Method for making an article

Abstract

The present invention provides a method for preparing an article comprising a fibrous structure, such as a continuous method, and more particularly to a method for preparing an article comprising a fibrous structure, such as a soluble fibrous structure comprising soluble filaments.

Description

[0001] Case Analysis

[0002] This application is a divisional application of patent application No. 201980006960.X, filed on January 22, 2019, entitled “Method for Preparing an Article,” which is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention relates to a method, for example a continuous method for preparing an article comprising a fibrous structure, and more specifically to a method for preparing an article comprising a fibrous structure, such as a soluble fibrous structure comprising soluble filaments, for example water-soluble filaments. Background Technology

[0004] Methods for preparing fibrous structures (e.g., soluble fibrous structures) and / or their components (such as soluble filaments) are known in the art. Furthermore, the fibrous structures and / or their components are ultimately incorporated into articles (such as consumer products), e.g., fabric care products, hair care products, dental care products, etc. However, to date, such known methods have been discontinuous. In other words, such known methods involve at least two or more discrete (discontinuous) steps or unit operations that interrupt the process of preparing the article; for example, one or more steps in manufacturing the fibrous structure are separated and / or discontinuous from one or more steps in converting the prepared fibrous structure into an article (e.g., a consumer product). Such discontinuous / discontinuous methods may include one or more of the following steps: 1) a filament forming composition preparation step, such as an intermittent method for preparing a filament forming composition; 2) a spinning step for spinning the filament forming composition to prepare filaments, such as soluble filaments; 3) optionally, a mixing (co-forming) step for mixing solid additives (e.g., particles) with the filaments; 4) a collection step for collecting the filaments and / or the mixed filaments and solid additives on a collection device to form a fibrous structure (e.g., a soluble fibrous structure); 5) a conversion processing operation (one or more steps for converting the fibrous structure (e.g., cutting and / or stacking and / or calendering and / or treating with trace components such as fragrances, enzymes, bleaching agents, flavoring agents, effervescent agents, etc., punching and printing) into one or more articles (e.g., consumer products); and 6) optionally, a packaging step for packaging articles.

[0005] One problem faced by formulation engineers is determining how to prepare such articles, including fibrous structures (e.g., soluble fibrous structures), in a continuous or more continuous manner than known discontinuous methods. In other words, a problem faced by formulation engineers is how to combine multiple method steps from the above into a continuous method so that they are not discrete, discontinuous method steps.

[0006] Therefore, there is a need for a method for preparing articles, such as consumer products, in a continuous or at least partially continuous manner, the articles comprising fibrous structures, such as soluble fibrous structures. Summary of the Invention

[0007] The present invention satisfies the above-mentioned need by providing a continuous method and / or continuous method steps within the method to prepare articles, such as consumer products comprising fibrous structures, such as soluble fiber structures.

[0008] One solution to the above problem is to provide a method for preparing articles, such as consumer products, in a continuous or semi-continuous manner, the articles comprising fibrous structures, such as soluble fibrous structures. Such continuous methods include at least the following steps: 1) a filament forming composition preparation step for preparing a filament forming composition; 2) a spinning step for spinning the filament forming composition to prepare a filament, such as a soluble filament; 3) optionally, a mixing (co-forming) step for mixing a solid additive (e.g., particles) with the filament; and 4) a collection step for collecting the filament and / or the mixed filament and solid additive on a collection device to form a fibrous structure (e.g., a soluble fibrous structure), wherein steps (1-4) are carried out continuously when present, one step after the next, without any interruption, pause or interruption: from the preparation of the filament forming composition to spinning the filament forming composition into a filament (optionally mixing the solid additive with the filament) to collecting the filament (and / or the mixed filament and solid additive) on a collection device to form a fibrous structure, which can then be converted into articles and finally packaged, for example, consumer product packaging. The continuous method may also include 5) a conversion processing operation (one or more steps for converting the fiber structure into one or more articles (e.g., cutting and / or stacking and / or calendering and / or treating with trace components such as fragrances, enzymes, bleaching agents, flavoring agents, effervescent agents, etc., punching and printing) into one or more articles (e.g., consumer products); and 6) a packaging step, optionally for packaging articles.

[0009] This invention provides a continuous method for preparing fiber structures and final products.

[0010] In one example of the present invention, a method for preparing a fiber structure is provided, the method comprising the following steps: a. Provide one or more soluble filament forming materials; b. Forming an aqueous composition comprising one or more soluble filament-forming materials; c. Processing the aqueous composition to prepare a filament forming composition; d. Delivering the filament forming composition to one or more dies; e. A spinning filament forming composition to form multiple soluble filaments; and f. Collect soluble filaments on a collecting device to form a fibrous structure.

[0011] In one example, one or more active agents may be added in at least one of steps b, c, and d of the method. Attached Figure Description

[0012] Figure 1 A schematic diagram illustrating an example of the method according to the present invention; Figure 2 A schematic diagram illustrating one example of a method according to the present invention; Figure 3 A schematic diagram of an example extruder screw suitable for use with the method according to the present invention; Figure 4 A schematic diagram illustrating one example of a method according to the present invention; Figure 5 This is a top plan view of a die head suitable for use with the method according to the present invention.

[0013] Figure 6 A schematic diagram illustrating an example of a method according to the invention; and

[0014] Figure 7 A schematic diagram of an example collection area on a collection device applicable to the method according to the invention. Detailed Implementation

[0015] definition

[0016] As used herein, "fiber structure" means a structure comprising one or more filaments and optionally one or more particles. In one example, the fiber structure according to the invention refers to the association of filaments and optionally particles that together form a functional structure such as an integral structure.

[0017] The fiber structure of the present invention can be single-layered or multi-layered. If multi-layered, the fiber structure may include at least two and / or at least three and / or at least four and / or at least five and / or at least six layers, such as one or more filament layers, one or more particle layers, and / or one or more composite structural layers having a mixture of filaments and particles. Layers may include particle layers within or between filament layers within the fiber structure. Layers comprising filaments may sometimes be referred to as sheets. Sheets may be fiber structures, which may be single-layered or multi-layered as described herein. In one example, a layer may be formed by a single spinning die and / or particle delivery source, or if the layer is a composite structural layer, it may be formed by a single spinning die and particle delivery source.

[0018] In one example, the fiber structure of the present invention may comprise a single layer or multiple layers, wherein at least one layer must comprise fibers. The layers may include additives (e.g., pastes or sprays) applied to the fibers and / or particles mixed with the fibers in the composite structure.

[0019] In one example, the single-layer fiber structure according to the invention or the multilayer fiber structure according to the invention comprising one or more fiber structure sheets can exhibit a basis weight of less than 5000 g / m² as measured by the basis weight test method described herein. 2 The basis weight. In one example, the single-layer or multi-layer fiber structure according to the invention can exhibit a basis weight greater than 10 g / m², as measured by the basis weight test method. 2 Approximately 5000g / m 2 and / or greater than 10 g / m 2 Approximately 3000g / m 2 and / or greater than 10 g / m 2 Approximately 2000g / m 2 and / or greater than 10 g / m 2 Approximately 1000g / m 2 and / or greater than 20 g / m 2 Approximately 800g / m 2 and / or greater than 30 g / m 2 Approximately 600g / m 2 and / or greater than 50 g / m 2 Approximately 500g / m 2 and / or greater than 300g / m 2 Approximately 3000g / m 2 and / or greater than 500g / m 2 Approximately 2000g / m 2 The base weight.

[0020] In one example, a single sheet comprising a multilayer fiber structure includes a first layer and a second layer. The first layer, for example, is a loosely woven layer comprising multiple filaments present on a basis weight of about 10 gsm to about 200 gsm and / or about 30 gsm to about 100 gsm and / or about 50 gsm to about 75 gsm. The second layer, for example, is a layer comprising multiple filaments alone or a composite structural layer comprising filaments and solid additives such as particles, present on a basis weight of about 400 gsm to about 3000 gsm and / or about 600 gsm to about 1500 gsm and / or about 800 gsm to about 1200 gsm.

[0021] In one example, the fiber structure of the present invention is a "monolithic fiber structure".

[0022] As used herein, a “monolithic fiber structure” refers to an arrangement comprising multiple groups of two or more and / or three or more filaments entangled or otherwise associated with each other to form a fiber structure and / or fiber structure sheets. The monolithic fiber structure of the present invention may be one or more sheets within a multilayer sheet fiber structure. In one example, the monolithic fiber structure of the present invention may include three or more different filaments. In another example, the monolithic fiber structure of the present invention may include two or more different filaments.

[0023] As used herein, “article” means a consumer use unit, a consumer unit dose unit, a consumer use commercially available unit, a single dose unit, or other use form that includes an integral fiber structure and / or includes one or more fiber structures of the present invention.

[0024] As used herein, a "fiber element" refers to a long, thin particle whose length greatly exceeds its average diameter, i.e., the ratio of its length to its average diameter is at least about 10. A fiber element can be a filament or a fiber. In one example, the fiber element is a single filament rather than a yarn comprising multiple filaments.

[0025] The fiber elements of the present invention can be spun from a fiber element forming composition (also known as a filament forming composition) by means of a suitable spinning process, such as meltblowing, spunbonding, electrospinning and / or rotational spinning.

[0026] The fiber element of the present invention can be single-component (a single, integral solid rather than two different parts, such as a core / shell bicomponent) and / or multi-component. For example, the fiber element may comprise bicomponent fibers and / or filaments. The bicomponent fibers and / or filaments may be in any form, such as side-by-side, core-sheath, island-of-the-sea, etc.

[0027] As used herein, “filament” refers to the elongated particles described above, exhibiting a length greater than or equal to 5.08 cm (2 in.) and / or greater than or equal to 7.62 cm (3 in.) and / or greater than or equal to 10.16 cm (4 in.) and / or greater than or equal to 15.24 cm (6 in.).

[0028] Filaments are generally considered to be substantially continuous or substantially continuous. Filaments are relatively longer than fibers. Non-limiting examples of filaments include meltblown and / or spunbond filaments. Non-limiting examples of polymers that can be spun into filaments include natural polymers (such as starch, starch derivatives, cellulose such as rayon and / or lyocell fibers and cellulose derivatives, hemicellulose, hemicellulose derivatives) and synthetic polymers (including but not limited to polyvinyl alcohol and thermoplastic polymer filaments such as polyester, nylon, polyolefins (such as polypropylene filaments, polyethylene filaments), and biodegradable thermoplastic fibers such as polylactic acid filaments, polyhydroxyalkanoate filaments, polyesteramide filaments, and polycaprolactone filaments).

[0029] As used herein, “fiber” refers to elongated particles as described above, exhibiting lengths of less than 5.08 cm (2 in.) and / or less than 3.81 cm (1.5 in.) and / or less than 2.54 cm (1 in.).

[0030] Fibers are generally considered to be substantially discontinuous. Non-limiting examples of fibers include short fibers, which are prepared by spinning the filaments or filament bundles of the present invention and then cutting the filaments or filament bundles into segments less than 5.08 cm (2 inches).

[0031] In one example, one or more fibers may be formed from the filaments of the present invention, such as when the filaments are cut to shorter lengths (e.g., less than 5.08 cm). Therefore, in one example, the present invention also includes fibers made from the filaments of the present invention, such as fibers comprising one or more filament-forming materials and one or more fiber auxiliaries such as surfactants. Therefore, unless otherwise specified, the filaments and / or filaments involved in the present invention also include fibers made from such filaments and / or filaments. Fibers are generally considered to be substantially discontinuous, as opposed to filaments that are considered substantially continuous.

[0032] As used herein, "fiber element forming composition" and / or "filament forming composition" means a composition suitable for preparing filaments of the present invention, such as by meltblowing and / or spunbonding. A filament forming composition comprises one or more filament forming materials that exhibit properties that make them suitable for spinning into filaments. In one example, the filament forming material comprises a polymer. In addition to one or more filament forming materials, the filament forming composition may also contain one or more fiber auxiliaries, such as one or more surfactants. Furthermore, the filament forming composition may contain one or more polar solvents such as water, in which one or more (e.g., all) of the filament forming material and / or one or more (e.g., all) of the surfactants are dissolved and / or dispersed prior to spinning the filament (such as a filament spun from a filament forming composition).

[0033] In one example, the filament produced from the filament forming composition of the present invention is a filament in which one or more fiber auxiliaries, such as one or more surfactants, may be present in the filament rather than on it, such as a coating composition containing one or more surfactants (which may be the same as or different from the surfactants in the filament and / or particles). The total content of the filament forming material and the total content of the surfactants present in the filament forming composition can be any suitable amount, provided that the filament of the present invention is produced therefrom.

[0034] In one example, one or more fiber auxiliaries, such as surfactants, may be present in the filament, and one or more additional fiber auxiliaries, such as surfactants, may be present on the surface of the filament. In another example, the filament of the present invention may contain one or more fiber auxiliaries, such as surfactants, which are present in the filament when initially manufactured, but subsequently released to the filament surface before and / or upon exposure to the intended use conditions of the filament.

[0035] As used herein, "fiber element forming material" and / or "filament forming material" means a material exhibiting properties suitable for the preparation of filaments, such as a polymer or a monomer capable of producing a polymer. In one example, the filament forming material comprises one or more substituted polymers such as anionic, cationic, amphoteric, and / or nonionic polymers. In another example, the polymer may comprise hydroxyl polymers such as polyvinyl alcohol ("PVOH"), partially hydrolyzed polyvinyl acetate and / or polysaccharides such as starch and / or starch derivatives, such as ethoxylated starch and / or acid-hydrolyzed starch, carboxymethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, and methyl cellulose. In another example, the polymer may comprise polyethylene and / or terephthalic acid. In yet another example, the filament forming material is soluble in polar solvents.

[0036] As used herein, “particle” refers to solid additives such as powders, granules, agglomerates, capsules, microcapsules, and / or spheres. Particles can be spherical, rod-shaped, plate-shaped, tubular, square, rectangular, disc-shaped, star-shaped, fibrous, or have a regular or irregular random shape. The particles of the present invention (at least 44 µm) can be measured using the particle size distribution testing methods described herein. For particles smaller than 44 µm, different testing methods, such as light scattering, can be used to determine particle sizes smaller than 44 µm; for example, the particle size of fragrance microcapsules is typically in the range of about 15 µm to about 44 µm and / or about 25 µm.

[0037] In one aspect, the particles may comprise recycled fibrous structural material, specifically wherein the fibrous material is recycled by grinding fibers into fine solids and then re-incorporating the fine solids into agglomerates, particles, or other particulate forms. In another aspect, the particles may comprise recycled fibrous structural material, specifically wherein the fibrous material is incorporated into a fluid paste, suspension, or solution and then processed to form agglomerates, particles, or other particulate forms. In yet another aspect, the fluid paste, suspension, or solution containing recycled fibrous material may be applied directly to the fiber layer during the preparation of a new fibrous article.

[0038] As used herein, “active agent-containing particles” refers to solid additives such as particles that contain one or more active agents. In one example, active agent-containing particles are active agents in granular form (in other words, the particles contain 100% of one or more active agents). Active agent-containing particles may exhibit a particle size of 5000 µm or smaller as measured by the particle size distribution testing methods described herein.

[0039] In one example of the invention, the fiber structure comprises a plurality of particles, such as particles containing an active agent (e.g., particles containing at least one active agent), and a plurality of filaments, wherein the weight ratio of the particles, such as particles containing an active agent, to the filaments is 1:100 or greater, and / or 1:50 or greater, and / or 1:10 or greater, and / or 1:3 or greater, and / or 1:2 or greater, and / or 1:1 or greater, and / or 2:1 or greater, and / or 3:1 or greater, and / or 4 :1 or greater, and / or 5:1 or greater, and / or 7:1 or greater, and / or 8:1 or greater, and / or 10:1 or greater, and / or about 10:1 to about 1:100, and / or about 8:1 to about 1:50, and / or about 7:1 to about 1:10, and / or about 7:1 to about 1:3, and / or about 6:1 to 1:2, and / or about 5:1 to about 1:1, and / or about 4:1 to about 1:1, and / or about 3:1 to about 1.5:1.

[0040] In another example of the invention, the fiber structure comprises a plurality of particles, such as particles containing an active agent, and a plurality of filaments, wherein the weight ratio of the particles, such as particles containing an active agent, to the filaments is about 20:1 to about 1:1, and / or about 10:1 to about 1:1, and / or about 10:1 to about 1.5:1, and / or about 8:1 to about 1.5:1, and / or about 8:1 to about 2:1, and / or about 7:1 to about 2:1, and / or about 7:1 to about 3:1, and / or about 6:1 to about 2.5:1.

[0041] In another example of the invention, the fiber structure comprises a plurality of particles, such as particles containing an active agent, and a plurality of filaments, wherein the weight ratio of the particles, such as particles containing an active agent, to the filaments is about 1:1 to about 1:100, and / or about 1:15 to about 1:80, and / or about 1:2 to about 1:60, and / or about 1:3 to about 1:50, and / or about 1:3 to about 1:40.

[0042] In another example, the fiber structure of the present invention comprises a plurality of particles, such as particles containing an active agent, wherein the basis weight of the particles is greater than 1 g / m², as measured by the basis weight test method described herein. 2 and / or greater than 10 g / m 2 and / or greater than 20 g / m 2 and / or greater than 30g / m 2 and / or greater than 40 g / m2 and / or about 1g / m 2 Approximately 5000g / m 2 and / or approximately 3500 g / m 2 and / or approximately 2000 g / m 2 and / or about 1g / m 2 Approximately 2000g / m 2 and / or approximately 10g / m 2 Approximately 1000g / m 2 and / or approximately 10g / m 2 Approximately 500g / m 2 and / or approximately 20g / m 2 Approximately 400g / m 2 and / or approximately 30g / m 2 Approximately 300g / m 2 and / or approximately 40g / m 2 Approximately 200g / m 2 .

[0043] In another example, the fiber structure of the present invention comprises multiple filaments, the basis weight of which, as measured by the basis weight test method described herein, is greater than 1 g / m². 2 and / or greater than 10 g / m 2 and / or greater than 20 g / m 2 and / or greater than 30 g / m 2 and / or greater than 40 g / m 2 and / or about 1g / m 2 Approximately 3000g / m 2 and / or approximately 10g / m 2 Approximately 5000g / m 2 and / or approximately 3000 g / m 2 and / or approximately 2000 g / m 2 and / or about 20g / m 2 Approximately 2000g / m 2 and / or approximately 30g / m 2 Approximately 1000g / m 2 and / or approximately 30g / m 2 Approximately 500g / m 2 and / or approximately 30g / m 2 Approximately 300g / m 2 and / or approximately 40g / m 2 Approximately 100g / m 2 and / or approximately 40g / m 2 Approximately 80g / m 2 In one example, the fiber structure comprises two or more layers, wherein the filaments are spaced at approximately 1 g / m². 2Approximately 500g / m 2 The basic weight exists in at least one of the layers.

[0044] As used herein, "mixed" and / or "mixed" refers to a state or form in which particles are mixed with fibrous elements such as filaments. The mixture of filaments and particles may be distributed throughout the composite structure or within a plane or region of the composite structure. In one example, the mixed filaments and particles may form at least one surface of the composite structure. In one example, the particles may be uniformly dispersed throughout the composite structure and / or within a plane and / or region of the composite structure. In one example, the particles may be uniformly distributed throughout the composite structure, which avoids and / or prevents particles within the composite structure from sinking and / or moving freely and / or migrating to other areas within the composite structure, thereby creating areas of higher particle concentration and areas of lower particle concentration or zero particle concentration within the composite structure. In one example, a µCT cross-section of the composite structure may show whether the particles are uniformly distributed throughout the composite structure.

[0045] As used herein, "fiber auxiliaries" refers to any material present in the filaments of the present invention, which is not a filament-forming material. In one example, a fiber auxiliary comprises an active agent. In another example, a fiber auxiliaries comprises a processing aid. In yet another example, a fiber auxiliaries comprises a filler. In one example, a fiber auxiliaries include any material present in the filaments whose absence would not cause the filaments to lose their filament structure; in other words, their absence would not cause the filaments to lose their solid form. In another example, fiber auxiliaries, such as active agents, comprise non-polymer materials.

[0046] In another example, the fiber auxiliaries may contain plasticizers for the filaments. Non-limiting examples of suitable plasticizers for this invention include polyols, copolyols, polycarboxylic acids, polyesters, and polydimethylsiloxane copolyols. Examples of usable polyols include, but are not limited to, glycerol, diglycerol, propylene glycol, ethylene glycol, butanediol, pentanediol, cyclohexanediol, hexanediol, 2,2,4-trimethylpentane-1,3-diol, polyethylene glycol (200-600), pentaerythritol, sugar alcohols such as sorbitol, mannitol, lactitol, and other mono- and poly-low molecular weight alcohols (e.g., C2-C8 alcohols); monosaccharides, disaccharides, and oligosaccharides, such as fructose, glucose, sucrose, maltose, lactose, and high-fructose corn syrup solids, and dextrin, and ascorbic acid.

[0047] In one example, the plasticizer includes glycerol and / or propylene glycol and / or glycerol derivatives such as propoxylated glycerol. In another example, the plasticizer is selected from: glycerol, ethylene glycol, polyethylene glycol, propylene glycol, glycidyl ether, urea, sorbitol, xylitol, maltitol, sugar, vinylidene dimethylformamide, amino acids, and mixtures thereof.

[0048] In another example, the fiber auxiliaries may comprise rheology modifiers, such as shear modifiers and / or stretch modifiers. Non-limiting examples of rheology modifiers include, but are not limited to, polyacrylamide, polyurethane, and polyacrylates, which can be used in the filaments of this invention. Non-limiting examples of rheology modifiers are commercially available from The Dow Chemical Company (Midland, MI).

[0049] In another example, the fiber auxiliaries may contain one or more colorants and / or dyes, which are incorporated into the filaments of the present invention to provide visual signals when the filaments are exposed to the intended use conditions and / or when the active agent is released from the filaments and / or when the morphology of the filaments changes.

[0050] In another example, the fiber auxiliaries may comprise one or more release agents and / or lubricants. Non-limiting examples of suitable release agents and / or lubricants include fatty acids, fatty acid salts, fatty alcohols, fatty acid esters, sulfonated fatty acid esters, fatty amine acetates, fatty acid amides, siloxanes, aminosiloxanes, fluoropolymers, and mixtures thereof. In one example, the release agent and / or lubricant may be applied to the filament, in other words, after the filament has been formed. In one example, one or more release agents / lubricants may be applied to the filament before it is collected on a collection device to form a fiber structure. In another example, one or more release agents / lubricants may be applied to the fiber structure formed from the filaments of the present invention before contact with one or more fiber structures, such as in a stack of fiber structures. In another example, one or more release agents / lubricants may be applied to the filaments of the present invention and / or the fiber structure containing the filaments before the filaments and / or the fiber structure contact a surface, such as the surface of a device used in a processing system, thereby facilitating the removal of the filaments and / or the fiber structure and / or preventing the layers of the filaments and / or the sheets of the fiber structure of the present invention from adhering to each other, even unintentionally. In one example, the stripper / lubricant contains microparticles.

[0051] In another example, the fiber auxiliaries may contain one or more anti-blocking agents and / or non-sticking agents. Non-limiting examples of suitable anti-blocking agents and / or non-sticking agents include starch, starch derivatives, croscarmellose, croscarmellose, microcrystalline cellulose, silica, metal oxides, calcium carbonate, talc, mica, and mixtures thereof.

[0052] As used herein, "intended use conditions" refers to the temperature, physical, chemical, and / or mechanical conditions that the filament and / or particle and / or fiber structure of the present invention is exposed to when used for one or more of its designed purposes. For example, if the filament and / or particle and / or fiber structure containing filaments is designed for use in a washing machine for laundry care purposes, the intended use conditions would include those temperature, chemical, physical, and / or mechanical conditions present in the washing machine during laundry operation, including any wash water. In another example, if the filament and / or particle and / or fiber structure containing filaments is designed for human use in a shampoo for hair care purposes, the intended use conditions would include those temperature, chemical, physical, and / or mechanical conditions present during the washing of human hair with the shampoo. Similarly, if filaments and / or particles and / or fiber structures containing filaments are designed for dishwashing operations by hand or by dishwasher, the expected conditions of use will include those temperature, chemical, physical, and / or mechanical conditions present in the dishwashing water and / or dishwasher during the dishwashing operation.

[0053] As used herein, "surfactant" refers to a fiber auxiliaries that produce a desired effect in an environment outside the filaments and / or granules and / or fiber structures containing the filaments of the present invention, when the filaments and / or granules and / or fiber structures are exposed to the intended conditions of use of the filaments and / or granules and / or fiber structures containing the filaments. In one example, the surfactant comprises fiber auxiliaries that treat surfaces such as hard surfaces (i.e., kitchen countertops, bathtubs, washrooms, toilets, sinks, floors, walls, teeth, vehicles, windows, mirrors, dishes) and / or soft surfaces (i.e., fabrics, hair, skin, carpets, crops, plants). In another example, the surfactant comprises additional fiber auxiliaries that produce a chemical reaction (i.e., foaming, bubbling, effervescent, coloring, heating, cooling, bubbling, disinfecting and / or clarifying and / or chlorinating, such as in clarified water and / or disinfected water and / or chlorinated water). In yet another example, the surfactant comprises fiber auxiliaries that treat an environment (i.e., deodorizing, purifying, scenting air). In one example, the surfactant may be formed in situ during the formation of filaments and / or particles containing the surfactant. For example, the filaments and / or particles may contain water-soluble polymers (e.g., starch) and surfactants (e.g., anionic surfactants), which may produce polymer complexes or aggregates that act as surfactants for treating fabric surfaces.

[0054] As used herein, “treatment” relative to treated surface refers to the beneficial effects that a surfactant provides to a surface or environment. Treatment includes modulating and / or immediately improving the appearance, cleanliness, odor, purity, and / or feel of a surface or environment. In one example, treatment involving the treatment of keratinized tissue (e.g., skin and / or hair) surfaces refers to modulating and / or immediately improving the cosmetic appearance and / or feel of the keratinized tissue. For example, “modulating the condition of skin, hair, or fingernails / toenails (keratinized tissue)” includes: thickening the skin, hair, or fingernails / toenails (e.g., the epidermis and / or dermis and / or subcutaneous [e.g., subcutaneous fat or muscle] layers that constitute the skin, and the keratinized layer of the applicable fingernails / toenails and hair shaft) to reduce atrophy of the skin, hair, or fingernails / toenails; increasing the curling of the dermal-epidermal boundary (also known as the reticular rim); preventing the rebound of loss of elasticity of the skin or hair (loss, destruction, and / or inactivation of functional skin elastin) such as elastic tissue degeneration, sagging, skin loss, or hair deformity; changes in the pigmentation of the skin, hair, or nails by melanin or non-melanin, such as dark circles, rashes (e.g., uneven redness caused by, for example, rosacea) (hereinafter referred to as erythema), grayish-yellow (grayish-white), discoloration caused by telangiectasia or arachnoidosis, and graying of hair. Treatments may include providing beneficial effects to fabrics during cleaning or softening in a washing machine, providing beneficial effects to hair during shampooing, conditioning, or coloring, or providing beneficial effects to the environment, such as a toilet, through cleaning or disinfection.

[0055] In another example, treatment refers to removing stains and / or odors from fabric products such as clothing, towels, linens, and / or hard surfaces such as countertops and / or dishes including jars and plates.

[0056] As used herein, “fabric care surfactant” means an agent that provides beneficial effects and / or improvements to a fabric when applied to it. Non-limiting examples of beneficial effects and / or improvements to fabrics include cleaning (e.g., cleaning by surfactants), stain removal, stain reduction, wrinkle reduction, color restoration, static control, wrinkle resistance, durable ironing, abrasion reduction, abrasion resistance, pilling removal, anti-pilling, descaling, scale prevention (including scale removal), shape retention, shrinkage reduction, softness, fragrance, antibacterial, antiviral, deodorizing, and odor removal.

[0057] As used herein, "dishwashing surfactant" means a surfactant that, when applied to dishes, glassware, jars, plates, utensils, and / or cooking boards, provides beneficial effects and / or improvements to dishes, glassware, plastic products, jars, plates, utensils, and / or cooking boards. Non-limiting examples of beneficial effects and / or improvements on tableware, glassware, plastic products, jars, plates, utensils, and / or cooking boards include food and / or descaling, cleaning (e.g., cleaning with surfactants), stain removal, stain reduction, grease removal, limescale and / or waterproofing, glass and metal care, disinfection, brightening, and polishing.

[0058] As used herein, "hard surfactant" means an agent that, when applied to floors, countertops, sinks, windows, mirrors, showers, bathtubs, and / or toilets, provides beneficial effects and / or improvements to those surfaces. Non-limiting examples of beneficial effects and / or improvements to floors, countertops, sinks, windows, mirrors, showers, bathtubs, and / or toilets include removal of food and / or dirt, cleaning (e.g., cleaning by surfactants), stain removal, stain reduction, grease removal, removal of water stains and / or waterproofing, descaling, disinfection, brightening, polishing, and freshening.

[0059] As used herein, “keratinizing agent” refers to an active agent that can be used to treat the condition of keratinized tissue (such as hair, skin, or nails). For hair care agents, “treatment” includes conditioning and / or immediately improving the cosmetic appearance and / or feel of keratinized tissue. For example, “modifying the condition of skin, hair, or fingernails / toenails” includes: thickening the skin, hair, or fingernails / toenails (e.g., the epidermis and / or dermis and / or subcutaneous [e.g., subcutaneous fat or muscle] layers that constitute the skin, and the stratum corneum of the applicable fingernails / toenails and hair shaft) to reduce atrophy of the skin, hair, or fingernails / toenails; increasing the curling of the dermal-epidermal boundary (also known as the reticular rim); preventing the rebound of loss of elasticity of the skin or hair (loss, destruction, and / or inactivation of functional skin elastin) such as elastic tissue degeneration, sagging, skin loss, or hair deformity; changes in the pigmentation of the skin, hair, or fingernails / toenails by melanin or non-melanin, such as dark circles, rashes (e.g., uneven redness caused by, for example, rosacea) (hereinafter referred to as “erythema”), grayish-yellow (grayish-white), discoloration caused by telangiectasia or arachnoidosis, and graying of hair. Another example of a keratinizing agent is a surfactant used to wash, condition, or dye hair with shampoo.

[0060] As used herein, "weight ratio" refers to the ratio between two materials based on their dry weight. For example, the weight ratio of filament-forming material to surfactant in a filament is the ratio of the weight (g or %) of the filament-forming material based on the dry weight of the filament to the weight (g or %) of fiber auxiliaries such as one or more surfactants based on the dry weight of the filament. In another example, the weight ratio of particles to filament in a fiber structure is the ratio of the weight (g or %) of the particles based on the dry weight of the fiber structure to the weight (g or %) of the filament based on the dry weight of the fiber structure.

[0061] As used in this article, "water-soluble material" refers to a material that is miscible in water. In other words, it is a material that can form a stable (without separation after more than 5 minutes of forming a homogeneous solution) homogeneous solution with water under environmental conditions.

[0062] As used in this article, “environmental conditions” refers to 23℃±1.0℃ and 50%±2% relative humidity.

[0063] As used herein, “weight-average molecular weight” refers to the weight-average molecular weight determined using gel permeation chromatography according to the procedures described in Colloids and Surfaces A. Physico Chemical & Engineering Aspects, Vol. 162, 2000, pp. 107-121. As determined by the weight-average molecular weight test method described herein.

[0064] As used in this article, the “length” of a filament refers to the length along the longest axis of the filament from one end to the other. If the filament has knots, curls, or bends, then the length is the length of the entire path along the filament from one end to the other.

[0065] As used herein, the “diameter” of the filament is measured according to the diameter testing method described herein. In one example, the filament of the present invention exhibits a diameter of less than 100 µm, and / or less than 75 µm, and / or less than 50 µm, and / or less than 25 µm, and / or less than 20 µm, and / or less than 15 µm, and / or less than 10 µm, and / or less than 6 µm, and / or greater than 1 µm, and / or greater than 3 µm.

[0066] As used herein, "triggering condition" in one example refers to anything, as an action or event, that stimulates and induces or causes a change in the filament and / or particle and / or fiber structure of the present invention, such as the loss or alteration of the physical structure of the filament and / or fiber structure and / or the release of fiber auxiliaries such as surfactants therefrom. In another example, the triggering condition may be present in an environment such as water when the filament and / or particle and / or fiber structure of the present invention is added to water. In other words, no changes exist in the water other than the fact that the filament and / or fiber structure of the present invention is added to water.

[0067] As used herein, "morphological change" in relation to filament and / or particle morphology refers to a change in the physical structure of the filament. Non-limiting examples of morphological changes in the filaments and / or particles of the present invention include dissolution, melting, swelling, shrinkage, fracturing, bursting, lengthening, shortening, and combinations thereof. When the filaments and / or particles of the present invention are exposed to the intended use conditions, they may completely or substantially lose their filament or particle physical structure, or may have their morphological changes, or may retain or substantially retain their filament or particle physical structure.

[0068] "By weight based on dry filament" and / or "By weight based on dry particles" and / or "By weight based on dry fiber structure" refers to the weight of the filament and / or particles and / or fiber structure immediately after conditioning for 2 hours in a conditioning chamber at a temperature of 23°C ± 1.0°C and a relative humidity of 50% ± 10%. In one example, "By weight based on dry filament" and / or "By weight based on dry particles" and / or "By weight based on dry fiber structure" refers to the dry weight of the filament and / or particles and / or fiber structure, as measured according to the moisture content testing method described herein, containing less than 20% and / or less than 15% and / or less than 10% and / or less than 7% and / or less than 5% and / or less than 3% and / or to 0% and / or to greater than 0% moisture, such as water, e.g., free water.

[0069] As used herein, for example, with respect to the total content of one or more surfactants present in filaments and / or granules and / or fiber structures, "total content" means the sum of the weight or weight percentage of all host materials, such as surfactants. In other words, the filaments and / or granules and / or fiber structures may contain 25% anionic surfactant based on the weight of the dried filaments and / or dried granules and / or dried fiber structures, 15% nonionic surfactant based on the weight of the dried filaments and / or dried granules and / or dried fiber structures, 10% chelating agent based on the weight of the dried filaments and / or dried granules and / or dried fiber structures, and 5% fragrance based on the weight of the dried filaments and / or dried granules and / or dried fiber structures, such that the total content of surfactants present in the filaments and / or granules and / or fiber structures is greater than 50%; that is, 55% based on the weight of the dried filaments and / or dried granules and / or dried fiber structures.

[0070] As used herein, "fiber structured product" refers to a solid form, such as a rectangular solid, sometimes referred to as a sheet, which contains one or more surfactants, such as fabric care surfactants, dishwashing surfactants, hard surfactants, and mixtures thereof. In one example, the fiber structured product of the present invention contains one or more surfactants, one or more enzymes (such as in the form of enzyme granules and / or enzyme solutions), one or more fragrances, and / or one or more defoamers.

[0071] In one example, one or more active agents in particulate or liquid form may be deposited onto one or more surfaces of the fibrous structure of the present invention. For example, enzyme suspensions, fragrances, microcapsule suspensions, oils, siloxanes, and surfactant pastes (sometimes referred to herein as trace components) may be deposited onto one or more surfaces of the fibrous structure during the preparation and / or conversion processing of the fibrous structure. Such applied components may reside on the surface of the fibrous layer or may be substantially absorbed into the fibrous structure.

[0072] In another example, the fiber structure product of the present invention comprises a detergent builder and / or a chelating agent. In yet another example, the fiber structure product of the present invention comprises a bleach (such as an encapsulated bleach).

[0073] As used herein, with respect to materials such as whole filaments and / or filament-forming materials and / or surfactants in filaments, "different from" or "different from" means that one material such as filaments and / or filament-forming materials and / or surfactants is chemically, physically, and / or structurally different from another material such as filaments and / or filament-forming materials and / or surfactants. For example, a filament-forming material in filament form has a different characteristic than the same filament-forming material in fiber form. Similarly, starch polymers are different from cellulose polymers. However, for the purposes of this invention, the same material of different molecular weights, such as starch of different molecular weights, are not materials that are different from each other.

[0074] As used herein, "random mixture of polymers" refers to the random combination of two or more different filament-forming materials to form filaments. Therefore, for the purposes of this invention, two or more different filament-forming materials that are orderedly combined to form filaments such as core-shell bicomponent filaments are not random mixtures of different filament-forming materials.

[0075] As used herein, in relation to filaments and / or particles, “associate,” “associated,” “association,” and / or “associating” refers to the combination of filaments and / or particles in direct and / or indirect contact to form a fibrous structure. In one example, associated filaments and / or particles may be bonded together, for example, by adhesives and / or thermal bonding. In another example, filaments and / or particles may be associated with each other by deposition onto the same fibrous structure to prepare tapes and / or patterned tapes.

[0076] As used in this article, "longitudinal" or "MD" refers to the direction of the fiber structure flow parallel to the fiber structure flow through the fiber structure preparation machine and / or the fiber structure product manufacturing equipment.

[0077] As used herein, "transverse" or "CD" refers to the direction perpendicular to the longitudinal direction in the same plane of the fiber structure and / or fiber structured products containing the fiber structure.

[0078] As used herein, "lamella" or "multiple lamellars" refers to a single fiber structure optionally arranged in a face-to-face relationship substantially continuous with other lamellars to form a multilayered fiber structure. It is also contemplated that a single fiber structure can effectively form two or more layers, for example, by folding itself. Lamellars may include filament layers, filament / particle blend layers, and / or particle layers. In another embodiment, filament layers or particle layers may be present between lamellars.

[0079] As used herein, the articles “a” and “an” when used herein, such as “an anionic surfactant” or “a fiber”, are understood to refer to one or more materials protected by or described in the claims.

[0080] Unless otherwise specified, all percentages and ratios are by weight. Unless otherwise specified, all percentages and ratios are based on the total composition.

[0081] Unless otherwise stated, all component or composition levels refer to the level of the active substance in that component or composition and do not include impurities that may be present in commercially available sources, such as residual solvents or byproducts.

[0082] Method for preparing an article

[0083] In one example of the present invention, such as Figure 1 As shown, a method 10 for preparing, for example, a continuous preparation of an article 12 comprising a fibrous structure 14 such as a soluble fibrous structure is provided. The method includes at least the following steps: 1) a filament forming composition preparation operation 16, which includes one or more steps of preparing a filament forming composition 18 and then delivering it, for example, via a pipe to the next operation; i.e., a spinning operation 20; 2) a spinning operation 20, which includes one or more steps of spinning the filament forming composition (e.g., the filament forming composition 18 prepared in the filament forming composition preparation operation 16) to prepare filaments 22 (e.g., soluble filaments); 3) optionally, a mixing operation 24 including one or more steps of mixing a variety of solid additives (e.g., particles 26) with the filaments 22, for example, co-forming; and 4) a collection operation 28, which includes steps of collecting... The apparatus includes one or more collection steps, such as collecting filaments 22 and / or mixed filaments 22 with solid additives (e.g., particles 26) on a belt and / or drum to form a fiber structure 14, the fiber structure (e.g., a soluble fiber structure) comprising filaments 22 and optional solid additives (e.g., particles 26), wherein operations (1-4) are carried out in a continuous manner when present, one step after the next, without any interruption or pause in the process: from the preparation of filament forming composition 18 to spinning filament forming composition 18 into filaments 22 (optionally mixing solid additives such as particles 26 with filaments 22) to collecting filaments 22 (and / or mixed filaments 22 and solid additives such as particles 26) on a collection device to form a fiber structure 14, the fiber structure comprising filaments 22 and optional solid additives such as particles 26.

[0084] Once the fiber structure 14 is formed, it can be subsequently converted into an article 12 via a conversion processing operation 30, which may be a consumable, marketable unit. This operation includes one or more steps for converting the fiber structure 14 into the article 12, wherein one or more of the conversion processing steps may be sequential with earlier operations (1-4) of method 10. Once the fiber structure 14 has been converted into an article 12 comprising the fiber structure 14, such as one or more, two or more, three or more, four or more, five or more layers of the fiber structure 14, the article 12 can be packaged into a package 32 comprising an outer packaging material 34 such as a packaging film, cardboard box, etc., via a packaging operation 36.

[0085] In one example, the methods and / or method steps for preparing an article, such as spinning operations, mixing (co-forming) operations, collecting operations, conversion processing operations, and packaging operations, can be carried out independently according to the invention at a relative humidity of about 20% to about 75% and / or about 30% to about 65% and / or about 35% to about 60%.

[0086] The conversion processing operation 30 may include one or more steps for converting the fiber structure 14 into one or more articles 12 (e.g., cutting and / or stacking and / or calendering and / or treating it with optional ingredients such as fragrances, enzymes, bleaching agents, flavoring agents, effervescent agents, etc. (e.g., adding optional ingredients to the fiber structure 14, such as adding to the surface of the fiber structure 14), punching and printing) into one or more articles 12 (e.g., consumer products); and 6) Optionally, the packaging operation 36 includes one or more steps for packaging one or more articles 12 (e.g., consumer products, such as soluble consumer products) into packages 32.

[0087] In one example, conversion processing operations may include die-cutting into a desired shape (e.g., maximizing the number of articles made from the fiber structure) or multiple desired shapes, printing, adding optional ingredients (trace components), and winding the fiber structure onto a roll as conversion processing line steps, including all of which are performed in a single process or on a single conversion processing line. For example, the method of the present invention may include one or more conversion processing operations and / or steps selected from: cutting, stacking, calendering, treatment with optional ingredients, die-cutting, printing, packaging, mechanical layer bonding, chemical layer bonding, and / or combinations thereof. In one example, one or all of these conversion processing operations and / or steps are performed on a single conversion processing line that may be directly connected to a fiber structure production line (e.g., spinning / blending / collecting operations) and a filament forming composition preparation operation. In one example, as described herein, the entire process for preparing articles according to the invention, from the filament forming composition operation to the conversion operation and optionally the packaging operation, may be performed on a single production line (e.g., a single continuous production line). The conversion processing operations may ultimately produce consumer-ready commercial units.

[0088] In one example, the method enables the fibrous structure (e.g., a composite structure) formed in the collection operation to be further converted into a consumer-ready commercial unit on an integrated production line, for example on any surface of a single-layer sheet, multi-layer sheet, or single-layer sheet article or multi-layer sheet article, by a selection of conversion processing operations and / or steps: cutting, stacking, calendering, treatment with optional components, die-cutting, printing, packaging, mechanical layer bonding, chemical layer bonding, and / or combinations thereof.

[0089] a. Preparation of filament forming composition (16)

[0090] like Figure 2 As shown, in one example, the filament forming composition 18 is prepared by the following steps: One or more filament forming materials 38 (e.g., one or more soluble filament forming materials, such as one or more hydroxyl polymers like polyvinyl alcohol) are provided, and water or another polar solvent is added thereto to produce an aqueous or polar solvent composition comprising the soluble filament forming material and water or a polar solvent. The aqueous or polar solvent composition is then processed (e.g., processing polymer) in an extruder to form a filament forming composition 18, which is subsequently adapted to be delivered to one or more dies to be spun into multiple filaments 22 in a spinning operation 20. In one example, the aqueous or polar solvent composition may be processed in a batch tank (not shown).

[0091] In one example, the filament forming material 38 is thoroughly cooked to form a homogeneous aqueous or polar solvent composition of the filament forming material 38.

[0092] In one example, during the filament forming composition preparation operation 16, at least about 30% and / or at least about 40% and / or about 70% and / or about 60% by weight of water is added to one or more filament forming materials 38.

[0093] In one example, the filament forming material 38 may be added at a solid concentration of greater than 40% and / or greater than 50% and / or greater than 60% and / or about 60% to about 80% and / or about 60% to about 70%.

[0094] In one example, the filament forming material 38 may be present in the filament forming composition at a content greater than 5% and / or greater than 10% and / or greater than 13% and / or less than 50% and / or less than 40% and / or less than 30% and / or less than 25%.

[0095] In one example, the filament forming material 38 may be present in the extruder at a content greater than 10% and / or greater than 20% and / or greater than 30% and / or less than 90% and / or less than 80% and / or less than 70% and / or less than 65%.

[0096] In one example, the filament forming material 38 may be in solid form, such as a dry solid form 40, like granules and / or powder. In one example, the filament forming material 38 and water and / or another polar solvent for dissolving the filament forming material 38 are added to an extruder 42 (e.g., a twin-screw extruder) via a hopper 44, and heated, processed, and mixed to dissolve the filament forming material 38. In one example, air entrained in the aqueous solution and / or polar solvent solution containing the filament forming material 18 within the extruder 40 is minimized and / or removed. Water and / or polar solvent may be added to the extruder 42 via a pump 46.

[0097] When the filament forming material 38 is in solid form, the solid filament forming material (e.g., one or more hydroxyl polymers, such as polyvinyl alcohol) is fed from hopper 44, for example, continuously, into extruder 42, which is an extruder such as a single-screw extruder or a twin-screw extruder, such as a Coperion ZSK 26 twin-screw extruder (maximum speed 1200 rpm, maximum torque per screw shaft 106 Nm, screw diameter 25.5 mm, screw length 900 mm, barrel section number #9, heating and cooling of each zone, screw channel depth 4.55 mm, expected throughput 20-60 kg / hr). In this example, as... Figure 3 As shown, the addition of solid filament forming material to extruder 42 occurs in region 1 of extruder 42. The purpose of adding filament forming material 38 to extruder 42 is to achieve water incorporation and dissolution of filament forming material 38, especially if it is initially in solid form.

[0098] Non-limiting examples of suitable filament forming materials 38 include polymers, such as those selected from: pullulan, hydroxypropyl methylcellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, methylcellulose, polyvinylpyrrolidone, carboxymethyl cellulose, sodium alginate, xanthan gum, tragacanth gum, guar gum, acacia gum, gum arabic, polyacrylic acid, methyl methacrylate copolymer, carboxyethylene polymer, dextrin, pectin, chitosan, fructan, elsinan, collagen, gelatin, zein, gluten, soy protein, casein, polyvinyl alcohol, carboxylated polyvinyl alcohol, sulfonated polyvinyl alcohol, starch, starch derivatives, hemicellulose, hemicellulose derivatives, proteins, deacetylated chitosan, deacetylated chitosan derivatives, polyethylene glycol, tetramethylene ether glycol, hydroxymethyl cellulose, polyethylene oxide, and mixtures thereof.

[0099] In one example, the filament forming material 38 is a water-soluble material that produces soluble filaments, such as water-soluble filaments.

[0100] In one example, the filament forming material 38 comprises polyvinyl alcohol.

[0101] Water and / or another polar solvent are added to the extruder 42 containing the filament forming material 18 via pump 46, for example, in a continuous manner, thereby mixing with and dissolving the filament forming material 18 within the extruder 42. Water and / or other polar solvents are added to region 3 of the extruder 42, such as... Figure 3 As shown.

[0102] The operable extruder 42 exhibits a wet flux of at least about 5 kg / hr and / or at least about 10 kg / hr and / or at least about 15 kg / hr and / or at least about 20 kg / hr and / or at least about 40 kg / hr, at least about 80 kg / hr and / or about 5 kg / hr to about 200 kg / hr and / or about 80 kg / hr to about 135 kg / hr, forming, in one example, about 100 kg / hr to about 700 kg / hr and / or about 345 kg / hr to about A total filament forming material flow rate of 575 kg / hr, at least about 2 kg / hr and / or at least about 4 kg / hr and / or at least about 6 kg / hr and / or at least about 10 kg / hr and / or at least about 15 kg / hr and / or at least about 20 kg / hr and / or about 2 kg / hr to about 120 kg / hr and / or about 10 kg / hr to about 85 kg / hr and / or about 20 kg / hr to about 85 kg / hr and / or about 50 kg / hr to about 85 kg / hr dry Flux, less than about 1600 rpm and / or less than about 1400 rpm and / or less than about 1200 rpm and / or about 200 rpm to about 1600 rpm and / or about 400 rpm to 1400 rpm and / or about 600 rpm to about 1200 rpm maximum screw speed, about 20% to about 95% and / or about 30% to about 85% and / or about 40% to about 70% of solids (filament forming material 38), about 10 bar to about 80 bar and / or about 15 bar to about 75 bar and / or an outlet pressure set at approximately 20 bar to approximately 65 bar, the filament forming composition can exit the extruder at an SME (solids flux basis) of approximately 0.10 kW-h / kg to approximately 0.50 kW-h / kg and / or approximately 0.12 kW-h / kg to approximately 0.45 kW-h / kg and / or approximately 0.14 kW-h / kg to approximately 0.35 kW-h / kg, and wherein the extruder subjects the filament forming composition to a temperature of at least 49°C, for example, the extruder barrel temperature is as shown in Table 1 below:

[0103] Table 1

[0104] In addition to dissolving the filament forming material 38 in the extruder 42 to produce the filament forming composition 18, one or more surfactants 48 (e.g., one or more surfactant blends, such as blends of anionic surfactants, such as two or more different anionic surfactants) may also be mixed with the filament forming composition 18 via one or more static mixers 50 such as SMX mixers.

[0105] In one example, the surfactant and / or surfactant blend comprises one or more anionic surfactants selected from: linear alkylbenzene sulfonates (LAS), alkyl sulfates (AS), and mixtures thereof. The surfactant may be blended with and / or co-neutralized with sodium hydroxide to form a paste with low water content. Other surfactants include alkyl ethoxylate sulfates (AES), auxiliary surfactants such as amine oxides, linear alcohol ethoxylates, glucosamide-based surfactants, and branched forms of alkyl chains such as MLAS and HSAS.

[0106] In one example, in addition to one or more surfactants, structural agents such as polyethylene oxide (e.g., PEO 100K and / or PEO N60K) and / or polyvinylpyrrolidone may be mixed with surfactants to provide phase stability. Optionally, other components may also be mixed with surfactants, such as salts, for example, sodium sulfate.

[0107] In one example, the filament forming composition 18 and at least one filament 22 produced thereby from the spinning filament forming composition 18 contain one or more surfactants 48, wherein the one or more surfactants 48 are present within the filament 22.

[0108] In one example, surfactant 48 comprises a surfactant selected from anionic surfactants, cationic surfactants, nonionic surfactants, amphoteric surfactants, amphoteric surfactants, and mixtures thereof.

[0109] In one example, one or more surfactants 48 are selected from: fabric care surfactants, dishwashing surfactants, carpet care surfactants, surface care surfactants, air care surfactants, oral care surfactants (e.g., dental cleaners, teeth whitening agents, dental care agents, periodontal and gingival care agents, mouthwashes, denture cleaners, tongue cleaners, breath fresheners, fluorides, mouthwashes, anti-caries agents, flavoring agents), hair care surfactants (shampoos and / or conditioners), cuticle care agents, toilet cleaners, skin care surfactants, and mixtures thereof.

[0110] In one example, at least one of the active agents 48 comprises one or more effervescent agents.

[0111] In one example, during the preparation of the filament forming composition, one or more toners, colorants, and / or dyes are added to the filament forming composition.

[0112] Filament forming materials

[0113] Filament forming materials are any suitable materials, such as polymers or monomers that can be used to produce polymers, that exhibit properties suitable for preparing fibrous elements, such as by spinning processes.

[0114] In one instance, the filament forming material may include a polar solvent-soluble material, such as an alcohol-soluble material and / or a water-soluble material.

[0115] In another example, the filament forming material may include a material that is soluble in nonpolar solvents.

[0116] In another example, the filament forming material may contain materials soluble in polar solvents and contain (less than 5% and / or less than 3% and / or less than 1% and / or 0% by weight based on the dry fibrous elements and / or dry soluble fibrous structures) materials soluble in nonpolar solvents.

[0117] In another example, the filament-forming material may be a film-forming material. In yet another example, the filament-forming material may be synthetic or of natural origin, and it may undergo chemical, enzymatic, and / or physical alterations.

[0118] In another example of the invention, the filament forming material may comprise polymers selected from the following: polymers derived from acrylic monomers such as olefinically unsaturated carboxyl monomers and olefinically unsaturated monomers, polyvinyl alcohol, polyacrylate, polymethyl methacrylate, copolymers of acrylic acid and methyl acrylate, polyvinylpyrrolidone, polyepoxide, starch and starch derivatives, amylopectin, gum, hydroxypropyl methylcellulose, methylcellulose and carboxymethylcellulose.

[0119] In another example, the filament forming material may comprise polymers selected from: polyvinyl alcohol, polyvinyl alcohol derivatives, starch, starch derivatives, cellulose derivatives, hemicellulose, hemicellulose derivatives, proteins, sodium alginate, hydroxypropyl methylcellulose, deacetylated chitosan, deacetylated chitosan derivatives, polyethylene glycol, tetramethylene ether glycol, polyvinylpyrrolidone, hydroxymethylcellulose, hydroxyethylcellulose, methylcellulose, and mixtures thereof.

[0120] In another example, the filament forming material comprises polymers selected from the following: amylopectin, hydroxypropyl methylcellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, methylcellulose, polyvinylpyrrolidone, carboxymethyl cellulose, sodium alginate, xanthan gum, tragacanth gum, guar gum, acacia gum, gum arabic, polyacrylic acid, methyl methacrylate copolymer, carboxyvinyl polymers, dextrin, pectin, chitin, fructan, sagelan, collagen, gelatin, zeatin, gluten, soy protein, casein, polyvinyl alcohol, starch, starch derivatives, hemicellulose, hemicellulose derivatives, proteins, deacetylated chitosan, deacetylated chitosan derivatives, polyethylene glycol, tetramethylene ether glycol, hydroxymethyl cellulose, and mixtures thereof.

[0121] Materials soluble in polar solvents

[0122] Non-limiting examples of materials soluble in polar solvents include polymers soluble in polar solvents. These polymers may be synthetic or of natural origin and may undergo chemical and / or physical modification. In one example, the polymer exhibits a weight-average molecular weight as determined by the weight-average molecular weight determination method described herein, of at least 10,000 g / mol and / or at least 20,000 g / mol and / or at least 40,000 g / mol and / or at least 80,000 g / mol and / or at least 100,000 g / mol and / or at least 1,000,000 g / mol and / or at least 3,000,000 g / mol and / or at least 10,000,000 g / mol and / or at least 20,000,000 g / mol and / or to about 40,000,000 g / mol and / or to about 30,000,000 g / mol.

[0123] In one example, the polar solvent-soluble polymer is selected from: alcohol-soluble polymers, water-soluble polymers, and mixtures thereof. Non-limiting examples of water-soluble polymers include water-soluble hydroxyl polymers, water-soluble thermoplastic polymers, water-soluble biodegradable polymers, water-soluble non-biodegradable polymers, and mixtures thereof. In one example, the water-soluble polymer comprises polyvinyl alcohol. In another example, the water-soluble polymer comprises starch. In yet another example, the water-soluble polymer comprises both polyvinyl alcohol and starch.

[0124] a. Water-soluble hydroxy polymersNon-limiting examples of water-soluble hydroxy polymers according to the invention include polyols such as polyvinyl alcohol, polyvinyl alcohol derivatives, polyvinyl alcohol copolymers, starch, starch derivatives, starch copolymers, deacetylated chitosan, deacetylated chitosan derivatives, deacetylated chitosan copolymers, cellulose derivatives such as cellulose ethers and cellulose ester derivatives, cellulose copolymers, hemicellulose, hemicellulose derivatives, hemicellulose copolymers, gums, arabinogalactan, galactan, proteins and a variety of other polysaccharides, and mixtures thereof.

[0125] In one example, the water-soluble hydroxy polymer of the present invention comprises a polysaccharide.

[0126] As used herein, “polysaccharide” refers to natural polysaccharides and polysaccharide derivatives and / or modified polysaccharides. Suitable water-soluble polysaccharides include, but are not limited to, starch, starch derivatives, deacetylated chitosan, deacetylated chitosan derivatives, cellulose derivatives, hemicellulose, hemicellulose derivatives, gums, arabinogalactan, galactan, and mixtures thereof. Water-soluble polysaccharides may exhibit a weight-average molecular weight of about 10,000 g / mol to about 40,000,000 g / mol and / or greater than 100,000 g / mol and / or greater than 1,000,000 g / mol and / or greater than 3,000,000 g / mol and / or greater than 3,000,000 g / mol to about 40,000,000 g / mol, as determined by the weight-average molecular weight determination method described herein.

[0127] Water-soluble polysaccharides may comprise non-cellulose and / or non-cellulose derivatives and / or non-cellulose copolymer water-soluble polysaccharides. Such non-cellulose water-soluble polysaccharides may be selected from: starch, starch derivatives, deacetylated chitosan, deacetylated chitosan derivatives, hemicellulose, hemicellulose derivatives, gums, arabinogalactan, galactan, and mixtures thereof.

[0128] In another example, the water-soluble hydroxyl polymers of the present invention include non-thermoplastic polymers.

[0129] Water-soluble hydroxyl polymers may have a weight-average molecular weight, as determined by the weight-average molecular weight testing method described herein, ranging from about 10,000 g / mol to about 40,000,000 g / mol and / or greater than 100,000 g / mol and / or greater than 1,000,000 g / mol and / or greater than 3,000,000 g / mol and / or greater than 3,000,000 g / mol to about 40,000,000 g / mol. Higher and lower molecular weight water-soluble hydroxyl polymers may be used in combination with hydroxyl polymers having a desired weight-average molecular weight.

[0130] Well-known modifications of water-soluble hydroxyl polymers, such as natural starch, include chemical and / or enzymatic modifications. For example, natural starch can be acid-hydrolyzed, hydroxyethylated, hydroxypropylated, and / or oxidized. Furthermore, water-soluble hydroxyl polymers may comprise molar-shaped corn starch.

[0131] Naturally occurring starches are generally mixtures of amylose and amylopectin polymers of D-glucose units. Amylose is essentially a linear polymer of D-glucose units linked by (1,4)-α-D bonds. Amylopectin is a highly branched polymer of D-glucose units linked at the branching point by (1,4)-α-D and (1,6)-α-D bonds. Naturally occurring starches typically contain relatively high amylopectin contents, such as corn starch (64-80% amylopectin), waxy corn (93-100% amylopectin), rice (83-84% amylopectin), potato (about 78% amylopectin), and wheat (73-83% amylopectin). While all starches are potentially available herein, the most commonly used in this invention are high-amylose natural starches derived from agricultural sources, which have the advantages of abundant supply, easy replenishment, and low cost.

[0132] As used herein, “starch” includes any naturally occurring unmodified starch, modified starch, synthetic starch, and mixtures thereof, as well as mixtures of amylose or amylopectin portions; said starch may be modified by physical, chemical, or biological methods, or a combination thereof. The choice of unmodified or modified starch in this invention may depend on the desired end product. In one embodiment of the invention, the starch or starch mixture used in this invention has an amylopectin content of about 20% to about 100%, more typically about 40% to about 90%, and even more typically about 60% to about 85% by weight of the starch or mixture thereof.

[0133] Suitable naturally occurring starches include, but are not limited to, corn starch, potato starch, sweet potato starch, wheat starch, sago palm starch, cassava starch, rice starch, soybean starch, bamboo taro starch, amylopectin starch, fern starch, lotus root starch, waxy corn starch, and high amylose corn starch. Naturally occurring starches, especially corn starch and wheat starch, are preferred starch polymers due to their economic efficiency and availability.

[0134] Other monomers can be used to graft polyvinyl alcohol (PVA) to modify its properties. Numerous monomers have been successfully grafted onto PVA. Non-limiting examples of such monomers include vinyl acetate, styrene, acrylamide, acrylic acid, 2-hydroxyethyl methacrylate, acrylonitrile, 1,3-butadiene, methyl methacrylate, methacrylic acid, maleic acid, itaconic acid, sodium vinyl sulfonate, sodium allyl sulfonate, sodium methyl allyl sulfonate, sodium phenyl allyl ether sulfonate, sodium phenyl methyl allyl ether sulfonate, 2-acrylamidomethylpropanesulfonic acid (AMP), vinylidene chloride, vinyl chloride, vinylamine, and various acrylates.

[0135] In one example, the water-soluble hydroxyl polymer is selected from: polyvinyl alcohol, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose, methyl cellulose, and mixtures thereof. Non-limiting examples of suitable polyvinyl alcohols include those available from Sekisui Specialty Chemicals America, LLC (Dallas, TX) under the trade name CELVOL. ® Commercially acquired hydroxypropyl methylcellulose. Non-limiting examples of suitable hydroxypropyl methylcellulose include those available from Dow Chemical Company (Midland, MI) under the trade name METHOCEL. ® Those acquired through commercial purchases include combinations with the hydroxypropyl methylcellulose mentioned above.

[0136] b. Water-soluble thermoplastic polymers Non-limiting examples of suitable water-soluble thermoplastic polymers include thermoplastic starch and / or starch derivatives, polylactic acid, polyhydroxyalkanoates, polycaprolactone, polyesteramides and certain polyesters, and mixtures thereof.

[0137] The water-soluble thermoplastic polymer of the present invention can be hydrophilic or hydrophobic. The water-soluble thermoplastic polymer can be modified by surface treatment and / or internal treatment to change the inherent hydrophilic or hydrophobic properties of the thermoplastic polymer.

[0138] Water-soluble thermoplastic polymers may include biodegradable polymers.

[0139] Any suitable weight-average molecular weight of the thermoplastic polymer can be used. For example, the weight-average molecular weight of the thermoplastic polymer according to the invention, as determined by the weight-average molecular weight test method described herein, is greater than about 10,000 g / mol, and / or greater than about 40,000 g / mol, and / or greater than about 50,000 g / mol, and / or less than about 500,000 g / mol, and / or less than about 400,000 g / mol, and / or less than about 200,000 g / mol.

[0140] Materials soluble in nonpolar solvents

[0141] Non-limiting examples of materials soluble in nonpolar solvents include polymers soluble in nonpolar solvents. Suitable non-limiting examples of materials soluble in nonpolar solvents include cellulose, chitin, chitin derivatives, polyolefins, polyesters, copolymers thereof, and mixtures thereof. Non-limiting examples of polyolefins include polypropylene, polyethylene, and mixtures thereof. Non-limiting examples of polyesters include polyethylene terephthalate.

[0142] Materials soluble in nonpolar solvents may include non-biodegradable polymers such as polypropylene, polyethylene, and certain polyesters.

[0143] Any suitable weight-average molecular weight of the thermoplastic polymer can be used. For example, the weight-average molecular weight of the thermoplastic polymer according to the invention, as determined by the weight-average molecular weight test method described herein, is greater than about 10,000 g / mol, and / or greater than about 40,000 g / mol, and / or greater than about 50,000 g / mol, and / or less than about 500,000 g / mol, and / or less than about 400,000 g / mol, and / or less than about 200,000 g / mol.

[0144] Surfactant

[0145] Surfactants are a class of fiber auxiliaries designed and intended to provide beneficial effects on certain substances other than the fiber elements and / or granules and / or soluble fiber structures themselves, such as beneficial effects on the environment outside the fiber elements and / or granules and / or soluble fiber structures. Surfactants can be any suitable fiber auxiliary that produces the desired effect under the intended use conditions of the fiber element. For example, surfactants may be selected from: personal care and / or conditioning agents, such as hair care agents such as shampoos and / or hair colorants, hair conditioners, skin care agents, sunscreens, and skin conditioning agents; laundry care and / or conditioning agents such as fabric care agents, fabric conditioners, fabric softeners, fabric anti-wrinkle agents, fabric care antistatic agents, fabric care stain removers, detergents, dispersants, defoamers, foam promoters, antifoaming agents, and fabric fresheners; liquid and / or powder dishwashing agents (for manual dishwashing and / or automatic dishwasher applications), hard surface care agents and / or conditioning agents and / or polishing agents; other cleaning and / or conditioning agents such as antimicrobial agents, antibacterial agents, antifungal agents, fabric colorants, fragrances, bleaching agents (such as oxidizing bleach, hydrogen peroxide, percarbonate bleach, perborate bleach, chlorine bleach), bleach activators, chelating agents, builders, detergents, brighteners, and air fresheners. Carpet conditioners, carpet conditioners, dye transfer inhibitors, clay removers, anti-redeposition agents, polymer soil strippers, polymer dispersants, alkoxylated polyamine polymers, alkoxylated polycarboxylic acid ester polymers, amphoteric graft copolymers, solubilizers, buffer systems, water softeners, water hardeners, pH adjusters, enzymes, flocculants, effervescent agents, preservatives, cosmetics, makeup removers, foaming agents, sedimentation aids, aggregate forming agents, clay, thickeners, latex, silica, desiccants, odor control agents, antiperspirants, coolants, warming agents, absorbent gels, anti-inflammatory agents, dyes, pigments, acids and alkalis; liquid treatment surfactants; agricultural surfactants; industrial surfactants; ingestible surfactants such as therapeutic agents, teeth whitening agents, dental care agents, mouthwashes, periodontal and gingival care agents, edible agents, dietary supplements, vitamins, minerals; water treatment agents such as water clarifiers and / or water disinfectants, and mixtures thereof.

[0146] Non-limiting examples of suitable cosmetics, skin care products, skin conditioning products, hair care products, and hair conditioning products are described in the CTFA Cosmetic Ingredient Handbook, Second Edition, The Cosmetic, Toiletries, and Fragrance Association, Inc., 1988, 1992.

[0147] One or more classes of chemicals may be used with one or more of the surfactants listed above. For example, surfactants may be used with any number of the surfactants mentioned above. Similarly, bleach may be used for fabric care, hard surface cleaning, dishwashing, and even teeth whitening. Therefore, those skilled in the art will know that surfactants will be selected based on the desired intended use of the fibrous elements and / or particles and / or the soluble fibrous structure thus formed.

[0148] For example, if the fiber elements and / or particles and / or the soluble fiber structures thus formed are used for hair care and / or conditioning, one or more suitable surfactants, such as foaming surfactants, may be selected to provide the desired beneficial effects to the consumer when exposed to the intended use conditions of the fiber elements and / or particles and / or the soluble fiber structures incorporated therein.

[0149] In one example, if the fiber elements and / or granules and / or the soluble fiber structure thus formed are designed or intended for use in washing clothes during a laundry operation, one or more suitable surfactants and / or enzymes and / or detergent builders and / or fragrances and / or defoamers and / or bleaches may be selected to provide the desired beneficial effects to the consumer when exposed to the intended use conditions of the fiber elements and / or granules and / or the soluble fiber structure incorporating the fiber elements and / or granules. In another example, if the fiber elements and / or granules and / or the soluble fiber structure thus formed are designed for use in washing clothes during a laundry operation and / or cleaning dishes during a dishwashing operation, the fiber elements and / or granules and / or soluble fiber structure may comprise a laundry detergent composition or a dishwashing composition or an active agent for such compositions. In another example, if the fibrous elements and / or granules and / or soluble fibrous structures thus made are designed for cleaning and / or disinfecting toilets, the fibrous elements and / or granules and / or soluble fibrous structures thus made may contain toilet cleaning compositions and / or effervescent compositions and / or surfactants used in such compositions.

[0150] In one example, the active agent is selected from: surfactants, bleaching agents, enzymes, defoamers, foam promoters, fabric softeners, denture cleaners, hair cleaners, hair conditioners, personal health care products, colorants, and mixtures thereof.

[0151] In one example, at least one of the active agents is selected from: skin-beneficial agents, pharmaceuticals, lotions, fabric care agents, dishwashing liquids, carpet care agents, surface care agents, hair care agents, air care agents, and mixtures thereof.

[0152] The filament forming composition 18 can then be mixed via a static mixer 50, such as an SMX mixer (jacketed or unjacketed), and / or pumped to the spinning operation 20 via pipes and / or pumps 46, such as a booster pump. The filament forming composition 18 produced by the filament forming composition preparation operation 16 can be delivered via one or more pumps 46 to one or more dies and / or one or more die housings. Before being delivered to the spinning operation 20, the rheological properties of the filament forming composition 18 can be measured, for example, offline or online using an online rheometer 52, thereby ensuring that the rheological properties of the filament forming composition 18 are suitable for spinning into filament 22 via the spinning operation 20.

[0153] In one example, two or more different filament forming compositions may be produced and spun during a spinning operation, for example by a sizing die (e.g., a 50 / 50 CD width sizing die), wherein each half of the die spins two or more different filament forming compositions during the spinning operation to form two or more different filaments, and ultimately produces a fiber structure comprising two or more different filaments produced by the two or more different filament forming compositions.

[0154] In another example, two or more different filament forming compositions may be produced and spun during a spinning operation, for example by two or more parallel dies (e.g., two or more parallel dies of full CD width), wherein each die spins a different filament forming composition during the spinning operation to form two or more different filaments, and ultimately produces a fiber structure comprising two or more different filaments produced by the two or more different filament forming compositions.

[0155] Filament formation and / or drawing requires a delicate balance of forces to be successful. First, the filament forming composition 18 must form a stable filament 20 upon exiting the die. If the viscosity of the filament forming composition 18 is too high, complete drawing cannot be achieved. If the viscosity of the filament forming composition 18 is too low, the filament 20 will break under the drawing forces. Furthermore, after the filament 20 has been drawn to a diameter of approximately 20 μm, stabilization then occurs. The stabilization process can be achieved in various ways, most notably drying and / or crystallization. The rheological properties of the filament 20 as it transforms from a liquid (filament forming composition 18) to a solid (filament 20) are crucial for successful filament spinning. In one example, the filament forming composition 18 of the present invention exhibits a capillary number greater than 1 and / or greater than 2 and / or greater than 3 and / or greater than 4 and / or greater than 5. In the fiber element spinning process, the fiber element needs to have initial stability upon exiting the spinning die. In one example, the filament forming composition 18 exhibits a capillary number of at least about 1 to about 50 and / or at least about 3 to about 50 and / or at least about 5 to about 30, such that the filament forming composition 18 can be effectively polymer-processed (spun) into filament 22.

[0156] The capillary number is a dimensionless number used to characterize the likelihood of droplet breakage. A larger capillary number indicates greater stability of the fluid as it leaves the die. The capillary number is defined as follows:

[0157] V is the fluid velocity at the die outlet (in length per time). η is the fluid viscosity under the conditions of the die head (in mass per length). time), σ is the surface tension of the fluid (unit: mass per time). 2 When velocity, viscosity, and surface tension are expressed in a consistent set of units, the resulting capillary number will not have its own unit; the units can cancel each other out.

[0158] The capillary number is defined as a condition for use at the die outlet. Fluid velocity is the average velocity of the fluid flowing through the die opening. The average velocity is defined as follows:

[0159] Vol' = Volumetric velocity (unit: length) 3 per time), Area = Cross-sectional area of ​​the die head exit (unit: length) 2 ).

[0160] When the die opening is a circular hole, the fluid velocity can be defined as follows:

[0161] R is the radius of the circular hole (in units of length).

[0162] Within the operating temperature range of spinning operation 20, the shear viscosity of the filament forming composition 18 is 3000 s. -1 The tensile viscosity can be in the range of about 0.1 Pa-s to about 50 Pa-s and / or about 0.3 Pa-s to about 40 Pa-s and / or about 0.5 Pa-s to about 35 Pa-s. As measured by an e-VROC instrument or equivalent instrument from RheoSense of San Ramon, CA, the tensile viscosity of the filament forming composition 18 is in the range of 700 s. -1 The strain rate can be in the range of about 50 Pa-s to about 200 Pa-s and / or about 60 Pa-s to about 180 Pa-s and / or about 70 Pa-s to about 150 Pa-s and / or about 75 Pa-s to about 125 Pa-s and / or about 75 Pa-s to about 100 Pa-s. The pressure P23 / P14 ratio on the SSEVR should be greater than 0.8 and / or greater than 0.9 and / or greater than 1.

[0163] In one example, the filament forming composition may comprise at least 20%, and / or at least 30%, and / or at least 40%, and / or at least 45%, and / or at least 50% to about 90%, and / or about 85%, and / or about 80%, and / or about 75% by weight of one or more filament forming materials, one or more surfactants, and mixtures thereof. The filament forming composition may comprise about 10% to about 80% by weight of a polar solvent, such as water.

[0164] In one example, based on the total weight of the filament-forming composition, the non-volatile component of the filament-forming composition comprises about 20% and / or 30% and / or 40% and / or 45% and / or 50% by weight, to about 75% and / or 80% and / or 85% and / or 90% by weight. The non-volatile component may consist of filament-forming materials, such as main-chain polymers, surfactants, and combinations thereof. The volatile component of the filament-forming composition will comprise the remaining percentage and, based on the total weight of the filament-forming composition, range from 10% to 80% by weight.

[0165] To successfully spin fibers from complex mixtures such as molten fatty alcohols or aqueous surfactant solutions, it is generally necessary to add a polymeric component called a structural agent. The purpose of a structural agent is to increase the shear and tensile viscosity of the fluid to enable fiber formation. Structural agents are typically high molecular weight substances, usually in the range of 100,000–6,000,000 g / mol. However, a balance is usually achieved between concentration and molecular weight, meaning that when using lower molecular weight substances, a higher concentration is required for them to function properly. Similarly, when using higher molecular weight substances, a lower concentration is available for fiber spinning. An important aspect of structural agents is their solubility in the spinning fluid, allowing viscosity to build up for fiber formation. Polyvinylpyrrolidone (PVP) and polyethylene oxide (PEO) have been found to be two such polymers that meet the solubility criteria in spinning fluids and can be prepared at high molecular weights.

[0166] b. Spinning operation (20)

[0167] The filament 22 of the present invention, comprising one or more filament forming materials 18 and one or more surfactants 48 optionally present within the filament 22, can be as follows: Figure 4 and Figure 5 Prepared as shown. As indicated. Figure 4 and Figure 5 As shown, the spinning operation 20 for preparing filament 22 from filament forming composition 18 in a continuous method according to the invention includes the following steps: a. Providing a filament forming composition 18 delivered from filament forming composition preparation operation 16 to spinning operation 20, wherein the filament forming composition 18 comprises one or more filament forming materials 38 and optionally one or more surfactants 48 and / or one or more polar solvents (such as water), and optionally one or more inhibitors; and b. Spinning the filament forming composition 18 into one or more filaments 22 comprising one or more filament forming materials 38 and optionally one or more activators 48 and one or more inhibitors via one or more dies (e.g., one or more spinning dies 54, such as multi-row capillary spinning dies, such as biaxial fiber membrane multi-row capillary dies).

[0168] In one example, the spinning step further includes providing a filament forming composition comprising one or more filament forming materials to one or more dies (e.g., one or more spinning dies 54).

[0169] When filament 22 is prepared from filament forming composition 18, filament forming composition 18 can be processed (spun) from spinning die 54 at a temperature of about 20°C to about 100°C and / or about 30°C to about 90°C and / or about 35°C to about 70°C and / or about 40°C to about 60°C.

[0170] The filament forming composition 18 can be conveyed via a suitable conduit 56 from the filament forming composition preparation operation 16 to the spinning die 54, with or without a pump 46. A pump 46 (such as Zenith) can be used. ® The pump 46, H-9000, with a capacity of 30 cc / rev and / or 45 cc / rev (manufactured by Colfax Corporation, Zenith Pumps division (Monroe, NC, USA),) is designed to facilitate the delivery of the filament forming composition 18 to the spinning die 54. The flow rate of the filament forming composition 18 from the filament forming composition preparation operation 16 to the spinning die 54 can be controlled by adjusting the revolutions per minute (rpm) of the pump 46.

[0171] The filaments 22 spun from the spinning die 54 can be continuously collected onto a collecting device 58, such as a belt and / or fabric such as a patterned belt, and / or a drum, which operates continuously to move the collected filaments 22, which form a fiber structure 14 on the collecting device 58, such as multiple intertwined filaments. The method further progresses to other operations for preparing the article 12 of the present invention.

[0172] In one example, the method may further include the following steps: spinning multiple filaments from a first die, such as a first spinning die, then collecting those first filaments on a collecting device, and subsequently collecting the mixed filaments and solid additives, such as particles, onto the first filaments already present on the collecting device.

[0173] When an active agent is present, the total content of one or more filament-forming materials present in the fiber element 10 may be less than 80% and / or less than 70% and / or less than 65% and / or 50% or less based on the weight of the dried fiber element and / or the dried soluble fiber structure, and when present in the fiber element, the total content of one or more active agents may be greater than 20% and / or greater than 35% and / or 50% or more, 65% or more, and / or 80% or more based on the weight of the dried fiber element and / or the dried soluble fiber structure.

[0174] like Figure 4 and Figure 5 As shown, the spinning die 54 may include a plurality of filament forming holes, each including a melt capillary 34 surrounded by a concentric decaying fluid hole 36 through which a fluid such as air passes to help draw the filament forming composition 22 into a fiber element 10 as it exits the filament forming composition 22.

[0175] In one example, such as Figure 5The spinning die 54 shown has two or more rows of annular extrusion nozzles (filament forming orifices 60) spaced apart from each other by a pitch P of about 1.524 mm (about 0.060 inches). The nozzles have a single inner diameter of about 0.305 mm (about 0.012 inches) and a single outer diameter of about 0.813 mm (about 0.032 inches). Each individual nozzle includes a melt capillary 62 surrounded by annular and diverging flared orifices (concentric attenuating fluid orifices 64) to provide attenuating air to each individual melt capillary 62. The generally cylindrical flow of moist air supplied through the orifices surrounds and attenuates the filament forming composition 18 extruded through the extrusion nozzles (filament forming orifices 60), thereby producing filaments 22.

[0176] Decayed air can be provided by heating compressed air from a source with a resistance heater (e.g., a heater manufactured by the Chromalox division of Emerson Electric in Pittsburgh (Pa., USA)).

[0177] The proto-filament 22 is dried by a stream of drying air, which passes through a resistance heater and / or a gas stove (directly or indirectly) (not shown) supplied by a drying nozzle and reaches a temperature of approximately 149°C (approximately 300°C). ) to about 315℃ (about 600) The filaments 22 are heated to a temperature of approximately 90° relative to the general direction of the spun filaments 22. The dried filaments 22 can be collected on a collection device 58, such as a belt or fabric. In one example, because the filaments 22 are collected on a belt or fabric, the belt or fabric can impart a pattern, such as a non-random repeating pattern, to the formed fiber structure 14. Adding a vacuum source 66 directly below the forming zone 68 (the area on the collection device 58 where the filaments 22 contact the collection device 58) can help collect the filaments 22 on the collection device 58. The spinning and collection of the filaments 22 produces a fiber structure 14, such as a soluble fiber structure, which comprises intertwined filaments.

[0178] In one example, the spinning housing 70 is a shell that at least partially encloses (in one example, completely encloses) the collecting device 58 and the fiber structure 14 supported on the collecting device 58 to such an extent that they can move freely below the spinning housing 70, through which the filament 22 is spun from the spinning die 54 to the collecting device 58. The spinning housing 70 at least partially controls the environment downstream of the spinning production line from the spinning die 54 to the collecting device 58 to which the filament 22 is exposed.

[0179] In one example, when filament 22 is formed, any volatile solvents, such as water, present in the filament forming composition 18 are removed during the spinning step, for example, by drying. In one example, greater than 30% and / or greater than 40% and / or greater than 50% by weight of volatile solvents, such as water, in the filament forming composition 18 are removed during the spinning step, for example, by drying the resulting filament 22.

[0180] In one example, filament 22 is spun by a die (e.g., a spinning die 54, such as a multi-row capillary die).

[0181] In one example, two or more different filaments 22 are spun by at least one die, such as a spinning die 54 (the same spinning die 54).

[0182] In one example, the filament 22 is spun by two or more dies, such as two or more spinning dies 54.

[0183] In one example, the method of the present invention may include two or more spinning operations 20. In one example, a first spinning operation 20 includes spinning filament 22 from a filament forming composition 18 via a mixing operation 24, the filament forming composition comprising one or more filament forming materials 38 having or not having an active agent 48 and not containing solid additives such as particles 26, to produce a fiber structure 14 on a collecting device 58, which may be the same collecting device 58 as that used to collect filament 22 from a second spinning operation 20. A second spinning operation 20 downstream of the first spinning operation 20 includes spinning filament 22 from a filament forming composition 18 via a mixing operation 24, the filament forming composition comprising one or more filament forming materials 38 having or not having an active agent 48 and containing solid additives such as particles 26, onto the fiber structure 14 formed by the first spinning operation 20.

[0184] The filament forming composition 18 may contain any suitable amount of filament forming material 38 and any suitable amount of surfactant 48, provided that the total content of filament forming material 38 in the filament 22 produced by the filament forming composition 18 is about 5% to 100% or less based on the weight of the dried filament and / or dried soluble fiber structure and the total content of surfactant 48 in the filament 22 is about 0% to 95% based on the weight of the dried filament and / or dried soluble fiber structure.

[0185] c. Mixed operations (24)

[0186] In one example, such as Figure 6As shown, particles 26 can be added to filament 22, which is spun within a spinning box 70 by a die such as spinning die 54. The addition of particles 26 can be completed during the formation of filament 22 and / or after the filament 22 is collected on a collecting device 58. Particles 26 can be added from a particle source 72 to the fiber structure 14 and / or the filament 22. Particles 26 can be added such that they are collected on the surface of the collecting device 58 within the spinning box 70. The collecting device 58 can operate within a forming zone 68, which is located inside the spinning box 70. The spinning box 70 can be positioned above the collecting device 58 and surrounds the forming zone 68 on the collecting device 58.

[0187] The addition of particles 26 may result in the particles 26 being encapsulated and / or entrained within the filaments 22 and / or fiber structures 14 collected on the collecting device 58.

[0188] A particle source 72 suitable for providing the particle flow, such as a feeder, is placed directly above the drying area of ​​the fiber element, such as... Figure 6 As shown. In this case, for example, using Retsch ® A vibrating feeder manufactured in Haan, Germany. To facilitate a uniform lateral distribution of particles, the particles are fed into a disc (not shown) that begins at the width of the particle source 72 and ends at the same width as the spinning die 54, ensuring that the particles 26 are delivered into all areas where the filament 22 is formed. The disc is completely enclosed except for the outlet to minimize disruption to the particle feed.

[0189] In one example, separate particle sources or two or more individual particle sources capable of delivering two or more different types of particles (e.g., different in type, composition, size, properties, etc.) can be used as particle sources in a mixing operation, such that the resulting fiber structure may include different regions and / or areas with different particles, which can ultimately produce a layered fiber structure with different particles in each layer after the initially formed fiber structure is cut and stacked.

[0190] When filament 22 is formed, particle source 72 is activated and particles 26 are introduced into the filament 22 stream. Particles 26 mix with the filament 22 within the spinning box 70. The mixed filament 22 and particles 26 are collected as a composite structure (filament 22 and particles 26 mixed together) on a collecting device 58. In one example, the step of collecting the mixed filament 22 and particles 26 on, for example, the collecting device 58 occurs within the spinning box 70. This composite structure is referred to as fiber structure 14.

[0191] Particles 26 can be introduced at any angle into the spinning box 70 between the spinning die 54 and the collecting device 58, such as Figure 4 and Figure 6As shown, it is sufficient that at least a portion of the particle 26 contacts the filament 22 at the forming region 68. Figure 6 As shown, if the introduction of particles 26 into the filament 22 flow is not controlled to cause particles 26 to contact filament 22 in the forming zone 68, the particles may terminate downstream of the forming zone 68 (the point in the process is closer to the finished product and / or packaged product relative to the reference point; for example, if the reference point is the spinning operation or the collection operation, then downstream refers to the conversion processing operation and / or the packaging operation). Figure 6 As shown by particle trajectory line A, and / or the particles may terminate upstream of forming zone 68 (the point in the process is further away from the finished product 12 and / or packaged article 32 relative to the reference point; for example, upstream refers to, for example, filament forming composition preparation operation 16, if the reference point is a spinning operation or a collection operation), as... Figure 6 The particle trajectory line B is shown in the figure.

[0192] In one example, a solid additive, such as particles 26, contacts filament 22 on the upstream side ("upstream side of the filament") of the spinning box 70.

[0193] In another example, a solid additive, such as granules 26, contacts filament 22 on the downstream side of the spinning box 70 (the downstream side of the "filament").

[0194] In another example, solid additives such as particles 26 contact filament 22 on the upstream and downstream sides ("upstream and downstream sides of the filament") of the spinning box 70.

[0195] Figure 7 Another example of the mixing operation 24 is illustrated schematically, in which particles 26 land on the collection device 58 in the particle landing area 74 and contact the filaments 22 in the forming area 68.

[0196] Solid additives such as particles 26 may have a contact angle greater than or equal to about 0° but less than or equal to about 90° and / or greater than or equal to about 10° but less than or equal to about 90° and / or greater than or equal to about 20° but less than or equal to about 90° and / or greater than or equal to about 30° but less than or equal to about 90° and / or at least about 40° but less than about 90° (the contact angle is relative to the direction of the filament flow that emerges from and flows out of the spinning die 54) and / or contact the filament 22 with a contact angle of at least about 45° but less than about 90°.

[0197] As measured according to the CD and MD basis weight change test methods described herein, solid additives such as particles 26 can be dispersed throughout the fiber structure 14 with a total MD basis weight change of less than 40.0% and / or less than 30.0% and / or less than 25.0% and / or less than 20.0% and / or less than 15.0% and / or less than 10.0% and / or less than 5.0% and / or about 0%.

[0198] As measured according to the CD and MD basis weight change test methods described herein, solid additives such as particles 26 can be dispersed throughout the fiber structure 14 with a total CD basis weight change of less than 40.0% and / or less than 30.0% and / or less than 25.0% and / or less than 20.0% and / or less than 15.0% and / or less than 10.0% and / or less than 5.0% and / or about 0%.

[0199] Solid additives such as particles 26 can contact the filament at speeds greater than 1 m / s and / or at least 2 m / s and / or at least 2.5 m / s and / or less than 10 m / s and / or less than 8 m / s and / or 6 m / s or less and / or about 1 m / s to about 20 m / s.

[0200] Solid additives such as granules 26 may be mixed with filaments 22 such that the solid additive inclusion efficiency (e.g., granule inclusion efficiency) as measured by the inclusion efficiency test method described herein is greater than 40% and / or at least 42% and / or at least 45% and / or at least 50% and / or at least 54% and / or at least 65% and / or at least 75% and / or at least 85% and / or at least 90% and / or at least 95% and / or at least 98%.

[0201] In one example, the mixing step includes introducing a solid additive, such as granules 26, into multiple filaments 22, such as soluble filaments, between at least one die, such as a spinning die 54, and a collecting device 58. In one example, the solid additive, such as granules 26, is introduced closer to at least one die (e.g., spinning die 54) than to the collecting device 58. In another example, the solid additive, such as granules 26, is introduced closer to the collecting device 58 than to at least one die (e.g., spinning die 54).

[0202] In one example, the mixing operation (step) includes introducing a solid additive, such as granules 26, into a filament 22, such as a soluble filament, spun by two different spinning dies 54.

[0203] Solid additives such as particles 26 may include one or more types or different types of particles 26. In one example, solid additives such as particles 26 include a mixture of particles 26 with different compositions. In another example, solid additives such as particles 26 include a blend of particles with different compositions. In yet another example, solid additives such as particles 26 include water-soluble particles and / or water-insoluble particles, which may include water-swellable particles. Furthermore, in one example, particles 26 may be in the form of agglomerates, such as agglomerates containing water-soluble materials and / or water-insoluble materials.

[0204] In one example, solid additives such as particles 26 may exhibit a D50 particle size of about 100 µm to about 5000 µm and / or about 100 µm to about 2000 µm and / or about 250 µm to about 1200 µm and / or about 250 µm to about 850 µm, as measured by the particle size distribution test method described herein.

[0205] In one example, solid additives such as particles 26 can exhibit a D10 of 250 µm as measured by the particle size distribution test method described herein.

[0206] In another example, solid additives such as particles 26 may exhibit a D90 of 1200 µm and / or 850 µm as measured by the particle size distribution test method described herein.

[0207] In one example, solid additives such as particles 26 may exhibit a D10 greater than 44 µm and / or greater than 90 µm and / or greater than 150 µm and / or greater than 212 µm and / or greater than 300 µm, as measured by the particle size distribution test method described herein.

[0208] In one example, solid additives such as particles 26 may exhibit a D90 of less than 1400 µm and / or less than 1180 µm and / or less than 850 µm and / or less than 600 µm and / or less than 425 µm, as measured by the particle size distribution test method described herein.

[0209] In one example, solid additives such as particles 26 may exhibit any combination of the above-mentioned D10, D50 and / or D90, provided that D50 (when present) is greater than D10 (when present) and D90 (when present) is greater than D10 and D50 (when present).

[0210] In one example, as long as D90 is greater than D10, solid additives such as granules 26 can exhibit any combination of D10 and D90 mentioned above.

[0211] In one example, solid additives such as particles 26 may exhibit a D10 greater than 212 µm and a D90 less than 1180 µm as measured by the particle size distribution test method described herein.

[0212] In one example, solid additives such as particles 26 may exhibit a D10 greater than 90 µm and a D90 less than 425 µm, as measured by the particle size distribution testing method described herein.

[0213] In one example, spinning operation 20 may include two or more spinning dies 54 arranged adjacent to each other in the longitudinal and / or transverse directions. In one example, when spinning operation 20 includes two or more dies arranged adjacent to each other in the longitudinal direction, mixing operation 24 may be positioned between two adjacent (in the longitudinal direction) dies, for example, between two adjacent spinning dies 54.

[0214] In this invention, the particles 26 used for mixing with the filament 22 can be particles containing an active agent.

[0215] d. Collection operation (28)

[0216] like Figure 1 , Figure 4 and Figure 6 As shown, filaments 22 from spinning operation 20 and solid additives such as particles 26 optionally from mixing operation 24 are collected on collecting device 58 during collecting operation 28 to form fiber structure 14, which may be a composite structure (mixed filaments 22 and particles 26).

[0217] In one example, the collecting device 58 may be a belt and / or a rotating drum, the belt being a patterned belt that imparts texture, such as a three-dimensional texture, to at least one surface of the fiber structure 14. The collecting device 58 may impart patterns, for example, which may be inherently continuous, discontinuous, and / or semi-continuous non-random repeating patterns. The collecting device 58 may form different regions within the fiber structure 14, for example, with different average densities.

[0218] Test methods

[0219] Unless otherwise specified, all tests described herein (including those in the definitions section and the following test methods) are performed on samples that have been conditioned for at least 2 hours prior to testing in a conditioning chamber at a temperature of 23°C ± 1.0°C and a relative humidity of 50% ± 2%. The sample being tested is a “usable unit.” As used herein, a “usable unit” refers to a sheet, a flat sheet from a roll, a pre-converted flat sheet, and / or a single-layer or multi-layer sheet product. All tests are performed under identical environmental conditions in such a conditioning chamber. Samples with defects such as wrinkles, tears, holes, etc., are not tested. For testing purposes, samples conditioned as described herein are considered dry samples (such as “dry filaments”). All instruments are calibrated according to the manufacturer’s instructions.

[0220] Basis weight test method

[0221] Basis weight is defined as the weight of the sample being tested, expressed in g / m². It is determined by accurately weighing the known area of ​​the conditioned sample using a suitable balance, recording the weight and area of ​​the sample, applying an appropriate conversion factor, and finally calculating the sample basis weight in g / m².

[0222] Basis weight was measured by cutting the sample from a single fiber web, a stack of fiber webs, or other suitable stacks, or a consumer-available unit, and weighing the sample using a top-loaded analytical balance with a resolution of ± 0.001 g. The sample must be at 73° ± 2° before cutting. The balance was equilibrated for at least two hours at a temperature of 23℃ ± 1℃ and a relative humidity of 50% (± 2%). During weighing, the balance was protected from airflow and other disturbances using an airflow shield. A precision-cut die (measuring 1.625 × 1.625 inches (41.275 × 41.275 mm)) was used to prepare all samples. Available sample areas were selected that were clean and free from holes, tears, wrinkles, and other defects.

[0223] For each sample, the above-mentioned punching machine was used to cut the sample, the sample mass was weighed, and the mass result was recorded to an accuracy of 0.001g.

[0224] The basis weight, expressed in g / m², is calculated as follows: Basis weight = (sample mass) / (sample area).

[0225] Or to be more specific, Basis weight (g / m2) = (mass of sample (g)) / (0.001704m2).

[0226] Record the results to an accuracy of 0.1 g / m². A similar precision cutter, as described above, can be used to change or alter the sample size. If the sample size becomes smaller, several samples should be measured, and the average value recorded as its basis weight.

[0227] Particle size distribution testing method

[0228] Particle size distribution testing was performed to determine the characteristic particle size of solid additives such as granules. This was done using ASTM D 502-89, "Standard Test Method for Particle Size of Soaps and Other Detergents," approved May 26, 1989, with further details on the sieve sizes and sieving times used in the analysis. Following Section 7, "Procedures for Using Machine Sieving Methods," clean, dry sieves and discs containing American Standard (ASTM E 11) sieves #4 (4.75 mm), #6 (3.35 mm), #8 (2.36 mm), #12 (1.7 mm), #16 (1.18 mm), #20 (850 μm), #30 (600 μm), #40 (425 μm), #50 (300 μm), #70 (212 μm), #100 (150 μm), #170 (90 μm), and #325 (44 μm) were required to cover the particle size range described herein. Use the above-described sieve set for the specified machine sieving method. A suitable sieve shaker is available from WSTyler Company, Ohio, USA. Shake the test sample to approximately 100 grams for 5 minutes.

[0229] The data is plotted on a semi-logarithmic plot by plotting the logarithmic x-axis with the micron-sized openings of each sieve and the linear y-axis with the finer cumulative mass percentage (CMPF). An example of the above data representation is given in Figure A.4 of ISO 9276-1:1998, “Representation of results of particle size analysis – Part 1: Graphical Representation”. For the purposes of this invention, the characteristic particle size (Dx, x = 10, 50, 90) is defined as the x-axis value of the point where the cumulative mass percentage equals x%, and is calculated by linear interpolation between data points directly above (a) and below (b) the x-value using the following formula: Dx = 10^[Log(Da) - (Log(Da) - Log(Db)) (Qa - x%) / (Qa - Qb)] Where Log is the logarithm with base 10, and Qa and Qb are the measured data immediately above or below x, respectively. th The cumulative mass percentage value; and Da and Db are the mesh size values ​​in micrometers corresponding to these data.

[0230] Example data and calculations:

[0231] For D10 (x = 10), the CMPF is 300 micrometers for sieves immediately above 10% (Da) and 212 micrometers for sieves below 10% (Db). The cumulative mass (Qa) immediately above 10% is 15.2%, and below 10% (Qb) is 6.8%. D10 = 10^[Log(300) – (Log(300) – Log(212)) [(15.2% - 10%) / (15.2% - 6.8%)] = 242 micrometers.

[0232] For D90 (x = 90), the CMPF is 1180 micrometers for sieves immediately above 90% (Da) and 850 micrometers for sieves below 90% (Db). The cumulative mass (Qa) is 99.3% for sieves immediately above 90% and 89.0% for sieves below 90% (Qb). D90 = 10^[Log(1180) - (Log(1180) - Log(850)) (99.3%) - 90%) / (99.3%) - 89.0%) ] = 878 micrometers.

[0233] For D50 (x = 50), the CMPF is 600 micrometers for sieves immediately above 50% (Da) and 425 micrometers for sieves below 50% (Db). The cumulative mass (Qa) is 60.3% for sieves immediately above 50% and 32.4% for sieves below 50% (Qb). D50 = 10^[Log(600) - (Log(600) - Log(425)) (60.3%) - 50%) / (60.3%) -32.4%)] = 528 micrometers.

[0234] CD and MD Basis Weight Change Test Methods

[0235] The transverse (CD) basis weight variation is measured as follows: Samples are taken across the fiber web at a given fixed longitudinal (MD) location along the transverse direction. The basis weight of the samples taken at that MD location is measured, and the percentage relative standard deviation (RSD) of the sample group is calculated. This analysis is performed on as many samples as possible across the entire transverse direction of the given fiber web. As a sampling example, if the fiber web is approximately 53 cm wide and the sample punch used for basis weighting as described herein is 4.1275 cm wide, approximately 12 samples can be obtained across the fiber web. Samples at the edges of the fiber web that may not completely fill the sampling die when cutting across the entire MD location (e.g., the punch extends beyond the edge of the fiber web) should be discarded. Sampling at a given MD location may vary slightly, provided that the entire CD width is sampled reasonably at the corresponding MD location. Sampling is completed for a total of 10 fixed MD locations spaced approximately 1 m apart. Record the CD weight change at each MD position, and use the value at each position to obtain the CD weight change % RSD for each MD sampling position. Record the average of the 10 sampled rows (or MD positions) as the total CD weight change % RSD.

[0236] The longitudinal (MD) basis weight change is measured as follows: the fiber web is sampled longitudinally at a given fixed transverse (CD) location, the basis weight of the sample taken at the given CD location is measured, the measurement is repeated at other CD locations, and then the total MD basis weight change % RSD for the entire sample group is calculated.

[0237] The percentage RSD of total CD basis weight change and the percentage RSD of total MD basis weight change can be averaged to obtain the percentage RSD of total fiber web basis weight change.

[0238] A program for measuring lateral variability at a fixed longitudinal position.

[0239] Choose the longitudinal position of the fiber web from which to sample.

[0240] The basis weight of all samples was measured following the basis weight testing method described in this article.

[0241] Cut the required number of samples at the given MD location to sample the entire fiber web width.

[0242] As an example, if the fiber mesh is approximately 53 cm wide and the sample punch is 4.1275 cm wide, approximately 12 samples can be obtained across the fiber mesh. Sampling at a given MD location can vary slightly, provided that the entire CD width is sampled reasonably at the corresponding MD location.

[0243] Discard samples located at the edges of the fiber mesh that do not completely fill the sampling head during cutting.

[0244] Calculate the basis weight of each sample taken along the given MD position.

[0245] Calculate the average sample basis weight at this fixed MD location.

[0246] Calculate the standard deviation of the samples at the fixed MD location.

[0247] The % RSD (relative standard deviation) of the sample at the MD position is calculated by dividing the standard deviation by the average sample base weight and multiplying by 100 to obtain the % value.

[0248] Repeat the above steps for a total of 10 rows or 10 MD locations, sampling at approximately 1-meter intervals in the fiber web from this method.

[0249] Take the average of the % RSD for all ten rows and record it as the total CD weight change % RSD. Record this value to the nearest 0.1%.

[0250] A program for measuring longitudinal variability at a fixed lateral position.

[0251] Samples were taken from the transverse centerline of the fiber web.

[0252] The basis weight of all samples was measured following the basis weight testing method described in this article.

[0253] Along the transverse centerline of the fiber web, ten samples are cut at approximately 1-meter intervals in the MD direction of the fiber web from this method.

[0254] Calculate the basis weight for each sample.

[0255] Calculate the average sample basis weight at the center line position of CD.

[0256] Calculate the standard deviation of the same sample group.

[0257] Calculate the % RSD of the MD base weight change at the CD centerline by dividing the standard deviation by the mean sample base weight and multiplying by 100 to obtain the % value. Record this value to an accuracy of 0.1%.

[0258] Repeat the above measurement of the transverse centerline position by sampling and measuring along the centerline on the left half of the CD centerline and then along the centerline on the right half of the CD centerline.

[0259] Based on the above analysis, three values ​​will be generated: % RSD at the center line of CD The % RSD of the center line on the left half of the CD center line. The % RSD of the center line on the right half of the CD center line. Take the average of the % RSD for these three CD positions and record it as the % RSD of the total MD base weight change. Record this value to an accuracy of 0.1%.

[0260] Includes efficiency testing methods

[0261] Entrainment efficiency is a measure of the percentage of solid additives, such as particles, trapped and retained in the fiber structure during the blending (co-forming) operation relative to the number of solid additives, such as particles, introduced (feeded) into the blending (co-forming) operation. A higher percentage of entrainment efficiency indicates a better entrainment effect of solid additives, such as particles, achieved through the blending (co-forming) operation and / or the co-forming equipment and / or the process conditions operable during the blending (co-forming) operation.

[0262] Generally speaking, efficiency is: Including efficiency = The ratio of particle mass to filament mass in the fiber structure × 100 The ratio of particle mass to the mass of the dried filament feed rate It is better calculated as follows: Including efficiency = 100 × (Composite fiber structure basis weight (g / m) 2 ) – Filament fiber ___ Structure (excluding solid additives) Basis weight (g / m 2 )) _________ (Filament fiber structure (without solid additives) Basis weight (g / m)) 2 ))) _____________________________________________________________ (Total particle feed rate (g / min)) / (Total filament forming composition feed rate (g / min)) × (Solid concentration of filament forming composition)

[0263] program

[0264] The mixing (co-forming) operation was carried out under steady-state conditions to prepare a basic fiber structure (filaments only) without particles.

[0265] The basis weight of a cut sample of a basic fiber structure is measured as defined in the basis weight method described herein.

[0266] The sample comes from the transverse center of the basic fiber structure or is located at the center line of the CD of the basic fiber structure.

[0267] Record it as the basis weight of the fiber structure (g / m 2 ).

[0268] Composite fiber structures (filaments + particles) are prepared at the desired dry mass feed rate.

[0269] The basis weight of a cut sample of a composite fiber structure is measured as defined in the basis weight method described herein.

[0270] The sample comes from the transverse center of the composite fiber structure or is located at the center line of the CD of the composite fiber structure.

[0271] Record it as the basis weight of the composite fiber structure (g / m 2 ).

[0272] The total particle feed rate and the total filament forming composition feed rate are process parameters. The total particle feed rate is measured by collecting the entire particle feed stream at one-minute intervals and recorded in g / min, accurate to 1 g / min. The total filament forming composition feed rate is measured using an online process flow meter and recorded in g / min, accurate to 1 g / min. The filament forming composition solids concentration is the ratio of the mass of the filament forming composition material remaining after drying to the mass of the starting filament forming composition. This can be measured using a Mettler Toledo HC103 or equivalent moisture analyzer. The filament forming composition solids concentration is recorded as a fraction, accurate to 0.01 units, or as a percentage, accurate to 1%.

[0273] For clarity, an example including efficiency calculations is shown below.

[0274] The base fiber structure (filament only – no particles) was made from a filament forming composition with a 55% (0.55) solids concentration. The filament forming composition was fed to the die at a rate of 1600 g / min. Samples cut along the centerline of the base fiber structure showed a yield of 264 g / min. 2 The basis weight was then determined. A composite fiber structure (filament + solid additives such as granules) was then prepared relative to the basic fiber structure as described above, but the solid additives, such as granules, were added to the filament at a total granule feed rate of 2350 g / min. Samples cut from the composite fiber structure showed a basis weight of 870 g / m. 2 The base weight. Using these values, an exemplary inclusion efficiency calculation is as follows: Including efficiency = (870g / m 2 – 264g / m 2 ) / (264g / m 2 ) × 100 = 86% (2350g / min) / (1600g / min 0.55) The records include efficiency, accurate to 1%.

[0275] Water content test method

[0276] The water (moisture) content present in fibrous elements and / or particles and / or fibrous structures is measured using the following water content test method. Prior to testing, the fibrous elements and / or particles and / or fibrous structures or portions thereof (“Samples”) are placed in a conditioning chamber at a temperature of 23°C ± 1.0°C and a relative humidity of 50% ± 2% for at least 24 hours in pre-cut slices. Each fibrous structure sample has an area of ​​at least 4 square inches, but is small enough to fit properly onto the weighing pan of a balance. Under the temperature and humidity conditions mentioned above, the weight of the sample is recorded every five minutes using a balance with at least four decimal places until a change in weight of less than 0.5% is detected within 10 minutes. The final weight is recorded as the “balance weight”. Within 10 minutes, the sample is placed in a forced-air drying oven at 70°C ± 2°C and a relative humidity of 4% ± 2% and dried on a metal sheet for 24 hours. After 24 hours of drying, the sample is removed and weighed within 15 seconds. This weight is expressed as the “dry weight” of the sample.

[0277] The water (moisture) content of the sample is calculated as follows: Water percentage in the sample = 100% × (Equilibrium weight of the sample – Dry weight of the sample) Dry weight of the sample The average of the water (moisture) percentage in the three equal aliquots is used to provide the reported water (moisture) percentage in the sample. Record the results to an accuracy of 0.1%.

[0278] Diameter testing method

[0279] The diameter of discontinuous fiber elements or fiber elements within fiber structures is determined using scanning electron microscopy (SEM) or optical microscopy and image analysis software. A magnification of 200 to 10,000x is selected to appropriately magnify the fiber elements for measurement. When using SEM, these samples are sputtered with gold or palladium compounds to prevent the fiber elements from becoming charged and vibrating in the electron beam. A manual procedure for determining the diameter of the fiber elements is used, derived from images captured by SEM or optical microscopy (on a monitor screen). Using a mouse and cursor tool, the edge of a randomly selected fiber element is searched, and then measured across its width (i.e., perpendicular to the fiber element direction at that point) to the other edge of the fiber element. Zooming and calibration image analysis tools provide zooming to obtain actual readings in µm. For fiber elements within fiber structures, multiple fiber elements are randomly selected by passing through the sample of the fiber structure using SEM or optical microscopy. At least two sections of the fiber structure are cut out and tested in this manner. At least 100 such measurements are performed in total, and all data are then recorded for statistical analysis. The recorded data is used to calculate the average diameter of the fiber element, the standard deviation of the fiber element diameter, and the median diameter of the fiber element.

[0280] Another available statistic is to calculate the number of fiber elements below a certain upper limit. To determine this statistic, software is programmed to count how many fiber elements have diameters below the upper limit, and this number (divided by the total number of data points and multiplied by 100%) is recorded as a percentage below the upper limit, such as, for example, a percentage of diameters below 1 micrometer or %-submicrometer. We denote the measured diameter (in micrometers) of a single circular fiber element as di.

[0281] When the fiber element has a non-circular cross-section, the measured value of the fiber element diameter is determined and set to be equal to the hydraulic diameter, which is four times the cross-sectional area of ​​the fiber element divided by the perimeter of the fiber element's cross-section (or the outer perimeter in the case of a hollow fiber element). The number-average diameter, or average diameter, is calculated as follows: d num =

[0282] Weight-average molecular weight test method

[0283] The weight-average molecular weight (Mw) of materials such as polymers is determined by gel permeation chromatography (GPC) using a mixed-bed column. High-performance liquid chromatography (HPLC) is also employed, which includes the following components: Millenium... ® The system included a Model 600E pump, system controller and control software version 3.2, a Model 717 Plus autosampler, and a CHM-009246 column heater, all manufactured by Waters Corporation (Milford, MA, USA). The column was a PL gel 20µm Mixed A column (gel molecular weight range 1,000 g / mol to 40,000,000 g / mol), 600 mm in length and 7.5 mm in inner diameter, with a PL gel 20µm guard column, 50 mm in length and 7.5 mm ID. The column temperature was 55°C and the injection volume was 200 µL. The detector was a DAWN. ® Enhanced Optical System (EOS), which includes Astra ® The software, version 4.73.04, is the detector software manufactured by Wyatt Technology (Santa Barbara, CA, USA). It is a laser scattering detector with a K5 unit and a 690nm laser. The gain on the odd-numbered detector is set to 101, and the gain on the even-numbered detector is set to 20.9. Wyatt Technology's Optilab ®The differential refractometer was set to 50°C. The gain was set to 10. The mobile phase was HPLC-grade dimethyl sulfoxide with 0.1% w / v LiBr, and the mobile phase flow rate was 1 mL / min, isocratic. The run time was 30 minutes.

[0284] Samples were prepared by dissolving the material in the mobile phase, specified as 3 mg material / 1 mL mobile phase. The sample was capped and stirred with a magnetic stirrer for approximately 5 minutes. The sample was then placed in a convection oven at 85°C for 60 minutes. The sample was then allowed to cool naturally to room temperature. The sample was then filtered through a 5 µm nylon membrane (Spartan-25 type, manufactured by Schleicher & Schuell (Keene, NH, USA)) into 5 mL autosampler vials using a 5 mL syringe.

[0285] For each series of samples (3 or more material samples) being measured, a solvent blank sample was injected into the column. Test samples were then prepared in a similar manner to those for the samples described above. The test samples contained 2 mg / mL pullulan (Polymer Laboratories) with a weight-average molecular weight of 47,300 g / mol. The test samples were analyzed before each series of samples were analyzed. The blank samples, test samples, and material test samples were tested in parallel. The blank samples were tested last. The light scattering detector and differential refractometer were based on the “Dawn EOS Light Scattering Instrument Hardware Manual” and “Optilab”. ® The DSP Interferometric Refractometer Hardware Manual is used in this document. Both are manufactured by Wyatt Technology Corp. (Santa Barbara, CA, USA) and are incorporated herein by reference.

[0286] The weight-average molecular weight of the sample was calculated using detector software. A dn / dc value (refractive index variation with concentration) of 0.066 was used. The baselines of the laser detector and refractive index detector were calibrated to eliminate the effects of detector dark current and solvent scattering. If the laser detector signal was saturated or exhibited excessive noise, it was not used to calculate the molecular weight. The region for molecular weight characterization was selected such that the signals from the 90°δ detectors used for laser scattering and refractive index were three times their respective baseline noise levels. Typically, the high molecular weight side of the chromatography is defined by the refractive index signal, and the low molecular weight side by the laser signal.

[0287] The weight-average molecular weight can be calculated using a first-order Sim plot as defined by the detector software. If the weight-average molecular weight of the sample is greater than 1,000,000 g / mol, both the first-order and second-order Sim plots are calculated, and the molecular weight is calculated using the result with the least regression fitting error. The reported weight-average molecular weight is the average of two runs of the material test sample.

[0288] The dimensions and values ​​disclosed herein should not be construed as strictly limited to the precise numerical values ​​cited. Rather, unless otherwise specified, each such dimension is intended to represent the stated value and a range around which it is functionally equivalent. For example, a dimension disclosed as “40 mm” is intended to represent “approximately 40 mm”.

[0289] Unless expressly excluded or otherwise limited, every reference cited herein, including any cross-references or related patents or patent applications, and any patent application or patent claiming priority to or benefiting from it, is incorporated herein by reference in its entirety. Reference to any reference is not an endorsement of it as prior art to any disclosed or protected art herein, nor is it an endorsement of any such invention, either on its own or in combination with any one or more references. Furthermore, where any meaning or definition of a term in this invention conflicts with any meaning or definition of the same term in referenced documents, the meaning or definition given to that term in this invention shall prevail.

[0290] While specific embodiments of the invention have been illustrated and described by way of example, it will be apparent to those skilled in the art that many other changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, it is intended that all such changes and modifications falling within the scope of the invention be covered by the appended claims.

Claims

1. A continuous method for preparing multiple articles, the method comprising the following steps: a. To provide one or more soluble fiber-forming materials; b. Forming an aqueous composition comprising one or more of the soluble filament-forming materials; c. Processing the aqueous composition to prepare a filament-forming composition; d. Delivering the filament forming composition to one or more dies; e. Spinning the filament from the one or more dies to form a composition to form a filament stream comprising a plurality of soluble filaments, wherein the soluble filaments contain one or more surfactants present within the soluble filaments; f. Introducing a variety of solid additives into the filament stream to mix the various solid additives with the multiple soluble filaments; g. Collecting the mixture of the soluble filaments and the solid additives on a collecting device to form a composite fiber structure, wherein the composite fiber structure comprises a mixture of solid additives and soluble filaments distributed throughout the composite fiber structure; h. The composite fiber structure is punched into multiple products; and i. Packaging the aforementioned multiple products Steps a through i are performed on a single continuous production line.

2. The method according to claim 1, wherein at least one of the one or more soluble filament forming materials comprises a hydroxyl polymer, preferably wherein the hydroxyl polymer is selected from: pullulan, hydroxypropyl methylcellulose, hydroxyethyl cellulose, methylcellulose, hydroxypropyl cellulose, polyvinylpyrrolidone, carboxymethyl cellulose, sodium alginate, xanthan gum, tragacanth gum, guar gum, acacia gum, gum arabic, polyacrylic acid, methyl methacrylate copolymer, carboxyvinyl polymer, dextrin, pectin, chitin, fructan, succinate, collagen, gelatin, zeatin, gluten, soy protein, casein, polyvinyl alcohol, carboxylated polyvinyl alcohol, sulfonated polyvinyl alcohol, starch, starch derivatives, hemicellulose, hemicellulose derivatives, protein, deacetylated chitosan, deacetylated chitosan derivatives, polyethylene glycol, tetramethylene ether glycol, hydroxymethyl cellulose, polyethylene oxide, and mixtures thereof, more preferably wherein the hydroxyl polymer comprises polyvinyl alcohol.

3. The method according to claim 1 or 2, wherein at least one of the one or more filament forming materials is in granular form.

4. The method according to any one of the preceding claims, wherein in step b, at least 30% by weight of water is added to the one or more filament forming materials, preferably wherein in step b, at least 40% by weight of water is added to the one or more filament forming materials.

5. The method according to any one of the preceding claims, wherein the step of processing the aqueous composition is carried out in an extruder, preferably wherein the extruder is a twin-screw extruder.

6. The method of claim 5, wherein the aqueous composition present in the extruder exhibits 20% to 95% solids, preferably wherein the aqueous composition present in the extruder exhibits 30% to 85% solids, more preferably wherein the aqueous composition present in the extruder exhibits 40% to 70% solids.

7. The method of claim 5, wherein the filament forming composition exits the extruder at an outlet pressure of 10 bar to 80 bar, preferably wherein the filament forming composition exits the extruder at an outlet pressure of 15 bar to 75 bar, and more preferably wherein the filament forming composition exits the extruder at an outlet pressure of 20 bar to 65 bar.

8. The method of claim 5, wherein the extruder subjectes the filament forming composition to a temperature of at least 49°C.

9. The method of claim 5, wherein the filament forming composition exits the extruder at a solids flux of 0.10 kW-h / kg to 0.50 kW-h / kg, preferably wherein the filament forming composition exits the extruder at a solids flux of 0.12 kW-h / kg to 0.45 kW-h / kg, more preferably wherein the filament forming composition exits the extruder at a solids flux of 0.14 kW-h / kg to 0.35 kW-h / kg.

10. The method according to any one of the preceding claims, wherein the plurality of solid additives comprises particles, preferably wherein the particles comprise water-soluble particles and / or water-insoluble particles.

11. The method of claim 10, wherein at least one of the particles is an agglomerate, preferably wherein the agglomerate comprises a water-soluble material and / or a water-insoluble material, more preferably wherein the agglomerate comprises water-soluble particles, water-insoluble particles, or a combination thereof.

12. The method of claim 10, wherein the particles comprise particles containing an active agent.

13. The method according to any one of the preceding claims, wherein at least one of the one or more surfactants is selected from: fabric care surfactants, dishwashing surfactants, carpet care surfactants, surface care surfactants, air care surfactants, oral care surfactants, hair care surfactants, shampoos, conditioning agents, keratinizing agents, toilet cleaners, skin care surfactants, and mixtures thereof.

14. The method according to claim 13, wherein at least one of the one or more active agents is added in at least one of steps b, c and d of the method.

15. The method of claim 1, wherein the method further comprises the step of: converting the fiber structure using one or more conversion processing operations selected from cutting; stacking; calendering; treatment with optional components; printing; and combinations thereof.

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