Note: Descriptions are shown in the official language in which they were submitted.
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UNIT DOSE SOFTENER DISPOSED IN WATER SOLUBLE CONTAINER
Field of the Invention
This invention relates to wash cycle unit dose laundry compositions for
softening
or conditioning fabrics. More particularly, this invention relates to unit
dose fabric
softening compositions which is contained in a water soluble container
suitable for use
in the wash cycle of an automatic washing machine.
Background of the Invention
Detergent compositions manufactured in the form of compacted detergent
powder are known in the art. U.S. 5,225,100, for example, describes a tablet
of
compacted powder comprising an anionic detergent compound which will
adequately
disperse in the wash water.
Although detergent compositions in the form of compacted granular tablets of
various shapes have received much attention in the patent literature, the use
of such
tablets to provide a unit dose fabric softener which will soften or condition
fabrics in the
wash cycle without impairing detergency or otherwise compromise the cleaning
benefits
provided by the detergent composition is not known.
Another possible option for providing a unit dose softener apart from the wash
cycle is to introduce the softening ingredients directly into the rinse cycle.
But, for this
type of product to be effective several practical requirements must be met. To
begin
with, the size and shape of the unit dose container must be readily compatible
with the
geometry of a wide variety of rinse cycle dispensers designed for home washing
machines in order to insure its easy introduction into the dispenser.
Moreover, in
common with the general use of rinse cycle softeners, it is necessary to clean
the rinse
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dispenser on a regular basis to avoid residue from accumulating within the
dispenser or
even, at times, prevent bacterial growth from occurring.
Still further, a unit dose composition for the rinse cycle must be formulated
to
readily dispense its contents upon contact with water in a period of time
corresponding
to the residence time of the unit dose in the dispenser, namely, the period of
time during
which water enters and flows through the rinse cycle dispenser. The
aforementioned
practical requirements have to date not been successfully met with any
commercially
available product and hence there remains a need in the art for a unit dose
softener
capable of activation in the rinse cycle.
Laundry detergent compositions which further include a fabric softener to
provide
softening or conditioning of fabrics in the wash cycle of the laundering
operation are
well-known in the art and described in the patent literature. See, for
example, U.S.
Patent 4,605,506 to Wixon; U.S. Patent 4,818,421 to Boris et al. and U.S.
Patent
4,569,773 to Ramachandran et al., all assigned to Colgate-Palmolive Co., and
U.S.
Patent 4,851,138 assigned to Akzo. U.S. Patent 5,972,870 to Anderson describes
a
multi-layered laundry tablet for washing which may include a detergent in the
outer layer
and a fabric softener, or water softener or fragrance in the inner layer. But,
these type
of multi-benefit products suffer from a common drawback, namely, there is an
inherent
compromise which the user necessarily makes between the cleaning and softening
benefits provided by such products as compared to using a separate detergent
composition solely for cleaning in the wash cycle and a separate softening
composition
solely for softening in the rinse cycle. In essence, the user of such
detergent softener
compositions does not have the ability to independently adjust the amount of
detergent
and softener added to the wash cycle of a machine in response to the cleaning
and
softening requirements of the particular wash load.
Some attempts have been made in the art to develop wash cycle active fabric
softeners, typically in powder form. But, these type products are
characterized by the
same inconvenience inherent with the use of powered detergents, namely,
problems of
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handling, caking in the container or wash cycle dispenser, and the need for a
dosing
device to deliver the desired amount of active softener material to the wash
water.
The use of a unit dose wash cycle fabric softening composition contained in a
water soluble container such as a sachet offers numerous advantages. To be
effective,
the unit dose fabric softening compositions, contained in a sachet, must be
able to
disperse in the wash liquor in a short period of time to avoid any residue at
the end of
the wash cycle.
Typically, the wash cycle time can be as short as 12 minutes and as long as 90
minutes (in typical European washers) depending on the type of washer and the
wash
conditions. Therefore, the water soluble sachet must be soluble in the wash
liquor
before the end of the cycle.
Summar)r of the Invention
The present invention provides a unit dose wash cycle fabric softening
composition contained in a water soluble container for softening or
conditioning fabrics
in the wash cycle of an automatic washing machine, said unit dose comprising
(a) a
water soluble container; and (b) disposed in the water soluble container is
granular
fabric softener composition, the amount of composition being sufficient to
form a unit
dose capable of providing effective softening or conditioning of fabrics in
the wash cycle
of said washing machine, wherein said fabric softener composition comprises a
treated
clay, a perfume and a colorant.
The term "granular" as used herein in describing the fabric softener is
intended to
encompass relatively coarser granules varying in size from about 150 to 2,000
microns
as well as finer powder having a size as small as 30 to 50 microns.
The term "fabric softener" is used herein for purposes of convenience to refer
to
materials which provide softening and/or conditioning benefits to fabrics in
the wash
cycle of a home or automatic laundering machine.
The granular fabric softener composition of the invention is preferably
comprised
of a fabric softening clay optionally in combination with an organic fatty
softening
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material. Especially preferred fabric softeners comprise a clay mineral
softener, such
as bentonite, in combination with a pentaerythritol ester compound as further
described
herein. Useful combinations of such softener may vary from about 80%, to about
90%,
by weight, of clay, and from about 10% to about 20%, by weight, of fatty
softening
material such as a pentaerythritol compound (often abbreviated herein as
"PEC").
The present invention is predicated on the use of a treated montmorillonite-
containing clay, preferably a treated bentonite, as herein defined, as an
active softening
ingredient in a unit dose softening composition for the wash cycle. The
resultant unit
dose composition has reduced tendency to gel on contact with water so that
when used
in conjunction with laundry detergent compositions it manifests improved
dispersion
properties in the wash water without having any adverse effect on its
softening
properties.
In accordance with the process aspect of the invention there is provided a
process for softening or conditioning laundry which comprises contacting the
laundry
with an effective amount of the unit dose laundry composition defined above.
Detailed Description of the Invention
The present invention relates to a water soluble sachet containing a unit dose
of
a fabric softener composition, wherein the water soluble sachet is formed from
a single
layer of water soluble thermo plastic film such as a polyvinyl alcohol,
wherein the inner
surface of the film is in contact with the fabric softener composition
The fabric softener composition contained in the water soluble container which
is
formed from a water soluble polymer which is selected from the group
consisting of
polyvinyl alcohols, polyvinyl alcohol copolymers such as polyvinyl
alcohol/polyvinyl
pyrrolidone, partially hydrolyzed polyvinyl acetate, polyvinyl pyrrolidone,
alkyl celluloses
such as methyl cellulose, ethyl cellulose and propyl cellulose, ethers and
esters of alkyl
celluloses of alkyl celluloses, hydroxy ethyl cellulose, hydroxy propyl
cellulose, carboxy
methyl cellulose sodium, dextrin, maltodextrin, such as methyl cellulose,
ethyl cellulose
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and propyl cellulose, water soluble polyacrylates, water soluble
polyacrylamides and
acrylic acid/maleic anhydride copolymers comprises approximately by weight:
(a) 87% to 98% of a clay mineral based softener and an organic fatty
softening material;
5 (b) 0 to 10%, more preferably 0.5% to 6% of a perfume; and
(c) 0 to 0.5%, more preferably 0.05% to 0.3% of a blue dye, wherein the
composition contains less than 10 wt. %, preferably less than 8wt. % water and
the
composition does not contain an anionic sulfate surfactant, an anionic
sulfonate
surfactant, a fatty acid, hexylene glycol or an amine oxide surfactant.
The instant compositions do not contain a detergent builder salt, a silicone
glycol
copolymer, a nonionic surfactant, a green colorant, a yellow colorant or a
poly(oxyalkylene) substrated colorant.
As used herein and in the appended claims the term "perfume" is used in its
ordinary sense to refer to and include any non-water soluble fragrant
substance or
mixture of substances including natural (i.e., obtained by extraction of
flower, herb,
blossom or plant), artificial (i.e., mixture of natural oils or oil
constituents) and
synthetically produced substance) odoriferous substances. Typically, perfumes
are
complex mixtures of blends of various organic compounds such as alcohols,
aldehydes,
ethers, aromatic compounds and varying amounts of essential oils (e.g.,
terpenes) such
as from 0% to 80%, usually from 10% to 70% by weight, the essential oils
themselves
being volatile odoriferous compounds and also serving to dissolve the other
components of the perfume.
In the present invention the precise composition of the perfume is of no
particular
consequence to cleaning performance so long as it meets the criteria of water
immiscibility and having a pleasing odor. Naturally, of course, especially for
cleaning
compositions intended for use in the home, the perfume, as well as all other
ingredients,
should be cosmetically acceptable, i.e., non-toxic, hypoallergenic, etc.
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The clay mineral softeners include the montmorillonite-containing clays which
have swelling properties (in water) and contain 5% to 18% by weight moisture
and
which are of smectite structure, so that they deposit on fibrous materials,
especially
cotton and cottonlsynthetic blends, such as cotton/polyester, to give such
fibers and
fabrics made from them a surface lubricity or softness. The best of the
smectite clays
for use in the present invention is bentonite and the best of the bentonites
are those
which have a substantial swelling capability in water, such as the sodium and
potassium
bentonites. Such swelling bentonites are also known as western or Wyoming
bentonites, which are essentially sodium bentonite. Other bentonites, such as
calcium
bentonite, are normally non-swelling and usually are, in themselves,
unacceptable as
fabric softening agents. However, it has been found that such non-swelling
bentonites
exhibit even better fabric softening than do the swelling bentonites, provided
that there
is present in the softening composition, a source of alkali metal or other
solubilizing ion,
such as sodium (which may come from sodium hydroxide, added to the
composition, or
from sodium salts, such as builders and fillers, which may be functional
components of
the composition). Among the preferred bentonites are those of sodium and
potassium,
which are normally swelling, and calcium and magnesium, which are normally non-
swelling. Of these it is preferred to utilize calcium (with a source of sodium
being
present) and sodium bentonites. The bentonites employed may be produced in the
United States of America, such as Wyoming bentonite, but also may be obtained
from
Europe, including Italy and Spain, as calcium bentonite, which may be
converted to
sodium bentonite by treatment with sodium carbonate, or may be employed as
calcium
bentonite. Also, other montmorillonite-containing smectite clays of properties
like those
of the bentonites described may be substituted in whole or in part for the
bentonites
described herein and similar fabric softening results will be obtained.
The swellable bentonites and similarly operative clays are of ultimate
particle
sizes in the micron range, e.g., 0.01 to 20 microns and of actual particle
sizes in the
range of No's. 100 to 400 sieves, preferably 140 to 325 sieves, U.S. Sieve
Series. The
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bentonite and other such suitable swellable clays may be agglomerated to
larger
particle sizes too, such as 60 to 120 sieves, but such agglomerates are not
preferred.
For purposes of providing a treated bentonite in accordance with the
invention, the initial
bentonite starting material is selected to have relatively low gelling and
swelling
properties. Specifically, the starting material bentonite is selected to have
the following
initial properties: (a) a montmorillonite content of at least 85%; and (b)
when the
bentonite is activated with sodium ions, dried and ground to particles, the
ground
particles do not swell more than about 2.5 fold over a period of 24 hours when
added to
deionized water at room temperature. The ground particles of bentonite for
purposes of
determining swelling herein are particles at least 90% of equal to or less
than about 75
microns in diameter.
A preferred clay is a calcium based bentonite : Quest Premium bentonite, grade
QPC 300 manufactured by Colin Stuart Minchem. This white bentonite contains
maximum 5 % cristobalite and 2 % quartz and has a minimum base exchange
capacity
of 70 meq/100 g. Particle size is below 53 microns ( 98.5 %) and the free
moisture is
maximum 14 %.
A main component of the invented compositions and articles of the present
invention, and which is used in combination with the fabric softening clay is
an organic
fatty softener. The organic softener can be anionic, cationic or nonionic
fatty chains
(C,o CZZ preferably C,~-C,8). Anionic softeners include fatty acids soaps.
Preferred
organic softeners are nonionics such as fatty esters, ethoxylated fatty
esters, fatty
alcohols and polyol polymers. The organic softener is most preferably a higher
fatty
acid ester of a pentaerythritol compound, which term is used in this
specification to
describe higher fatty acid esters of pentaerythritol, higher fatty acid esters
of
pentaerythritol oligomers, higher fatty acid esters of lower alkylene oxide
derivatives of
pentaerythritol and higher fatty acid esters of lower alkylene oxide
derivatives of
pentaerythritol oligomers. Pentaerythritol compound is often abbreviated as
PEC
herein, which description and abbreviation may apply to any or all of
pentaerythritol,
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oligomers, thereof and alkoxylated derivatives thereof, as such, or more
preferably and
more usually, as the esters, as may be indicated by the context.
The oligomers of pentaerythritol are preferably those of two to five
pentaerythritol
moieties, more preferably 2 or 3, with such moieties being joined together
through
etheric bonds. The lower alkylene oxide derivatives thereof are preferably of
ethylene
oxide or propylene oxide monomers, dimers or polymers, which terminate in
hydroxyls
and are joined to the pentaerythritol or oligomer of pentaerythritol through
etheric
linkages. Preferably there will be one to ten alkylene oxide moieties in each
such
alkylene oxide chain, more preferably 2 to 6, and there will be one to ten
such groups
on a PEC, depending on the oligomer. At least one of the PEC OH groups and
preferably at least two, e.g., 1 or 2 to 4, are esterified by a higher fatty
acid or other
higher aliphatic acid, which can be of an odd number of carbon atoms.
The higher fatty acid esters of the pentaerythritol compounds (PEC's) are
preferably partial esters. And more preferably there will be at least two free
hydroxyls
thereon after esterification (on the pentaerythritol, oligomer or alkoxyalkane
groups).
Frequently, the number of such free hydroxyls is two or about two but
sometimes it may
by one, as in pentaerythritol tristearate. The higher aliphatic or fatty acids
that may be
employed as esterifying acids are those of carbon atom contents in the range
of 8 to 24,
preferably 12 to 22 and more preferably 12 to 18, e.g., lauric, myristic,
palmitic, oleic,
stearic and behenic acids. Such may be mixtures of such fatty acids, obtained
from
natural sources, such as tallow or coconut oil, or from such natural materials
that have
been hydrogenated. Synthetic acids of odd or even numbers of carbon atoms may
also
be employed. Of the fatty acids lauric and stearic acids are often preferred,
and such
preference may depend on the pentaerythritol compound being esterified.
Examples of some esters (PEC's) within the present invention follow:
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9
Monopentaerythritol Esters
CHZ- R2
R 1- CH2 - C - CHz - R3
CH2 R4
Monopentaerythritol Dilaurate
R,=CH3 - (CH2),o -COO-
RZ CH3 - (CH2),o -COO-
RS OH
R4 OH
Monopentaerythritol Monostearate
R,=CH3 - (CH2),6 -COO-
R2 OH
R3 OH
R4=OH
Monopentaerythritol Distearate
R,=CH3 - (CHz),6 -COO-
R2 CH3 - (CH2),6 -COO-
RS OH
R4 OH
Monopentaerythritol Tristearate
R,=CH3 - (CH2),6 -COO-
R2 CH3 - (CHz),6 -COO-
R3=CH3 - (CH2),6 -COO-
R4 OH
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Monopentaerythritol Monobehenate
R,=CH3 - (CH2)2o -COO-
R2 OH
R3 OH
5 R4 OH
Monopentaerythritol Dibehenate
R,=CH3 - (CHz)zo -COO-
R2 CH3 - (CH~)ZO -COO-
RS OH
10 R4=O H
Dipentaerythritol Esters
CHZORI CH20R2
I I
HO CHZ- C- CH2- O -CH2- C- CHZOH
CH20R3 CHZOR4
Dipentaerythritol Tetralaurate
R,=CH3 - (CH2),o -CO
Rz CH3 - (CHZ),a -CO
R3 CH3 - (CH2),o -CO
R4=CH3 - (CH2),0 -CO
Dipentaerythritol Tetrastearate
R,=CH3 - (CHz),6 -CO
R2 CH3 - (CH2),s -CO
R3 CH3 - (CH2),6 -CO
R4 CH3 - (CH2),6 -CO
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11
Pentaer)/thritol 10 Ethylene Oxide Ester
CH2- O- (CH2- CH20)"H
I
RZ-CH2-C-CH2-R2
I
CH2- O- (CH2-CH20)11~H
withn+n'=10
Monopentaerythritol 10 Ethylene Oxide Distearate
R,=CH3 - (CH2),6 -COO-
R2 CH3 - (CH2),s -COO-
Pentaer)/thritol 4 Propylene Oxide Esters
CHZ - O - (CH2 - CH - CH20)2H
R, - CH2 - C- CHz= R2
CH2 - O - (CH2 - CH - CH2O)2H
Monopentaerythritol 4 Propylene Oxide Monostearate
R,=CH3 - (CH2),6 -COO-
R2 OH
Monopentaerythritol 4 Propylene Oxide Distearate
R,=CH3 - (CHz),6 -COO-
R2 CH3 - (CHZ),6 -COO-
Although in the formulas given herein some preferred pentaerythritol compounds
that are useful in the practice of this invention are illustrated it will be
understood that
various other such pentaerythritol compounds within the description thereof
may also be
employed herein, including such as pentaerythritol dihydrogenated tallowate,
pentaerythritol ditallowate, pentaerythritol dipalmitate, and
dipentaerythritol
tetratallowate.
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To enhance the softening efficacy of the unit dose compositions described
herein
cationic softeners such as conventional quaternary ammonium softening
compounds
may optionally be added in minor amounts.
The combination of bentonite and organic fatty softening material is generally
from about 10% to about 100% bentonite and from about 1 % to about 100% fatty
softening material, preferably from about 50% to about 95% bentonite and about
5% to
about 50% fatty softening material, and most preferably from about 80% to 90%
bentonite and from about 10% to about 20% fatty softening material.
Other useful ingredients for the unit dose granular compositions of the
invention
include disintegration materials to enhance the disintegration of the unit
dose in the
wash water. Such materials include an effervescent matrix such as citric acid
combined
with baking soda, or materials such as PVP polymer and cellulose. Granulating
agents
may be used such as polyethylene glycol; bactericides, perfumes, dyes and
materials to
protect against color fading, dye transfer, anti-pilling and anti-shrinkage.
For purposes
of enhancing the aesthetic properties of the final composition, cosmetic
ingredients such
as dyes, micas and waxes may be used as coating ingredients to improve the
appearance and feel of the unit dose.
The water soluble container which can be in the form of a sachet, a blow
molded
capsule or other blow molded shapes, an injected molded ampoule or other
injection
molded shapes, or rotationally molded spheres or capsules are formed from a
water
soluble thermoplastic polymer. The water soluble polymers are selected from
the group
consisting of polyvinyl alcohols, polyvinyl alcohol copolymers such as
polyvinyl
alcohol/polyvinyl pyrrolidone, partially hydrolyzed polyvinyl acetate,
polyvinyl
pyrrolidone, alkyl celluloses such as methyl cellulose, ethyl cellulose and
propyl
cellulose, ethers and esters of alkyl celluloses of alkyl celluloses, hydroxy
ethyl
cellulose, hydroxy propyl cellulose, carboxy methyl cellulose sodium, dextrin,
maltodextrin, such as methyl cellulose, ethyl cellulose and propyl cellulose,
water
soluble polyacrylates, water soluble polyacrylamides and acrylic acid/maleic
anhydride
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13
copolymers. Especially preferred soluble plastics which may be considered for
forming
the container include low molecular weight and/or chemically modified
polylactides;
such polymers have been produced by Chronopol, Inc. and sold under the Heplon
trademark. Also included in the water soluble polymer family are melt
processable
polyvinyl) alcohol resins (PVA); such resins are produced by Texas Polymer
Services,
Inc., tradenamed Vinex, and are produced under license from Air Products and
Chemicals, Inc. and Monosol film produced by Monosol LLC. Other suitable
resins
include poly (ethylene oxide) and cellulose derived water soluble
carbohydrates. The
former are produced by Union Carbide, Inc. and sold under the tradename
Polyox; the
latter are produced by Dow Chemical, Inc. and sold under the Methocel
trademark.
Typically, the cellulose derived water soluble polymers are not readily melt
processable.
The preferred water soluble thermoplastic resin for this application is PVA
produced by
Monosol LLC. Any number or combination of PVA resins can be used. The
preferred
grade, considering resin processability, container durability, water
solubility
characteristics, and commercial viability is Monosol film having a weight
average
molecular weight range of about 55,000 to 65,000 and a number average
molecular
weight range of about 27,000 to 33,000.
The sachet may be formed from polyvinyl) alcohol film. The palletized, pre-
dried, melt processable polyvinyl alcohol (PVA) resin, is feed to a film
extruder. The
feed material may also contain pre-dried color concentrate which uses a PVA
carrier
resin. Other additives, similarly prepared, such as antioxidants, UV
stabilizers, anti-
blocking additives, etc. may also be added to the extruder. The resin and
concentrate
are melt blended in the extruder. The extruder die may consist of a circular
die for
producing blown film or a coat hanger die for producing cast film. Circular
dies may
have rotating die lips and/or mandrels to modify visual appearance andlor
properties.
Alternatively, the PVA resins can also be dissolved and formed into film
through a
solution-casting process, wherein the PVA resin or resins are dissolved and
mixed in an
aqueous solution along with additives. This solution is cast through a coat
hanger die,
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14
or in front of a doctor blade or through a casting box to produce a layer of
solution of
consistent thickness. This layer of solution is cast or coated onto a drum or
casting
band or appropriate substrate to convey it through an oven or series of ovens
to reduce
the moisture content to an appropriate level. The extruded or cast film is
slit to the
appropriate width and wound on cores. Each core holds one reel of film.
Typical film properties are:
1. Tensile strength (125 mil, break, 50% RH) = 4,700 to 5,700 psi
2. Tensile modulus (125 mil, 50% RH) = 47,000 to 243,000 psi; preferred
range is 140,000 to 150,000 psi
3. Tear resistance (mean) (ASTM-D-199gm/ml) = 900-1500
4. Impact strength (mean) (ASTM-D-1709, gm) = 600-1,000
5. 100% Elongation (mean) (ASTM-D-882, psi) = 300-600
6. Oygen transmission (1.5 mil, 0% RH, 1 atm) = 0.0350 to 0.450 cc/100 sq.
in./24 h
7. Oxygen transmission (1.5 mil, 50% RH, 1 atm) = 1.20 to 1.50 cc/100 sq.
in./24 h
8. 100% modulus (mean) (ASTM-D-882, psi) = 1000-3000
9. Solubility (sec) (MSTM-205,75°F) disintegration = 1-15; dissolution
= 10-30
Typical resin properties are:
1. Glass Transition Temperature (°C) = 28 to 38; preferred is 28 to 33,
2. Weight Average Molecular Weight (Mw) = 15,000 to 95,000; preferred is
55,00(
65,000
3. Number Average Molecular Weight (Mn) = 7,500 to 60,000; preferred is
27,000 to 33,000. Preferred polyvinyl) alcohol film is formed from Monosol
7030 or
Monoso18630
Reels of slit film are fed to a form, fill, seal machine (FFS).. The Form,
Fill, Seal
machine (FFS) makes the appropriate sachet shape (cylinder, square, pillow,
oval, etc.)
from the film , fills the sachet with product, and seals the sachet. There are
many types of
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form fill seal machines that can convert water soluble films, including
vertical, horizontal
and rotary machines. To make the appropriate sachet shape, one or multiple
films can be
used. The sachet shape can be folded into the film, mechanically deformed into
the film,
or thermally deformed into the film. The sachet forming can also utilize
thermal bonding of
5 multiple layers of film, or solvent bonding of multiple layers of film. When
using polyvinyl)
alcohol the most common solvent is water. Once the appropriately shaped sachet
is filled
with product, the sachet can be sealed using either thermal bonding of the
film, or solvent
bonding of the film.
Blow molded capsules are formed from the polyvinyl) alcohol resin having a
10 molecular weight of about 50,000 to about 70,000 and a glass transition
temperature of
about 28 to 33°C. Pelletized resin and concentrates) are feed into an
extruder. The
extruder into which they are fed has a circular, oval, square or rectangular
die and an
appropriate mandrel. The molten polymer mass exits the die and assumes the
shape of
the die/mandrel combination.. Air is blown into the interior volume of the
extrudate
15 (parison) while the extrudate contacts a pair of split molds. The molds
control the final
shape of the package. While in the mold, the package is filled with the
appropriate volume
of liquid. The mold quenches the plastic. The liquid is contained within the
interior volume
of the blow molded package.
An injection molded ampoule or capsule is formed from the polyvinyl) alcohol
resin having a molecular weight of about 50,000 to about 70,000 and a glass
transition
temperature of about 28 to 38°C. Pelletized resin and concentrates) are
fed to the
throat of an reciprocating screw, injection molding machine. The rotation of
the screw
pushes the pelletized mass forward while the increasing diameter of the screw
compresses the pellets and forces them to contact the machine's heated barrel.
The
combination of heat, conducted to the pellets by the barrel and frictional
heat, generated
by the contact of the pellets with the rotating screw, melts the pellets as
they are pushed
forward. The molten polymer mass collects in front of the screw as the screw
rotates
and begins to retract to the rear of the machine. At the appropriate time, the
screw
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16
moves forward forcing the melt through the nozzle at the tip of the machine
and into a
mold or hot runner system which feeds several molds. The molds control the
shape of
the finished package. The package may be filled with liquid either while in
the mold or
after ejection from the mold. The filling port of the package is heat sealed
after filling is
completed. This process may be conducted either in-line or off-line.
A rotationally molded sphere or capsule is formed from the polyvinyl) alcohol
resin having a molecular weight of about 50,000 to about 70,000 and a glass
transition
temperature of about 28 to 38°C. Pelletized resin and concentrate are
pulverized to an
appropriate mesh size, typically 35 mesh. A specific weight of the pulverized
resin is
fed to a cold mold having the desired shape and volume. The mold is sealed and
heated while simultaneously rotating in three directions. The powder melts and
coats
the entire inside surface of the mold. While continuously rotating, the mold
is cooled so
that the resin solidifies into a shape which replicates the size and texture
of the mold.
After rejection of the finished package, the liquid is injected into the
hollow package
using a heated needle or probe after filling, the injection port of the
package is heat
sealed.
Typical unit dose compositions for use herein may vary from about 5 to about
20
ml corresponding on a weight basis to about 5 to about 20grams (which includes
the
weight of the capsule), and the number of doses per wash is two.
Alternatively, when
using 1 unit dose/wash, the corresponding volume and weight is from about 10
to about
40 ml and from about 10 to about 40 grams (including the capsule weight),
respectively.
The following examples illustrate granular cleaning compositions of the
described
invention. Unless otherwise specified, the proportions in the film and
elsewhere in the
specification are by weight.
Example 1
The following fabric softener composition formula was prepared in wt. % by
simple mixing:
CA 02494718 2005-O1-27
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hite clay/PDT (comprising 15% 94.44
of pentaerythritol
distearate, 85% of Bentonite
Perfume 3.63
Blue d a 0.14
ater 1.79%
The above formulas were filed at a dosage of 15.5 g by the previously
described
method into a polyvinyl alcohol sachet having a film thickness of about 0.25
to 5 mils,
more preferably 1 to 3 mils.
Dissolution tests were conducted in an European washing machine ( Miele
Novotronic 935 super) at different temperatures (15 to 40°C) with
different laundry loads
( from 3.5 to 4.5 kg).
The different articles of the load were visually examined after 5 minutes
washing.
The complete dissolution of sachets was achieved : no residue was observed on
the
fabrics.
