through the coating zone by a conveyor belt. . In an embodiment, the web or packet is delivered via suspension of the powder in air. In an embodiment, the web or packet is rotationally mixed with the powder in a trough-like device. In an embodiment that can be combined with any of the other embodiments, electrostatic forces are used to enhance the attractive force between the powder and the packet or web. This type of process can be based on negatively charged powder particles and directing these charged particles into grounded packets or webs. In another alternative embodiment, the powder is transferred by a secondary transfer tool, including, but not limited to, a rotating brush in contact with the powder, or by a powdered glove capable of transferring the powder from the container to the web or packet. Applies to web or packet. In another embodiment, the powder is applied by dissolving or suspending the powder in a non-aqueous solvent or carrier, which is then atomized and sprayed onto a web or packet. In one embodiment, the solvent or carrier is then evaporated leaving the active agent powder. In certain embodiments, the powder is applied to the web or packet in precise dosage. This embodiment utilizes a closed-system dry lubricant application machine, such as the Powder Applicator PM 700 D from PekuTECH. In this process, the powder is fed into the feed trough of the application machine, optionally batchwise or continuously. The web or packet is conveyed from the output belt of a standard rotating drum pouch machine onto the conveyor belt of a powder application machine, where controlled doses of powder are applied to the web or packet. The web or packet can then be transferred to a suitable secondary packaging process.

In embodiments in which the adjuvant is in liquid form or solution, the above can be used, for example, in spin casting, spraying of solutions such as aerosolized solutions, roll coating, flow coating, curtain coating, extrusion, knife coating, and the like. The combination may be dispersed in the fibers, dispersed on the face of the nonwoven web, or a combination thereof.

Adjuvants, such as chemical exfoliants, mechanical exfoliants, fragrance and/or perfume microcapsules, repellents, surfactants, colorants, enzymes, skin conditioners, oil removers, beautifying agents, or combinations thereof, when present in the nonwoven web, It is present in an amount of at least about 0.1% by weight, or ranging from about 0.1% to about 99% by weight, to provide additional functionality to the nonwoven web. Chemical exfoliants, mechanical exfoliants, fragrance and/or perfume microcapsules, repellents, surfactants, colorants, enzymes, skin conditioners, oil removers, cosmetic agents, or combinations thereof may be used as solids (e.g., powders, granules, crystals). , pieces, or ribbons), liquids, fluids, pastes, gases, etc., and can optionally be encapsulated.

In embodiments, the nonwoven web can be colored, printed, and/or dyed to provide improved aesthetics over water-soluble films. Suitable colorants for use in nonwoven webs include indicator dyes, such as pH indicators (e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), moisture/water indicators (e.g., hydrochromic inks or leuco dyes), or thermochromic inks, where the ink changes color when temperature increases and/or decreases. Suitable colorants include, but are not limited to, triphenylmethane dyes, azo dyes, anthraquinone dyes, perylene dyes, indigoid dyes, food, drug and cosmetic (FD&C) colorants, organic pigments, inorganic pigments, or combinations thereof. do. Examples of colorants include, but are not limited to, FD&C Red #40; Red #3; FD&C Black #3; Black #2; Mica-based pearlescent pigments; FD&C Yellow #6; Green #3; Blue #1; Blue #2; Titanium dioxide (food grade); Brilliant Black; and combinations thereof.

In embodiments, the nonwoven web may include any one of the surfactants disclosed herein. In embodiments, the nonwoven web may include one or more of the following groups: sodium cocoyl isethionate, glucotine, phoenamide, cola lipid, cocamide such as cocamide ethanolamine, ethylene oxide based surfactant, and saponified oils of avocado and palm.

The nonwoven web of the disclosure can have any thickness. Suitable thicknesses include, but are not limited to, about 5 microns (μm) to about 10,000 μm (1 cm), about 5 μm to about 5,000 μm, about 5 μm to about 1,000 μm, about 5 μm to about 500 μm, about 200 μm. to about 500 μm, from about 5 μm to about 200 μm, from about 20 μm to about 100 μm, or from about 40 μm to about 90 μm, or from about 50 μm to 80 μm, or from about 60 μm to 65 μm, e.g. It may include 50 μm, 65 μm, 76 μm, or 88 μm. The nonwoven webs of the disclosure may be characterized as high loft or low loft. “Loft” refers to the ratio of thickness to mass per unit area (i.e., basis weight). High loft nonwoven webs can be characterized by a high ratio of thickness to mass per unit area. As used herein, “high loft” refers to a nonwoven web of the disclosure having a basis weight as defined herein and a thickness exceeding 200 μm. The thickness of the nonwoven web may be determined according to ASTM D5729-97, ASTM D5736, and/or ISO 9073-2:1995 and may include, for example, subjecting the nonwoven web to a load of 2 N and measuring the thickness. . High loft materials may be used according to methods known in the art, for example, cross-wrapping using a cross-lapper to fold over the unbonded web itself to achieve loft and basis weight. You can. Without intending to be bound by theory, in contrast to water-soluble films where the solubility of the film may depend on the thickness of the film, the solubility of a nonwoven web is not believed to be dependent on the thickness of the web. In this regard, since the individual fibers, regardless of the thickness of the nonwoven web, provide a greater surface area than the water-soluble film, the parameter that limits water access to and thereby dissolution of the fibers is the basis weight (i.e. of fiber density).

Generally, the dynamic coefficient of friction for a nonwoven web of the disclosure, and the ratio of the static to dynamic coefficient of friction, results in increased surface roughness of the nonwoven web relative to the water-soluble film, which provides reduced surface contact to the nonwoven web. Due to this, the dynamic coefficient of friction for the water-soluble film will be lower than the ratio of the static coefficient of friction to the dynamic coefficient of friction. Advantageously, this surface roughness provides an improved feel to the consumer (i.e., cloth-like instead of rubber-like), improved aesthetics (i.e., less gloss than a water-soluble film) and/or a smoother surface of the processing equipment/mould. This can facilitate processability in manufacturing thermoformed, vertically formed, filled, and sealed, and/or multichamber packets that require web pulling. Accordingly, the soluble and/or non-soluble fibers must be rough enough to provide surface roughness to the resulting nonwoven web without being too rough to create drag.

The solubility in water of the nonwoven webs of the disclosure is a function of the basis weight of the web as well as the type of fiber(s) used to make the web. Without intending to be bound by theory, the solubility profile of a nonwoven web will follow the same solubility profile of the fiber(s) used to make the nonwoven web, and the solubility profile of the fibers will generally be that of the polymer(s) from which the fibers are made. It is believed that they follow the same solubility profile. For example, for nonwoven webs comprising PVOH fibers, the degree of hydrolysis of the PVOH polymer can be selected such that the water solubility of the nonwoven web is also affected. At a given temperature, as the degree of hydrolysis of the PVOH polymer increases from partial hydrolysis (88% DH) to complete hydrolysis (≧98% DH), the water solubility of the polymer generally decreases. Accordingly, in exemplary embodiments, the nonwoven web may be cold water soluble. For a co-poly(vinyl acetate vinyl alcohol) polymer that does not contain any other monomers (e.g., is not copolymerized with anionic monomers), a cold water soluble web that is soluble in water at temperatures below 10° C. has a temperature of about 75° C. % to about 90%, or from about 75% to about 89%, or from about 80% to about 90%, or from about 85% to about 90%, or from about 90% to about 99.5%. It may include fibers of PVOH with a degree of hydrolysis in the range. In other exemplary embodiments, the nonwoven web may be hot water soluble. For example, for a co-poly(vinyl acetate vinyl alcohol) polymer that does not contain any other monomers (e.g., is not copolymerized with anionic monomers), the hot water soluble web has a degree of hydrolysis of at least about 98%. By comprising fibers of PVOH, it can be soluble in water at a temperature of at least about 60°C.

Modification of the PVOH polymer increases the solubility of the PVOH polymer. Therefore, at a given temperature, the solubility of a nonwoven web or film made from a modified PVOH copolymer is expected to be higher than that of a nonwoven web or film made from a PVOH copolymer with the same degree of hydrolysis as the modified PVOH copolymer. do. Following this trend, nonwoven webs with specific solubility properties can be designed by blending polymers within the fibers and/or blending fibers within the nonwoven web. Additionally, as described herein, nonwoven webs include a plurality of fibers, which in some cases may include two or more fiber types with different solubilities.

The inclusion of non-soluble fibers and/or non-soluble fiber-forming materials within the plurality of fibers of the nonwoven web can also be used to design nonwoven webs with specific solubility and/or extended release properties. Without intending to be bound by theory, as the weight percentage of non-soluble fibers comprised within the nonwoven web (based on the total weight of the nonwoven web) increases, the solubility of the nonwoven web generally decreases, and the solubility of the nonwoven web comprising the nonwoven web generally decreases. The extended release properties of the pouch are generally believed to increase. Upon contact with water at or above the melting temperature of the soluble fibers, the nonwoven web comprising soluble and non-soluble fibers will begin to disperse as the soluble fibers dissolve, thereby causing the web structure to collapse and/or or the pore size of the pores of the nonwoven web increases. The more the web structure collapses or the pore size increases, the faster water can access the contents of the pouch, and the faster the contents of the pouch will be released. Similarly, extended release of the contents of a pouch comprising the nonwoven web of the disclosure can be achieved by using blends of water-soluble fibers with different solubility properties and/or different solubility temperatures. When the faster dissolving fibers dissolve and thereby collapse the web, the less soluble fibers will have a greater exposed surface area, which promotes dissolution of the less soluble fibers and release of the pouch contents. In embodiments where the nonwoven web includes soluble fibers and non-soluble fibers, the ratio of soluble fibers to non-soluble fibers is not particularly limited. The water-soluble fibers comprise from about 1% to about 99% by weight, from about 20% to about 80% by weight, from about 40% to about 90% by weight, from about 50% to about 90% by weight, of the total weight of the plurality of fibers. or from about 60% to about 90% by weight, wherein the non-water soluble fibers comprise from about 1% to about 99% by weight, from about 20% to about 80% by weight, from about 10% to about 10% by weight of the total weight of the fibers. It may comprise about 60% by weight, about 10% by weight to about 50% by weight, or about 10% by weight to about 40% by weight. In an embodiment, the plurality of fibers comprises from about 10% to about 80% water soluble fibers by weight, based on the total weight of the fibers, with the remainder being non-soluble fibers.

In embodiments, the nonwoven web, plurality of fibers, foam, water-soluble film, or combinations thereof disclosed herein may include a biodegradable polymer. In certain embodiments, the plurality of fibers can include a non-soluble fiber-forming material that is biodegradable. In an embodiment, the plurality of fibers include a first fiber that is a non-water soluble biodegradable fiber, and a first fiber that is soluble in water at a temperature of about 10°C to about 20°C according to MSTM 205 or about 30°C or less according to MSTM 205. It may include a second fiber that is not soluble in water at that temperature. In embodiments, the nonwoven web is non-water soluble and biodegradable.

In an embodiment, the nonwoven web is biodegradable. As used herein, when a nonwoven web is referred to as being biodegradable, at least 50% of the nonwoven web is biodegradable, e.g., at least 60%, at least 70%, at least 80%, at least 90% of the nonwoven web. , or 100% biodegradable.

Nonwoven webs as disclosed herein can include composites comprising a plurality of fibers comprising a first fiber type and a second fiber type, wherein the first and second fiber types include diameter, length, toughness, shape, There are differences in rigidity, elasticity, solubility, melting point, glass transition temperature (T _g ), chemical composition, color, or combinations thereof. In embodiments, the first fiber type may comprise a PVOH homopolymer fiber-forming material, a PVOH copolymer fiber-forming material, a modified PVOH copolymer fiber-forming material, or a combination thereof. In an embodiment, the first fiber type comprises two or more PVOH homopolymer fiber-forming materials, two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a combination thereof. can do. In embodiments, the second fiber type may comprise a PVOH homopolymer fiber-forming material, a PVOH copolymer fiber-forming material, a modified PVOH copolymer fiber-forming material, or a combination thereof. In an embodiment, the second fiber type comprises two or more PVOH homopolymer fiber-forming materials, two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a combination thereof. can do. In embodiments, the first fiber type and/or the second fiber type are non-soluble fiber-forming materials. In embodiments, the first fiber type may comprise a non-water soluble polymeric fiber-forming material and the second fiber type, when provided as a film or as the sole fiber-forming material of a nonwoven web, the resulting web or film. and a polyvinyl alcohol fiber-forming material that is soluble in water at temperatures ranging from about 0° C. to about 20° C. according to MSTM 205. In embodiments, the first fiber type may comprise a non-water soluble polymeric fiber-forming material and the second fiber type, when provided as a film or as the sole fiber-forming material of a nonwoven web, the resulting web or film. PVOH homopolymer or copolymer fiber-forming material that is not soluble in water at temperatures of 20° C. or less according to MSTM 205. In embodiments, the first fiber type is a combination of two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a PVOH copolymer fiber-forming material and a modified PVOH copolymer fiber-forming material. Contains a combination of substances. In embodiments, the second fiber type is a combination of two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a PVOH copolymer fiber-forming material and a modified PVOH copolymer fiber-forming material. Contains a combination of substances.

The plurality of fibers included in the nonwoven web of the disclosure can have any toughness. The toughness of a fiber is correlated with the coarseness of the fiber. As the toughness of the fiber decreases, the roughness of the fiber increases. The fibers used to make the nonwoven webs of the disclosure have a weight of about 1 to about 100 cN/dtex, or about 1 to about 75 cN/dtex, or about 1 to about 50 cN/dtex, or about 1 to about 45 cN/dtex. dtex, or about 1 to about 40 cN/dtex, or about 1 to about 35 cN/dtex, or about 1 to about 30 cN/dtex, or about 1 to about 25 cN/dtex, or about 1 to about 20 cN/ dtex, or about 1 to about 15 cN/dtex, or about 1 to about 10 cN/dtex, or about 3 to about 8 cN/dtex, or about 4 to about 8 cN/dtex, or about 6 to about 8 cN/dtex. dtex, or range from about 4 to about 7 cN/dtex, or from about 10 to about 20, or from about 10 to about 18, or from about 10 to about 16, or from about 1 cN/dtex, or from about 2 cN/dtex, or from about 3 cN/dtex, about 4 cN/dtex, about 5 cN/dtex, about 6 cN/dtex, about 7 cN/dtex, about 8 cN/dtex, about 9 cN/dtex, about 10 cN/dtex, about 11 cN/ dtex, about 12 cN/dtex, about 13 cN/dtex, about 14 cN/dtex, or about 15 cN/dtex. In embodiments, the plurality of fibers has a toughness ranging from about 3 cN/dtex to about 15 cN/dtex, or from about 5 cN/dtex to about 12 cN/dtex, or from about 5 cN/dtex to about 10 cN/dtex. You can have it.

The toughness of the nonwoven web may be the same or different from the toughness of the plurality of fibers used to make the web. Without intending to be bound by theory, it is believed that the toughness of a nonwoven web is related to the strength of the nonwoven web, where higher toughness provides higher strength to the nonwoven web. The toughness of a nonwoven web can be modified by using fibers with different toughnesses. The toughness of nonwoven webs can also be affected by processing. The nonwoven webs of the disclosure have relatively high toughness, that is, they are self-supporting webs that can be used as a standalone material for making articles and/or pouches. On the other hand, nonwoven webs made according to melt blown, electrospinning, and/or rotary spinning processes may have lower toughness and may not be free-standing or usable as a stand-alone web to form articles or pouches.

The fibers used to make the nonwoven webs of the disclosure can have any fineness. The fineness of a fiber is related to the amount of fiber present in the cross section of a yarn of a given thickness. The fineness of a fiber can be measured by linear mass density, which is a measure of the ratio of fiber mass per unit length. The main physical unit of linear mass density is 1 tex, which is equal to 1000 m of fiber weighing 1 g. The unit dtex is used, which represents 1 g/10,000 m of fiber. The linear mass unit determines the nonwoven web's appropriate stiffness/handle, torsional stiffness, reflection and interaction of light, absorption of dyes and/or other actives/additives, ease of spinning the fibers in the manufacturing process, and uniformity of the finished article. may be selected to provide a nonwoven web having As the linear mass density of the fibers increases, the resulting nonwovens exhibit higher uniformity, improved tensile strength, extensibility, and gloss. Additionally, without intending to be bound by theory, it is believed that finer fibers will result in slower dissolution times compared to larger fibers based on density. Also, without intending to be bound by theory, if a blend of fiber types is used, the average linear mass density may be determined using a weighted average of the individual fiber types. Fibers can be characterized as very fine (dtex ≤1.22), fine (1.22≤ dtex ≤1.54), medium (1.54≤ dtex ≤1.93), semi-coarse (1.93≤ dtex ≤2.32), and coarse (dtex ≥2.32). The nonwoven webs of the disclosure may include fibers that are very fine, fine, medium, medium coarse, or combinations thereof. In embodiments, the nonwoven web has an average linear mass density ranging from about 1 dtex to about 5 dtex, or from about 1 dtex to about 3 dtex, or from about 1.5 dtex to about 2.5 dtex. In an embodiment, the nonwoven web includes a blend of fibers, wherein the first fibers include a 1.7 dtex average linear mass density and the second fibers include a 2.2 dtex average linear mass density.

The plurality of fibers used to make the nonwoven web of the disclosure may have a length of about 10 microns to 300 microns, such as at least 10 microns, at least 25 microns, at least 50 microns, at least 100 microns, or at least 125 microns and up to about 300 microns. It has a diameter in the range of microns, up to about 275 microns, up to about 250 microns, up to about 225 microns, or up to about 200 microns. In embodiments, the plurality of fibers used to make the nonwoven web of the disclosure can have a diameter of greater than 100 microns to about 300 microns. In embodiments, the diameter of the plurality of fibers used to make the nonwoven web of the disclosure has a substantially uniform diameter. In embodiments, one or more fiber types may have an average diameter ranging from about 10 microns to about 300 microns, or from about 50 microns to 200 microns, or from about 50 microns to about 100 microns.

The plurality of fibers used to make the nonwoven web of the disclosure may be of any length. In embodiments, the length of the plurality of fibers is from about 30 millimeters (mm) to about 100 mm, from about 10 mm to about 60 mm, or from about 30 mm to about 60 mm, e.g., at least about 30 mm, at least about 35 mm. mm, at least about 40 mm, at least about 45 mm, or at least about 50 mm, and at most about 100 mm, at most about 95 mm, at most about 90 mm, at most about 80 mm, at most about 70 mm, or at most about 60 mm. It may be a range. In embodiments, the length of the plurality of fibers is less than about 30 mm, or between about 0.25 mm and less than about 30 mm, such as at least about 0.25 mm, at least about 0.5 mm, at least about 0.75 mm, at least about 1 mm, at least about 2.5 mm, at least about 5 mm, at least about 7.5 mm, or at least about 10 mm and up to about 29 mm, up to about 28 mm, up to about 27 mm, up to about 26 mm, up to about 25 mm, up to about 20 mm, or may range up to about 15 mm. In embodiments, the fibers have an average length of from about 30 mm to about 100 mm, or from about 30 mm to about 60 mm. In an embodiment, the nonwoven web includes a blend of fiber types, wherein the first fiber type includes a length of about 38 mm and the second fiber type includes a length of about 54 mm.

The plurality of fibers used to make the nonwoven web of the disclosure can have any length to diameter (L/D) ratio. Advantageously, the toughness of the nonwoven webs of the disclosure can be adjusted using the L/D ratio of the fibers and the respective amounts of fibers with various L/D ratios in the nonwoven composition. As the L/D of the fiber is reduced, its resistance to bending and stiffness increases, providing a rougher feel. The fibers of the disclosure impart a rough feel to a nonwoven web comprising them when the fibers have a low L/D ratio ranging from about 0.5 to about 15, or from about 0.5 to about 25, or from about 1 to about 5. . These low L/D fibers range from about 0 to about 50 weight percent, for example, from about 0.5 weight percent to about 25 weight percent, or from about 1 weight percent to about 15 weight percent, based on the total weight of the fibers in the nonwoven web. Amounts in the range of % may be provided to the nonwoven web. If the amount of low L/D fibers in the nonwoven web is not known, the amount can be estimated by visual inspection of micrographs of the nonwoven web. In embodiments where the first fibers comprise a blend of fiber-forming materials comprising a first polyvinyl alcohol fiber-forming material, at least a portion of the first fibers have about 0.5 to about 25, or about 0.5 to about 15, or It may have an L/D ratio of about 1 to about 5.

Pore size can be determined using high magnification and alignment surface analysis techniques, including, but not limited to, Brunauer-Emmett-Teller (BET), and molecular adsorption methods.

Nonwoven webs can be characterized by basis weight. The basis weight of a nonwoven web is the mass per unit area of the nonwoven web. Basis weight can be modified by varying manufacturing conditions as known in the art. The nonwoven web may have the same basis weight before and after bonding. Alternatively, the bonding method can change the basis weight of the nonwoven web. For example, when bonding occurs through the application of heat and pressure, the thickness of the nonwoven (and thus the area of the nonwoven) can be reduced, thereby increasing the basis weight. Accordingly, as used herein and unless otherwise specified, basis weight of a nonwoven refers to the basis weight of the nonwoven after bonding.

The nonwoven web of the disclosure has a weight of about 0.1 g/m ² to about 700 g/m ² , about 0.5 g/m ² to about 600 g/m ² , about 1 g/m ² to about 500 g/m ² , about 1 g/m 2 g/m ² to about 400 g/m ² , about 1 g/m ² to about 300 g/m ² , about 1 g/m ² to about 200 g/m ² , about 1 g/m ² to about 100 g /m ² , about 30 g/m ² to about 100 g/m ² , about 20 g/m ² to about 100 g/m ² , about 20 g/m ² to about 80 g/m ² , or about 25 g It can have any basis weight ranging from /m ² to about 70 g/m ² .

Additionally, as the basis weight of the web increases, the dissolution rate of the web decreases, provided the fiber composition and web thickness remain constant because there is more material to dissolve. For example, at a given temperature, a water-soluble web made from fibers comprising PVOH polymer(s) and having a basis weight of, for example, 40 g/m ² may have a weight of, for example, 30 g/m ² It is expected to dissolve more slowly than a water-soluble web that has a higher basis weight but is otherwise identical. Accordingly, basis weight can also be used to modify the solubility properties of the nonwoven web. The nonwoven web has a weight of about 1 g/m ² to about 700 g/m ² , about 1 g/m ² to about 600 g/m ² , about 1 g/m ² to about 500 g/m ² , about 1 g/m ² to about 400 g/m ² , about 1 g/m ² to about 300 g/m ² , about 1 g/m ² to about 200 g/m ² , about 10 g/m ² to about 100 g/m ² , from about 30 g/m ² to about 100 g/m ² , from about 20 g/m ² to about 100 g/m ² , from about 20 g/m ² to about 80 g/m ² , from about 25 g/m ² It may have any basis weight ranging from about 70 g/m ² , or from about 40 g/m ² to about 60 g/m ² .

The nonwoven webs of the disclosure may be used as a single layer or may be layered with other nonwoven webs or may be in the form of a laminate with a water-soluble film. In some embodiments, the nonwoven web comprises a single layer of nonwoven web. In some embodiments, the nonwoven web is a multilayer nonwoven web comprising two or more layers of the nonwoven web. Two or more layers can be stacked on top of each other. In this improved embodiment, the two or more layers can be identical (eg, made from the same fibers and basis weight). In this improved embodiment, the two or more layers can be different (eg, made from different types of fibers, fiber chemicals and/or have different basis weights).

Multilayer nonwoven webs can have a basis weight that is the sum of the basis weights of the individual layers. Therefore, a multilayer nonwoven web will take longer to dissolve than either of the individual layers provided as a single layer.

water soluble foam

In exemplary embodiments, suitable water-soluble foams include any suitable resin chemistry, such as PVOH homopolymer; PVOH copolymer; Modified PVOH copolymers, such as PVOH copolymers modified with maleic anhydride (MA), monomethyl maleate (MMM), modified PVOH copolymers, and AMPS (2-methylacrylamido-2-methylpropanesulfonic acid ) modified PVOH copolymer; Cellulose and cellulose derivatives; PVP; protein; casein; Big head; or any water-dispersible or water-soluble resin. In certain embodiments, the water-soluble foam substrate has a thickness of 3 microns to 3000 microns and is suitable for use in foam manufacturing applications including, but not limited to, casting, extrusion, melt processing, coating, chemical blown, mechanical aeration, air injection, and turbulent extrusion processes. It can be formed using any suitable manufacturing process known to. The water-soluble foam substrate may be porous or non-porous and may be cold or hot water soluble. Components based on water-soluble foam may include, for example, folded layers or plies, laminated layers or plies, or rolled layers or plies.

In exemplary embodiments, the water-soluble foam substrate may further comprise any adjuvant as disclosed herein for nonwoven webs, fibers and/or films. The adjuvant may be applied to one or more sides of the water-soluble foam substrate or an article comprising it, for example a packet, by any suitable means. In an embodiment, the adjuvant is in powder form. In this improved embodiment, one or more stationary powder spray guns are used to direct a powder stream from one or more directions toward the water-soluble foam substrate or packets, while the water-soluble foam substrate or packets are moved to the coating zone by a conveyor belt. is transported through In embodiments, the water-soluble foam substrate or packet is delivered via suspension of the powder in air. In an embodiment, the water-soluble foam substrate or packet is rotationally mixed with the powder in a trough-like device. In an embodiment that can be combined with any of the other embodiments, electrostatic forces are used to enhance the attractive force between the powder and the packet or water-soluble foam substrate. This type of process can be based on negatively charged powder particles, which are guided into grounded packets or water-soluble foam substrates. In other alternative embodiments, the powder is formed into a water-soluble foam by a secondary transport tool that includes, but is not limited to, a rotating brush in contact with the powder, or by a powdering glove capable of transferring the powder from the container to the water-soluble foam substrate or packet. Applies to substrate or packet. In another embodiment, the powder is applied by dissolving or suspending the powder in a non-aqueous solvent or carrier, which is then atomized and sprayed onto a water-soluble foam substrate or packet. In one embodiment, the solvent or carrier is then evaporated leaving the active agent powder. In certain embodiments, the powder is applied to a water-soluble foam substrate or packet in precise dosage. This embodiment utilizes a closed-system dry lubricant application machine, such as the Powder Applicator PM 700 D from PekuTECH. In this process, the powder is fed into the feed trough of the application machine, optionally batchwise or continuously. The water-soluble foam substrate or packets are conveyed from the output belt of a standard rotating drum pouch machine onto the conveyor belt of a powder application machine, where controlled doses of powder are applied to the water-soluble foam substrate or packets. The water-soluble foam substrate or packets can then be transferred to a suitable secondary packaging process.

In embodiments in which the adjuvant is present in liquid form or solution, these can be used, for example, in spin casting, spraying of solutions such as aerosolized solutions, roll coating, flow coating, curtain coating, extrusion, knife coating, and the like. The combination may be dispersed in a water-soluble foam substrate, dispersed on a side of a water-soluble foam substrate, or a combination thereof.

Adjuvants, such as chemical exfoliants, mechanical exfoliants, fragrance and/or perfume microcapsules, repellents, surfactants, colorants, enzymes, skin conditioners, degreasers, cosmetic agents, or combinations thereof, when present in the water-soluble foam base. , is present in an amount of at least about 0.1% by weight, or in the range of about 0.1% by weight to about 99% by weight, to provide additional functionality to the water-soluble foam substrate. Chemical exfoliants, mechanical exfoliants, fragrance and/or perfume microcapsules, repellents, surfactants, colorants, enzymes, skin conditioners, oil removers, cosmetic agents, or combinations thereof may be used as solids (e.g., powders, granules, crystals). , pieces, or ribbons), liquids, fluids, pastes, gases, etc., and can optionally be encapsulated.

In embodiments, the water-soluble foam substrate can be colored, printed, and/or dyed to provide improved aesthetics over water-soluble films. Suitable colorants for use in water-soluble foam substrates include indicator dyes, such as pH indicators (e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), moisture/water indicators (e.g., hydrochromic inks) or leuco dyes), or thermochromic inks, wherein the ink changes color when temperature increases and/or decreases. Suitable colorants include, but are not limited to, triphenylmethane dyes, azo dyes, anthraquinone dyes, perylene dyes, indigoid dyes, food, drug and cosmetic (FD&C) colorants, organic pigments, inorganic pigments, or combinations thereof. do. Examples of colorants include, but are not limited to, FD&C Red #40; Red #3; FD&C Black #3; Black #2; Mica-based pearlescent pigments; FD&C Yellow #6; Green #3; Blue #1; Blue #2; Titanium dioxide (food grade); Brilliant Black; and combinations thereof.

In embodiments, the water-soluble foam substrate may include any one of the surfactants disclosed herein. In embodiments, the water-soluble foam substrate may comprise one or more of the following groups: sodium cocoyl isethionate, glucotine, phoenamide, cola lipid, cocamide such as cocamide ethanolamine, ethylene oxide based surfactant. , and saponified oils of avocado and palm.

The water-soluble foam substrate of the disclosure can have any thickness. Suitable thicknesses include, but are not limited to, about 5 microns (μm) to about 10,000 μm (1 cm), about 3 μm to about 5,000 μm, about 5 μm to about 1,000 μm, about 5 μm to about 500 μm, about 200 μm. to about 500 μm, from about 5 μm to about 200 μm, from about 20 μm to about 100 μm, or from about 40 μm to about 90 μm, or from about 50 μm to 80 μm, or from about 60 μm to 65 μm, e.g. It may include 50 μm, 65 μm, 76 μm, or 88 μm. The water-soluble foam substrates of the disclosure may be characterized as high loft or low loft. “Loft” refers to the ratio of thickness to mass per unit area (i.e., basis weight). High loft water-soluble foam substrates may be characterized by a high ratio of thickness to mass per unit area. As used herein, “high loft” refers to the water-soluble foam substrate of the disclosure having a basis weight as defined herein and a thickness exceeding 200 μm. The thickness of the water-soluble foam substrate may be determined according to ASTM D5729-97, ASTM D5736, and/or ISO 9073-2:1995 and may include, for example, subjecting the water-soluble foam substrate to a load of 2 N and measuring the thickness. You can. High loft materials can be used according to methods known in the art, for example, cross-wrapping, using a cross-wrapper to fold over the unbonded web itself to achieve loft and basis weight.

The dynamic coefficient of friction for the water-soluble foam substrate of the disclosure, and the ratio of the static to dynamic coefficient of friction, results in increased surface roughness of the water-soluble foam substrate relative to the water-soluble film, which provides reduced surface contact to the water-soluble foam substrate. Due to this, the dynamic coefficient of friction for the water-soluble film will be lower than the ratio of the static coefficient of friction to the dynamic coefficient of friction. Advantageously, this surface roughness provides an improved feel to the consumer (i.e., cloth-like instead of rubber-like), improved aesthetics (i.e., less gloss than a water-soluble film) and/or a smoother surface of the processing equipment/mould. This can facilitate processability in manufacturing thermoformed, vertically formed, filled, and sealed, and/or multichambered packets that are required to pull water-soluble foam substrates. Accordingly, the water-soluble and/or non-water-soluble fibers must be rough enough to provide surface roughness to the resulting water-soluble foam substrate without being too rough to create drag.

The solubility of the soluble foam substrate of the disclosure in water is a function of the basis weight of the water-soluble foam substrate as well as the type of fiber(s) used to make the water-soluble foam substrate. Without intending to be bound by theory, the solubility profile of a water-soluble foam substrate will follow the same solubility profile of the fiber(s) used to make the water-soluble foam substrate, and the solubility profile of the fiber will generally be similar to that of the polymer(s) from which the fibers are made. ) are believed to follow the same solubility profile of For example, for a water-soluble foam substrate comprising PVOH fibers, the degree of hydrolysis of the PVOH polymer can be selected such that the water solubility of the water-soluble foam substrate is also affected. Generally, at a given temperature, as the degree of hydrolysis of the PVOH polymer increases from partial hydrolysis (88% DH) to complete hydrolysis (≧98% DH), the water solubility of the polymer generally decreases. Accordingly, in exemplary embodiments, the water-soluble foam substrate may be cold water soluble. For a co-poly(vinyl acetate vinyl alcohol) polymer that does not contain any other monomers (e.g., is not copolymerized with anionic monomers), a cold water soluble web that is soluble in water at temperatures below 10° C. has a temperature of about 75° C. % to about 90%, or from about 75% to about 89%, or from about 80% to about 90%, or from about 85% to about 90%, or from about 90% to about 99.5%. It may include fibers of PVOH with a degree of hydrolysis in the range. In other exemplary embodiments, the water-soluble foam substrate may be hot water soluble. For example, for a co-poly(vinyl acetate vinyl alcohol) polymer that does not contain any other monomers (e.g., is not copolymerized with anionic monomers), the hot water soluble foam substrate has a degree of hydrolysis of at least about 98%. It may be soluble in water at a temperature of at least about 60° C. by comprising fibers of PVOH having .

Modification of the PVOH polymer increases the solubility of the PVOH polymer. Therefore, at a given temperature, the solubility of a water-soluble foam substrate made from a modified PVOH copolymer is expected to be higher than that of a water-soluble foam substrate made from a PVOH copolymer with the same degree of hydrolysis as the modified PVOH copolymer. Following this trend, water-soluble foam substrates with specific dissolution properties can be designed by blending polymers within fibers and/or blending fibers within water-soluble foam substrates. Additionally, as described herein, water-soluble foam substrates include a plurality of fibers, which in some cases may include two or more fiber types with different solubilities.

The inclusion of non-water soluble fibers and/or non-water soluble fiber-forming materials within a plurality of fibers of a water soluble foam substrate can also be used to design a water soluble foam substrate with specific solubility and/or extended release properties. Without intending to be bound by theory, as the weight percentage of non-water soluble fibers comprised within the water soluble foam substrate increases (based on the total weight of the water soluble foam substrate), the solubility of the water soluble foam substrate generally decreases, and the solubility of the water soluble foam substrate generally decreases. It is generally believed that the extended release properties of pouches containing the substrate are increased. Upon contact with water at or above the melting temperature of the water-soluble fibers, the water-soluble foam substrate comprising water-soluble fibers and non-water-soluble fibers will begin to disperse as the water-soluble fibers dissolve, thereby causing the foam structure to collapse. /or the pore size of the pores of the water-soluble foam substrate increases. The more the foam structure collapses or the pore size increases, the faster water can access the contents of the pouch and the faster the contents of the pouch will be released. Similarly, extended release of the contents of a pouch comprising the water-soluble foam substrate of the disclosure can be achieved by using blends of water-soluble fibers with different solubility properties and/or different solubility temperatures. When the more rapidly dissolving fibers dissolve and thereby collapse the foam, the less soluble fibers will have a greater exposed surface area, which promotes dissolution of the less soluble fibers and release of the pouch contents. In embodiments where the foam substrate includes soluble fibers and non-soluble fibers, the ratio of soluble fibers to non-soluble fibers is not particularly limited. The water-soluble fibers comprise from about 1% to about 99% by weight, from about 20% to about 80% by weight, from about 40% to about 90% by weight, from about 50% to about 90% by weight, of the total weight of the plurality of fibers. or from about 60% to about 90% by weight, wherein the non-water soluble fibers comprise from about 1% to about 99% by weight, from about 20% to about 80% by weight, from about 10% to about 10% by weight of the total weight of the fibers. It may comprise about 60% by weight, about 10% by weight to about 50% by weight, or about 10% by weight to about 40% by weight. In an embodiment, the plurality of fibers comprises from about 10% to about 80% water soluble fibers by weight, based on the total weight of the fibers, with the remainder being non-soluble fibers.

In embodiments, the nonwoven web, plurality of fibers, foam, water-soluble film, or combinations thereof disclosed herein may include a biodegradable polymer. In certain embodiments, the plurality of fibers can include a non-soluble fiber-forming material that is biodegradable. In an embodiment, the plurality of fibers include a first fiber that is a non-water soluble biodegradable fiber, and a first fiber that is soluble in water at a temperature of about 10°C to about 20°C according to MSTM 205 or about 30°C or less according to MSTM 205. It may include a second fiber that is not soluble in water at that temperature. In embodiments, the nonwoven web is non-water soluble and biodegradable.

In an embodiment, the water-soluble foam substrate is biodegradable. As used herein, when a water-soluble foam substrate is referred to as being biodegradable, at least 50% of the water-soluble foam substrate is biodegradable, e.g., at least 60%, at least 70%, at least 80% of the water-soluble foam substrate, At least 90%, or 100% biodegradable.

In an exemplary embodiment, a water-soluble foam substrate as disclosed herein can comprise a plurality of fibers comprising a first fiber type and a second fiber type, wherein the first and second fiber types have diameter, length, and toughness. , have differences in shape, rigidity, elasticity, solubility, melting point, glass transition temperature (T _g ), chemical composition, color, or combinations thereof. In embodiments, the first fiber type may comprise a PVOH homopolymer fiber-forming material, a PVOH copolymer fiber-forming material, a modified PVOH copolymer fiber-forming material, or a combination thereof. In an embodiment, the first fiber type comprises two or more PVOH homopolymer fiber-forming materials, two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a combination thereof. can do. In embodiments, the second fiber type may comprise a PVOH homopolymer fiber-forming material, a PVOH copolymer fiber-forming material, a modified PVOH copolymer fiber-forming material, or a combination thereof. In an embodiment, the second fiber type comprises two or more PVOH homopolymer fiber-forming materials, two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a combination thereof. can do. In embodiments, the first fiber type and/or the second fiber type are non-soluble fiber-forming materials. In embodiments, the first fiber type may comprise a non-water soluble polymeric fiber-forming material and the second fiber type, when provided as a film or as the sole fiber-forming material of a nonwoven web, the resulting web or film. and a polyvinyl alcohol fiber-forming material that is soluble in water at temperatures ranging from about 0° C. to about 20° C. according to MSTM 205. In embodiments, the first fiber type may comprise a non-water soluble polymeric fiber-forming material and the second fiber type is provided as the sole fiber-forming material of the water soluble foam substrate, wherein the resulting water soluble foam substrate is MSTM 205 PVOH copolymers or modified copolymer fiber-forming materials that are not soluble in water at temperatures of 20° C. or less. In embodiments, the first fiber type is a combination of two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a PVOH copolymer fiber-forming material and a modified PVOH copolymer fiber-forming material. Contains a combination of substances. In embodiments, the second fiber type is a combination of two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a copolymer fiber-forming material and a modified PVOH copolymer fiber-forming material. Includes a combination of

The plurality of fibers included in the water-soluble foam substrate of the disclosure can have any toughness. The toughness of a fiber is correlated with the roughness of the fiber. As the toughness of the fiber decreases, the roughness of the fiber increases. The fibers used to make the nonwoven webs of the disclosure have a weight of about 1 to about 100 cN/dtex, or about 1 to about 75 cN/dtex, or about 1 to about 50 cN/dtex, or about 1 to about 45 cN/dtex. dtex, or about 1 to about 40 cN/dtex, or about 1 to about 35 cN/dtex, or about 1 to about 30 cN/dtex, or about 1 to about 25 cN/dtex, or about 1 to about 20 cN/ dtex, or about 1 to about 15 cN/dtex, or about 1 to about 10 cN/dtex, or about 3 to about 8 cN/dtex, or about 4 to about 8 cN/dtex, or about 6 to about 8 cN/dtex. dtex, or range from about 4 to about 7 cN/dtex, or from about 10 to about 20, or from about 10 to about 18, or from about 10 to about 16, or from about 1 cN/dtex, or from about 2 cN/dtex, or from about 3 cN/dtex, about 4 cN/dtex, about 5 cN/dtex, about 6 cN/dtex, about 7 cN/dtex, about 8 cN/dtex, about 9 cN/dtex, about 10 cN/dtex, about 11 cN/ dtex, about 12 cN/dtex, about 13 cN/dtex, about 14 cN/dtex, or about 15 cN/dtex. In embodiments, the plurality of fibers may have a toughness of from about 3 cN/dtex to about 15 cN/dtex, or from about 5 cN/dtex to about 12 cN/dtex, or from about 5 cN/dtex to about 10 cN/dtex. there is.

The toughness of the water-soluble foam substrate may be the same or different from the toughness of the plurality of fibers used to make the web. Without intending to be bound by theory, it is believed that the toughness of the water-soluble foam substrate is related to the strength of the nonwoven web, where higher toughness provides higher strength to the nonwoven web. The toughness of a water-soluble foam substrate can be modified using fibers with different toughnesses. The toughness of water-soluble foam substrates can also be affected by processing. The water-soluble foam substrate of the disclosure has relatively high toughness, i.e., the water-soluble foam substrate is a free-standing substrate that can be used as a standalone material for making articles and/or pouches. On the other hand, water-soluble foam substrates made according to melt blown, electrospinning, and/or rotary spinning processes have low toughness and may not be free-standing or usable as a stand-alone substrate for forming articles or pouches.

The water-soluble foam substrate can be characterized by basis weight. The basis weight of a water-soluble foam substrate is the mass per unit area of the water-soluble foam substrate. Basis weight can be modified by varying manufacturing conditions as known in the art. The water-soluble foam substrate may have the same basis weight before and after bonding. Alternatively, the bonding method can vary the basis weight of the water-soluble foam substrate. For example, when bonding occurs through the application of heat and pressure, the thickness of the water-soluble foam substrate (and thus the area of the water-soluble foam substrate) can be reduced, thereby increasing the basis weight. Accordingly, as used herein and unless otherwise specified, basis weight of a water-soluble foam substrate refers to the basis weight of the water-soluble foam substrate after bonding.

The water-soluble foam substrate of the disclosure has a weight of about 0.1 g/m ² to about 700 g/m ² , about 0.5 g/m ² to about 600 g/m ² , about 1 g/m ² to about 500 g/m ² , about 1 g/m ² to about 400 g/m ² , about 1 g/m ² to about 300 g/m ² , about 1 g/m ² to about 200 g/m ² , about 1 g/m ² to about 100 g/m ² , about 30 g/m ² to about 100 g/m ² , about 20 g/m ² to about 100 g/m ² , about 20 g/m ² to about 80 g/m ² , or about 25 It can have any basis weight ranging from g/m ² to about 70 g/m ² .

Additionally, as the basis weight of the water-soluble foam substrate increases, the dissolution rate of the water-soluble foam substrate decreases, provided the fiber composition and web thickness remain constant because there is more material to dissolve. For example, at a given temperature, a water-soluble foam substrate made from fibers comprising PVOH polymer(s) and having a basis weight of, for example, 40 g/m ² may have a weight of, for example, 30 g/m ² It is expected to dissolve more slowly than a water-soluble web that has a higher basis weight but is otherwise identical. Accordingly, basis weight can also be used to modify the solubility properties of water-soluble foam substrates. The water-soluble foam substrate has a weight of about 1 g/m ² to about 700 g/m ² , about 1 g/m ² to about 600 g/m ² , about 1 g/m ² to about 500 g/m ² , about 1 g/m 2 m ² to about 400 g/m ² , about 1 g/m ² to about 300 g/m ² , about 1 g/m ² to about 200 g/m ² , about 10 g/m ² to about 100 g/m ² , about 30 g/m ² to about 100 g/m ² , about 20 g/m ² to about 100 g/m ² , about 20 g/m ² to about 80 g/m ² , about 25 g/m ² It can have any basis weight ranging from about 70 g/m ² , or from about 40 g/m ² to about 60 g/m ² .

The water-soluble foam substrates of the disclosure may be used as a single layer or may be layered with other water-soluble foam substrates or may be in the form of a laminate with a water-soluble film. In some embodiments, the water-soluble foam substrate comprises a single layer. In some embodiments, the water-soluble foam substrate is a multilayer water-soluble foam substrate comprising two or more layers. Two or more layers can be stacked on top of each other. In this improved embodiment, the two or more layers can be identical (eg, made from the same fibers and basis weight). In this improved embodiment, the two or more layers can be different (eg, made from different types of fibers, fiber chemicals and/or have different basis weights).

Multilayer water-soluble foam substrates can have a basis weight that is the sum of the basis weights of the individual layers. Accordingly, a multilayer water-soluble foam substrate will take longer to dissolve than either of the individual layers provided as a single layer.

water soluble film

The water-soluble films described herein include any one of the water-soluble polymers disclosed herein. In embodiments, the water-soluble films of the disclosure comprise polyvinyl alcohol (PVOH) resin, modified polyvinyl alcohol resin, or combinations thereof. In an embodiment, the water-soluble film comprises a PVOH resin selected from the group consisting of PVOH homopolymers, PVOH copolymers, PVOH copolymers with anionic modifications, and combinations of the foregoing. In embodiments, the water-soluble film may comprise a single PVOH polymer or a blend of PVOH polymers. In an embodiment, the water-soluble film comprises a PVOH copolymer. In an embodiment, the water-soluble film comprises a hot water soluble PVOH copolymer. In embodiments where the nonwoven web includes a surfactant and/or exfoliant, the water-soluble film may include a PVOH copolymer with an anionic modification. In an embodiment, the water-soluble film is a water-soluble polyvinyl alcohol copolymer or modified copolymer that, when provided to the film as the sole film-forming material, the film is soluble in water at temperatures ranging from about 0° C. to about 20° C. according to MSTM 205. may include. In embodiments, the water-soluble film may comprise a water-soluble polyvinyl alcohol copolymer or modified copolymer that, when provided to the film as the sole film-forming material, the film would not be water-soluble at water temperatures of 20° C. or less according to MSTM 205. there is.

Water-soluble films include polyvinyl alcohol, water-soluble acrylate copolymers, polyethyleneimine, pullulan, water-soluble natural polymers including, but not limited to, guar gum, acacia gum, xanthan gum, carrageenan, and starch, water-soluble polymer modified starches, any of the above. and other film forming polymers, including but not limited to copolymers of the above, or combinations of any of the above. Other water-soluble polymers include polyalkylene oxides, polyacrylamides, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetate, polycarboxylic acids and their salts, polyamino acids, polyamides, gelatin, methylcellulose, carboxymethylcellulose. and salts thereof, dextrin, ethylcellulose, hydroxyethyl cellulose, hydroxypropyl methylcellulose, maltodextrin, polymethacrylate, or a combination of any of the above. These water-soluble polymers are commercially available from a variety of sources. In embodiments, the water-soluble film may comprise a PVOH homopolymer, a PVOH copolymer, a modified PVOH copolymer, or a combination thereof. In embodiments, the water-soluble film comprises a single PVOH copolymer or a blend of PVOH copolymers. In a further embodiment, the water-soluble film comprises a PVOH copolymer having a viscosity ranging from 5 cP to 23 cP and a degree of hydrolysis ranging from 86% to 92%.

The film may have any suitable thickness, and a film thickness of about 76 microns (μm) is typical and particularly contemplated. Other values and ranges contemplated include the range from about 5 μm to about 200 μm, or from about 20 μm to about 100 μm, or from about 40 μm to about 90 μm, or from about 50 μm to 80 μm, or from about 60 μm to 65 μm. ranges, for example, include values of 65 μm, 76 μm, or 88 μm.

In embodiments, the water-soluble film may include adjuvants as described above. In embodiments, the water-soluble film may be substantially free of adjuvants as described above. In embodiments, the water-soluble film may include a plasticizer as described above. The total amount of non-aqueous plasticizer provided in the water-soluble film may be from about 1% to about 45% by weight, or from about 5% to about 45% by weight, or from about 10% to about 40% by weight, or about range from 20% to about 30% by weight, from about 1% to about 4% by weight, or from about 1.5% to about 3.5% by weight, or from about 2.0% to about 3.0% by weight, for example, about 1% by weight. %, about 2.5% by weight, about 5% by weight, about 10% by weight, about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, or about 40% by weight. . In an embodiment, the water-soluble film comprises one or more of propylene glycol, glycerol, diglycerol, sorbitol, xylitol, maltitol, trimethylol propane (TMP), and polyethylene glycol (100-1000 molecular weight).

In embodiments, the water-soluble film may include a surfactant as described above. In various embodiments, the amount of surfactant in the water-soluble film is about 0.01% by weight, about 2.5% by weight, about 0.1% by weight to about 2.5% by weight, about 1.0% by weight to about 2.0% by weight, about 0.01% by weight to about 0.25% by weight. % by weight, or in the range of about 0.10% to 0.20% by weight. In an embodiment, the water-soluble film comprises one or more of polysorbate 80, lecithin from various plant sources, and sodium lauryl sulfate (SLS), etc., or any combination thereof.

In embodiments, adjuvants of the water-soluble film may include fillers/extenders/anti-blocking agents/de-adhesives. Suitable fillers/extenders/anti-blocking agents/deadhesives include, but are not limited to, cross-linked polyvinylpyrrolidone, cross-linked cellulose, microcrystalline cellulose, silica, metal oxides, calcium carbonate, talc, mica, stearic acid, and metal salts thereof, such as magnesium stearate. Optionally, additional unmodified starches or modified starches include, for example, polyvinyl alcohol copolymers in which the polyvinyl alcohol is unmodified or anionic modified polyvinyl alcohol copolymers when the anionic modifier is not an acrylate. hydroxypropylated starch, if present in an amount ranging from about 5 phr to about 30 phr, or modified starch having a strain greater than about 2%, present in an amount ranging from about 2.5 phr to about 30 phr. , or certain starch components described above, such as unmodified starch having an amylose content ranging from about 20% to about 80%, or hydroxypropyl modified starch having an amylose content ranging from about 23% to about 95%. It may be included in a water-soluble film in addition to one of the following. Preferred materials are starch, modified starch, and silica. In one embodiment, the amount of filler/extender/anti-blocking agent/deadhesive in the water-soluble film is, for example, from about 1% to about 6% by weight, or from about 1% to about 4% by weight, or about 2% by weight. to about 4 weight percent, or from about 1 phr to about 6 phr, or from about 1 phr to about 4 phr, or from about 2 phr to about 4 phr. In embodiments, when starch or modified starch is included in the water-soluble film secondary to one of the specific starch components described above, the additional starch component is present in an amount of less than about 50% by weight based on the total weight of all starches included in the film. will be provided Without intending to be bound by theory, any benefits provided to the water-soluble film of the disclosure by including the starch components described above may be replaced by additional starch components that provide less benefit to the water-soluble film or provide no advantage to the water-soluble film. It is not believed to be affected by the inclusion of .

The water-soluble film may further have a residual moisture content of at least 4% by weight, for example in the range of about 4% to about 10% by weight, as measured by Karl Fischer titration.

Fiber manufacturing method

Wet Cooled Gel Spinning

In an embodiment, the plurality of water-soluble fibers may comprise water-soluble fibers prepared according to a wet cool gel spinning process, wherein the wet cool gel spinning process includes the following steps:

(a) dissolving a water-soluble polymer (or polymers) in solution to form a polymer mixture, optionally including an auxiliary agent;

(b) extruding the polymer mixture through a spinneret nozzle into a coagulation bath to form an extruded polymer mixture;

(c) passing the extruded polymer mixture through a solvent exchange bath;

(d) optionally wet drawing the extruded polymer mixture; and

(e) finishing the extruded polymer mixture to provide water-soluble fibers.

The solvent in which the water-soluble polymer is dissolved may suitably be any solvent in which the water-soluble polymer can be dissolved. In an embodiment, the solvent in which the water-soluble polymer is dissolved comprises a polar aprotic solvent. In an embodiment, the solvent in which the water-soluble polymer is dissolved comprises dimethyl sulfoxide (DMSO).

The coagulation bath contains a cooled solvent to gel the extruded polymer mixture. The coagulation bath can generally be at any temperature that promotes solidification of the extruded polymer mixture. The coagulation bath may be a mixture containing a solvent in which the polymer can be dissolved and a solvent in which the polymer cannot be dissolved. The solvent in which the polymer cannot be dissolved is generally the primary solvent, where the solvent in which the polymer cannot dissolve accounts for more than 50% by volume of the mixture.

After passing the coagulation bath, the extruded polymer mixture gel may pass through one or more solvent exchange baths. The solvent exchange bath further solidifies the extruded polymer mixture by replacing the solvent in which the water-soluble polymer can be dissolved with a solvent in which the water-soluble polymer cannot, and further causes the solvent in which the water-soluble polymer can be dissolved to evaporate more easily. It is provided to replace the phosphorus solvent and thereby reduce the drying time. The solvent exchange bath may be a series of solvent exchange baths with a gradient of solvents in which the water-soluble polymer can dissolve and solvents in which the water-soluble polymer cannot, or a series of solvent exchange baths with the only solvent in which the water-soluble polymer cannot dissolve, or It may include a single solvent exchange bath having only a solvent in which the water-soluble polymer cannot be dissolved. In embodiments, the at least one solvent exchange bath may consist essentially of a solvent in which the water-soluble polymer cannot be dissolved.

Finished fibers are sometimes referred to as staple fibers, shortcut fibers, or pulp. In an embodiment, finishing includes drying the extruded polymer mixture. In embodiments, finishing includes cutting or crimping the extruded polymer mixture to form individual fibers. Wet drawing of the extruded polymer mixture can provide the extruded polymer mixture with a substantially uniform diameter from which fibers are cut. Drawing is separate from extrusion, as is well known in the art. In particular, "extrusion" involves the act of producing fibers by forcing the resin mixture through a spinneret head, while drawing involves the fabrication of fibers in the machine direction to promote polymer chain orientation and crystallinity for increased fiber strength and toughness. It involves mechanical pulling.

In embodiments where the water-soluble fibers are made from a wet cool gel spinning process, the water-soluble polymer can generally be any water-soluble polymer or a blend thereof, e.g., two or more different polymers as generally described herein. In this improved embodiment, the polymer(s) may have, for example, 10 to 10,000,000, e.g., at least 10, at least 20, at least 50, at least 100, at least 200, at least 300, at least 400, at least 500, at least 750, or at least 1000 and up to 10,000,000, up to 5,000,000, up to 2,500,00, up to 1,000,000, up to 900,000, up to 750,000, up to 500,000, up to 250,000, up to 100,000, up to 90,000, up to 75 ,000, up to 50,000, up to 25,000, up to 12,000, Up to 10,000, up to 5,000, or up to 2,500 range, for example 1000 to about 50,000, 1000 to about 25,000, 1000 to about 12,000, 1000 to about 5,000, 1000 to about 2,500, about 50 to about 12,000, about 50 to about 50 to about 50 to 10,000, about 50 to about 5,000, about 50 to about 2,500, about 50 to about 1000, about 50 to about 900, about 100 to about 800, about 150 to about 700, about 200 to about 600, or about 250 to about 500. It may have an arbitrary degree of polymerization (DP) in the range. In an embodiment, the DP is at least 1,000. Auxiliaries as described herein may be added to the fibers themselves or to the nonwoven web during the carding and/or bonding process.

Thermoplastic fiber spinning

Thermoplastic fiber spinning is well known in the art. Briefly, thermoplastic fiber spinning involves the following steps:

(a) preparing a polymer mixture comprising a fiber-forming polymer, optionally including an auxiliary agent;

(b) extruding the polymer mixture through a spinneret nozzle to form an extruded polymer mixture;

(c) optionally drawing the extruded polymer; and

(d) finishing the extruded polymer mixture to provide fibers.

The finished staple fibers of the thermoplastic fiber spinning process can be finished by drying, cutting, and/or crimping to form individual fibers. Drawing of the extruded polymer mixture mechanically pulls the fibers in the machine direction to promote polymer chain orientation and crystallinity for increased fiber strength and toughness. Preparing the polymer mixture for thermoplastic fiber spinning involves (a) extruding the solution through a spinneret, such that when the solution is contacted with a stream of hot air, the solvent readily evaporates, leaving the solid fiber behind the fiber-forming material; and preparing a solution of an immediately volatile solvent; or (b) extruding the hot polymer through a spinneret and then melting the polymer such that the polymer is quenched by cooling air and solidifies. The thermoplastic fiber spinning process is characterized in that at least (a) in the thermoplastic fiber spinning process, the extruded fibers are solidified by evaporation of a solvent or by quenching the hot solid fibers with cooling air rather than by the use of a coagulation bath; and (b) the wet cool gel spinning method is distinguished from the wet cool gel spinning method in that any drawing is performed while the fibers are in a gel state rather than a solid state.

The fiber-forming material for making fibers from a thermoplastic fiber spinning process can be any fiber-forming polymer or blend thereof, e.g., two or more different polymers, provided that the polymer or blend thereof is readily soluble in a volatile solvent. It has suitable solubility and/or has a melting point that is below and distinct from its decomposition temperature. Additionally, when blends of fiber-forming polymers are used to make fibers, the fiber-forming materials have similar thermal profiles and/or have similar thermal profiles in readily volatile solvents such that the two or more fiber-forming materials melt at similar temperatures. It must have solubility. On the other hand, the fiber-forming material for producing fibers from the wet cooled gel spinning process is not limited, and the fibers can be prepared from a blend of any two or more polymers that are soluble in the same solvent system, and the solvent system is a single solvent or It doesn't even have to be a volatile solvent.

The fiber-forming polymer(s) for making the thermoplastic fiber spun fiber may have, for example, 10 to 10,000, e.g., at least 10, at least 20, at least 50, at least 100, at least 200, at least 300, at least 400, It can have a degree of polymerization (DP) ranging from at least 500, at least 750, or at least 1000 and at most 10,000, at most 5,000, at most 2,500, at most 1,000, at most 900, at most 750, at most 500, or at most 250. In embodiments, the DP is less than 1,000.

melt spinning

Melt spinning is well known in the art and is understood to refer to both spun bond processes and melt blown processes. Melt spinning is a continuous process that produces nonwoven webs directly with fiber formation. As such, fibers formed by melt spinning are not finished but cut to any length (e.g., staple fibers are not made by this process). Additionally, melt spinning does not involve a drawing step, the only control over the diameter of the resulting melt spun fibers is the size of the hole through which the fiber-forming material is extruded, and the polymer chains are not oriented in any particular direction. .

In an exemplary embodiment, melt spinning includes the following steps:

(a) preparing a polymer mixture comprising a fiber-forming polymer, optionally including an auxiliary agent;

(b) extruding the polymer mixture into a die assembly to form an extruded polymer mixture;

(c) quenching the extruded polymer mixture;

(d) depositing the quenched, extruded polymer mixture onto a belt to form a nonwoven web; and

(e) Joining the nonwoven web.

In the spunbond process, the extruded polymer mixture is pumped as molten polymer to a die assembly and is quenched with cooling air as it passes through the die assembly. In the melt blown process, the extruded polymer mixture is pumped into a die assembly with hot air blown through it and quenched as it exits the die assembly and comes in contact with ambient temperature air. In both processes, the fibers are dropped continuously onto a belt or drum, usually facilitated by drawing a vacuum under the belt or drum.

The melt spun fibers may have a diameter of about 0.1 to about 50 microns, for example, at least about 0.1 micron, at least about 1 micron, at least about 2 microns, at least about 5 microns, at least about 10 microns, at least about 15 microns, or at least about 20 microns and up to about 50 microns, up to about 40 microns, up to about 30 microns, up to about 25 microns, up to about 20 microns, up to about 15 microns, up to about 10 microns, about 0.1 microns to about 50 microns, about 0.1 microns. to about 40 microns, about 0.1 microns to about 30 microns, about 0.1 microns to about 25 microns, about 0.1 microns to about 20 microns, about 0.1 microns to about 15 microns, about 0.1 microns to about 10 microns, about 0.1 microns to about 0.1 microns. 9 microns, about 0.1 microns to about 8 microns, about 0.1 microns to about 7 microns, about 0.1 microns to about 6 microns, about 0.1 microns to about 6 microns, about 5 microns to about 35 microns, about 5 microns to about 30 microns. , from about 7.5 microns to about 25 microns, from about 10 microns to about 25 microns, or from about 15 microns to about 25 microns. Although the melt blown process can provide fine fibers with an average diameter in the range of about 1-10 microns, the melt blown process has very large variations in fiber-to-fiber diameter, e.g., 100-300% variation. is well known in the art. Spunbond fibers can also have a larger average fiber diameter, for example about 15 to about 25 microns, but improved uniformity between fibers, for example about 10% variation.

Fiber-forming materials for thermally extruded processes (eg, melt spinning, thermoplastic fiber spinning) are more limited than for wet cooled gel spinning processes. For example, the degree of polymerization for thermal extrusion processes is limited to a range of about 200 to about 500. As the degree of polymerization is reduced below 200, the viscosity of the fiber-forming material is very low and the individual fibers produced by pumping the material into the die assembly do not maintain adequate separation after exiting the die assembly. Similarly, as the degree of polymerization increases beyond 500, the viscosity becomes too high to pump sufficient material through the small orifices of the die assembly to run the process at high speeds, thereby reducing process efficiency and fiber and/or nonwoven uniformity. Gender is lost. Additionally, processes requiring heating of the fiber-forming material are not suitable for polyvinyl alcohol homopolymers because the homopolymers do not generally have the required thermal stability.

The wet cooling gel spinning process advantageously provides fibers comprising a blend of water-soluble polymers, provides control over the diameter of the fibers, provides relatively large diameter fibers, and provides control over the length of the fibers. providing, providing control over the toughness of the fibers, providing high toughness fibers, providing fibers from polymers with a high degree of polymerization, and/or fibers that can be used to provide free-standing nonwoven webs. It provides one or more benefits, such as providing . Continuous processes such as spunbond, meltblown, electrospinning, and rotary spinning generally do not blend water-soluble polymers (e.g., due to the difficulty of matching the melt index of the various polymers) and do not allow large diameters (e.g., 50 It fails to form fibers (exceeding microns), cannot control the length of the fibers, fails to provide high-toughness fibers, and cannot use polymers with a high degree of polymerization. Additionally, the wet cooled gel spinning process is advantageously not limited to melt processable polymers and thus allows fibers made from fiber-forming materials with very high molecular weight, high melting point, low melt flow index, or combinations thereof. available, which provides fibers with stronger physical properties and different chemical functionality compared to fibers made by thermal extrusion processes. More advantageously, the wet cool gel spinning process is not limited by the viscosity of the polymer. On the other hand, it is known in the art that processes requiring melting of fiber-forming materials are limited to fiber-forming materials having a viscosity of 5 cP or less. Accordingly, fibers comprising polymers, including polyvinyl alcohol homopolymers and copolymers, with a viscosity greater than 5 cP are available only by wet cool gel spinning.

Method of manufacturing non-woven web

The nonwoven web of the disclosure is a sheet-like structure having two outer surfaces, and the nonwoven web includes a plurality of fibers. Nonwoven webs of the disclosure can be made from fibers using any method known in the art. As is known in the art, when fibers are spunbonded or meltblown, the fibers are continuously laid down to form a nonwoven web, followed by bonding of the fibers.

Staple fibers can be carded or airlaid and bonded to provide a nonwoven web. Methods of carding and airlaying are well known in the art.

Methods for joining nonwoven webs are well known in the art. For example, bonding may include thermal, mechanical, and/or chemical bonding. Thermal bonding may include, but is not limited to, calendering, embossing, air-through, and ultrasound. Mechanical bonding may include, but is not limited to, hydro-entangling (spunlace), needle-punching, and stitch-bonding. Chemical bonding may include, but is not limited to, solvent bonding and resin bonding.

Thermal bonding is achieved by applying heat and pressure and maintains the pore size, shape and alignment created by the carding process. Conditions for thermal bonding can be easily determined by one skilled in the art. If the applied heat and/or pressure is very low, the fibers will not bond sufficiently to form a free-standing web, and if the heat and/or pressure are very high, the fibers will begin to blend together. Fiber chemistry determines the upper and lower limits of heat and/or pressure for thermal bonding. Without intending to be bound by theory, it is believed that at temperatures above 235° C., polyvinyl alcohol-based fibers decompose. Embossing methods for thermal bonding of fibers are known. Embossing may be single-sided embossing or double-sided embossing. Embossing of water-soluble fibers involves single-sided embossing using a single embossing roll consisting of steel rolls with aligned circular arrays and flat surfaces. As embossing increases (eg, as surface features are imparted to the web), the surface area of the web increases. Without intending to be bound by theory, it is expected that as the surface area of the web increases, the solubility of the web increases. Accordingly, the solubility properties of the nonwoven web can advantageously be adjusted by varying the surface area through embossing.

Air-through bonding requires a high thermoplastic content in the nonwoven web and two different melting point materials. In air-through bonding, an unbonded nonwoven web circulates around the drum while hot air flows from the outside of the drum toward the center of the drum. Air-through bonding can provide nonwovens with lower densities and higher basis weights (eg, greater than 20 to about 2000 g/m ² ). Nonwoven fabrics bonded by air-bonding are very soft.

Chemical bonds include solvent bonds and resin bonds. In particular, chemical bonding can use a binder solution of solvent and resin (e.g., latex or waste polymer left over from making fibers). Nonwoven fabrics can be coated using a binder solution and heat and pressure applied to cure the binder and bond the nonwoven fabric. The binder solution can be applied by soaking the nonwoven in a bath of binder solution, spraying the binder solution onto the nonwoven, extruding the binder solution onto the web (foam bonding), and/or applying the binder solution as a print or gravure. .

Chemical bonding can create smaller, less ordered pores compared to pores produced by carding/melt spinning. Without intending to be bound by theory, it is believed that a non-porous nonwoven web can be formed if the resin solution used for chemical bonding is sufficiently concentrated and/or sufficient pressure is applied. Solvents used in chemical bonding induce partial dissolution of the existing fibers in the web, thereby fusing and bonding the fibers together. Accordingly, the solvent for chemical bonding may be any solvent capable of at least partially dissolving one or more fiber-forming substances of the fibers of the nonwoven fabric. In an embodiment, the solvent is selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof. In an embodiment, the solvent is selected from the group consisting of water, glycerin, and combinations thereof. In an embodiment, the binder solution comprises a solvent selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof, and further selected from the group consisting of polyvinyl alcohol, latex, and polyvinylpyrrolidone. Contains resins that are The binder provided in solution assists the fusion process to provide a more mechanically robust web. The temperature of the polymer solution is not particularly limited and may be provided at room temperature (about 23° C.).

In some embodiments, a second layer of fibers can be used to join the nonwoven web. In embodiments, the nonwoven layers can be bonded using thermal, mechanical, or chemical bonding alone or in addition to bonding using additional layers of nonwoven webs/fibers.

Method for laminating films to nonwoven webs or foam substrates

Methods for making laminates (e.g., water-soluble films and nonwovens) may include, but are not limited to, calendar lamination (using pressure and heat) or melt bonding.

Calendar lamination is achieved by applying heat and pressure. Conditions for calendar lamination can be easily determined by one skilled in the art. If the applied heat and/or pressure is very low, the fibers will not sufficiently bond to the water-soluble film to form a laminate, and if the heat and/or pressure are very high, the fibers will begin to mix with each other and with the film. . Fiber chemistry and film chemistry determine the upper and lower limits of heat and/or pressure for calendar lamination. Without intending to be bound by theory, it is believed that at temperatures above 235° C., polyvinyl alcohol-based fibers decompose. In embodiments, the heat applied to the overlaid nonwoven fabric and water-soluble film is from about 50°C to about 200°C, e.g., from about 100°C to about 200°C, from about 110°C to about 190°C, from about 120°C. About 180°C, or about 130°C to about 160°C. In embodiments, the pressure applied to the overlaid nonwoven fabric and water-soluble film is from about 5 psi to about 50 psi, such as about 10 psi to about 40 psi, about 15 psi to about 30 psi, or about 20 psi to about 30 psi. . In an embodiment, the heat applied to the overlaid nonwoven and water-soluble film is about 150° C. and the pressure applied is about 25 psi. In an embodiment, heat and pressure are applied for about 2-4 seconds. Embossing methods for calendar lamination of fibers and/or films are contemplated. Embossing may be single-sided embossing or double-sided embossing. Embossing of water-soluble fibers and/or water-soluble films involves single-sided embossing using a single embossing roll consisting of a steel roll with an aligned circular arrangement and a flat surface. As embossing increases (eg, imparting an increased amount of surface features to the web and/or film), the surface area of the laminate increases. Without intending to be bound by theory, it is believed that as the surface area of the article decreases, the solubility of the web and/or film decreases. Accordingly, the solubility properties of the nonwoven web and/or water-soluble film can advantageously be adjusted by varying the surface area through embossing. Without intending to be bound by theory, it is believed that as the degree of lamination of a unit dose article increases, the surface area of the laminate decreases, and the bond between the water-soluble film and the nonwoven fabric increases, which causes decreased solubility and increased liquid release time. It is considered.

Melt adhesive lamination is achieved by applying the adhesive directly to the water-soluble film, the non-woven web is then placed on top of the water-soluble film with the applied adhesive, and subjected to cold lamination for adhesion of the non-woven web and water-soluble film. As used herein, the term “cold lamination” refers to a lamination process that involves pressure but not applied heat. The adhesive may be any suitable adhesive of one of ordinary skill in the art. In an embodiment, the adhesive is Henkel National Adhesive. Direct application of the adhesive to the water-soluble film can be applied by any suitable method to one of the skill in the art, such as a hot melt-spray process. In an embodiment, the melt adhesive lamination process may include a hot melt spray process at 160° C. followed by cool lamination at a pressure of 94 N/mm ² .

The laminates of the disclosure generally include a water-soluble film and a nonwoven web. In embodiments, the laminate may have a degree of lamination from about 1% to about 100%, e.g., a degree of lamination from about 1% to about 90%, or from about 25% to about 75%, or from about 1% to about 1%. It may range from about 50%, or from about 5% to about 25%, or from about 25% to about 100%, or from about 50% to about 100%. As used herein, the term “degree of lamination” refers to the amount of total area of water-soluble film bonded to the nonwoven web. For example, a laminate having a degree of lamination of about 25% or less means that about 25% or less of the area of the water-soluble film is bonded to the nonwoven web, for example, a seal-only lamination. For example, a laminate having a degree of lamination of about 100% means that about 100% of the area of the water-soluble film is bonded to the nonwoven web. In embodiments where the degree of lamination is about 25% or less, lamination may be accomplished during a heat sealing process, where lamination occurs in each seal of the unit dose article. In embodiments where the laminate has a degree of lamination of about 25% or less, this low degree of lamination not only provides physical separation for components with incompatible chemistries, but also facilitates two-step delivery of the composition in a unit dose article. It can be advantageous to have internal hollow spaces where the water-soluble film and nonwoven web do not stack, providing an opportunity for the system. In embodiments, the degree of lamination ranges from about 5% to about 25%. In embodiments, the degree of lamination ranges from about 50% to about 100%.

Dissolution and Decomposition Test (Modified MSTM-205)

Nonwoven webs, water-soluble films, or laminate structures can be characterized or tested for dissolution time and degradation time according to MonoSol Test Method 205 (MSTM 205), a method known in the art. See, for example, U.S. Patent No. 7,022,656. The description provided below relates to nonwoven webs, while it is equally applicable to water-soluble films or laminate structures.

Devices and Materials:

600 mL beaker

Magnetic stirrer (Labline Model No. 1250 or equivalent)

Magnetic stir bar (5 cm)

Thermometer (0 to 100 ℃ ±1 ℃)

Template, stainless steel (3.8 cm x 3.2 cm)

Timer (0 - 300 seconds, accurate to the nearest second)

Polaroid 35 mm slide Mount (or equivalent)

MonoSol 35 mm Slide Mount Holder (or equivalent)

Distilled water

For each nonwoven web tested, three test specimens are cut from a nonwoven web sample that is a 3.8 cm x 3.2 cm specimen. Specimens should be cut from areas of the web equally spaced along the transverse direction of the web. Each test specimen is then analyzed using the following procedure.

Fix each specimen on a separate 35 mm slide mount.

Fill the beaker with 500 mL of distilled water. Measure the water temperature with a thermometer and, if necessary, heat or cool the water to maintain the temperature at the temperature at which dissolution is determined, e.g., 20° C. (about 68° F.).

Indicates the height of the water column. Place the magnetic stirrer at the bottom of the holder. Place the beaker on a magnetic stirrer, add a magnetic stir bar to the beaker, turn on the stirrer, and adjust the stirring speed until a vortex is generated at approximately 1/5 the height of the water column. Indicates the depth of the vortex.

Fix the 35 mm slide mount in the alligator clamp of the 35 mm slide mount holder so that the long end of the slide mount is parallel to the water surface. The length adjuster of the holder should be set so that the end of the clamp is 0.6 cm below the water level when dropped. One of the short sides of the slide mount should be next to the side of the beaker, and the other should be positioned directly above the center of the stir bar so that the nonwoven web surface is perpendicular to the water flow.

In one motion, the fixed slide and clamp are dropped into the water and the timer is started. Rupture occurs when the sample is damaged within the slide, for example when a hole is created. Decomposition occurs when the nonwoven web is broken and no sample material remains within the slide. When all visible nonwoven web has been expelled from the slide mount, lift the slide out of the water while continuously monitoring the solution for undissolved nonwoven web fragments. Dissolution occurs when all nonwoven web segments are no longer visible and the solution becomes clear. Rupture and decomposition can occur simultaneously for nonwoven samples, where the fibers are made from polyvinyl alcohol polymers with a low degree of hydrolysis (e.g., about 65-88%). When there is a difference of 5 seconds or more between rupture and dissolution, the dissolution time is recorded independently of the rupture time.

Thinning time can also be determined using MSTM-205. Thinning of a nonwoven web occurs when some of the fibers that make up the nonwoven web dissolve while other fibers remain intact. Thinning of the web occurs before decomposition of the web. Thinning is characterized by a decrease in the opacity, or an increase in the transparency, of the nonwoven web. The change from opacity to increasing transparency can be visually observed. During MSTM-205, the opacity/transparency of the nonwoven web is monitored after the fixed slide and clamp are dropped into water. At the point when no change in opacity/transparency is observed (i.e., the web does not become somewhat less opaque or more transparent), this time is recorded as the thinning time.

Results should include: complete sample identification; Individual and average decomposition and dissolution times; and the water temperature at which the sample is tested.

I _{correction value} = I _{measurement value} × (standard thickness/measured thickness) ^1.93 [1]

S _{correction value} = S _{measurement value} × (standard thickness/measured thickness) ^1.83 [2]

Method for Determining Single Fiber Solubility

The solubility of a single fiber can be characterized by its water breaking temperature. Fiber break temperature can be determined as follows. A load of 2 mg/dtex is applied to a fiber with a fixed length of 100 mm. The water temperature starts at 1.5°C and is then increased by 1.5°C increments every 2 minutes until the fiber breaks. The temperature at which the fiber breaks is expressed as the water breaking temperature.

The solubility of a single fiber can also be characterized by its complete dissolution temperature. The complete dissolution temperature can be determined as follows. 0.2 g of fiber with a fixed length of 2 mm is added to 100 mL of water. The water temperature starts at 1.5°C and is then increased by 1.5°C increments every 2 minutes until the fibers are completely dissolved. Samples are shaken at each temperature. The temperature at which the fiber completely dissolves in less than 30 seconds is referred to as the complete melt temperature.

Diameter test method

The diameter of individual fibers or fibers within the nonwoven web is determined using scanning electron microscopy (SEM) or optical microscopy and image analysis software. A magnification of 200 to 10,000 times is selected so that the fiber is suitably magnified for measurement. When using SEM, the sample is sputtered with a gold or platinum compound to avoid vibration and electrical charging of the fibers in the electron beam. Manual procedures for determining fiber diameter are used from images (on a monitor screen) taken with an SEM or light microscope. Using the mouse and cursor tools, a randomly selected edge of the fiber is located and its width to the other edge of the fiber is then measured (i.e. perpendicular to the fiber direction at this point). Scaled and calibrated image analysis tools provide scaling to obtain true readings in microns. For fibers within a nonwoven web, a number of fibers are randomly selected for a sample of the nonwoven web using SEM or optical microscopy. At least two sections of nonwoven web material are cut and tested in this manner. At least 100 such measurements are made and all data are subsequently recorded for statistical analysis. Use the recorded data to calculate the fiber mean (mean value), fiber standard deviation, and median fiber diameter.

Tensile strength, modulus, and elongation testing

Nonwoven webs, water-soluble films, characterized by or tested for tensile strength according to the Tensile Strength (TS) test, modulus (or tensile stress) according to the Modulus (MOD) test, and elongation according to the elongation test, Alternatively, the laminate structure is analyzed as follows. The description provided below relates to nonwoven webs, while it is equally applicable to water-soluble films or laminate structures. The procedure includes determination of modulus at 10% elongation and determination of tensile strength according to ASTM D 882 (“Standard Test Method for Tensile Properties of Thin Plastic Sheets”) or equivalent methods. An INSTRON tensile tester (Model 5544 Tensile Tester or equivalent) is used for calibration of nonwoven web data. To ensure dimensional stability and reproducibility, at least three test specimens, each cut with a reliable cutting tool, were tested in machine direction (MD) for each measurement (where applicable). Tests are conducted in a standard laboratory atmosphere at 23 ± 2.0°C and 35 ± 5% relative humidity. For tensile strength or modulus determination, prepare a 1"-wide (2.54 cm) sample of nonwoven web. The sample is then transferred to an INSTRON tensile testing machine and tested with minimal exposure in a 35% relative humidity environment. Tensile Testing The machine is prepared according to the manufacturer's instructions, equipped with a 500 N load cell, and calibrated. Fix the correct grips and faces (INSTRON grips with rubber coating and 25 mm wide face model number 2702-032 or equivalent). ). Samples are mounted on a tensile testing machine and analyzed to determine 100% modulus (i.e., the stress required to achieve 100% film elongation), tensile strength (i.e., the stress required to break the film), and % elongation (initial Determine the sample length at break relative to the sample length. In general, the higher the % elongation for a sample, the better the processability properties for the nonwoven web (e.g., increased formability into packets or pouches). ).

Textile Shrinkage Test (MSTM)

The shrinkage of a fiber when contacted with a suitable amount of carrier solvent can be determined according to the fiber shrinkage test under Monosol standard operating procedures.

Devices and Materials:

1. Fiber sample (approximately 3 grams)

2. 500 mL beaker

3. Cooled distilled water (placed in refrigerator)

4. Deionized water

5. Paper clip

6. Alligator clamp (solubility stand)

7. Stir plate

8. Timer

Prepare the sample as follows:

1. Obtain small bundles of untangled fibers. This is secured to paper clips and alligator clamps, sufficient to ensure that the approximate weight of the fiber bundle is between 0.013 grams (g) and 0.015 g.

2. Grab a paper clip and pull the end of the fiber through the cross section of the paper clip.

3. Each unique fiber being tested is run with N=3 replicates for each test temperature, 23°C and 10°C.

Device settings:

1. Fill 400 ml of water of each temperature into a 500 ml beaker. Check the water temperature with a temperature probe before and during the test.

2. Tape a ruler to the top of the alligator clamp, thereby suspending the ruler parallel to the clamp.

3. Place the beaker on the stir plate, place the solubility stand next to the stir plate, dip the ruler into the beaker and then read the length.

Test Procedure:

1. Attach the free end of the treated fiber with a paper clip in the alligator clamp.

2. Dip the test sample into the beaker so that the test sample is aligned next to the ruler.

3. Start the timer and record the initial length of the fiber. The test sample fiber length is from the end of the alligator clamp to the top of the paper clip.

4. After 2 minutes, record the final length of the fiber.

5. Lift the clamp out of the water and remove the sample from the clamp. Ensure that the outside and inside of the clamp are completely dry between each test.

Shrinkage rate calculation:

Shrunken Length = Initial Length - Final Length [3]

Fiber shrinkage (%) = (Shrinked length/Initial length) × 100% [4]

Nonwoven Shrinkage Test (MSTM)

The shrinkage of a nonwoven sheet when contacted with a suitable amount of carrier solvent can be determined according to the nonwoven shrinkage test under Monosol standard operating procedures.

Prepare the sample as follows:

1. Using a Cricut Maker machine, a 2 inch by 2 inch (5.08 cm x 5.08 cm) square nonwoven sample was cut.

2. Each square nonwoven was weighed. The nonwoven density (unit gsm) of each square was calculated prior to testing.

3. Cleaning formulations were made and diluted to different moisture content concentrations.

4. Set the camera at a height of approximately 11 ¼ inches (28.6 cm) to record the shrinkage rate of the WSNW.

Shrinkage tests on nonwoven samples were performed as follows:

5. Place a square (5.08 cm x 5.08 cm) non-woven fabric in a 100 × 1 mm Petri dish.

6. Heat the cleaning solution to the set temperature.

7. Place the Petri dish with the sample under the camera. For higher temperatures, a hot plate is placed underneath the Petri dish and heat is applied to maintain a constant temperature.

8. When the cleaning liquid reached the appropriate temperature, the camera was started to record.

9. 10 mL of cleaning solution was injected into the square nonwoven fabric with a syringe. Once the square was covered with cleaning solution, a 5 minute timer was started.

10. After 5 minutes, the final shrinkage was recorded according to random observations.

11. The shrinkage rate was calculated using the initial and final areas of the square.

12. Repeat 3 times for each set.

13. For shrinkage at 1 hour, nonwoven samples were measured 1 hour after initial exposure to the cleaning composition. For higher temperatures, exposed samples were placed in an oven at set temperature and then removed after 1 hour for shrinkage measurements.

Use of single unit dose articles

The single unit dose articles of the disclosure are suitable for a variety of commercial applications. Suitable commercial applications for single unit dose articles of the disclosure include, but are not limited to, for delivering cleaning formulations comprising laundry detergents, soaps, fabric softeners, bleaches, laundry accelerators, stain removers, optical brighteners, or water softeners. May include pouches and packets. In an exemplary embodiment, the active cleaning formulation includes, without limitation, activators, detergents, surfactants, emulsifiers, chelating agents, dirt suspenders, stain removers, enzymes, pH adjusters, builders, decontamination polymers, structurants, glass fragrances, The encapsulation may include fragrances, preservatives, solvents, minerals, and/or any ingredients suitable for personal hygiene, laundry detergents, dish detergents, and/or household surface cleaners or cleansers. Other examples include dish detergent, soap or cleaner, shampoo, conditioner, body wash, face wash, skin lotion, skin treatment, body oil, fragrance, hair treatment, bath salt, essential oil, bath bomb, or enzyme. The active cleaning formulation may be in the form of a solid, for example a powder or a plurality of granules or particles, a gel, liquid, or slurry formulation, or any suitable combination of powders, solids, gels, liquids, or slurry formulations, for example. there is.

Additional applications for the unit dose articles of the disclosure include personal care products such as exfoliants, shampoos, conditioners, body washes, face washes, skin lotions, skin treatments, hair treatments, bath salts, essential oils, or combinations thereof. It may include pouches and packets for delivering.

Additional considered applications include those involving a constant flow of water, for example automatic cleaning applications and/or dish washing applications. Advantageously, in these applications, when at least a portion of the composition is released from a unit dose, the nonwoven web foams and/or contaminates without damaging the surface being cleaned, such as paint on an automobile or a non-stick cookware surface. Vigorous rubbing can be used to facilitate removal.

Additional applications to be considered include those where the active agent is required to remain separate until the point of use. Advantageously, the unit dose article of the disclosure may comprise a first active agent within a first interior space formed by the water-soluble film and a second active agent may be comprised within a second interior space formed by the nonwoven web. The unit dose can be designed to: (a) release the second active agent upon exposure to cooler water, such that the second active agent does not come into contact with the first active agent prior to release of the second active agent in the water; and releasing the first active agent upon exposure to warmer water; or (b) releasing the first active agent from the first interior space prior to substantial dissolution of the nonwoven web such that the first active agent and the second active agent are contacted/mixed in the second interior space prior to substantially release of the composition from the unit dose.

Additional contemplated applications include those where the composition contained in a unit dose may be damaged or otherwise become unsuitable over time, for example upon exposure to oxygen, and would otherwise require release of extracts of the composition upon use. You can. These applications may include, but are not limited to, tea leaves and pouched tobacco products. Advantageously, the unit dose of the disclosure can provide a gas barrier to the water-soluble film to maintain freshness, which will dissolve at the point of use (e.g., hot water or placement in the consumer's mouth and contact with saliva). extracts (e.g., caffeine, flavoring, and/or tobacco extract) while retaining the solid portions (e.g., leaves) of the composition comprised within a non-woven web that is non-water-soluble, biodegradable, or compostable. makes release possible. The nonwoven web can then be appropriately placed and biodegraded or composted.

Method for manufacturing unit dose articles

Unit dose articles, including pouches and packets, may be manufactured using any suitable equipment and methods. For example, single compartment pouches can be manufactured using vertical filling, horizontal filling, or rotating drum filling techniques commonly known in the art. These processes may be continuous or intermittent. A layered nonwoven web, film, or laminate structure can be wetted and/or heated to increase its malleability. The method may also include the use of a vacuum to draw the layered nonwoven web, film, or laminate structure into a suitable mold. The vacuum drawing the nonwoven web, film, or laminate into the mold is applied for about 0.2 to about 5 seconds, or about 0.3 to about 3, or about 0.5 seconds, when the layered nonwoven web, film, or laminate structure is in the horizontal portion of the surface. It may be applied for about 1.5 seconds. This vacuum may be intended to provide an under-pressure in the range of 10 mbar to 1000 mbar, or for example in the range of 100 mbar to 600 mbar.

The mold from which the packets can be manufactured can have any shape, length, width and depth depending on the desired dimensions of the pouch. The molds may also vary in size and shape from one another, if desired. For example, the final pouch volume may be from about 5 ml to about 300 ml, or from about 10 ml to 150 ml, or from about 20 ml to about 100 ml, and the mold size adjusted accordingly.

thermoforming

A thermoformable nonwoven web, film, or laminate is one that can be formed by applying heat and force. Thermoforming a nonwoven web, film, or laminate structure is the process of heating, forming it (e.g., in a mold), and then cooling the resulting nonwoven web, film, or laminate. and wherein the nonwoven web, film, or laminate will maintain its shape, e.g., the shape of the mold. Heat may be applied using any suitable means. For example, a nonwoven web, film, or laminate can be heated directly before feeding it onto a surface, or while on the surface, by passing hot air through it or under a heating element. Alternatively, it can be heated indirectly, for example by heating the surface or applying a hot article onto the nonwoven web, film, or laminate. In embodiments, the nonwoven web, film, or laminate is heated using infrared light. The nonwoven web, film, or laminate has a temperature ranging from about 50°C to about 150°C, from about 50°C to about 120°C, from about 60°C to about 130°C, from about 70°C to about 120°C, or from about 60°C to about 90°C. It can be heated to a temperature of Thermoforming may be performed by any one or more of the following processes: manual draping of the thermally softened nonwoven web, film, or laminate onto a mold, or draping the softened nonwoven web, film, or laminate onto a mold. , or pressure-induced forming (e.g. vacuum forming) of laminates, or automatic high-speed indexing of freshly extruded sheets with accurately known temperatures at forming and trimming stations, or automatic placement, plugs, and /or pneumatic stretching and pressure forming of nonwoven webs, films, or laminates.

Alternatively, the nonwoven web, film, or laminate may be coated with a wetting agent (water, (including polymer compositions, plasticizers for nonwoven webs, films, or laminate compositions, or any combination of the foregoing) may be wetted directly by spraying, or by wetting a surface, or applied onto a nonwoven web, film, or laminate. Wetting can be done indirectly by applying a wetting article.

When the nonwoven web, film, or laminate has been heated and/or wetted, it can be drawn into a suitable mold, preferably using a vacuum. Filling of the formed nonwoven web, film, or laminate may be accomplished using any suitable means. In the embodiment, the most preferred method will depend on the product type and required filling rate. In embodiments, the formed nonwoven web, film, or laminate is filled by in-line filling techniques. The filled open packets are then closed to form a pouch using a second nonwoven web, film, or laminate by any suitable method. This can be achieved in a horizontal position and while in continuous, constant motion. Closing involves continuously feeding a second nonwoven web, film, or laminate onto and onto an open packet and then forming the first and second nonwoven webs, films, or laminates, typically in the areas between the molds and thus between the packets. This can be achieved by sealing together.

sealed

Any suitable method of sealing the packet and/or its individual compartments may be used. Non-limiting examples of such means include heat sealing, solvent fusion, solvent or wet sealing, and combinations thereof. Typically, only the area forming the seal is treated with heat or solvent. Heat or solvent may be applied by any method, usually to the sealing material, usually only to the area forming the seal. If solvent or wet sealing or fusion is used, it may be desirable for heat to also be applied. A preferred wet or solvent sealing/fusion method selectively deposits the solvent onto the area between the molds or onto the sealing material, for example by spraying or printing it onto these areas and then applying pressure over these areas where the seal is formed. Includes application. For example, sealing rolls and belts (optionally also providing heat) can be used.

In embodiments, the inner nonwoven web, foam, film, or laminate is sealed to the outer nonwoven web(s), film(s), or laminate(s) by solvent sealing. The sealing solution is generally an aqueous solution. In an embodiment, the sealing solution comprises water. In an embodiment, the sealing solution comprises water and further one or more diols and/or glycols such as 1,2-ethanediol (ethylene glycol), 1,3-propanediol, 1,2-propanediol, 1,4 -Butanediol (tetramethylene glycol), 1,5-pantanediol (pentamethylene glycol), 1,6-hexanediol (hexamethylene glycol), 2,3-butanediol, 1,3-butanediol, 2-methyl-1, 3-propanediol, various polyethylene glycols (e.g., diethylene glycol, triethylene glycol), and combinations thereof. In an embodiment, the sealing solution comprises erythritol, threitol, arabitol, xylitol, ribitol, mannitol, sorbitol, galactitol, fusitol, iditol, inositol, bolemitol, isomal, maltitol, lactitol. . In an embodiment, the sealing solution includes a water-soluble polymer.

The sealing solution may be applied to the interface region of the interior nonwoven web, foam, film, or laminate in any amount suitable to bond the interior and exterior nonwoven webs or laminates. As used herein, the term “coating weight” refers to the amount of sealing solution applied to a nonwoven web, foam, film, or laminate in grams of solution per square meter of nonwoven web, foam, film, or laminate. Generally, if the coating weight of the sealing solvent is very low, the nonwoven web, foam, film, or laminate will not adhere properly and the risk of pouch failure at the seams increases. Additionally, if the coating weight of the sealing solvent is very high, the risk of solvent migrating from the interfacial area increases, which increases the likelihood that the etch holes may form a random film comprising the sides of the pouch. Coating weight window refers to the range of coating weight that can be applied to a given film or laminate while maintaining good adhesion while avoiding the formation of etch holes. A wide coating weight window is desirable because a wider window provides a strong seal over a wide range of operations. A suitable coating weight window is at least about 3 g/m ² , or at least about 4 g/m ² , or at least about 5 g/m ² , or at least about 6 g/m ² .

Cutting of unit capacity articles

The formed pouch can be cut by a cutting device. Cleavage can be accomplished using any known method. The cutting may also preferably be carried out in a continuous manner, preferably using a constant speed, preferably while in a horizontal position. The cutting device may be, for example, a sharp article, or a hot article, or a laser, whereby in the latter case the hot article or laser 'burns' the film/seal area.

Vertical form, filled and sealed

In embodiments, the nonwoven webs, foams, films, or laminates of the disclosure can be formed into sealed articles. In an embodiment, the sealed article is a vertical, filled, and sealed article. The vertical form, fill, and seal (VFFS) process is a conventional automated process. VFFS includes devices such as assembly machines that wrap a single piece of nonwoven web, foam, film, or laminate around a vertically oriented feed tube. The machine heats the seal or otherwise fastens opposing edges of the nonwoven web, foam, film, or laminate together to create a side seal, forming a hollow tube of the nonwoven web, foam, film, or laminate. The machine then heats the seal or otherwise creates a bottom seal, thereby defining a portion of the container with an open top, where the top seal will then be formed. The machine injects a specific amount of a flowable product, such as an active cleaning formulation, into a portion of the container through the open upper end. When the container contains the desired amount of product, the machine advances the nonwoven web, foam, film, or laminate, for example, to another heat-sealing device to create a top seal. Finally, the machine advances the nonwoven web, film, or laminate with a cutter that cuts the film just above the top seal, providing a filled package.

In operation, an assembly machine advances a nonwoven web, foam, film, or laminate from a roll to form a package. Accordingly, the nonwoven web, foam, film, or laminate must be able to be easily advanced through a machine and not be brittle enough to adhere to the machine assembly or break during processing.

Example

As described herein, a single unit dose article may include one of the following components:

(a) Disposable cold water soluble nonwoven sheets folded or laminated in an overlapping structure and saturated with an active cleaning formulation, wherein, in certain embodiments, the nonwoven sheets are wrapped with a water soluble nonwoven web or a layer of water soluble foam or film material to act as a barrier and to protect the consumer. Disposable cold water soluble non-woven sheets that deliver an active cleaning formulation to the hands or body or surface, for example;

(b) a disposable cold water soluble cleaning sachet comprising a water-soluble nonwoven substrate containing a bulk or loose active cleaning formulation in the form of a liquid, slurry, or solid, e.g., powder;

(c) a foam sheet, e.g., an open-cell or closed-cell foam sheet, folded or laminated into an overlapping structure and saturated with an active cleaning formulation, wherein in certain embodiments, the foam sheet is a water-soluble nonwoven web or a water-soluble foam or a sheet of foam wrapped with a layer of film material to act as a barrier and deliver the active cleaning formulation to the consumer's hands or body or, for example, to a surface;

(d) a disposable water-soluble nonwoven sheet comprising an active cleaning formulation or having an active cleaning formulation attached to the surface of the nonwoven sheet;

(e) a water-soluble nonwoven sheet folded or laminated in an overlapping structure and saturated with an active cleaning formulation, wherein, in certain embodiments, the nonwoven sheet is wrapped with a layer of a water-soluble nonwoven web or water-soluble foam or film material not comprising an active agent to serve as a barrier. A water-soluble non-woven sheet that acts and delivers an active cleaning formulation to the consumer's hands or body or, for example, to a surface;

(f) a disposable cold water soluble foam substrate (open cell or closed cell) having a low moisture or substantially moisture free laundry detergent on the surface of the foam substrate for cleaning garments, wherein the foam substrate is coated with cold water to deliver one or more cleaning agents. Disposable, cold water soluble, degradable on contact, the outer surface of the foam substrate can be at least partially covered by or surrounded by a water-soluble non-woven fabric for a “plastic-free” or “natural” aesthetic for completion of garment wash cycles. Foam substrate (open cell or closed cell);

(g) Disposable cold water soluble foam substrate (open cell or closed cell) having a low moisture or substantially moisture free laundry detergent within the core or matrix of the foam substrate for cleaning garments, wherein the foam substrate is exposed to cold water to deliver one or more cleaning agents. Disposable cold water that is decomposable on contact with, and the outer surface of the foam substrate can be at least partially covered by or surrounded by a water-soluble non-woven fabric for a "plastic-free" or "natural" aesthetic for completion of a garment wash cycle. Soluble foam substrate (open cell or closed cell);

(h) Disposable cold water soluble foam substrate (open cell or closed cell) having a low moisture or substantially moisture free laundry detergent on the surface of the foam substrate for cleaning garments, wherein the foam substrate is one for completion of a garment wash cycle. Disposable cold water soluble foam substrate (open cell or closed cell) that is decomposable on contact with cold water to deliver more than one cleaning agent;

(i) Disposable cold water soluble foam substrate (open cell or closed cell) having a low moisture or substantially moisture-free laundry detergent within the core or matrix of the foam substrate for cleaning garments, wherein the foam substrate is used for the completion of a garment cleaning cycle. Disposable cold water soluble foam substrate (open cell or closed cell) that is decomposable on contact with cold water to deliver one or more cleaning agents; and

(j) a solid, liquid, or slurry disposed or coated on the surface of the core substrate, adhered to the surface of the core substrate, embedded within the core substrate, or dispersed within the matrix of the core substrate, or any suitable combination thereof. A core substrate comprising a water-soluble nonwoven web or sheet, a water-soluble foam substrate, or a water-soluble film substrate with an active cleaning formulation in the form of a water-soluble nonwoven web or sheet.

Exemplary embodiments of the disclosure are described in the numbered paragraphs below. These exemplary embodiments are intended to be illustrative in character and not limiting.

In an exemplary embodiment, the single unit dose article includes a water-soluble core substrate comprising a water-soluble resin. The water-soluble core substrate contains an active cleaning formulation. When the water-soluble core substrate is contacted with water having a temperature above 20° C., the water-soluble core substrate is soluble to release the active cleaning formulation. In exemplary embodiments, the water-soluble nonwoven material and/or water-soluble film surrounds the water-soluble nonwoven substrate. In certain embodiments, the water-soluble film is laminated to a water-soluble nonwoven material. The bonding interface is configured to create a seal surrounding the water-soluble core substrate. The active cleaning formulation is in at least one of powder, solid, liquid, gel, or slurry form. In an exemplary embodiment, the active cleaning formulation is either disposed on or embedded within a water-soluble core substrate. In an exemplary embodiment, the water-soluble core substrate is at least one of saturated with an active cleaning formulation, coated with an active cleaning formulation, or impregnated with an active cleaning formulation. In an exemplary embodiment, the active cleaning formulation is in a water-soluble core substrate.

In an exemplary embodiment, the single unit dose article includes a water-soluble nonwoven substrate comprising a water-soluble resin. The water-soluble nonwoven substrate includes an active cleaning formulation. When the water-soluble nonwoven substrate is contacted with water having a temperature above 20° C., the water-soluble nonwoven substrate becomes soluble to release the active cleaning formulation. In exemplary embodiments, the water-soluble nonwoven material and/or water-soluble film surrounds the water-soluble nonwoven substrate. In an exemplary embodiment, the water-soluble film is laminated to a water-soluble nonwoven material. In certain embodiments, the bonding interface is configured to create a seal surrounding the water-soluble nonwoven substrate and the active cleaning formulation. The active cleaning formulation is in the form of at least one of a powder, solid, liquid, gel, or slurry formulation. In an exemplary embodiment, the water-soluble nonwoven substrate comprises a plurality of fibers, wherein the plurality of fibers is saturated with an active cleaning compound, the active cleaning compound is embedded in the plurality of fibers, and/or the active cleaning compound is adjacent one of the plurality of layers. placed between layers. In an exemplary embodiment, the water-soluble nonwoven substrate is a continuous sheet of a water-soluble nonwoven web that is folded into a serpentine configuration to form a plurality of layers. In other embodiments, the water-soluble nonwoven substrate includes a plurality of separate substrate sheets in an overlapping structure. The plurality of fibers may be saturated with the active cleaning formulation, the active cleaning formulation may be embedded in the plurality of fibers, or the active cleaning formulation may be disposed on, for example coated with, a surface of the water-soluble nonwoven substrate, or the active cleaning formulation may be embedded in the plurality of fibers. It can be placed on the surface of the fiber or, for example, coated. In an exemplary embodiment, the water-soluble nonwoven material defines an interior space surrounding and containing the water-soluble nonwoven substrate and the active cleaning formulation, e.g., a liquid active cleaning formulation.

In an exemplary embodiment, the single unit dose article comprises a water-soluble foam substrate comprising a water-soluble resin. The water-soluble foam substrate contains an active cleaning formulation. When the water-soluble foam substrate is contacted with water having a temperature above 20° C., the water-soluble foam substrate becomes soluble to release the active cleaning formulation. In an exemplary embodiment, the water-soluble nonwoven material and/or water-soluble film at least partially surrounds the water-soluble foam substrate. In certain embodiments, the water-soluble film is laminated to a water-soluble nonwoven material. In certain embodiments, the bonding interface is configured to create a seal surrounding the water-soluble core substrate. The active cleaning formulation may be in at least one of the following forms: powder, solid, liquid, gel, or slurry. In certain embodiments, the water-soluble foam substrate is saturated with an active cleaning formulation, and the active cleaning formulation can be embedded in the water-soluble foam substrate, or the active cleaning formulation can be disposed on the surface of the water-soluble foam substrate, e.g., coated. You can.

In an exemplary embodiment, the single unit dose article includes a first water-soluble nonwoven web comprising a first water-soluble resin and an opposing second water-soluble nonwoven web comprising a second water-soluble resin. The active cleaning formulation is disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web. When at least one of the first water-soluble nonwoven web or the second water-soluble nonwoven web is contacted with water having a temperature greater than 20° C., at least one of the first water-soluble nonwoven web or the second water-soluble nonwoven web is soluble to release the active cleaning formulation. am. The active cleaning formulation may be in at least one of the following forms: powder, solid, liquid, gel, or slurry. In certain embodiments, the bonding interface is configured to define an interior space and create a seal between the first water-soluble nonwoven web and the second water-soluble nonwoven web surrounding the active cleaning formulation within the interior space. In an exemplary embodiment, the water-soluble film substrate is disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web. The active cleaning formulation may be embedded within the water-soluble film substrate or the active cleaning formulation may be disposed on, for example coated, the surface of the water-soluble film substrate.

In an exemplary embodiment, the single unit dose article includes a water-soluble material comprising a water-soluble resin. The water-soluble material is bound at bonding interfaces along the edges of the water-soluble material to define the interior space of the single unit dose article. The active cleaning formulation is disposed in the interior space. When the water-soluble material is contacted with water having a temperature above 20° C., the water-soluble material is soluble to release the active cleaning formulation. In an exemplary embodiment, the water-soluble material includes either a water-soluble nonwoven web or a water-soluble foam material. The active cleaning formulation may be in at least one of the following forms: powder, solid, liquid, gel, or slurry. In an exemplary embodiment, the water-soluble material has a first surface opposing the interior space and an opposing second surface. The single unit dose article further includes a water-soluble film disposed on the first surface. In an exemplary embodiment, the water-soluble material comprises a water-soluble composite comprising a water-soluble film material made from a first water-soluble resin connected to either a water-soluble foam material made from a second water-soluble resin or a water-soluble nonwoven material.

In an exemplary embodiment, a method of making a single unit dose article comprising an active cleaning formulation comprises forming a water-soluble core substrate comprising a water-soluble resin comprising the active cleaning formulation, wherein the water-soluble core substrate has a temperature above 20°C. wherein the water-soluble core substrate is soluble to release the active cleaning formulation when contacted with water having a temperature; forming an outer water-soluble material comprising at least one of a water-soluble nonwoven material, a water-soluble foam material, a water-soluble film material, or a composite thereof into an open pouch defining an interior space configured to contain a water-soluble core substrate and an active cleaning formulation; introducing a water-soluble core substrate and an active cleaning formulation into the interior space; and sealing the external water-soluble material to surround the internal space. In an exemplary embodiment, forming a water-soluble core substrate comprising a water-soluble resin comprising an active cleaning formulation includes forming one of a water-soluble nonwoven substrate, a water-soluble foam substrate, or a water-soluble film substrate. In an exemplary embodiment, forming the water-soluble core substrate includes forming the water-soluble nonwoven substrate into a plurality of layers, and the active cleaning formulation is disposed between adjacent layers of the plurality of layers. A continuous sheet of water-soluble nonwoven web can be folded into a serpentine configuration to form a plurality of layers of water-soluble nonwoven substrate, or, for example, a plurality of separate substrate sheets can be stacked in an overlapping structure to form a water-soluble nonwoven substrate. In an exemplary embodiment, forming a water-soluble core substrate comprising a water-soluble resin comprising an active cleaning formulation comprises saturating the water-soluble core with the active cleaning formulation, disposing the active cleaning formulation on the surface of the water-soluble core substrate. It includes at least one of: coating the surface of the water-soluble core substrate with the active cleaning formulation, embedding the active cleaning formulation within the water-soluble core substrate, or impregnating the water-soluble core substrate with the active cleaning formulation. In an exemplary embodiment, sealing the external water-soluble material includes forming a seal at the bonding interface to surround the water-soluble core substrate and the active cleaning formulation in the interior space.

In the examples, a nonwoven substrate comprising an active cleaning formulation and/or a carrier solvent is described as an example of a core substrate for illustrative purposes only. The core substrate and active cleaning formulation may have any composition and/or form as described herein. For example, the core substrate may include water-soluble nonwoven, foam, and/or film substrates or layers, or any combination thereof. One or more additional water-soluble nonwoven, foam, or film substrates or layers, or any combination thereof, may be disposed thereon and used to seal the core substrate with the cleaning formulation. This core substrate may include one or more PVOH polymers, such as vinyl alcohol-vinyl acetate copolymer. For example, in certain embodiments, the core substrate includes at least one nonwoven substrate or layer comprising a plurality of fibers. The plurality of fibers comprises a first type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%, and polyvinyl alcohol having a degree of hydrolysis ranging from about 90% to about 99.5%. and a second type of fiber comprising a copolymer. The first type of fiber and the second type of fiber may be, for example, from about 1:99 to about 75:25, from about 5:95 to about 75:25, from about 1:99 to about 50:50, by weight. Suitable ratios range from about 5:95 to about 50:50, from about 10:90 to about 50:50. In some embodiments, the first type of fiber and the second type of fiber are blended together in at least one nonwoven fabric. In some embodiments, the at least one nonwoven substrate or layer comprises a first type of nonwoven sheet or layer made from a first type of fiber and a second type of nonwoven sheet or layer made from a second type of fiber. . Two types of fibers exist in different nonwoven sheets.

In the single unit dose articles described herein, the water-soluble core substrate can include a plurality of layers selected from nonwoven sheets, foam layers, films, or any combination thereof. The plurality of layers may comprise separate sheets, such as nonwoven sheets in an overlapping configuration, or continuous layers, such as one nonwoven sheet folded into a serpentine configuration. The active cleaning formulation may be disposed on and/or embedded within a water-soluble core substrate. For example, upon contact with a carrier solvent at 20° C. for a period of 5 minutes or more, the single dose article described herein or the core substrate therein has a moisture content in the range of 0.5% to 65%, e.g., 0.5% to 25%. It indicates the degree of shrinkage in the range of %.

In the single unit dose articles described herein, the water-soluble core substrate may or may not include a carrier solvent as described herein. In certain embodiments, a carrier solvent may be used during the manufacturing process. The carrier solvent can be dried and the resulting single unit dose article can be free of carrier solvent. In alternative embodiments, the carrier solvent is used during the manufacturing process and may be present in the resulting single unit dose article.

fibers used

As shown in Table 1, there are two types of fibers, Fiber 1 (“F1”) and Fiber 2 (“F2” comprising a copolymer of vinyl acetate and vinyl alcohol with degrees of hydrolysis of 88% and 96%, respectively. ") was used as a starting material. These fibers have a uniform composition and have additional properties shown in Table 1. In the examples described herein, fiber F1 comprised a 50:50 mixture of fibers with a fineness-length of 1.7 dtex - 38 mm and 2.2 dtex - 51 mm, respectively, and fiber F2 had a fineness - length of 1.4 dtex - 38 mm and 2.2 dtex, respectively. - It contained a 50:50 mixture of fibers with a length - fineness of 51 mm. In the examples, polymers comprising vinyl alcohol moieties are referred to as “polyvinyl alcohol polymers” and fibers comprising such polymers are referred to as “polyvinyl alcohol fibers.”

As shown in Table 2, nonwoven core substrates were prepared using two types of fibers under different bonding conditions, such as calendar-partial bonding. The two types of fibers were also mixed to produce one type of nonwoven (“blended nonwoven”) as the core substrate. Unless otherwise specified, samples have a partial binding pattern.

As shown in Table 1, experimental samples, such as Ex. 1, Ex. 2, Ex. 3, Ex. 4, and Ex. The fibers F1 and F2 used in Fig. 5 are the first and second type fibers comprising polyvinyl alcohol copolymer with hydrolysis degrees of 88% and 96%, respectively. These two fibers were mixed and combined to form a nonwoven sheet as the core substrate for a single unit dose article as described herein. 16-19 and 23-24, the term “% by weight of fiber F2” refers to the content of fiber F2 by weight in the total weight of fiber F1 and fiber 2 of the nonwoven sheet. Detergent formulations with weight percent water (“xx”) are expressed in the format “MS-LLD-xx”. For example, detergent formulation MS-LLD-20 means that this detergent contains 20% water by weight. The detergent formulation is miscible with the water in which it is formulated or used and is comprised of the active cleaning formulations of the present disclosure and surfactants, such as lauryl alcohol ethoxylate, a high fatty acid containing from about 8 to 24 carbon atoms. Alkali metal salts, and propylene glycol. Detergents may also include carrier solvents of the present disclosure, such as glycerol.

The dielectric constants of the detergent compositions used comprising 5%, 20%, 35%, 50%, and 65% water by weight were also measured at 25° C. using a frequency of 100 KHz. The detergent composition containing 50% water was a gel and unless it was heated to 45° C. it was difficult to place it in a test cell for holding liquid samples. The dielectric constant of this detergent composition was measured at both 45°C and 25°C. The measured dielectric constant values of the detergent composition were 38.7, 395.0, 2016, 6458, and 7320, which correspond to moisture contents of 5%, 20%, 35%, 50%, and 65% by weight, respectively. The dielectric constant increases linearly with moisture content. For experimental samples, their shrinkage in a detergent composition increases with the dielectric constant (i.e. polarity) of the detergent composition. The range of dielectric constants also illustrates the range of carrier solvents that can be used.

The sample did not show any shrinkage in a detergent formulation with 5% water by weight at 45°C. Shrinkage of these samples was observed in detergent formulations containing 20% or more water by weight. Figure 16 shows shrinkage results for these samples in a detergent formulation with 20% water at 45°C. The test time was 5 minutes. As shown in Figure 16, the shrinkage rate using 5 minutes decreases as the fiber F2 content increases up to 90%. The sample with a fiber F1:F2 ratio of 10:90 (i.e. Ex. 4) has the lowest shrinkage. The nonwoven sample with fiber F1 alone (i.e., Ex. 5) is sample Ex. It has a shrinkage rate that is about 6 times higher than that of 4. The nonwoven sample with fiber F2 alone (i.e., Ex. 1) is sample Ex. It has a shrinkage rate that is about 1.9 times higher than that of 4. These nonwoven samples continued to shrink after 5 minutes, but at a slower rate. For example, the nonwoven sample with fiber F1 alone (i.e., Ex. 5) showed an additional 7.8% shrinkage over 1 hour.

Figure 17 shows Ex. of detergent formulations with 35% water at 20°C, 35°C, and 45°C, respectively. 1, Ex. 2, Ex. 3, Ex. 4, and Ex. Shrinkage results for experimental samples containing 5 are shown. Figure 17 shows the effect of the content (% by weight) of fiber F2 in the total weight of fibers F1 and F2 on the shrinkage of nonwoven samples. Shrinkage was observed for all samples in detergent formulations with 35% water at three temperatures. Similar to what is shown in Figure 16, the shrinkage at 5 minutes decreases as the content of fiber F2 increases up to 90%. Samples with a content of fiber F2 ranging from about 75% to 90% have the lowest shrinkage. When the temperature increases, the shrinkage of the samples increases, but the difference in shrinkage between samples with fiber F1 and fiber F2 decreases. At 45°C, the shrinkage of these nonwoven samples did not change after 5 minutes, but continued to increase at lower temperatures.

Similar to Figure 17, Figure 18 shows shrinkage results for experimental samples of detergent formulations with 50% water at 20°C, 35°C, and 45°C, respectively. This detergent formulation is a gel at 20°C, while it is fluid at 35°C and 45°C. Shrinkage was observed for all samples of this detergent formulation at three temperatures. Similar to what is shown in Figure 17, the shrinkage at 5 minutes decreases with increasing fiber F2 content up to 90%. Samples with 90% fiber F2 have the least shrinkage. At 45°C, these nonwoven samples showed similar shrinkage. The shrinkage of these nonwoven samples after 5 minutes did not increase consistently at 30°C and 45°C, but did increase steadily at 20°C.

Similar to Figure 17, Figure 19 shows shrinkage results for experimental samples of detergent formulations with 65% water at 20°C, 35°C, and 45°C, respectively. Shrinkage was observed for all samples of this detergent formulation at three temperatures. Similar to what is shown in Figures 17 and 18, shrinkage within 5 minutes decreases with increasing fiber F2 content up to 90%. Samples with 90% fiber F2 have the least shrinkage. In these detergent formulations, the shrinkage is less dependent on the test temperature, while most samples have shrinkage in the range of 78% to 86%. At 45°C, these nonwoven samples showed similar shrinkage. The shrinkage of these nonwoven samples after 5 minutes did not consistently increase for this detergent formulation at any of the three temperatures.

Figure 20 shows shrinkage results for an example sample comprising at least one nonwoven layer with a plurality of fibers with different basis weights (fiber F1 alone) in a detergent formulation with 35% water at 20°C. As shown in Figure 20, the shrinkage of the samples is independent of the basis weight. This means that when the nonwoven layers have the same fiber content with the same bond pattern, the denser water soluble nonwoven layer shrinks at the same rate as the thinner water soluble nonwoven layer. The same trend was observed for the solubility of the samples.

21 shows at least one having a plurality of fibers (fiber F1 alone) having a basis weight of 50 gsm with different bonding patterns, including a partial bonding pattern and a daisy bonding pattern with tighter bonding points than the partial bonding pattern. Shrinkage results (in a detergent formulation with 35% water at 20°C) of an example sample comprising a nonwoven layer of are shown. The partially bonded nonwoven layer shrank 32.5% more than the daisy bonded nonwoven layer with the same composition under the same test conditions. Daisy bonds are much more dense than partial bonds, which creates reduced surface area and less shrinkage in detergent formulations. A similar trend was also observed for the solubility of these samples.

Figure 22 shows Ex. 1, Ex. 2, Ex. 3, Ex. 4, and Ex. Decomposition time results for experimental samples containing 5 are shown. Figure 23 shows the time to rupture results for the same example samples at 20°C, 35°C, and 45°C. The rupture time is defined as the time at which a water-soluble nonwoven sample develops a hole in its structure. The decomposition time is the time for the water-soluble nonwoven sample to completely disintegrate from the cotton, fall off, and dissolve. As shown in Figure 22, the decomposition (dissolution) time increases as the content of fiber F2 in the nonwoven fabric blended with F1 and F2 increases. Dissolution time decreases as temperature increases. At 20°C, samples with 75% or more fiber F2 do not decompose within the maximum test time of 5 minutes.

24 shows at least one nonwoven layer or sheet (daisy-bonded, Degradation time results (at 20°C, 35°C, 45°C) are shown for example samples comprising core substrates with different basis weights. Figure 25 shows time to rupture results for the same example samples at 20°C, 35°C, and 45°C. At 20°C, samples with 75% or more fiber F2 do not decompose within the maximum test time of 5 minutes. Dissolution time decreases as test temperature increases. The dissolution time is about 16 times lower than that at 20°C.

Figures 26 and 27 compare the results of rupture time and decomposition (dissolution) time of samples with the same composition but different bond patterns in water at 20°C, 35°C, and 45°C. The example sample comprised one nonwoven layer with a plurality of fibers (fiber F1 alone) with a basis weight of 50 gsm. The two different bonding patterns included a partial bonding pattern, and a daisy bonding pattern with tighter bonding points than the partial bonding pattern. Nonwoven layers with partial bonding dissolve faster than their daisy bonded counterparts. For example, the dissolution time of the daisy bonded sample nonwoven layer is 67% longer than that of the partially bonded sample nonwoven layer at 20°C. This difference between daisy and partially bonded samples decreases with increasing temperature.

The following paragraphs describe further aspects of the disclosure:

1. As a single unit dose article,

A water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin, the water-soluble core substrate comprising a carrier solvent having an active cleaning formulation,

wherein when at least one fiber of the plurality of fibers is contacted with the carrier solvent at a temperature in the range of 10° C. to 20° C. for a period of 5 minutes or more, the core substrate exhibits a shrinkage of 0.5% to 65%;

A single unit dose article wherein the active cleaning formulation is disposed on or contained within a water-soluble core substrate.

2. The single unit dose article of clause 1, further comprising a water-soluble nonwoven material surrounding the water-soluble core substrate.

3. The single unit dose article of clause 2, further comprising a water-soluble film surrounding the water-soluble nonwoven substrate.

4. The single unit dose article of clause 3, wherein the water-soluble film is laminated to a water-soluble nonwoven material.

5. The single unit dose article of clause 2 further comprising a bonding interface configured to create a seal surrounding the water-soluble core substrate.

6. The single unit dose article of any of clauses 1-5, wherein the active cleaning formulation is in at least one of the following: solid, gel, liquid, gel, or slurry forms.

7. The single unit dose article of any one of clauses 1-6, wherein the water-soluble core substrate has been at least one of saturated with an active cleaning formulation, coated with an active cleaning formulation, or impregnated with an active cleaning formulation.

8. The single unit dose article of any of clauses 1-7, wherein the active cleaning formulation is within a water-soluble core substrate.

9. The single unit dose article of any one of clauses 1-8, wherein the water-soluble core substrate is soluble according to MSTM-205 such that when the water-soluble core substrate is contacted with water having a temperature of at least 10° C., the water-soluble core substrate releases the active cleaning formulation. .

10. The single unit dose article of any one of clauses 1-9, wherein after being contacted with water having a temperature of at least 10° C. for up to 300 seconds, the active cleaning formulation is substantially released from the water-soluble core substrate.

11. The single unit dose article of any of clauses 1-10, wherein the resin is a polymer comprising a vinyl alcohol moiety.

12. The single unit dose article of clause 11, wherein the polymer comprising vinyl alcohol moieties comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

13. The single unit dose article of clause 12, wherein the polyvinyl alcohol copolymer is a copolymer of vinyl acetate and vinyl alcohol, or an anionically modified copolymer.

14. The single unit dose article of clause 13, wherein the anionically modified copolymer comprises a carboxylate, a sulfonate, or a combination thereof.

15. The single unit dose article of any of clauses 11-14, wherein the plurality of fibers comprises a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%.

16. The method of any one of clauses 11-14, wherein the plurality of fibers comprises two types of fibers comprising a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%, and the two types A single unit dose article, wherein the fibers have differences in diameter, length, toughness, shape, stiffness, elasticity, solubility, color, or combinations thereof.

17. The method of any one of clauses 11-14, wherein the plurality of fibers comprises a first type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89% and a degree of hydrolysis ranging from about 90% to about 99.5%. A single unit dose article comprising a second type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis in the range of %.

18. The single unit dose article of clause 17, wherein the ratio of the first type of fiber to the second type of fiber ranges from about 1:99 to about 75:25 by weight.

19. The single unit dose article of clause 17, wherein the ratio of the first type of fiber to the second type of fiber ranges from about 5:95 to about 50:50 by weight.

20. The single unit dose article of any of clauses 17-19, wherein the water-soluble core substrate comprises at least one nonwoven sheet comprising a mixture of fibers of the first type and fibers of the second type.

21. The single unit dose article of any one of clauses 17-19, wherein the water-soluble core substrate comprises a plurality of layers, the plurality of layers being selected from nonwoven sheets, foam layers, films, or any combination thereof. .

22. The single unit dose article of clause 21, wherein the plurality of layers comprise separate sheets in an overlapping configuration or continuous sheets folded in a serpentine configuration.

23. As a single unit dose article,

A water-soluble nonwoven substrate comprising a plurality of fibers comprising a water-soluble resin, the water-soluble nonwoven substrate comprising a carrier solvent having an active cleaning formulation,

wherein when at least one fiber of the plurality of fibers is contacted with the carrier solvent at a temperature in the range of 10° C. to 20° C. for a period of 5 minutes or more, the nonwoven substrate exhibits a shrinkage of 0.5% to 65%,

A single unit dose article wherein the active cleaning formulation is disposed on or contained within a water-soluble core substrate.

24. The single unit dose article of clause 23, further comprising a water-soluble nonwoven material surrounding the water-soluble nonwoven substrate.

25. The single unit dose article of clause 24, further comprising a water-soluble film surrounding the water-soluble nonwoven substrate.

26. The single unit dose article of clause 25, wherein the water-soluble film is laminated to a water-soluble nonwoven material.

27. The single unit dose article of any one of clauses 24-26, further comprising a bonding interface configured to create a seal surrounding the water-soluble nonwoven substrate.

28. The single unit dose article of any of clauses 23-27, wherein the active cleaning formulation is in the form of at least one of the following: solid, gel, liquid, or slurry formulation.

29. The single unit dose article of any of clauses 23-28, wherein the plurality of fibers are saturated with an active cleaning formulation.

30. The single unit dose article of any of clauses 23-29, wherein the active cleaning formulation is contained within a plurality of fibers.

31. The single unit dose article of any of clauses 23-30, wherein the water-soluble nonwoven substrate comprises a plurality of layers, and the active cleaning formulation is disposed between adjacent layers of the plurality of layers.

32. The single unit dose article of clause 31, wherein the water-soluble nonwoven substrate is a continuous sheet of a water-soluble nonwoven web folded into a serpentine configuration to form a plurality of layers.

33. The single unit dose article of clause 31, wherein the water-soluble nonwoven substrate comprises a plurality of separate substrate sheets in an overlapping structure.

34. The single unit dose article of any of clauses 31-33, wherein the plurality of fibers are saturated with an active cleaning formulation.

35. The single unit dose article of any of clauses 31-33, wherein the active cleaning formulation is contained within a plurality of fibers.

36. The single unit dose article of clause 32, wherein the active cleaning formulation is disposed on the surface of the water-soluble nonwoven substrate and/or on the surface of the plurality of fibers.

37. The single unit dose article of any one of clauses 31-36, further comprising a water-soluble nonwoven material surrounding the water-soluble nonwoven substrate.

38. The single unit dose article of any of clauses 23-37, further comprising a water-soluble nonwoven material defining an interior space, wherein the active cleaning formulation is a liquid active cleaning formulation contained within the interior space.

39. The single unit dose article of any of clauses 23-38, wherein the water-soluble nonwoven substrate is soluble according to MSTM-205 such that when the water-soluble nonwoven substrate is contacted with water having a temperature of at least 10° C., the water-soluble nonwoven substrate releases an active cleaning formulation. .

40. The single unit dose article of clause 39, wherein the active cleaning formulation is substantially released from the water-soluble nonwoven substrate when the water-soluble nonwoven substrate is contacted with water having a temperature of at least 10° C. for up to 300 seconds.

41. The single unit dose article of any of clauses 23-40, wherein the water-soluble resin is a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

42. The single unit dose article of clause 41, wherein the polyvinyl alcohol copolymer is a copolymer of vinyl acetate and vinyl alcohol, or an anionically modified copolymer of vinyl acetate and vinyl alcohol.

43. The method of clause 23, wherein the plurality of fibers comprises a first type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%, and a degree of hydrolysis ranging from about 90% to about 99.5%. A single unit dose article comprising a second type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis.

44. The single unit dose article of clause 43, wherein the ratio of the first type of fiber to the second type of fiber ranges from about 1:99 to about 75:25 by weight.

45. As a single unit dose article,

a first water-soluble nonwoven web comprising a first water-soluble resin and a second water-soluble nonwoven web comprising a second water-soluble resin; and

A carrier solvent having an active cleaning formulation disposed between a first water-soluble nonwoven web and a second water-soluble nonwoven web, wherein at least one of the first water-soluble nonwoven web or the second water-soluble nonwoven web is contacted with water having a temperature greater than 10° C. wherein at least one of the first water-soluble nonwoven web or the second water-soluble nonwoven web is soluble according to MSTM-205 to release the active cleaning formulation disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web. carrier solvent having

A single unit dose article comprising:

46. The method of clause 45, wherein the first water-soluble nonwoven web comprises a plurality of fibers comprising a first water-soluble resin, wherein the carrier solvent and at least one fiber of the plurality of fibers are heated at 20° C. for a period of 5 minutes or more. When contacted, the first water-soluble nonwoven web exhibits a shrinkage of 0.5% to 65%.

47. The single unit dose article of any of clauses 45-46, wherein the active cleaning formulation is in at least one of the following: solid, gel, liquid, or slurry forms.

48. The method of any one of clauses 45-47, further comprising a bonding interface configured to create a seal between the first water-soluble nonwoven web and the second water-soluble nonwoven web defining the interior space and surrounding the active cleaning formulation in the interior space. A single unit dose article.

49. The single unit dose article of any of clauses 45-48, further comprising a water-soluble film substrate disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web.

50. The single unit dose article of clause 49, wherein the active cleaning formulation is contained within a water-soluble film substrate.

51. The single unit dose article of any of clauses 49-50, wherein the active cleaning formulation is disposed on the surface of the water-soluble film substrate.

52. The method of any one of clauses 45-51, wherein when at least one of the first water-soluble nonwoven web or the second water-soluble nonwoven web is contacted with water having a temperature of at least 10° C. for up to 300 seconds, the active cleaning formulation is the first water-soluble nonwoven web. A single unit dose article substantially released between a water-soluble nonwoven web and a second water-soluble nonwoven web.

53. As a single unit dose article,

A water-soluble material comprising a plurality of fibers comprising a water-soluble resin, the water-soluble material bonded at a bonding interface along an edge of the water-soluble material to define an interior space of a single unit dose article; and

A carrier solvent having an active cleaning formulation disposed in the interior space, wherein the water-soluble material is soluble according to MSTM-205 so that when contacted with water having a temperature above 10° C., the water-soluble material releases the active cleaning formulation from the interior space. , carrier solvent with active cleaning formulation

A single unit dose article comprising:

54. The single unit dose article of clause 53, wherein when at least one fiber of the plurality of fibers is contacted with the carrier solvent, the at least one fiber exhibits a shrinkage of 0.5% to 65%.

55. The single unit dose article of any of clauses 53-54, wherein the water-soluble material comprises one of a water-soluble nonwoven web, a water-soluble foam material, or a water-soluble film material.

56. The single unit dose article of any of clauses 53-55, wherein the active cleaning formulation is in at least one of the following: solid, gel, liquid, or slurry forms.

57. The method of any one of clauses 53-56, wherein the water-soluble material has a first surface opposing the interior space and an opposing second surface, and the single unit dose article further comprises a water-soluble film disposed on the first surface. A single unit dose article.

58. The method of any one of clauses 53-57, wherein the water-soluble material comprises a water-soluble composite comprising a water-soluble film material made from a first water-soluble resin connected to either a water-soluble foam material made from a second water-soluble resin or a water-soluble nonwoven material. A single unit dose article comprising:

59. The single unit dose article of any of clauses 53-58, wherein the water-soluble resin is a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

60. The single unit dose article of clause 59, wherein the polyvinyl alcohol copolymer is a copolymer of vinyl acetate and vinyl alcohol, or an anionically modified copolymer of vinyl acetate and vinyl alcohol.

61. The method of any one of clauses 53-60, wherein the plurality of fibers comprises a first type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%, and a degree of hydrolysis ranging from about 90% to about 89%. A single unit dose article comprising a second type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis in the range of 99.5%.

62. The single unit dose article of clause 61, wherein the ratio of the first type of fiber to the second type of fiber ranges from about 1:99 to about 75:25 by weight.

63. A method of making a single unit dose article comprising a carrier solvent with an active cleaning formulation, said method comprising:

Forming a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin, the water-soluble core substrate comprising a carrier solvent with an active cleaning formulation, and subjecting the water-soluble core substrate to a temperature ranging from 10° C. to 20° C. for 5 minutes or more. When the carrier solvent and at least one of the plurality of fibers are in contact, the water-soluble core substrate exhibits a shrinkage of 0.5% to 65%;

Forming an outer water-soluble material comprising at least one of a water-soluble nonwoven material, a water-soluble foam material, a water-soluble film material, or a composite thereof into an open pouch defining an interior space configured to contain a water-soluble core substrate and a carrier solvent with an active cleaning formulation. steps;

introducing a carrier solvent with a water-soluble core substrate and an active cleaning formulation into the interior space; and

sealing the external water-soluble material to surround the internal space

How to include .

64. The method of clause 63, wherein forming a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin comprises forming one of a water-soluble nonwoven substrate, a water-soluble foam substrate, or a water-soluble film substrate.

65. The method of any one of clauses 63-64, wherein forming a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin comprises saturating the water-soluble core substrate with an active cleaning formulation on the surface of the water-soluble core substrate. at least one of disposing the active cleaning formulation on the water-soluble core substrate, coating the surface of the water-soluble core substrate with the active cleaning formulation, embedding the active cleaning formulation within the water-soluble core substrate, or impregnating the water-soluble core substrate with the active cleaning formulation. How to include .

66. The method of any of clauses 63-65, wherein sealing the external water-soluble material comprises forming a seal at the bonding interface to surround the water-soluble core substrate and the carrier solvent with the active cleaning formulation in the interior space.

67. The method of any one of clauses 63-66, wherein forming a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin comprises forming a water-soluble nonwoven substrate into a plurality of layers, a carrier solvent and an active cleaning formulation. A method comprising being disposed between adjacent layers of a plurality of layers.

68. The method of clause 67, wherein forming the water-soluble nonwoven substrate into a plurality of layers comprises folding a continuous sheet of the water-soluble nonwoven web into a serpentine configuration to form the plurality of layers.

69. The method of clause 67, wherein forming the water-soluble nonwoven substrate into a plurality of layers comprises laminating a plurality of separate substrate sheets in an overlapping configuration.

70. The method of clause 67, further comprising applying the carrier solvent comprising glycerol with the active cleaning formulation to the surface of the water-soluble nonwoven substrate at a maximum coating weight of 120 gsm for the carrier solvent with the active cleaning formulation. method.

71. The method of clause 70, wherein the carrier solvent comprising glycerol with the active cleaning formulation is applied to the surface of the water-soluble nonwoven substrate until the single unit dose article comprises 55% by weight of the active cleaning formulation.

72. The method of clause 71, further comprising forming the water-soluble nonwoven substrate into 25 to 110 layers.

73. The method of any one of items 63-72, wherein the water-soluble resin is a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

74. As a single unit dose article,

A water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin, the water-soluble core substrate comprising an active cleaning formulation; and

A water-soluble nonwoven material surrounding a water-soluble core substrate.

Includes,

A single unit dose article wherein the active cleaning formulation is disposed on or contained within a water-soluble core substrate.

75. The single unit dose article of clause 74, further comprising a water-soluble film laminated on and surrounding the water-soluble nonwoven substrate.

76. The single unit dose article of any of clauses 74-75, wherein the water-soluble core substrate further comprises a carrier solvent comprising an active cleaning formulation.

A single unit dose article according to any one of paragraphs 74-76 may further comprise any of the features recited in any of paragraphs 1-73.

All percentages, parts and ratios mentioned herein are based on the total dry weight of the fiber composition, film composition, or total weight of the packaging composition of the present disclosure, as the case may be, and all measurements are based on about 25%, unless otherwise specified. It takes place at ℃. All percentages, parts and ratios mentioned herein for liquid formulations are based on the total weight of the liquid formulation. All such weights as they relate to the ingredients listed are based on the activity level and therefore do not include carriers or by-products that may be contained in commercially available materials, unless otherwise specified.

All ranges presented herein include all possible subsets of the range and any combination of such subset ranges. Basically, the range includes the stated endpoints, unless otherwise stated. Where a range of values is provided, it is understood that each intervening value between the upper and lower limits of this range and any other stated or intervening value within the stated range is encompassed by the disclosure. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed by the disclosure, and any limits specifically excluded from the stated ranges apply. Where a stated range includes one or both of the limits, ranges excluding one or both of the included limits are also considered part of the present disclosure.

For any numerical value described herein, e.g., as a parameter of the described subject matter or as part of a range relevant to the described subject matter, alternatives forming part of the description are functionally equivalent ranges around the particular numerical value (e.g., " For a dimension disclosed as "40 millimeters (mm)" it is expressly contemplated that a contemplated alternative embodiment would be "about 40 mm".

References throughout this specification to “exemplary embodiments” or “embodiments” mean that a particular feature, structure, or characteristic described in connection with a particular embodiment can be included in at least one embodiment of the claimed subject matter. can do. Accordingly, the expressions of the phrase “exemplary embodiments” or “exemplary embodiment” in various places throughout this specification are not necessarily intended to refer to the same embodiment or to any one particular embodiment described. Additionally, it should be understood that specific features, structures, or properties described may be combined in a variety of ways in one or more embodiments. In general, of course, these and other issues may vary depending on the specific usage situation. Accordingly, the specific context of the description or use of these terms can provide helpful guidance regarding inferences drawn about this context.

Although the subject matter is described in terms specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, specific features and acts are disclosed as example forms of implementing the claims.

Those skilled in the art will recognize that a virtually unlimited number of variations to the above description are possible, and that the examples and accompanying drawings are intended to illustrate one or more embodiments of implementation only.

It will be understood by those skilled in the art that various other changes may be made and equivalents may be substituted without departing from the claimed subject matter. Additionally, many variations may be made to adapt the teachings of the claimed subject matter to a particular context without departing from the central concept described herein. Accordingly, it is intended that the claimed subject matter is not limited to the specific embodiments disclosed, but that such claimed subject matter may also include all embodiments falling within the scope of the appended claims, and equivalents thereof.

In the above detailed description, numerous specific details are set forth to provide a thorough understanding of the claimed subject matter. However, it will be understood by those skilled in the art that the claimed subject matter may be practiced without these specific details. In other instances, methods, devices, or systems known to those skilled in the art have not been described in detail so as not to obscure the claimed subject matter.

Claims (76)

A single unit dose article comprising a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin,
The water-soluble core substrate includes a carrier solvent with an active cleaning formulation,
When at least one fiber of the plurality of fibers is contacted with a carrier solvent at a temperature ranging from 10° C. to 20° C. for a period of 5 minutes or more, the core substrate exhibits a shrinkage of 0.5% to 65%,
The active cleaning formulation is a single unit dose article disposed on or embedded within a water-soluble core substrate. 2. The single unit dose article of claim 1, further comprising a water-soluble nonwoven material surrounding the water-soluble core substrate. 3. The single unit dose article of claim 2, further comprising a water-soluble film surrounding the water-soluble nonwoven substrate. 4. The single unit dose article of claim 3, wherein the water-soluble film is laminated to a water-soluble nonwoven material. 3. The single unit dose article of claim 2, further comprising a bonding interface configured to create a seal surrounding the water-soluble core substrate. The single unit dose article of claim 1, wherein the active cleaning formulation is in at least one of the following forms: solid, gel, liquid, gel, or slurry. 2. The single unit dose article of claim 1, wherein the water-soluble core substrate has been at least one of saturated with an active cleaning formulation, coated with an active cleaning formulation, or impregnated with an active cleaning formulation. 2. The single unit dose article of claim 1, wherein the active cleaning formulation is within a water-soluble core substrate. The single unit dose article of claim 1 wherein the water-soluble core substrate is soluble according to MSTM-205 so that when the water-soluble core substrate is contacted with water having a temperature of at least 10° C., the water-soluble core substrate releases the active cleaning formulation. 10. The single unit dose article of claim 9, wherein after being contacted with water having a temperature of at least 10° C. for up to 300 seconds, the active cleaning formulation is substantially released from the water-soluble core substrate. 2. The single unit dose article of claim 1, wherein the resin is a polymer comprising vinyl alcohol moieties. 12. The single unit dose article of claim 11, wherein the polymer comprising vinyl alcohol moieties comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. 13. The single unit dose article of claim 12, wherein the polyvinyl alcohol copolymer is a copolymer of vinyl acetate and vinyl alcohol, or an anionically modified copolymer. 14. The single unit dose article of claim 13, wherein the anionically modified copolymer comprises a carboxylate, a sulfonate, or a combination thereof. 12. The single unit dose article of claim 11, wherein the plurality of fibers comprises a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%. 12. The method of claim 11, wherein the plurality of fibers comprises two types of fibers comprising a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%, and wherein the two types of fibers have a diameter and a length. , single unit dose articles having differences in toughness, shape, stiffness, elasticity, solubility, color, or combinations thereof. 12. The method of claim 11, wherein the plurality of fibers comprises a first type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89% and a degree of hydrolysis ranging from about 90% to about 99.5%. A single unit dose article comprising a second type of fiber comprising a polyvinyl alcohol copolymer having 18. The single unit dose article of claim 17, wherein the ratio of the first type of fiber to the second type of fiber ranges from about 1:99 to about 75:25 by weight. 18. The single unit dose article of claim 17, wherein the ratio of the first type of fiber to the second type of fiber ranges from about 5:95 to about 50:50 by weight. 18. The single unit dose article of claim 17, wherein the water-soluble core substrate comprises at least one nonwoven sheet comprising a mixture of the first type of fiber and the second type of fiber. 18. The single unit dose article of claim 17, wherein the water-soluble core substrate comprises a plurality of layers, the plurality of layers being selected from nonwoven sheets, foam layers, films, or any combination thereof. 22. The single unit dose article of claim 21, wherein the plurality of layers comprise separate sheets in an overlapping configuration or continuous sheets folded in a serpentine configuration. A single unit dose article comprising a water-soluble nonwoven substrate comprising a plurality of fibers comprising a water-soluble resin,
The water-soluble nonwoven substrate includes a carrier solvent with an active cleaning formulation,
When at least one fiber of the plurality of fibers is contacted with a carrier solvent at a temperature ranging from 10° C. to 20° C. for a period of 5 minutes or more, the nonwoven substrate exhibits a shrinkage of 0.5% to 65%,
The active cleaning formulation is a single unit dose article disposed on or contained within a water-soluble core substrate. 24. The single unit dose article of claim 23, further comprising a water-soluble nonwoven material surrounding the water-soluble nonwoven substrate. 25. The single unit dose article of claim 24, further comprising a water-soluble film surrounding the water-soluble nonwoven substrate. 26. The single unit dose article of claim 25, wherein the water-soluble film is laminated to a water-soluble nonwoven material. 25. The single unit dose article of claim 24, further comprising a bonding interface configured to create a seal surrounding the water-soluble nonwoven substrate. 24. The single unit dose article of claim 23, wherein the active cleaning formulation is in the form of at least one of a solid, gel, liquid, or slurry formulation. 24. The single unit dose article of claim 23, wherein the plurality of fibers are saturated with an active cleaning formulation. 24. The single unit dose article of claim 23, wherein the active cleaning formulation is contained within a plurality of fibers. 24. The single unit dose article of claim 23, wherein the water-soluble nonwoven substrate comprises a plurality of layers and the active cleaning formulation is disposed between adjacent layers of the plurality of layers. 32. The single unit dose article of claim 31, wherein the water-soluble nonwoven substrate is a continuous sheet of a water-soluble nonwoven web folded into a serpentine configuration to form a plurality of layers. 32. The single unit dose article of claim 31, wherein the water-soluble nonwoven substrate comprises a plurality of separate substrate sheets in an overlapping configuration. 32. The single unit dose article of claim 31, wherein the plurality of fibers are saturated with an active cleaning formulation. 32. The single unit dose article of claim 31, wherein the active cleaning formulation is contained within a plurality of fibers. 33. The single unit dose article of claim 32, wherein the active cleaning formulation is disposed on the surface of the water-soluble nonwoven substrate and/or on the surface of the plurality of fibers. 32. The single unit dose article of claim 31, further comprising a water-soluble nonwoven material surrounding the water-soluble nonwoven substrate. 24. The single unit dose article of claim 23, further comprising a water-soluble nonwoven material defining the interior space, wherein the active cleaning formulation is a liquid active cleaning formulation contained within the interior space. 24. The single unit dose article of claim 23, wherein the water-soluble nonwoven substrate is soluble according to MSTM-205 so that when the water-soluble nonwoven substrate is contacted with water having a temperature of at least 10° C., the water-soluble nonwoven substrate releases an active cleaning formulation. 40. The single unit dose article of claim 39, wherein the active cleaning formulation is substantially released from the water-soluble nonwoven substrate when the water-soluble nonwoven substrate is contacted with water having a temperature of at least 10° C. for up to 300 seconds. 24. The single unit dose article of claim 23, wherein the water-soluble resin is a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. 42. The single unit dose article of claim 41, wherein the polyvinyl alcohol copolymer is a copolymer of vinyl acetate and vinyl alcohol, or an anionically modified copolymer of vinyl acetate and vinyl alcohol. 24. The method of claim 23, wherein the plurality of fibers comprises a first type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%, and a hydrolysis degree ranging from about 90% to about 99.5%. A single unit dose article comprising a second type of fiber comprising a polyvinyl alcohol copolymer having a degree of degradation. 44. The single unit dose article of claim 43, wherein the ratio of the first type of fiber to the second type of fiber ranges from about 1:99 to about 75:25 by weight. As a single unit dose article,
a first water-soluble nonwoven web comprising a first water-soluble resin and a second water-soluble nonwoven web comprising a second water-soluble resin; and
A carrier solvent having an active cleaning formulation disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web, wherein at least one of the first water-soluble nonwoven web or the second water-soluble nonwoven web is contacted with water having a temperature greater than 10° C. wherein at least one of the first water-soluble nonwoven web or the second water-soluble nonwoven web is soluble according to MSTM-205 to release the active cleaning formulation disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web. carrier solvent having
A single unit dose article comprising: 46. The method of claim 45, wherein the first water-soluble nonwoven web comprises a plurality of fibers comprising a first water-soluble resin, and wherein at least one fiber of the plurality of fibers is contacted with a carrier solvent at 20° C. for a period of 5 minutes or more. When applied, the first water-soluble nonwoven web exhibits a shrinkage of 0.5% to 65%. 46. The single unit dose article of claim 45, wherein the active cleaning formulation is in at least one of solid, gel, liquid, or slurry form. 46. The single unit dose article of claim 45, further comprising a bonding interface configured to define an interior space and create a seal between the first water-soluble nonwoven web and the second water-soluble nonwoven web surrounding the active cleaning formulation in the interior space. 46. The single unit dose article of claim 45, further comprising a water-soluble film substrate disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web. 50. The single unit dose article of claim 49, wherein the active cleaning formulation is contained within a water-soluble film substrate. 50. The single unit dose article of claim 49, wherein the active cleaning formulation is disposed on the surface of the water-soluble film substrate. 46. The method of claim 45, wherein when at least one of the first water-soluble nonwoven web or the second water-soluble nonwoven web is contacted with water having a temperature of at least 10° C. for less than 300 seconds, the active cleaning formulation is A single unit dose article substantially released between water-soluble nonwoven webs. As a single unit dose article,
A water-soluble material comprising a plurality of fibers comprising a water-soluble resin, the water-soluble material bonded at a bonding interface along an edge of the water-soluble material to define an interior space of a single unit dose article; and
A carrier solvent with an active cleaning formulation disposed in the interior space, wherein the water-soluble material is soluble according to MSTM-205 so that when contacted with water having a temperature above 10° C., the water-soluble material releases the active cleaning formulation from the interior space. Carrier solvent with active cleaning formulation
A single unit dose article comprising: 54. The single unit dose article of claim 53, wherein when at least one fiber of the plurality of fibers is contacted with the carrier solvent, the at least one fiber exhibits a shrinkage of 0.5% to 65%. 54. The single unit dose article of claim 53, wherein the water-soluble material comprises one of a water-soluble nonwoven web, a water-soluble foam material, or a water-soluble film material. 54. The single unit dose article of claim 53, wherein the active cleaning formulation is in at least one of solid, gel, liquid, or slurry form. 54. The single unit dose article of claim 53, wherein the water-soluble material has a first surface opposing the interior space and an opposing second surface, and the single unit dose article further comprises a water-soluble film disposed on the first surface. 54. The single unit dose article of claim 53, wherein the water-soluble material comprises a water-soluble composite comprising a water-soluble film material made from a first water-soluble resin connected to one of a water-soluble foam material made from a second water-soluble resin or a water-soluble nonwoven material. . 54. The single unit dose article of claim 53, wherein the water-soluble resin is a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. 60. The single unit dose article of claim 59, wherein the polyvinyl alcohol copolymer is a copolymer of vinyl acetate and vinyl alcohol, or an anionically modified copolymer of vinyl acetate and vinyl alcohol. 54. The method of claim 53, wherein the plurality of fibers comprises a first type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%, and a hydrolysis degree ranging from about 90% to about 99.5%. A single unit dose article comprising a second type of fiber comprising a polyvinyl alcohol copolymer having a degree of degradation. 62. The single unit dose article of claim 61, wherein the ratio of the first type of fiber to the second type of fiber ranges from about 1:99 to about 75:25 by weight. 1. A method of making a single unit dose article comprising a carrier solvent with an active cleaning formulation, comprising:
Forming a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin, the water-soluble core substrate comprising a carrier solvent with an active cleaning formulation, and subjecting the water-soluble core substrate to a temperature ranging from 10° C. to 20° C. for 5 minutes or more. When the carrier solvent and at least one of the plurality of fibers are in contact, the water-soluble core substrate exhibits a shrinkage of 0.5% to 65%;
Forming an outer water-soluble material comprising at least one of a water-soluble nonwoven material, a water-soluble foam material, a water-soluble film material, or a composite thereof into an open pouch defining an interior space configured to contain a water-soluble core substrate and a carrier solvent with an active cleaning formulation. steps;
introducing a carrier solvent with a water-soluble core substrate and an active cleaning formulation into the interior space; and
sealing the external water-soluble material to surround the internal space
A manufacturing method comprising: 64. The method of claim 63, wherein forming a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin comprises forming one of a water-soluble nonwoven substrate, a water-soluble foam substrate, or a water-soluble film substrate. 64. The method of claim 63, wherein forming the water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin comprises saturating the water-soluble core substrate with an active cleaning formulation, disposing the active cleaning formulation on the surface of the water-soluble core substrate. A method of manufacturing comprising at least one of: coating the surface of the water-soluble core substrate with the active cleaning formulation, embedding the active cleaning formulation within the water-soluble core substrate, or impregnating the water-soluble core substrate with the active cleaning formulation. 64. The method of claim 63, wherein sealing the external water-soluble material comprises forming a seal at the bonding interface to surround the water-soluble core substrate and the carrier solvent with the active cleaning formulation in an interior space. 64. The method of claim 63, wherein forming a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin comprises forming the water-soluble nonwoven substrate into a plurality of layers, wherein the carrier solvent and the active cleaning formulation are applied to adjacent layers of the plurality of layers. A manufacturing method comprising being disposed between. 68. The method of claim 67, wherein forming the water-soluble nonwoven substrate into a plurality of layers includes folding a continuous sheet of the water-soluble nonwoven web into a serpentine structure to form the plurality of layers. 68. The method of claim 67, wherein forming the water-soluble nonwoven substrate into a plurality of layers includes laminating a plurality of separate substrate sheets in an overlapping structure. 68. The preparation of claim 67, further comprising applying the carrier solvent comprising glycerol with the active cleaning formulation to the surface of the water-soluble nonwoven substrate at a maximum coating weight of 120 gsm for the carrier solvent with the active cleaning formulation. method. 71. The method of claim 70, wherein the carrier solvent comprising glycerol with the active cleaning formulation is applied to the surface of the water-soluble nonwoven substrate until the single unit dose article comprises 55% by weight of the active cleaning formulation. 72. The method of claim 71, further comprising forming the water-soluble nonwoven substrate into 25 to 110 layers. 64. The method of claim 63, wherein the water-soluble resin is a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. As a single unit dose article,
A water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin, the water-soluble core substrate comprising an active cleaning formulation; and
A water-soluble nonwoven material surrounding a water-soluble core substrate.
Includes,
The active cleaning formulation is a single unit dose article disposed on or contained within a water-soluble core substrate. 75. The single unit dose article of claim 74, further comprising a water-soluble film laminated on and surrounding the water-soluble nonwoven substrate. 75. The single unit dose article of claim 74, wherein the water-soluble core substrate further comprises a carrier solvent comprising an active cleaning formulation.