Process for forming particles

Abstract

A process for forming particles. The process includes a step of mixing a gas into a precursor material, where the gas contains from about 50 volume % to about 100 volume % argon and from about 0 volume % to about 50 volume % other components. The precursor material is deposited on a moving conveyor. The precursor material is cooled to form a plurality of particles.

Description

Technical Field

[0001] A process for forming particles.

Background Art

[0002] Consumers desire products that can simplify the processes they use for doing laundry, which can help reduce the time spent handling soiled laundry and can help achieve a high level of benefit. Consumers are in a position to understand the amount of fabric care composition necessary to provide the benefits they desire. As a result, fabric care products that allow consumers to customize the amount of fabric care composition used are supported by many consumers.

[0003] Fabric care products that can be delivered into the wash liquor are particularly convenient for consumers. For example, a consumer can simply place the fabric care product together with the laundry in the washing machine tub and start the washing machine cycle.

[0004] Typically, consumers use fabric care detergent compositions that contain significant amounts of surfactants and other cleaning components. Such fabric care compositions are often provided in soluble unit dose pouches that contain a predetermined amount of fabric care active. Fabric care compositions are also provided in liquid or powder form, and consumers are provided with a measuring cup to provide a measured amount of the fabric care composition. These types of products can be referred to as fully formulated fabric care compositions.

[0005] To provide fabric care benefits beyond what can be provided by using a fully formulated fabric care composition, fabric care products that are additives are popular with consumers. Consumers enjoy and are satisfied with using packaged fabric care additives in a manner that allows the consumer to use a custom amount of fabric care additive based on the consumer's judgment of how much fabric care additive is needed to provide the desired benefit. Such fabric care additives are conveniently provided through laundering with a fully formulated fabric care composition, but are introduced separately from the fully formulated fabric care composition.

[0006] Fabric care additives in the form of particles have become attractive to many consumers. Some fabric care additive particles are provided with a porous structure. Particles with a porous structure can float in water when a wash liquor is formed. Since particles that sink can be trapped in the folds, wrinkles, and pockets of the laundry during washing, floating particles may tend to dissolve more completely in the wash compared to sinking particles. Undissolved particles tend to incompletely deliver the fabric care beneficial active agent contained in the particles, which may not be desirable for the consumer. Particles that float and contain a non-encapsulated fragrance can provide a pleasant scent to the headspace above the wash liquor and the room in which the washing machine is located. Further, floating particles can better distribute the fabric care additive to the laundry during the wash cycle.

[0007] Melt processing is a common technique for forming particles. One problem associated with producing porous particles via a melting process is that as the molten precursor material solidifies, the gas bubbles within the melt tend to coalesce and rise out of the molten material. This can result in large pores on or near the outer surface of the particles, an irregular and rough outer surface, an irregular distribution of pore sizes within the solidified particles, and the ejection of gas bubbles and molten material from the surface of the particles as they solidify. Such particles may have a less efficient outer surface, be prone to becoming dusty, be difficult to use, and may appear to be of poor quality and have lower durability compared to particles with a better outer surface. The tendency for gas bubbles within the melt to coalesce and rise out of the molten material as the molten precursor material solidifies can also effectively limit the volume of pores that can be provided within the particles without causing these adverse effects. SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0008] Considering these limitations, there remains a continuing, unaddressed need for particulate form fabric care additives having a uniform distribution of pore sizes throughout the particles. Further, a process for forming such porous particles is needed. MEANS FOR SOLVING THE PROBLEM

[0009] A process for forming particles, comprising: supplying a precursor material to a supply pipe; mixing a gas into the precursor material, wherein the gas comprises from about 50 volume % to about 100 volume % argon and from about 0 volume % to about 100 volume % other components; providing a dispenser having a plurality of holes; moving the precursor material from the supply pipe to the dispenser; passing the precursor material through the holes; providing a movable conveyor below the holes; depositing the precursor material onto the movable conveyor; and cooling the precursor material to form a plurality of particles. BRIEF DESCRIPTION OF THE DRAWINGS

[0010]

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DETAILED DESCRIPTION OF THE INVENTION

[0011] Water-soluble carrier Particles, and thus the precursor materials described below, may contain a water-soluble carrier. The water-soluble carrier can be a water-soluble polymer. The water-soluble carrier acts to carry the capsules into the cleaning liquid. When the water-soluble carrier dissolves, the capsules are dispersed in the cleaning liquid and adhere to the laundry.

[0012] The water-soluble carrier can be a material that is soluble in the cleaning liquid in a short time, for example, less than about 10 minutes.

[0013] Water-soluble means that a material, carrier material, or particle is soluble or dispersible in water and has a water solubility of at least 50%, optionally at least 75%, or even at least 95% when measured by the method shown below in this specification using a glass filter with a maximum pore size of 20 microns. The method is as follows: That is, (50 grams ± 0.1 gram of the carrier is added to a pre-weighed 400 mL beaker, and 245 mL ± 1 mL of distilled water is added. This is vigorously stirred for 30 minutes with a magnetic stirrer set at 600 rpm. Then, the mixture is filtered through a sintered glass filter with the pore size (maximum 20 micrometers) defined above. The process is carried out at a temperature of 23°C ± 1.0°C and a relative humidity of 50% ± 2%. By any conventional method, water is dried from the recovered filtrate, and the weight of the remaining material is determined (this is the dissolved or dispersed fraction). Then, the percentage of solubility or dispersion can be calculated.

[0014] The water-soluble carrier can be selected from the group consisting of water-soluble inorganic alkali metal salts, water-soluble alkaline earth metal salts, water-soluble organic alkali metal salts, water-soluble organic alkaline earth metal salts, water-soluble carbohydrates, water-soluble silicates, water-soluble ureas, and any combination thereof.

[0015] The alkali metal salts can be selected from the group consisting of, for example, salts of lithium, salts of sodium, and salts of potassium, and any combination thereof. Useful alkali metal salts can be selected from the group consisting of, for example, alkali metal fluorides, alkali metal chlorides, alkali metal bromides, alkali metal iodides, alkali metal sulfates, alkali metal bisulfates, alkali metal phosphates, alkali metal monohydrogen phosphates, alkali metal dihydrogen phosphates, alkali metal carbonates, alkali metal bicarbonates, alkali metal acetates, alkali metal citrates, alkali metal lactates, alkali metal pyruvates, alkali metal silicates, alkali metal ascorbates, and combinations thereof.

[0016] The alkali metal salts can be selected from the group consisting of sodium fluoride, sodium chloride, sodium bromide, sodium iodide, sodium sulfate, sodium bisulfate, sodium phosphate, sodium monohydrogen phosphate, sodium dihydrogen phosphate, sodium carbonate, sodium bicarbonate, sodium acetate, sodium citrate, sodium lactate, sodium tartrate, sodium silicate, sodium ascorbate, potassium fluoride, potassium chloride, potassium bromide, potassium iodide, potassium sulfate, potassium bisulfate, potassium phosphate, potassium monohydrogen phosphate, potassium dihydrogen phosphate, potassium carbonate, potassium bicarbonate, potassium acetate, potassium citrate, potassium lactate, potassium tartrate, potassium silicate, potassium ascorbate, and combinations thereof.

[0017] The alkaline earth metal salt can be selected from the group consisting of salts of magnesium, salts of calcium, etc., and combinations thereof. The alkaline earth metal salt can be selected from the group consisting of alkali metal fluorides, alkali metal chlorides, alkali metal bromides, alkali metal iodides, alkali metal sulfates, alkali metal bisulfates, alkali metal phosphates, alkali metal monohydrogen phosphates, alkali metal dihydrogen phosphates, alkali metal carbonates, alkali metal bicarbonates, alkali metal acetates, alkali metal citrates, alkali metal lactates, alkali metal pyruvates, alkali metal silicates, alkali metal ascorbates, and combinations thereof. The alkaline earth metal salt can be selected from the group consisting of magnesium fluoride, magnesium chloride, magnesium bromide, magnesium iodide, magnesium sulfate, magnesium phosphate, magnesium monohydrogen phosphate, magnesium dihydrogen phosphate, magnesium carbonate, magnesium bicarbonate, magnesium acetate, magnesium citrate, magnesium lactate, magnesium tartrate, magnesium silicate, magnesium ascorbate, calcium fluoride, calcium chloride, calcium bromide, calcium iodide, calcium sulfate, calcium phosphate, calcium monohydrogen phosphate, calcium dihydrogen phosphate, calcium carbonate, calcium bicarbonate, calcium acetate, calcium citrate, calcium lactate, calcium tartrate, calcium silicate, calcium ascorbate, and combinations thereof.

[0018] Inorganic salts such as inorganic alkali metal salts and inorganic alkaline earth metal salts do not contain carbon. Organic salts such as organic alkali metal salts and organic alkaline earth metal salts contain carbon. The organic salt can be an alkali metal salt or an alkaline earth metal salt of sorbic acid (i.e., sorbate). The sorbate can be selected from the group consisting of sodium sorbate, potassium sorbate, magnesium sorbate, calcium sorbate, and combinations thereof.

[0019] The water-soluble carrier may be or may contain a material selected from the group consisting of water-soluble inorganic alkali metal salts, water-soluble organic alkali metal salts, water-soluble inorganic alkaline earth metal salts, water-soluble organic alkaline earth metal salts, water-soluble carbohydrates, water-soluble silicates, water-soluble urea, and combinations thereof. The water-soluble carrier may be selected from the group consisting of sodium chloride, potassium chloride, calcium chloride, magnesium chloride, sodium sulfate, potassium sulfate, magnesium sulfate, sodium carbonate, potassium carbonate, sodium bicarbonate, potassium bicarbonate, sodium acetate, potassium acetate, sodium citrate, potassium citrate, sodium tartrate, potassium tartrate, potassium sodium tartrate, calcium lactate, water glass, sodium silicate, potassium silicate, dextrose, fructose, galactose, isoglucose, glucose, sucrose, raffinose, isomalt, xylitol, rock sugar, raw sugar, and combinations thereof. In one embodiment, the water-soluble carrier can be sodium chloride. In one embodiment, the water-soluble carrier can be table salt.

[0020] The water-soluble carrier may be or may contain a material selected from the group consisting of sodium bicarbonate, sodium sulfate, sodium carbonate, sodium formate, calcium formate, sodium chloride, sucrose, maltodextrin, corn syrup solids, corn starch, wheat starch, rice starch, potato starch, tapioca starch, clay, silicate, carboxymethyl cellulose citrate, fatty acid, fatty alcohol, glyceryl diester of hydrogenated tallow, glycerol, and combinations thereof.

[0021] The water-soluble carrier may be selected from the group consisting of water-soluble organic alkali metal salts, water-soluble inorganic alkaline earth metal salts, water-soluble organic alkaline earth metal salts, water-soluble carbohydrates, water-soluble silicates, water-soluble urea, starch, clay, water-insoluble silicate, carboxymethyl cellulose citrate, fatty acid, fatty alcohol, glyceryl diester of hydrogenated tallow, glycerol, polyethylene glycol, and combinations thereof.

[0022] The water-soluble carrier can be selected from the group consisting of disaccharides, polysaccharides, silicates, zeolites, carbonates, sulfates, citrates, and combinations thereof.

[0023] The water-soluble carrier can be selected from the group consisting of polyethylene glycol, sodium acetate, sodium bicarbonate, sodium chloride, sodium silicate, polypropylene glycol polyoxalkylene, polyethylene glycol fatty acid ester, polyethylene glycol ether, sodium sulfate, starch, and mixtures thereof.

[0024] The water-soluble carrier can be a water-soluble polymer. The water-soluble polymer can be selected from the group consisting of C8-C22 alkyl polyalkoxylates containing more than about 40 alkoxylate units, ethoxylated nonionic surfactants having an ethoxylation degree of more than about 30, polyalkylene glycols having a weight average molecular weight of about 2000 to about 15000, and combinations thereof.

[0025] The water-soluble polymer is of formula (I), (II), (III) or (IV), R 1 O-(EO)x-(PO)y-R 2 (I), R 1 O--(PO)x-(EO)y-R 2 (II), R 1 O-(EO)o-(PO)p-(EO)q-R 2 (III), R 1 O--(PO)o-(EO)p-(PO)q-R 2 (IV), or a combination thereof (wherein EO is a -CH 2 CH 2 O- group, PO is a -CH(CH 3 )CH 2 O- group, R 1 and R 2is independently H or a C1-C22 alkyl group, x, y, o, p, and q are independently from 1 to 100, provided that the sum of x and y is greater than 35, the sum of o, p, and q is greater than 35, and the block copolymer can be a block copolymer having a molecular weight in the range of about 3000 g / mol to about 15,000 g / mol).

[0026] The water-soluble polymer can be a block copolymer or a plurality of block copolymers, for example, a block copolymer based on ethylene oxide and propylene oxide selected from the group consisting of PLURONIC-F38, PLURONIC-F68, PLURONIC-F77, PLURONIC-F87, PLURONIC-F88, and combinations thereof. The PLURONIC materials are available from BASF.

[0027] Water-soluble polymers may be selected from the group consisting of polyvinyl alcohol (PVA), modified PVA; polyvinyl pyrrolidone; PVA copolymers such as PVA / polyvinyl pyrrolidone and PVA / polyvinyl amine; partially hydrolyzed polyvinyl acetate; polyalkylene oxides such as polyethylene oxide; polyethylene glycol; acrylamide; acrylic acid; cellulose, such as alkyl cellulose-based materials such as methyl cellulose, ethyl cellulose, and propyl cellulose; cellulose ethers; cellulose esters; cellulose amides; polyvinyl acetate; polycarboxylic acids and salts; polyamino acids or peptides; polyamides; polyacrylamide; copolymers of maleic acid / acrylic acid; polysaccharides including starch, modified starch; gelatin; alginate; other hemicellulose-based polysaccharides including xyloglucan, xylan, glucuronoxylan, arabinoxylan, mannan, glucomannan, and galactoglucomannan; and natural gums such as pectin, xanthan, and carrageenan, locust bean, arabic, tragacanth; and combinations thereof. In one embodiment, the polymer comprises polyacrylate, particularly sulfonated polyacrylate and water-soluble acrylate copolymers; and alkyl hydroxycellulose-based materials such as methyl cellulose, sodium carboxymethyl cellulose, modified carboxy-methyl cellulose, dextrin, ethyl cellulose, propyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose, maltodextrin, polymethacrylate. In yet another embodiment, the water-soluble polymer is selected from the group consisting of PVA; PVA copolymers; hydroxypropyl methyl cellulose (HPMC); and mixtures thereof.

[0028] The water-soluble polymer can be selected from the group consisting of polyvinyl alcohol, modified polyvinyl alcohol, polyvinyl pyrrolidone, polyvinyl alcohol / polyvinyl pyrrolidone, polyvinyl alcohol / polyvinyl amine, partially hydrolyzed polyvinyl acetate, polyalkylene oxide, polyethylene glycol, acrylamide, acrylic acid, cellulose, alkyl cellulose-based materials, methyl cellulose, ethyl cellulose, propyl cellulose, cellulose ether, cellulose ester, cellulose amide, polyvinyl acetate, polycarboxylic acid and salts, polyamino acid or peptide, polyamide, polyacrylamide, copolymer of maleic acid / acrylic acid, polysaccharide, starch, modified starch, gelatin, alginate, xyloglucan, hemicellulose-based polysaccharides, xylan, glucuronoxylan, arabinoxylan, mannan, glucomannan, galactoglucomannan, natural gum, pectin, xanthan, carrageenan, locust bean, arabic, tragacanth, polyacrylate, sulfonated polyacrylate, water-soluble acrylate copolymer, alkyl hydroxycellulose-based materials, methyl cellulose, sodium carboxymethyl cellulose, modified carboxy-methyl cellulose, dextrin, ethyl cellulose, propyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose, maltodextrin, polymethacrylate, polyvinyl alcohol polymer, hydroxypropyl methyl cellulose, and mixtures thereof.

[0029] The water-soluble polymer can be an organic material. The organic water-soluble polymer can provide the benefit of being readily soluble in water.

[0030] The water-soluble polymer can be selected from the group consisting of polyethylene glycol, polypropylene glycol polyoxoalkylene, polyethylene glycol fatty acid ester, polyethylene glycol ether, starch, and mixtures thereof.

[0031] The water-soluble polymer can be polyethylene glycol (PEG). PEG can be sufficiently water-soluble to dissolve during the washing cycle when the particles have a mass within the ranges disclosed herein, and thus can be a convenient material to use in making the particles. Further, PEG can be easily processed as a melt. The onset of the melting temperature of PEG can vary as a function of the molecular weight of PEG. The particles can contain from about 20 wt% to about 94 wt% of PEG having a weight average molecular weight of from about 2,000 to about 15,000. PEG is relatively low cost, can be formed into many different shapes and sizes, minimizes the diffusion of non-encapsulated fragrance, and dissolves well in water. PEG is provided in a variety of weight average molecular weights. Suitable ranges of weight average molecular weight of PEG are from about 2,000 to about 13,000, or from about 4,000 to about 13,000, or from about 4,000 to about 12,000, or from about 4,000 to about 11,000, or from about 5,000 to about 11,000, or from about 6,000 to about 10,000, or from about 7,000 to about 9,000, or combinations thereof. PEG is available from BASF, for example, as PLURIOL E 8000, or other PLURIOL products. The water-soluble polymer can also be a mixture of two or more polyethylene glycol compositions, one having a first weight average molecular weight (e.g., 9000) and the other having a second weight average molecular weight (e.g., 4000), the second weight average molecular weight being different from the first weight average molecular weight.

[0032] The particles can contain from about 20 wt% to about 99 wt% of a water-soluble carrier. The particles can contain from about 35 wt% to about 95 wt%, optionally from about 50 wt% to about 80 wt%, optionally a combination thereof, and any total percentage or range of total percentages within any of the foregoing ranges of the water-soluble carrier.

[0033] A plurality of particles can include individual particles containing from about 20 wt% to about 99 wt% of a water-soluble carrier of the particles and from about 0.1 wt% to about 20 wt% of particle capsules, the capsules being dispersed in a matrix of the water-soluble polymer.

[0034] The particles may contain from about 20 wt% to about 99 wt% of PEG per individual particle. Optionally, each individual particle may contain from about 20 wt% to about 95 wt%, optionally from about 35 wt% to about 95 wt%, optionally from about 50 wt% to about 80 wt%, optionally any combination thereof, and any total percentage or range of total percentages within any of the foregoing ranges of PEG.

[0035] The water-soluble polymer is a polyalkylene polymer of the formula H-(C 2 H 4 O) x -(CH(CH 3 )CH 2 O) y -(C 2 H 4 O) z -OH (wherein x is from about 50 to about 300, y is from about 20 to about 100, and z is from about 10 to about 200); a polyethylene glycol fatty acid ester of the formula (C 2 H 4 O) q -C(O)O-(CH 2 ) r -CH 3 (wherein q is from about 20 to about 200 and r is from about 10 to about 30); a polyethylene glycol fatty alcohol ether of the formula HO-(C 2 H 4 O) s -CH 2 ) t )-CH 3 (wherein s is from about 30 to about 250 and t is from about 10 to about 30); and may contain a material selected from the group consisting of mixtures thereof. The polyalkylene polymer of the formula H-(C 2 H 4 O) x -(CH(CH 3 )CH 2 O) y -(C 2 H 4 O) z -OH (wherein x is from about 50 to about 300, y is from about 20 to about 100, and z is from about 10 to about 200) can be a block copolymer or a random copolymer.

[0036] Water-soluble polymers include polyethylene glycol; polyalkylene polymers of the formula H-(C 2 H 4 O) x -(CH(CH 3 )CH 2 O) y -(C 2 H 4 O) z -OH (where x is from about 50 to about 300, y is from about 20 to about 100, and z is from about 10 to about 200); polyethylene glycol fatty acid esters of the formula (C 2 H 4 O) q -C(O)O-(CH 2 ) r -CH 3 (where q is from about 20 to about 200 and r is from about 10 to about 30); and polyethylene glycol fatty alcohol ethers of the formula HO-(C 2 H 4 O) s -(CH 2 ) t )-CH 3 (where s is from about 30 to about 250 and t is from about 10 to about 30).

[0037] The water-soluble polymer may include from about 20 wt% to about 95 wt% of a plurality of particles or individual particles of a polyalkylene polymer of the formula H-(C 2 H 4 O) x -(CH(CH 3 )CH 2 O) y -(C 2 H 4 O) z -OH (where x is from about 50 to about 300, y is from about 20 to about 100, and z is from about 10 to about 200).

[0038] The water-soluble polymer may include from about 1 wt% to about 20 wt% of a plurality of particles or individual particles of a polyethylene glycol fatty acid ester of the formula (C 2 H 4 O) q -C(O)O-(CH2 ) r -CH 3 (wherein q is from about 20 to about 200, and r is from about 10 to about 30) may contain a polyethylene glycol fatty acid ester.

[0039] The water-soluble polymer may contain from about 1 wt% to about 10 wt% of a plurality of particles or individual particles of the formula HO-(C 2 H 4 O) s -CH 2 ) t )-CH 3 (wherein s is from about 30 to about 250, and t is from about 10 to about 30) may contain a polyethylene glycol fatty alcohol ether.

[0040] The water-soluble carrier is a plasticizer polyol (0 wt% to 3 wt% of the particles), where the plasticizer polymer is optionally a plasticizer polyol that is liquid at 20 °C and 1 atm, water (1 wt% to 20 wt% of the particles, or 1 wt% to 12 wt% of the particles, or 6 wt% to 8 wt% of the particles), and a sugar alcohol polyol selected from the group consisting of erythritol, xylitol, mannitol, isomalt, maltitol, lactitol, trehalose, lactose, tagatose, sucralose, and mixtures thereof (45 wt% to 80 wt% of the particles, or 50 wt% to 70 wt% of the particles, or 50 wt% to 60 wt% of the particles). The particles can further include (a) a modified starch having a dextrose equivalent of 15 to 20, where the sugar alcohol polyol and the modified starch are present in a weight ratio of the sugar alcohol polyol to the modified starch of 2:1 to 16:1, or 2:1 to 10:1, or 2:1 to 3:1; or (b) a modified starch having a dextrose equivalent of less than 4 to 15, where the sugar alcohol polyol and the modified starch are present in a weight ratio of the sugar alcohol polyol to the modified starch of 1.5:1 to 16:1, or 1.5:1 to 10:1, or 1.5:1 to 4:1. The modified starch can have a dextrose equivalent of 15 to 20, and the sugar alcohol polyol and the modified starch can be present in a ratio of 2:1 to 16:1, or 2:1 to 10:1, or 2:1 to 3:1. The modified starch can have a dextrose equivalent of less than 4 to 15, and the sugar alcohol polyol and the modified starch can be present in a weight ratio of the sugar alcohol polyol to the modified starch of 1.5:1 to 16:1, or 1.5:1 to 10:1, or 1.5:1 to 4:1. The modified starch can have a dextrose equivalent of 4 to 12. The modified starch can be maltodextrin. The sugar alcohol polyol can be mannitol. The plasticizer polyol can be selected from the group consisting of glycerin, dipropylene glycol, propylene glycol, and mixtures thereof.

[0041] The particles may contain more than about 20% by weight of a water-soluble carrier. The particles may contain more than about 40% by weight of a water-soluble carrier. The particles may contain from about 20% to about 99% by weight of a water-soluble carrier. Optionally, the particles may contain from about 35% to about 85%, or even from about 50% to about 80% by weight of the particles of a water-soluble carrier. The water-soluble carrier is a polyalkylene polymer of the formula H-(C 2 H 4 O) x -(CH(CH 3 )CH 2 O) y -(C 2 H 4 O) z -OH (wherein x is from 50 to 300, y is from 20 to 100, and z is from 10 to 200); a polyethylene glycol fatty acid ester of the formula (C 2 H 4 O) q -C(O)O-(CH 2 ) r -CH 3 (wherein q is from 20 to 200 and r is from 10 to 30); a polyethylene glycol aliphatic alcohol ether of the formula HO-(C 2 H 4 O) s -(CH 2 ) t )-CH 3 (wherein s is from 30 to 250 and t is from 10 to 30); a C8-C22 alkyl polyalkoxylate containing more than 40 alkoxylate units; a polyethylene glycol having a weight average molecular weight of from 2000 to 15000; an EO / PO / EO block copolymer; a PO / EO / PO block copolymer; an EO / PO block copolymer; a PO / EO block copolymer; a polypropylene glycol; an ethoxylated nonionic surfactant having an ethoxylation degree of more than 30; polyvinyl alcohol; a polyalkylene glycol having a weight average molecular weight of from 2000 to 15000; and may be selected from the group consisting of mixtures thereof.

[0042] Budesonide beneficial active agent The particles may contain from about 0.1% to about 99% by weight of a fabric care beneficial agent. The fabric care beneficial agent is a substance provided as part of the composition of the particles in an amount sufficient to impart benefit to the fabric being treated with the particles.

[0043] The fabric care beneficial agent may be selected from the group consisting of amines, surfactant systems, nonionic surfactants, water-binding agents, sulfites, fatty acids and / or their salts, enzymes, encapsulated beneficial agents, soil release polymers, colorants, builders, chelating agents, migration inhibitors, dispersants, enzyme stabilizers, catalyst materials, bleaching agents, bleaching catalysts, bleach activators, polymer dispersants, cyclodextrin complex beneficial agents, soil removal / redeposition preventers, encapsulated fragrances, polymer dispersants, polymer fabric detergents, optical brighteners, antifoaming agents, dyes, colorants, free fragrances, structure elasticizers, fabric softeners, quaternary amines, hardened and softened tallow, carriers, fillers, hydrotropes, organic solvents, antibacterial agents and / or preservatives, neutralizing agents and / or pH adjusters, processing aids, fillers, antioxidants, rheology modifiers or structuring agents, opacifiers, pearl essence agents, pigments, corrosion and / or anti-discoloration agents, and mixtures thereof.

[0044] Fragrance The fabric care beneficial agent may be a fragrance. A fragrance is an oil or perfume containing one or more odoriferous compounds, such as esters, ethers, aldehydes, ketones, alcohols, and hydrocarbon-type synthetic products. Mixtures of various odoriferous substances that together produce an attractive aromatic note may be used. Such perfumed oils may also include natural mixtures of odoriferous compounds that are obtainable from vegetable sources.

[0045] The fragrance may be a substantially water-insoluble composition containing fragrance components optionally mixed with a suitable solvent or diluent. Suitable solvents or diluents include compounds selected from the group consisting of ethanol, isopropanol, diethylene glycol monoethyl ether, dipropylene glycol, diethyl phthalate, triethyl citrate, and mixtures thereof.

[0046] The fragrance can be supplied as a non-encapsulated fragrance. The fragrance can be supplied in a fragrance delivery system. Zeolites and cyclodextrins are examples of fragrance delivery systems. The fragrance can be encapsulated in starch. For example, an emulsion of starch and essential oil can be spray-dried to form starch particles having droplets of the fragrance dispersed within the starch matrix. The fragrance delivery system can be a particulate or fine particulate material that can be difficult to handle in a manufacturing environment due to the potential for the particles to be suspended in air.

[0047] The fragrance can be an encapsulated fragrance. Encapsulated fragrances are generally used in laundry products. An encapsulated fragrance contains a plurality of droplets of a liquid fragrance, each encapsulated within a capsule shell. The fragrance can be encapsulated in a water-soluble or water-insoluble capsule shell. The capsule shell can include melamine-urea-formaldehyde, melamine formaldehyde, urea formaldehyde, starch, and similar materials. The capsule shell can be a material selected from polyethylene; polyamide; polyvinyl alcohol optionally containing other comonomers; polystyrene; polyisoprene; polycarbonate; polyester; polyacrylate; polyolefin; polysaccharides such as alginate and / or chitosan; gelatin; shellac; epoxy resin; vinyl polymer; water-insoluble inorganic material; silicone; aminoplast; and mixtures thereof. When the capsule shell includes an aminoplast, the aminoplast can include polyureas, polyurethanes, and / or polyurea urethanes. The polyurea can include polyoxymethylene urea and / or melamine formaldehyde. Encapsulates having a capsule shell that includes a polysaccharide can be practical. The capsule shell can be selected from the group consisting of chitosan, gum arabic, alginate, β-glucan, starch, starch derivatives, plant proteins, gelatin, alyssum homolocarpum seed gum, and combinations thereof.

[0048] The encapsulation shell may contain from about 90 wt% to 100 wt%, optionally from about 95 wt% to 100 wt%, optionally from about 99 wt% to 100 wt% of inorganic materials of the shell. The inorganic materials are selected from the group consisting of metal oxides, metalloid oxides, metals, minerals, and mixtures thereof, and optionally SiO 2 、TiO 2 、Al 2 O 3 、ZrO 2 、ZnO 2 、CaCO 3 、Ca 2 SiO 4 、Fe 2 O 3 、Fe 3 O 4 、 clay, gold, silver, iron, nickel, copper, and mixtures thereof, optionally SiO 2 、TiO 2 、Al 2 O 3 、CaCO 3 、 and mixtures thereof, and may optionally be SiO 2 . The encapsulation shell is a first shell component including a condensation layer and a nanoparticle layer, the condensation layer contains a condensation product of a precursor, the nanoparticle layer contains inorganic nanoparticles, the condensation layer is disposed between the core and the nanoparticle layer, and a second shell component surrounding the first shell component, the second shell component surrounding the nanoparticle layer, and may include the first shell component. The encapsulation may be any of the encapsulations described in US Patent Application Publication Nos. 2020 / 0330948(A1), 2020 / 0330949(A1), and 2020 / 0330950(A1), and US Patent Application No. 63 / 092,829.

[0049] The fragrance may contain one or more plant-derived fragrances. A plant-derived fragrance is a concentrated hydrophobic liquid containing volatile chemical compounds extracted from plants. The plant-derived fragrance may be selected from the group consisting of allspice berry, angelica seed, anise seed, basil, bay laurel, bay, bergamot, blood orange, camphor, caraway seed, cardamom seed, carrot seed, cassia, catnip, cedarwood, celery seed, chamomile german, chamomile roman, cinnamon bark, cinnamon leaf, citronella, clary sage, clove bud, coriander seed, cypress, elemi, eucalyptus, fennel, fir needle, frankincense, geranium, ginger, grapefruit pink, helichrysum, hop, hyssop, juniper berry, labdanum, lavender, lemon, lemongrass, lime, magnolia, mandarin, marjoram, melissa, mugwort, myrrh, myrtle, neroli, niaouli, nutmeg, orange sweet, oregano, palmarosa, patchouli, pennyroyal, pepper black, peppermint, ptychopetalum, pine needle, radiata, ravintsara, rose, rosemary, rosewood, sage, sandalwood, spearmint, spikenard, spruce, star anise, sweet annie, tangerine, tea tree, thyme red, verbena, vetiver, wintergreen, wormwood, yarrow, iran iran extra, and iran iran III, and mixtures thereof.

[0050] The particles may contain from about 0.1 wt% to about 20 wt% of the fragrance, optionally from about 0.1 wt% to about 15 wt% of the particles, optionally from about 0.1 wt% to about 12 wt%, optionally from about 1 wt% to about 15 wt%, optionally from about 2 wt% to about 20 wt%, optionally from about 8 wt% to about 10 wt% of the fragrance.

[0051] Fragrance emulsion composition The fabric care beneficial agent can be a fragrance emulsion composition. The fragrance emulsion composition comprises an amino-functional silicone containing one or more primary amine moieties and having a total amine content of about 0.05 to about 2.2, one or more emulsifiers, one or more fragrance raw materials containing an aldehyde moiety, a ketone moiety, or a combination thereof, and water.

[0052] The fragrance emulsion composition can be any of those described in European Patent Office Application No. 20156010.9 filed on February 7, 2020.

[0053] The amino-functional silicone is as follows: (a) a total amine content of about 0.071 to about 2.14, or about 0.071 to about 1.78, or about 0.71 to about 1.43, or about 0.14 to about 1.07, or about 0.14 to about 0.71, or about 0.21 to about 0.71, or about 0.36 to about 0.71, and / or (b) a primary amine content of about 0.05 to about 2.2, preferably about 0.071 to about 2.14, or about 0.071 to about 1.78, or about 0.71 to about 1.43, or about 0.14 to about 1.07, or about 0.14 to about 0.71, or about 0.21 to about 0.71, or about 0.36 to about 0.71, and / or (c) a ratio of the primary amine content to the total amine content of about 1:2 to about 1:1, preferably about 1.2:2, more preferably about 1.5:2, or even more preferably about 1.8:2.

[0054] The amino-functional silicone has the following formula: [R 1 R 2 R 3 SiO 1 / 2 (j+2l+2) [R 4 R 5 SiO 2 / 2 m [R 6 SiO 3 / 2 j [SiO​​​4 / 2 l (wherein j is an integer from 0 to 150, preferably from 0 to 50, more preferably from 0 to 20, m is an integer from 10 to 1500, preferably from 10 to 1000, more preferably from 20 to 500, l is an integer from 0 to 150, preferably from 1 to 150, more preferably from 0 to 50, most preferably from 0 to 20, provided that j + m + l is equal to an integer of 50 or more, R 1 、R 2 、R 3 、R 4 、R 5 、and R 6 each of the moieties is independently H, OH, C 1 ~C 32 alkyl, C 1 ~C 32 substituted alkyl, C 6 ~C 32 aryl, C 5 ~C 32 substituted aryl, C 6 ~C 32 alkylaryl, C 6 ~C 32 substituted alkylaryl, C 1 ~C 32 alkoxy, and C 1 ~C 32 substituted alkoxy, and is selected from the group consisting of X-Z, and at least one of moieties R 1 ~R 6 is X-Z, preferably, each R 1~6 is independently selected from the group consisting of OH, C 1 ~C 2 alkyl, C 1 ~C 2 substituted alkyl, C 1 ~C 2 alkoxy, C 1 ~C 2 substituted alkoxy, and X-Z, ​In the formula, each X is independently a substituted or unsubstituted divalent alkylene or alkylidene radical containing 2 to 12 carbon atoms, preferably each X is independently a substituted or unsubstituted divalent alkylene or alkylidene radical containing 2 to 6 carbon atoms, and most preferably each X is independently a substituted or unsubstituted divalent alkylene or alkylidene radical containing 2 to 4 carbon atoms. In the formula, each Z is a moiety containing one or more primary amine moieties. Preferably, each Z is independently a group -NH 2 , -N(H)-X-NH 2 , or a mixture thereof).

[0055] The emulsion composition has the following properties (a) to (d). (a) Containing about 10% to about 70% by weight, or about 25% to about 65% by weight, or about 50% to about 65% by weight of an amino-functional silicone in the silicone emulsion, and / or (b) Containing about 30% to about 90% by weight, or about 35% to about 75% by weight, or about 35% to about 50% by weight of water in the emulsion, and / or (c) Characterized by a viscosity of about 10 to about 500 Pa·s, preferably about 20 to about 400 Pa·s, more preferably about 25 to about 300 Pa·s, and even more preferably about 100 to about 300 Pa·s, measured at 0.1 rad / s and 25 °C, and / or (d) Containing a plurality of droplets, characterized by an average diameter of about 1 micron to about 5 microns, and may be characterized by at least one of the above.

[0056] One or more fragrance raw materials are as follows. a. Oncidal, methyl nonyl acetaldehyde, adoxal, melanal, calypsone, or a mixture thereof; b. cumin aldehyde, benzaldehyde, anisaldehyde, heliotropin, isocyclocitral, triplal / ligustral, 3,6 - ivy carbaldehyde, ligustral, scentenal, or a mixture thereof; c. satinaldehyde (jasmorange), otropal, cyclamen homoaldehyde, cyclamen aldehyde (cyclamal), lilial, cantoxal, floralozone, cinnemic aldehyde, or a mixture thereof; d. delta - damascone, beta - damascone, alpha - damascone, nectaryl, or a mixture thereof; e. vanillin, ethyl vanillin, or a mixture thereof; or f. a material combination selected from at least two categories of a, b, c, d, and e.

[0057] One or more emulsifiers may include a non - ionic surfactant. Preferably, the non - ionic surfactant includes an alkoxylated fatty alcohol. Even more preferably, one or more emulsifiers are characterized by an HLB value of about 5 to about 20, preferably about 8 to about 16.

[0058] One or more emulsifiers include a first emulsifier and a second emulsifier different from the first emulsifier. Preferably, the first emulsifier is a linear non - ionic surfactant and / or preferably, the second emulsifier is a branched non - ionic surfactant.

[0059] Fabric softening The fabric care active beneficial agent can be a fabric softening active substance. The particles can contain from about 5% to about 45% by weight of a quaternary ammonium compound. The quaternary ammonium compound can be an ester quaternary ammonium compound. The quaternary ammonium compound can be those described in U.S. Patent Application Publication Nos. 2019 / 0169538 (A1), 2019 / 0169539 (A1), 2019 / 0169777 (A1), 2019 / 0169532 (A1), 2019 / 0169533 (A1), and 2019 / 0169534 (A1). The quaternary ammonium compound can be di-(tallow oil oxyethyl)-N,N-methylhydroxyethylammonium methyl sulfate.

[0060] The fabric softening active substance can be an aliphatic amine. The particles can contain from about 8% to about 45% by weight of an aliphatic amine. The aliphatic amine can be those described in U.S. Patent Application Publication No. 2020 / 0354652 (A1).

[0061] The fabric softening active substance can be a silicone. The particles can contain from about 1% to about 50% by weight of a silicone. The silicone can be those described in U.S. Patent Application Publication No. 2017 / 0349865.

[0062] Branched polyester The fabric care active beneficial agent can be a branched polyester. The particles can contain from about 5% to about 45% by weight of a branched polyester. The branched polyester can be those described in U.S. Patent Application Publication No. 2019 / 0367841 (A1). The branched polyester can be those described in and claimed in U.S. Patent Application Publication No. 2019 / 0233764 (A1).

[0063] Cationic polymer The buccal care active beneficial agent can be a cationic polymer. The particles can contain from about 0.1 wt% to about 10 wt% of the cationic polymer. The cationic polymer can be selected from the group consisting of cationic polysaccharides, polyquaternium-4, polyquaternium-6, polyquaternium-7, polyquaternium-10, polyquaternium-22, polyquaternium-67, and mixtures thereof. The cationic polysaccharide can be a polymeric quaternary ammonium salt of hydroxyethyl cellulose reacted with an epoxide substituted with trimethylammonium groups.

[0064] Enzyme The buccal care active beneficial agent can be an enzyme. The particles can contain from about 0.0001 wt% to about 5 wt% of the enzyme. The enzyme can be selected from the group consisting of proteases, xyloglucanases, mannanases, and combinations thereof. The enzyme can be as described in U.S. Patent Application Publication Nos. 2017 / 0260481 (A1) and 2017 / 0260482 (A1).

[0065] Graft copolymer The buccal care active beneficial agent can be a graft copolymer. The particles can contain from about 1 wt% to about 75 wt% of the graft copolymer. The graft copolymer can be as described in U.S. Patent Application No. 69 / 951,274. The graft copolymer can be as described in U.S. Patent Application No. 69 / 722,492.

[0066] Antioxidant The buccal care beneficial agent can be an antioxidant. The particles can contain from about 0.2 wt% to about 2 wt% of the antioxidant. The antioxidant can be dispersed in the matrix of the water-soluble carrier. The antioxidant can be as described in U.S. Patent Application No. 63 / 034,766. The antioxidant can be butylated hydroxytoluene.

[0067] Apparatus and process for forming particles An apparatus 1 for forming particles is shown in FIG. 1. The precursor material 20 can be a melt of any of the compositions disclosed herein for the particles 90. The precursor material 20 can contain more than about 20 wt% of a water-soluble carrier. The precursor material 20 can contain more than about 20 wt% of a water-soluble polymer. The precursor material 20 can contain from about 20 wt% to about 99 wt% of a water-soluble carrier. The precursor material 20 can contain from about 20 wt% to about 99 wt% of a water-soluble polymer.

[0068] The precursor material 20 can contain more than about 20 wt%, optionally more than about 40 wt%, of polyethylene glycol having a weight average molecular weight of from about 2000 to about 13000, and from about 0.1 wt% to about 20 wt% of a fragrance.

[0069] The raw materials can be supplied to a batch mixer 10. The batch mixer 10 can have a capacity sufficient to hold the volume of the supplied raw materials for a residence time sufficient to allow for the desired level of mixing or reaction of the raw materials. The material leaving the batch mixer 10 can be the precursor material 20. Optionally, the precursor material can be supplied to a supply pipe 40 from some other upstream mixing process, such as in-line mixing, in-line static mixing, etc. The precursor material 20 can be a melt. The batch mixer 10 can be a dynamic mixer. A dynamic mixer is a mixer to which energy is applied to mix the contents of the mixer. The batch mixer 10 can include one or more impellers for mixing the contents within the batch mixer 10.

[0070] If desired, between the batch mixer 10 that exists as desired and the dispenser 30, the precursor material 20 may move through the supply pipe 40. The supply pipe 40 may be in fluid communication with the batch mixer 10. One or more gas supply lines 155 may be provided to be in fluid communication with the supply pipe 40 downstream of the batch mixer 10. One or more gas supply lines 155 may be provided to be in fluid communication with the supply pipe 40 between the batch mixer 10 and the dispenser 30. The mill 200 may be provided in the line of the supply pipe 40 downstream of one or more gas supply lines 155. The mill 200 may be provided in the line of the supply pipe 40 downstream of one or more gas supply lines 155 and upstream of the dispenser 30.

[0071] The precursor material 20 may be supplied to the supply pipe 40. The supply pipe 40 is a transport means for transporting the precursor material 20. The supply pipe 40 includes a transport means between an element of the device 1 and a transport means for transporting the precursor material within the components of the device 1. For example, the mill 200 may be provided in a unit including a part of the transport means entering the mill 200 and a part of the transport means exiting the mill 200. Each of these parts is a part of the supply pipe 40. Therefore, the supply pipe 40 can be regarded as the entire transport means between the batch mixer 10 and the dispenser 30, and various elements such as one or more gas supply lines 155, the mill 200, the intermediate mixer 50, and the supply pump 140 exist in the middle of the supply pipe 40. If there is no batch mixer 10 upstream of the supply pipe 40, the supply pipe 40 can be regarded as the entire transport means upstream of the dispenser 30, and various elements such as one or more gas supply lines 155, the mill 200, the intermediate mixer 50, and the supply pump 140 exist in the middle of the supply pipe 40.

[0072] The intermediate mixer 55 can be provided downstream of the mill 200 and in the line of the supply pipe 40. The intermediate mixer 55 can be a static mixer 50. The intermediate mixer 55 can be in fluid communication with the supply pipe 40 between the mill 200 and the dispenser 30. The intermediate mixer 55, which can be a static mixer 50, can be downstream of the batch mixer 10. In other words, when used, the batch mixer 10 can be upstream of the intermediate mixer 55 or the static mixer 55. The intermediate mixer 55 can be in the line of the supply pipe 40. The intermediate mixer 55 can be a rotor-stator mixer. The intermediate mixer 55 can be a colloid mill. The intermediate mixer 55 can be a driven in-line fluid disperser. The intermediate mixer 55 can be an Ultra Turrax disperser, a Dispax-reactor disperser, a Colloid Mil MK, or a Cone Mill MKO available from IKA (Wilmington, North Carolina, United States of America). The intermediate mixer 55 can be a perforated disk mill, a toothed colloid mill, or a DIL in-line homogenizer available from FrymaKoruma (Rheinfelden, Switzerland). The static mixer 50 can be a spiral static mixer. The static mixer 50 can be a Kenics KMS 6 (inner diameter 1.905 cm) available from Chemineer (Dayton, OH, USA).

[0073] Without being bound by theory, it is believed that an intermediate mixer 55, such as the static mixer 50, can provide a precursor material 20 of a more uniform temperature within the dispenser 30 or the stator 100. At the downstream end of the intermediate mixer 55 or the static mixer 50 when used, the temperature of the precursor material 20 within the supply pipe 40 across the entire cross-section of the supply pipe 40 orthogonal to the direction of flow can vary by less than about 10 °C, or less than about 5 °C, or less than about 1 °C, or less than about 0.5 °C.

[0074] In the absence of the static mixer 50, the temperature across the cross-section of the supply pipe 40 perpendicular to the flow direction can be non-uniform. The temperature of the precursor material 20 at the centerline of the supply pipe 40 may be higher than the temperature of the precursor supply material 20 at the peripheral wall of the supply pipe 40. When the precursor material 20 is discharged into the dispenser 30 or the stator 100, the temperature of the precursor material 20 can vary at different positions within the dispenser or the stator 100. Without being bound by theory, by using the static mixer 50 as described in this specification, by providing a uniform temperature across the entire cross-section of the supply pipe 40, it is considered that more uniform particles 90 can be manufactured compared to the apparatus 1 without the static mixer 50.

[0075] The dispenser 30 can be provided with a plurality of holes 60. The precursor material 20 can pass through the holes 60. After passing through the holes 60, the precursor material 20 can be deposited on the moving conveyor 80 provided below the dispenser 30. The precursor material 20 can be deposited on the moving conveyor 80 during the movement of the conveyor 80. The conveyor 80 can be translatable relative to the dispenser 30. The conveyor 80 can be a continuous moving conveyor 80. The conveyor 80 can be an intermittent moving conveyor 80. The continuous moving conveyor 80 can provide a higher processing speed. The intermittent moving conveyor 80 can better control the shape of the particles 90 to be manufactured.

[0076] The precursor material 20 can be cooled on the moving conveyor 80 to form a plurality of solid particles 90. The cooling can be provided by ambient cooling. Optionally, the cooling can be provided by spraying normal temperature water or cold water under the conveyor 80.

[0077] Once the particles 90 have a sufficiently high cohesiveness, the particles 90 can be transferred from the conveyor 80 to a processing apparatus downstream of the conveyor 80 for further processing and / or packaging.

[0078] The dispenser 30 can be a cylinder 110 rotatably attached around the stator 100 (this stator is in fluid communication with the supply pipe 40), but the cylinder 110 may have an outer surface portion 120, and a plurality of holes 60 may be present in the outer surface portion 120 as shown in FIG. 2. Thus, the apparatus 1 can include a stator 100 in fluid communication with the supply pipe 40. After the precursor material 20 passes through the mill 200, the supply pipe 40 can supply the precursor material 20 to the stator 100.

[0079] The apparatus 1 can include a cylinder 110 rotatably attached around the stator 100. The precursor material is supplied to the stator 100 via one or both ends 130 of the cylinder 110. The cylinder 110 can have a longitudinal axis L passing through the cylinder 110, but the cylinder 110 rotates around it. The cylinder 110 has an outer surface portion 120. A plurality of holes 60 may be present in the outer surface portion 120 of the cylinder 110.

[0080] Since the cylinder 110 is rotationally driven around its longitudinal axis L, the holes 60 can be intermittently in fluid communication with the stator 100 when the cylinder 110 rotates around the stator 100. The cylinder 110 can be considered to have a machine direction MD in the moving direction of the outer surface portion 120 spanning the stator 100, and a machine transverse direction on the outer surface portion 120 perpendicular to the machine direction MD. The stator 100 can similarly be considered to have a machine transverse direction CD parallel to the longitudinal axis L. The machine transverse direction of the stator 100 can be aligned with the machine transverse direction of the cylinder 110. The stator 100 can have a plurality of distribution ports 122 arranged in the machine transverse direction CD of the stator 100. The distribution ports 122 are the portions or regions of the stator 100 to which the precursor material 20 is supplied.

[0081] Generally, the precursor material 20 can be supplied to the stator 100 by passing through one or more gas supply lines 155 through the mill 200 and the supply pipe 40. The stator 100 distributes the precursor supply material 20 across the operating width of the cylinder 110. Since the cylinder 110 rotates about its longitudinal axis, the precursor material 20 is supplied through the holes 60 as the holes 60 pass through the stator 100. Individual chunks of the precursor material 20 are supplied through each hole 60 as each hole 60 encounters the stator 100. The chunks of the precursor material 20 supplied through each hole 60 as each hole 60 passes through the stator 100 can be controlled by controlling one or both of the pressure of the precursor material within the stator 100 and the rotational speed of the cylinder 110, or by arbitrarily controlling the viscosity of the precursor material 20 by controlling the temperature of the precursor material 20.

[0082] A small amount of the precursor material 20 is deposited across the operating width of the cylinder 110 onto the conveyor 80. The conveyor 80 can be translatable parallel to the longitudinal axis of the cylinder 110. The speed of the conveyor 80 can be set relative to the tangential speed of the cylinder 110 to control the shape that the precursor material 20 has when deposited on the conveyor 80. The speed of the conveyor 80 can be approximately the same as the tangential speed of the cylinder 110.

[0083] As shown in FIG. 1, the flow rate of the precursor material 20 passing through the supply pipe 40 can be provided by the flow rate caused by the gravity from the batch mixer 10 and the dispenser 30. To improve the controllability of the manufacturing, the apparatus 1 can be provided with a supply pump 140 as shown in FIG. 2. The supply pump 140 can be present in the line of the supply pipe 40, where "in the line" means in the line of the flow of the precursor material 20. The supply pump 140 can be between the batch mixer 10 and the dispenser 30. The supply pump 140 can be upstream of the dispenser 30. When using the stator 100, the supply pump 140 can be present in the line of the supply pipe 40, where "in the line" means in the line of the flow of the precursor material 20. When using the stator 100, the supply pump 140 can be between the batch mixer 10 and the stator 100. The supply pump 140 can be upstream of the stator 100. When explaining the position of the supply pump 140, "between ~" is used to explain that the supply pump 140 is downstream of the batch mixer 10 in the line and upstream of the dispenser 30 or upstream of the stator 100 when using the stator 100.

[0084] One or more gas supply lines 155 and the mill 200 may be located in the line between the supply pump 140 and the dispenser 30 or the stator 100 (when used in the apparatus 1).

[0085] The flow rate of the precursor material 20 can be about 3 L / min. The precursor material 20 can be a molten material containing any of the compositions described herein for the precursor material 20 or the particles 90.

[0086] Device 1 may include one or more gas supply lines 155. If the gas mixed into the precursor material is actually supplied via a single gas supply line 155, the single gas supply line 155 may be practical. As described herein, a single-component gas or a gas containing multiple components may be desirable. A single-component gas or a multi-component gas can be provided in a single container 157. For example, a mixture of argon, carbon dioxide, and nitrogen can be supplied in a gas cylinder. Optionally, the gas mixture can be continuously provided from the environment via a reaction process or by combining it with another gas supplied from a container. The gas can be pressurized via a compressor.

[0087] One or more gas supply lines 155 may include a flow regulator 158. The flow regulator 158 can adjust the flow rate of the gas to the supply line 40. The volume of the added gas per unit volume of the precursor material 20 can be controlled by setting the flow regulator 158 to a desired flow rate. Supplying more gas to the precursor material 20 in the supply line 40 will result in more gas being contained in the particles 90. One or more gas supply lines 155 may be provided for mixing the gas into the precursor material 20.

[0088] The flow regulator 158 can be a Key Instruments Flo-Rite Series GS 65mm (part number 60410-R5). The supply line 40 can be a 1 1 / 2-inch stainless steel sanitary pipe. The gas supply line 155 can be a polyethylene pipe with an inner diameter of 1 / 4 inch. The gas can be supplied in the gas supply line 155 at a pressure exceeding about 4 bar, for example, 5.9 bar.

[0089] If two or more gas supply lines 155 are separately connected to the supply pipe 40, flow regulators can be provided along each gas supply line 155 to adjust the flow rate of the gas in each gas supply line 155. If a gas mixture is introduced into the supply pipe 40 via a single gas supply line 155, a single flow regulator 158 may be practical.

[0090] An injection quill device for introducing gas may be provided at the connection between the gas supply line 155 and the supply pipe.

[0091] The gas may be supplied at a temperature and pressure such that when the gas reaches ambient temperature and pressure, the desired volume of the gas is present within the particles 90. The ideal gas law may be used to determine the desired delivery temperature and pressure. The gas may also contain water. The water may be in gaseous or liquid form. The amount of water in the gas may be selected to be at a desired level.

[0092] The mill 200 may be a rotor-stator type mill. The mill may be a Quadro Z1 in-line mixer with a single-stage medium rotor-stator operating at about 400 RPM.

[0093] The mill 200 and one or more gas supply lines 155 may be incorporated into a single unit.

[0094] The Oakes Foamer (Model 2MT1A continuous foamer manufactured by E.T.Oakes Corporation, 686 Old Willets Path, Hauppauge, NY 11788) may be used to provide the gas supply line 155, the flow regulator 158, and the mill 200 as a single unit.

[0095] Apparatus 1 as viewed in the machine direction MD is shown in FIG. 3. As shown in FIG. 3, the apparatus 1 may have an operating width W, but the cylinder 110 may rotate about the longitudinal axis L.

[0096] The apparatus 1 for forming particles 90 may include a supply pipe, one or more gas supply lines 155 attached to be in fluid communication with a supply pipe 40 downstream of a batch mixer 10, a mill 200 downstream of the one or more gas supply lines 155 and in the line of the supply pipe 40, and a dispenser 30 downstream of the mill 200 and in fluid communication with the supply pipe 40, and the dispenser 30 includes a plurality of holes 60. The apparatus 1 may include a conveyor under the dispenser 30 and translatable relative to the dispenser 30. The dispenser 30 may include a stator 100 in fluid communication with the supply pipe 40. The dispenser 30 may include a cylinder 110 rotatably mounted around the stator 100 and rotatable around the longitudinal axis L of the cylinder 110. The cylinder 110 may have an outer surface portion 120, but the cylinder 110 may have a plurality of holes 60 disposed around the outer surface portion 120. The holes 60 may be in intermittent fluid communication with the stator 100 when the cylinder 110 rotates around the stator 100. The apparatus may include a conveyor 80 under the cylinder 110, and the conveyor 80 may be translatable relative to the longitudinal axis L. The apparatus 1 for forming particles 90 may include a batch mixer 10. The supply pipe 40 may be in fluid communication with the batch mixer 10.

[0097] The process for forming particles 90 may include supplying a precursor material 20 to a supply pipe 40, mixing a gas into the precursor material 20, wherein the gas contains from about 50% to about 100% by volume, optionally from about 55% to about 100% by volume, optionally from about 60% to about 100% by volume, optionally from about 70% to about 100% by volume, optionally from about 80% to about 100% by volume, optionally from about 90% to about 100% by volume, optionally 100% by volume of argon, providing a dispenser 30 having a plurality of holes 60, moving the precursor material 20 from the supply pipe 40 to the dispenser 30, passing the precursor material 20 through the holes 60, providing a movable conveyor 80 under the holes 60, depositing the precursor material 20 on the movable conveyor 80, and cooling the precursor material 20 to form a plurality of particles 90.

[0098] The gas can be incorporated into the precursor material 20 as a gas mixture. For example, the gas mixture can be directed towards the precursor material 20 via a single gas supply line 155. The gas mixture can contain from about 50% to about 100% by volume, optionally from about 55% to about 100% by volume, optionally from about 60% to about 100% by volume, optionally from about 70% to about 100% by volume, optionally from about 80% to about 100% by volume, optionally from about 90% to about 100% by volume, optionally 100% by volume of argon, and from about 0% to about 50% by volume of other components. The mixture can be supplied from a container 157 containing the gas mixture. For example, the container 157 can be a gas cylinder filled with the desired gas which is a mixture of different gases.

[0099] Optionally, argon can be supplied from a primary container 157a and the other components of the gas can be supplied from one or more secondary containers 157b (Figure 4). The primary container 157a and the secondary containers 157b can be supplied to a single gas supply line 155. A flow regulator 158 can control the flow of gas from the primary container 157a and the secondary containers 157b into the gas supply line 155. Optionally, an in-line mixer can be provided within or upstream of the gas supply line 155 to mix the gases from the primary container 157a and the secondary containers 157b.

[0100] The primary container 157a can contain argon. The other components of the gas can be supplied from the secondary container 157b. The other components of the gas can be supplied from the secondary container 157b as air or carbon dioxide. Containers of air and containers of carbon dioxide are readily commercially available. Similarly, containers of argon are readily commercially available. The operator of the apparatus 1 can obtain cylinders of argon and cylinders of air and set the flow regulator 158 to provide the desired gas. Argon and the other components of the gas can be combined before being incorporated into the precursor material 20 to form a single stream of gas.

[0101] Optionally, the primary container 157a can be supplied to the primary gas supply line 155, and the secondary container 157b can be supplied to the secondary gas supply line 155. The gas flow in each gas supply line 155 can be adjusted by a flow regulator 158 dedicated to such a gas supply line 155.

[0102] During operation, it may be practical to supply the precursor material 20 into the supply pipe at an operating pressure of about 2 bar to about 8 bar. The gas can be supplied to the supply pipe at a pressure higher than the operating pressure of the supply pipe 40. The gas or its argon component can be mixed in at a pressure of about 3 to more than about 4 bar, or further more than about 4 bar, or further more than about 5 bar.

[0103] The solubility of argon in the precursor material 20 can be made greater than the solubility of most of the volume of the other components of the gas. When argon gas is supplied to the flow of the precursor material 20 at the operating pressure, the argon solubilizes in the precursor material 20. The other components of the gas may or may not solubilize in the precursor material 20 at the operating pressure. Those components having a low solubility in the precursor material 20 relative to argon mainly remain as bubbles in the precursor material 20.

[0104] As the precursor material 20 passes through the holes 60, the pressure decreases towards or to atmospheric pressure. The precursor material 20 may also begin to cool. The precursor material 20 may continue to cool as the precursor material 20 moves from the holes 60 to the movable conveyor 80. After the precursor material 20 is deposited on the movable conveyor 80, the cooling continues. Heat is removed from the precursor material 20 by the conveyor, and the side of the belt of the precursor material 20 in contact with the movable conveyor 80 begins to solidify. Similarly, the surface of the precursor material 20 continues to cool even after the precursor material 20 is deposited on the movable conveyor 80. Thus, upon deposition on the movable conveyor 80, the cooling of the precursor material 20 is a three-dimensional time-dependent process.

[0105] As the molten precursor material 20 cools, a solidification front develops from the side of the precursor material 20 facing the belt, and the solidification front moves away from the movable conveyor 80 and advances over time. The side of the precursor material 20 facing the air, which is away from the surface of the precursor material facing the belt, also cools as a function of time. This results in a solidification front that advances from the surface facing the air of the precursor material 20 towards the center of the particles formed on the movable conveyor 80 as the precursor material 20 cools.

[0106] When the gas incorporated into the precursor material 20 is air, which is approximately 78% by volume nitrogen, approximately 21% by volume oxygen, approximately 0.93% by volume argon, and approximately 0.03% by volume carbon dioxide, most of that gas has a limited solubility in the precursor material 20, and the air remains as bubbles in the precursor material 20 through the process of making the particles. This limits the amount of air that can be incorporated into the precursor material 20 and still allows particles to be made that have the desired stability and appearance. After the precursor material 20 is deposited on the movable belt 40, the buoyancy of the bubbles within the precursor material 20 and the solidification front advancing from the side of the precursor material 20 facing the belt tend to drive some of the bubbles away from the movable conveyor 80. As the bubbles are driven upward, they can coalesce to form larger bubbles. Some of the bubbles may escape through the side of the precursor material 20 facing the air. The escaped bubbles no longer contribute to the porosity of the particles 90. If a skin layer forms on the side of the precursor material 20 facing the air, the bubbles may eject through the skin layer, resulting in particles 90 having a physically unstable outer surface. A physically unstable outer surface is undesirable because it can make the particles prone to peeling off and difficult to use.

[0107] The problem associated with using air as the gas to be incorporated is that when the precursor material 20 is deposited on the movable belt 40, air bubbles are present within the precursor material 20, and the phenomenon described in the preceding paragraph occurs, and as a result, insufficient particles 90 may be produced. Surprisingly, by using a gas containing from about 50 volume % to about 100 volume %, optionally from about 55 volume % to about 100 volume %, optionally from about 60 volume % to about 100 volume %, optionally from about 70 volume % to about 100 volume %, optionally from about 80 volume % to about 100 volume %, optionally from about 90 volume % to about 100 volume %, optionally 100 volume % of argon, when cooling the precursor material 20 on the movable conveyor 80 to form the particles 90, the ability of the precursor material 20 to retain air bubbles can be improved. This can result in particles 90 having a higher porosity and fewer large air bubbles on or near the surface of the particles 90 facing the air.

[0108] Argon may be relatively soluble in the precursor material 20 as compared to other gas components. Gas components that are relatively insoluble in the precursor material 20 may exist as bubbles. When the operating pressure on the precursor material is released to or towards ambient pressure, the argon comes out of the solution. The process by which argon comes out of the solution from the precursor material 20 is a time-dependent process. Bubbles of gas components that are relatively insoluble in the precursor material 20, if present, may act as nucleation sites for the argon to come out of the solution from the precursor material. While the argon comes out of the solution, the precursor material 20 is also cooled. As described above, the solidification front may develop from the side facing the belt of the precursor material 20, and the side of the precursor material 20 facing the air is also solidified. The solidified or solidifying precursor material 20 forms a barrier to the bubbles escaping from the precursor material 20. As the argon gradually comes out of the solution from the precursor material 20, argon bubbles may be formed and / or the argon may come out of the solution and enter existing bubbles of relatively insoluble gas components. The delayed formation of argon bubbles, or the expansion of existing bubbles of relatively insoluble gas components when the argon nucleates on such bubbles, allows larger volume bubbles to be formed in the precursor material 20. And these subsequently formed bubbles are less likely to escape from the precursor material 20. When the precursor material 20 is completely solidified, the formed particles 90 may have large volume voids.

[0109] A gas containing from about 50% to about 100% by volume, optionally from about 55% to about 100% by volume, optionally from about 60% to about 100% by volume, optionally from about 70% to about 100% by volume, optionally from about 80% to about 100% by volume, optionally from about 90% to about 100% by volume, optionally 100% by volume of argon can be more advantageous than air or a gas that is carbon dioxide in an amount greater than about 50% by volume. Bubbles emerge from the solution and form over a time-dependent process in order for the dissolved gas to contribute to the void volume of the solidified particles 90. In the case of bubble formation caused by a change in gas solubility as a function of a pressure change or a decompression nucleation, the rate of bubble formation decreases with solubility. The rate of bubble formation from a decompression nucleation using argon, which is partially soluble in the precursor material 20, can be much faster than the rate of bubble formation when using a more soluble gas such as carbon dioxide. This can occur when the precursor material 20 contains a water-soluble polymer in an amount greater than about 20% by weight, or more specifically, polyethylene glycol having a weight average molecular weight of from about 2000 to about 13000.

[0110] If the rate of bubble formation from vacuum nucleation is slower than the rate of solidification, the phase change will result in bubble formation. Bubble formation within the solidification precursor material 20 caused by the phase change can rupture the surface of the particles and solidify the expanding melt on the surface of the particles. This is an undesirable aesthetic for the particles 90 and can also lead to the accumulation of broken particles 90 within the product package, which is also undesirable. For particles formed by the dispenser 30 that maintains the molten precursor material 20 under pressure until it is essentially released from the dispenser 30, an acceptable gas can provide a partial solubility in the molten precursor material 20 at atmospheric pressure and have a time-dependent nucleation rate during deposition of the precursor material 20 that is faster than the solidification rate of the precursor material 20 that ultimately forms the particles 90. For polyethylene glycol carriers having a weight average molecular weight of about 2000 to about 13000 and a pressure change of at least 3 bar through the dispenser 30, argon can provide these desired properties. Argon is partially soluble in water-soluble polymers such as polyethylene glycol and can be more advantageous than a blend of air and carbon dioxide. The nitrogen portion of air has a relatively low solubility in polyethylene glycol compared to argon, so at the same temperature and pressure, argon has a much higher solubility in polyethylene glycol than air. However, compared to carbon dioxide, argon has a much lower solubility as the amount of injected carbon dioxide dissolves almost completely at a line pressure of only 3 bar, while the same amount of argon only partially dissolves at 10 bar. The gas can be incorporated at a pressure of about 3 bar to about 10 bar.

[0111] Particle Particles 90 can be formed as described herein and can contain from about 25 wt% to about 99 wt% water-soluble carrier. Particles 90 can further contain from about 0.1 wt% to about 20 wt% fabric care benefit agent. Each of the particles can have a mass of from about 5 mg to about 200 mg, preferably from about 10 mg to about 100 mg, preferably from about 20 mg to about 50 mg. The particles can have a hemispherical or compressed hemispherical shape.

[0112] The fabric care beneficial active agent can be selected from the group consisting of amines, surfactant systems, nonionic surfactants, water binders, sulfites, fatty acids and / or their salts, enzymes, encapsulated beneficial agents, soil release polymers, colorants, builders, chelating agents, migration inhibitors, dispersants, enzyme stabilizers, catalyst materials, bleaching agents, bleaching catalysts, bleach activators, polymer dispersants, cyclodextrin complex beneficial agents, soil removal / redeposition inhibitors, encapsulated fragrances, polymer dispersants, polymer fabric detergents, optical brighteners, antifoaming agents, dyes, colorants, free fragrances, structure elasticizers, fabric softeners, quaternary amines, hardened and softened tallow, carriers, fillers, hydrotropes, organic solvents, antibacterial agents and / or preservatives, neutralizing agents and / or pH adjusters, processing aids, fillers, antioxidants, rheology modifiers or structuring agents, opacifiers, pearl essence agents, pigments, corrosion and / or discoloration resistant agents, and mixtures thereof.

[0113] The fabric care beneficial active agent can be selected from the group consisting of antibacterial agents, antioxidants, fragrances, fabric conditioning agents, dyes, dyeing process agents, and combinations thereof. The fabric care beneficial active agent can be a non-encapsulated fragrance or an encapsulated fragrance.

[0114] Each of the particles 90 can have a mass of about 5 mg to about 200 mg, optionally about 10 mg to about 100 mg, and optionally about 20 mg to about 50 mg. The particles can have a hemispherical shape or a compressed hemispherical shape.

[0115] Particle 90 can be manufactured as follows. A 50 kg batch of precursor material 20 can be prepared in a mixer. The molten PEG8000 can be added to a jacketed mixer maintained at 70 °C and stirred at 125 rpm using a pitched blade agitator. Butylated hydroxytoluene may be added to the mixer in an amount of about 0.01 wt% of the precursor material 20. An aqueous slurry of flavor microcapsules may be added to the mixer in an amount of about 4 wt% of the precursor material 20. Non-encapsulated flavor may be added to the mixer in an amount of about 8 wt% of the precursor material 20. Dye may be added to the mixer at a concentration of about 0.01 wt% of the precursor material 20. The PEG may account for the weight percentage of the remaining part of the precursor material 20. The precursor material 20 may be mixed for 30 minutes.

[0116] The precursor material 20 may be formed into particles 90 with a SANDVIK ROTOFORM 3000 having a belt 750 mm wide and 10 m long. The cylinder 110 may have holes 60 with a diameter of 2 mm set at a pitch of 10 mm in the machine cross direction CD and a pitch of 9.35 mm in the machine direction MD. The cylinder can be set about 3 mm above the belt. The belt speed and the rotational speed of the cylinder 110 can be set at 10 m / min.

[0117] After mixing the precursor material 20, the precursor material 20 can be extruded from the mixer 10 at a constant rate of 3.1 kg / min or even 4 kg / min through a plate and frame heat exchanger set, and the outlet temperature can be controlled at 50 °C. The pressure in the supply pipe 40 downstream of the pump 140 can be about 2 to about 7 bar, or about 5.5 bar or about 5 bar, and this pressure is in the supply pipe 40 downstream of the mill 200.

[0118] The gas can be mixed into the precursor material 20 at a volume flow ratio of the precursor material to the gas of about 1.3:1 to about 2.6:1, or further about 1.3:1 to about 1.6:1. The pressure of the gas in the gas supply line 155 must be higher than the pressure in the supply pipe 40 in order to ensure the flow and mixing of the gas into the precursor material 20. The flow rate of the precursor material 20 can be about 4.5 liters per minute, and the gas flow rate can be about 3.4 liters per minute. The gas can be argon, a mixture of argon and carbon dioxide, or a mixture of argon and other relatively insoluble gases.

[0119] The precursor material 20 with the mixed gas can be passed through a Quadro Z1 mill equipped with a medium-sized rotor / stator element. After grinding, the precursor material can optionally be passed through a Kenics 1.905 cm KMS 6 static mixer 50 installed 91.44 cm upstream of the stator 100 of the rotoforming device.

[0120] Combination: A. A process for forming particles, comprising: a. Supplying a precursor material (20) to a supply pipe (40); b. Mixing a gas into the precursor material, wherein the gas comprises about 50 vol% to about 100 vol%, optionally about 55 vol% to about 100 vol%, optionally about 60 vol% to about 100 vol%, optionally about 70 vol% to about 100 vol%, optionally about 80 vol% to about 100 vol%, optionally about 90 vol% to about 100 vol%, optionally about 100 vol% of argon and about 0 vol% to about 50 vol% of other components; c. Providing a dispenser (30) having a plurality of holes (60); d. Moving the precursor material (20) from the supply pipe to the dispenser; e. Passing the precursor material through the holes; f. Providing a movable conveyor (80) below the holes; g. Depositing the precursor material on the movable conveyor; h. Cooling the precursor material to form a plurality of particles (90). B. When the dispenser is a. A stator (100) in fluid communication with the supply pipe, b. A cylinder (110) rotatably attached around the stator and rotatable around the longitudinal axis (L) of the cylinder, the cylinder having an outer surface portion (120), the cylinder comprising the plurality of holes disposed around the outer surface portion, and when the cylinder rotates around the stator, the holes being intermittently in fluid communication with the stator. The process according to paragraph A, comprising the cylinder. C. The process according to paragraph A or B, further comprising a step of pulverizing the precursor material after the step of mixing the gas into the precursor material. D. The process according to paragraph C, wherein the step of pulverizing the precursor material after the step of mixing the gas into the precursor material is performed using an in-line rotor stator mill. E. The process according to any one of paragraphs A to D, wherein the gas is mixed as a gas mixture. F. The process according to paragraph E, wherein the gas mixture is from a container containing the gas mixture. G. The process according to any one of paragraphs A to E, wherein the argon is supplied from a primary container (157a) and the other components of the gas are supplied from one or more secondary containers (157b). H. The process according to paragraph G, wherein the argon and the other components of the gas are combined into a single stream of the gas before being mixed into the precursor material. I. The process according to paragraph H, wherein the other components of the gas are supplied as air from the secondary container. J. The process according to any one of paragraphs A to I, wherein the argon is mixed at a pressure of more than 2 bar and a minimum flow rate of about 0.5 liter / minute. K. The process according to any one of paragraphs A to J, wherein more than 50% by volume of the other components are less soluble in the precursor material than the argon. L. The process according to any one of paragraphs A - K, wherein the precursor material further comprises more than about 20% by weight of a water - soluble polymer. M. The water - soluble polymer is a. a polyalkylene polymer of the formula H-(C 2 H 4 O) x -(CH(CH 3 )CH 2 O) y -(C 2 H 4 O) z -OH (wherein x is from 50 to 300, y is from 20 to 100, and z is from 10 to 200); b. a polyethylene glycol fatty acid ester of the formula (C 2 H 4 O) q -C(O)O-(CH 2 ) r -CH 3 (wherein q is from 20 to 200 and r is from 10 to 30); c. a polyethylene glycol aliphatic alcohol ether of the formula HO-(C 2 H 4 O) s -(CH 2 ) t -CH 3 (wherein s is from 30 to 250 and t is from 10 to 30); d. a C8 - C22 alkyl polyalkoxylate containing more than 40 alkoxylate units; e. a polyethylene glycol having a weight - average molecular weight of from 2000 to 15000; f. an EO / PO / EO block copolymer; g. a PO / EO / PO block copolymer; h. an EO / PO block copolymer; i. a PO / EO block copolymer; j. a polypropylene glycol; k. an ethoxylated non - ionic surfactant having an ethoxylation degree of more than 30; l. a polyvinyl alcohol; The process according to paragraph L, selected from the group consisting of polyalkylene glycols having a weight average molecular weight of from 2000 to 15000; and mixtures thereof. N. The process according to any one of paragraphs A to M, wherein the precursor material comprises polyethylene glycol having a weight average molecular weight of from about 2000 to about 13000. O. The process according to any one of paragraphs A to N, wherein the precursor material comprises more than about 40% by weight of polyethylene glycol. P. The process according to any one of paragraphs A to O, wherein the particles have an individual mass of from about 0.1 mg to about 2 g. Q. The process according to any one of paragraphs A to P, wherein the precursor material comprises from about 0.1% to about 20% by weight of a fragrance. R. The process according to paragraph Q, wherein the fragrance comprises an encapsulated fragrance. S. The process according to paragraph Q, wherein the fragrance comprises an encapsulated fragrance and a non-encapsulated fragrance. T. The process according to any one of paragraphs A to S, wherein the precursor material comprises from about 0.1% to about 20% by weight of an encapsulated fragrance. U. The process according to any one of paragraphs A to T, wherein the step of cooling the precursor material is carried out by ambient cooling. V. The process according to any one of paragraphs A to U, wherein the precursor material is supplied from the batch mixer (10) to the supply pipe. W. The process according to any one of paragraphs A to V, wherein the other component is selected from the group consisting of oxygen, nitrogen, argon, and mixtures thereof. X. The process according to any one of paragraphs A to W, wherein the precursor material comprises a fabric care benefit agent selected from the group consisting of amines, surfactant systems, nonionic surfactants, water binders, sulfites, fatty acids and / or their salts, enzymes, encapsulated benefit agents, soil release polymers, colorants, builders, chelating agents, migration inhibitors, dispersants, enzyme stabilizers, catalyst materials, bleaching agents, bleaching catalysts, bleach activators, polymer dispersants, cyclodextrin complex benefit agents, soil removal / redeposition inhibitors, encapsulated fragrances, polymer dispersants, polymer fat detergents, optical brighteners, antifoaming agents, dyes, colorants, free fragrances, structure elasticizers, fabric softeners, quaternary amines, hardened and softened tallow, carriers, fillers, hydrotropes, organic solvents, antibacterial agents and / or preservatives, neutralizing agents and / or pH adjusters, processing aids, fillers, antioxidants, rheology modifiers or structuring agents, opacifiers, pearl essence agents, pigments, corrosion and / or discoloration inhibitors, and mixtures thereof. Y. The process according to any one of paragraphs A to X, wherein the gas is argon. Z. The process according to any one of paragraphs A to Y, wherein the gas is incorporated at a pressure of about 3 bar to about 10 bar.

[0121] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

[0122] All documents cited herein, including any patents or patent applications that are cross-referenced or related, and any patent applications or patents for which this application claims priority or the benefit thereof, are hereby incorporated by reference in their entirety, except as expressly excluded or otherwise limited. The citation of any document shall not be construed as an admission that it is prior art with respect to any invention disclosed or claimed herein, nor shall it be construed as teaching, suggesting, or disclosing any such invention, either alone or in combination with any other one or more references. Further, any meaning or definition of a term in this document shall be given precedence over any meaning or definition of the same term in a document incorporated by reference if the two conflict.

[0123] Although specific embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is intended that all such changes and modifications within the scope of the invention be covered by the appended claims.

Claims

1. A process for forming particles, comprising: supplying a precursor material (20) to a supply pipe (40); mixing a gas into the precursor material, wherein the gas comprises from about 50 vol% to about 100 vol% argon and from about 0 vol% to about 50 vol% of other components; providing a dispenser (30) having a plurality of holes (60); moving the precursor material (20) from the supply pipe to the dispenser; passing the precursor material through the holes; providing a movable conveyor (80) below the holes; depositing the precursor material onto the movable conveyor; cooling the precursor material to form a plurality of particles (90).

2. The dispenser comprises: a stator (100) in fluid communication with the supply pipe; a cylinder (110) rotatably mounted around the stator and rotatable about the longitudinal axis (L) of the cylinder, the cylinder having an outer surface portion (120), the cylinder comprising the plurality of holes disposed around the outer surface portion, and the holes being intermittently in fluid communication with the stator when the cylinder rotates around the stator. The process according to claim 1.

3. The process according to claim 1 or 2, further comprising pulverizing the precursor material after the step of mixing the gas into the precursor material.

4. The process according to claim 3, wherein the step of pulverizing the precursor material after the step of mixing the gas into the precursor material is performed using an in-line rotor stator mill.

5. The process according to any one of claims 1 to 4, wherein the gas is mixed as a gas mixture.

6. The process according to claim 5, wherein the gas mixture is from a container containing the gas mixture.

7. The process according to any one of claims 1 to 6, wherein the argon is supplied from a primary container (157a) and the other component of the gas is supplied from one or more secondary containers (157b).

8. The process according to claim 7, wherein the other component of the gas is supplied as air from the secondary container.

9. The process according to any one of claims 1 to 8, wherein the argon and the other component of the gas are combined into a single stream of the gas before being mixed into the precursor material.

10. The process according to any one of claims 1 to 9, wherein the argon is mixed at a pressure of more than 2 bar and at a minimum flow rate of about 0.5 liter / minute.

11. The process according to any one of claims 1 to 10, wherein more than 50% by volume of the other component is less soluble in the precursor material than the argon.

12. The process according to any one of claims 1 to 11, wherein the precursor material contains more than about 20% by weight of a water-soluble polymer.

13. The water-soluble polymer is Formula H-(C ２ H ４ O) ｘ -(CH(CH ３ )CH ２ O) ｙ -(C ２ H ４ O) ｚ -OH (where x is 50 to 300, y is 20 to 100, and z is 10 to 200) polyalkylene polymer; Formula (C ２ H ４ O) ｑ -C(O)O-(CH ２ ) ｒ -CH ３ (wherein q is 20 to 200 and r is 10 to 30) polyethylene glycol fatty acid ester; HO-(C ２ H ４ O) ｓ -(CH ２ ) ｔ )-CH ３ (wherein s is from 30 to 250 and t is from 10 to 30) polyethylene glycol fatty alcohol ether; a C8 - C22 alkyl polyalkoxylate containing more than 40 alkoxylate units; a polyethylene glycol having a weight average molecular weight of 2000 - 15000; an EO / PO / EO block copolymer; a PO / EO / PO block copolymer; an EO / PO block copolymer; a PO / EO block copolymer; a polypropylene glycol; an ethoxylated nonionic surfactant having an ethoxylation degree of more than 30; a polyvinyl alcohol; a polyalkylene glycol having a weight average molecular weight of 2000 - 15000; and a mixture thereof, the process according to claim 12.

14. The process according to any one of claims 1 to 13, wherein the precursor material contains a polyethylene glycol having a weight average molecular weight of about 2000 to about 13000.

15. The process according to any one of claims 1 to 14, wherein the other component is selected from oxygen, nitrogen, carbon dioxide, and mixtures thereof.

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