Note: Descriptions are shown in the official language in which they were submitted.
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WATER-SOLUBLE UNIT DOSE ARTICLE INCLUDING
WATER-SOLUBLE CORE CONSTRUCTION
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No.
63/185,592, filed
May 7, 2021, which application is expressly incorporated by reference herein
in its entirety.
FIELD
[0002] The present disclosure relates generally to water-soluble unit dose
articles including
water-soluble core constructions. More particularly, the disclosure relates to
water-soluble unit
dose articles configured to contain a cleaning formulation.
BACKGROUND
[0003] Water-soluble packaging materials are commonly used to simplify
dispersing, pouring,
dissolving, and dosing of a material to be delivered. Traditional packaging
materials include
water-soluble films and pouches made from the water-soluble films are commonly
used to
package formulations, such as laundry detergents, dish detergents, or personal
care formulations.
A consumer can directly add the pouched formulation to water. Advantageously,
this provides
for accurate dosing while eliminating the need for the consumer to measure the
formulation.
However, some currently marketed pouches made of water-soluble polymeric
films, for example,
have an unpleasant rubbery or plastic-like feel when handled by the consumer.
Additionally,
bulk or concentrated detergents are not always stable and may contain
relatively incompatible
ingredients which destabilize when contacting other ingredients. For example,
enzymes
destabilize in various solvents, which can affect the properties of the film,
for example, the
mechanical properties of the film may deteriorate over time. As a result,
traditional pouches,
such as detergent pouches, include a limited number of cavities or
compartments. Further, the
construction of a traditional water-soluble, film-based unit dose is
complicated and expensive,
requiring the creation of the film, the detergent, and the pod separately.
[0004] Thus, there exists a need in the art for unit dose articles having a
construction that is
easily manufacturable and provides for chemical stability during shipping and
storage, for
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example, but is pleasant to handle and dissolves quickly without leaving
undesired residue
during intended use, e.g., when the unit dose article is placed in a washing
machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIGS. 1-14 are sectional schematic views of example single unit dose
(SUD) articles
containing an active cleaning formulation, according to example embodiments;
[0006] FIG. 15 illustrates an example method for making a SUD article,
according to an
example embodiment;
[0007] FIG. 16 shows shrinkage results (in a detergent formulation with 20%
water at 45 C)
for example samples including a core substrate comprising at least one
nonwoven layer or sheet
having a plurality of fibers, which include a first type of fiber ("Fl")
comprising a polyvinyl
alcohol copolymer having a degree of hydrolysis of 88% and a second type of
fiber ("F2-)
comprising a polyvinyl alcohol copolymer having a degree of hydrolysis of 96%;
[0008] FIG. 17 shows shrinkage results (in a detergent formulation with 35%
water at 20 C,
35 C, 45 C) for example samples including a core substrate comprising at least
one nonwoven
layer or sheet having a plurality of fibers, which include a first type of
fiber ("Fl") comprising a
polyvinyl alcohol copolymer having a degree of hydrolysis of 88% and a second
type of fiber
("F2") comprising a polyvinyl alcohol copolymer having a degree of hydrolysis
of 96%;
[0009] FIG. 18 shows shrinkage results (in a detergent formulation with 50%
water at 20 C,
350C, 45 C) for the example samples as shown in FIG. 17;
[0010] FIG. 19 shows shrinkage results (in a detergent formulation with 65%
water at 20 C,
350C, 45 C) for the example samples as shown in FIG. 17;
[0011] FIG. 20 shows shrinkage results (in a detergent formulation with 35%
water at 20 C) of
example samples including at least one nonwoven layer having a plurality of
fibers (Fiber Fl)
having different basis weight;
[0012] FIG. 21 shows shrinkage results (in a detergent formulation with 35%
water at 20 C) of
example samples including at least one nonwoven layer having a plurality of
fibers (Fiber Fl)
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having a basis weight of 50 gsm with different bonding patterns, which include
a point bonding
pattern and a daisy bonding pattern with denser bonding points than the point
bonding pattern;
[0013] FIG. 22 shows disintegration time results (at 20 C, 35 C, 45 C) for
example samples
including a core substrate comprising at least one nonwoven layer or sheet (50
gsm, point-
bonded) having a plurality of fibers, which include a first type of fiber ("Fl-
) comprising a
polyvinyl alcohol copolymer having a degree of hydrolysis of 88% and a second
type of fiber
("F2") comprising a polyvinyl alcohol copolymer having a degree of hydrolysis
of 96%;
[0014] FIG. 23 shows rupture time results (at 20 C, 35 C, 45 C) for the
example samples as
shown in FIG. 22;
[0015] FIG. 24 shows disintegration time results (at 20 C, 35 C, 45 C) for
example samples
including a core substrate comprising at least one nonwoven layer or sheet
(daisy-bonded, with
different basis weight) having a plurality of fibers, which include a first
type of fiber ("Fl")
comprising a polyvinyl alcohol copolymer having a degree of hydrolysis of 88%;
[0016] FIG. 25 shows rupture time results (at 20 C, 35 C, 45 C) for the
example samples as
shown in FIG. 24;
[0017] FIG. 26 shows rupture time results (in water at 20 C, 35 C, 45 C) for
example samples
including at least one nonwoven layer having a plurality of fibers (Fiber Fl)
having a basis
weight of 50 gsm with one of two different bonding patterns including a point
bonding pattern
and a daisy bonding pattern with denser boning points than the point bonding
pattern; and
[0018] FIG. 27 shows disintegration time results (in water at 20 C, 35 C, 45
C) for the
example samples as shown in FIG. 26.
DETAILED DESCRIPTION
[0019] In example embodiments described herein, single unit dose (SUD)
articles include one
or more core substrates, e.g., one or more open or closed foam core substrates
or one or more
nonwoven web core substrates, having precision dosing to deliver cleaning
agents for washing
clothes, for example. In example embodiments, the substrate includes a water-
soluble polymer,
such as polyvinyl alcohol (PVOH) based polymers and/or starch derivatives, for
example, or
blends thereof with otherwise water dispersible polymers that have a high
degree of
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biodegradation activity or can be composted or recycled. In example
embodiments, the core
substrate(s) are contained 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, the
consumer simply places the SUD article, which includes the activated substrate
pre-dosed with
one or more active cleaning formulations for chemical and mechanical cleaning
action, that will
disperse, dissolve, and/or biodegrade during the washing cycle without leaving
undesired
residue.
[0020] The SUD article and, more specifically, in example embodiments, the
water-soluble
core substrate, is configured to contain a carrier solvent with one or more
active cleaning
formulations, such as a laundry detergent formulation. In example embodiments,
the carrier
solvent with the active cleaning formulation is disposed on or coats one or
more surfaces of the
water-soluble core substrate or is embedded in and/or adhered to the water-
soluble core
substrate. The water-soluble core substrate may include a single layer, for
example, a single layer
nonwoven core substrate or foam core substrate, or may include a plurality of
layers, for
example, a sheet of nonwoven core substrate or foam core substrate folded in a
serpentine
arrangement or plied to form layers with the carrier solvent with the active
cleaning formulation
disposed between adjacent layers of the water-soluble nonwoven core substrate,
for example. As
an example, the active cleaning formulation may include, without limitation, a
laundry detergent,
a soap, a fabric softener, a bleaching agent, a laundry booster, a stain
remover, an optical
brightener, or a water softener. Other examples include a dish detergent, soap
or cleaner, a
shampoo, a conditioner, a body wash, a face wash, a skin lotion, a skin
treatment, a body oil,
fragrance, a hair treatment, a bath salt, an essential oil, a bath bomb, or an
enzyme. In certain
example embodiments, the water-soluble core substrate is enclosed by a water-
soluble nonwoven
material, a water-soluble foam material, and/or a water-soluble film material.
Further, the carrier
solvent may include, without limitations, any suitable polar solvent, water,
polyols such as
glycerol, DPG, or any combination thereof. In example embodiments, the water-
soluble core
substrate includes a plurality of fibers including a water-soluble resin. Upon
contact of a suitable
amount of the carrier solvent, e.g., a saturation amount, with at least one
fiber of the plurality of
fibers, the at least one fiber exhibits a degree of shrinkage of 0.5% to 65%.
The example process
as disclosed herein to incorporate the active cleaning formulation in the
water-soluble core
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substrate facilitates preservation of active agents, such as enzymes, and
improves the overall
performance of the SUD articles.
[0021] As used herein and unless specified otherwise, the term "water-
dispersible" refers to
any nonwoven substrate (or nonwoven web), foam substrate, film, or laminate
wherein upon
submersion in water at a specified temperature, the nonwoven substrate, foam
substrate, film, or
laminate physically disassociates into smaller constituent pieces. The smaller
pieces may or may
not be visible to the naked eye, may or may not remain suspended in the water,
and may or may
not ultimately dissolve. In example embodiments wherein a dispersion
temperature is not
specified, the nonwoven substrate, foam substrate, film, or laminate will
disintegrate in 300
seconds or less at a temperature of about 100 C or less, according to MSTM-
205. For example,
the disintegration time optionally can be 200 seconds or less, 100 seconds or
less, 60 seconds or
less, or 30 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. For example,
such dispersion
parameters can be characteristic of a nonwoven substrate, foam substrate,
film, or laminate
structure having a thickness of 6 mil (about 152 p.m)
[0022] As used herein and unless specified otherwise, the term "water-soluble"
refers to any
nonwoven web, foam, film, or laminate having a dissolution time of 300 seconds
or less at a
specified temperature as determined according to MSTM-205 as set forth herein.
For example,
the dissolution time of the nonwoven web, foam, film, or laminate optionally
can be 200 seconds
or less, 100 seconds or less, 60 seconds or less, or 30 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. In embodiments wherein 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 no greater than about 80 C. In example embodiments, "water-soluble
film" means
that at a thickness of 1.5 mil, the film dissolves in 300 seconds or less at a
temperature no greater
than 80 C according to MSTM-205. For example, a 1.5 mil (about 38 t.tm) thick
water-soluble
film can 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 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.
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[0023] As used herein and unless specified otherwise, the term "cold water-
soluble" refers to
any water-soluble nonwoven web, foam, film, or laminate having a dissolution
time of 300
seconds or less at a temperature in a range of about 10 C to about 20 C as
determined according
to MSTM-205. For example, the dissolution time of the nonwoven web, foam,
film, or laminate
optionally can be 200 seconds or less, 100 seconds or less, 60 seconds or
less, or 30 seconds at a
temperature in a range of about 10 C to about 20 C according to MSTM-205. In
embodiments,
"cold water-soluble film" means that at a thickness of 1.5 mil (about 38 nm),
the film dissolves
in 300 seconds or less at a temperature not greater than 20 C according to
MSTM-205 For
example, a 1.5 mil (about 38 p.m) thick water-soluble film can 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 about 20 C or about 10 C according to MSTM-205.
[0024] As used herein and unless specified otherwise, the term "hot water-
soluble" refers to
any water-soluble nonwoven web, foam, film, or laminate having a dissolution
time of 300
seconds or less at a temperature greater than about 20 C, for example in a
range of about 21 C to
about 80 C, as determined according to MSTM-205. For example, the dissolution
time of the
nonwoven web, foam, film, or laminate optionally can be 200 seconds or less,
100 seconds or
less, 60 seconds or less, or 30 seconds at a temperature greater than about 20
C according to
MSTM-205, for example, in a range of 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 about 40 C,
or about 30 C to about 40 C. In example embodiments, -hot water-soluble film"
means that at a
thickness of 1.5 mil (about 38 p.m), the film dissolves in 300 seconds or less
at a temperature no
less than about 21 C according to MSTM-205. For example, a 1.5 mil (about 38
nm) thick
water-soluble film can 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
about 80 C, 70 C,
about 60 C, about 50 C, about 40 C, about 30 C, about 25 C, or about 21 C
according to
MSTM-205. In example embodiments, a hot water-soluble substrate, such as a
"hot water-
soluble nonwoven substrate" or a "hot water-soluble nonwoven web," remains
stable, e.g., does
not dissolve, when contacted with water having a temperature less than its hot
water-soluble
temperature but is soluble, e.g., dissolves, when contacted with water having
a temperature equal
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to its hot water-soluble temperature for a suitable dissolution time, e.g.,
not greater than 300
seconds.
[0025] As used herein and unless specified otherwise, the term "nonwoven web"
refers to a
web or sheet comprising, consisting of, or consisting essentially of fibers
arranged (e.g., by a
carding process) and bonded to each other. Thus, the term "nonwoven web- can
be considered
short hand for nonwoven fiber-based webs. Further, as used herein, "nonwoven
web" includes
any structure including a nonwoven web or sheet, including, for example, a
nonwoven web or
sheet having a film laminated to a surface thereof. Methods of preparing
nonwoven webs from
fibers are well known in the art, for example, as described in Nonwoven
Fabrics Handbook,
prepared by Ian Butler, edited by Subhash Batra et al., Printing by Design,
1999, herein
incorporated by reference in its entirety. As used herein and unless specified
otherwise, the term
"film" refers to a continuous film or sheet, e.g., prepared by a casting or
extrusion process.
[0026] As used herein, a "plurality of fibers- can consist of a sole fiber
type or can comprise
two or more different fiber types. In example embodiments wherein the
plurality of fibers
comprise two or more different fiber types, each fiber type can be included in
generally any
amount, for example, from about 0.5 wt.% to about 99.5 wt.% of the total
weight of the plurality
of fibers. In embodiments wherein the plurality of fibers consists of a sole
fiber type, the
plurality of fibers is substantially free of a second or more fiber types. A
plurality of fibers is
substantially free of a second or more fiber types when the plurality of
fibers comprise less than
about 0.5 wt.% of the second or more fiber types. In general, the difference
between fiber types
can be a difference in fiber length to diameter ratio (L/D), tenacity, shape,
rigidness, elasticity,
solubility, melting point, glass transition temperature (Tg), chemical
composition, color, or a
combination thereof.
[0027] As used herein, the terms "packet(s)" and "pouch(es)" should be
considered
interchangeable. In certain embodiments, the terms "packet(s)" and
"pouch(es)," respectively,
are used to refer to single unit dose articles including a water-soluble core
substrate containing
one or more active cleaning formulations. In certain embodiments, the pouches
are sealed with
an outer water-soluble material to enclose and contain the water-soluble core
substrate
containing the one or more active cleaning formulations. The sealed pouches
can be made using
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any suitable method, including such processes and features such as heat
sealing, solvent welding
or sealing, and/or adhesive sealing (e.g., with use of a water-soluble
adhesive).
[0028] As used herein, the terms "resin(s)" and "polymer(s)" should be
considered
interchangeable. In certain embodiments, the terms resin(s) and polymer(s),
respectively are used
to refer to a polymer optionally combined with one or more additional
polymers, and to a single
type of polymer, e.g., a resin can comprise more than one polymer.
[0029] As used herein and unless specified otherwise, the terms "wt.%" and
"wt%" are
intended to refer to the composition of the identified element in "dry" (non-
water) parts by
weight of the entire water-soluble film, for example, including residual
moisture in the water-
soluble film, or parts by weight of the entire composition, depending on
context.
[0030] As used herein and unless specified otherwise, the term "PHR" ("phr")
is intended to
refer to the composition of the identified element in parts per one hundred
parts water-soluble
polymer resin(s) (whether PVOH or other polymer resins, unless specified
otherwise) in the
water-soluble film, or a solution used to make the water-soluble film.
[0031] As used herein and unless specified otherwise, the term "comprising-
means that
various components, ingredients, or steps can be conjointly employed in
practicing the present
disclosure. Accordingly, the term "comprising- encompasses the more
restrictive terms
"consisting essentially of' and "consisting of" The present compositions can
comprise, consist
essentially of, or consist of any of the required and optional elements
disclosed herein. The
disclosure illustratively disclosed herein suitably may be practiced in the
absence of any element
or step which is not specifically disclosed herein.
[0032] When values are expressed as approximations, by use of the antecedent -
about,- it will
be understood that the particular value forms another embodiment. As used
herein, "about X"
(where X is a numerical value) in example embodiments refers to 10% (for
example, 5%) of
the recited value, inclusive.
[0033] The SUD articles, the water-soluble nonwoven materials, the water-
soluble foam
materials, and the water-soluble film materials, and related methods of making
and using the
SUD articles, the water-soluble nonwoven materials, the water-soluble foam
materials, and the
water-soluble film materials are contemplated to include embodiments including
any
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combination of one or more of the additional optional elements, features, and
steps further
described below, unless stated otherwise.
[0034] In example embodiments, the single unit dose article includes a water-
soluble core
substrate including a water-soluble resin. In example embodiments, the water-
soluble core
substrate includes one of more 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. The water-soluble core substrate contains a carrier
solvent with an active
cleaning formulation. Upon contact with a suitable amount of the carrier
solvent, e.g., a
saturation amount, the water-soluble core substrate exhibits a degree of
shrinkage of 0.5% to
65%. In example embodiments when the water-soluble core substrate includes a
water-soluble
nonwoven substrate including a plurality of fibers, the at least one fiber or
the core substrate
exhibits a degree of shrinkage of 0.5% to 65% upon contact with a suitable
amount of the carrier
solvent. In example embodiments, when the core substrate is contacted water
having a
temperature as low as 5 C to 10 C, the core substrate is dispersible, i e ,
disintegrates, to release
the active cleaning formulation. In example embodiments, when 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 example
embodiments, the active
cleaning formulation is in the form of at least one of a solid, e.g., a powder
or a plurality of
granules or particles, a gel, a liquid, or a slurry form, or any suitable
combination thereof. In
certain embodiments, the water-soluble core substrate is saturated with the
active cleaning
formulation. In other embodiments, the active cleaning formulation is embedded
in, coated on, or
adhered to the water-soluble core substrate, e.g., the active cleaning
formulation is disposed on a
surface of the water-soluble core substrate. In example embodiments, the water-
soluble core
substrate is at least one of coated with the active cleaning formulation or
impregnated with the
active cleaning formulation. In example embodiments, the active cleaning
formulation is present
in the water-soluble core substrate, e.g., present in the fiber-forming
composition, the foam-
forming composition, or the film-forming composition.
[0035] In example embodiments, the single unit dose article includes a water-
soluble
nonwoven material, a water-soluble foam material, or a water-soluble film
material, or a
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composite water-soluble material including a combination thereof, for example,
a water-soluble
film material laminated to a water-soluble nonwoven material or a water-
soluble foam material,
enclosing the water-soluble core substrate and/or the active cleaning
formulation. In example
embodiments, water-soluble outer material defines an interior volume in which
the water-soluble
core substrate and the active cleaning formulation is contained. A bonding
interface is configured
to create a seal to enclose the water-soluble core substrate and the active
cleaning formulation
within the interior volume. In certain embodiments, the water-soluble film is
laminated to the
water-soluble nonwoven material. For example, the water-soluble film is
disposed on a first
surface, e.g., an inner surface, of the water-soluble nonwoven material.
[0036] Referring to the Figures and, initially, to FIGS. 1-3, a single unit
dose article 20
includes a water-soluble nonwoven substrate 22 comprising a plurality of
fibers including a
water-soluble resin. In example embodiments, water-soluble nonwoven substrate
22 includes any
suitable fiber chemistry including, without limitation, PVOH fibers or PVOH
fibers blended with
up to 90 wt.% cellulose-type fibers. In alternative embodiments, the nonwoven
substrate is made
of water-dispersible fibers In example embodiments, water-soluble nonwoven
substrate 22 has a
basis weight of 15 gsm (grams per square meter) to 150 gsm, and, more
particularly, 30 gsm to
65 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable
fiber diameter. The
fibers of water-soluble nonwoven substrate 22 may be bonded using any suitable
method
including, without limitation, heat, thermal, chemical, water, or solution
bonding or any suitable
bonding method known in the art of nonwoven fiber bonding. As described below
and shown in
FIGS. 1-3, water-soluble nonwoven substrate 22 may include any suitable number
of layers or
plies, for example, 1 layer or ply to 50 layers or plies, or more in certain
embodiments. Water-
soluble nonwoven substrate 22 may be porous or non-porous and cold water-
soluble or hot
water-soluble. Water-soluble nonwoven substrate 22 may be formed using any
suitable
manufacturing process known in the nonwoven manufacturing art including,
without limitation,
a carded process. The construction of water-soluble substrate 22 may include,
for example,
folded layers or plies, stacked layers or plies, or rolled layers or plies.
[0037] As shown in FIGS. 1-3, in example embodiments, water-soluble nonwoven
substrate
22 includes a plurality of layers 24 For example, water-soluble nonwoven
substrate 22 may
include layers 24, 24n+i, 24n+2, 24n+3, etc. In example embodiments, water-
soluble nonwoven
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substrate 22 is a continuous sheet of a water-soluble nonwoven web folded in a
serpentine
construction to form the plurality of layers 24. In example alternative
embodiments, water-
soluble nonwoven substrate 22 includes a plurality of separate water-soluble
nonwoven substrate
sheets in a plied, stacked, or layered construction to form the plurality of
layers 24. In example
embodiments, each layer 24 may contain the same active cleaning formulation 26
or each layer
24 may contain a cleaning formulation 26 different from one or more other
layers 24. For
example, in particular embodiments, a first layer 24n contains protease, a
second layer 24n+1
contains amylase, a third layer 24n+2 contains lipase, a fourth layer 24n+3
contains a surfactant, a
fifth layer 24n+4 contains chelants, and a sixth layer 24n+5 contains a
builder.
[0038] In example embodiments, water-soluble nonwoven substrate 22 contains a
carrier
solvent 25 with an active cleaning formulation 26. In example embodiments,
active cleaning
formulation 26 is a liquid formulation. In example embodiments, upon contact
of a suitable
amount of carrier solvent 25, e.g., a saturation amount, with the water-
soluble nonwoven
substrate 22, e.g., one or more fibers of a plurality of fibers forming water-
soluble nonwoven
substrate 22, the one or more fibers exhibit the at least one fiber or the
nonwoven substrate
exhibits a degree of shrinkage of 0.5% to 65%. In example embodiments, the
fibers will have a
crystallinity of at least 25% and, more particularly, between 30% and 35%. In
example
embodiments, the carrier solvent 25 incudes any suitable polar solvent and may
include, without
limitation, water, polyols such as glycerol, DPG (dipropylene glycol), or any
combination
thereof. In other example embodiments, carrier solvent 25 is first disposed
on, e.g., coated on or
applied to, water-soluble nonwoven substrate 22 to shrink or swell the fibers
of water-soluble
nonwoven substrate 22 and then active cleaning formulation 26 is applied to
water-soluble
nonwoven substrate 22. In example embodiments, the carrier solvent 25 with the
active cleaning
formulation 26 facilitates containing the active cleaning in the core
substrate, such as water-
soluble nonwoven substrate 22, creating SUD article stability while
maintaining acceptable
detergency and solubility.
[0039] In example embodiments, when water-soluble nonwoven substrate 22 is
contacted with
water having a temperature of at least 10 C, water-soluble nonwoven substrate
22 is soluble to
release active cleaning formulation 26 from water-soluble nonwoven substrate
22. Further, when
water-soluble nonwoven substrate 22 is contacted with water having a
temperature of at least
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C for not more than 300 seconds, active cleaning formulation 26 is
substantially released
from water-soluble nonwoven substrate 22. In alternative embodiments, when a
water-
dispersible nonwoven substrate is contacted with water having a temperature
less than 10 C, the
water-dispersible nonwoven substrate is dispersible to release the active
cleaning formulation
from the water-dispersible nonwoven substrate. When the water-dispersible
nonwoven substrate
is contacted with water having a temperature less than 10 C for not more than
300 seconds, the
active cleaning formulation is substantially released from the water-
dispersible nonwoven
substrate.
[0040] Active cleaning formulation 26 may be in the form of a solid, e.g., a
powder or a
plurality of granules or particles, a gel, a liquid, or a slurry formulation,
or any suitable
combination of a powder, a solid, a gel, a liquid, or a slurry formulation,
for example. In example
embodiments, active cleaning formulation 26 is in any suitable phase
including, for example, a
solid phase, a liquid phase, a slurry phase (a liquid containing solids and
multiple phases), and
any suitable combination of phases. For example, active cleaning formulation
26 may include
fine powders or granules, gels, one or more liquids, or a slurry (e g , a
liquid containing solids
and multiple phases), or multiple phases. Active cleaning formulation may
include, without
limitation, detergents, surfactants, emulsifiers, chelants, dirt suspenders,
stain releasers, enzymes,
pH adjusters, builders, soil release polymers, structurants, free fragrance,
encapsulated fragrance,
preservatives, solvent, minerals, and/or any ingredients suitable in personal
care, laundry
detergent, dish detergent, and/or home surface cleaners or cleansers. In
example embodiments,
single unit dose article 20 includes active cleaning formulation having a mass
of 0.5 gram (g) to
250 grams and a volume of 1.0 milliliter (m1) to 250 ml. In embodiments
wherein active cleaning
formulation 26 is a solid phase, the particles or granules have a size of 1
micron to 100 microns,
or may be in tablet form.
[0041] In example embodiments, carrier solvent 25 with active cleaning
formulation 26 is
contained by water-soluble nonwoven substrate 22, for example, by saturating
water-soluble
nonwoven substrate 22 with carrier solvent 25 with active cleaning formulation
26, as shown in
FIGS. 1 and 2, by embedding carrier solvent 25 with active cleaning
formulation 26 in a matrix
of water-soluble nonwoven substrate 22, e.g., in one or more layers 24 of
water-soluble
nonwoven substrate 22, as shown in FIG. 3, and/or by disposing carrier solvent
25 with active
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cleaning formulation 26 between adjacent layers 24 of water-soluble nonwoven
substrate 22,
e.g., coating one or more surfaces of layer 24n, one or more surfaces of layer
2411+1, and/or one or
more surfaces of layer 24n+2, for example, with carrier solvent 25 with active
cleaning
formulation 26. Carrier solvent 25 with active cleaning formulation 26 may be
adsorbed in
and/or adhered or bonded to a surface of water-soluble nonwoven substrate 22,
for example. In
example embodiments such as shown in FIG. 1, single unit dose article 20
includes a multi-layer,
water-soluble nonwoven substrate 22, carrier solvent 25 with active cleaning
formulation 26 in a
liquid phase surrounding water-soluble nonwoven substrate 22, and water-
soluble nonwoven
material 28 enclosing and containing water-soluble nonwoven substrate 22,
carrier solvent 25,
and active cleaning formulation 26. In example embodiments, such as shown in
FIG. 2, single
unit dose article 20 includes a multi-layer, water-soluble nonwoven substrate
22 containing
carrier solvent 25 with active cleaning formulation 26 in a liquid phase, and
water-soluble
nonwoven material 28 enclosing and containing water-soluble nonwoven substrate
22 and carrier
solvent 25 with active cleaning formulation 26. In example embodiments, such
as shown in FIG.
3, single unit dose article 20 includes a multi-layer, water-soluble nonwoven
substrate 22
containing active cleaning formulation 26 in a solid phase, and water-soluble
nonwoven material
28 enclosing and containing water-soluble nonwoven substrate 22 and carrier
solvent 25 with
active cleaning formulation 26.
[0042] Referring further to FIGS. 1-3, in example embodiments, water-soluble
nonwoven
substrate 22 includes a plurality of fibers (detailed structures of fibers not
shown in FIGS. 1-3).
In example embodiments, one or more fibers of the plurality of fibers is
saturated with carrier
solvent 25 with active cleaning formulation 26. Carrier solvent 25 with active
cleaning
formulation 26 may be embedded in one or more of fibers of the plurality of
fibers or carrier
solvent 25 with active cleaning formulation 26 may be disposed on, e.g.,
coated on, a surface of
one or more fibers of the plurality of fibers.
[0043] In example embodiments, a water-soluble nonwoven material 28, as shown
in FIGS. 1-
3, for example, and/or a water-soluble film (see, for example, FIGS. 13 and
14) at least partially
encloses water-soluble nonwoven substrate 22 and defines an interior volume
32, in which
water-soluble nonwoven substrate 22 and carrier solvent 25 with active
cleaning formulation 26
are contained. For example, in certain embodiments, a water-soluble film (for
example, as
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described in FIGS. 13 and 14) is laminated to a first surface, e.g., an inner
surface, of water-
soluble nonwoven material 28. In example embodiments, water-soluble nonwoven
material 28
includes any suitable fiber chemistry including, without limitation, PVOH
fibers or PVOH fibers
blended with up to 90 wt.% cellulose-type fibers. In alternative embodiments,
the nonwoven
material is made of water-dispersible fibers. In example embodiments, 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, heat, thermal,
chemical, water,
or solution bonding or any suitable bonding method known in the art of
nonwoven fiber bonding.
Water-soluble nonwoven material 28 may include any suitable number of layers
or plies, for
example, 1 layer or ply to 50 layers or plies, or more in certain embodiments.
Water-soluble
nonwoven material 28 may be porous or non-porous and cold water-soluble or hot
water-soluble.
Water-soluble nonwoven material 28 may be formed using any suitable
manufacturing process
known in the nonwoven manufacturing art including, without limitation, a
carded process. The
construction of water-soluble material 28 may include, for example, folded
layers or plies,
stacked layers or plies, or rolled layers or plies. In example embodiments, a
first side or surface
may have a fibrous appearance and a second side or surface, e.g., opposing
first side or surface,
may be smooth or coated with water to create a continuous layer using heat
and/or water. The
first surface is the inner surface and the second surface is the outer surface
in certain
embodiments.
[0044] As shown in FIGS. 1-3, a bonding interface 34 is formed or configured
to create a seal
36 to enclose water-soluble nonwoven substrate 22 and carrier solvent 25 with
active cleaning
formulation 26 within interior volume 32. A suitable bonding interface or seal
36 may be formed
using a liquid, solvent, heat, chemical, through-air, or mechanical
entanglement (needle punch)
bond or seal 36. For example, as shown in FIG. 1, carrier solvent 25 with a
liquid active cleaning
formulation 26 is contained within interior volume 32.
[0045] Referring now to FIGS. 4 and 5, a single unit dose article 120 includes
a water-soluble
nonwoven substrate 122 comprising a water-soluble resin. In example
embodiments, water-
soluble nonwoven substrate 122 includes any suitable fiber chemistry
including, without
limitation, PVOH fibers or PVOH fibers blended with up to 90 wt.% cellulose-
type fibers. In
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alternative embodiments, the nonwoven substrate is made of water-dispersible
fibers. In example
embodiments, 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, heat, thermal, chemical, water, or solution bonding or any
suitable bonding
method known in the art of nonwoven fiber bonding. In example embodiments,
water-soluble
nonwoven substrate 122 may include any suitable number of layers or plies, for
example, 1 layer
or ply to 50 layers or plies, or more in certain embodiments. Water-soluble
nonwoven substrate
122 may be porous or non-porous and cold water-soluble or hot water-soluble.
Water-soluble
nonwoven substrate 122 may be formed using any suitable manufacturing process
known in the
nonwoven manufacturing art including, without limitation, a carded process.
The construction of
water-soluble nonwoven substrate 122 may include, for example, folded layers
or plies, stacked
layers or plies, rolled layers or plies, or a high loft nonwoven substrate.
[0046] In example embodiments, water-soluble nonwoven substrate 122 contains a
carrier
solvent 125 with an active cleaning formulation 126 In example embodiments,
when water-
soluble nonwoven substrate 122 is contacted with water having a temperature
greater than 20 C,
water-soluble nonwoven substrate 122 is soluble to release active cleaning
formulation 126.
Active cleaning formulation 126 may be in the form of a solid, a gel, a
liquid, or a slurry
formulation, or any suitable combination of a solid, a gel, a liquid, or a
slurry formulation, for
example. In example embodiments, such as shown in FIGS. 4 and 5, active
cleaning formulation
126 is in a solid phase, e.g., tablets, solid particles, granules, or fine
powders. Active cleaning
formulation 126 may include, without limitation, actives, detergents,
surfactants, emulsifiers,
chelants, dirt suspenders, stain releasers, enzymes, pH adjusters, builders,
soil release polymers,
structurants, free fragrance, encapsulated fragrance, preservatives, solvent,
minerals, and/or any
ingredients suitable in personal care, laundry detergent, dish detergent,
and/or home surface
cleaners or cleansers. In example embodiments, single unit dose article 120
includes active
cleaning formulation having a mass of 0.5 gram (g) to 250 grams and a volume
of 1.0 milliliter
(m1) to 250 ml, and a particle or granule size of 1.0 micron to 100 microns In
example
embodiments, carrier solvent 125 with active cleaning formulation 126 is
contained by water-
soluble nonwoven substrate 122, for example, by the solid particles or
granules of active
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cleaning formulation 126 being embedded or adsorbed in or bound to a surface
of water-soluble
nonwoven substrate 122, as shown in FIG. 4, and/or by the solid particles or
granules of active
cleaning formulation 126 being embedded, adsorbed, or bound within a matrix of
water-soluble
nonwoven substrate 122, as shown in FIG. 5. Example single unit dose article
120 is shown in
FIGS. 4 and 5 for demonstration purposes only. Water-soluble nonwoven
substrate 122, carrier
solvent 125, and active cleaning formulation 126 can be examples of or the
same as water-
soluble nonwoven substrate 22, carrier solvent 25, and active cleaning
formulation 26,
respectively, as described in FIGS. 1-3. Single unit dose article 120 as shown
in FIGS. 4 and 5
can be a part of single unit dose article 20, as shown in FIGS. 1-3.
[0047] Referring now to FIGS. 6-9, in example embodiments, a single unit dose
article 220
includes a water-soluble foam substrate 222 comprising a water-soluble resin.
In example
embodiments, water-soluble foam substrate 222 includes any suitable resin
chemistry, such as a
PVOH homopolymer; a PVOH copolymer; a modified PVOH copolymer such as maleic
anhydride (MA) modified PVOH copolymer, monomethyl maleate (M_MIV1) Modified
PVOH
copolymer, 2-acrylamido-2-methylpropanesulfonic acid (AMPS) Modified PVOH
copolymer,
cellulose and cellulose derivatives, polyvinylpyrrolidone (PVP), proteins,
casein, soy, or any
water-dispersible or water-soluble resin. In certain embodiments, water-
soluble foam substrate
222 has a thickness of 3 microns to 3000 microns and can be formed using any
suitable
manufacturing process known in the foam manufacturing art including, without
limitation, a cast,
extruded, melt processed, coated, chemically blown, mechanically aerated, air
injected, turbulent
extrusion process. Water-soluble foam substrate 222 may be porous or non-
porous and cold
water-soluble or hot water-soluble. The construction of water-soluble foam
substrate 222 may
include, for example, folded layers or plies, stacked layers or plies, or
rolled layers or plies.
[0048] Water-soluble foam substrate 222 is configured to contain a carrier
solvent 225 with an
active cleaning formulation 226. In example embodiments, upon contact of
carrier solvent 25
with water-soluble foam substrate 222, water-soluble foam substrate 222
exhibits a carrier
solvent absorptive capacity of 1% to 1300%. Further, when the water-soluble
foam substrate 222
is contacted with water having a temperature greater than 20 C, water-soluble
foam substrate
222 is soluble to release active cleaning formulation 226. In certain
embodiments, as shown in
FIGS. 6-8, a water-soluble nonwoven material 228 at least partially encloses
and contains water-
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soluble foam substrate 222 and carrier solvent 225 with active cleaning
formulation 226. Active
cleaning formulation 226 may be in the form of a solid, a liquid, a gel, or a
slurry formulation, or
any suitable combination of a solid, a liquid, a gel, or a slurry formulation,
for example. In
example embodiments, such as shown in FIGS. 6-9, active cleaning formulation
226 is in a solid
phase but, in certain embodiments, may be in any suitable phase including, for
example, a liquid
phase, a slurry phase (a liquid containing solids and multiple phases), and
any suitable
combination of phases. Active cleaning formulation may include, without
limitation, actives,
detergents, surfactants, emulsifiers, chelants, dirt suspenders, stain
releasers, enzymes, pH
adjusters, builders, soil release polymers, structurants, free fragrance,
encapsulated fragrance,
preservatives, solvent, minerals, and/or any ingredients suitable in personal
care, laundry
detergent, dish detergent, and/or home surface cleaners or cleansers. In
example embodiments,
single unit dose article 220 includes a structurant or an adhesive material
for holding solid,
liquid, or gel active cleaning formulations 226, which is bonded to water-
soluble foam substrate
222 to provide a barrier to the consumer's hand. In example embodiments,
single unit dose
article 220 includes active cleaning formulation 226 having a mass of 0.5 gram
(g) to 250 grams
and a volume of 1.0 milliliter (m1) to 250 ml. In example embodiments, such as
shown in FIGS.
7-9, active cleaning formulation 226 includes fine powder or granules having a
particle size of 1
micron to 100 microns, or solid active cleaning formulations 226 in tablet
form.
[0049] In example embodiments, carrier solvent 225 with active cleaning
formulation 226 is
contained by water-soluble foam substrate 222, for example, by saturating
water-soluble foam
substrate 222 with carrier solvent 225 with active cleaning formulation 226,
as shown in FIG. 6,
or by adhering, adsorbing, or bonding solid, e.g., powder or granules, carrier
solvent 225 with
active cleaning formulations 226 to a surface of water-soluble foam substrate
222, as shown in
FIGS. 7-9, or disposing or embedding carrier solvent 225 with active cleaning
formulation 226 in
one or more layers or surfaces, or a matrix of water-soluble foam substrate
222, e.g., coating one
or more surfaces with carrier solvent 225 with a solid active cleaning
formulation 226. In
example embodiments such as shown in FIG. 6, single unit dose article 20
includes water-soluble
foam substrate 222 and carrier solvent 225 with active cleaning formulation
226 contained in
water-soluble foam substrate 222, and a water-soluble nonwoven material 228
enclosing and
containing water-soluble foam substrate 222 and carrier solvent 225 with
active cleaning
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formulation 226. In example embodiments, such as shown in FIGS. 7 and 8,
single unit dose
article 220 includes water-soluble foam substrate 222 containing carrier
solvent 225 with active
cleaning formulation 226 in a solid phase, e.g., powder or granular form, and
water-soluble
nonwoven material 228 at least partially enclosing and containing water-
soluble foam substrate
222 and carrier solvent 225 with active cleaning formulation 226. In the
example shown in FIG.
7, a bonding interface 234 is formed or configured to create a seal 236 to
enclose water-soluble
foam substrate 222 and carrier solvent 225 with active cleaning formulation
226 within an
interior volume 232 of water-soluble nonwoven material 228. In example
embodiments, such as
shown in FIG. 9, single unit dose article 220 includes water-soluble foam
substrate 222
containing carrier solvent 225 with active cleaning formulation 226 in a solid
phase, e.g., a
powder or granular form, adhered or bonded to a surface of water-soluble foam
substrate 222,
without a water-soluble nonwoven material 228 enclosing water-soluble foam
substrate 222 and
carrier solvent 225 with active cleaning formulation 226. Example single unit
dose article 220 is
shown in FIGS. 6-9 for demonstration purposes only. Water-soluble nonwoven
substrate 222,
carrier solvent 225, active cleaning formulation 226, and water-soluble
nonwoven material 228
may be made of the same materials as water-soluble nonwoven substrate 22,
carrier solvent 25,
active cleaning formulation 26, and water-soluble nonwoven material 28,
respectively, as
described in FIGS. 1-3. Bonding interface 234 and seal 236 may be the same as
bonding
interface 34 and seal 36, respectively, as shown in FIGS. 1-3.
[0050] In example embodiments, a water-soluble nonwoven material 228, as shown
in FIGS.
6-8, for example, and/or a water-soluble film (see, for example, FIGS. 13 and
14) at least
partially encloses water-soluble foam substrate 222 defining an interior
volume 232 in which
water-soluble foam substrate 222 and carrier solvent 225 with active cleaning
formulation 226
are contained. For example, in certain embodiments, a water-soluble film is
laminated to a first
surface, e.g., an inner surface, of water-soluble nonwoven material 228. In
example
embodiments, water-soluble nonwoven material 228 includes any suitable fiber
chemistry, such
as PVOH fibers or PVOH fibers blended with up to 90 wt.% cellulose-type
fibers. In alternative
embodiments, the nonwoven material is made of water-dispersible fibers. In
example
embodiments, 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
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water-soluble nonwoven material 28 may be bonded using any suitable method
including,
without limitation, heat, thermal, chemical, water, or solution bonding or any
suitable bonding
method known in the art of nonwoven fiber bonding. Water-soluble nonwoven
material 228 may
include any suitable number of layers or plies, for example, 1 layer or ply to
50 layers or plies, or
more in certain embodiments. Water-soluble nonwoven material 228 may be porous
or non-
porous and cold water-soluble or hot water-soluble. Water-soluble nonwoven
material 228 may
be formed using any suitable manufacturing process known in the nonwoven
manufacturing art
including, without limitation, a carded process. The construction of water-
soluble material 228
may include, for example, folded layers or plies, stacked layers or plies, or
rolled layers or plies.
In example embodiments, a first side or surface may have a fibrous appearance
and a second side
or surface, e.g., opposing first side or surface, may be smooth or coated with
water to create a
continuous layer using heat and/or water.
[0051] In example embodiments such as shown in FIGS. 8 and 9, for example, a
single use
laundry bag or hamper liner includes a water-soluble foam substrate alone or
in combination
with a water-soluble film substrate and/or a water-soluble nonwoven substrate
containing a
suitable amount of one or more active cleaning formulations for washing a load
of laundry. The
active cleaning formulation may be embedded in or contained in the polymer
matrix of the
water-soluble foam substrate and/or disposed on one or more surfaces of the
water-soluble foam
substrate. The consumer can simply place the laundry bag or hamper liner
containing dirty
laundry into the washing machine and start the washing cycle. In example
embodiments, the
water-soluble single use laundry bag or hamper liner dissolves complete, or
otherwise disperse to
release the active cleaning formulations to clean the dirty laundry. In other
example
embodiments, a single unit dose article, e.g., in the form of tag or sticker,
may be sewn on or
otherwise adhered to an article of clothing to be cleaned. The consumer may
benefit from a high
performance cleaning ability to separate otherwise incompatible cleaning
agents or actives,
natural or more sustainable appearance, and convenience.
[0052] Referring now to FIG. 10, in example embodiments, a single unit dose
article 320
includes a carrier solvent 325 with an active cleaning formulation 326. Active
cleaning
formulation 326 may be in the form of a solid, a powder or granules, a gel, a
liquid, or a slurry
formulation, or any suitable combination of a powder, a solid, a liquid, or a
slurry formulation,
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for example. In example embodiments, such as shown in FIG. 10, active cleaning
formulation
326 is in a solid phase including a plurality of solid particles or granules
but, in certain
embodiments, active cleaning formulation 326 may be in any suitable phase
including, for
example, a liquid phase, a slurry phase (a liquid containing solids and
multiple phases), or any
suitable combination of phases. Active cleaning formulation may include,
without limitation,
actives, detergents, surfactants, emulsifiers, chelants, dirt suspenders,
stain releasers, enzymes,
pH adjusters, builders, soil release polymers, structurants, free fragrance,
encapsulated fragrance,
preservatives, solvent, minerals, and/or any ingredients suitable in personal
care, laundry
detergent, dish detergent, and/or home surface cleaners or cleansers. In
example embodiments,
single unit dose article 20 includes active cleaning formulation having a mass
of 0.5 gram (g) to
250 grams and a volume of 1.0 milliliter (m1) to 250 ml. In example
embodiments, active
cleaning formulation 326 includes a plurality of fine powder particles or
granules having a
particle size of 1 micron to 100 microns or tablet form. The particles,
granules, or tablets in
active cleaning formulation 326 may have different particle sizes in one or
dual particle size
distribution, for example.
[0053] In example embodiments, a water-soluble nonwoven material 328, as shown
in FIG.
10, for example, and/or a water-soluble film (see, for example, FIGS. 13 and
14) defines an
interior volume 332 to contain carrier solvent 325 with active cleaning
formulation 326. In
example embodiments, water-soluble nonwoven material 328 includes any suitable
fiber
chemistry, such as PVOH fibers or PVOH fibers blended with up to 90 wt%
cellulose-type
fibers. In alternative embodiments, the nonwoven material is made of water-
dispersible fibers. In
example embodiments, 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, heat, thermal, chemical, water, or solution
bonding or any suitable
bonding method known in the art of nonwoven fiber bonding. Water-soluble
nonwoven material
328 may include any suitable number of layers or plies, for example, 1 layer
or ply to 50 layers
or plies, or more in certain embodiments. Water-soluble nonwoven material 328
may be porous
or non-porous and cold water-soluble or hot water-soluble. Water-soluble
nonwoven material
328 may be formed using any suitable manufacturing process known in the
nonwoven
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manufacturing art including, without limitation, a carded process. The
construction of water-
soluble material 328 may include, for example, folded layers or plies, stacked
layers or plies, or
rolled layers or plies. In example embodiments, a first side or surface may
have a fibrous
appearance and a second side or surface, e.g., opposing first side or surface,
may be smooth or
coated with water to create a continuous layer using heat and/or water.
[0054] As shown in FIG. 10, a bonding interface 334 is formed or configured to
create a seal
336 to enclose carrier solvent 325 with active cleaning formulation 326 within
interior volume
332. A suitable bonding interface 334 or seal 336 may be formed using a
liquid, solvent, heat,
chemical, through-air, or mechanical entanglement (needle punch) bond or seal
336. In example
embodiments, when water-soluble nonwoven material 328 is contacted with water
having a
temperature greater than 20 C, water-soluble nonwoven material 328 is soluble
to release active
cleaning formulation 326. Example single unit dose article 320 is shown in
FIG. 10 for
demonstration purposes only. Carrier solvent 325, active cleaning formulation
326, and water-
soluble nonwoven material 328 may be made of the same materials as carrier
solvent 25, active
cleaning formulation 26, and water-soluble nonwoven material 28, respectively,
as described in
FIGS. 1-3. Bonding interface 334 and seal 336 may be the same as bonding
interface 34 and seal
36, respectively, as shown in FIGS. 1-3. The particles, granules, or tablets
in active cleaning
formulation 326 having different particle sizes in one or dual particle size
distribution, for
example, are also applicable to single unit dose article 20 shown in FIGS. 1-
3.
[0055] As shown in FIGS. 11 and 12, a single unit dose article 420 includes a
water-soluble
nonwoven material 428 having a first water-soluble nonwoven web 428a including
a first water-
soluble resin and an opposing second water-soluble nonwoven web 428b, the same
or different
than the first water-soluble nonwoven web, including a second water-soluble
resin. An active
cleaning formulation 426 is disposed between the first water-soluble nonwoven
web and the
second water-soluble nonwoven web, wherein, when the first water-soluble
nonwoven web
and/or the second water-soluble nonwoven web is contacted with water having a
temperature
greater than 20 C, the first water-soluble nonwoven web and/or the second
water-soluble
nonwoven web is soluble to release the active cleaning formulation. A water-
soluble film
substrate 422 disposed between the first water-soluble nonwoven web 428a and
the second
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water-soluble nonwoven web 428b, and carrier solvent 425 with an active
cleaning formulation
426 is disposed on a surface of, e.g., embedded in or bonded to, water-soluble
film substrate 422.
[0056] In example embodiments, water-soluble film substrate 422 includes a
water-soluble
resin. In example embodiments, water-soluble film substrate 422 includes any
suitable
chemistry, such as a PVOH homopolymer, a PVOH copolymer, MA modified PVOH
copolymer, M1VIA/1 Modified PVOH copolymer, AMPS Modified PVOH copolymer,
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 foam
manufacturing art
including, without limitation, a cast, extruded, melt processed, coated
process. Water-soluble
film substrate 422 may be cold water-soluble or hot water-soluble. In example
embodiments,
water-soluble film substrate 422 includes a suitable structurant or an
adhesive material to hold or
bond a solid, liquid, and/or gel active cleaning formulation 426 to water-
soluble film substrate
422.
[0057] In example embodiments, water-soluble film substrate 422 contains
carrier solvent 425
with active cleaning formulation 426. In example embodiments, when water-
soluble film
substrate 422 is contacted with water having a temperature greater than 20 C,
water-soluble film
substrate 422 is soluble to release active cleaning formulation 426. Active
cleaning formulation
426 may be in the form of a solid, e.g., fine powder or granules, a powder, a
liquid, or a slurry
formulation, or any suitable combination of a solid, e.g., fine powder or
granules, a liquid, or a
slurry formulation, for example. In example embodiments, such as shown in
FIGS. 11 and 12,
active cleaning formulation 426 is in a solid phase, but may be in any
suitable phase including,
for example, a liquid phase, a slurry phase (a liquid containing solids and
multiple phases), and
any suitable combination of phases. Active cleaning formulation may include,
without limitation,
actives, detergents, surfactants, emulsifiers, chelants, dirt suspenders,
stain releasers, enzymes,
pH adjusters, builders, soil release polymers, structurants, free fragrance,
encapsulated fragrance,
preservatives, solvent, minerals, and/or any ingredients suitable in personal
care, laundry
detergent, dish detergent, and/or home surface cleaners or cleansers. In
example embodiments,
single unit dose article 20 includes active cleaning formulation having a mass
of 0.5 gram (g) to
250 grams and a volume of 1.0 milliliter (m1) to 250 ml. In example
embodiments, active
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cleaning formulation 426 includes a fine powder or granules having a particle
size of 1 micron to
100 microns or tablet form. The powder or granules may have different sizes
with a particle size
distribution or bimodal particle size distribution, for example.
[0058] In example embodiments such as shown in FIGS. 11 and 12, single unit
dose article
420 includes water-soluble film substrate 422 and carrier solvent 425 with
active cleaning
formulation 426 in a solid phase adhered, adsorbed, or bound to a surface of
water-soluble film
substrate 422, and water-soluble nonwoven material 428 at least partially
enclosing and
containing water-soluble film substrate 422 and carrier solvent 425 with
active cleaning
formulation 426. In example embodiments, such as shown in FIG. 11, single unit
dose article
420 includes water-soluble film substrate 422 containing carrier solvent 425
with active cleaning
formulation 426 in a solid phase, and water-soluble nonwoven material 428
enclosing and
containing water-soluble film substrate 422 with carrier solvent 425 with
active cleaning
formulation 426. In example embodiments, such as shown in FIG. 12, single unit
dose article
420 includes water-soluble film substrate 422 containing carrier solvent 425
with active cleaning
formulation 426 in a solid phase, and water-soluble nonwoven material 428
partially enclosing
and containing water-soluble film substrate 422 with carrier solvent 425 with
active cleaning
formulation 426. Example single unit dose article 420 is shown in FIG. 10 for
demonstration
purposes only. Carrier solvent 425, active cleaning formulation 426, and water-
soluble
nonwoven material 428 may be made of the same materials as carrier solvent 25,
active cleaning
formulation 26, and water-soluble nonwoven material 28, respectively, as
described with
reference to FIGS. 1-3.
[0059] In example embodiments, water-soluble nonwoven material 428 includes
any suitable
fiber chemistry, such as PVOH fibers or PVOH fibers blended with up to 90 wt
,% cellulose-type
fibers. In alternative embodiments, the nonwoven material is made of water-
dispersible fibers. In
example embodiments, 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, heat, thermal, chemical, water, or solution
bonding or any suitable
bonding method known in the art of nonwoven fiber bonding. Water-soluble
nonwoven material
428 may include any suitable number of layers or plies, for example, 1 layer
or ply to 50 layers
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or plies, or more in certain embodiments. Water-soluble nonwoven material 428
may be porous
or non-porous and cold water-soluble or hot water-soluble. Water-soluble
nonwoven material
428 may be formed using any suitable manufacturing process known in the
nonwoven
manufacturing art including, without limitation, a carded process. The
construction of water-
soluble nonwoven material 428 may include, for example, folded layers or
plies, stacked layers
or plies, or rolled layers or plies. In example embodiments, a first side or
surface may have a
fibrous appearance and a second side or surface, e.g., opposing first side or
surface, may be
smooth or coated with water to create a continuous layer using heat and/or
water. The first
surface may be an interior surface and the second surface may be an exterior
surface of single
unit dose article 420 in certain embodiments.
[0060] As shown in FIG. 11, a bonding interface 434 is formed or configured to
create a seal
436 to enclose water-soluble film substrate 422 and carrier solvent 425 with
active cleaning
formulation 426 within an interior volume 432 defined by water-soluble
nonwoven material 428.
A suitable bonding interface or seal 436 may be formed using a liquid,
solvent, heat, chemical,
through-air, or mechanical entanglement (needle punch) bond or seal 436
Bonding interface 434
and seal 436 may be the same as bonding interface 34 and seal 36,
respectively, as shown in
FIGS. 1-3
[0061] Referring now to FIGS. 13 and 14, a single unit dose article 520
includes a water-
soluble composite material 528 including, for example, a water-soluble film
522 material made
of a water-soluble resin, as described herein, coupled, bonded, or laminated
to a water-soluble
nonwoven material 527 or a water-soluble foam material 529 made of water-
soluble resin, as
described herein. For example, as shown in FIG. 13, water-soluble composite
material 528
includes a water-soluble nonwoven web 527 having a first surface 527a facing
interior volume
532 and an opposing second surface 527b, e.g., an outer surface, with a water-
soluble film
material 522 disposed on the first surface. Water-soluble composite material
528 is bonded at a
bonding interface 534 along an edge of the water-soluble material to define an
interior volume
532 of single unit dose article 520. A seal 536 is also formed. An active
cleaning formulation
526 is disposed in interior volume 532. In example embodiments, when water-
soluble composite
material 528 is contacted with water having a temperature greater than 20 C,
at least a portion of
water-soluble composite material 528 is soluble to release active cleaning
formulation 526.
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[0062] In example embodiments, as shown in FIG. 13, for example, the water-
soluble
nonwoven material 527 of water-soluble composite material 528 includes any
suitable fiber
chemistry, such as PVOH fibers or PVOH fibers blended with up to 90 wt.%
cellulose-type
fibers. In alternative embodiments, the nonwoven material 527 is made of water-
dispersible
fibers. In example embodiments, 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, heat, thermal, chemical, water, or
solution bonding or any
suitable bonding method known in the art of nonwoven fiber bonding. The water-
soluble
nonwoven material 527 may include any suitable number of layers or plies, for
example, 1 layer
or ply to 50 layers or plies, or more in certain embodiments. The water-
soluble nonwoven
material 527 may be porous or non-porous and cold water-soluble or hot water-
soluble. The
water-soluble nonwoven material may be formed using any suitable manufacturing
process
known in the nonwoven manufacturing art including, without limitation, a
carded process. The
construction of the water-soluble nonwoven material may include, for example,
folded layers or
plies, stacked layers or plies, or rolled layers or plies. In example
embodiments, a first side or
surface may have a fibrous appearance and a second side or surface, e.g.,
opposing first side or
surface, may be smooth or coated with water to create a continuous layer using
heat and/or
water.
[0063] In example embodiments, as shown in FIG. 14, for example, the water-
soluble foam
substrate 529 of water-soluble composite material 528 includes any suitable
resin chemistry,
such as a homopolymer, MA modified PVOH copolymer, MMIN4 Modified PVOH
copolymer,
AMPS Modified PVOH copolymer, 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 formed using any suitable
manufacturing
process known in the foam manufacturing art including, without limitation, a
cast, extruded, melt
processed, coated, chemically blown, mechanically aerated, air injected,
turbulent extrusion
process. The water-soluble foam material 529 may be porous or non-porous and
cold water-
soluble or hot water-soluble. The construction of the water-soluble foam
material 529 may
include, for example, folded layers or plies, stacked layers or plies, or
rolled layers or plies.
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[0064] In example embodiments, carrier solvent 525 with active cleaning
formulation 526
may be in the form of a solid, e.g., a powder or granules, a liquid, or a
slurry formulation, or any
suitable combination of a solid, a liquid, or a slurry formulation, for
example. In example
embodiments, such as shown in FIGS. 13 and 14, active cleaning formulation 526
is in a liquid
phase but, in certain embodiments, may be in any suitable phase including, for
example, a liquid
phase, a slurry phase (a liquid containing solids and multiple phases), a
solid phase, and any
suitable combination of phases. Active cleaning formulation may include,
without limitation,
actives, detergents, surfactants, emulsifiers, chelants, dirt suspenders,
stain releasers, enzymes,
pH adjusters, builders, soil release polymers, structurants, free fragrance,
encapsulated fragrance,
preservatives, solvent, minerals, and/or any ingredients suitable in personal
care, laundry
detergent, dish detergent, and/or home surface cleaners or cleansers. In
example embodiments,
single unit dose article 520 includes active cleaning formulation 526 having a
mass of 0.5 gram
(g) to 250 grams and a volume of 1.0 milliliter (m1) to 250 ml. In example
embodiments, active
cleaning formulation 526 includes a fine powder or granules having a particle
size of 1 micron to
100 microns or tablet form.
[0065] In example embodiments such as shown in FIG. 13, single unit dose
article 520
includes carrier solvent 525 with active cleaning formulation 526 in a liquid
phase contained
within water-soluble composite material 528 including a water-soluble film
material laminated to
a water-soluble nonwoven material enclosing and containing carrier solvent 525
with active
cleaning formulation 526. In example embodiments, such as shown in FIG. 14,
single unit dose
article 520 includes carrier solvent 525 with active cleaning formulation 526
in a liquid phase
contained within water-soluble composite material 528 including a water-
soluble film material
laminated to a water-soluble foam material enclosing and containing carrier
solvent 525 with
active cleaning formulation 526. FIGS. 13 and 14 are shown for demonstration
purposes. Carrier
solvent 525 and active cleaning formulation 526 may be the same as those
described with
reference to FIGS. 2-12. Carrier solvent 525 and active cleaning formulation
526 may also be
adsorbed on, embedded in, or loaded, applied or layered between one or more
layers of water-
soluble core substrates, such as nonwoven, foam and/or film, with one of the
configurations
described with reference to FIGS. 2-12 inside the pouch.
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[0066] In example embodiments, a single unit dose article includes a water-
soluble nonwoven
material, for example, and/or a water-soluble film defines an interior volume
to contain an active
cleaning formulation. In example embodiments, the water-soluble nonwoven
material includes
any suitable fiber chemistry, such as PVOH fibers or PVOH fibers blended with
up to 90 wt%
cellulose-type fibers. In alternative embodiments, the nonwoven material is
made of water-
dispersible fibers. In example embodiments, 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, heat, 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, 1 layer or
ply to 50 layers or plies, or more in certain embodiments. The water-soluble
nonwoven material
may be porous or non-porous and cold water-soluble or hot water-soluble. The
water-soluble
nonwoven material may be formed using any suitable manufacturing process known
in the
nonwoven manufacturing art including, without limitation, a carded process.
The construction of
the water-soluble material may include, for example, folded layers or plies,
stacked layers or
plies, or rolled layers or plies. In example embodiments, a first side or
surface may have a
fibrous appearance and a second side or surface, e.g., opposing first side or
surface, may be
smooth or coated with water to create a continuous layer using heat and/or
water.
[0067] In example embodiments, the active cleaning formulation is in the form
of a solid, e.g.,
a powder, but the active cleaning formulation may be in the form of a gel, a
liquid, or a slurry
formulation, or any suitable combination of a solid, a liquid, or a slurry
formulation, for example.
The active cleaning formulation may include, without limitation, actives,
detergents, surfactants,
emulsifiers, chelants, dirt suspenders, stain releasers, enzymes, pH
adjusters, builders, soil
release polymers, structurants, free fragrance, encapsulated fragrance,
preservatives, solvent,
minerals, and/or any ingredients suitable in personal care, laundry detergent,
dish detergent,
and/or home surface cleaners or cleansers. In example embodiments, the single
unit dose article
includes the active cleaning formulation having a mass of 0.5 gram (g) to 250
grams and a
volume of 1.0 milliliter (m1) to 250 ml. In example embodiments, the active
cleaning formulation
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includes a plurality of fine powder particles or granules having a particle
size of 1 micron to 100
microns or tablet form.
[0068] A bonding interface 534 is formed or configured to create a seal 536 to
enclose the
active cleaning formulation within the interior volume. A suitable bonding
interface or seal may
be formed using a liquid, solvent, heat, chemical, through-air, or mechanical
entanglement
(needle punch) bond or seal. In example embodiments, 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 volume.
[0069] A consumer is able to place one or more single unit dose articles,
e.g., single unit dose
article 20, 120, 220, 320, 420, or 520, into a washing vessel, such as washer
or wash basin, for
example, to deliver or introduce an active cleaning formulation, e.g., active
cleaning formulation
26, 126, 226, 326, 426, 526, into the washing vessel to wash a person's body
or articles
including, without limitation, clothes, dishes, and/or surfaces. In example
embodiments, the
materials of the single unit dose article dissolve completely or substantially
completely, or
otherwise disperses without negatively affecting a perceived appearance of
cleanliness by the
consumer. In certain example embodiments, the single unit dose article is
coupled to or attached
to, e.g., sewn on or adhered to, an article, such as a piece of clothing, to
be cleaned. Other
examples include a single unit dose article in the form of a tag attached to
clothing or a sticker
adhesively coupled to a surface to be cleaned.
[0070] Further, the single unit dose article 520 may be configured as a bag or
a container for
dirty articles for unit washing, and an overall simplified washing process,
e.g., a laundry bag
containing an active cleaning formulation. The laundry bag containing the
dirty articles can be
placed in the washing machine and will dissolve completely or substantially
completely, or
otherwise disperse, as the dirty articles are being washed. Consumer perceived
benefits of the
single unit dose article include, for example, high performance cleaning,
ability to physically
separate otherwise incompatible cleaning agents, a natural and more
sustainable appearance,
convenience, and/or product differentiation and novelty.
[0071] Referring now to FIG. 15, in example embodiments, a method 600 for
making a single
unit dose article containing a carrier solvent with an active cleaning
formulation includes any or
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all of steps 602, 604, 606, and 608. At step 602, a water-soluble core
substrate comprising a
water-soluble resin is formed. In example embodiments, forming a water-soluble
core substrate
comprising a water-soluble resin, the water-soluble core substrate containing
a carrier solvent
with 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 example
embodiments, the water-soluble nonwoven substrate is formed into a plurality
of layers with the
carrier solvent with the 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 a
water-soluble nonwoven web in a serpentine construction or by stacking a
plurality of separate
substrate sheets in a plied construction, for example.
[0072] The water-soluble core substrate contains a carrier solvent with an
active cleaning
formulation, such as described herein. In example embodiments, the water-
soluble core substrate
is saturated with the 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, a
surface of the water-soluble core substrate is coated with the carrier solvent
with the active
cleaning formulation, the carrier solvent with the active cleaning formulation
is embedded in the
water-soluble core substrate, and/or the water-soluble core substrate is
impregnated with the
carrier solvent with the active cleaning formulation.
[0073] In example embodiments, method 600 includes applying the carrier
solvent comprising
glycerol with the active cleaning formulation to a surface of the water-
soluble nonwoven sheet,
e.g., a 30 gsm water-soluble nonwoven sheet, to a maximum coat weight of 120
gsm for the
carrier solvent with the active cleaning formulation, which limits an amount
of active cleaning
formulation that can be applied to each water-soluble nonwoven sheet and
dictates the number of
plies of water-soluble nonwoven sheets required to construct the water-soluble
core substrate.
The carrier solvent comprising a maximum amount of solvent, e.g., 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
example embodiments, the water-soluble nonwoven substrate is formed into a
number of layers
such that the single unit dose article comprises 55% by weight of the active
cleaning formulation.
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[0074] In example embodiments, method 600 includes forming a water-soluble
core substrate
comprising a plurality of fibers including a water-soluble resin. The water-
soluble core substrate
contains a carrier solvent with an active cleaning formulation. Upon contact
of the carrier solvent
with at least one fiber of the plurality of fibers, the at least one fiber or
the water-soluble core
substrate exhibits a degree of shrinkage of 0.5% to 65%. In example
embodiments, method 600
includes contacting the carrier solvent with the water-soluble solid
substrate, wherein upon
contact with the carrier solvent, the at least one fiber or the substrate
exhibits a degree of
shrinkage of 0.5% to 65%. In example embodiments, 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. Further,
when the water-soluble core substrate is contacted with water having a
temperature of at least
C for not more than 300 seconds, the active cleaning formulation is
substantially released
from the water-soluble core substrate.
[0075] At step 604, an outer water-soluble material is formed into an open
pouch defining an
interior volume configured to contain the water-soluble core substrate and the
carrier solvent
with the active cleaning formulation. The outer water-soluble material
includes a water-soluble
nonwoven material, a water-soluble foam material, a water-soluble film
material, or a composite
material including a water-soluble nonwoven material, a water-soluble foam
material, and/or a
water-soluble film material. In example embodiments, the outer water-soluble
material includes
a dispersible barrier coating layer on an inner surface of the outer water-
soluble material facing
the water-soluble core substrate, e.g., formed of a film layer, formed by
bonding the inner
surface of the outer water-soluble material to form a substantially continuous
smooth surface, or
formed by applying a wax coating or a hydrophobic material to the inner
surface of the outer
water-soluble material. Any suitable dispersible barrier coating is applied to
the outer water-
soluble material to facilitate decreasing hand transfer of the active cleaning
formulation, e.g.,
laundry detergent, to a hand of user. At step 606, the water-soluble core
substrate and the carrier
solvent with the active cleaning formulation are introduced into the interior
volume. In example
embodiments, at step 608, the outer water-soluble material is sealed to
enclose the interior
volume. For example, a seal is formed at a bonding interface to enclose the
water-soluble core
substrate and the active cleaning formulation in the interior volume.
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[0076] In example embodiments, forming a water-soluble core substrate
comprising a plurality
of fibers including a water-soluble resin comprises forming a water-soluble
nonwoven substrate
into a plurality of layers, with the carrier solvent and the active cleaning
formulation disposed
between adjacent layers of the plurality of layers. In example embodiments, a
continuous sheet
of a water-soluble nonwoven web is folded in a serpentine construction to form
the plurality of
layers or a plurality of separate substrate sheets is stacked in a plied
construction. A carrier
solvent comprising glycerol with the active cleaning formulation is applied to
a surface of the
water-soluble nonwoven substrate to a maximum coat weight of 120 gsm for the
carrier solvent
with the active cleaning formulation until the single unit dose article
comprises 55% by weight
of the active cleaning formulation, for example. In example embodiments, the
water-soluble
nonwoven substrate is formed into 25 layers to 110 layers.
[0077] In example embodiments, a method for making a single unit dose article
containing a
carrier solvent with an active cleaning formulation includes forming a water-
soluble foam
substrate including a water-soluble resin. The water-soluble foam substrate
contains 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
absorptive capacity of 1% to 1300%. For example, the water-soluble foam
substrate exhibits a
carrier solvent absorptive capacity in a range of from 10% to 1000%, from 10%
to 500%, from
10% to 200%, or from 10% to 100%. In example embodiments, 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 material thereof, is formed into
an open pouch
defining an interior volume configured to contain the water-soluble foam
substrate and the
carrier solvent with the active cleaning formulation. The water-soluble foam
substrate and the
carrier solvent with the active cleaning formulation are introduced into the
interior volume and,
in example embodiments, the outer water-soluble material is sealed to enclose
the interior
volume.
Water-Soluble Film and Fiber-Forming Materials
[0078] Water-soluble polymers for use in the water-soluble fibers, water-
soluble nonwoven
webs, water-soluble foams, and water-soluble films include, but are not
limited to, a polyvinyl
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alcohol (PVOH) polymer, polyacrylate, water-soluble acrylate copolymer,
polyvinyl pyrrolidone,
polyethyleneimine, pullulan, water-soluble natural polymers including, but not
limited to, guar
gum, gum Acacia, xanthan gum, carrageenan, and starch, water-soluble polymer
derivatives
including, but not limited to, modified starches, ethoxylated starch, and
hydroxypropylated
starch, copolymers of the forgoing and combinations of any of the foregoing.
Other water-
soluble polymers can include polyalkylene oxides, polyacrylamides, polyacrylic
acids and salts
thereof, celluloses, cellulose ethers, cellulose esters, cellulose amides,
polyvinyl acetates,
polycarboxylic acids and salts thereof, polyaminoacids, polyami des,
gelatines, methyl cellul oses,
carboxymethylcelluloses and salts thereof, dextrins, ethylcelluloses,
hydroxyethyl celluloses,
hydroxypropyl methylcelluloses, maltodextrins, polymethacrylates, and
combinations of any of
the foregoing. Such water-soluble polymers, whether PVOH polymers or
otherwise, are
commercially available from a variety of sources.
[0079] In general, the fibers, foams, and films as described herein include
polyvinyl alcohol.
Polyvinyl alcohol is a synthetic polymer generally prepared by the
alcoholysis, usually termed
"hydrolysis" or "saponification," of polyvinyl acetate Fully hydrolyzed PVOH,
where virtually
all the acetate groups have been converted to alcohol groups, is a strongly
hydrogen-bonded,
highly crystalline polymer which dissolves only in hot water - greater than
about 140 F (about
60 C). If a sufficient number of acetate groups are allowed to remain after
the hydrolysis of
polyvinyl acetate, that is the PVOH polymer is partially hydrolyzed, then the
polymer is more
weakly hydrogen-bonded, less crystalline, and is generally soluble in cold
water - less than about
50 F (about 10 C). As such, the partially hydrolyzed polymer is a vinyl
alcohol-vinyl acetate
copolymer that is a PVOH copolymer, but is commonly referred to as PVOH.
[0080] In certain embodiments, suitable examples of such a polymer include,
without
limitation, a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, a
modified
polyvinyl alcohol copolymer, and combinations thereof. For example, the
polyvinyl alcohol
copolymer is a copolymer of vinyl acetate and vinyl alcohol in some
embodiments. For example,
in some embodiments, the modified polyvinyl alcohol copolymer comprises an
anionically
modified copolymer, which may be a copolymer of vinyl acetate and vinyl
alcohol further
comprising additional groups, such as a carboxylate, a sulfonate, or
combinations thereof. As
such, the partially hydrolyzed polymer is a vinyl alcohol-vinyl acetate
copolymer that is a PVOH
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copolymer, but is commonly referred to as "polyvinyl alcohol (PVOH)" or "PVOH
polymer."
For brevity, the term "PVOH polymer" used herein is understood to encompass a
homopolymer,
a copolymer, and a modified copolymer comprising vinyl alcohol moieties, for
example, 50% or
higher of vinyl alcohol moieties. The term "PVOH fiber" used herein refers to
fiber comprising a
PVOH polymer.
[0081] The fibers, foams, and/or films described herein can include one or
more polyvinyl
alcohol (PVOH) homopolymers, one or more polyvinyl alcohol copolymers, one or
more
modified polyvinyl alcohol copolymers, or a combination thereof. As used
herein, the term
"homopolymer" generally includes polymers having a single type of monomeric
repeating unit
(e.g., a polymeric chain consisting of or consisting essentially of a single
monomeric repeating
unit). For the particular case of PVOH, the term "PVOH polymer") further
includes copolymers
consisting of a distribution of vinyl alcohol monomer units and vinyl acetate
monomer units,
depending on the degree of hydrolysis (e.g., a polymeric chain consisting of
or consisting
essentially of vinyl alcohol and vinyl acetate monomer units). In the limiting
case of 100%
hydrolysis, a PVOH homopolymer can include a true homopolymer having only
vinyl alcohol
units. In some embodiments, the fibers, foams, and/or films of the disclosure
include polyvinyl
alcohol copolymers. In some embodiments, the fibers, foams, and/or films of
the disclosure
include cold-water soluble or hot water-soluble polyvinyl alcohol copolymers.
[0082] Unless expressly indicated otherwise, the term "degree of hydrolysis"
is understood as
a percentage (e.g., a molar percentage) of hydrolyzed moieties among all
hydrolyzable moieties
of an initial polymer. For example, for a polymer comprising at least one of a
vinyl acetate
moiety or a vinyl alcohol moiety, partial replacement of an ester group in
vinyl acetate moieties
with a hydroxyl group occurs during hydrolysis, and a vinyl acetate moiety
becomes a vinyl
alcohol moiety. The degree of hydrolysis of a polyvinyl acetate homopolymer
may be considered
as zero, while the degree of hydrolysis of a polyvinyl alcohol homopolymer may
be considered
100%. The degree of hydrolysis of a copolymer of vinyl acetate and vinyl
alcohol is equal to a
percentage of vinyl alcohol moieties among a total of vinyl acetate and vinyl
alcohol moieties,
and is between zero and 100%.
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[0083] In some embodiments, the polyvinyl alcohol polymer includes a modified
polyvinyl
alcohol, for example, a copolymer. The modified polyvinyl alcohol can include
a co-polymer or
higher polymer (e.g., ter-polymer) including one or more monomers in addition
to the vinyl
acetate/vinyl alcohol groups. Optionally, the modification is neutral, e.g.,
provided by an
ethylene, propylene, N-vinylpyrrolidone or other non-charged monomer species.
Optionally, the
modification is a cationic modification, e.g., provided by a positively
charged monomer species.
Optionally, the modification is an anionic modification. Thus, in some
embodiments, the
polyvinyl alcohol polymer includes an anionic modified polyvinyl alcohol
[0084] An anionic modified polyvinyl alcohol can include a partially or fully
hydrolyzed
PVOH copolymer that includes an anionic monomer unit, a vinyl alcohol monomer
unit, and
optionally a vinyl acetate monomer unit (i.e., when not completely
hydrolyzed). In some
embodiments, the modified PVOH copolymer can include two or more types of
anionic
monomer units. General classes of anionic monomer units which can be used for
the PVOH
copolymer include the vinyl polymerization units corresponding to sulfonic
acid vinyl monomers
and their esters, monocarboxylic acid vinyl monomers, their esters and
anhydrides, dicarboxylic
monomers having a polymerizable double bond, their esters and anhydrides, and
alkali metal
salts of any of the foregoing. Examples of suitable anionic monomer units
include the vinyl
polymerization units corresponding to vinyl anionic monomers including vinyl
acetic acid,
maleic acid, monoalkyl maleate, dialkyl maleate, maleic anhydride, fumaric
acid, monoalkyl
fumarate, dialkyl fumarate, itaconic acid, monoalkyl itaconate, dialkyl
itaconate, citraconic acid,
monoalkyl citraconate, dialkyl citraconate, citraconic anhydride, mesaconic
acid, monoalkyl
mesaconate, dialkyl mesaconate, glutaconic acid, monoalkyl glutaconate,
dialkyl glutaconate,
alkyl acrylates, alkyl alkacrylates, 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 foregoing (e.g., sodium, potassium, or other alkali metal salts),
esters of the foregoing
(e.g., methyl, ethyl, or other C1-C4 or C6 alkyl esters), and combinations of
the foregoing (e.g.,
multiple types of anionic monomers or equivalent forms of the same anionic
monomer). In some
embodiments, the modified PVOH copolymer can include two or more types of
monomer units
selected from neutral, anionic, and cationic monomer units
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[0085] The level of incorporation of the one or more anionic monomer units in
the PVOH
copolymers is not particularly limited. In certain embodiments, the one or
more anionic
monomer units are present in the PVOH copolymer in an amount in a range of
about 1 mol.% or
2 mol.% to about 6 mol.% or 10 mol.% (e.g., at least 1.0, 1.5, 2.0, 2.5, 3.0,
3.5, or 4.0 mol.%
and/or up to about 3.0, 4.0, 4.5, 5.0, 6.0, 8.0, or 10 mol.% in various
embodiments).
[0086] Polyvinyl alcohols can be subject to changes in solubility
characteristics. The acetate
group in the co-poly(vinyl acetate vinyl alcohol) polymer (PVOH copolymer) is
known by those
skilled in the art to be hydrolysable by either acid or alkaline hydrolysis.
As the degree of
hydrolysis increases, a polymer composition made from the PVOH copolymer will
have
increased mechanical strength but reduced solubility at lower temperatures
(e.g., requiring hot
water temperatures for complete dissolution). Accordingly, exposure of a PVOH
copolymer to
an alkaline environment (e.g., resulting from a laundry bleaching additive)
can transform the
polymer from one which dissolves rapidly and entirely in a given aqueous
environment (e.g., a
cold-water medium) to one which dissolves slowly and/or incompletely in the
aqueous
environment, potentially resulting in undissolved polymeric residue
[0087] 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 can be in a range of about 75% to about 99.9% (e.g.,
about 79% 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 for cold-water-soluble
compositions; 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, a fiber, foam, or
film made from the
polymer will have reduced mechanical strength but faster solubility at
temperatures below about
20 C. As the degree of hydrolysis increases, a fiber, foam, or film made from
the polymer will
tend to be mechanically stronger and the thermoformability will tend to
decrease. The degree of
hydrolysis of the PVOH can be chosen such that the water-solubility of the
polymer is
temperature dependent, and thus the solubility of a film, foam, or fiber made
from the polymer
and additional ingredients is also influenced. In certain embodiments, the
film, foam, and/or
fibers are cold water-soluble. For a co-poly(vinyl acetate vinyl alcohol)
polymer that does not
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include any other monomers (e.g., a copolymer not copolymerized with an
anionic monomer) a
cold water-soluble fiber, foam, or film, soluble in water at a temperature of
less than 10 C, can
include PVOH with a degree of hydrolysis in a range of about 75% to about 90%,
about 75% to
about 89%, or in a range of about 80% to about 90%, or in a range of about 85%
to about 90%.
In another embodiment, the fiber, foam, or film is hot water-soluble. For a co-
poly(vinyl acetate
vinyl alcohol) polymer that does not include any other monomers (e.g., a
copolymer not
copolymerized with an anionic monomer) a hot water-soluble fiber, foam, or
film that is soluble
in water at a temperature of at least about 60 C, can include PVOH with a
degree of hydrolysis
of at least about 98%. In embodiments, one of more of the plurality of fibers
comprise a
polyvinyl alcohol polymer having a degree of hydrolysis in a range of about
75% to about
99.9%. In embodiments, one or more of the plurality of fibers comprise a
polyvinyl alcohol
polymer having a degree of hydrolysis in a range of about 75% to about 98%. In
embodiments,
one of more of the plurality of fibers comprise a polyvinyl alcohol polymer
having a degree of
hydrolysis in a range of about 75% to about 89%. In embodiments, one of more
of the plurality
of fibers comprise a polyvinyl alcohol polymer having a degree of hydrolysis
in a range of about
90% to about 99.9%. In embodiments, the water-soluble film comprises a
polyvinyl alcohol
copolymer or a modified PVOH copolymer having a degree of hydrolysis in a
range of about
75% to about 99.9%. In embodiments, the water-soluble film comprises a
polyvinyl alcohol
homopolymer or a polyvinyl alcohol copolymer having a degree of hydrolysis in
a range of
about 75% to about 98%.
[0088] The degree of hydrolysis of a polymer blend can also be characterized
by the
arithmetic weighted, average degree of hydrolysis (H ). For example, H for a
PVOH
polymer that includes two or more PVOH polymers is calculated by the formula
where W, is the molar percentage of the respective PVOH polymer and H, is
the respective degrees of hydrolysis. When a polymer is referred to as having
(or not having) a
specific degree of hydrolysis, the polymer can be a single polyvinyl alcohol
polymer having the
specified degree of hydrolysis or a blend of polyvinyl alcohol polymers having
an average
degree of hydrolysis as specified.
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[0089] The viscosity of a PVOH polymer (pt) is determined by measuring a
freshly made
solution 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 international
practice to state the
viscosity of 4% aqueous polyvinyl alcohol solutions at 20 C. All viscosities
specified herein in
Centipoise (cP) should be understood to refer to the viscosity of 4% aqueous
polyvinyl alcohol
solution at 20 C, unless specified otherwise. Similarly, when a polymer is
described as having
(or not having) a particular viscosity, unless specified otherwise, it is
intended that the specified
viscosity is the average viscosity for the polymer, which inherently has a
corresponding
molecular weight distribution, i.e., the weighted natural log average
viscosity. It is well known in
the art that the viscosity of PVOH polymers is correlated with the weight
average molecular
weight Pw) of the PVOH polymer, and often the viscosity is used as a proxy for
the "w .
[0090] In embodiments, the PVOH resin may have a viscosity of about 1.0 to
about 50.0 cP,
about 1.0 to about 40.0 cP, or about 1.0 to about 30.0 cP, for example, about
4 cP, 8 cP, 15 cP,
18 cP, 23 cP, or 26 cP. In embodiments, the PVOH homopolymers and/or
copolymers may have
a viscosity of about 1.0 to about 40.0 cP, or about 5 cP to about 23 cP, for
example, about 1 cP,
1.5 cP, 2 cP, 2.5 cP, 3 cP, 3.5 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 homopolymers and/or copolymers may have a
viscosity of
about 21 cP to 26 cP. In embodiments, the PVOH homopolymers and/or copolymers
can have a
viscosity of about 5 cP to about 14 cP. In embodiments, the PVOH homopolymers
and/or
copolymers can have a viscosity of about 5 cP to about 23 cP.
[0091] The water-soluble polymers, whether polyvinyl alcohol polymers or
otherwise, can be
blended. When the polymer blend includes a blend of polyvinyl alcohol
polymers, the PVOH
polymer blend can include a first PVOH polymer ("first PVOH polymer") which
can include a
PVOH copolymer or a modified PVOH copolymer including one or more types of
anionic
monomer units (e.g., a PVOH ter- (or higher co-) polymer) and a second PVOH
polymer
("second PVOH polymer") which can include a PVOH copolymer or a modified PVOH
copolymer including one or more types of anionic monomer units (e.g., a PVOH
ter- (or higher
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co-) polymer). In some embodiments, the PVOH polymer blend includes only the
first PVOH
polymer and the second PVOH polymer (e.g., a binary blend of the two
polymers). Alternatively,
or additionally, the PVOH polymer blend or a fiber, foam, or film made
therefrom can be
characterized as being free or substantially free from other polymers (e.g.,
other water-soluble
polymers generally, other PVOH-based polymers specifically, or both). As used
herein,
-substantially free" means that the first and second PVOH polymers make up at
least 95 wt.%, at
least 97 wt.%, or at least 99 wt.% of the total amount of water-soluble
polymers in the water-
soluble fiber, foam, or film. In other embodiments, the water-soluble fiber,
foam, or film can
include one or more additional water-soluble polymers. For example, the PVOH
polymer blend
can include 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). For example, the water-soluble film can include at
least a third (or
fourth, fifth, etc.) water-soluble polymer which is other than a PVOH polymer
(e.g., other than
PVOH copolymers or modified PVOH copolymers, with or without anionic monomer
units). A
PVOH homopolymer may also be included in each blend.
Biodegradability
[0092] Polyvinyl alcohol polymers are generally biodegradable as they
decompose in the
presence of water and enzymes under aerobic, anaerobic, soil, and compost
conditions. In
general, as the degree of hydrolysis of a 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 above
80% does not
appreciably affect biodegradability. Additionally, the stereoregularity of the
hydroxyl groups of
polyvinyl alcohol polymers has a large effect on the biodegradability activity
level and the more
isotactic the hydroxyl groups of the polymer sequence, the higher the
degradation activity
becomes. Without intending to be bound by theory, for soil and/or compost
biodegradation, it is
believed that a nonwoven web prepared from a polyvinyl alcohol fiber will have
higher
biodegradation activity levels relative to a water-soluble film prepared from
a similar polyvinyl
alcohol polymer, due to the increase in the polymer surface area provided by
the nonwoven web
relative to a film. Further, without intending to be bound by theory, it is
believed that while the
degree of polymerization of the polyvinyl alcohol polymer has little to no
effect on the
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biodegradability of a film, foam, or nonwoven web prepared with the polymer,
the
polymerization temperature may have an effect on the biodegradability of a
film, foam, or
nonwoven because the polymerization temperature can affect the crystallinity
and aggregating
status of a polymer. As the crystallinity decreases, the polymer chain
hydroxyl groups become
less aligned in the polymer structure and the polymer chains become more
disordered allowing
for chains to accumulate as amorphous aggregates, thereby decreasing
availability of ordered
polymer structures such that the biodegradation activity is expected to
decrease for soil and/or
compost biodegradation mechanisms wherein the polymer is not dissolved.
Without intending to
be bound by theory, it is believed that because the stereoregularity of the
hydroxyl groups of
polyvinyl alcohol polymers has a large effect on biodegradability activity
levels, the substitution
of functionalities other than hydroxyl groups (e.g., anionic AMPS functional
groups, carboxylate
groups, or lactone groups) is expected to decrease the biodegradability
activity level, relative to a
polyvinyl alcohol copolymer having the same degree of hydrolysis, unless the
functional group
itself is also biodegradable, in which case biodegradability of the polymer
can be increased with
substitution. Further, it is believed that while the biodegradability activity
level of a substituted
polyvinyl alcohol can be less than that of the corresponding homopolymer or
copolymer, the
substituted polyvinyl alcohol will still exhibit biodegradability.
[0093] Methods of determining biodegradation activity are known in the art,
for example, as
described 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. Further
methods and standards
can be found in ECHA' s Annex XV Restriction Report ¨ Microplastics, Version
number 1,
January 11, 2019, which is incorporated herein by reference in its entirety.
Suitable standards
include OECD 301B (ready biodegradation), OECD 301B (enhanced biodegradation),
OECD
302B (inherent biodegradation), OECD 311(anaerobic), and ASTM D5988 (soil).
[0094] In example embodiments, the fibers described herein can be of the
standard ready
biodegradation or enhanced degradation. As used herein, the term "ready
biodegradation" refers
to a standard that is met if the material (e.g., a fiber) reached 60%
biodegradation
(mineralization) within 28 days of the beginning of the test, according to the
OECD 301B test as
described in said ECHA's Annex XV. As used herein, the term "enhanced
biodegradation" refers
to a standard that is met if the material (e.g., a fiber) reaches 60%
biodegradation within 60 days
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from the beginning of the test, according to the OECD 301B test as described
in said ECHA's
Annex XV. In example embodiments, the fibers meet the standards of ready
biodegradation. In
example embodiments, the films herein meet the standards of ready
biodegradation or enhanced
degradation. In example embodiments, the laminate (nonwoven and film or foam
and film) as
used herein meet the standards of ready biodegradation or enhanced
biodegradation.
Carrier Solvent
[0095] In example embodiments, the carrier solvent comprises a polar solvent.
In example
embodiments, the solvent comprises 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 a
combination thereof. In example embodiments, the carrier solvent comprises n-
octanol, n-
heptanol, n-hexanol, n-pentanol, n-butanol, isobutanol, sec-butanol, ter l-
butanol, n-propanol,
isopropanol, acetone, ethanol, N-methylpyrrolidone, methanol, acetonitrile,
N,N-
dimethylformamide, dimethyl sulfoxide, formic acid, water, or a combination
thereof. In
example embodiments, the carrier solvent comprises n-propanol, acetone,
ethanol, N-
methylpyrrolidone, methanol, acetonitrile, /V,N-dimethylformamide, dimethyl
sulfoxide, formic
acid, water, or a combination thereof. In example embodiments, the carrier
solvent comprises an
alcohol that is a liquid under the admixing conditions. In example
embodiments, the carrier
solvent comprises methanol. In example embodiments, the carrier solvent
comprises methanol
and at least one additional solvent. In embodiments, the carrier solvent
comprises methanol and
water. In example embodiments, the carrier solvent comprises at least one of
butanol, pentanol,
hexanol, heptanol, and octanol in combination with water. In example
embodiments, the carrier
solvent comprises DMSO and water. In example embodiments, the carrier solvent
comprises
DMSO and water and the DMSO and water are provided in a weight ratio of about
40/60 to
80/20. Without intending to be bound by theory, it is believed that as the
amount of water
increases above 60% or the amount of DMSO increases above about 80%, the
interaction of the
respective solvents with polyvinyl alcohol increases, resulting in increased
swelling and gelling
of the polymer.
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[0096] In example embodiments, the carrier solvent comprises a nonpolar
solvent. In example
embodiments, the carrier solvent comprises hexanes, cyclohexane,
methylpentane, pentane,
cyclopropane, dioxane, benzene, pyridine, xylene, toluene, diethyl ether,
chloroform, or a
combination thereof.
[0097] In example embodiments, the carrier solvent comprises a mixture of a
first carrier
solvent and a second carrier solvent. In example embodiments, the first
carrier solvent comprises
a polar solvent and the second carrier solvent comprises a nonpolar solvent.
In example
embodiments, the first carrier solvent has a first dielectric constant and the
second carrier solvent
has a second dielectric constant and the dielectric constant of the first
carrier solvent is different
from, e.g., higher than, the dielectric constant of the second carrier
solvent. In example
embodiments, the first dielectric constant is 5 or less, 4 or less, 3 or less,
or 2 or less. In example
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 example
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 example
embodiments, wherein 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 can be provided in any ratio
provided the fiber is
not soluble in the mixture prior to treatment, during treatment, and after
treatment. In example
embodiments, the first carrier solvent and the second carrier solvent can be
provided in a weight
ratio 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 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 about 40/60, about 55/45 to about
45/55, or about
50/50.
Active Cleaning Formulations
[0098] In example embodiments, the SUD article and, more specifically, the
water-soluble
core substrate, is configured to contain one or more active cleaning
formulations, such as a
laundry detergent formulation. In example embodiments, the active cleaning
formulation is
disposed on or coats one or more surfaces of the water-soluble core substrate
or is embedded in
and/or adhered to the water-soluble core substrate. The water-soluble core
substrate may include
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a single layer, for example, a single layer foam core substrate, or may
include a plurality of
layers, for example, a sheet of nonwoven core substrate folded in a serpentine
arrangement or
plied to form layers with the active cleaning formulation disposed between
adjacent layers of the
water-soluble nonwoven core substrate, for example. As an example, the active
cleaning
formulation may include, without limitation, an active, a laundry detergent, a
soap, a fabric
softener, a bleaching agent, a laundry booster, a stain remover, an optical
brightener, or a water
softener. Other examples include a dish detergent, soap or cleaner, a shampoo,
a conditioner, a
body wash, a face wash, a skin lotion, a skin treatment, a body oil,
fragrance, a hair treatment, a
bath salt, an essential oil, a bath bomb, or an enzyme. In certain example
embodiments, the
water-soluble core substrate is enclosed by a water-soluble nonwoven material,
a water-soluble
foam material, and/or a water-soluble film material.
Auxiliary Agents
[0099] In general, along with the film-, foam-, and/or fiber-forming material,
the fibers,
nonwoven webs, foam, and/or water-soluble films of the disclosure can include
auxiliary agents
such as, but not limited to, plasticizers, plasticizer compatibilizers,
surfactants, lubricants, release
agents, fillers, extenders, cross-linking agents, antiblocking agents,
antioxidants, detackifying
agents, antifoams, nanoparticles such as layered silicate-type nanoclays
(e.g., sodium
montmorillonite), bleaching agents (e.g., sodium metabisulfite, sodium
bisulfite or others),
aversive agents such as bitterants (e.g., denatonium salts such as denatonium
benzoate,
denatonium saccharide, and denatonium chloride; sucrose octaacetate; quinine;
flavonoids such
as quercetin and naringen; and quassinoids such as quassin and brucine) and
pungents (e.g.,
capsaicin, piperine, allyl isothiocyanate, and resinferatoxin), and other
functional ingredients, in
amounts suitable for their intended purposes. As used herein and unless
specified otherwise,
"auxiliary agents" include secondary additives, processing agents, and active
agents. Specific
such auxiliary agents can 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.
[0100] In example embodiments, the fibers, foams, and/or films can be free of
auxiliary
agents. As used herein and unless specified otherwise, "free of auxiliary
agents" with respect to
the fiber means that the fiber includes less than about 0.01 wt.%, less than
about 0.005 wt.%, or
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less than about 0.001 wt% of auxiliary agents, based on the total weight of
the fiber. As used
herein and unless specified otherwise, "free of auxiliary agents" with respect
to the film or
nonwoven web means that the nonwoven web includes less than about 0.01 wt.%,
less than about
0.005 wt.%, or less than about 0.001 wt.% of auxiliary agents, based on the
total weight of the
film, foam, or nonwoven web. In embodiments, the water-soluble fibers comprise
a plasticizer.
In embodiments, the water-soluble fibers comprise a surfactant. In
embodiments, the non-water-
soluble fibers comprise a plasticizer. In embodiments, the non-water-soluble
fibers comprise a
surfactant. In embodiments, the nonwoven web includes a plasticizer. In
embodiments, the
nonwoven web includes a surfactant.
[0101] A plasticizer is a liquid, solid, or semi-solid that is added
to a material (usually a resin
or elastomer) making that material softer, more flexible (by decreasing the
glass-transition
temperature of the polymer), and easier to process. A polymer can
alternatively be internally
plasticized by chemically modifying the polymer or monomer. In addition, or in
the alternative, a
polymer can be externally plasticized by the addition of a suitable
plasticizing agent. Water is
recognized as a very efficient plasticizer for PVOH polymers and other
polymers including, but
not limited to, water-soluble polymers; however, the volatility of water makes
its utility limited
because polymer films need to have at least some resistance (robustness) to a
variety of ambient
conditions including low and high relative humidity.
[0102] The plasticizer can include, without limitation, glycerin,
diglycerin, sorbitol, xylitol,
maltitol, ethylene glycol, diethylene glycol, triethylene glycol, dipropylene
glycol, tetraethylene
glycol, propylene glycol, polyethylene glycols up to 1000 MW, neopentyl
glycol,
trimethylolpropane, polyether polyols, sorbitol, 2-methyl-1,3-propanediol
(1\TPDiolg),
ethanolamines, and a mixture thereof.
[0103] Surfactants for use in films are well known in the art and can suitably
be used in the
fibers, foam, films, and/or compositions of the disclosure. Optionally,
surfactants are included to
aid in the dispersion of the fibers during carding. Optionally, surfactants
are included as cleaning
aids. Suitable surfactants can include the nonionic, cationic, anionic and
zwitterionic classes.
Suitable surfactants include, but arc not limited to, sodium alkyl sulfates
(sodium dodecyl
sulfate) and other surfactants suitable for laundry applications as cleaning
aids, propylene
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glycols, diethylene glycols, monoethanolamine, polyoxyethylenated
polyoxypropylene glycols,
alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylenic glycols and
alkanolamides
(nonionics), polyoxyethylenated amines, quaternary ammonium salts and
quaternized
polyoxyethylenated amines (cationics), alkali metal salts of higher fatty
acids containing about 8
to 24 carbon atoms, alkyl sulfates, alkyl polyethoxylate sulfates and
alkylbenzene sulfonates
(anionics), and amine oxides, N-alkylbetaines and sulfobetaines
(zwitterionics). Other suitable
surfactants include 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, polysorbate 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 compounds,
alkali metal salts
of higher fatty acids containing about 8 to 24 carbon atoms, alkyl sulfates,
alkyl polyethoxylate
sulfates, alkylbenzene sulfonates, monoethanolamine, lauryl alcohol
ethoxylate, propylene
glycol, diethylene glycol, sodium cocoyl isethionate, sodium lauryl sulfate,
glucotain,
phoenamids, cola lipid, cocamides, such as cocamide ethanolamines, ethylene
oxide based
surfactants, saponified oils of avocado and palm, salts thereof and
combinations of any of the
foregoing. In embodiments, the surfactant comprises a cocamide. Without
intending to be bound
by theory, it is believed that a cocamide can aid in foam formation, enhancing
the foaming
experience of an article comprising a personal care composition. In various
embodiments, the
amount of surfactant in the fiber is in a range of about 0.01 wt.% to about 10
wt.%, about 0.1
wt.% to about 5 wt.%, about 1.0 wt.% to about 2.5 wt%, about 0.01 wt.% to
about 1.5 wt.%,
about 0.1 wt.% to about 1 wt.%, about 0.01 wt.% to 0.25 wt.%, or about 0.10 wt
% to 0.20 wt.%.
In various embodiments, the amount of surfactant in a personal care
composition contained
within the pouch can be in a range of about 5 wt.% to about 50 wt.%, about 10
wt.% to about 45
wt.%, or about 10 wt.% to about 40 wt.%.
[0104] In embodiments, the nonwoven webs, foam, and/or films of the disclosure
can further
comprise auxiliary agents such as one or more auxiliary agents in the group
of: an exfoliant
(chemical exfoliants and mechanical exfoliants), a fragrance and/or perfume
microcapsule, an
aversive agent, a surfactant, a colorant, an enzyme, a skin conditioner, a de-
oiling agent, and a
cosmetic agent.
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[0105] In embodiments, an auxiliary agent is provided in or on one or more of
the nonwoven
web, the foam, the plurality of fibers, and the water-soluble film. In
embodiments, an active
cleaning formulation is provided on or in one or more of the group of the
nonwoven web, the
plurality of fibers, and the water-soluble film. In embodiments, one or more
auxiliary agents can
be provided on the surface of the nonwoven web. In embodiments, one or more
auxiliary agents
can be dispersed among the fibers of the nonwoven web. In embodiments, one or
more auxiliary
agents can be dispersed on a face of the nonwoven web. In embodiments, one or
more auxiliary
agents can be dispersed in the fibers. In embodiments, one or more auxiliary
agents can be
dispersed on the fibers. In embodiments, one or more auxiliary agents can be
provided on a face
of the water-soluble film. In embodiments, one or more auxiliary agents can be
dispersed within
the water-soluble film. In embodiments, the nonwoven web in the form of a
pouch has an
exterior face facing away from the interior volume, and an active cleaning
formulation is
provided on the exterior face. In embodiments, the nonwoven web in the form of
a pouch has an
exterior face facing away from the interior volume, and one or more auxiliary
agents is provided
on the exterior face.
[0106] The chemical exfoliants, mechanical exfoliants, fragrances and/or
perfume
microcapsules, aversive agents, surfactants, colorants, proteins, peptides,
enzymes, skin
conditioners, de-oiling agents, cosmetic agents, or a combination thereof,
when present, can be
provided in an amount of at least about 0.1 wt.%, or in a range of about 0.1
wt.% to about 99
wt.% based on the weight of the polymeric mixture (e.g., fiber-forming
material or film-forming
material). In embodiments, the chemical exfoliants, mechanical exfoliants,
fragrances and/or
perfume microcapsules, aversive agents, surfactants, colorants, enzymes, skin
conditioners, de-
oiling agents, and/or cosmetic agents can be provided in an amount sufficient
to provide
additional functionality to the fiber and/or film, such as exfoliation of
human skin. The chemical
exfoliants, mechanical exfoliants, fragrances and/or perfume microcapsules,
aversive agents,
surfactants, colorants, enzymes, skin conditioners, de-oiling agents, cosmetic
agents, or a
combination thereof, can take any desired form, including as a solid (e.g.,
powder, granulate,
crystal, flake, or ribbon), a liquid, a mull, a paste, a gas, etc., and
optionally can be encapsulated,
such as microcapsules.
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[0107] In certain embodiments, the nonwoven web, foam, and/or film can
comprise an
enzyme. Suitable enzymes include enzymes categorized in any one of the six
conventional
Enzyme Commission (EC) categories, i.e., the oxidoreductases of EC 1 (which
catalyze
oxidation/reduction reactions), the transferases of EC 2 (which transfer a
functional group, e.g., a
methyl or phosphate group), the hydrolases of EC 3 (which catalyze the
hydrolysis of various
bonds), the lyases of EC 4 (which cleave various bonds by means other than
hydrolysis and
oxidation), the isomerases of EC 5 (which catalyze isomerization changes
within a molecule) and
the ligases of EC 6 (which join two molecules with covalent bonds). Examples
of such enzymes
include dehydrogenases and oxidases in EC 1, transaminases and kinases in EC
2, lipases,
cellulases, amylases, mannanases, and peptidases (a.k.a. proteases or
proteolytic enzymes) in EC
3, decarboxylases in EC 4, isomerases and mutases in EC 5 and synthetases and
synthases of EC
6. Suitable enzymes from each category are described in, for example, U.S.
Patent No.
9,394,092, the entire disclosure of which is herein incorporated by reference.
In certain
embodiments, enzymes can include bromeline (pineapple extract), papain
(papaya), ficin (fig),
actinidin (kiwi), hyaluronidase, lipase, peroxidase, superoxide dismutase,
tyrosinase, alkaline
phosphatase, or a combination thereof. In embodiments, the enzyme can be
encapsulated in the
form of, for example, nanoemulsions, nanocapsules, granules or a combination
thereof.
[0108] Enzymes for use in laundry and dishwashing applications can include one
or more of
protease, amylase, lipase, dehydrogenase, transaminase, kinase, cellulase,
mannanase, peptidase,
decarboxylase, isomerase, mutase, synthetase, synthase, and oxido-reductase
enzymes, including
oxido-reductase enzymes that catalyze the formation of bleaching agents.
[0109] It is contemplated that an enzyme for use herein can come from any
suitable source or
combination of sources, for example, bacterial, fungal, plant, or animal
sources. In one
embodiment, a mixture of two or more enzymes will come from at least two
different types of
sources. For example, a mixture of protease and lipase can come from a
bacterial (protease) and
fungal (lipase) sources.
[0110] Optionally, an enzyme for use herein, including but not limited to any
enzyme class or
member described herein, is one which works in alkaline pH conditions, e.g., a
pH in a range of
about 8 to about 11. Optionally, an enzyme for use herein, including but not
limited to any
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enzyme class or member described herein, is one which works in a temperature
in a range of
about 5 C to about 45 C.
[0111] In embodiments, the nonwoven web, foam, and/or film can comprise a
protein and/or
peptide. Suitable proteins and/or peptides can include, but are not limited
to, collagen and/or
collagen peptides, or amino acids, for example, aspartic acid, glutamic acid,
serine, histidine,
glycine, threonine, arginine, alanine, tyrosine, cysteine, valine, methionine,
phenylalanine,
isoleucine, leucine, lysine, hydroxyproline, or proline.
[0112] In embodiments, the nonwoven web, foam, and/or film can comprise a
colorant.
Suitable colorants can include an indicator dye, such as a pH indicator (e.g.,
thymol blue,
bromothymol, thymolphthalein, and thymolphthalein), a moisture/water indicator
(e.g.,
hydrochromic inks or leuco dyes), or a thermochromic ink, wherein the ink
changes color when
temperature increases and/or decreases. Suitable colorants include, but are
not limited to, a
triphenylmethane dye, an azo dye, an anthraquinone dye, a perylene dye, an
indigoid dye, a food,
drug and cosmetic (FD&C) colorant, an organic pigment, an inorganic pigment,
or a combination
thereof. Examples of colorants include, but are not limited to, FD&C Red #40;
Red #3; FD&C
Black #3; Black #2; Mica-based pearlescent pigment; FD&C Yellow #6; Green #3;
Blue #1;
Blue it2; titanium dioxide (food grade); brilliant black; and a combination
thereof. Other
examples of suitable colorants can be found in U.S. Patent No. 5,002,789,
hereby incorporated
by reference in its entirety.
[0113] Other embodiments can include one or more fragrances in the nonwoven
webs, foams,
and/or films of the disclosure. As used herein, the term "fragrance- refers to
any applicable
material that is sufficiently volatile to produce a scent. Embodiments
including fragrances can
include fragrances that are scents pleasurable to humans, or alternatively
fragrances that are
scents repellant to humans, animals, and/or insects. Suitable fragrances
include, but are not
limited to, fruits including, but not limited to, lemon, apple, cherry, grape,
pear, pineapple,
orange, strawberry, raspberry, musk, and flower scents including, but not
limited to, lavender-
like, rose-like, iris-like and carnation-like. Optionally, the fragrance is
one which is not also a
flavoring. Other fragrances include herbal scents including, but not limited
to, rosemary, thyme,
and sage; and woodland scents derived from pine, spruce, and other forest
smells. Fragrances
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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, and the like
or any combination
thereof. Suitable fragrant oils can be found in U.S. Patent No. 6,458,754,
hereby incorporated by
reference in its entirety. Suitable fragrant oils include, but are not limited
to, 442,2,6-
trimethylcyclohex-1-eny1)-2-en-4-one, acetaldehyde phenyletheyl propyl acetal,
2,6,10-
trimethy1-9-undecenal, hexanoic acid 2-propenyl ester, 1-octen-3-ol, trans-
anethole, iso butyl (z)-
2-methy1-2-butenoate, anisaldehyde diethyl acetal, 3-methy1-5-propyl-
cyclohezen- I-one, 2,4-
dimethyl-3-cycl ohexene-l-carbal dehyde, trans-4-decenal, decanal, 2-
pentylcyclopentanone,
ethyl anthranilate, eugenol, 3-(3-isopropylphenyl)butanoal, methyl 2-
octynoate, isoeugenol, cis-
3-hexenyl methyl carbonate, linalool, methyl-2-nonynonate, benzoic acid 2-
hydroxymethyl ester,
nonal, octanal, 2-nonennitrile, 4-nonanolide, 9-decen-1-ol, and 10-undecen-1-
al. Applicable
fragrances can also be found in U.S. Patent Nos. 4,534,981; 5,112,688;
5,145,842; 6,844,302;
and Perfumes Cosmetics and Soaps, Second Edition, edited by W. A. Poucher,
1959, all hereby
incorporated by reference in their entireties. These fragrances include
acacia, cassie, chypre,
cyclamen, fern, gardenia, hawthorn, heliotrope, honeysuckle, hyacinth,
jasmine, lilac, lily,
magnolia, mimosa, narcissus, freshly-cut hay, orange blossom, orchids, reseda,
sweet pea, trefle,
tuberose, vanilla, violet, wallflower, and the like, or any combination
thereof.
[0114] Fragrances can include perfumes. The perfume may comprise neat perfume,
encapsulated perfume, or mixtures thereof. In example embodiments, the perfume
includes neat
perfume. A portion of the perfume may be encapsulated in a core-shell
encapsulate. In other
embodiments, the perfume will not be encapsulated in a core/shell encapsulate.
[0115] As used herein, the term "perfume" encompasses the perfume raw
materials (PRMs)
and perfume accords. The term "perfume raw material" as used herein refers to
compounds
having a molecular weight of at least about 100 g/mol and which are useful in
imparting an odor,
fragrance, essence or scent, either alone or with other perfume raw materials.
As used herein, the
terms "perfume ingredient" and "perfume raw material" are interchangeable. The
term "accord"
as used herein refers to a mixture of two or more PRMs. In embodiments, any of
the perfume
accords, perfume raw materials, or fragrances can be encompassed in a
microcapsule, termed
"perfume microcapsules" as used herein.
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[0116] Typical PRM comprise inter alia alcohols, ketones, aldehydes, esters,
ethers, nitrites,
and alkenes, such as terpene. A listing of common PRMs can be found in various
reference
sources, 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). The PRMs are characterized by
their boiling
points (B.P.) measured at the normal pressure (760 mm Hg), and their
octanol/water partitioning
coefficient (P). Based on these characteristics, the PRMS may be categorized
as Quadrant I,
Quadrant II, Quadrant III, or Quadrant IV perfumes.
[0117] In embodiments, the nonwoven web, foam, and/or film can include an
exfoliant. In
embodiments, the exfoliant can comprise a chemical exfoliant or a mechanical
exfoliant. Suitable
mechanical exfoliants for use herein can include, but are not limited to,
apricot shells, sugar,
oatmeal, salt, silica, diatomaceous earth, clay, aluminum hydrates, PVOH
microbeads, pumice,
or a combination thereof Suitable chemical exfoliants for use herein can
include, but are not
limited to, alpha hydroxyl acid, beta hydroxyl acid, enzyme, salicylic acid,
glycolic acid, citric
acid, malic acid, or a combination thereof.
[0118] In certain embodiments, the aversive agents, surfactants, colorants,
enzymes, skin
conditioners, de-oiling agents, cosmetic agents, or a combination thereof, are
encapsulated,
allowing for controlled release. Suitable microcapsules can include or be made
from one or more
of 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,
silicones,
poly(lactideco-glycolide), paraffin, carnauba, spermaceti, beeswax, stearic
acid, stearyl alcohol,
glyceryl stearates, shellac, cellulose acetate phthalate, zein, and
combinations thereof In one
type of embodiment, the microcapsule is characterized by a mean particle size
(e.g., Dv50) of at
least about 0.1 micron, or in a range of about 0.1 micron to about 200
microns, for example. In
alternate embodiments, the microcapsules can form agglomerates of individual
particles, for
example wherein the individual particles have a mean particle size of at least
about 0.1 micron,
or in a range of about 0.1 micron to about 200 microns.
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Water-Soluble Fibers
[0119] Water-soluble fibers include fibers and/or fiber-forming materials made
of any
material that, when provided as the sole resin in a film or foam, or sole
fiber-forming material in
a nonwoven, the film, foam, or nonwoven dissolves in 300 seconds or less at
temperatures of
80 C or less, as determined by MSTM-205. The water-soluble fibers can include
a single water-
soluble polymer or a blend of water-soluble polymers. Suitable water-soluble
polymers include,
but are not limited to, polyvinyl alcohol homopolymer, polyvinyl alcohol
copolymer, modified
polyvinyl alcohol copolymer, polyacrylate, water-soluble acrylate copolymer,
polyvinyl
pyrrolidone, polyethyleneimine, pullulan, water-soluble natural polymer
including, but not
limited to, guar gum, gum Acacia, xanthan gum, carrageenan, and starch, water-
soluble polymer
derivatives including, but not limited to, modified starches, ethoxylated
starch, and
hydroxypropylated starch, copolymers of the forgoing and combinations of any
of the foregoing.
Yet other water-soluble fibers can include polyalkylene oxides,
polyacrylamides, polyacrylic
acids and salts thereof, celluloses, cellulose ethers, cellulose esters,
cellulose amides, polyvinyl
acetates, polycarboxylic acids and salts thereof, polyaminoacids, polyamides,
gelatines,
methyl cellul oses, carboxymethylcelluloses and salts thereof, dextrins, ethyl
cellul oses,
hydroxyethyl celluloses, hydroxypropyl methylcelluloses, maltodextrins,
polymethacrylates, and
combinations of any of the foregoing. In embodiments, the water-soluble fibers
can include a
PVOH copolymer fiber-forming material, modified PVOH copolymer fiber-forming
material, or
a combination thereof. In embodiments, the water-soluble fibers can comprise a
sole PVOH
homopolymer fiber-forming material or a blend of PVOH copolymer fiber-forming
materials. In
embodiments, the water-soluble fibers can comprise a hot water-soluble PVOH
copolymer fiber-
forming material. In further embodiments, the water-soluble fibers can
comprise a PVOH
copolymer fiber-forming material with a viscosity in a range of 5 cP to 23 cP
and a degree of
hydrolysis in a range of 86% to 92%.
[0120] In embodiments, the water-soluble fibers can include an auxiliary agent
as described
above. In embodiments, the water-soluble fibers can be substantially free of
auxiliary agents as
described above. In embodiments, the water-soluble fibers can include a
plasticizer as described
above. The total amount of the non-water plasticizer provided in the water-
soluble fiber can be in
a range of about 1 wt.% to about 45 wt.%, or about 5 wt.% to about 45 wt.%, or
about 10 wt.%
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to about 40 wt.%, or about 20 wt% to about 30 wt.%, about 1 wt.% to about 4
wt.%, or about 1.5
wt.% to about 3.5 wt.%, or about 2.0 wt.% to about 3.0 wt.%, for example about
1 wt.%, about
2.5 wt.%, about 5 wt.%, about 10 wt.%, about 15 wt.%, about 20 wt.%, about 25
wt.%, about 30
wt.%, about 35 wt.%, or about 40 wt.%, based on total fiber weight. In
embodiments, the water-
soluble fibers comprise glycerin, sorbitol, or a combination thereof. In
embodiments, the water-
soluble fibers comprise glycerin. In embodiments, the water-soluble fibers
comprise sorbitol. In
certain embodiments, the water-soluble fibers can include glycerin, for
example, in about 10
wt.% based on total fiber weight, and sorbitol, for example, in about 5 wt.%
based on the total
fiber weight.
[0121] In embodiments, the water-soluble fibers can include a surfactant as
described above.
In various embodiments, the amount of surfactant in the water-soluble fiber is
in a range of about
0.01 wt.%, to about 2.5 wt.%, about 0.1 wt.% to about 2.5 wt.%, about 1.0 wt.%
to about 2.0
wt.%, about 0.01 wt.% to 0.25 wt.%, or about 0.10 wt.% to 0.20 wt.%.
[0122] In embodiments, any of the auxiliary agents disclosed herein can be
added to the fibers
of the disclosure. In refinements of the forgoing embodiment, the auxiliary
agents can be added
to the fiber-forming material prior to formation of the fiber such that the
auxiliary agents are
dispersed in the fiber. In addition, and/or in the alternative, auxiliary
agents can be added to the
surface of a fiber after fiber formation (e.g., dispersed on the fibers).
[0123] When included in the water-soluble fiber, a colorant can be provided in
an amount of
0.01% to 25% by weight of the polymer mixture, such as, 0.02%, 0.05%, 0.1%,
0.5%, 1%, 2%,
3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%,
20%,
21%, 22%, 23%, and 24% by weight of the polymer mixture.
Non-Water-Soluble Fibers
[0124] Non-water-soluble fibers include fibers and/or fiber-forming materials
made of any
material that, when provided in a film as the sole film-forming material or
provided in a
nonwoven web or foam as the sole fiber-forming material, the film, the
nonwoven web, or the
foam does not dissolve in 300 seconds or less at temperatures of 80 C or less,
as determined by
MSTM-205. The non-water-soluble fibers can include a sole non-water-soluble
polymer fiber-
forming material or a blend of non-water-soluble polymer fiber-forming
materials. Suitable non-
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water-soluble fibers and/or non-water-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 fiber, and
combinations thereof. In
embodiments, the non-water-soluble fiber-forming material and/or non-water-
soluble fibers
comprise one or more of the group of: 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 a
combination thereof
[0125] In embodiments, the non-water-soluble fibers can include an auxiliary
agent as
described above. In embodiments, the non-water-soluble fibers can be
substantially free of
auxiliary agents as described above. In embodiments, the non-water-soluble
fibers can include a
plasticizer as described above. The total amount of the non-water plasticizer
provided in the non-
water-soluble fiber can be in a range of about 1 wt.% to about 45 wt.%, or
about 5 wt.% to about
45 wt.%, or about 10 wt% to about 40 wt%, or about 20 wt.% to about 30 wt.%,
about 1 wt.%
to about 4 wt.%, or about 1.5 wt.% to about 3.5 wt.%, or about 2.0 wt.% to
about 3.0 wt.%, for
example, about 1 wt.%, about 2.5 wt.%, about 5 wt.%, about 10 wt.%, about 15
wt.%, about 20
wt.%, about 25 wt.%, about 30 wt.%, about 35 wt.%, or about 40 wt.%, based on
total fiber
weight. In embodiments, the non-water-soluble fibers comprise glycerin,
sorbitol, or a
combination thereof. In embodiments, the non-water-soluble fibers comprise
glycerin. In
embodiments, the non-water-soluble fibers comprise sorbitol. In certain
embodiments, the non-
water-soluble fibers can include a plasticizer such as glycerin, for example
in about 10 wt%
based on total fiber weight, and sorbitol, for example in about 5 wt% based on
the total fiber
weight.
[0126] In embodiments, the non-water-soluble fibers can include a surfactant
as described
above. In various embodiments, the amount of surfactant in the water-soluble
fiber is in a range
of about 0.01 wt.%, to about 2.5 wt.%, about 0.1 wt.% to about 2.5 wt.%, about
1.0 wt.% to
about 2.0 wt.%, about 0.01 wt.% to 0.25 wt.%, or about 0.10 wt.% to 0.20 wt.%.
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[0127] In embodiments, any of the auxiliary agents disclosed herein can be
added to the fibers
of the disclosure. In refinements of the forgoing embodiment can be added to
the fiber-forming
material prior to formation of the fiber such that the auxiliary agents can be
added to the surface
of a fiber after fiber formation. In refinements of the foregoing embodiments,
the auxiliary
agents can be added to a surface of the fiber after fiber formation.
[0128] When included in the non-water-soluble fiber, the colorant can be
provided in an
amount of 0.01% to 25% by weight of the polymer mixture, such as, 0.02%,
0.05%, 0.1%, 0.5%,
1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%,
18%,
19%, 20%, 21%, 22%, 23%, and 24% by weight of the polymer mixture.
Nonwoven Webs or Substrates
[0129] The nonwoven web or nonwoven substrates of the disclosure can be water-
soluble,
non-water-soluble, or at least partially non-water-soluble. The unit dose
article of the disclosure
can include a nonwoven web, wherein at least a portion of the nonwoven web is
soluble in water
at a temperature in a range of about 0 C to about 20 C according to MSTM 205,
or at least a
portion of the nonwoven web is not soluble in water at a temperature of 20 C
or less according
to MSTM 205, or the nonwoven web is not soluble in water at a temperature of
20 C or less
according to MSTM 205, or the nonwoven web is soluble in water at a
temperature in a range of
about 0 C to about 20 C according to MSTM 205. It will be understood that "at
least a portion"
of a nonwoven web is soluble (or not soluble) at a given temperature if the
nonwoven web
includes in the plurality of the fibers, a fiber type which when provided in a
nonwoven as the
sole fiber type, the nonwoven web consisting of that fiber type is soluble (or
not soluble) at the
given temperature, according to MSTM-205.
[0130] The nonwoven web of the disclosure includes a plurality of fibers. A
nonwoven web
refers to an arrangement of fibers bonded to one another, wherein the fibers
are neither woven
nor knitted. The plurality of fibers can be arranged in any orientation. In
embodiments, the
plurality of fibers are arranged randomly (i.e., do not have an orientation).
In embodiments, the
plurality of fibers are arranged in a unidirectional orientation. In
embodiments, the plurality of
fibers are arranged in a bidirectional orientation. In some embodiments, the
plurality of fibers are
multi-directional, having different arrangements in different areas of the
nonwoven web.
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[0131] The plurality of fibers in any given nonwoven web can include any fiber-
forming
materials disclosed herein. The nonwoven web can include (1) a single fiber
type including a
single fiber-forming material, (2) a single fiber type including a blend of
fiber-forming materials,
(3) a blend of fiber types, each fiber type including a single fiber-forming
material, (4) a blend of
fiber types, each fiber type including a blend of fiber-forming materials, or
(5) a blend of fiber
types, each fiber type including a single fiber-forming material or a blend of
fiber-forming
materials. In embodiments including a blend of fiber types, the different
fiber types can have a
difference in one or more of the group of length to diameter ratio (LID),
tenacity, shape,
rigidness, elasticity, solubility, melting point, glass transition temperature
(TO, fiber-forming
material chemistries, and color. In certain embodiments, the plurality of
fibers can comprise two
or more types of water-soluble fibers. In embodiments, the plurality of fibers
can comprise at
least one fiber type comprising at least one type of water-soluble fiber-
forming materials and at
least one fiber type comprising at least type of one non-water-soluble fiber.
In embodiments, the
plurality of fibers can comprise two or more fiber types comprising at least
one type of non-
water-soluble fiber-forming material.
[0132] In embodiments, the nonwoven web can further comprise any auxiliary
agents as
disclosed herein for fibers and/or films. In embodiments, the auxiliary agents
can be added to the
fiber itself, to the nonwoven web during carding of the nonwoven web, to the
nonwoven web
prior to bonding (e.g., after carding), to the nonwoven web after bonding, or
a combination
thereof. The auxiliary agents added to the fibers during carding can be
distributed throughout the
nonwoven web. The auxiliary agents added to the nonwoven web after carding but
prior to
bonding can be selectively added to one or both faces of the nonwoven web.
[0133] The auxiliary agents can be applied to one or more faces of a nonwoven
web or to an
article containing same, e.g., a packet, by any suitable means. In
embodiments, the auxiliary
agents are in powder form. In refinements of the foregoing embodiment, one or
more stationary
powder spray guns are used to direct the powder stream towards the web or a
packet, from one or
more than one direction, while the web or packet is transported through the
coating zone by
means of a belt conveyor. In embodiments, a web or packet is conveyed through
a suspension of
the powder in air. In embodiments, the webs or packets are tumble-mixed with
the powder in a
trough-like apparatus. In embodiments, which can be combined with any other
embodiment,
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electrostatic forces are employed to enhance the attraction between the powder
and the packet or
web. This type of process may be based on negatively charging the powder
particles and
directing these charged particles to the grounded packets or webs. In other
alternative
embodiments, the powder is applied to the web or packet by a secondary
transferring tool
including, but not limited to, rotating brushes, which are in contact with the
powder or by
powdered gloves, which can transfer the powder from a container to the web or
packet. in yet
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 the web or
packet. In one
embodiment, the solvent or carrier subsequently evaporates, leaving the active
agent powder
behind. In certain embodiments, the powder is applied to the web or packet in
an accurate dose.
These embodiments utilize closed-system dry lubricant application machinery,
such as
PekuTECH's powder applicator PM 700 D. In this process, the powder, optionally
batch-wise or
continuously, is fed to a feed trough of application machinery. The webs or
packets are
transferred from the output belt of a standard rotary drum pouch machine onto
a conveyor belt of
the powder application machine, wherein a controlled dosage of the powder is
applied to the web
or packet. The web or packet can thereafter be conveyed to a suitable
secondary packaging
process.
[0134] In embodiments wherein the auxiliary agents are in liquid form or in a
solution, the
foregoing can be dispersed among the fibers, dispersed on a face of the
nonwoven web, or a
combination thereof, for example, by spin casting, spraying a solution such as
an aerosolized
solution, roll coating, flow coating, curtain coating, extrusion, knife
coating, and combinations
thereof.
[0135] The auxiliary agents, such as chemical exfoliants, mechanical
exfoliants, fragrances
and/or perfume microcapsules, aversive agents, surfactants, colorants,
enzymes, skin
conditioners, de-oiling agents, cosmetic agents, or a combination thereof,
when present in the
nonwoven web, are in an amount of at least about 0.1 wt.%, or in a range of
about 0.1 wt.% to
about 99 wt.%, provides additional functionality to the nonwoven web. The
chemical exfoliants,
mechanical exfoliants, fragrances and/or perfume microcapsules, aversive
agents, surfactants,
colorants, enzymes, skin conditioners, de-oiling agents, cosmetic agents, or a
combination
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thereof, can take any desired form, including as a solid (e.g., powder,
granulate, crystal, flake, or
ribbon), a liquid, a mull, a paste, a gas, etc., and optionally can be
encapsulated.
[0136] In embodiments, the nonwoven web can be colored, pigmented, and/or dyed
to provide
an improved aesthetic effect relative to water-soluble films. Suitable
colorants for use in the
nonwoven web can include an indicator dye, such as a pH indicator (e.g.,
thymol blue,
bromothymol, thymolphthalein, and thymolphthalein), a moisture/water indicator
(e.g.,
hydrochromic inks or leuco dyes), or a thermochromic ink, wherein the ink
changes color when
temperature increases and/or decreases. Suitable colorants include, but are
not limited to, a
triphenylmethane dye, an azo dye, an anthraquinone dye, a perylene dye, an
indigoid dye, a food,
drug and cosmetic (FD&C) colorant, an organic pigment, an inorganic pigment,
or a combination
thereof. Examples of colorants include, but are not limited to, FD&C Red #40;
Red #3; FD&C
Black #3; Black #2; Mica-based pearlescent pigment; FD&C Yellow #6; Green #3;
Blue #1;
Blue #2; titanium dioxide (food grade); brilliant black; and a combination
thereof.
[0137] In embodiments, the nonwoven web can include any of the surfactants
disclosed
herein. In embodiments, the nonwoven web can comprise one or more of the group
of: sodium
cocoyl isethionate, glucotain, phoenamids, cola lipid, cocamides, such as
cocamide
ethanolamines, ethylene oxide-based surfactants, and saponified oils of
avocado and palm.
[0138] The nonwoven webs of the disclosure can have any thickness. Suitable
thicknesses can
include, but are not limited to, about 5 microns (lam) to about 10,000 lam (1
cm), about 5 lam to
about 5,000 p.m, about 5 p.m to about 1,000 p.m, about 5 j.tm to about 500 um,
about 200 [im to
about 500 p.m, about 5 p.m to about 200 p.m, about 20 p.m to about 100 p.m, or
about 40 jtm to
about 90 m, or about 50 p.m to 80 m, or about or about 60 tm to 65 jtm, for
example, 50 l.tm,
65 pm, 76 p.m, or 88 p.m. The nonwoven webs of the disclosure can be
characterized as high loft
or low loft. "Loft" refers to a 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 p.m. The thickness of the nonwoven web
can be
determined according to ASTM D5729-97, ASTM D5736, and/or ISO 9073-2:1995 and
can
include, for example, subjecting the nonwoven web to a load of 2 N and
measuring the thickness.
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High loft materials can be used according to known methods in the art, for
example, cross-
lapping, which uses a cross-lapper to fold the unbonded web over onto itself
to build loft and
basis weight. Without intending to be bound by theory, in contrast to water-
soluble films wherein
the solubility of the film can be dependent 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, it is
believed that because the individual fibers provide a higher surface area than
a water-soluble
film, regardless of the thickness of the nonwoven web, the parameter that
limits approach of
water to the fibers and, thereby, dissolution of the fibers is the basis
weight (i.e., fiber density in
the nonwoven).
[0139] In general, the coefficient of dynamic friction and the ratio of the
coefficient of static
friction to the coefficient of dynamic friction for a nonwoven web of the
disclosure will be lower
than the coefficient of dynamic friction and the ratio of the coefficient of
static friction to the
coefficient of dynamic friction for a water-soluble film due to the increased
surface roughness of
the nonwoven web relative to a water-soluble film, which provides decreased
surface contact to
the nonwoven web Advantageously, this surface roughness can provide an
improved feel to the
consumer (i.e., a cloth-like hand-feel instead of a rubbery hand-feel),
improved aesthetics (i.e.,
less glossy than a water-soluble film), and/or facilitate processability in
preparing thermoformed,
and/or vertical formed, filled, and sealed, and/or multichamber packets which
require drawing
the web along a surface of the processing equipment/mold. Accordingly, the
water-soluble fibers
and/or non-water-soluble fibers should be sufficiently coarse to provide a
surface roughness to
the resulting nonwoven web without being so coarse as to produce drag.
[0140] The solubility in water of the nonwoven webs of the disclosure is a
function of the
type of fiber(s) used to prepare the web as well as the basis weight of the
web. Without intending
to be bound by theory, it is believed that the solubility profile of a
nonwoven web follows the
same solubility profile of the fiber(s) used to prepare the nonwoven web, and
the solubility
profile of the fiber generally follows the same solubility profile of the
polymer(s) from which the
fiber is prepared. For example, for nonwoven webs comprising PVOH fibers, the
degree of
hydrolysis of the PVOH polymer can be chosen such that the water-solubility of
the nonwoven
web is also influenced. At a given temperature, as the degree of hydrolysis of
the PVOH polymer
increases from partially hydrolyzed (88% DH) to fully hydrolyzed (>98% DH),
water solubility
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of the polymer generally decreases. Thus, in example embodiments, the nonwoven
web can be
cold water-soluble. For a co-poly(vinyl acetate vinyl alcohol) polymer that
does not include any
other monomers (e.g., not copolymerized with an anionic monomer) a cold water-
soluble web,
soluble in water at a temperature of less than 10 C, can include fibers of
PVOH with a degree of
hydrolysis in a range of about 75% to about 90%, or in a range of about 75% to
about 89%, or in
a range of about 80% to about 90%, or in a range of about 85% to about 90%, or
in a range of
about 90% to about 99.5%. In other example embodiments, the nonwoven web can
be hot water-
soluble. For example, a co-poly(vinyl acetate vinyl alcohol) polymer that does
not include any
other monomers (e.g., not copolymerized with an anionic monomer), a hot water-
soluble web
can be soluble in water at a temperature of at least about 60 C, by including
fibers of PVOH with
a degree of hydrolysis of at least about 98%.
[0141] Modification of a PVOH polymer increases the solubility of the PVOH
polymer. Thus,
it is expected that at a given temperature the solubility of a nonwoven web or
film prepared from
a modified PVOH copolymer would be higher than that of a nonwoven web or film
prepared
from a PVOH copolymer having the same degree of hydrolysis as the modified
PVOH
copolymer. Following these trends, a nonwoven web having specific solubility
characteristics
can be designed by blending polymers within the fibers and/or blending fibers
within the
nonwoven web. Further, as described herein, the nonwoven web includes a
plurality of fibers
that may, in some cases, include two or more fiber types that differ in
solubility.
[0142] Inclusion of non-water-soluble fiber and/or non-water-soluble fiber-
forming material in
the plurality of fibers of a nonwoven web can also be used to design a
nonwoven web having
specific solubility and/or prolonged release properties. Without intending to
be bound by theory,
it is believed that as the weight percent of non-water-soluble fiber included
in a nonwoven web is
increased (based on the total weight of the nonwoven web), the solubility of
the nonwoven web
generally decreases and the prolonged release properties of a pouch comprising
a nonwoven web
generally increases. Upon contact with water at a temperature at or above the
solubility
temperature of the water-soluble fiber, a nonwoven web comprising water-
soluble fiber and non-
water-soluble fiber will begin to disperse as the water-soluble fiber
dissolves, thereby breaking
down the web structure and/or increasing the pore size of the pores of the
nonwoven web. The
larger the break-down of the web structure or increase in the pore size, the
faster the water can
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access the contents of the pouch and the faster the contents of the pouch will
be released.
Similarly, prolonged release of the contents of a pouch comprising the
nonwoven web of the
disclosure can be achieved by using a blend of water-soluble fibers having
different solubility
properties and/or different solubility temperatures. Once the faster
dissolving fiber has dissolved,
thereby breaking up the web, the less soluble fibers will have a larger
surface area exposed,
facilitating dissolution of the less soluble fibers and release of the pouch
contents. In
embodiments wherein the nonwoven web includes water-soluble fibers and non-
water-soluble
fibers, the ratio of soluble fibers to non-water-soluble fibers is not
particularly limited. The
water-soluble fibers can comprise about 1% to about 99%, about 20% to about
80%, about 40%
to about 90%, about 50% to about 90%, or about 60% to about 90% by weight, of
the total
weight of the plurality of fibers, and the non-water-soluble fibers can
comprise about 1% to
about 99%, about 20% to about 80%, about 10% to about 60%, about 10% to about
50%, or
about 10% to about 40% by weight, of the total weight of the fibers. In
embodiments, the
plurality of fibers comprise about 10% to about 80% water-soluble fibers by
weight, based on the
total weight of the fibers and the balance being non-water-soluble fibers.
[0143] In embodiments, the nonwoven web, the plurality of fibers, the foam,
the water-soluble
film, or a combination thereof, disclosed herein can comprises a biodegradable
polymer. In
certain embodiments, the plurality of fibers can comprise non-water-soluble
fiber-forming
materials that are biodegradable. In embodiments, the plurality of fibers can
comprise first fibers
that are non-water-soluble biodegradable fibers, and second fibers that are
soluble in water at a
temperature of about 10 C to about 20 C according to MSTM 205 or not soluble
in water at a
temperature of about 30 C or less according to MSTM 205, according to MSTM
205. In
embodiments, the nonwoven web is non-water-soluble and biodegradable.
[0144] In embodiments, the nonwoven web is biodegradable. As used herein, when
the
nonwoven web is said to be biodegradable, at least 50% of the nonwoven web is
biodegradable,
for example, at least 60%, at least 70%, at least 80%, at least 90%, or 100%,
of the nonwoven
web is biodegradable.
[0145] The nonwoven web as disclosed herein can comprise a composite material
including
the plurality of fibers comprising a first fiber type and a second fiber type,
wherein the first and
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second fiber types have a difference in diameter, length, tenacity, shape,
rigidness, elasticity,
solubility, melting point, glass transition temperature (TO, chemical
composition, color, or a
combination thereof. In embodiments, the first fiber type can 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 embodiments, the first
fiber type can
comprise 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. In embodiments, the second fiber type can
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
embodiments,
the second fiber type can comprise 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. In embodiments, the first
fiber type and/or the
second fiber type are non-water-soluble fiber-forming material. In
embodiments, the first fiber
type can comprise a non-water-soluble polymer fiber-forming material and the
second fiber type
can comprise a polyvinyl alcohol fiber-forming material that, when provided as
the sole fiber-
forming material of a nonwoven web or as a film, the resulting web or film is
soluble in water at
a temperature in a range of about 0 C to about 20 C according to MSTM 205. In
embodiments,
the first fiber type can comprise a non-water-soluble polymer fiber-forming
material and the
second fiber type can comprise a PVOH homopolymer or copolymer fiber-forming
material that,
when provided as the sole fiber-forming material of a nonwoven web or as a
film, the resulting
web or film is not soluble in water at a temperature of 20 C or less according
to MSTM 205. In
embodiments, the first fiber type comprises two or more PVOH copolymer fiber-
forming
materials, two or more modified PVOH copolymer fiber-forming materials, or a
combination of
PVOH copolymer fiber-forming materials and modified PVOH copolymer fiber-
forming
materials. In embodiments, the second fiber type comprises two or more PVOH
copolymer fiber-
forming materials, two or more modified PVOH copolymer fiber-forming
materials, or a
combination of PVOH copolymer fiber-forming materials and modified PVOH
copolymer fiber-
forming materials.
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[0146] The plurality of fibers comprised in the nonwoven webs of the
disclosure can have any
tenacity. The tenacity of the fiber correlates to the coarseness of the fiber.
As the tenacity of the
fiber decreases, the coarseness of the fiber increases. Fibers used to prepare
the nonwoven webs
of the disclosure can have a tenacity in a range 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, 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, or about 4 to about 7 cN/dtex, or about 10 to about 20, or
about 10 to about 18,
or about 10 to about 16, or about 1 cN/dtex, about 2 cN/dtex, 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 can have a tenacity in a
range of about 3 cN/dtex
to about 15 cN/dtex, or about 5 cN/dtex to about 12 cN/dtex, or about 5
cN/dtex to about 10
cN/dtex.
[0147] The tenacity of the nonwoven web can be the same or different from the
tenacity of the
plurality of fibers used to prepare the web. Without intending to be bound by
theory, it is
believed that the tenacity of the nonwoven web is related to the strength of
the nonwoven web,
wherein a higher tenacity provides a higher strength to the nonwoven web. The
tenacity of the
nonwoven web can be modified by using fibers having different tenacities. The
tenacity of the
nonwoven web may also be affected by processing. The nonwoven webs of the
disclosure have
relatively high tenacities, i.e., the nonwoven web is a self-supporting web
that can be used as the
sole material for preparing an article and/or pouch. In contrast, nonwoven
webs prepared
according to melt blown, electro-spinning, and/or rotary spinning processes
may have low
tenacities and may not be self-supporting or capable of being used as a sole
web for forming an
article or pouch.
[0148] The fibers used to prepare the nonwoven webs of the disclosure can have
any fineness.
The fineness of the fiber correlates to how many fibers are present in a cross-
section of a yarn of
a given thickness. The fineness of a fiber can be measured by the linear mass
density, a measure
of the ratio of fiber mass per unit length. The main physical unit of linear
mass density is 1 tex,
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which is equal to 1000 m of fiber weighing 1 g. The unit dtex is used,
representing 1g/10,000 m
of fiber. The linear mass density can be selected to provide a nonwoven web
having suitable
stiffness/hand-feel of the nonwoven web, torsional rigidity, reflection and
interaction with light,
absorption of dye and/or other actives/additives, ease of fiber spinning in
the manufacturing
process, and uniformity of the finished article. As the linear mass density of
the fibers increases
the nonwovens resulting therefrom demonstrate higher uniformity, improved
tensile strengths,
extensibility, and luster. Additionally, without intending to be bound by
theory it is believed that
finer fibers will lead to slower dissolution times as compared to larger
fibers based on density.
Further, without intending to be bound by theory, when a blend of fiber types
is used, the
average linear mass density can 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), slightly coarse (1.93< dtex < 2.32), and coarse (dtex
>2.32). The nonwoven
web of the disclosure can include fibers that are very fine, fine, medium,
slightly coarse, or a
combination thereof. In embodiments, the nonwoven web has an average linear
mass density in a
range of about 1 dtex to about 5 dtex, or about 1 dtex to about 3 dtex, or
about 1.5 dtex to about
2.5 dtex. In embodiments, the nonwoven web comprises a blend of fibers wherein
first fiber
comprises 1.7 dtex average linear mass density and second fiber comprises 2.2
dtex average
linear mass density.
[0149] The plurality of fibers used to prepare the nonwoven webs of the
disclosure have a
diameter in a range of about 10 microns to 300 microns, for example, 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, 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 prepare the
nonwoven webs
of the disclosure can have a diameter greater than 100 microns to about 300
microns. In
embodiments, the diameters of the plurality of fibers used to prepare the
nonwoven webs of the
disclosure have diameters that are substantially uniform. In embodiments, the
one or more fiber
types can have a mean diameter in a range of about 10 microns to about 300
microns, or about 50
microns to 200 microns, or about 50 microns to about 100 microns.
[0150] The plurality of fibers used to prepare the nonwoven webs of the
disclosure can be of
any length. In embodiments, the length of the plurality of fibers can be in a
range of about 30
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millimeters (mm) to about 100 mm, about 10 mm to about 60 mm, or about 30 mm
to about 60
mm, for example, at least about 30 mm, at least about 35 mm, at least about 40
mm, at least
about 45 mm, or at least about 50 mm, and up to about 100 mm, up to about 95
mm, up to about
90 mm, up to about 80 mm, up to about 70 mm, or up to about 60 mm. In
embodiments, the
length of the plurality of fibers can be less than about 30 mm or in a range
of about 0.25 mm to
less than about 30 mm, for example, 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 up to about 15 mm. In
embodiments,
the fibers have an average length of about 30 mm to about 100 mm, or about 30
mm to about 60
mm. In embodiments, the nonwoven web comprises a blend of fiber types wherein
first fiber
type comprises a length of about 38 mm and second fiber type comprises a
length of about 54
mm.
[0151] The plurality of fibers used to prepare the nonwoven webs of the
disclosure can have
any length to diameter (L/D) ratio. Advantageously, the tactility of a
nonwoven web of the
disclosure can be controlled using the L/D ratio of the fibers and the
respective amounts of fibers
having various L/D ratios in the nonwoven composition. As the L/D of the fiber
decreases, the
stiffness and resistance to bending increases, providing a rougher hand feel.
The fibers of the
disclosure impart a rough feel to a nonwoven web including same, when the
fibers have a low
L/D ratio in a range of about 0.5 to about 15, or about 0.5 to about 25, or
about 1 to about 5.
Such low L/D fibers can be provided in a nonwoven web in an amount in a range
of about 0 to
about 50 % by weight, based on the total weight of the fibers in the nonwoven
web, for example,
in a range of about 0.5 wt.% to about 25 wt.%, or about 1 wt.% to about 15
wt.%. If the amount
of low L/D fibers in a nonwoven web is not known, the amount can be estimated
by visual
inspection of a micrograph of a nonwoven web. In embodiments wherein a first
fiber includes a
blend of fiber-forming materials including a first polyvinyl alcohol fiber-
forming material, at
least a portion of the first fibers can have a L/D ratio of about 0.5 to about
25, or about 0.5 to
about 15, or about 1 to about 5.
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[0152] Pore sizes can be determined using high magnification and ordered
surface analysis
techniques including, but not limited to Brunauer-Emmett-Teller theory (BET),
and molecular
adsorption.
[0153] 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 is known in the art. A nonwoven web can have the
same basis
weight prior to and after bonding. Alternatively, the bonding method can
change the basis weight
of the nonwoven web. For example, wherein bonding occurs through the
application of heat and
pressure, the thickness of the nonwoven (and, thus, the area of the nonwoven)
can be decreased,
thereby increasing the basis weight. Accordingly, as used herein and unless
specified otherwise,
the basis weight of a nonwoven refers to the basis weight of the nonwoven
after bonding.
[0154] The nonwoven webs of the disclosure can have any basis weight in a
range of about 0.1
g/m2 to about 700 g/m2, about 0.5 g/m2 to about 600 g/m2, about 1 g/m2 to
about 500 g/m2, about
1 g/m2 to about 400 g/m2, about 1 g/m2 to about 300 g/m2, about 1 g/m2 to
about 200 g/m2, about
1 g/m2 to about 100 g/m2, about 30 g/m2 to about 100 g/m2, about 20 g/m2 to
about 100 g/m2,
about 20 g/m2 to about 80 g/m2, or about 25 g/m2 to about 70 g/m2.
[0155] Further, as the basis weight of the web increases, the rate of
dissolution of the web
decreases, provided the fiber composition and web thickness remain constant,
as there is more
material to be dissolved. For example, at a given temperature, a water-soluble
web prepared from
fibers comprising PVOH polymer(s) and having a basis weight of, e.g., 40 g/m2,
is expected to
dissolve slower than an otherwise-identical water-soluble web having a basis
weight of, e.g., 30
g/m2. Accordingly, basis weight can also be used to modify the solubility
characteristics of the
nonwoven web. The nonwoven web can have any basis weight in a range of about 1
g/m2 to
about 700 g/m2, about 1 g/m2 to about 600 g/m2, about 1 g/m2 to about 500
g/m2, about 1 g/m2 to
about 400 g/m2, about 1 g/m2 to about 300 g/m2, about 1 g/m2 to about 200
g/m2, about 10 g/m2
to about 100 g/m2, about 30 g/m2 to about 100 g/m2, about 20 g/m2 to about 100
g/m2, about 20
g/m2 to about 80 g/m2, about 25 g/m2 to about 70 g/m2, or about 40 g/m2 to
about 60 g/m2.
[0156] The nonwoven web of the disclosure can be used as a single layer or can
be layered
with other nonwoven webs or can be in the form of a laminate with a water-
soluble film. In some
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embodiments, the nonwoven web includes a single layer of nonwoven web. In some
embodiments, the nonwoven web is a multilayer nonwoven web comprising two or
more layers
of nonwoven webs. The two or more layers can be laminated to each other. In
refinements of the
foregoing embodiment, the two or more layers can be the same (e.g., be
prepared from the same
fibers and basis weight). In refinements of the foregoing embodiment, the two
or more layers can
be different (e.g., be prepared from different types of fibers, fiber
chemistries, and/or have
different basis weights).
[0157] A multilayer nonwoven web can have a basis weight that is the sum of
the basis
weights of the individual layers. Accordingly, a multilayer nonwoven web will
take longer to
dissolve than any of the individual layers provided as a single layer.
Water-Soluble Foams
[0158] In example embodiments, a suitable water-soluble foam includes any
suitable resin
chemistry, such as a PVOH homopolymer; a PVOH copolymer; a modified PVOH
copolymer,
such as maleic anhydride (MA) modified PVOH copolymer, monomethyl maleate
(MMM),
Modified PVOH copolymer, and AMPS (2-methylacrylamido-2-methylpropanesulfonic
acid)
Modified PVOH copolymer; cellulose and cellulose derivatives; PVP; proteins;
casein; soy; 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 can be formed using
any suitable
manufacturing process known in the foam manufacturing art including, without
limitation, a cast,
extruded, melt processed, coated, chemically blown, mechanically aerated, air
injected, turbulent
extrusion process. The water-soluble foam substrate may be porous or non-
porous and cold
water-soluble or hot water-soluble. The construction of the water-soluble foam
substrate may
include, for example, folded layers or plies, stacked layers or plies, or
rolled layers or plies.
[0159] In example embodiments, the water-soluble foam substrate can further
comprise any
auxiliary agents as disclosed herein for nonwoven webs, fibers and/or films.
The auxiliary agents
can be applied to one or more faces of a water-soluble foam substrate or to an
article containing
same, e.g., a packet, by any suitable means. In embodiments, the auxiliary
agents are in powder
form. In refinements of the foregoing embodiment, one or more stationary
powder spray guns are
used to direct the powder stream towards the water-soluble foam substrate or a
packet, from one
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or more than one direction, while the water-soluble foam substrate or packet
is transported
through the coating zone by means of a belt conveyor. In embodiments, a water-
soluble foam
substrate or packet is conveyed through a suspension of the powder in air. In
embodiments, the
water-soluble foam substrate or packets are tumble-mixed with the powder in a
trough-like
apparatus. In embodiments, which can be combined with any other embodiment,
electrostatic
forces are employed to enhance the attraction between the powder and the
packet or water-
soluble foam substrate. This type of process may be based on negatively
charging the powder
particles and directing these charged particles to the grounded packets or
water-soluble foam
substrates. In other alternative embodiments, the powder is applied to the
water-soluble foam
substrate or packet by a secondary transferring tool including, but not
limited to, rotating brushes
which are in contact with the powder or by powdered gloves which can transfer
the powder from
a container to the water-soluble foam substrate or the packet. In yet 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 the water-soluble foam substrate or
packet. In one
embodiment, the solvent or carrier subsequently evaporates, leaving the active
agent powder
behind. In certain embodiments, the powder is applied to the water-soluble
foam substrate or
packet in an accurate dose. These embodiments utilize closed-system dry
lubricant application
machinery, such as PekuTECH's powder applicator PM 700 D. In this process, the
powder,
optionally batch-wise or continuously, is fed to a feed trough of application
machinery. The
water-soluble foam substrates or packets are transferred from the output belt
of a standard rotary
drum pouch machine onto a conveyor belt of the powder application machine,
wherein a
controlled dosage of the powder is applied to the water-soluble foam substrate
or packet The
water-soluble foam substrate or packet can thereafter be conveyed to a
suitable secondary
packaging process.
[0160] In embodiments wherein the auxiliary agents are in liquid form or in a
solution, the
foregoing can be dispersed in the water-soluble foam substrate, dispersed on a
face of the water-
soluble foam substrate, or a combination thereof, for example, by spin
casting, spraying a
solution such as an aerosolized solution, roll coating, flow coating, curtain
coating, extrusion,
knife coating, and combinations thereof.
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[0161] The auxiliary agents, such as chemical exfoliants, mechanical
exfoliants, fragrances
and/or perfume microcapsules, aversive agents, surfactants, colorants,
enzymes, skin
conditioners, de-oiling agents, cosmetic agents, or a combination thereof,
when present in the
water-soluble foam substrate, are in an amount of at least about 0.1 wt.%, or
in a range of about
0.1 wt.% to about 99 wt.%, provides additional functionality to the water-
soluble foam substrate.
The chemical exfoliants, mechanical exfoliants, fragrances and/or perfume
microcapsules,
aversive agents, surfactants, colorants, enzymes, skin conditioners, de-oiling
agents, cosmetic
agents, or a combination thereof, can take any desired form, including as a
solid (e.g., powder,
granulate, crystal, flake, or ribbon), a liquid, a mull, a paste, a gas, etc.,
and optionally can be
encapsulated.
[0162] In embodiments, the water-soluble foam substrate can be colored,
pigmented, and/or
dyed to provide an improved aesthetic effect relative to water-soluble films.
Suitable colorants
for use in the water-soluble foam substrate can include an indicator dye, such
as a pH indicator
(e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), a
moisture/water
indicator (e g , hydrochromic inks or leuco dyes), or a thermochromic ink,
wherein the ink
changes color when temperature increases and/or decreases. Suitable colorants
include, but are
not limited to, a triphenylmethane dye, an azo dye, an anthraquinone dye, a
perylene dye, an
indigoid dye, a food, drug and cosmetic (FD&C) colorant, an organic pigment,
an inorganic
pigment, or a combination thereof. Examples of colorants include, but are not
limited to, FD&C
Red #40, Red #3, FD&C Black #3; Black #2, Mica-based pearlescent pigment, FD&C
Yellow
#6; Green #3; Blue #1; Blue #2; titanium dioxide (food grade); brilliant
black; and a combination
thereof.
[0163] In embodiments, the water-soluble foam substrate can include any of the
surfactants
disclosed herein. In embodiments, the water-soluble foam substrate can
comprise one or more of
the group of: sodium cocoyl isethionate, glucotain, phoenamids, cola lipid,
cocamides, such as
cocamide ethanolamines, ethylene oxide-based surfactants, and saponified oils
of avocado and
palm.
[0164] The water-soluble foam substrate of the disclosure can have any
thickness. Suitable
thicknesses can include, but are not limited to, about 5 microns (i.tm) to
about 10,000 Jim (1 cm),
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about 3 um to about 5,000 um, about 5 um to about 1,000 um, about 5 um to
about 500 um,
about 200 um to about 500 um, about 5 um to about 200 um, about 20 um to about
100 um, or
about 40 um to about 90 um, or about 50 um to 80 um, or about or about 60 um
to 65 um, for
example, 50 um, 65 um, 76 um, or 88 um. The water-soluble foam substrate of
the disclosure
can be characterized as high loft or low loft. -Loft" refers to a ratio of
thickness to mass per unit
area (i.e., basis weight). High loft water-soluble foam substrates can be
characterized by a high
ratio of thickness to mass per unit area. As used herein, "high loft" refers
to a water-soluble foam
substrate of the disclosure having a basis weight as defined herein and a
thickness exceeding 200
um. The thickness of the water-soluble foam substrate can be determined
according to ASTM
D5729-97, ASTM D5736, and/or ISO 9073-2:1995 and can include, for example,
subjecting the
water-soluble foam substrate to a load of 2 N and measuring the thickness.
High loft materials
can be used according to known methods in the art, for example, cross-lapping,
which uses a
cross-lapper to fold the unbonded web over onto itself to build loft and basis
weight.
[0165] The coefficient of dynamic friction and the ratio of the coefficient of
static friction to
the coefficient of dynamic friction for a water-soluble foam substrate of the
disclosure will be
lower than the coefficient of dynamic friction and the ratio of the
coefficient of static friction to
the coefficient of dynamic friction for a water-soluble film due to the
increased surface
roughness of the water-soluble foam substrate relative to a water-soluble
film, which provides
decreased surface contact to the water-soluble foam substrate. Advantageously,
this surface
roughness can provide an improved feel to the consumer (i.e., a cloth-like
hand-feel instead of a
rubbery hand-feel), improved aesthetics (i.e., less glossy than a water-
soluble film), and/or
facilitate processability in preparing thermoformed, and/or vertical formed,
filled, and sealed,
and/or multichamber packets which require drawing the water-soluble foam
substrate along a
surface of the processing equipment/mold. Accordingly, the water-soluble
fibers and/or non-
water-soluble fibers should be sufficiently coarse to provide a surface
roughness to the resulting
water-soluble foam substrate without being so coarse as to produce drag.
[0166] The solubility in water of the soluble foam substrate closure is a
function of the type of
fiber(s) used to prepare the water-soluble foam substrate as well as the basis
weight of the water-
soluble foam substrate. Without intending to be bound by theory, it is
believed that the solubility
profile of a water-soluble foam substrate follows the same solubility profile
of the fiber(s) used
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to prepare the water-soluble foam substrate, and the solubility profile of the
fiber generally
follows the same solubility profile of the polymer(s) from which the fiber is
prepared. For
example, for the water-soluble foam substrates comprising PVOH fibers, the
degree of
hydrolysis of the PVOH polymer can be chosen such that the water-solubility of
the water-
soluble foam substrate is also influenced. In general, at a given temperature,
as the degree of
hydrolysis of the PVOH polymer increases from partially hydrolyzed (88% DH) to
fully
hydrolyzed (>98% DH), water solubility of the polymer generally decreases.
Thus, in example
embodiments, the water-soluble foam substrate can be cold water-soluble. For a
co-poly(vinyl
acetate vinyl alcohol) polymer that does not include any other monomers (e.g.,
not
copolymerized with an anionic monomer) a cold water-soluble web, soluble in
water at a
temperature of less than 10 C, can include fibers of PVOH with a degree of
hydrolysis in a range
of about 75% to about 90%, or in a range of about 75% to about 89%, or in a
range of about 80%
to about 90%, or in a range of about 85% to about 90%, or in a range of about
90% to about
99.5%. In other example embodiments, the water-soluble foam substrate can be
hot water-
soluble. For example, a co-poly(vinyl acetate vinyl alcohol) polymer that does
not include any
other monomers (e.g., not copolymerized with an anionic monomer), a hot water-
soluble foam
substrate can be soluble in water at a temperature of at least about 60 C, by
including fibers of
PVOH with a degree of hydrolysis of at least about 98%.
[0167] Modification of a PVOH polymer increases the solubility of the PVOH
polymer. Thus,
it is expected that at a given temperature the solubility of a water-soluble
foam substrate
prepared from a modified PVOH copolymer would be higher than that of a water-
soluble foam
substrate prepared from a PVOH copolymer having the same degree of hydrolysis
as the
modified PVOH copolymer. Following these trends, a water-soluble foam
substrate having
specific solubility characteristics can be designed by blending polymers
within the fibers and/or
blending fibers within the water-soluble foam substrate. Further, as described
herein, the water-
soluble foam substrate includes a plurality of fibers that may, in some cases,
include two or more
fiber types that differ in solubility.
[0168] Inclusion of non-water-soluble fiber and/or non-water-soluble fiber-
forming material in
the plurality of fibers of a water-soluble foam substrate can also be used to
design a water-
soluble foam substrate having specific solubility and/or prolonged release
properties. Without
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intending to be bound by theory, it is believed that as the weight percent of
non-water-soluble
fiber included in a water-soluble foam substrate is increased (based on the
total weight of the
water-soluble foam substrate), the solubility of the water-soluble foam
substrate generally
decreases and the prolonged release properties of a pouch comprising a water-
soluble foam
substrate generally increases. Upon contact with water at a temperature at or
above the solubility
temperature of the water-soluble fiber, a water-soluble foam substrate
comprising water-soluble
fiber and non-water-soluble fiber will begin to disperse as the water-soluble
fiber dissolves,
thereby breaking down the foam structure and/or increasing the pore size of
the pores of the
water-soluble foam substrate. The larger the break-down of the foam structure
or increase in the
pore size, the faster the water can access the contents of the pouch and the
faster the contents of
the pouch will be released. Similarly, prolonged release of the contents of a
pouch comprising
the water-soluble foam substrate of the disclosure can be achieved by using a
blend of water-
soluble fibers having different solubility properties and/or different
solubility temperatures. Once
the faster dissolving fiber has dissolved, thereby breaking up the foam, the
less soluble fibers
will have a larger surface area exposed, facilitating dissolution of the less
soluble fibers and
release of the pouch contents. In embodiments wherein the foam substrate
includes water-soluble
fibers and non-water-soluble fibers, the ratio of soluble fibers to non-water-
soluble fibers is not
particularly limited. The water-soluble fibers can comprise about 1% to about
99%, about 20% to
about 80%, about 40% to about 90%, about 50% to about 90%, or about 60% to
about 90% by
weight, of the total weight of the plurality of fibers, and the non-water-
soluble fibers can
comprise about 1% to about 99%, about 20% to about 80%, about 10% to about
60%, about 10%
to about 50%, or about 10% to about 40% by weight, of the total weight of the
fibers. In
embodiments, the plurality of fibers comprise about 10% to about 80% water-
soluble fibers by
weight, based on the total weight of the fibers and the balance being non-
water-soluble fibers.
[0169] In embodiments, the nonwoven web, the plurality of fibers, the foam,
the water-soluble
film, or a combination thereof, disclosed herein can comprises a biodegradable
polymer. In
certain embodiments, the plurality of fibers can comprise non-water-soluble
fiber-forming
materials that are biodegradable. In embodiments, the plurality of fibers can
comprise first fibers
that are non-water-soluble biodegradable fibers, and second fibers that are
soluble in water at a
temperature of about 10 C to about 20 C according to MSTM 205 or not soluble
in water at a
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temperature of about 30 C or less according to MSTM 205, according to MSTM
205. In
embodiments, the nonwoven web is non-water-soluble and biodegradable.
[0170] In embodiments, the water-soluble foam substrate is biodegradable. As
used herein,
when the water-soluble foam substrate is said to be biodegradable, at least
50% of the water-
soluble foam substrate is biodegradable, for example, at least 60%, at least
70%, at least 80%, at
least 90%, or 100%, of the water-soluble foam substrate is biodegradable.
[0171] In example embodiments, the water-soluble foam substrate as disclosed
herein can
comprise the plurality of fibers comprising a first fiber type and a second
fiber type, wherein the
first and second fiber types have a difference in diameter, length, tenacity,
shape, rigidness,
elasticity, solubility, melting point, glass transition temperature (TO,
chemical composition,
color, or a combination thereof. In embodiments, the first fiber type can
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
embodiments, the first
fiber type can comprise 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. In embodiments, the second fiber
type can 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
embodiments,
the second fiber type can comprise 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. In embodiments, the first
fiber type and/or the
second fiber type are non-water-soluble fiber-forming material. In
embodiments, the first fiber
type can comprise a non-water-soluble polymer fiber-forming material and the
second fiber type
can comprise a polyvinyl alcohol fiber-forming material that, when provided as
the sole fiber-
forming material of a nonwoven web or as a film, the resulting web or film is
soluble in water at
a temperature in a range of about 0 C to about 20 C according to MSTM 205. In
embodiments,
the first fiber type can comprise a non-water-soluble polymer fiber-forming
material and the
second fiber type can comprise a PVOH copolymer or modified copolymer fiber-
forming
material that, when provided as the sole fiber-forming material of a water-
soluble foam substrate,
the resulting water-soluble foam substrate is not soluble in water at a
temperature of 20 C or less
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according to MSTM 205. In embodiments, the first fiber type comprises two or
more PVOH
copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-
forming
materials, or a combination of PVOH copolymer fiber-forming materials and
modified PVOH
copolymer fiber-forming materials. In embodiments, the second fiber type
comprises two or
more PVOH copolymer fiber-forming materials, two or more modified PVOH
copolymer fiber-
forming materials, or a combination of copolymer fiber-forming materials and
modified PVOH
copolymer fiber-forming materials.
[0172] The plurality of fibers comprised in the water-soluble foam substrate
of the disclosure
can have any tenacity. The tenacity of the fiber correlates to the coarseness
of the fiber. As the
tenacity of the fiber decreases the coarseness of the fiber increases. Fibers
used to prepare the
nonwoven webs of the disclosure can have a tenacity in a range 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, 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, or about 4 to about 7 cN/dtex, or about 10 to
about 20, or about 10 to
about 18, or about 10 to about 16, or about 1 cN/dtex, about 2 cN/dtex, 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 can have a tenacity
in a range of about
3 cN/dtex to about 15 cN/dtex, or about 5 cN/dtex to about 12 cN/dtex, or
about 5 cN/dtex to
about 10 cN/dtex.
[0173] The tenacity of the water-soluble foam substrate can be the same or
different from the
tenacity of the plurality of fibers used to prepare the web. Without intending
to be bound by
theory, it is believed that the tenacity of the water-soluble foam substrate
is related to the
strength of the nonwoven web, wherein a higher tenacity provides a higher
strength to the
nonwoven web. The tenacity of the water-soluble foam substrate can be modified
by using fibers
having different tenacities. The tenacity of the water-soluble foam substrate
may also be affected
by processing. The water-soluble foam substrate of the disclosure has
relatively high tenacities,
i.e., the water-soluble foam substrate is a self-supporting substrate that can
be used as the sole
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material for preparing an article and/or pouch. In contrast, water-soluble
foam substrate prepared
according to melt blown, electro-spinning, and/or rotary spinning processes
have low tenacities
and may not be self-supporting or capable of being used as a sole substrate
for forming an article
or pouch.
[0174] Water-soluble foam substrates 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 is known
in the art. A
water-soluble foam substrate can have the same basis weight prior to and after
bonding.
Alternatively, the bonding method can change the basis weight of the water-
soluble foam
substrate. For example, wherein 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 decreased, thereby increasing the basis weight. Accordingly,
as used herein and
unless specified otherwise, the basis weight of a water-soluble foam substrate
refers to the basis
weight of the water-soluble foam substrate after bonding.
[0175] The water-soluble foam substrate of the disclosure can have any basis
weight in a
range of about 0.1 g/m2 to about 700 g/m2, about 0.5 g/m2 to about 600 g/m2,
about 1 g/m2 to
about 500 g/m2, about 1 g/m2 to about 400 g/m2, about 1 g/m2 to about 300
g/m2, about 1 g/m2 to
about 200 g/m2, about 1 g/m2 to about 100 g/m2, about 30 g/m2 to about 100
g/m2, about 20 g/m2
to about 100 g/m2, about 20 g/m2 to about 80 g/m2, or about 25 g/m2 to about
70 g/m2.
[0176] Further, as the basis weight of the water-soluble foam substrate
increases the rate of
dissolution of the water-soluble foam substrate decreases, provided the fiber
composition and
web thickness remain constant, as there is more material to be dissolved. For
example, at a given
temperature, a water-soluble foam substrate prepared from fibers comprising
PVOH polymer(s)
and having a basis weight of, e.g., 40 g/m2, is expected to dissolve slower
than an otherwise-
identical water-soluble web having a basis weight of, e.g., 30 g/m2.
Accordingly, basis weight
can also be used to modify the solubility characteristics of the water-soluble
foam substrate. The
water-soluble foam substrate can have any basis weight in a range of about 1
g/m2 to about 700
g/m2, about 1 g/m2 to about 600 g/m2, about 1 g/m2 to about 500 g/m2, about 1
g/m2 to about 400
g/m2, about 1 g/m2 to about 300 g/m2, about 1 g/m2 to about 200 g/m2, about 10
g/m2 to about
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100 g/m2, about 30 g/m2 to about 100 g/m2, about 20 g/m2 to about 100 g/m2,
about 20 g/m2 to
about 80 g/m2, about 25 g/m2 to about 70 g/m2, or about 40 g/m2 to about 60
g/m2.
[0177] The water-soluble foam substrate of the disclosure can be used as a
single layer or can
be layered with other water-soluble foam substrates or can be in the form of a
laminate with a
water-soluble film. In some embodiments, the water-soluble foam substrate
includes a single
layer. In some embodiments, the water-soluble foam substrate is a multilayer
water-soluble foam
substrate comprising two or more layers. The two or more layers can be
laminated to each other.
In refinements of the foregoing embodiment, the two or more layers can be the
same (e.g., be
prepared from the same fibers and basis weight). In refinements of the
foregoing embodiment,
the two or more layers can be different (e.g., be prepared from different
types of fibers, fiber
chemistries, and/or have different basis weights).
[0178] A multilayer water-soluble foam substrate 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 any of the individual layers provided as a
single layer.
Water-Soluble Films
[0179] The water-soluble film described herein comprises any of the water-
soluble polymers
disclosed herein. In embodiments, the water-soluble film of the disclosure
comprises a polyvinyl
alcohol (PVOH) resin, a modified polyvinyl alcohol resin, or combinations
thereof In
embodiments, the water-soluble film includes a PVOH resin selected from the
group consisting
of a PVOH homopolymer, a PVOH copolymer, a PVOH copolymer having an anionic
modification, and combinations of the foregoing. In embodiments, the water-
soluble film can
comprise a single PVOH polymer or a blend of PVOH polymer. In embodiments, the
water-
soluble film comprises a PVOH copolymer. In embodiments, the water-soluble
film comprises a
hot water-soluble PVOH copolymer. In embodiments wherein the nonwoven web
includes a
surfactant and/or an exfoliant, the water-soluble film can comprise a PVOH
copolymer having an
anionic modification. In embodiments, the water-soluble film can comprise a
water-soluble
polyvinyl alcohol copolymer or modified copolymer that, when provided in a
film as the sole
film forming material, the film is soluble in water at a temperature in a
range of about 0 C to
about 20 C according to MSTM 205. In embodiments, the water-soluble film can
comprise a
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water-soluble polyvinyl alcohol copolymer or modified copolymer that, when
provided in a film
as the sole film forming material, the film is not water-soluble at a water
temperature of 20 C or
less according to MSTM 205, according to MSTM 205.
[0180] The water-soluble film can include other film forming polymers
including, but not
limited to, polyvinyl alcohols, water-soluble acrylate copolymers,
polyethyleneimine, pullulan,
water-soluble natural polymers including, but not limited to, guar gum, gum
Acacia, xanthan
gum, carrageenan, and starch, water-soluble polymer modified starches,
copolymers of the
foregoing, or a combination of any of the foregoing. Other water-soluble
polymers can include
polyalkylene oxides, polyacrylamides, celluloses, cellulose ethers, cellulose
esters, cellulose
amides, polyvinyl acetates, polycarboxylic acids and salts thereof,
polyaminoacids, polyamides,
gelatines, methylcelluloses, carboxymethylcelluloses and salts thereof,
dextrins, ethylcelluloses,
hydroxyethyl celluloses, hydroxypropyl methylcelluloses, maltodextrins,
polymethacrylates, or a
combination of any of the foregoing. Such water-soluble polymers are
commercially available
from a variety of sources. In embodiments, the water-soluble film can include
a PVOH
homopolymer, PVOH copolymer, 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 further embodiments, the water-soluble film comprises a PVOH
copolymer with
a viscosity in a range of 5 cP to 23 cP and a degree of hydrolysis in a range
of 86% to 92%.
[0181] The film can have any suitable thickness, and a film thickness of about
76 microns
(p.m) is typical and particularly contemplated. Other values and ranges
contemplated include
values in a range of about 5 pm to about 200 pm, or in a range of about 20 pm
to about 100 pm,
or about 40 pm to about 90 pm, or about 50 pm to 80 pm, or about or about 60
pm to 65 p.m, for
example, 65 um, 76 um, or 88 um.
[0182] In embodiments, the water-soluble films can include an auxiliary agent
as described
above. In embodiments, the water-soluble films can be substantially free of
auxiliary agents as
described above. In embodiments, the water-soluble films can include a
plasticizer as described
above. The total amount of the non-water plasticizer provided in the water-
soluble film can be in
a range of about 1 wt.% to about 45 wt.%, or about 5 wt.% to about 45 wt.%, or
about 10 wt.%
to about 40 wt.%, or about 20 wt% to about 30 wt.%, about 1 wt.% to about 4
wt.%, or about 1.5
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wt.% to about 3.5 wt.%, or about 2.0 wt.% to about 3.0 wt.%, for example,
about 1 wt.%, about
2.5 wt.%, about 5 wt.%, about 10 wt.%, about 15 wt.%, about 20 wt.%, about 25
wt.%, about 30
wt.%, about 35 wt.%, or about 40 wt.%, based on total film weight. In
embodiments, 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).
[0183] In embodiments, the water-soluble films can include a surfactant as
described above. In
various embodiments, the amount of surfactant in the water-soluble film is in
a range of about
0.01 wt.%, to about 2.5 wt.%, about 0.1 wt.% to about 2.5 wt.%, about LO wt.%
to about 2.0
wt.%, about 0.01 wt.% to 0.25 wt.%, or about 0.10 wt.% to 0.20 wt.%. In
embodiments, the
water-soluble film comprises one or more of polysorbate 80, lecithin from
various plant sources,
and sodium lauryl sulfate (SLS) and the like or any combination thereof.
[0184] In embodiments, the auxiliary agents of the water-soluble film can
include
fillers/extenders/antiblocking agents/detackifying agents. Suitable
fillers/extenders/antiblocking
agents/detackifying agents include, but are not limited to, cross-linked
polyvinylpyrrolidone,
cross-linked cellulose, microcrystalline cellulose, silica, metallic oxides,
calcium carbonate, talc,
mica, stearic acid, and metal salts thereof, for example, magnesium stearate.
Optionally, an
additional unmodified starch or modified starch can be included the water-
soluble in addition to
one of the specific starch components described above, for example,
hydroxypropylated starch
present in an amount in a range of about 5 phr to about 30 phr, or modified
starch having a
degree of modification of greater than about 2% and is present in an amount in
a range of about
2.5 phr to about 30 phr, or an unmodified starch having an amylose content in
a range of about
20% to about 80%, or a hydroxypropyl modified starch having an amylose content
in a range of
about 23% to about 95% when the polyvinyl alcohol comprises an unmodified
polyvinyl alcohol
copolymer or an anionic modified polyvinyl alcohol copolymer with the proviso
that the anionic
modifier is not an acrylate. Preferred materials are starches, modified
starches, and silica. In one
embodiment, the amount of filler/extender/antiblocking agent/detackifying
agent in the water-
soluble film can be in a range of about 1 wt.% to about 6 wt.%, or about 1
wt.% to about 4 wt.%,
or about 2 wt.% to about 4 wt.%, or about 1 phr to about 6 phr, or about 1 phr
to about 4 phr, or
about 2 phr to about 4 phr, for example. In embodiments, when a starch or
modified starch is
included in the water-soluble film in addition to one of the specific starch
components described
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above, the additional starch component will be provided in an amount of less
than about 50
wt.%, based on the total weight of all starches included in the film. Without
intending to be
bound by theory, it is believed that any benefit provided to the water-soluble
films of the
disclosure from the inclusion of the starch component described above is not
affected by
including an additional starch component that provides a lesser benefit to the
water-soluble film
or no benefit to the water-soluble film.
[0185] The water-soluble film can further have a residual moisture content of
at least 4 wt.%,
for example, in a range of about 4 wt.% to about 10 wt.%, as measured by Karl
Fischer titration.
Methods of Preparing Fibers
[0186] Wet Cooled Gel Spinning
[0187] In embodiments, the plurality of water-soluble fibers can include water-
soluble fibers
prepared according to a wet cooled gel spinning process, the wet cooled gel
spinning process
including the steps of:
(a) dissolving the water-soluble polymer (or polymers) in solution to form a
polymer mixture,
the polymer mixture optionally including auxiliary agents;
(b) extruding the polymer mixture through a spinneret nozzle to a
solidification 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 the water-soluble fibers
[0188] The solvent in which the water-soluble polymer is dissolved can
suitably be any
solvent in which the water-soluble polymer is soluble. In embodiments, the
solvent in which the
water-soluble polymer is dissolved includes a polar aprotic solvent. In
embodiments, the solvent
in which the water-soluble polymer is dissolved includes dimethyl sulfoxide
(DMS0).
[0189] The solidification bath includes a cooled solvent for gelling the
extruded polymer
mixture. The solidification bath can generally be at any temperature that
facilitates solidification
of the extruded polymer mixture. The solidification bath can be a mixture
including a solvent in
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which the polymer is soluble and a solvent in which the polymer is not
soluble. The solvent in
which the polymer is not soluble is generally the primary solvent, wherein the
solvent in which
the polymer is not soluble makes up greater than 50% of the mixture by volume.
[0190] After passing through the solidification bath, the extruded polymer
mixture gel can be
passed through one or more solvent replacement baths. The solvent replacement
baths are
provided to replace the solvent in which the water-soluble polymer is soluble
with the solvent in
which the water-soluble polymer is not soluble to further solidify the
extruded polymer mixture
and, further, to replace the solvent in which the water-soluble polymer is
soluble with a solvent
that will more readily evaporate, thereby reducing the drying time. Solvent
replacement baths
can include a series of solvent replacement baths having a gradient of solvent
in which the water-
soluble polymer is soluble with the solvent in which the water-soluble polymer
is not soluble, a
series of solvent replacement baths having only the solvent in which the water-
soluble polymer is
not soluble, or a single solvent replacement bath having only the solvent in
which the water-
soluble polymer is not soluble. In embodiments, at least one solvent
replacement bath can consist
essentially of a solvent in which the water-soluble polymer is not soluble
[0191] Finished fibers are sometimes referred to as staple fibers, shortcut
fibers, or pulp. In
embodiments, 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 a substantially
uniform diameter to
the extruded polymer mixture and, thus, the fibers cut therefrom. Drawing is
distinct from
extruding, as is well known in the art. In particular, -extruding" refers to
the act of making fibers
by forcing the resin mixture through the spinneret head whereas drawing refers
to mechanically
pulling the fibers in the machine direction to promote polymer chain
orientation and crystallinity
for increased fiber strength and tenacity.
[0192] In embodiments wherein the water-soluble fibers are prepared from a wet
cooled gel
spinning process, the water-soluble polymer can be generally any water-soluble
polymer or
blend thereof, e.g., two or more different polymers, as generally described
herein. In refinements
of the foregoing embodiment, the polymer(s) can have any degree of
polymerization (DP), for
example, in a range of 10 to 10,000,000, for example, at least 10, at least
20, at least 50, at least
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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, for example in a range
of 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 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. In embodiments, the DP
is at least 1,000.
Auxiliary agents, as described above, can be added to the fibers themselves or
to the nonwoven
web during the carding and/or bonding process.
[0193] Thermoplastic Fiber Spinning
[0194] Thermoplastic fiber spinning is well known in the art. Briefly,
thermoplastic fiber
spinning includes the steps of:
(a) preparing a polymer mixture including the fiber-forming polymer optionally
including
auxiliary agents;
(b) extruding the polymer mixture through a spinneret nozzle to form an
extruded polymer
mixture;
(c) optionally drawing the extruded polymer mixture; and
(d) finishing the extruded polymer mixture to provide the fibers.
[0195] 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, promoting
polymer chain
orientation and crystallinity for increased fiber strength and tenacity.
Preparing the polymer
mixture for thermoplastic fiber spinning can include (a) preparing a solution
of a fiber-forming
material and a readily volatile solvent such that after extruding the solution
through the spinneret
when the solution is contacted with a stream of hot air, the solvent readily
evaporates leaving
solid fibers behind or (b) melting the polymer such that after extruding the
hot polymer through
the spinneret, the polymer solidifies by quenching with cool air. The
thermoplastic fiber spinning
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method is distinct from the wet cooled gel spun method at least in that (a) in
the thermoplastic
fiber spinning method the extruded fibers are solidified by evaporation of the
solvent or by
quenching hot solid fibers with cool air, rather than by use of a
solidification bath; and (b) in the
wet-cool gel spun method, the optional drawing is performed while the fibers
are in a gel state
rather than a solid state.
[0196] Fiber-forming materials for preparing 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 has suitable solubility in a
readily volatile solvent
and/or have a melting point lower than and distinct from their degradation
temperature. Further,
when a blend of fiber-forming polymers are used to make a fiber, the fiber-
forming materials
must have similar solubility in a readily volatile solvent and/or have similar
heat profiles such
that the two or more fiber-forming materials will melt at similar
temperatures. In contrast, the
fiber-forming materials for preparing fibers from the wet cooled gel spinning
process are not as
limited and 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 need not be a single solvent
or even a volatile
solvent.
[0197] The fiber-forming polymer(s) for preparing thermoplastic fiber spun
fibers can have a
degree of polymerization (DP), for example, in a range of 10 to 10,000 for
example, 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, up to 5,000, up to 2,500, up to 1,000,
up to 900, up to 750,
up to 500, or up to 250. In embodiments, the DP is less than 1,000.
[0198] Melt Spinning
[0199] 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
which directly
prepares a nonwoven web in-line with fiber formation. As such, the melt-spun
formed fibers are
not finished and cut to any consistent length (e.g., staple fibers are not
prepared by these
processes). Additionally, melt spinning does not include a drawing step and,
therefore, the only
control over the diameter of the resulting melt-spun fibers is the size of the
holes through which
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the fiber-forming materials are extruded, and the polymer chains are not
oriented in any specific
direction.
[0200] In example embodiments, melt spinning includes the steps of:
(a) preparing a polymer mixture including the fiber-forming polymer optionally
including
auxiliary agents;
(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 on a belt to form a
nonwoven web; and
(e) bonding the nonwoven web.
[0201] In the spun bond process, the extruded polymer mixture is pumped into
the die
assembly as molten polymer and quenched with cold air once passed through the
die assembly.
In the melt blown process, the extruded polymer mixture is pumped into a die
assembly having
hot air blown through it and is quenched upon exiting the die assembly and
coming into contact
with ambient temperature air. In both processes, the fibers are continuously
dropped onto a belt
or drum, usually facilitated by pulling a vacuum under the belt or drum.
[0202] The diameter of melt-spun fibers are in a range of about 0.1 to about
50 micron, for
example, at least about 0.1 micron, at least about 1 micron, at least about 2
micron, at least about
micron, at least about 10 micron, at least about 15 micron, or at least about
20 micron and up to
about 50 micron, up to about 40 micron, up to about 30 micron, up to about 25
micron, up to
about 20 micron, up to about 15 micron, up to about 10 micron, about 0.1
micron to about 50
micron, about 0.1 micron to about 40 micron, about 0.1 micron to about 30
micron, about 0.1
micron to about 25 micron, about 0.1 micron to about 20 micron, about 0.1
micron to about 15
micron, about 0.1 micron to about 10 micron, about 0.1 micron to about 9
micron, about 0.1
micron to about 8 micron, about 0.1 micron to about 7 micron, about 0.1 micron
to about 6
micron, about 0.1 micron to about 6 micron, about 5 micron to about 35 micron,
about 5 micron
to about 30 micron, about 7.5 micron to about 25 micron, about 10 micron to
about 25 micron, or
about 15 micron to about 25 micron. It is well known in the art that melt
blown processes can
provide micro-fine fibers having an average diameter in a range of about 1-10
micron, however,
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the melt blown process has very high variation in fiber-to-fiber diameter,
e.g., 100-300%
variation. Further, it is well known in the art that spun bond fibers can have
larger average fiber
diameters, e.g., about 15 to about 25 micron, but improved uniformity between
fibers, e.g.,
about 10% variation.
[0203] The fiber-forming material for heat extruded processes (e.g., melt-
spun, thermoplastic
fiber spinning) is more limited than for the wet-cooled gel spun process. For
example, the degree
of polymerization for heat extruding processes is limited to a range of about
200 to about 500. As
the degree of polymerization decreases below 200, the viscosity of the fiber-
forming material is
too low and the individual fibers prepared by pumping the material through the
die assembly do
not maintain adequate separation after exiting the die assembly. Similarly, as
the degree of
polymerization increases above 500, the viscosity is too high to efficiently
pump the material
through sufficiently small holes in the die assembly to run the process at
high speeds, thus losing
process efficiency and fiber and/or nonwoven uniformity. Further, processes
requiring heating of
the fiber-forming material, are unsuitable for polyvinyl alcohol homopolymers
as the
homopolymers generally do not have the thermal stability required
[0204] The wet cooled gel spinning process advantageously provides one or more
benefits
such as providing a fiber that includes a blend of water-soluble polymers,
providing control over
the diameter of the fibers, providing relatively large diameter fibers,
providing control over the
length of the fibers, providing control over the tenacity of the fibers,
providing high tenacity
fibers, providing fibers from polymers having a large degree of
polymerization, and/or providing
fibers which can be used to provide a self-supporting nonwoven web. Continuous
processes such
as spun bond, melt blown, electro-spinning and rotary spinning generally do
not allow for
blending of water-soluble polymers (e.g., due to difficulties matching the
melt index of various
polymers), forming large diameter (e.g., greater than 50 micron) fibers,
controlling the length of
the fibers, providing high tenacity fibers, and the use of polymers having a
high degree of
polymerization. Further, the wet cooled gel spinning process advantageously is
not limited to
polymers that are only melt processable and, therefore, can access fibers made
from fiber-
forming materials having very high molecular weights, high melting points, low
melt flow index,
or a combination thereof, providing fibers having stronger physical properties
and different
chemical functionalities compared to fibers prepared by a heat extrusion
process. Further still,
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advantageously, the wet cooled gel spinning process is not limited by the
viscosity of the
polymer. In contrast, it is known in the art that processes that require
melting of the fiber-
forming material are limited to fiber-forming materials having viscosities of
5 cP or less. Thus,
fibers including polymers, including polyvinyl alcohol homopolymers and
copolymers, having a
viscosity of greater than 5 cP are only accessible by wet cooled gel spinning.
Methods of Preparing Nonwoven Webs
[0205] The nonwoven webs of the disclosure are sheet-like structures having
two exterior
surfaces, the nonwoven webs including a plurality of fibers. The nonwoven webs
of the
disclosures can be prepared from fibers using any known methods in the art. As
is known in the
art, when fibers are spun bond or melt blown, the fibers are continuously laid
down to form the
nonwoven web, followed by bonding of the fibers.
[0206] 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.
[0207] Methods of bonding nonwoven webs are well known in the art. For
example, bonding
can include thermal, mechanical, and/or chemical bonding. Thermal bonding can
include, but is
not limited to calendering, embossing, air-through, and ultra-sound.
Mechanical bonding can
include, but is not limited to, hydro-entangling (spunlace), needle-punching,
and stitch-bonding.
Chemical bonding can include, but is not limited to, solvent bonding and resin
bonding.
[0208] Thermal bonding is achieved by applying heat and pressure, and
maintains the pore
size, shape, and alignment produced by the carding process. The conditions for
thermal bonding
can be readily determined by one of ordinary skill in the art. If the heat
and/or pressure applied is
too low, the fibers will not sufficiently bind to form a free-standing web and
if the heat and/or
pressure is too high, the fibers will begin to meld together. The fiber
chemistry dictates 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 degrade.
Methods of embossment for thermal bonding of fibers are known. The embossing
can be a one-
sided embossing or a double-sided embossing. Embossing of water-soluble fibers
includes one-
sided embossing using a single embossing roll consisting of an ordered
circular array and a steel
roll with a plain surface. As embossing is increased (e.g., as surface
features are imparted to the
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web), the surface area of the web is increased. Without intending to be bound
by theory it is
expected that as the surface are of the web is increased, the solubility of
the web is increased.
Accordingly, the solubility properties of the nonwoven web can be
advantageously tuned by
changing the surface area through embossing.
[0209] Air-through bonding requires a high thermoplastic content in the
nonwoven web and
two different melting point materials. In air-through bonding, the nonbonded
nonwoven web is
circulated around a drum while hot air flows from the outside of the drum
toward the center of
the drum. Air-through bonding can provide nonwovens having low density and
higher basis
weight (e.g., greater than 20 to about 2000 g/m2). Nonwovens bonded by air-
bonding is very
soft.
[0210] Chemical bonding includes solvent bonding and resin bonding. In
particular, chemical
bonding may use a binder solution of a solvent and a resin (e.g., latex or the
waste polymer left
over from preparing the fibers). The nonwoven can be coated with the binder
solution and heat
and pressure applied to cure the binder and bond the nonwoven. The binder
solution can be
applied by immersing 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.
[0211] Chemical bonding can result in smaller, less ordered pores relative to
the pores as
carded/melt-spun. Without intending to be bound by theory, it is believed that
if the resin
solution used for chemical bonding is sufficiently concentrated and/or
sufficient pressure is
applied, a nonporous nonwoven web can be formed. The solvent used in chemical
bonding
induces partial solubilization of the existing fibers in the web to weld and
bond the fibers
together. Thus, the solvent for chemical bonding can be any solvent that can
at least partially
solubilize one or more fiber-forming materials of the fibers of the nonwoven.
In embodiments,
the solvent is selected from the group consisting of water, ethanol, methanol,
DMSO, glycerin,
and a combination thereof. In embodiments, the solvent is selected from the
group consisting of
water, glycerin, and a combination thereof In embodiments, the binder solution
comprises a
solvent selected from the group consisting of water, ethanol, methanol, DMSO,
glycerin, and a
combination thereof and further comprises a resin selected from the group
consisting of
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polyvinyl alcohol, latex, and polyvinylpyrrolidone. The binder provided in the
solution assists in
the welding process to provide a more mechanically robust web. The temperature
of the polymer
solution is not particularly limited and can be provided at room temperature
(about 23 C).
[0212] In some embodiments, a second layer of fibers can be used to bond the
nonwoven web.
In embodiments, the nonwoven layer can be bonded using thermal, mechanical, or
chemical
bonding, alone or in addition to bonding using an additional layer of nonwoven
web/fibers.
Methods of Laminating Films to Nonwoven Webs or Foam Substrates
[0213] Methods of preparing a laminate (e.g., water-soluble film and a
nonwoven) can
include, but is not limited to, calender lamination (thermal with pressure) or
melt adhesion.
[0214] Calender lamination is achieved by applying heat and pressure. The
conditions for
calender lamination can be readily determined by one of ordinary skill in the
art. If the heat
and/or pressure applied is too low, the fibers will not sufficiently bind to
the water-soluble film
to form a laminate and if the heat and/or pressure is too high, the fibers
will begin to meld
together with each other and the film. The fiber chemistry and film chemistry
dictates the upper
and lower limits of heat and/or pressure for cal ender lamination. Without
intending to be bound
by theory, it is believed that at temperatures above 235 C, polyvinyl alcohol-
based fibers
degrade. In embodiments, the heat added to the overlaid nonwoven and water-
soluble film is
about 50 C to about 200 C, for example, about 100 C to about 200 C, about 110
C to about
190 C, about 120 C to about 180 C, or about 130 C to about 160 C. In
embodiments, the
pressure applied to the overlaid nonwoven and water-soluble film is 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 embodiments, the heat added to the overlaid nonwoven and water-soluble film
is about 150 C
and the pressure applied is about 25 psi. In embodiments, the heat and
pressure are applied for
about 2-4 seconds. Methods of embossment for calender lamination of fibers
and/or the film are
contemplated. The embossing can be a one-sided embossing or a double-sided
embossing.
Embossing of water-soluble fibers and/or water-soluble films includes one-
sided embossing
using a single embossing roll consisting of an ordered circular array and a
steel roll with a plain
surface. As embossing is increased (e.g., increased amounts of surface
features are imparted to
the web and/or the film), the surface area of the laminate is increased.
Without intending to be
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bound by theory it is believed that as the surface of the article is
decreased, the solubility of the
web and/or film is decreased. Accordingly, the solubility properties of the
nonwoven web and/or
water-soluble film can be advantageously tuned by changing the surface area
through embossing.
Without intending to be bound by theory, it is believed that as the degree of
lamination of the
unit dose article is increased, the surface area of the laminate decreases and
the bonding between
the water-soluble film and nonwoven increases, resulting in the solubility
decreasing and the
liquid release time increasing.
[0215] Melt adhesion lamination is achieved by applying an adhesive directly
to the water-
soluble film and the nonwoven web is then laid on top of the water-soluble
film with the applied
adhesive and is subjected to cold lamination for adhesion of the nonwoven web
and the water-
soluble film. As used herein, the term "cold lamination" refers to a
lamination process that
involves pressure but does not involve added heat. The adhesive can be any
suitable adhesive to
one of ordinary skill in the art. In embodiments, the adhesive is a Henkel
National Adhesive. The
application of the adhesive directly to the water-soluble film can be applied
by any suitable
method to one of ordinary skill in the art, such as, a hot melt-spray process
In embodiments, the
melt adhesion lamination process can include a hot melt spray process at 160
C, followed by
cold lamination at a pressure of 94 N/mm2.
[0216] The laminate of the disclosure generally includes a water-soluble film
and a nonwoven
web. In embodiments, the laminates can have a degree of lamination of about 1%
to about 100%,
for example, the degree of lamination can be in a range of about 1% to about
90%, or about 25%
to about 75%, or about 1% to about 50%, or about 5% to about 25%, or about 25%
to about
100%, or about 50% to about 100%. As used herein, the term "degree of
lamination" refers to the
amount of total area of the water-soluble film that is 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 water-soluble film's area is bonded to the nonwoven web, e.g., lamination
at the seals only.
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 wherein the
degree of lamination is about 25% or less, the laminate can be achieved during
the heat seal
process wherein the lamination occurs at each seal of the unit dose article.
In embodiments
wherein the laminate has a degree of lamination of about 25% or less, this low
degree of
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lamination can be advantageous as there is an interior void volume where the
water-soluble film
and the nonwoven web are not laminated providing physical separation for
components having
non-compatible chemistries, as well as providing an opportunity for a 2-step
delivery system of
compositions in a unit dose article. In embodiments, the degree of lamination
is in a range of
about 5% to about 25%. In embodiments, the degree of lamination is in a range
of about 50% to
about 100%.
Dissolution and Disintegration Test (Modified MSTM-205)
[0217] A nonwoven web, water-soluble film, or laminate structure can be
characterized by or
tested for Dissolution Time and Disintegration Time according to the 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 refers to a nonwoven web, while it is equally
applicable to a water-
soluble film or laminate structure.
[0218] Apparatus and Materials:
600 mL Beaker
Magnetic Stirrer (Labline Model No. 1250 or equivalent)
Magnetic Stirring Rod (5 cm)
Thermometer (0 to 100 C 1 C)
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
[0219] For each nonwoven web to be 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 web
evenly spaced along the traverse direction of the web. Each test specimen is
then analyzed using
the following procedure.
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Lock each specimen in a separate 35 mm slide mount.
Fill beaker with 500 mL of distilled water. Measure water temperature with
thermometer
and, if necessary, heat or cool water to maintain the temperature at the
temperature for which
dissolution is being determined, e.g., 20 C (about 68 F).
Mark height of column of water. Place magnetic stirrer on base of holder.
Place beaker
on magnetic stirrer, add magnetic stirring rod to beaker, turn on stirrer, and
adjust stir speed until
a vortex develops which is approximately one-fifth the height of the water
column. Mark depth
of vortex.
Secure the 35 mm slide mount in the alligator clamp of the 35 mm slide mount
holder
such that the long end of the slide mount is parallel to the water surface.
The depth adjuster of
the holder should be set so that when dropped, the end of the clamp will be
0.6 cm below the
surface of the water. One of the short sides of the slide mount should be next
to the side of the
beaker with the other positioned directly over the center of the stirring rod
such that the
nonwoven web surface is perpendicular to the flow of the water.
In one motion, drop the secured slide and clamp into the water and start the
timer.
Rupture occurs when the sample has become compromised within the slide, for
example, when a
hole is created. Disintegration occurs when the nonwoven web breaks apart and
no sample
material is left in the slide. When all visible nonwoven web is released from
the slide mount,
raise the slide out of the water while continuing to monitor the solution for
undissolved
nonwoven web fragments. Dissolution occurs when all nonwoven web fragments are
no longer
visible and the solution becomes clear. Rupture and dissolution can happen
concurrently for
nonwoven samples wherein the fibers are prepared from polyvinyl alcohol
polymer having a low
degree of hydrolysis (e.g., about 65-88%). Dissolution times are recorded
independently of
rupture times when there is a 5 second or greater difference between rupture
and dissolution.
[0220] Thinning time can also be determined using MSTM-205. Thinning of a
nonwoven web
occurs when some of the fibers making up the nonwoven web dissolve, while
other fibers remain
intact. The thinning of the web occurs prior to disintegration of the web.
Thinning is
characterized by a decrease in opacity, or increase in transparency, of the
nonwoven web. The
change from opaque to increasingly transparent and can be visually observed.
During MSTM-
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205, after the secured slide and clamp have been dropped into the water the
opacity/transparency
of the nonwoven web is monitored. At the time point wherein no change in
opacity/transparency
is observed (i.e., the web does not become any less opaque or more
transparent), the time is
recorded as the thinning time.
[0221] The results should include the following: complete sample
identification; individual
and average disintegration and dissolution times; and water temperature at
which the samples
were tested.
'corrected ¨ Imeasured X (reference thickness/measured thickness)193
[1]
Scorrected = Smeasured X (reference thickness/measured thickness)"3
[2]
Method for Determining Single Fiber Solubility
[0222] The solubility of a single fiber can be characterized by the water
breaking temperature.
The fiber breaking temperature can be determined as follows. A load of 2
mg/dtex is put on a
fiber having a fixed length of 100 mm. Water temperature starts at 1.5 C and
is then raised by
1.5 C increments every 2 minutes until the fiber breaks. The temperature at
which the fiber
breaks is denoted as the water breaking temperature.
[0223] The solubility of a single fiber can also be characterized by the
temperature of
complete dissolution. The temperature of complete dissolution can be
determined as follows. 0.2
g of fibers having a fixed length of 2 mm are added to 100 mL of water. Water
temperature starts
at 1.5 C and is then raised by 1.5 C increments every 2 minutes until the
fiber completely
dissolves. The sample is agitated at each temperature. The temperature at
which the fiber
completely dissolves in less than 30 seconds is denoted as the complete
dissolution temperature.
Diameter Test Method
[0224] The diameter of a discrete fiber or a fiber within a nonwoven web is
determined by
using a scanning electron microscope (SEM) or an optical microscope and an
image analysis
software. A magnification of 200 to 10,000 times is chosen such that the
fibers are suitably
enlarged for measurement. When using the SEM, the samples are sputtered with
gold or a
palladium compound to avoid electric charging and vibrations of the fiber in
the electron beam.
A manual procedure for determining the fiber diameters is used from the image
(on monitor
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screen) taken with the SEM or the optical microscope. Using a mouse and a
cursor tool, the edge
of a randomly selected fiber is sought and then measured across its width
(i.e., perpendicular to
the fiber direction at that point) to the other edge of the fiber. A scaled
and calibrated image
analysis tool provides the scaling to get an actual reading in microns. For
fibers within a
nonwoven web, several fibers are randomly selected across the sample of
nonwoven web using
the SEM or the optical microscope. At least two portions of the nonwoven web
material are cut
and tested in this manner. Altogether at least 100 such measurements are made
and then all data
are recorded for statistical analysis. The recorded data are used to calculate
average (mean) of the
fibers, standard deviation of the fibers, and median fiber diameters.
Tensile Strength, Modulus, and Elongation Test
[0225] A nonwoven web, water-soluble film, or laminate structure characterized
by or to be
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 is
analyzed as follows. The description provided below refers to a nonwoven web,
while it is
equally applicable to a water-soluble film or laminate structure. The
procedure includes the
determination of tensile strength and the determination of modulus at 10%
elongation according
to ASTM D 882 ("Standard Test Method for Tensile Properties of Thin Plastic
Sheeting") or
equivalent. An INSTRON tensile testing apparatus (Model 5544 Tensile Tester or
equivalent) is
used for the collection of nonwoven web data. A minimum of three test
specimens, each cut with
reliable cutting tools to ensure dimensional stability and reproducibility,
are tested in the
machine direction (MD) (where applicable) for each measurement. Tests are
conducted in the
standard laboratory atmosphere of 23 2.0 C and 35 5 % relative humidity.
For tensile
strength or modulus determination, 1"-wide (2.54 cm) samples of a nonwoven web
are prepared.
The sample is then transferred to the INSTRON tensile testing machine to
proceed with testing
while minimizing exposure in the 35% relative humidity environment. The
tensile testing
machine is prepared according to manufacturer instructions, equipped with a
500 N load cell, and
calibrated. The correct grips and faces are fitted (INSTRON grips having model
number 2702-
032 faces, which are rubber coated and 25 mm wide, or equivalent). The samples
are mounted
into the tensile testing machine and analyzed to determine the 100% modulus
(i.e., stress
required to achieve 100% film elongation), tensile strength (i.e., stress
required to break film),
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and elongation % (sample length at break relative to the initial sample
length). In general, the
higher the elongation % for a sample, the better the processability
characteristics for the
nonwoven web (e.g., increased formability into packets or pouches).
Fiber Shrinkage Percent Test (MSTM)
[0226] A percent shrinkage of a fiber when contacted with a suitable amount of
a carrier
solvent can be determined according to a Fiber Shrinkage Percent rlest under
MonoSol Standard
Operating Procedure.
[0227] Apparatus and Materials:
1. Fiber samples (approx. 3 grams)
2. 500 mL beaker
3. Chilled deionized water (located in refrigerator)
4. Deionized water
5. Paper clip
6. Alligator clamp (solubility stand)
7. Stir plate
8. Timer
[0228] Samples are prepared as follows:
1. Obtain a small bundle of fibers that isn't entangled. Enough to ensure
it will hold
in the paper clip and the alligator clamp, approximate weight of fiber bundle
is 0.013 gram (g) to
0.015 g.
2. Take a paper clip and pull an end of the fiber through the cross
sections of the
paper clip.
3. Do this so each unique fiber to be tested has a replicate of N=3 for
each testing
temperature, 23 C and 10 C.
[0229] Apparatus set-up:
1. Fill 500 ml beaker with 400 ml of respective temperature water. Make
sure to
check the water temperature with a temperature probe before and during
testing.
2. Tape a ruler to the top of the alligator clamp so the ruler hangs
parallel to the
clamp.
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3. Place the beaker on a stir plate and place the solubility
stand next to the stir plate,
submerging ruler into beaker so then you can read the length.
[0230] Testing procedure:
1. Attach the free end of the paper clipped fiber in the alligator clamp.
2. Submerge 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 alligator clip to the top of the paper clip.
4. After two minutes, record the final length of the fiber.
5. Lift the clamp out of the water and remove the sample from the clamp. Be
sure to
thoroughly dry off the outside of the clamp and the inside of clamp between
each test.
[0231] Calculating Shrinkage Percent:
Shrinked length = initial length - final length [3]
Fiber Shrinkage (%) = (shrinked length/initial length) x 100% [4]
Nonwoven Shrinkage Percent Test (MSTM)
[0232] A percent shrinkage of a nonwoven sheet when contacted with a suitable
amount of a
carrier solvent can be determined according to a Nonwoven Shrinkage Percent
Test under
MonoSol Standard Operating Procedure.
[0233] Samples are prepared as follows:
1. Using the Cricut Maker machine, 2 inch by 2 inch (5.08 cm x 5.08 cm)
squares of
nonwoven samples were cut out.
2. Each nonwoven square was weighed. The nonwoven density of each square
(in
gsm) was calculated prior to testing.
3. A cleaning formulation was made and diluted to different water content
concentrations.
4. A camera was set up at approximately 111/4 in. (28.6 cm) in height to
record the
shrinkage of the WSNW.
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[0234] Shrinkage Testing on nonwoven samples were performed as follows:
5. A nonwoven square (5.08 cm x 5.08 cm) was set into a 100 x 1 mm petri
dish.
6. The cleaning solution was warmed up to a set temperature.
7. The petri dish with sample was set under the camera. For higher
temperatures, a
hot plate was set underneath petri dish to add heat to keep at constant
temperature.
8. Once the cleaning solution reached the ideal temperature, the camera was
started
to record.
9. 10 mL of the cleaning solution was syringed on the nonwoven square. Once
the
cleaning solution was covering the square, a 5-minute timer was started.
10. After 5 minutes, the final shrinkage was recorded along with any
observations.
11. The shrinkage was calculated using an initial area and a final area of
the square.
12. Replicates of 3 were done for each set.
13. For shrinkage at 1 hour, the nonwoven samples were measured after 1
hour after
initial exposure to the cleaning composition. For higher temperatures, exposed
samples were
placed in the oven at a set temperature and then removed after 1 hour for
shrinkage
measurements.
Uses of Single Unit Dose Articles
[0235] The single unit dose articles of the disclosure are suitable for a
variety of commercial
applications. Suitable commercial applications for the single unit dose
articles of the disclosure
can include pouches and packets for delivering cleaning formulations
including, without
limitation, a laundry detergent, a soap, a fabric softener, a bleaching agent,
a laundry booster, a
stain remover, an optical brightener, or a water softener. in example
embodiments, the active
cleaning formulation may include, without limitation, actives, detergents,
surfactants,
emulsifiers, chelants, dirt suspenders, stain releasers, enzymes, pH
adjusters, builders, soil
release polymers, structurants, free fragrance, encapsulated fragrance,
preservatives, solvent,
minerals, and/or any ingredients suitable in personal care, laundry detergent,
dish detergent,
and/or home surface cleaners or cleansers. Other examples include a dish
detergent, soap or
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cleaner, a shampoo, a conditioner, a body wash, a face wash, a skin lotion, a
skin treatment, a
body oil, fragrance, a hair treatment, a bath salt, an essential oil, a bath
bomb, or an enzyme. The
active cleaning formulation may be in the form of a solid, e.g., a powder or a
plurality of
granules or particles, a gel, a liquid, or a slurry formulation, or any
suitable combination of a
powder, a solid, a gel, a liquid, or a slurry formulation, for example.
[0236] Additional applications for the unit dose articles of the disclosure
can include pouches
and packets for delivering personal care products such as exfoliating
materials, shampoo,
conditioner, body wash, face wash, skin lotion, skin treatment, hair
treatment, bath salts,
essential oil, or a combination thereof.
[0237] Additional contemplated applications include those that can involve a
constant flow of
water, for example, automotive cleaning applications and/or dish cleaning
applications.
Advantageously, in such applications, once at least a portion of the
composition is released form
the unit dose, the nonwoven web can be used to facilitate foaming and /or
scrubbing hard to
remove grime without damaging the surface being cleaned, for example, the
paint on a car or a
non-stick cooking surface.
[0238] Additional contemplated applications include those that require keeping
active agents
separated until the point of use. Advantageously, unit dose articles of the
disclosure can contain a
first active agent within the first interior volume formed by the water-
soluble film and a second
active agent can be contained within the second interior volume formed by the
nonwoven web.
The unit dose can be designed to: (a) release the second active agent upon
exposure to colder
water and the first active agent upon exposure to warmer water such that the
second active agent
does not come in contact with the first active agent prior to the second
active agent being
released into the water; or (b) release the first active agent from the first
interior volume prior to
substantial dissolution of the nonwoven web such that the first active agent
and the second active
agent will come into contact/mix in the second interior volume prior to either
composition being
substantially released from the unit dose.
[0239] Additional contemplated applications can include those wherein the
composition
contained in the unit dose can become stale or otherwise unsuitable over time
when exposed to,
e.g., oxygen, and otherwise require release of the extract of the composition
upon use. Such
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applications can include, but are not limited to, tea leaves and pouched
tobacco products.
Advantageously, the unit dose of the disclosure can provide a gas barrier in
the water-soluble
film to maintain freshness, which can dissolve at the point of use (e.g., hot
water or placement in
the mouth of consumer and contacted with saliva), allowing the release of the
extract (e.g.,
caffeine, flavor, and/or tobacco extracts) while keeping the solid portions of
the composition
(e.g., leaves) contained within the non-water-soluble, biodegradable, or
compostable, nonwoven
web. The nonwoven web can then be disposed of as appropriate and allowed to
biodegrade or
compost.
Methods of Making Unit Dose Articles
[0240] The unit dose articles comprising pouches and packets may be made using
any suitable
equipment and method. For example, single compartment pouches may be made
using vertical
form filling, horizontal form filling, or rotary drum filling techniques
commonly known in the
art. Such processes may be either continuous or intermittent. The layered
nonwoven web, film,
or laminate structure may be dampened, and/or heated to increase the
malleability thereof. The
method may also involve 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 can be applied for about 0.2 to about 5 seconds, or
about 0.3 to about 3, or
about 0.5 to about 1.5 seconds, once the layered nonwoven web, film, or
laminate structure is on
the horizontal portion of the surface. This vacuum can be such that it
provides an under-pressure
in a range of 10 mbar to 1000 mbar, or in a range of 100 mbar to 600 mbar, for
example.
[0241] The molds, in which packets may be made, can have any shape, length,
width and
depth, depending on the required dimensions of the pouches. The molds may also
vary in size
and shape from one to another, if desirable. For example, the volume of the
final pouches may be
about 5 ml to about 300 ml, or about 10 ml to 150 ml, or about 20 ml to about
100 ml, and that
the mold sizes are adjusted accordingly.
[0242] Thermoforming
[0243] A thermoformable nonwoven web, film, or laminate is one that can be
shaped through
the application of heat and a force. Thermoforming a nonwoven web, film, or
laminate structure
is the process of heating the nonwoven web, film, or laminate structure,
shaping it (e.g., in a
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mold), and then allowing the resulting nonwoven web, film, or laminate to
cool, whereupon the
nonwoven web, film, or laminate will hold its shape, e.g., the shape of the
mold. The heat may
be applied using any suitable means. For example, the nonwoven web, film, or
laminate may be
heated directly by passing it under a heating element or through hot air,
prior to feeding it onto a
surface or once on a surface. Alternatively, it may be heated indirectly, for
example by heating
the surface or applying a hot item onto the nonwoven web, film, or laminate.
In embodiments,
the nonwoven web, film, or laminate is heated using an infrared light. The
nonwoven web, film,
or laminate may be heated to a temperature in a range of about 50 C to about
150 C, about 50 C
to about 120 C, about 60 C to about 130 C, about 70 C to about 120 C, or about
60 C to about
90 C. Thermoforming can be performed by any one or more of the following
processes: the
manual draping of a thermally softened nonwoven web, film, or laminate over a
mold, or the
pressure induced shaping of a softened nonwoven web, film, or laminate to a
mold (e.g., vacuum
forming), or the automatic high-speed indexing of a freshly extruded sheet
having an accurately
known temperature into a forming and trimming station, or the automatic
placement, plug and/or
pneumatic stretching and pressuring forming of a nonwoven web, film, or
laminate.
[0244] Alternatively, the nonwoven web, film, or laminate can be wetted by any
suitable
means, for example directly by spraying a wetting agent (including water, a
polymer
composition, a plasticizer for the nonwoven web, film, or laminate
composition, or any
combination of the foregoing) onto the nonwoven web, film, or laminate, prior
to feeding it onto
the surface or once on the surface, or indirectly by wetting the surface or by
applying a wet item
onto the nonwoven web, film, or laminate.
[0245] Once a nonwoven web, film, or laminate has been heated and/or wetted,
it may be
drawn into an appropriate mold, preferably using a vacuum. The filling of the
molded nonwoven
web, film, or laminate can be accomplished by utilizing any suitable means. In
embodiments, the
most preferred method will depend on the product form and required speed of
filling. In
embodiments, the molded nonwoven web, film, or laminate is filled by in-line
filling techniques.
The filled, open packets are then closed forming the pouches, using a second
nonwoven web,
film, or laminate, by any suitable method. This may be accomplished while in
horizontal position
and in continuous, constant motion. The closing may be accomplished by
continuously feeding a
second nonwoven web, film, or laminate, over and onto the open packets and
then sealing the
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first and second nonwoven web, film, or laminate together, typically in the
area between the
molds and thus between the packets.
[0246] Sealing
[0247] Any suitable method of sealing the packet and/or the individual
compartments thereof
may be utilized. Non-limiting examples of such means include heat sealing,
solvent welding,
solvent or wet sealing, and combinations thereof. Typically, only the area
which is to form the
seal is treated with heat or solvent. The heat or solvent can be applied by
any method, typically
on the closing material, and typically only on the areas which are to form the
seal. If solvent or
wet sealing or welding is used, it may be preferred that heat is also applied.
Preferred wet or
solvent sealing/welding methods include selectively applying solvent onto the
area between the
molds, or on the closing material, by for example, spraying or printing this
onto these areas, and
then applying pressure onto these areas, to form the seal. Sealing rolls and
belts (optionally also
providing heat) can be used, for example.
[0248] In embodiments, an inner nonwoven web, foam, film, or laminate is
sealed to outer
nonwoven web(s), film(s), or laminate(s) by solvent sealing. The sealing
solution is generally an
aqueous solution. In embodiments, the sealing solution includes water. In
embodiments, the
sealing solution includes water and further includes 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
embodiments, the sealing
solution includes erythritol, threitol, arabitol, xylitol, ribitol, mannitol,
sorbitol, galactitol, fucitol,
iditol, inositol, volemitol, isomal, maltitol, lactitol. In embodiments, the
sealing solution includes
a water-soluble polymer.
[0249] The sealing solution can be applied to the interfacial areas of the
inner nonwoven web,
foam, film, or laminate in any amount suitable to adhere the inner and outer
nonwoven webs or
laminates. As used herein, the term "coat weight" refers to the amount of
sealing solution applied
to the nonwoven web, foam, film, or laminate in grams of solution per square
meter of
nonwoven web, foam, film, or laminate. In general, when the coat weight of the
sealing solvent
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is MO low, the nonwoven webs, foam, films, or laminates do not adequately
adhere and the risk
of pouch failure at the seams increases. Further, when the coat weight of the
sealing solvent is
too high, the risk of the solvent migrating from the interfacial areas
increases, increasing the
likelihood that etch holes may form any films comprising the sides of the
pouches. The coat
weight window refers to the range of coat weights that can be applied to a
given film or laminate
while maintaining both good adhesion and avoiding the formation of etch holes.
A broad coat
weight window is desirable as a broader window provides robust sealing under a
broad range of
operations. Suitable coat weight windows are at least about 3 g/m2, or at
least about 4 g/m2, or at
least about 5 g/m2, or at least about 6 g/m2.
[0250] Cutting the Unit Dose Articles
[0251] Formed pouches may be cut by a cutting device. Cutting can be
accomplished using
any known method. It may be preferred that the cutting is also done in
continuous manner, and
preferably with constant speed and preferably while in horizontal position.
The cutting device
can, for example, be a sharp item, or a hot item, or a laser, whereby in the
latter cases, the hot
item or laser 'burns' through the film/sealing area.
[0252] Vertical Form, Fill and Seal
[0253] In embodiments, the nonwoven web, foam, film, or laminate of the
disclosure can be
formed into a sealed article. In embodiments, the sealed article is a vertical
form, filled, and
sealed article. The vertical form, fill, and seal (VFFS) process is a
conventional automated
process. VFFS includes an apparatus such as an assembly machine that wraps a
single piece of
the nonwoven web, foam, film, or laminate around a vertically oriented feed
tube. The machine
heat seals or otherwise secures the opposing edges of the nonwoven web, foam,
film, or laminate
together to create the side seal and form a hollow tube of nonwoven web, foam,
film, or
laminate. Subsequently, the machine heat seals or otherwise creates the bottom
seal, thereby
defining a container portion with an open top where the top seal will later be
formed. The
machine introduces a specified amount of flowable product, e.g., the active
cleaning formulation,
into the container portion through the open top end. Once the container
includes the desired
amount of product, the machine advances the nonwoven web, foam, film, or
laminate to another
heat-sealing device, for example, to create the top seal. Finally, the machine
advances the
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nonwoven web, film, or laminate to a cutter that cuts the film immediately
above the top seal to
provide a filled package.
[0254] During operation, the assembly machine advances the nonwoven web, foam,
film, or
laminate from a roll to form the package. Accordingly, the nonwoven web, foam,
film, or
laminate must be able to readily advance through the machine and not adhere to
the machine
assembly or be so brittle as to break during processing.
EXAMPLES
[0255] As described herein, the single unit dose article may include one of
the following
constructions:
(a) a single-use cold water-soluble nonwoven sheet is folded or stacked in a
plied
construction and saturated with an active cleaning formulation and, in certain
embodiments, the
nonwoven sheet is wrapped in a water-soluble nonwoven web or water-soluble
foam or film
material layer to act as a barrier and transfer the active cleaning
formulation to a consumer's
hand or body or to a surface, for example;
(b) a single-use cold water-soluble cleaning sachet including a water-soluble
nonwoven
substrate containing a bulk or loose active cleaning formulation, in a liquid,
slurry, or solid, e.g.,
powder, form;
(c) a foam sheet, e.g., an open -cell or closed-cell foam sheet, folded or
stacked in a plied
construction and saturated with an active cleaning formulation, and, in
certain embodiments, the
foam sheet is wrapped in a water-soluble nonwoven web or water-soluble foam or
film material
layer to act as a barrier and transfer the active cleaning formulation to a
consumer's hand or body
or to a surface, for example;
(d) a single-use water-soluble nonwoven sheet containing an active cleaning
formulation,
or having an active cleaning formulation adhered to a surface of the nonwoven
sheet;
(e) a water-soluble nonwoven sheet is folded or stacked in a plied
construction and
saturated with an active cleaning formulation and, in certain embodiments, the
nonwoven sheet
is wrapped in a water-soluble nonwoven web or water-soluble foam or film
material layer not
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containing an active agent to act as a barrier and transfer the active
cleaning formulation to a
consumer's hand or body or to a surface, for example;
(f) a single use cold water-soluble foam substrate (open cell or closed cell)
having low
moisture or substantially no moisture laundry detergent on a surface of the
foam substrate for
cleaning clothes, the foam substrate is dissolvable upon contact with the cold
water to deliver
one or more cleansing agents, the outer surface of the foam substrate may be
at least partially
covered by or enclosed in a water-soluble nonwoven fabric for a "plastic free"
or "natural"
aesthetic for completion of the clothes washing cycle;
(g) a single-use cold water-soluble foam substrate (open cell or closed cell)
having low
moisture or substantially no moisture laundry detergent in the core or matrix
of the foam
substrate for cleaning clothes, the foam substrate is dissolvable upon contact
with cold water to
deliver one or more cleansing agents, the outer surface of the foam substrate
may be at least
partially covered by or enclosed in a water-soluble nonwoven fabric for a
"plastic free- or
"natural" aesthetic for completion of the clothes washing cycle;
(h) a single-use cold water-soluble foam substrate (open cell or closed cell)
having low
moisture or substantially no moisture laundry detergent on a surface of the
foam substrate for
cleaning clothes, the foam substrate is dissolvable upon contact with the cold
water to deliver
one or more cleansing agents for completion of the clothes washing cycle;
(i) a single-use cold water-soluble foam substrate (open cell or closed cell)
having low
moisture or substantially no moisture laundry detergent in the core or matrix
of the foam
substrate for cleaning clothes, the foam substrate is dissolvable upon contact
with cold water to
deliver one or more cleansing agents for completion of the clothes washing
cycle; and
(j) a core substrate including a water-soluble nonwoven web or sheet, a water-
soluble
foam substrate, or a water-soluble film substrate having an active cleaning
formulation in the
form of a solid, a liquid, or a slurry disposed or coated on a surface of the
core substrate, adhered
to a surface of the core substrate, embedded in the core substrate, or
dispersed in a matrix of the
core substrate, or a suitable combination thereof
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[0256] Example embodiments of the disclosure are described in the following
numbered
paragraphs. These example embodiments are intended to be illustrative in
nature and not
intended to be limiting.
[0257] In example embodiments, a 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 greater than 20 C, the water-soluble core substrate is soluble to
release the active
cleaning formulation. In example embodiments, a water-soluble nonwoven
material and/or a
water-soluble film encloses the water-soluble nonwoven substrate. In certain
embodiments, the
water-soluble film is laminated to the water-soluble nonwoven material. A
bonding interface is
configured to create a seal to enclose the water-soluble core substrate. The
active cleaning
formulation is in the form of at least one of a powder, a solid, a liquid, a
gel, or a slurry form. In
example embodiments, the active cleaning formulation is one or disposed on or
embedded in the
water-soluble core substrate. In example embodiments, the water-soluble core
substrate is at least
one of saturated with the active cleaning formulation, coated with the active
cleaning formulation
or impregnated with the active cleaning formulation. In example embodiments,
the active
cleaning formulation is present in the water-soluble core substrate.
[0258] In example embodiments, a single unit dose article includes a water-
soluble nonwoven
substrate comprising a water-soluble resin. The water-soluble nonwoven
substrate contains an
active cleaning formulation. When the water-soluble nonwoven substrate is
contacted with water
having a temperature greater than 20 C, the water-soluble nonwoven substrate
is soluble to
release the active cleaning formulation. In example embodiments, a water-
soluble nonwoven
material and/or a water-soluble film encloses the water-soluble nonwoven
substrate. In example
embodiments, the water-soluble film is laminated to the water-soluble nonwoven
material. In
certain embodiments, a bonding interface is configured to create a seal to
enclose 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, a solid, a liquid, a gel, or a
slurry formulation. In
example embodiments, the water-soluble nonwoven substrate includes a plurality
of fibers,
wherein the plurality of fibers is saturated with the active cleaning
formulation, the active
cleaning formulation is embedded in the plurality of fibers, and/or the active
cleaning
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formulation is disposed between adjacent layers of the plurality of layers. In
example
embodiments, the water-soluble nonwoven substrate is a continuous sheet of a
water-soluble
nonwoven web folded in a serpentine construction to form the plurality of
layers. In other
embodiments, the water-soluble nonwoven substrate includes a plurality of
separate substrate
sheets in a plied construction. 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, e.g., coated on, a surface of
the water-soluble
nonwoven substrate or disposed on, e.g., coated on, a surface of the plurality
of fibers. In
example embodiments, a water-soluble nonwoven material defines an interior
volume to enclose
and contain the water-soluble nonwoven substrate and the active cleaning
formulation, e.g., a
liquid active cleaning formulation.
[0259] In example embodiments, a single unit dose article includes 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 greater than 20 C, the water-soluble foam substrate is soluble to
release the active
cleaning formulation. In example embodiments, a water-soluble nonwoven
material and/or a
water-soluble film at least partially encloses the water-soluble foam
substrate. In certain
embodiments, the water-soluble film is laminated to the water-soluble nonwoven
material. In
certain embodiments, a bonding interface is configured to create a seal to
enclose the water-
soluble core substrate. The active cleaning formulation may be in the form of
at least one of a
powder, a solid, a liquid, a gel, or a slurry form. In certain embodiments,
the water-soluble foam
substrate is saturated with the active cleaning formulation, the active
cleaning formulation may
be embedded in the water-soluble foam substrate, or the active cleaning
formulation may be
disposed on, e.g., coated on, a surface of the water-soluble foam substrate.
[0260] In example embodiments, a 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. An 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,
the at least one
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of first water-soluble nonwoven web or the second water-soluble nonwoven web
is soluble to
release the active cleaning formulation. The active cleaning formulation may
be in the form of at
least one of a powder, a solid, a liquid, a gel, or a slurry form. In certain
embodiments, a bonding
interface is configured to create a seal between the first water-soluble
nonwoven web and the
second water-soluble nonwoven web to define an interior volume and enclose the
active cleaning
formulation within the interior volume. In example embodiments, a water-
soluble film substrate
disposed between the first water-soluble nonwoven web and the second water-
soluble nonwoven
web. The active cleaning formulation may be embedded in the water-soluble film
substrate or the
active cleaning formulation is disposed on, e.g., coated on, a surface of the
water-soluble film
substrate.
[0261] In example embodiments, a single unit dose article includes a water-
soluble material
comprising a water-soluble resin. The water-soluble material is bonded at a
bonding interface
along an edge of the water-soluble material to define an interior volume of
the single unit dose
article. An active cleaning formulation is disposed in the interior volume.
When the water-
soluble material is contacted with water having a temperature greater than 20
C, the water-
soluble material is soluble to release the active cleaning formulation. In
example embodiments,
the water-soluble material comprises one of a water-soluble nonwoven web or a
water-soluble
foam material. The active cleaning formulation may be in the form of at least
one of a powder, a
solid, a liquid, a gel, or a slurry form. In example embodiments, the water-
soluble material has a
first surface facing the interior volume and an opposing second surface. The
single unit dose
article further includes a water-soluble film disposed on the first surface.
In example
embodiments, the water-soluble material includes a water-soluble composite
material comprising
a water-soluble film material made of a first water-soluble resin coupled to
one of a water-
soluble nonwoven material or a water-soluble foam material made of a second
water-soluble
resin.
[0262] In example embodiments, a method for making a single unit dose article
containing an
active cleaning formulation includes forming a water-soluble core substrate
comprising a water-
soluble resin, the water-soluble core substrate containing an active cleaning
formulation,
wherein, when the water-soluble core substrate is contacted with water having
a temperature
greater than 20 C, the water-soluble core substrate is soluble to release the
active cleaning
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formulation; 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
material thereof, into an open pouch defining an interior volume configured to
contain the water-
soluble core substrate and the active cleaning formulation; introducing the
water-soluble core
substrate and the active cleaning formulation into the interior volume; and
sealing the outer
water-soluble material to enclose the interior volume. In example embodiments,
forming a water-
soluble core substrate comprising a water-soluble resin, the water-soluble
core substrate
containing 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 example
embodiments, forming a water-soluble core substrate includes forming a water-
soluble
nonwoven substrate into a plurality of layers, with the active cleaning
formulation disposed
between adjacent layers of the plurality of layers. A continuous sheet of a
water-soluble
nonwoven web may be folded in a serpentine construction to form the plurality
of layers of the
water-soluble nonwoven-substrate or a plurality of separate substrate sheets
may be stacked in a
plied construction to form the water-soluble nonwoven-substrate, for example.
In example
embodiments, forming a water-soluble core substrate comprising a water-soluble
resin, the
water-soluble core substrate containing an active cleaning formulation,
includes at least one of
saturating the water-soluble core with the active cleaning formulation,
disposing the active
cleaning formulation on a surface of the water-soluble core substrate, coating
a surface of the
water-soluble core substrate with the active cleaning formulation, embedding
the active cleaning
formulation in the water-soluble core substrate, or impregnating the water-
soluble core substrate
with the active cleaning formulation. In example embodiments, sealing the
outer water-soluble
material includes forming a seal at a bonding interface to enclose the water-
soluble core substrate
and the active cleaning formulation in the interior volume.
[0263] In the Examples, a nonwoven substrate including an active cleaning
formulation and/or
a carrier solvent is described as one example of the core substrate for
illustration only. The core
substrate and the active cleaning formulation can have any composition and/or
form as described
herein. For example, the core substrate can include a water-soluble nonwoven,
foam, and/or film
substrate or layer, or any combination thereof One or more additional water-
soluble nonwoven,
foam, or film substrate or layer, or any combination thereof, can be disposed
thereon and may be
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used to seal the core substrate with the cleaning formulation. Such core
substrate may include
one or more PVOH polymers, such as a vinyl alcohol-vinyl acetate copolymer.
For example, in
certain embodiments, the core substrate includes at least one nonwoven
substrate or layer
comprising the plurality of fibers. The plurality of fibers comprise a first
type of fiber comprising
a polyvinyl alcohol copolymer having a degree of hydrolysis in a range of
about 75% to about 89
%, and a second type of fiber comprising a polyvinyl alcohol copolymer having
a degree of
hydrolysis in a range of about 90% to about 99.5%. The first type of fiber and
the second type of
fiber are at a suitable ratio, for example, in a range of from about 1:99 to
about 75:25, from about
5:95 to about 75:25, from about 1:99 to about 50:50, from about 5:95 to about
50:50, from about
10:90 to about 50:50, by weight. In some embodiments, the first type of fiber
and the second
type of fiber are mixed together in the at least one nonwoven. In some
embodiments, the at least
one nonwoven substrate or layer comprises a first type of nonwoven sheet or
layer made of the
first type of fiber, and a second type of nonwoven sheet or layer made of the
second type of
fiber. The two types of fibers are in different nonwoven sheets.
[0264] In the single unit dose article described herein, the water-soluble
core substrate may
comprise a plurality of layers, which are selected from a nonwoven sheet, a
foam layer, a film, or
any combination thereof The plurality of layers may include separate sheets,
for example,
nonwoven sheets in a plied construction, or a continuous layer such as one
nonwoven sheet
folded in a serpentine construction. The active cleaning formulation can be
disposed on and/or
embedded in the water-soluble core substrate. Upon contact with the carrier
solvent at 20 C for a
period of time of 5 minutes or longer, for example, the single dose article
described herein or the
core substrate therein exhibits a degree of shrinkage in a range of from 0.5%
to 65%, for
example, in a range of from 0.5% to 25%.
[0265] In the single unit dose article described herein, the water-soluble
core substrate may or
may not contain the carrier solvent as described. In certain embodiments, the
carrier solvent may
be used during a manufacturing process. The carrier solvent may be dried off
and a resulting
single unit dose article may not contain the carrier solvent. In alternative
embodiments, a carrier
solvent may be used during a manufacturing process and also exist in the
resulting single unit
dose article.
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Fibers Used
[0266] As shown in Table 1, two type of fibers, namely, Fiber 1 ("Fl") and
Fiber 2 ("F2"),
which comprise a copolymer of vinyl acetate and vinyl alcohol having a degree
of hydrolysis of
88% and 96%, respectively, were used as the starting materials. These fibers
have uniform
composition, and have additional properties shown in Table 1. In the Examples
described herein,
Fiber Fl included a 50:50 mixture of fibers having fineness - length of 1.7
dtex ¨ 38 mm and 2.2
dtex- 51 mm, respectively, and Fiber F2 included a 50:50 mixture of fibers
having fineness -
length of 1.4 dtex ¨ 38 mm and 2.2 dtex- 51 mm, respectively. In the Examples,
a polymer
comprising vinyl alcohol moieties is referred as "a polyvinyl alcohol
polymer," and a fiber
comprising such a polymer is referred as "a polyvinyl alcohol fiber."
[0267] Table 1
Viscosity
DH Fineness Solubility Tenacity
Elongation
Fiber (4%
solution) (mol%) (dtex) Temp ( C) (cN/dtex)
(%)
Fl 88 1.7,2.2 70 5
70
F2 22-23 96 1.4, 2.2 40 7
15
[0268] As shown in Table 2, under different bonding conditions, such as a
calender-point
bonding, the two type of fibers were used to make nonwoven core substrates.
The two type of
fibers were also mixed to make one type of nonwoven (referred to as a "blended
nonwoven") as
the core substrate. Unless specified otherwise, the samples have point bonding
patterns.
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[0269] Table 2
Experimental Samples Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5
Fiber Fl
0 50 25 10
100
(wt.%)
Composition
Fiber F2
100 50 75 90 0
(wt.%)
Target gsm 50 50 50 50
50
Calender -
Point bond
8 8 8 8
8
point per sq.
Process cm
Conditions Calender- 122 124 124 124 160
Temperature
C 132 134 134 134
153
Calender -
Pressure 40 40 40 40
40
Kg/linear cm
Measured
56 55 53 58
51
asm
Tenacity MD
26.1 30.2 27.8 24.4 8.65
U,, N/5 cm
a.)
t Elongation
9 10.2 7.7 3.1
42.22
szl. MD %
o
4 Tenacity CD
3 3.3 2.5 8.1
2.48
ai N/5 cm
E Elongation
47 46.9 56.3 42.3
40.72
CD %
':'
MD:CD Ratio 8.7:1 9.1:1 11.1:1 3.0:1
1 : 3.49
Caliper 0,5
1.005 1.065 0.83 0.98 0.6
kpa
[0270] As shown in Table 1, Fibers Fl and F2 used in the Experimental Samples,
e.g., Ex. 1,
Ex. 2, Ex. 3, Ex. 4, and Ex. 5 as shown in Table 2, are the first type of
fiber and the second type
of fiber comprising a polyvinyl alcohol copolymer having a degree of
hydrolysis of 88% and
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96%, respectively. These two fibers were mixed and bonded to form a nonwoven
sheet as a core
substrate for the single unit dose article as described herein. In FIGS. 16-19
and 23-24, the term
"wt.% of Fiber F2" represents the content of Fiber F2 by weight in a total
weight of Fiber Fl and
Fiber 2 in the nonwoven sheet. The detergent formulations having a weight
percent ("xx") of
water are represented in a format of -MS-LLD- xx." For example, a detergent
formulation MS-
LLD-20 means that such a detergent contains 20 wt.% of water. The detergent
formulations are
thus miscible with water as-formulated or in use, and comprise active cleaning
formulations and
surfactants of the present disclosure, such as lauryl alcohol ethoxylates,
alkali metal salts of
higher fatty acids containing about 8 to 24 carbon atoms, and propylene
glycol. The detergents
may also comprise carrier solvents of the present disclosure, such as
glycerol.
[0271] The dielectric constant of the detergent compositions used, which
contained 5%, 20%,
35%, 50%, and 65% by weight of water, were also measured with a frequency of
100 KHz at
25 C. The detergent composition comprising 50% water was a gel, and it was
difficult to be put
into a testing cell for holding a liquid sample, unless it was heated to 45 C.
The dielectric
constant of such a detergent composition was measured at both 45 C and 25 C.
The measured
dielectric constant values of the detergent compositions used were 38.7,
395.0, 2016, 6458, and
7320, corresponding to the water content of 5%, 20%, 35%, 50%, and 65% by
weight,
respectively. The dielectric constant linearly increases with the water
content. For the
Experimental Samples, their shrinkage in a detergent composition increases
with the dielectric
constant (i.e., the polarity) of the detergent composition. The range of
dielectric constants also
illustrates a range of carrier solvents that can be used.
[0272] The samples did not show any shrinkage in a detergent formulation
having 5 wt.% of
water at 45 C. Shrinkage of these samples was observed in the detergent
formulation containing
water of 20 wt.% or higher. FIG. 16 shows shrinkage results for these samples
in the detergent
formulation with 20% water at 45 C. The testing time was 5 minutes. As shown
in FIG. 16, the
shrinkage with 5 minutes decreases with increasing Fiber F2 content up to 90%.
The sample (i.e.,
Ex. 4) having a ratio of Fibers F1:F2 of 10:90 has the lowest shrinkage. The
nonwoven sample
having Fiber Fl only (i.e., Ex. 5) has a shrinkage about six times as high as
that of Sample Ex. 4.
The nonwoven sample having Fiber F2 only (i.e., Ex. 1) has a shrinkage about
1.9 times as high
as that of Sample Ex. 4. These nonwoven samples continued to shrink after five
minutes but at a
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much slower rate. For example, the nonwoven sample having Fiber Fl only (i.e.,
Ex. 5) showed
an additional 7.8% shrinkage over one hour.
[0273] FIG. 17 shows shrinkage results for the Experimental Samples including
Ex. 1, Ex. 2,
Ex. 3, Ex. 4, and Ex. 5 in a detergent formulation with 35% water at 20 C, 35
C, and 45 C,
respectively. FIG. 17 shows the effect of the content (wt. %) of Fiber F2 in
the total weight of
Fibers Fl and F2 on the shrinkage of the nonwoven samples. Shrinkage was
observed for all the
samples in the detergent formulation with 35% water at the three temperatures.
Similar to what is
shown in FIG. 16, the shrinkage with 5 minutes decreases with increase in the
content of Fiber
F2 up to 90%. The samples with the content of Fiber F2 in a range of about 75%
to 90% have the
minimum shrinkage. When the temperature increases, the shrinkage of the
samples increases, but
the difference in shrinkage between the samples with Fiber Fl and Fiber F2
decreases. A 45 C,
the shrinkage of these nonwoven samples did not change after five minutes, but
continued to
increase at lower temperatures.
[0274] Similar to FIG. 17, FIG. 18 shows shrinkage results of the Experimental
Samples in a
detergent formulation with 50% water at 20 C, 35 C, and 45 C, respectively.
Such a detergent
formulation is a gel at 20 C, while it is a fluid at 35 C and 45 C. Shrinkage
was observed for all
the samples in this detergent formulation at the three temperatures. Similar
to what is shown in
FIG. 17, the shrinkage with 5 minutes decreases with increase in the content
of Fiber F2 up to
90%. The sample with 90% of Fiber F2 has a minimum shrinkage. At 45 C, these
nonwoven
samples showed similar shrinkage. The shrinkage of these nonwoven samples
after five minutes
did not continue to increase at 30 C and 45 C, but continued to increase at 20
C.
[0275] Similar to FIG. 17, FIG. 19 shows shrinkage results of the Experimental
Samples in a
detergent formulation with 65% water at 20 C, 35 C, and 45 C, respectively.
Shrinkage was
observed for all the samples in this detergent formulation at the three
temperatures. Similar to
what is shown in FIGS. 17 and 18, the shrinkage within 5 minutes decreases
with increase in the
content of Fiber F2 up to 90%. The sample with 90% of Fiber F2 has a minimum
shrinkage. In
such a detergent formulation, shrinkage is less dependent on a testing
temperature, while most of
the samples have a shrinkage in a range of from 78% to 86%. At 45 C, these
nonwoven samples
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showed similar shrinkage. The shrinkage of these nonwoven samples after five
minutes did not
continue to increase in such a detergent formulation at any of the three
temperatures.
[0276] FIG. 20 shows shrinkage results of the Example Samples including at
least one
nonwoven layer having a plurality of fibers (Fiber Fl only) having different
basis weight in a
detergent formulation with 35% water at 20 C. As shown in FIG. 20, the
shrinkage of the
samples is independent of basis weight. This means that denser water-soluble
nonwoven layers
shrink at the same rate as thinner water-soluble nonwoven layers when the
nonwoven layers have
the same fiber content with the same bonding pattern. A same trend was
observed for solubility
of the samples.
[0277] FIG. 21 shows shrinkage results (in a detergent formulation with 35%
water at 20 C) of
example samples including at least one nonwoven layer having a plurality of
fibers (Fiber Fl
only) having a basis weight of 50 gsm with different bonding patterns, which
include a point
bonding pattern and a daisy bonding pattern with denser boning points than the
point bonding
pattern. The point bonded nonwoven layers shrink 32.5% more than the daisy
bonded nonwoven
layers having the same composition under the same testing conditions. Daisy
bonding is
significantly denser than point bonding, resulting in a reduced surface area
and less shrinkage in
a detergent formulation. A similar trend was also observed for solubility of
these samples.
[0278] FIG. 22 shows disintegration time results for the Experimental Samples
including Ex.
1, Ex. 2, Ex. 3, Ex. 4, and Ex. 5 with point bonding patterns in water at 20
C, 35 C, and 45 C.
FIG. 23 shows rupture time results of the same example samples at 20 C, 35 C,
45 C. Rupture
time is defined as when a water-soluble nonwoven sample develops a hole in its
structure.
Disintegration time is when the water-soluble nonwoven sample fully breaks
away from the side
and dissolves. As shown in FIG. 22, the disintegration (solubility) time
increases with the
increase in the content of Fiber F2 in the Fl and F2 blended nonwovens. The
solubility time
decreases with increasing temperature. At 20 C, the samples with 75% or more
of Fiber F2 do
not disintegrate within the maximum testing time of five minutes.
[0279] FIG. 24 shows disintegration time results (at 20 C, 35 C, 45 C) for
example samples
including a core substrate comprising at least one nonwoven layer or sheet
(daisy-bonded, with
different basis weight) having a plurality of fibers, which include a first
type of fiber ("F1-)
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comprising a polyvinyl alcohol copolymer having a degree of hydrolysis of 88%.
FIG. 25 shows
rupture time results for the same example samples at 20 C, 35 C, and 45 C. At
20 C, the samples
with 75% or more of Fiber F2 do not disintegrate within the maximum testing
time of five
minutes. The solubility time decreases with increasing testing temperature.
The solubility time is
about 16 times lower than that at 20 C.
[0280] FIGS. 26 and 27 compare the results of the rupture time and the
disintegration
(solubility) time of the samples having the same composition but different
bonding patterns in
water at 20 C, 35 C, and 45 C. The example samples included one nonwoven layer
having a
plurality of fibers (Fiber Fl only) having a basis weight of 50 gsm. The two
different bonding
patterns included a point bonding pattern and a daisy bonding pattern, which
has denser bonding
points than the point bonding pattern. The nonwoven layer having point bonding
dissolves much
faster than the daisy bonded counterpart. For example, the solubility time of
the daisy bonded
sample nonwoven layer is 67% longer than that of the point bonded sample
nonwoven layer at
20 C. Such a difference between the daisy and point bonded samples decreases
with increasing
ternperature
[0281] The following paragraphs describe further aspects of the disclosure:
1. A single unit dose article, comprising:
a water-soluble core substrate comprising a plurality of fibers including a
water-soluble
resin, the water-soluble core substrate containing a carrier solvent with an
active cleaning
formulation,
wherein upon contact of the carrier solvent with at least one fiber of the
plurality of fibers
at a temperature in a range of 10 C to 20 C for a period of time of 5 minutes
or longer, the core
substrate exhibits a degree of shrinkage of 0.5% to 65%, and
wherein the active cleaning formulation is disposed on or embedded in the
water-soluble
core substrate.
2. The single unit dose article according to clause 1, further comprising a
water-
soluble nonwoven material enclosing the water-soluble core substrate.
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3. The single unit dose article according to clause 2, further comprising a
water-
soluble film enclosing the water-soluble nonwoven substrate.
4. The single unit dose article according to clause 3, wherein the water-
soluble film
is laminated to the water-soluble nonwoven material.
5. The single unit dose article according to clause 2, further comprising a
bonding
interface configured to create a seal to enclose the water-soluble core
substrate.
6. The single unit dose article according to any of clauses 1-5, wherein
the active
cleaning formulation is in the form of at least one of the following: a solid,
a gel, a liquid, a gel,
or a slurry form.
7. The single unit dose article according to any of clauses 1-6, wherein
the water-
soluble core substrate is at least one of saturated with the active cleaning
formulation, coated
with the active cleaning formulation, or impregnated with the active cleaning
formulation.
8. The single unit dose article according to any of clauses 1-7, wherein
the active
cleaning formulation is present in the water-soluble core substrate.
9. The single unit dose article according to any of clauses 1-8, wherein,
when the
water-soluble core substrate is contacted with water having a temperature of
at least 10 C, the
water-soluble core substrate is soluble according to MSTM-205 to release the
active cleaning
formulation.
10. The single unit dose article according to any of clauses 1-9, wherein,
after contact
with water having a temperature of at least 10 C for not more than 300
seconds, the active
cleaning formulation is substantially released from the water-soluble core
substrate.
11. The single unit dose article according to any of clauses 1-10, wherein
the resin is
a polymer comprising a vinyl alcohol moiety.
12. The single unit dose article according to clause 11, wherein the
polymer
comprising a vinyl alcohol moiety includes a polyvinyl alcohol homopolymer, a
polyvinyl
alcohol copolymer, or a combination thereof
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13. The single unit dose article according to 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 according to clause 13, wherein the
anionically
modified copolymer comprises a carboxylate, a sulfonate, or combinations
thereof.
15. The single unit dose article according to any of clauses 11-14, wherein
the
plurality of fibers comprise a polyvinyl alcohol copolymer having a degree of
hydrolysis in a
range of about 75% to about 89%.
16. The single unit dose article according to any of clauses 11-14, wherein
the
plurality of fibers comprise two types of fibers comprising a polyvinyl
alcohol copolymer having
a degree of hydrolysis in a range of about 75% to about 89%, and the two types
fibers have a
difference in diameter, length, tenacity, shape, rigidness, elasticity,
solubility, color, or a
combination thereof.
17. The single unit dose article according to any of clauses 11-14, wherein
the
plurality of fibers comprise a first type of fiber comprising a polyvinyl
alcohol copolymer having
a degree of hydrolysis in a range of about 75% to about 89%, and a second type
of fiber
comprising a polyvinyl alcohol copolymer having a degree of hydrolysis in a
range of about 90%
to about 99.5%.
18. The single unit dose article according to clause 17, wherein a ratio of
the first type
of fiber to the second type of fiber is in a range of from about 1:99 to about
75:25 by weight.
19. The single unit dose article according to clause 17, wherein a ratio of
the first type
of fiber to the second type of fiber is in a range of from about 5:95 to about
50:50 by weight.
20. The single unit dose article according to any clauses 17-19, wherein
the water-
soluble core substrate comprises at least one nonwoven sheet including a
mixture of the first type
of fiber and the second type of fiber.
21. The single unit dose article according to any of clauses 17-19, wherein
the water-
soluble core substrate comprises a plurality of layers, the plurality of
layers selected from a
nonwoven sheet, a foam layer, a film, or any combination thereof
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22 The single unit dose article according to clause 21,
wherein the plurality of layers
includes separate sheets in a plied construction or a continuous sheet folded
in a serpentine
construction.
23. A single unit dose article, comprising.
a water-soluble nonwoven substrate comprising a plurality of fibers including
a water-
soluble resin, the water-soluble nonwoven substrate containing a carrier
solvent with an active
cleaning formulation,
wherein upon contact of the carrier solvent with at least one fiber of the
plurality of fibers
at a temperature in a range of 10 C to 20 C for a period of time of 5 minutes
or longer, the
nonwoven substrate exhibits a degree of shrinkage of 0.5% to 65%, and
wherein the active cleaning formulation is disposed on or embedded in the
water-soluble
core substrate.
24. The single unit dose article according to clause 23, further comprising
a water-
soluble nonwoven material enclosing the water-soluble nonwoven substrate.
25. The single unit dose article according to clause 24, further comprising
a water-
soluble film enclosing the water-soluble nonwoven substrate.
26. The single unit dose article according to clause 25, wherein the water-
soluble film
is laminated to the water-soluble nonwoven material.
27. The single unit dose article according to any of clauses 24-26, further
comprising
a bonding interface configured to create a seal to enclose the water-soluble
nonwoven substrate.
28. The single unit dose article according to any of clauses 23-27, wherein
the active
cleaning formulation is in the form of at least one of the following: a solid,
a gel, a liquid, or a
slurry formulation.
99. The single unit dose article according to any of clauses
23-28, wherein the
plurality of fibers is saturated with the active cleaning formulation.
30. The single unit dose article according to any of clauses
23-29, wherein the active
cleaning formulation is embedded in the plurality of fibers.
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31. The single unit dose article according to any of clauses 23-30, wherein
the water-
soluble nonwoven substrate includes 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 according to clause 31, wherein the water-
soluble
nonwoven substrate is a continuous sheet of a water-soluble nonwoven web
folded in a
serpentine construction to form the plurality of layers.
33. The single unit dose article according to clause 31, wherein the water-
soluble
nonwoven substrate includes a plurality of separate substrate sheets in a
plied construction.
34. The single unit dose article according to any of clauses 31-33, wherein
the
plurality of fibers is saturated with the active cleaning formulation.
35. The single unit dose article according to any of clauses 31-33, wherein
the active
cleaning formulation is embedded in the plurality of fibers.
36. The single unit dose article according to clause 32, wherein the active
cleaning
formulation is disposed on a surface of the water-soluble nonwoven substrate,
and/or on a
surface of the plurality of fibers.
37. The single unit dose article according to any of clauses 31-36, further
comprising
a water-soluble nonwoven material enclosing the water-soluble nonwoven
substrate.
38. The single unit dose article according to any of clauses 23-37, further
comprising
a water-soluble nonwoven material defining an interior volume, wherein the
active cleaning
formulation is a liquid active cleaning formulation contained within the
interior volume.
39. The single unit dose article according to any of clauses 23-38,
wherein, when the
water-soluble nonwoven substrate is contacted with water having a temperature
of at least 10 C,
the water-soluble nonwoven substrate is soluble according to MSTM-205 to
release the active
cleaning formulation.
40. The single unit dose article according to clause 39, wherein, when the
water-
soluble nonwoven substrate is contacted with water having a temperature of at
least 10 C for not
more than 300 seconds, the active cleaning formulation is substantially
released from the water-
soluble nonwoven substrate.
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41. The single unit dose article according to 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 according to 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 single unit dose article according to clause 23, wherein the
plurality of fibers
comprise a first type of fiber comprising a polyvinyl alcohol copolymer having
a degree of
hydrolysis in a range of about 75% to about 89%, and a second type of fiber
comprising a
polyvinyl alcohol copolymer having a degree of hydrolysis in a range of about
90% to about 99.5
%.
44. The single unit dose article according to clause 43, wherein a ratio of
the first type
of fiber to the second type of fiber is in a range of from about 1:99 to about
75:25 by weight.
45. A single unit dose article, comprising:
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 with an active cleaning formulation disposed between the
first water-
soluble nonwoven web and the second water-soluble nonwoven web, 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 greater than 10 C, the at least one of 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.
46. The single unit dose article according to clause 45, wherein the first
water-soluble
nonwoven web comprises a plurality of fibers including the first water-soluble
resin, wherein
upon contact of the carrier solvent with at least one fiber of the plurality
of fibers at 20 C for a
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period of time of five minutes or longer, the first water-soluble nonwoven web
exhibits a degree
of shrinkage of 0.5% to 65%.
47. The single unit dose article according to any of clauses 45-46, wherein
the active
cleaning formulation is in the form of at least one of the following. a solid,
a gel, a liquid, or a
slurry form.
48. The single unit dose article according to any 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 to define an interior volume and
enclose the active
cleaning formulation within the interior volume.
49. The single unit dose article according to 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 according to clause 49, wherein the active
cleaning
formulation is embedded in the water-soluble film substrate.
51. The single unit dose article according to any of clauses 49-50, wherein
the active
cleaning formulation is disposed on a surface of the water-soluble film
substrate.
52. The single unit dose article according to any of clauses 45-51,
wherein, when the
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 not more
than 300 seconds, the
active cleaning formulation is substantially released from between the first
water-soluble
nonwoven web and the second water-soluble nonwoven web.
53. A single unit dose article, comprising:
a water-soluble material comprising a plurality of fibers including 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 volume of the single unit dose article; and
a carrier solvent with an active cleaning formulation disposed in the interior
volume,
wherein, when the water-soluble material is contacted with water having a
temperature greater
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than 10 C, the water-soluble material is soluble according to MSTM-205 to
release the active
cleaning formulation from the interior volume.
54. The single unit dose article according to clause 53, wherein upon
contact of the
carrier solvent with at least one fiber of the plurality of fibers, the at
least one fiber exhibits a
degree of shrinkage of 0.5% to 65%.
55. rt he single unit dose article according to 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 according to any of clauses 53-55, wherein
the active
cleaning formulation is in the form of at least one of the following: a solid,
a gel, a liquid, or a
slurry form.
57. The single unit dose article according to any of clauses 53-56, wherein
the water-
soluble material has a first surface facing the interior volume and an
opposing second surface,
the single unit dose article further comprising a water-soluble film disposed
on the first surface.
58. The single unit dose article according to any of clauses 53-57, wherein
the water-
soluble material includes a water-soluble composite material comprising a
water-soluble film
material made of a first water-soluble resin coupled to one of a water-soluble
nonwoven material
or a water-soluble foam material made of a second water-soluble resin.
59. The single unit dose article according to 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 according to 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 single unit dose article according to any of clauses 53-60, wherein
the
plurality of fibers comprise a first type of fiber comprising a polyvinyl
alcohol copolymer having
a degree of hydrolysis in a range of about 75% to about 89%, and a second type
of fiber
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comprising a polyvinyl alcohol copolymer having a degree of hydrolysis in a
range of about 90%
to about 99.5 %.
62. The single unit dose article according to clause 61, wherein a ratio of
the first type
of fiber to the second type of fiber is in a range of from about 1.99 to about
75.25 by weight.
63. A method for making a single unit dose article containing a carrier
solvent with an
active cleaning formulation, the method comprising:
forming a water-soluble core substrate comprising a plurality of fibers
including a water-
soluble resin, the water-soluble core substrate containing a carrier solvent
with an active cleaning
formulation, wherein upon contact of the carrier solvent with at least one
fiber of the plurality of
fibers at a temperature in a range from 10 C to 20 C for five minutes or
longer, the water-soluble
core substrate exhibits a degree of 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
material thereof, into an open pouch defining an interior volume configured to
contain the water-
soluble core substrate and the carrier solvent with the active cleaning
formulation;
introducing the water-soluble core substrate and the carrier solvent with the
active
cleaning formulation into the interior volume; and
sealing the outer water-soluble material to enclose the interior volume.
64. The method according to clause 63, wherein forming a water-soluble core
substrate comprising a plurality of fibers including 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 according to any of clauses 63-64, wherein forming a water-
soluble
core substrate comprising a plurality of fibers including a water-soluble
resin comprises at least
one of saturating the water-soluble core substrate with the active cleaning
formulation, disposing
the active cleaning formulation on a surface of the water-soluble core
substrate, coating a surface
of the water-soluble core substrate with the active cleaning formulation,
embedding the active
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cleaning formulation in the water-soluble core substrate, or impregnating the
water-soluble core
substrate with the active cleaning formulation.
66. The method according to any of clauses 63-65, wherein sealing the outer
water-
soluble material comprises forming a seal at a bonding interface to enclose
the water-soluble
core substrate and the carrier solvent with the active cleaning formulation in
the interior volume.
67. The method according to any of clauses 63-66, wherein forming a water-
soluble
core substrate comprising a plurality of fibers including a water-soluble
resin comprises forming
a water-soluble nonwoven substrate into a plurality of layers, with the
carrier solvent and the
active cleaning formulation disposed between adjacent layers of the plurality
of layers.
68. The method according to clause 67, wherein forming a water-soluble
nonwoven-
substrate into a plurality of layers comprises folding a continuous sheet of a
water-soluble
nonwoven web in a serpentine construction to form the plurality of layers.
69. The method according to clause 67, wherein forming a water-soluble
nonwoven
substrate into a plurality of layers comprises stacking a plurality of
separate substrate sheets in a
plied construction.
70. The method according to clause 67, further comprising applying the
carrier
solvent comprising glycerol with the active cleaning formulation to a surface
of the water-
soluble nonwoven substrate to a maximum coat weight of 120 gsm for the carrier
solvent with
the active cleaning formulation.
71. The method according to 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 according to clause 71, further comprising forming the water-
soluble
nonwoven substrate into 25 layers to 110 layers.
73. The method according to any of clauses 63-72, wherein the water-soluble
resin is
a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a
combination thereof
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74. A single unit dose article, comprising:
a water-soluble core substrate comprising a plurality of fibers including a
water-soluble
resin, the water-soluble core substrate containing an active cleaning
formulation; and
a water-soluble nonwoven material enclosing the water-soluble core substrate,
wherein the active cleaning formulation is disposed on or embedded in the
water-soluble
core substrate.
75. The single unit dose article according to clause 74, further comprising
a water-
soluble film laminated on and enclosing the water-soluble nonwoven substrate.
76. The single unit dose article according to any of clauses 74-75, wherein
the water-
soluble core substrate further comprises a carrier solvent including the
active cleaning
formulation.
The single unit dose article according to any of clause 74-76 may further
include any of
the features described in any of clauses 1-73.
[0282] All percentages, parts and ratios referred to herein are based upon the
total dry weight
of the fiber composition, film composition, or total weight of the packaging
material composition
of the present disclosure, as the case may be, and all measurements made are
at about 25 C,
unless otherwise specified. All percentages, parts and ratios referred to
herein for liquid
formulations are based upon the total weight of the liquid formulation. All
such weights as they
pertain to listed ingredients are based on the active level and therefore do
not include carriers or
by-products that may be included in commercially available materials, unless
otherwise
specified.
[0283] All ranges set forth herein include all possible subsets of ranges and
any combinations
of such subset ranges. By default, ranges are inclusive of the stated
endpoints, unless stated
otherwise. Where a range of values is provided, it is understood that each
intervening value
between the upper and lower limit of that range and any other stated or
intervening value in that
stated range, is encompassed within the disclosure. The upper and lower limits
of these smaller
ranges may independently be included in the smaller ranges, and are also
encompassed within
the disclosure, subject to any specifically excluded limit in the stated
range. Where the stated
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range includes one or both of the limits, ranges excluding either or both of
those included limits
are also contemplated to be part of the disclosure.
[0284] It is expressly contemplated that for any number value described
herein, e.g., as a
parameter of the subject matter described or part of a range associated with
the subject matter
described, an alternative which forms part of the description is a
functionally equivalent range
surrounding the specific numerical value (e.g., for a dimension disclosed as
"40 millimeters
(mm)" an alternative embodiment contemplated is "about 40 mm").
[0285] Reference throughout this specification to "example embodiment" or "an
embodiment"
may mean that a particular feature, structure, or characteristic described in
connection with a
particular embodiment may be included in at least one embodiment of claimed
subject matter.
Thus, appearances of the phrase "example embodiments" or "an example
embodiment" in
various places throughout this specification is not necessarily intended to
refer to the same
embodiment or to any one particular embodiment described. Further, it is to be
understood that
particular features, structures, or characteristics described may be combined
in various ways in
one or more embodiments. In general, of course, these and other issues may
vary with the
particular context of usage. Therefore, the particular context of the
description or the usage of
these terms may provide helpful guidance regarding inferences to be drawn for
that context.
[0286] Although the subject matter has been described in language 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, the
specific features and acts are disclosed as illustrative forms of implementing
the claims.
[0287] One skilled in the art will realize that a virtually unlimited number
of variations to the
above descriptions are possible, and that the examples and the accompanying
figures are merely
to illustrate one or more examples of implementations.
[0288] It will be understood by those skilled in the art that various other
modifications may be
made, and equivalents may be substituted, without departing from claimed
subject matter.
Additionally, many modifications may be made to adapt a particular situation
to the teachings of
claimed subject matter without departing from the central concept described
herein. Therefore, it
is intended that claimed subject matter is not limited to the particular
embodiments disclosed, but
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that such claimed subject matter may also include all embodiments falling
within the scope of
the appended claims, and equivalents thereof.
[0289] In the detailed description above, numerous specific details are set
forth to provide a
thorough understanding of claimed subject matter. However, it will be
understood by those
skilled in the art that claimed subject matter may be practiced without these
specific details. In
other instances, methods, apparatuses, or systems that would be known by one
of ordinary skill
have not been described in detail so as not to obscure claimed subject matter.
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