Method for forming particles

Abstract

A method for forming particles is provided. The method includes the step of entraining a gas into a precursor material, wherein the gas includes from about 50 vol% to about 75 vol% carbon dioxide and from about 25 vol% to about 50 vol% other components. The precursor material is deposited onto a moving conveyor. The precursor material is cooled to form a plurality of particles.

Description

Technical Field

[0001] A method for forming particles. Background Art

[0002] Consumers expect products that can simplify the process they use for washing clothes, help them reduce the time they spend dealing with dirty clothes, and help them achieve a high level of benefits. Consumers are adequately positioned to understand the amount of fabric care composition required to provide the desired benefits. Thus, fabric care products that enable consumers to customize the amount of fabric care composition they use are popular among many consumers.

[0003] Fabric care products that can be delivered during washing are particularly easy for consumers to use. For example, consumers can simply place the fabric care product in the drum of the washing machine together with the clothes and start the washing machine cycle.

[0004] Generally, consumers use fabric care cleaning compositions containing significant amounts of surfactants and other cleaning ingredients. Such fabric care compositions are typically provided in the form of soluble unit dose pouches containing a specified amount of fabric care active agent. 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 the above fabric care benefits and fabric care benefits beyond those that can be provided by using fully formulated fabric care compositions, fabric care products as additives are popular among consumers. Consumers enjoy and are satisfied with using fabric care additives packaged in such a way that enables them to use a customized amount of the fabric care additive based on the consumer's judgment of how much fabric care additive is needed to provide the desired benefits. Such fabric care additives are conveniently provided during washing together with the fully formulated fabric care composition, but are metered separately from the fully formulated fabric care composition.

[0006] Fabric care additive particles in particulate form are attractive to many consumers. Some fabric care additive particles are provided with a porous structure. When forming the wash liquid, the particles having a porous structure can float in water. Compared with the particles that sink, the floating particles may be more easily and completely dissolved during washing because the particles that sink may be trapped in the folds, creases, and pockets of the clothes during washing. Undissolved particles tend to incompletely deliver the fabric care active agent contained in the particles, which may be undesirable to consumers. The floating particles that include unencapsulated fragrance can provide a pleasant fragrance to the headspace above the wash liquid and the room where the washing machine is located. In addition, the floating particles can better distribute the fabric care additive into the clothes during the washing cycle.

[0007] Melt processing is a common method for forming particles. One problem with preparing porous particles via the melt method is that when the molten precursor material solidifies, the gas bubbles in the melt tend to coalesce and rise out of the molten material. This can result in larger pores at or near the outer surface of the particles, an irregular and rough outer surface, an irregular distribution of pore diameters within the solidified particles, and the ejection of gas bubbles and molten material from the particle surface when the particles solidify. The durability of such particles may be less than that of particles with a more robust outer surface and they are prone to becoming powdery, messy to use, and of poor appearance. The tendency of the gas bubbles in the melt to coalesce and rise out of the molten material when the molten precursor material solidifies can also effectively limit the volume of pores that can be provided in the particles without these adverse consequences.

[0008] Given these limitations, there is a continuing unmet need for fabric care additives in the form of particles having a uniform pore diameter distribution throughout the particles. There is also a need for a method for forming such porous particles. Summary of the Invention

[0009] A method for forming particles includes the steps of: providing a precursor material to a feed tube; entraining a gas into the precursor material, wherein the gas comprises from about 50 volume % to about 75 volume % carbon dioxide and from about 25 volume % to about 50 volume % other components; providing a dispenser including a plurality of holes; conveying the precursor material from the feed tube 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. Description of the Drawings

[0010] Figure 1 Is a device for forming particles.

[0011] Figure 2 Is part of a device for forming particles.

[0012] Figure 3 Is an end view of a device for forming particles.

[0013] Figure 4 Is part of a device for forming particles. Detailed Description

[0014] Water-soluble carrier

[0015] The particles and thus the precursor materials described below may include a water-soluble carrier. The water-soluble carrier may be a water-soluble polymer. The water-soluble carrier is used to carry the capsules into the wash liquid. When the water-soluble carrier dissolves, the capsules disperse into the wash liquid and deposit onto the clothing.

[0016] The water-soluble carrier can be a material that can dissolve in the washing liquid within a short time, such as less than about 10 minutes.

[0017] Water-soluble means that the material, carrier material or particles can dissolve or disperse in water and optionally have a water solubility of at least 50%, optionally at least 75% or even at least 95% measured by the method described below, which uses a glass filter with a maximum pore size of 20 microns: Add 50 g ± 0.1 g of the carrier to a pre-weighed 400 mL beaker and add 245 mL ± 1 mL of distilled water. Stir it vigorously for 30 minutes on a magnetic stirrer set at 600 rpm. Then, filter the mixture through a porous glass filter with the above-specified pore size (maximum 20 microns). This step is carried out at a temperature of 23 °C ± 1.0 °C and a relative humidity of 50% ± 2%. Dry the water in the collected filtrate by any conventional method and determine the weight of the remaining material (the dissolved or dispersed part). Then, the percentage of solubility or dispersibility can be calculated.

[0018] The water-soluble carrier can be selected from 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.

[0019] The alkali metal salts can be selected, for example, from lithium salts, sodium salts and potassium salts and any combination thereof. The available alkali metal salts can be selected, for example, from alkali metal fluorides, alkali metal chlorides, alkali metal bromides, alkali metal iodides, alkali metal sulfates, alkali metal hydrogen sulfates, alkali metal phosphates, alkali metal monohydrogen phosphates, alkali metal dihydrogen phosphates, alkali metal carbonates, alkali metal hydrogen carbonates, alkali metal acetates, alkali metal citrates, alkali metal lactates, alkali metal pyruvates, alkali metal silicates, alkali metal ascorbates and combinations thereof.

[0020] The alkali metal salts can be selected from sodium fluoride, sodium chloride, sodium bromide, sodium iodide, sodium sulfate, sodium hydrogen sulfate, sodium phosphate, sodium monohydrogen phosphate, sodium dihydrogen phosphate, sodium carbonate, sodium hydrogen carbonate, sodium acetate, sodium citrate, sodium lactate, sodium tartrate, sodium silicate, sodium ascorbate, potassium fluoride, potassium chloride, potassium bromide, potassium iodide, potassium sulfate, potassium hydrogen sulfate, potassium phosphate, potassium monohydrogen phosphate, potassium dihydrogen phosphate, potassium carbonate, potassium hydrogen carbonate, potassium acetate, potassium citrate, potassium lactate, potassium tartrate, potassium silicate, potassium, ascorbic acid and combinations thereof.

[0021] The alkaline earth metal salts may be selected from magnesium salts, calcium salts, etc. and combinations thereof. The alkaline earth metal salts may be selected from 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 salts may be selected from 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.

[0022] 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 may be an alkali metal salt or an alkaline earth metal salt of sorbic acid (i.e., sorbate). The sorbate may be selected from sodium sorbate, potassium sorbate, magnesium sorbate, calcium sorbate and combinations thereof.

[0023] The water-soluble carrier may be or comprise 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 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, dextran, fructose, galactose, isoglucose, glucose, sucrose, raffinose, isomaltitol, xylitol, confectioner's sugar, granulated sugar, and combinations thereof. In one embodiment, the water-soluble carrier may be sodium chloride. In one embodiment, the water-soluble carrier may be table salt.

[0024] The water-soluble carrier may be or comprise 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 acids, fatty alcohols, diglycerides of hydrogenated tallow, glycerol, and combinations thereof.

[0025] The water-soluble carrier may be selected from 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 silicates, carboxymethyl cellulose citrate, fatty acids, fatty alcohols, diglycerides of hydrogenated tallow, glycerol, polyethylene glycol, and combinations thereof.

[0026] The water-soluble carrier may be selected from disaccharides, polysaccharides, silicates, zeolites, carbonates, sulfates, citrates, and combinations thereof.

[0027] The water-soluble carrier may be selected from polyethylene glycol, sodium acetate, sodium bicarbonate, sodium chloride, sodium silicate, polypropylene glycol polyoxyalkylene, polyethylene glycol fatty acid ester, polyethylene glycol ether, sodium sulfate, starch, and mixtures thereof.

[0028] The water-soluble carrier may be a water-soluble polymer. The water-soluble polymer may 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 greater than about 30, polyalkylene glycols having a weight-average molecular weight of about 2000 to about 15000, and combinations thereof.

[0029] The water-soluble polymer may be a block copolymer having the formula (I), (II), (III), or (IV), namely 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 combinations thereof; wherein EO is a -CH 2 CH 2 O- group, and PO is a -CH(CH 3 )CH 2 O- group; R 1 and R 2 are independently H or C1-C22 alkyl groups; x, y, o, p, and q are independently 1-100; provided that the sum of x and y is greater than 35, and the sum of o, p, and q is greater than 35; wherein the block copolymer has a molecular weight in the range of about 3000 g / mol to about 15,000 g / mol.

[0030] The water-soluble polymer can be one or more block copolymers, such as block copolymers 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.

[0031] The water-soluble polymer can be selected from the group consisting of: polyvinyl alcohol (PVA), modified PVA; polyvinylpyrrolidone; PVA copolymers such as PVA / polyvinylpyrrolidone and PVA / polyvinylamine; partially hydrolyzed polyvinyl acetate; polyalkylene oxides such as ethylene oxide; polyethylene glycol; acrylamide; acrylic acid; cellulose, alkyl celluloses 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; glucuronoxylan, other hemicellulose polysaccharides including xylan, glucuronoxylan, arabinoxylan, mannan, glucomannan and galactoglucomannan; natural gums such as pectin, xanthan gum, carrageenan, locust bean gum, gum arabic, tragacanth gum; and combinations thereof. In one embodiment, the polymer comprises: polyacrylates, especially sulfonated polyacrylates and water-soluble acrylate copolymers; and alkyl hydroxy celluloses such as methyl cellulose, sodium carboxymethyl cellulose, modified carboxymethyl cellulose, dextrin, ethyl cellulose, propyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose, maltodextrin, polymethacrylate. In another embodiment, the water-soluble polymer can be selected from PVA; PVA copolymers; hydroxypropyl methyl cellulose (HPMC); and mixtures thereof.

[0032] The water-soluble polymer may be selected from the group consisting of polyvinyl alcohol, modified polyvinyl alcohol, polyvinylpyrrolidone, polyvinyl alcohol / polyvinylpyrrolidone, polyvinyl alcohol / polyvinylamine, partially hydrolyzed polyvinyl acetate, polyalkylene oxide, polyethylene glycol, acrylamide, acrylic acid, cellulose, alkyl cellulose, methyl cellulose, ethyl cellulose, propyl cellulose, cellulose ether, cellulose ester, cellulose amide, polyvinyl acetate, polycarboxylic acid and salts, polyamino acid or peptide, polyamide, polyacrylamide, maleic acid / acrylic acid copolymer, polysaccharide, starch, modified starch, gelatin, alginate, glucomannan, hemicellulose polysaccharide, xylan, glucuronoxylan, arabinoxylan, mannan, glucomannan, galactoglucomannan, natural gum, pectin, xanthan gum, carrageenan, locust bean gum, gum arabic, tragacanth gum, polyacrylate, sulfonated polyacrylate, water-soluble acrylate copolymer, alkyl hydroxy cellulose, methyl cellulose, sodium carboxymethyl cellulose, modified carboxymethyl cellulose, dextrin, ethyl cellulose, propyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose, maltodextrin, polymethacrylate, polyvinyl alcohol copolymer, hydroxypropyl methyl cellulose, and mixtures thereof.

[0033] The water-soluble polymer may be an organic material. The organic water-soluble polymer may provide the beneficial effect of being readily soluble in water.

[0034] The water-soluble polymer may be selected from the group consisting of polyethylene glycol, polypropylene glycol polyalkylene oxide, polyethylene glycol fatty acid ester, polyethylene glycol ether, starch, and mixtures thereof.

[0035] The water-soluble polymer can be polyethylene glycol (PEG). PEG can be a convenient material for preparing the particles because when the particles have the mass ranges disclosed herein, PEG can have sufficient water solubility to dissolve during the washing cycle. In addition, PEG can be easily processed in the melt form. The melting onset temperature of PEG can vary depending on the molecular weight of PEG. The particles can contain from about 20% to about 94% by weight of PEG having a weight average molecular weight of from about 2,000 to about 15,000. PEG has a low cost, can be formed into many different shapes and sizes, minimizes the diffusion of unencapsulated fragrance, and is well soluble in water. PEG has a variety of weight average molecular weights. Suitable ranges of PEG weight average molecular weights include 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 purchased from BASF, such as PLURIOL E 8000, or other PLURIOL products. The water-soluble polymer can 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.

[0036] The particles can contain from about 20% to about 99% by weight of a water-soluble carrier. The particles can contain from about 35% to about 95% by weight of the particles, optionally from about 50% to about 80%, optionally combinations thereof, and any percentage integer or percentage integer range within any of the foregoing ranges of the water-soluble carrier.

[0037] A plurality of particles can include a single particle containing from about 20% to about 99% by weight of the particle of a water-soluble carrier; and from about 0.1% to about 20% by weight of the particle of a capsule; wherein the capsule is dispersed in a matrix of the water-soluble polymer.

[0038] The particles can contain from about 20% to about 99% by weight of the single particle of PEG. Optionally, the single particle can contain from about 20% to about 95% by weight of the particle, optionally from about 35% to about 95%, optionally from about 50% to about 80%, optionally combinations thereof, and any percentage integer or percentage integer range within any of the foregoing ranges of PEG.

[0039] The water-soluble polymer can include a material selected from the group consisting of: the formula H-(C 2 H 4 O) x -(CH(CH 3 )CH2 O) y -(C 2 H 4 O) z -OH polyalkylene polymer, 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; formula (C 2 H 4 O) q -C(O)O-(CH 2 ) r -CH 3 polyethylene glycol fatty acid ester of, where q is from about 20 to about 200 and r is from about 10 to about 30; formula HO-(C 2 H 4 O) s -(CH 2 ) t )-CH 3 polyethylene glycol fatty alcohol ether of, where s is from about 30 to about 250 and t is from about 10 to about 30; and mixtures thereof. Formula H-(C 2 H 4 O) x -(CH(CH 3 )CH 2 O) y -(C 2 H 4 O) z -OH polyalkylene polymer may be a block copolymer or a random copolymer, 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.

[0040] The water-soluble polymer may comprise: polyethylene glycol; formula H-(C 2 H 4 O) x -(CH(CH 3 )CH 2 O) y -(C 2 H 4 O) z -OH polyalkylene polymer, 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; formula (C 2 H 4 O) q -C(O)O-(CH 2 ) r -CH 3 polyethylene glycol fatty acid ester of, where q is from about 20 to about 200 and r is from about 10 to about 30; and formula HO-(C 2 H 4 O)s -(CH 2 ) t )-CH 3 Polyethylene glycol fatty alcohol ether, where s is from about 30 to about 250 and t is from about 10 to about 30.

[0041] The water-soluble polymer may comprise from about 20% to about 95% by weight of the particles or by weight of a single particle of the formula H-(C 2 H 4 O) x -(CH(CH 3 )CH 2 O) y -(C 2 H 4 O) z -OH polyalkylene polymer, 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.

[0042] The water-soluble polymer may comprise from about 1% to about 20% by weight of the particles or by weight of a single particle of the formula (C 2 H 4 O) q -C(O)O-(CH 2 ) r -CH 3 Polyethylene glycol fatty acid ester, where q is from about 20 to about 200 and r is from about 10 to about 30.

[0043] The water-soluble polymer may comprise from about 1% to about 10% by weight of the particles or by weight of a single particle of the formula HO-(C 2 H 4 O) s -(CH 2 ) t )-CH 3 Polyethylene glycol fatty alcohol ether, where s is from about 30 to about 250 and t is from about 10 to about 30.

[0044] The water-soluble carrier may comprise a plasticizer polyol (0% to 3% by weight of the particles), wherein the plasticizer polymer is optionally liquid at 20 °C and 1 atmosphere; water (1% to 20%, or 1% to 12%, or 6% to 8% by weight of the particles); a sugar alcohol polyol selected from the group consisting of erythritol, xylitol, mannitol, isomalt, maltitol, lactitol, trehalose, lactose, tagatose, sucralose, and mixtures thereof (45% to 80%, or 50% to 70%, or 50% to 60% by weight of the particles); wherein the particles further comprise: (a) a modified starch having a dextrose equivalent of 15 to 20, and 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 4 to less than 15, and 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 may have a dextrose equivalent of 15 to 20, and the sugar alcohol polyol and the modified starch may 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 may have a dextrose equivalent of 4 to less than 15, and the sugar alcohol polyol and the modified starch may 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 may have a dextrose equivalent of 4 to 12. The modified starch may be maltodextrin. The sugar alcohol polyol may be mannitol. The plasticizer polyol may be selected from the group consisting of glycerol, dipropylene glycol, propylene glycol, and mixtures thereof.

[0045] The particles may comprise more than about 20% by weight of the water-soluble carrier. The particles may comprise more than about 40% by weight of the water-soluble carrier. The particles may comprise from about 20% to about 99% by weight of the water-soluble carrier. Optionally, the particles may comprise from about 35% to about 85%, or even from about 50% to about 80% by weight of the particles of the water-soluble carrier. The water-soluble carrier may be selected from the group consisting of 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, wherein x is from 50 to 300, y is from 20 to 100, and z is from 10 to 200; of the formula (C 2 H 4O) q -C(O)O-(CH 2 ) r -CH 3 polyethylene glycol fatty acid esters, where q is from 20 to 200 and r is from 10 to 30; the formula HO-(C 2 H 4 O) s -(CH 2 ) t )-CH 3 polyethylene glycol fatty alcohol ethers, where s is from 30 to 250 and t is from 10 to 30; C8-C22 alkyl polyalkoxylates containing more than 40 alkoxylate units; polyethylene glycol with a weight average molecular weight of from 2000 to 15000; EO / PO / EO block copolymers; PO / EO / PO block copolymers; EO / PO block copolymers; PO / EO block copolymers; polypropylene glycol; ethoxylated nonionic surfactants with an ethoxylation degree greater than 30; polyvinyl alcohol; polyalkylene glycols with a weight average molecular weight of from 2000 to 15000; and mixtures thereof.

[0046] Beneficial fabric care active agent

[0047] The particles may comprise from about 0.1% to about 99% by weight of a fabric care benefit active agent. A fabric care benefit active agent is a substance provided as part of the particulate composition in an amount sufficient to impart a beneficial effect to the fabric treated with the particles.

[0048] The fabric care benefit active agents may be 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, dye transfer inhibitors, dispersants, enzyme stabilizers, catalytic materials, bleaches, bleach catalysts, bleach activators, polymeric dispersants, cyclodextrin complexed benefit agents, soil removal / antiredeposition agents, encapsulated fragrances, polymeric dispersants, polymeric grease cleaners, optical brighteners, antifoaming agents, dyes, colorants, free fragrances, structural elasticizers, fabric softeners, quaternary amines, tallow, carriers, fillers, hydrotropes, organic solvents, antimicrobial agents and / or preservatives, neutralizing agents and / or pH regulators, processing aids, fillers, antioxidants, rheology modifiers or structurants, opacifiers, pearlescents, pigments, corrosion inhibitors and / or rust inhibitors, and mixtures thereof.

[0049] Fragrance

[0050] The fabric care benefit agent can be a fragrance. A fragrance is an oil or perfume that includes one or more odoriferous compounds, such as synthetic products of the ester, ether, aldehyde, ketone, alcohol, and hydrocarbon types. Mixtures of various odoriferous substances can be used, which together produce an appealing fragrance. Such fragrance oils can also contain natural mixtures of odoriferous compounds, such as those obtainable from plant sources.

[0051] The fragrance can 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.

[0052] The fragrance can be provided as an unencapsulated fragrance. The fragrance can be provided 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 fragrance oil can be spray-dried to form starch granules having fragrance droplets dispersed within the starch matrix. The fragrance delivery system can be particulate material or fine particulate material that may be difficult to handle in a manufacturing environment due to the particles potentially being suspended in the air.

[0053] The fragrance can be an encapsulated fragrance. Encapsulated fragrances are commonly used in laundry products. The encapsulated fragrance contains multiple liquid fragrance droplets, each droplet encapsulated in an encapsulation shell. The fragrance can be encapsulated in a water-soluble or water-insoluble encapsulation shell. The encapsulation shell can include materials such as melamine-urea-formaldehyde, melamine formaldehyde, urea formaldehyde, starch, etc. The encapsulation shell wall can be a material selected from the following: 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; siloxane; aminoplast; and mixtures thereof. When the encapsulation shell contains an aminoplast, the aminoplast can contain polyurea, polyurethane, and / or polyureamine. The polyurea can include polyformaldehyde urea and / or melamine formaldehyde. Encapsulates having an encapsulation shell containing polysaccharides can be practical. The encapsulation shell can be selected from the group consisting of: chitosan, gum arabic, alginate, β-glucan, starch, starch derivatives, plant proteins, gelatin, tragacanth gum, and combinations thereof.

[0054] The encapsulation shell can contain about 90% to 100%, optionally about 95% to 100%, optionally about 99% to 100% inorganic material by weight of the shell. The inorganic material can be selected from the group consisting of: metal oxides, metalloid oxides, metals, minerals, and mixtures thereof, optionally selected from the group consisting of: SiO 2 、TiO2 、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 selected from the group consisting of: SiO 2 、TiO 2 、Al 2 O 3 、CaCO 3 and mixtures thereof, optionally SiO 2 。 The encapsulation shell may include a first shell component and a second shell component. The first shell component includes a condensation layer and a nanoparticle layer, where the condensation layer contains the condensation product of a precursor, and where the nanoparticle layer contains inorganic nanoparticles, and where the condensation layer is disposed between the core and the nanoparticle layer. The second shell component surrounds the first shell component, where the second shell component surrounds the nanoparticle layer. The encapsulant can be any of those encapsulants described in U.S. Patent Publication Nos. 2020 / 0330948A1, 2020 / 0330949A1, and 2020 / 0330950A1 and U.S. Patent Application No. 63 / 092,829.

[0055] The fragrance may include one or more plant-derived fragrances. A plant-derived fragrance is a concentrated hydrophobic liquid containing volatile compounds extracted from plants. Plant-derived fragrances are optionally selected from the group consisting of: allspice berries, angelica seeds, fennel seeds, basil, bay tree, bay leaf, bergamot, blood orange, camphor, caraway seeds, cardamom seeds, carrot seeds, cinnamon, catnip, cedarwood, celery seeds, chamomile, roman chamomile, cinnamon bark, cinnamon leaves, citronella, sage, clove buds, coriander seeds, cypress, elemi, eucalyptus, fennel, fir, frankincense, geranium, ginger, pink grapefruit, helichrysum, hops, hyssop, juniper berries, labdanum, lavender, lemon, lemongrass, lime, magnolia, mandarin orange, marjoram, melissa, mugwort, myrrh, myrtle, neroli, melaleuca, nutmeg, sweet orange, oregano, palmarosa, patchouli, peppermint oil, black pepper, peppermint, orange leaves, pine needles, radiata, rosemary leaves, rose, rosemary, sandalwood, spearmint, valerian, spruce, star anise, wormwood, tangerine, tea tree, thyme red, verbena, vetiver, wintergreen, absinthe, yarrow, extrait de ylang-ylang, and ylang-ylang III, and mixtures thereof.

[0056] The particles may contain from about 0.1% to about 20% by weight of the fragrance, optionally from about 0.1% to about 15%, optionally from about 0.1% to about 12%, optionally from about 1% to about 15%, optionally from about 2% to about 20%, optionally from about 8% to about 10% by weight of the fragrance.

[0057] Fragrance emulsion composition

[0058] The fabric care benefit agent may be a fragrance emulsion composition. The fragrance emulsion composition may comprise: an amino-functionalized silicone, wherein the amino-functionalized silicone comprises one or more primary amine moieties, and wherein the amino-functionalized silicone is characterized by a total amine content of from about 0.05 to about 2.2; one or more emulsifiers; one or more fragrance ingredients, wherein the one or more fragrance ingredients comprise an aldehyde moiety, a ketone moiety, or a combination thereof; and water.

[0059] The fragrance emulsion composition may be any one of the fragrance emulsion compositions described in European Patent Office Application No. 20156010.9 filed on February 7, 2020.

[0060] The amino-functionalized silicone may be characterized by:

[0061] (a) a total amine content of from about 0.071 to about 2.14, or from about 0.071 to about 1.78, or from about 0.71 to about 1.43, or from about 0.14 to about 1.07, or from about 0.14 to about 0.71, or from about 0.21 to about 0.71, or from about 0.36 to about 0.71; and / or

[0062] (b) a primary amine content of from about 0.05 to about 2.2, preferably from about 0.071 to about 2.14, or from about 0.071 to about 1.78, or from about 0.71 to about 1.43, or from about 0.14 to about 1.07, or from about 0.14 to about 0.71, or from about 0.21 to about 0.71, or from about 0.36 to about 0.71; and / or

[0063] (c) a ratio of primary amine content to total amine content of from about 1:2 to about 1:1, preferably about 1.2:2,

[0064] more preferably about 1.5:2, or even more preferably about 1.8:2.

[0065] The amino-functionalized silicone may be characterized by the following formula:

[0066] [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

[0067] wherein

[0068] j is an integer from 0 to 150, preferably from 0 to 50, more preferably from 0 to 20;

[0069] m is an integer from 10 to 1500, preferably from 10 to 1000, more preferably from 20 to 500;

[0070] 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;

[0071] provided that j + m + l is an integer greater than or equal to 50;

[0072] R 1 、R 2 、R 3 、R 4 、R 5 and R 6 each of the parts is independently selected from 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 X-Z, wherein at least one of the parts R 1 to R 6 = X-Z,

[0073] preferably, each R 1-6 is independently selected from 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;

[0074] wherein each X is independently a substituted or unsubstituted divalent alkylene or alkylidene group containing 2 to 12 carbon atoms, preferably each X is independently a substituted or unsubstituted divalent alkylene or alkylidene group containing 2 to 6 carbon atoms, and most preferably each X is independently a substituted or unsubstituted divalent alkylene or alkylidene group containing 2 to 4 carbon atoms;

[0075] wherein each Z is a moiety containing said one or more primary amine moieties,

[0076] preferably, wherein each Z is independently selected from the groups -NH 2 、-N(H)-X-NH 2 or mixtures thereof.

[0077] The emulsion composition may be characterized by at least one of features (a) to (d):

[0078] (a) comprising from about 10% to about 70%, or from about 25% to about 65%, or from about 50% to about 65% of an amino-functionalized silicone based on the weight of the silicone emulsion; and / or

[0079] (b) comprising from about 30% to about 90%, or from about 35% to about 75%, or from about 35% to about 50% of water based on the weight of the emulsion; and / or

[0080] (c) characterized by a viscosity measured at 0.1 rad / s and 25 °C of from about 10 Pa·s to about 500 Pa·s, preferably from about 20 Pa·s to about 400 Pa·s, more preferably from about 25 Pa·s to about 300 Pa·s, and even more preferably from about 100 Pa·s to about 300 Pa·s; and / or

[0081] (d) comprising a plurality of droplets, wherein the plurality of droplets are characterized by an average diameter of from about 1 micron to about 5 microns.

[0082] One or more fragrance raw materials may comprise materials selected from:

[0083] a. oncidal, methyl nonyl acetaldehyde, adoxal, melonal, calypsone or mixtures thereof;

[0084] b. cumin aldehyde, benzaldehyde, anisaldehyde, heliotropin, isocyclocitral, triplal / ligustral, 3,6-ivy aldehyde, ligustral, zephyr aldehyde or mixtures thereof;

[0085] c. Salbutamol (jasminaldehyde), o tropal, cyclamenaldehyde, cyclamal, lily aldehyde, khusimol, sea breeze aldehyde, cinnamaldehyde or mixtures thereof;

[0086] d. δ - dihydrodamascone, β - dihydrodamascone, α - dihydrodamascone, ambrosial or mixtures thereof;

[0087] e. Vanillin, ethyl vanillin or mixtures thereof; or

[0088] f. A combination of materials selected from at least two of categories a, b, c, d and e.

[0089] One or more emulsifiers may comprise a non - ionic surfactant, preferably wherein the non - ionic surfactant comprises an alkoxylated fatty alcohol, and even more preferably wherein one or more emulsifiers are characterized by an HLB value of from about 5 to about 20, preferably from about 8 to about 16.

[0090] One or more emulsifiers may include a first emulsifier and a second emulsifier, wherein the second emulsifier is different from the first emulsifier, preferably wherein the first emulsifier is a straight - chain non - ionic surfactant, and / or preferably wherein the second emulsifier is a branched - chain non - ionic surfactant.

[0091] Fabric softening

[0092] The fabric - care active beneficial agent may be a fabric - softening active substance. The granules may comprise from about 5% to about 45% by weight of a quaternary ammonium compound. The quaternary ammonium compound may be an ester quaternary ammonium compound. The quaternary ammonium compound may be those described in U.S. Patent Publications 2019 / 0169538A1, 2019 / 0169539A1, 2019 / 0169777A1, 2019 / 0169532A1, 2019 / 0169533A1 and 2019 / 0169534A1. The quaternary ammonium compound may be di - (tallow acyloxyethyl) - N,N - methyl hydroxyethyl methyl ammonium sulfate.

[0093] The fabric - softening active substance may be a fatty amine. The granules may comprise from about 8% to about 45% by weight of a fatty amine. The fatty amine may be those described in U.S. Patent Publication 2020 / 0354652A1.

[0094] The fabric - softening active substance may be a silicone. The granules may comprise from about 1% to about 50% by weight of a silicone. The silicone may be the silicone described in U.S. Patent Publication 2017 / 0349865.

[0095] Branched polyester

[0096] The fabric care active beneficial agent can be a branched polyester. The particles can contain from about 5% to about 45% by weight of the branched polyester. The branched polyester can be those described in U.S. Patent Publication 2019 / 0367841A1. The branched polyester can be those described and claimed in U.S. Patent Publication 2019 / 0233764A1.

[0097] Cationic polymer

[0098] The fabric care active beneficial agent can be a cationic polymer. The particles can contain from about 0.1% to about 10% by weight 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 that has been reacted with an epoxide substituted with trimethylammonium groups.

[0099] Enzyme

[0100] The fabric care active beneficial agent can be an enzyme. The particles can contain from about 0.0001% to about 5% by weight of the enzyme. The enzyme can be selected from the group consisting of: proteases, xyloglucanases, mannanases, and combinations thereof. The enzyme can be those described in U.S. Patent Publications 2017 / 0260481A1 and 2017 / 0260482A1.

[0101] Graft copolymer

[0102] The fabric care active beneficial agent can be a graft copolymer. The particles can contain from about 1% to about 75% by weight of the graft copolymer. The graft copolymer can be those described in U.S. Patent Application 69 / 951,274. The graft copolymer can be those described in U.S. Patent Application 69 / 722,492.

[0103] Antioxidant

[0104] The fabric care active beneficial agent can be an antioxidant. The particles can contain from about 0.2% to about 2% by weight of the antioxidant. The antioxidant can be dispersed in the matrix of the water-soluble carrier. The antioxidant can be those described in U.S. Patent Application 63 / 034,766. The antioxidant can be butylated hydroxytoluene.

[0105] Equipment and method for forming particles

[0106] In Figure 1Device 1 for forming particles is shown. The precursor material 20 can be a melt of any composition disclosed herein for the particles 90. The precursor material 20 can comprise more than about 20% by weight of a water-soluble carrier. The precursor material 20 can comprise more than about 20% by weight of a water-soluble polymer. The precursor material 20 can comprise from about 20% to about 99% by weight of a water-soluble carrier. The precursor material 20 can comprise from about 20% to about 99% by weight of a water-soluble polymer.

[0107] The precursor material 20 can comprise more than about 20%, optionally more than about 40%, by weight of polyethylene glycol having a weight average molecular weight of from about 2000 to about 13000, and from about 0.1% to about 20% by weight of a fragrance.

[0108] One or more raw materials can be provided to the batch mixer 10. The batch mixer 10 can have sufficient capacity to hold a given volume of raw materials provided to it for a sufficient residence time to allow a desired level of raw material mixing and / or reaction to occur. The material leaving the batch mixer 10 can be the precursor material 20. Optionally, the precursor material can be provided to the feed pipe 40 from some other upstream mixing process (e.g., in-line mixing, in-line static mixing, etc.). The precursor material 20 can be a molten product. The batch mixer 10 can be a dynamic mixer. A dynamic mixer is a mixer that applies energy to mix the contents of the mixer. The batch mixer 10 can comprise one or more impellers to mix the contents of the batch mixer 10.

[0109] Between the batch mixer 10 (optionally present) and the dispenser 30, the precursor material 20 can be conveyed through the feed pipe 40. The feed pipe 40 can be in fluid communication with the batch mixer 10. One or more gas feed lines 155 can be provided to be in fluid communication with the feed pipe 40 downstream of the batch mixer 10. One or more gas feed lines 155 can be provided to be in fluid communication with the feed pipe 40 between the batch mixer 10 and the dispenser 30. The grinder 200 can be provided downstream of one or more gas feed lines 155 and in series with the feed pipe 40. The grinder 200 can be provided to be in series with the feed pipe 40 downstream of one or more gas feed lines 155 and upstream of the dispenser 30.

[0110] The precursor material 20 can be supplied to the feed pipe 40. The feed pipe 40 is a transport device for carrying the precursor material 20. The feed pipe 40 includes a transport device between the components of the apparatus 1 and a transport device through which the precursor material is carried within the components of the apparatus 1. For example, a grinder 200 can be provided in a unit where a part of the transport device is close to the grinder 200 and a part of the transport device departs from the grinder 200. Each of these parts is a part of the feed pipe 40. Thus, the feed pipe 40 can be regarded as the entire transport device between the batch mixer 10 and the dispenser 30, and the feed pipe 40 is interrupted by various components such as one or more gas feed lines 155, the grinder 200, the intermediate mixer 50, and the feed pump 140. In the case where there is no batch mixer 10 upstream of the feed pipe 40, the feed pipe 40 can be regarded as the entire transport device upstream of the dispenser 30, and the feed pipe 40 is interrupted by various components such as one or more gas feed lines 155, the grinder 200, the intermediate mixer 50, and the feed pump 140.

[0111] An intermediate mixer 55 can be provided downstream of the grinder 200 and in series with the feed pipe 40. The intermediate mixer 55 can be a static mixer 50. The intermediate mixer 55 can be in fluid communication with the feed pipe 40 between the grinder 200 and the dispenser 30. The intermediate mixer 55 can be a static mixer 50, which can be downstream of the batch mixer 10. In other words, the batch mixer 10 can be upstream of the intermediate mixer 55 or the static mixer 55 (if used). The intermediate mixer 55 can be in series with the feed 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 an in-line driven fluid disperser. The intermediate mixer 55 can be an Ultra Turrax disperser, a Dispax-reactor disperser, a ColloidMil MK, or a Cone Mill MKO, purchased from IKA, Wilmington, North Carolina, United States of America. The intermediate mixer 55 can be a porous disk mill, a toothed colloid mill, or a DIL Inline Homogenizer, purchased from FrymaKoruma, Rheinfelden, Switzerland. The static mixer 50 can be a helical static mixer. The static mixer 50 can be a Kenics 1.905 cm inner diameter KMS 6, purchased from Chemineer, Dayton, OH, USA.

[0112] Without being bound by theory, it is believed that the intermediate mixer 55, such as the static mixer 50, can provide a more uniform temperature of the precursor material 20 within the dispenser 30 stator 100. At the downstream end of the intermediate mixer 55 or the static mixer 50 (if used), the temperature of the precursor material 20 within the feed tube 40 across a cross-section orthogonal to the flow direction can change 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.

[0113] In the absence of the static mixer 50, the temperature across a cross-section orthogonal to the flow direction in the feed tube 40 can be non-uniform. The temperature of the precursor material 20 at the centerline of the feed tube 40 can be higher than the temperature of the precursor feed material 20 at the peripheral wall of the feed tube 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 locations within the dispenser or stator 100. Without being bound by theory, it is believed that providing a uniform temperature across the entire cross-section of the feed tube 40 by using a static mixer 50 as described herein can result in more uniform particles 90 compared to an apparatus 1 without a static mixer 50.

[0114] 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 a moving conveyor 80 disposed below the dispenser 30. When the conveyor 80 is moving, the precursor material 20 can be deposited on the moving conveyor 80. The conveyor 80 can be translatable relative to the dispenser 30. The conveyor 80 can be a continuously moving conveyor 80. The conveyor 80 can be an intermittently moving conveyor 80. A continuously moving conveyor 80 can provide a higher processing speed. An intermittently moving conveyor 80 can provide improved control over the shape of the prepared particles 90.

[0115] 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 water or cooling water at ambient temperature on the underside of the conveyor 80.

[0116] Once the particles 90 have sufficient stickiness, the particles 90 can be transferred from the conveyor 80 to downstream processing equipment of the conveyor 80 for further processing and / or packaging.

[0117] The dispenser 30 can be a cylinder 110 rotatably mounted around the stator 100, which is in fluid communication with the feed tube 40, and the cylinder 110 can have a periphery 120 and can have a plurality of holes 60 in the periphery 120, such as Figure 2As shown in [figure]. Thus, the device 1 may include a stator 100 that is in fluid communication with a feed pipe 40. After the precursor material 20 has passed through the grinder 200, the feed pipe 40 may feed the precursor material 20 into the stator 100.

[0118] The device 1 may include a cylinder 110 rotatably mounted around the stator 100. The stator 100 feeds the precursor material through one or both ends 130 of the cylinder 110. The cylinder 110 may have a longitudinal axis L passing through the cylinder 110 around which the cylinder 110 rotates. The cylinder 110 has a perimeter 120. A plurality of holes 60 may be present in the perimeter 120 of the cylinder 110.

[0119] When driving the cylinder 110 to rotate around its longitudinal axis L, the holes 60 may be intermittently in fluid communication with the stator 100 as the cylinder 110 rotates around the stator 100. It can be considered that the cylinder 110 has a longitudinal MD in the direction of movement across the perimeter 120 of the stator 100 and a transverse direction orthogonal to the longitudinal MD on the perimeter 120. Similarly, it can be considered that the stator 100 has a transverse CD parallel to the longitudinal axis L. The transverse of the stator 100 may be aligned with the transverse of the cylinder 110. The stator 100 may have a plurality of distribution ports 122 that are arranged on the transverse CD of the stator 100. The distribution ports 122 are parts or regions of the stator 100 for supplying the precursor material 20.

[0120] Generally speaking, the precursor material 20 may be fed through one or more gas feed lines 155 through the grinder 200 and the feed pipe 40 into the stator 100. The stator 100 distributes the precursor feed material 20 over the entire operating width of the cylinder 110. When the cylinder 110 rotates around its longitudinal axis, the precursor material 20 is fed through the holes 60 when the holes 60 pass through the stator 100. When each hole 60 encounters the stator 100, a discontinuous amount of the precursor material 20 is fed through each hole 60. The amount of the precursor material 20 fed through each hole 60 when each hole 60 passes through the stator 100 can be controlled by controlling one or both of the precursor material pressure in the stator 100 and the rotational speed of the cylinder 110, or optionally by controlling the temperature of the precursor material 20 to control the viscosity of the precursor material 20.

[0121] Droplets of the precursor material 20 are deposited on the conveyor 80 over the entire operating width of the cylinder 110. The conveyor 80 may be translatable relative to the longitudinal axis of the cylinder 110. The speed of the conveyor 80 may be set relative to the tangential speed of the cylinder 110 so as to control its shape once the precursor material 20 is deposited on the conveyor 80. The speed of the conveyor 80 may be substantially the same as the tangential speed of the cylinder 110.

[0122] As Figure 1As shown, the flow of precursor material 20 through feed tube 40 can be provided by gravity-driven flow from batch mixer 10 and dispenser 30. To provide more controllable manufacturing, apparatus 1 can be provided with a feed pump 140, as Figure 2 shown. Feed pump 140 can be in series with feed tube 40, which means in line with the flow of precursor material 20. Feed pump 140 can be between batch mixer 10 and dispenser 30. Feed pump 140 can be upstream of dispenser 30. If stator 100 is used, feed pump 140 can be in series with feed tube 40, which means in line with the flow of precursor material 20. If stator 100 is used, feed pump 140 can be between batch mixer 10 and stator 100. Feed pump 140 can be upstream of stator 100. When describing the position of feed pump 140, intermediate is used to describe feed pump 140 in series with the downstream of batch mixer 10 and the upstream of dispenser 30, or, if used, the upstream of stator 100.

[0123] If used in apparatus 1, one or more gas feed lines 155 and grinder 200 can be positioned in series between feed pump 140 and dispenser 30 or stator 100.

[0124] The flow rate of precursor material 20 can be about 3 L / min. Precursor material 20 can be a molten material comprising any composition described herein for precursor material 20 or particles 90.

[0125] Apparatus 1 can include one or more gas feed lines 155. A single gas feed line 155 can be practical if the gas to be entrained into the precursor material can actually be supplied via a single gas feed line 155. As described herein, a gas comprising multiple components may be desirable. The multi-component gas can be provided in a single container 157. For example, a mixture of carbon dioxide and nitrogen can be provided in a gas cylinder. Optionally, the gas mixture can be continuously provided from the environment via a reaction process or by combining air with another gas from a container. The gas can be pressurized via a compressor.

[0126] One or more gas feed lines 155 can include a flow regulator 158. Flow regulator 158 can regulate the flow rate of the gas entering feed tube 40. The volume of gas added per unit volume of precursor material 20 can be controlled by setting flow regulator 158 to a desired flow rate. The more gas fed into precursor material 20 within feed tube 40, the more gas will be contained within particles 90. One or more gas feed lines 155 can be used to entrain gas into precursor material 20.

[0127] The flow regulator 158 can be a Key Instruments Flo-Rite series GS 65mm flowmeter, part number 60410-R5. The feed pipe 40 can be 1 1 / 2 inch stainless steel sanitary pipe. The gas feed line 155 can be a polyethylene pipe with a 1 / 4 inch inner diameter. Gas can be supplied to the gas feed line 155 at a pressure greater than about 4 bar (e.g., 5.9 bar).

[0128] If two or more gas feed lines 155 are respectively connected to the feed pipe 40, flow regulators can be provided along each gas feed line 155 to regulate the gas flow in each corresponding gas feed line 155. If the gas mixture is introduced into the feed pipe 40 via a single gas feed line 155, a single flow regulator 158 can be practical.

[0129] At the connection between the gas feed line 155 and the feed pipe, an injection bushing device for introducing gas can be provided.

[0130] Gas can be supplied at a certain temperature and pressure such that when the gas reaches ambient temperature and pressure, a desired volume of gas is present in the particles 90. The ideal gas law can be used to determine the desired temperature and pressure for delivery. The gas can also contain water. The water can be in gaseous or liquid form. The amount of water in the gas can be selected to be at a desired level.

[0131] The grinder 200 can be a rotor-stator type grinder. The grinder can be a Quadro Z1 in-line mixer with a single-stage middle rotor stator, which operates at about 400 RPM.

[0132] The grinder 200 and one or more gas feed lines 155 can be combined in a single unit.

[0133] Oakes foaming agent (E.T.Oakes Corporation, 686 Old Willets Path, Hauppauge, NY 11788) 2MT1A continuous foaming agent can be used to set the gas feed line 155, the flow regulator 158, and the grinder 200 in a single unit.

[0134] A view of the device 1 in the longitudinal MD is shown in Figure 3 . As shown in Figure 3 , the device 1 can have an operating width W and the cylinder 110 can rotate about the longitudinal axis L.

[0135] The apparatus 1 for forming the particles 90 may include: a feed pipe; one or more gas feed lines 155 installed in fluid communication with the feed pipe 40 downstream of the batch mixer 10; a grinder 200 located downstream of the one or more gas feed lines 155 and in series with the feed pipe 40; and a dispenser 30 located downstream of the grinder 200 and in fluid communication with the feed pipe 40, wherein the dispenser 30 includes a plurality of holes 60. The apparatus 1 may include a conveying device located below the dispenser 30 and translatable relative to the dispenser 30. The dispenser 30 may include a stator 100 in fluid communication with the feed pipe 40. The dispenser 30 may include a cylinder 110 rotatably mounted around the stator 100 and rotatable about the longitudinal axis L of the cylinder 110. The cylinder 110 may have a perimeter 120, and the cylinder 110 may have a plurality of holes 60 disposed around the perimeter 120. The holes 60 may be intermittently in fluid communication with the stator 100 as the cylinder 110 rotates around the stator 100. The apparatus may include a conveying device 80 below the cylinder 110, and the conveying device 80 may be translatable relative to the longitudinal axis L. The apparatus 1 for forming the particles 90 may include a batch mixer 10. The feed pipe 40 may be in fluid communication with the batch mixer 10.

[0136] The method for forming the particles 90 may include the steps of: providing a precursor material 20 to the feed pipe 40; entraining a gas into the precursor material 20, wherein the gas comprises from about 50% to about 75% carbon dioxide and from about 25% to about 50% other components; providing a dispenser 30 having a plurality of holes 60; conveying the precursor material 20 from the feed pipe 40 to the dispenser 30; passing the precursor material 20 through the holes 60; providing a movable conveying device 80 below the holes 60; depositing the precursor material 20 onto the movable conveying device 80; and cooling the precursor material 20 to form a plurality of particles 90.

[0137] The gas may be entrained in the precursor material 20 as a gas mixture. For example, the gas mixture may be directed into the precursor material 20 via a single gas feed line 155. The gas mixture may comprise from about 50 vol% to about 75 vol% carbon dioxide and from about 25 vol% to about 50 vol% other components. The mixture may be provided from a container 157 that houses the gas mixture. For example, the container 157 may be a gas cylinder filled with a desired gas that is a mixture of different gases.

[0138] Optionally, carbon dioxide may be provided from a main container 157a, while the other components of the gas may be provided from one or more secondary containers 157b ( Figure 4)。The main container 157a and the secondary container 157b can be fed into a single gas feed line 155. The flow regulator 158 can control the gas flow from the main container 157a and the secondary container 157b into the gas feed line 155. Optionally, an in-line mixer can be provided in or upstream of the gas feed line 155 to mix the gases from the main container 157a and the secondary container 157b.

[0139] The main container 157a can contain carbon dioxide. Other components of the gas can be provided from the secondary container 157b. Other components of the gas can be provided as air from the secondary container 157b. Air containers are readily commercially available. Similarly, carbon dioxide containers are readily commercially available. The operator of the apparatus 1 can obtain a carbon dioxide cylinder and an air cylinder and set the flow regulator 158 to provide the desired gas. Carbon dioxide and the other components of the gas can be combined into a single gas stream before being entrained into the precursor material 20.

[0140] Optionally, the main container 157a can be fed into the main gas feed line 155 and the secondary container 157b can be fed into the secondary gas feed line 155. The gas flow within each gas feed line 155 can be regulated by a flow regulator 158 dedicated to such a gas feed line 155.

[0141] In operation, it is feasible to provide the precursor material 20 in the feed tube at an operating pressure of about 2 bar to about 8 bar. The gas can be fed into the feed tube at a pressure higher than the operating pressure of the feed tube 40. The gas or its carbon dioxide component can be entrained at a pressure greater than about 3 bar to about 4 bar, or even greater than about 4 bar, or even greater than about 5 bar.

[0142] The solubility of carbon dioxide in the precursor material 20 can be greater than the solubility of most of the volumes of the other components of the gas. When carbon dioxide gas is fed into the stream of the precursor material 20 at the operating pressure, the carbon dioxide dissolves into the precursor material 20. The other components of the gas may or may not dissolve into the precursor material 20 at the operating pressure. Those components with low solubility relative to carbon dioxide in the precursor material 20 mainly remain in the precursor material 20 as bubbles.

[0143] As the current precursor material 20 passes through the orifice 60, the pressure drops towards or to atmospheric pressure. The precursor material 20 may also begin to cool. As the precursor material 20 travels from the orifice 60 to the movable conveyor 80, the precursor material 20 may continue to cool. Cooling continues after the precursor material 20 is deposited on the movable conveyor 80. Heat is removed from the precursor material 20 through the conveyor, and the side of the precursor material 20 in contact with the movable conveyor 80 begins to solidify. Similarly, after the precursor material 20 is deposited on the movable conveyor 80, the surface of the precursor material 20 continues to cool. Thus, the cooling of the precursor material 20 after deposition on the movable conveyor 80 is a three-dimensional time-dependent process.

[0144] As the molten precursor material 20 cools, a solidification front develops from the belt-facing side of the precursor material 20, and this solidification front advances away from the movable conveyor 80 over time. The air-facing side of the precursor material 20 (which is remote from the belt-facing surface of the precursor material) also cools over time. This results in a solidification front advancing from the air-facing surface towards the center of the particles on the movable conveyor 80 as the precursor material 20 cools.

[0145] If the gas entrained in the precursor material 20 is air, which is approximately 78 vol% nitrogen, approximately 21 vol% oxygen, approximately 0.93 vol% argon and approximately 0.03 vol% carbon dioxide, most of this gas has limited solubility in the precursor material 20 and air remains in the precursor material 20 as bubbles throughout the process of preparing the particles. This may limit the amount of air that can be entrained in the precursor material 20 and still allow the particles to have the desired stability and appearance. After the precursor material 20 is deposited on the movable belt, the buoyancy of the bubbles in the precursor material 20 and the solidification front advancing from the belt-facing side of the precursor material 20 tend to drive some of the bubbles away from the movable conveyor 80. As the bubbles are driven upwards, they may coalesce to form larger bubbles. Some bubbles may escape through the air-facing side of the precursor material 20. The escaped bubbles no longer contribute to the porosity of the particles 90. If a skin has formed on the air-facing side of the precursor material 20, the bubbles may burst through this skin, which may result in particles 90 with a physically unstable outer surface. A physically unstable outer surface is undesirable as this causes the particles to flake and makes the particles messy in use.

[0146] The problem with using air as the gas to be entrained is that when the precursor material 20 is deposited onto the movable belt, air bubbles are present in the precursor material 20 and the phenomenon described in the previous paragraph occurs, which can lead to unsatisfactory particles 90. Surprisingly, using a gas containing from about 50 vol% to about 75 vol% carbon dioxide can improve the ability of the precursor material 20 to retain air bubbles when the precursor material 20 cools on the movable conveyor device 80 to form the particles 90. This can result in the particles 90 having a higher porosity and fewer large air bubbles at or near the air-facing surface of the particles 90.

[0147] Compared to other gas components, carbon dioxide is relatively soluble in the precursor material 20. Gas components that are relatively insoluble in the precursor material 20 can exist as air bubbles. When the operating pressure on the precursor material is released to ambient pressure or near ambient pressure, carbon dioxide flows out of the solution. The process of carbon dioxide flowing out of the solution of the precursor material 20 is a time-dependent process. The air bubbles of gas components that are relatively insoluble in the precursor material 20 can serve as nucleation sites for the carbon dioxide to flow out of the solution of the precursor material. When the carbon dioxide flows out of the solution, the precursor material 20 is also cooling. As previously described, the solidification front can develop from the belt-facing side of the precursor material 20, and the air-facing side of the precursor material 20 is also solidifying. The solidifying or solidified precursor material 20 forms a barrier to the air bubbles escaping from the precursor material 20. As the carbon dioxide gradually flows out of the solution of the precursor material 20, air bubbles of carbon dioxide can be formed and / or the carbon dioxide can flow out of the solution into the existing air bubbles of the relatively insoluble gas components. The delayed formation of the carbon dioxide air bubbles or the expansion of the existing air bubbles of the relatively insoluble gas components when the carbon dioxide nucleates on such air bubbles allows for the formation of a larger volume of air bubbles in the precursor material 20. And these later-formed air bubbles are less likely to escape from the precursor material 20. Once the precursor material 20 is completely solidified, the formed particles 90 can have a large volume of voids.

[0148] Particle

[0149] The particles 90 that can be formed as described herein can comprise from about 25% to about 99% by weight of a water-soluble carrier. The particles 90 can also comprise from about 0.1% to about 20% by weight of a fabric care benefit active agent. Each particle 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.

[0150] The fabric care beneficial active agents may be optionally selected from the group consisting of: amines, surfactant systems, nonionic surfactants, water binders, sulfites, fatty acids and / or their salts, enzymes, encapsulated beneficial agents, detergency polymers, colorants, builders, chelating agents, dye transfer inhibitors, dispersants, enzyme stabilizers, catalytic materials, bleaches, bleach catalysts, bleach activators, polymeric dispersants, cyclodextrin complexed beneficial agents, soil release / antiredeposition agents, encapsulated fragrances, polymeric dispersants, polymeric grease cleaners, optical brighteners, foam suppressants, dyes, colorants, free fragrances, fabric stiffeners, fabric softeners, quaternary amines, hard and soft tallow, carriers, fillers, hydrotropes, organic solvents, antimicrobial agents and / or preservatives, neutralizing agents and / or pH regulators, processing aids, fillers, antioxidants, rheology modifiers or structurants, opacifiers, pearlescents, pigments, corrosion inhibitors and / or rust inhibitors, and mixtures thereof.

[0151] The fabric care beneficial active agents may be optionally selected from the group consisting of: antimicrobial agents, antioxidants, fragrances, fabric conditioners, dyes, dye fixatives, and combinations thereof. The fabric care beneficial active agent may be an unencapsulated fragrance or an encapsulated fragrance.

[0152] Each particle 90 may have a mass of about 5 mg to about 200 mg, optionally about 10 mg to about 100 mg, optionally about 20 mg to about 50 mg. The particles may have a hemispherical or compressed hemispherical shape.

[0153] The particles 90 may be prepared as follows. A batch of 50 kg of precursor material 20 may be prepared in a mixer. Molten PEG8000 may be added to a jacketed mixer maintained at 70 °C and stirred with an inclined blade paddle at 125 rpm. Butylated hydroxytoluene may be added to the mixer in an amount of about 0.01% by weight of the precursor material 20. An aqueous slurry of fragrance microcapsules may be added to the mixer in an amount of about 4% by weight of the precursor material 20. Unencapsulated fragrance may be added to the mixer in an amount of about 8% by weight of the precursor material 20. Dye may be added to the mixer in an amount of about 0.01% by weight of the precursor material 20. PEG may make up the balance by weight of the precursor material 20. The precursor material 20 may be mixed for 30 minutes.

[0154] The precursor material 20 may be formed into particles 90 on 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, which are arranged at a pitch of 10 mm in the transverse CD and at a pitch of 9.35 mm in the longitudinal MD. The cylinder may be disposed approximately 3 mm above the belt. The belt speed and the rotational speed of the cylinder 110 may be set to 10 m / min.

[0155] After mixing the precursor material 20, the precursor material 20 can be pumped from the mixer 10 through a plate and frame heat exchanger at a constant rate of 3.1 kg / min or even 4 kg / min, and the plate and frame heat exchanger is configured to control the outlet temperature to 50 °C. The pressure in the feed pipe 40 downstream of the pump 140 can be from about 2 bar to about 7 bar, and optionally about 5.5 bar or about 5 bar, and this pressure is the pressure in the feed pipe 40 downstream of the grinder 200.

[0156] Gas can be entrained in the precursor material 20, where the volume flow rate ratio of the precursor material to the gas is from about 1.3:1 to about 2.6:1, or even from about 1.3:1 to about 1.6:1. The pressure of the gas in the gas feed line 155 must be higher than the pressure in the feed pipe 40 to ensure gas flow and entrainment 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 a mixture of carbon dioxide and other insoluble gases.

[0157] Wherein the precursor material 20 entrained with gas can pass through a Quadro Z1 grinder with a medium rotor / stator element. After grinding, the precursor material can optionally pass through a Kenics 1.905 cm KMS 6 static mixer 50 installed 91.44 cm upstream of the stator 100 of the rotary forming device.

[0158] Combination :

[0159] A method for forming particles, the method comprising the following steps:

[0160] a. Providing a precursor material (20) to a feed pipe (40);

[0161] b. Entraining a gas into the precursor material, wherein the gas comprises about 50 vol% to about 75 vol% carbon dioxide and about 25 vol% to about 50 vol% of other components;

[0162] c. Providing a dispenser (30) comprising a plurality of holes (60);

[0163] d. Transferring the precursor material (20) from the feed pipe to the dispenser;

[0164] e. Passing the precursor material through the holes;

[0165] f. Providing a movable conveyor (80) below the holes;

[0166] g. Depositing the precursor material onto the movable conveyor; and

[0167] h. Cool the precursor material to form a plurality of particles (90).

[0168] B. The method according to paragraph A, wherein the dispenser comprises:

[0169] a. A stator (100) that is in fluid communication with the feed pipe;

[0170] b. A cylinder (110) that is rotatably mounted around the stator and is capable of rotating around the longitudinal axis (L) of the cylinder, wherein the cylinder has a perimeter (120) and the cylinder comprises the plurality of holes disposed around the perimeter, wherein the holes are intermittently in fluid communication with the stator as the cylinder rotates around the stator.

[0171] C. The method according to paragraph A or B, the method further comprising the step of: grinding the precursor material after the step of entraining the gas into the precursor material.

[0172] D. The method according to paragraph C, wherein the step of grinding the precursor material after the step of entraining the gas into the precursor material is performed using an in-line rotor-stator grinder.

[0173] E. The method according to any one of paragraphs A to D, wherein the gas is entrained as a gas mixture.

[0174] F. The method according to paragraph E, wherein the gas mixture is from a container containing the mixture of the gases.

[0175] G. The method according to any one of paragraphs A to E, wherein the carbon dioxide is provided from a main container (157a), and the other components of the gas are provided from one or more secondary containers (157b).

[0176] H. The method according to paragraph G, wherein the carbon dioxide and the other components of the gas are combined into a single stream of the gas before being entrained into the precursor material.

[0177] I. The method according to paragraph H, wherein the other components of the gas are provided as air from the secondary container.

[0178] J. The method according to any one of paragraphs A to I, wherein the carbon dioxide is entrained at a minimum flow rate of about 0.5 liters per minute at a pressure greater than 2 bar.

[0179] K. The method according to any one of paragraphs A to J, wherein the solubility of more than 50 volume % of the other components in the precursor material is less than that of the carbon dioxide.

[0180] L. A method according to any one of paragraphs A to K, wherein the precursor material comprises more than about 20% by weight of a water-soluble polymer.

[0181] M. A method according to paragraph L, wherein the water-soluble polymer is selected from the group consisting of:

[0182] 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, where x is from 50 to 300, y is from 20 to 100, and z is from 10 to 200;

[0183] b. A polyethylene glycol fatty acid ester of the formula (C 2 H 4 O) q -C(O)O-(CH 2 ) r -CH 3 , where q is from 20 to 200, and r is from 10 to 30;

[0184] c. A polyethylene glycol fatty alcohol ether of the formula HO-(C 2 H 4 O) s -(CH 2 ) t )-CH 3 , where s is from 30 to 250, and t is from 10 to 30;

[0185] d. A C8-C22 alkyl polyalkoxylate containing more than 40 alkoxylate units;

[0186] e. Polyethylene glycol having a weight-average molecular weight of from 2000 to 15000;

[0187] f. An EO / PO / EO block copolymer;

[0188] g. A PO / EO / PO block copolymer;

[0189] h. An EO / PO block copolymer;

[0190] i. A PO / EO block copolymer;

[0191] j. Polypropylene glycol;

[0192] k. An ethoxylated nonionic surfactant having an ethoxylation degree greater than 30;

[0193] l. Polyvinyl alcohol;

[0194] m. A polyalkylene glycol having a weight-average molecular weight of from 2,000 to 15,000; and mixtures thereof.

[0195] N. A method 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 2,000 to about 13,000.

[0196] O. A method according to any one of paragraphs A to N, wherein the precursor material comprises more than about 40% by weight of polyethylene glycol.

[0197] P. A method according to any one of paragraphs A to O, wherein the particles have an individual mass of between about 0.1 mg and about 2 mg.

[0198] Q. A method 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.

[0199] R. A method according to paragraph Q, wherein the fragrance comprises an encapsulated fragrance.

[0200] S. A method according to paragraph Q, wherein the fragrance comprises an encapsulated fragrance and an unencapsulated fragrance.

[0201] T. A method 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.

[0202] U. A method according to any one of paragraphs A to T, wherein the step of cooling the precursor material is carried out by ambient cooling.

[0203] V. A method according to any one of paragraphs A to U, wherein the precursor material is provided from a batch mixer (10) to the feed pipe.

[0204] W. A method according to any one of paragraphs A to V, wherein the other components are selected from the group consisting of oxygen, nitrogen, argon, and mixtures thereof.

[0205] X. A method 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, detergency polymers, colorants, builders, chelating agents, dye transfer inhibitors, dispersants, enzyme stabilizers, catalytic substances, bleaches, bleach catalysts, bleach activators, polymeric dispersants, cyclodextrin complexed benefit agents, soil release / antiredeposition agents, encapsulated fragrances, polymeric dispersants, polymeric grease cleaners, optical brighteners, foam suppressants, dyes, colorants, free fragrances, structural elasticizers, fabric softeners, quaternary amines, hard and soft butters, carriers, fillers, hydrotropes, organic solvents, antimicrobials and / or preservatives, neutralizing agents and / or pH regulators, processing aids, fillers, antioxidants, rheology modifiers or structurants, opacifiers, pearlescents, pigments, corrosion inhibitors and / or rust inhibitors, and mixtures thereof.

[0206] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, 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".

[0207] Unless expressly excluded or otherwise limited, each document cited herein, including any cross-referenced or related patent or patent application and any patent application or patent to which this application claims priority or its benefit, is hereby incorporated by reference in its entirety. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any one or more other references, teaches, suggests or discloses any such invention. Further, when any meaning or definition of a term in this invention conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to the term in this invention shall govern.

[0208] 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 that fall within the scope of the invention be covered by the appended claims.

Claims

1. A method for forming particles, the method comprising the steps of: providing a precursor material (20) to a feed pipe (40), wherein the precursor material comprises more than 20% by weight of a water-soluble polymer; entraining a gas into the precursor material, wherein the gas comprises 50 vol% to 75 vol% of carbon dioxide and 25 vol% to 50 vol% of other components, and wherein more than 50 vol% of the other components have a lower solubility in the precursor material than the carbon dioxide; providing a dispenser (30) comprising a plurality of holes (60); transferring the precursor material (20) from the feed 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; and cooling the precursor material to form a plurality of particles (90).

2. The method according to claim 1, wherein the dispenser comprises: a stator (100) in fluid communication with the feed pipe; a cylinder (110) rotatably mounted around the stator and capable of rotating about the longitudinal axis (L) of the cylinder, wherein the cylinder has a perimeter (120) and the cylinder comprises the plurality of holes disposed around the perimeter, and wherein the holes are intermittently in fluid communication with the stator as the cylinder rotates around the stator.

3. The method according to claim 1 or claim 2, the method further comprising the steps of: grinding the precursor material after the step of entraining the gas into the precursor material.

4. The method according to claim 1, wherein the gas is entrained as a gas mixture.

5. The method according to claim 4, wherein the gas mixture is from a container containing the mixture of the gas.

6. The method according to claim 1, wherein the carbon dioxide is provided from a main container (157a), and the other components of the gas are provided from one or more secondary containers (157b).

7. The method according to claim 6, wherein the carbon dioxide and the other components of the gas are combined into a single stream of the gas before being entrained into the precursor material.

8. The method according to claim 7, wherein the other components of the gas are provided as air from the secondary container.

9. The method according to claim 1, wherein the carbon dioxide is entrained at a minimum flow rate of 0.5 liters per minute at a pressure greater than 2 bar.

10. The method according to claim 1, wherein the water-soluble polymer is selected from: 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 50 to 300, y is from 20 to 100, and z is from 10 to 200; Formula (C 2 H 4 O) q -C(O)O-(CH 2 ) r -CH 3 Polyethylene glycol fatty acid esters, where q is from 20 to 200 and r is from 10 to 30; The polyethylene glycol fatty alcohol ether of the formula HO-(C 2 H 4 O) s -(CH 2 ) t -CH 3 where s is from 30 to 250 and t is from 10 to 30; C8-C22 alkyl polyalkoxylates containing more than 40 alkoxylate units; polyethylene glycols having a weight average molecular weight of 2000 to 15000; EO / PO / EO block copolymers; PO / EO / PO block copolymers; EO / PO block copolymers; PO / EO block copolymers; polypropylene glycols; ethoxylated nonionic surfactants having an ethoxylation degree greater than 30; polyvinyl alcohols; Polyalkylene glycols having a weight-average molecular weight of from 2,000 to 15,000; and mixtures thereof.

11. The method according to claim 1, wherein the precursor material comprises polyethylene glycol having a weight-average molecular weight of from 2,000 to 13,000.

12. The method according to claim 1, wherein the precursor material comprises from 0.1% to 20% by weight of a perfume.

13. The method according to claim 1, wherein the step of cooling the precursor material is effected by ambient cooling.

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