Skin cleansing article comprising a water-dispersible and / or water-soluble core substrate - Patent Application 20070229633

Abstract

Provided is a skin cleansing article configured to deliver a cosmetic or skin therapeutic to the skin of a user, and a method for making the same. For example, the skin cleansing article includes a core substrate comprising a resin. The core substrate has a first region containing a first active cleansing formulation and a second region containing a second active cleansing formulation. The skin cleansing article is substantially dry or solid, and water-dispersible or water-soluble. When the water-soluble core substrate is in contact with water having a temperature higher than 10°C for a period of time, the core substrate becomes dispersible or soluble according to test method MSTM-205, and releases the first active cleansing formulation and / or the second active cleansing formulation.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 63 / 185,725, filed May 7, 2021, the entirety of which is expressly incorporated herein by reference.

[0002] Field The present disclosure generally relates to water-dispersible and / or water-soluble skin cleansing articles that include a water-dispersible or water-soluble core structure. More specifically, the present disclosure relates to water-dispersible and / or water-soluble skin cleansing articles that include a water-dispersible and / or water-soluble substrate, such as a nonwoven, that is configured to contain an active cleansing formulation. [Background technology]

[0003] background Facial masks are usually placed on the face of a user to apply active skin agents. Conventional facial masks made of paper-based substrates are usually uncomfortable to the touch due to the stiff or inflexible structure of the facial mask, and do not adhere to the face of the user to maintain contact between the active skin agent and the skin of the user. Furthermore, because conventional facial masks get wet during use, these conventional facial masks may lose the structure and integrity required to keep the facial mask accurately positioned on the face of the user and to deliver the active skin agent to the desired location on the face of the user. As a result, the active skin agent may migrate or move from the facial mask and into the eyes, nostrils and / or mouth of the user, resulting in unpleasant or undesirable effects, such as caustic or acidic ingredients flowing into the eyes, nostrils and / or mouth of the user, causing skin and / or membrane irritation and / or pain.

[0004] Furthermore, conventional facial masks are often stored in separate secondary packaging made of plastic, foil, or composite materials that are required to keep the facial mask dry during shipping and / or storage. A moisture barrier, such as a moisture barrier film coupled to the surface of the facial mask or encapsulating the facial mask, may also be required to maintain the structure and integrity of the facial mask as well as the moisture content of the facial mask before use. This secondary packaging is generally not environmentally friendly, compostable, recyclable, or biodegradable. Summary of the Invention [Problem to be solved by the invention]

[0005] Therefore, there is a need in the art for a skin cleansing article that can be easily manufactured and has a structure that maintains its structure and integrity to keep one or more areas of the facial mask aligned with the respective locations of the face of the user and the facial mask accurately positioned on the face of the user.Furthermore, there is a need in the art for a facial mask that contains a skin cleansing formulation that can be easily applied to the face of the user and easily removed.Furthermore, there is a need in the art for a facial mask that significantly reduces the need for secondary packaging during transportation and storage of the facial mask before use. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a schematic plan view of an exemplary water-dispersible skin cleansing article in the form of a facial mask according to an exemplary embodiment, containing one or more active cleansing formulations in one or more respective regions of the facial mask.

[0007] [Diagram 2] FIG. 2 is a schematic cross-sectional view of an exemplary water-dispersible skin cleansing article taken along section line AA as shown in FIG. 1 according to an exemplary embodiment.

[0008] [Diagram 3] FIG. 3 is a schematic cross-sectional view of another exemplary water-dispersible skin cleansing article, according to an exemplary embodiment.

[0009] [Figure 4] FIG. 4 is a perspective view of an exemplary secondary package suitable for storing a plurality of water-dispersible or water-soluble skin cleansing articles, according to an exemplary embodiment.

[0010] [Diagram 5] FIG. 5 illustrates an example method of making a water-dispersible skin cleansing article according to an example embodiment.

[0011] [Figure 6] FIG. 6 shows solubility results (at 23° C.) for an exemplary sample including a core substrate including at least one nonwoven layer or sheet having a plurality of fibers including a first type of fiber (“F1”) including a polyvinyl alcohol copolymer having a degree of hydrolysis of 88% and a second type of fiber (“F2”) including a polyvinyl alcohol copolymer having a degree of hydrolysis of 96%.

[0012] [Figure 7] FIG. 7 shows the solubility results (at 23° C.) of exemplary samples including the core substrate of FIG. 6 containing an active cleansing formulation.

[0013] [Figure 8] FIG. 8 shows solubility results (at 40° C.) of an exemplary core substrate including at least one nonwoven layer or sheet having a plurality of fibers including a first type of fiber (“F1”) comprising a polyvinyl alcohol copolymer having a degree of hydrolysis of 88% and a second type of fiber (“F2”) comprising a polyvinyl alcohol copolymer having a degree of hydrolysis of 96%.

[0014] [Figure 9] FIG. 9 shows the solubility results (at 40° C.) of exemplary samples including the core substrate of FIG. 8 containing an active cleansing formulation.

[0015] [Figure 10] FIG. 10 shows Fourier transform infrared spectroscopy (FI-IR) curves illustrating the transfer of an active cleansing formulation from a water-soluble nonwoven layer or sheet as a core substrate to the surface of a separate object made of polyester. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Detailed Description In the exemplary embodiment described herein, the water-dispersible and / or water-soluble skin cleansing article comprises one or more water-dispersible substrates and / or one or more water-soluble core substrates, such as one or more water-dispersible nonwoven substrates and / or one or more water-soluble nonwoven substrates, and has a precision dosage to deliver active cleansing formulations, such as one or more cleaning agents, for delivering cosmetics and / or one or more skin treatments to the skin of the user. In the exemplary embodiment, the water-soluble skin cleansing article comprises a water-soluble core substrate comprising a water-soluble resin. The water-soluble core substrate has one or more areas or regions configured to contain one or more active cleansing formulations, such as cosmetics or skin treatment formulations. For example, the water-soluble core substrate may have a first region containing a first active cleansing formulation and a second region containing a second active cleansing formulation, which may be the same as or different from the first active cleansing formulation. When the water-soluble core substrate is contacted with water having a temperature higher than 10° C. or having a temperature between 30° C. and 40° C. for a period of 30 to 300 seconds (or 30 to 600 seconds or 30 to 900 seconds), the water-soluble core substrate becomes soluble and releases at least one of one or more active cleansing formulations, such as at least one of the first active cleansing formulation or the second active cleansing formulation. In an exemplary embodiment, the water-dispersible core substrate is cold water dispersible or the water-soluble core substrate is cold water soluble, which tends to close skin pores, and may be advantageous for, for example, refining skin pores and skin surface during the exfoliation process. Alternatively, the water-dispersible core substrate is warm water dispersible or the water-soluble substrate is warm water soluble, which tends to open skin pores, and may be advantageous for, for example, delivering active cleansing formulations to pores and skin during the acne treatment process. In an exemplary embodiment, the water-dispersible skin cleansing article is initially dry, i.e., dry during storage and prior to use. In an exemplary embodiment, the transition of the nonwoven substrate to a hydrogel as the water-dispersible core substrate is accomplished by contacting the substrate with water at a desired temperature for a suitable amount of time, e.g., 300 seconds.In certain exemplary embodiments, a film layer is created as the water-soluble core substrate dissolves to facilitate the removal of any remaining components of the water-soluble skin cleansing article after use.In certain embodiments, the water-dispersible or water-soluble skin cleansing article comprises a film layer, for example, a water-dispersible or water-soluble film connected to the water-dispersible or water-soluble core substrate.The water-dispersible or water-soluble film may comprise additional active cleansing formulations for delivery to the skin of the user, and / or may be used to facilitate the removal of any remaining components of the water-dispersible or water-soluble skin cleansing article after use.

[0017] In exemplary embodiments, the skin cleansing article is configured to be at least water-dispersible or water-soluble when in contact with water for a period of time. The water-dispersible or water-soluble skin cleansing articles described herein are initially provided in a substantially dry or solid state, and water is added or applied to activate the skin cleansing article before or during use. Before water is added or applied, such a substantially dry or substantially solid state skin cleansing article may contain no moisture or solvent or less than 10% by weight (such as less than 5% by weight) moisture or solvent. In exemplary embodiments, the terms "substantially dry", "substantially solid", "dry" or "solid" can refer to a skin cleansing article that does not contain moisture or solvent or contains less than 10% by weight (such as less than 5% by weight) moisture or solvent.

[0018] In exemplary embodiments, the core substrate comprises a resin (i.e., a polymer) and may be water-dispersible or water-soluble. For example, the core substrate comprises at least one nonwoven substrate comprising a plurality of fibers comprising a resin selected from at least one of a water-dispersible resin or a water-soluble resin. In addition to the nonwoven substrate, the substrate may also be a foam substrate or a film substrate. The resin may be any suitable polymer or may include one or more such polymers. For example, in exemplary embodiments, the resin is a polymer comprising a vinyl alcohol moiety. A "polymer comprising a vinyl alcohol moiety" or a "PVOH polymer" includes a polyvinyl alcohol (PVOH) homopolymer, a polyvinyl alcohol (PVOH) copolymer, or a combination thereof. For example, a polyvinyl alcohol copolymer is, in some embodiments, a copolymer of vinyl acetate and vinyl alcohol. Such a polyvinyl alcohol copolymer may be an anionically modified copolymer, which may be a copolymer of vinyl acetate and vinyl alcohol further comprising additional groups such as carboxylate, sulfonate, or a combination thereof. Such a polymer comprising at least one vinyl acetate moiety or vinyl alcohol moiety may also include additional polymers, for example in a blend. In an exemplary embodiment, the water-dispersible skin cleansing article is configured to deliver a cosmetic or skin treatment agent to the skin of a user. The water-dispersible skin cleansing article includes a water-dispersible core substrate that includes a water-dispersible resin.The water-dispersible core substrate comprises a first region containing a first active cleansing formulation and a second region containing a second active cleansing formulation, wherein when the water-dispersible core substrate contacts with water having a first temperature, e.g., water having a temperature of 10°C or water having a temperature of 40°C or less, the water-dispersible core substrate is activated by MSTM-205 to release the first active cleansing formulation and / or the second active cleansing formulation from the water-dispersible core substrate to deliver the first active cleansing formulation and / or the second active cleansing formulation to the skin of the user, and when the water-dispersible core substrate contacts with water having a second temperature equal to or higher than the first temperature, e.g., water having a temperature equal to or higher than 40°C, for a period of 30 to 300 seconds (or 30 to 600 seconds or 30 to 900 seconds), the water-dispersible core substrate becomes dispersible.

[0019] In another exemplary embodiment, the water-soluble skin cleansing article is configured to deliver a cosmetic or skin treatment agent to the skin of a user. The water-soluble skin cleansing article includes a water-soluble core substrate that includes a water-soluble resin. The water-soluble core substrate comprises a first region containing a first active cleansing formulation and a second region containing a second active cleansing formulation, and when the water-soluble core substrate contacts with water having a first temperature, e.g., water having a temperature of 10°C, or water having a temperature of 40°C or less, the water-soluble core substrate is activated by MSTM-205 to release the first active cleansing formulation and / or the second active cleansing formulation from the water-soluble core substrate to deliver the first active cleansing formulation and / or the second active cleansing formulation to the skin of the user, and when the water-soluble core substrate contacts with water having a second temperature equal to or higher than the first temperature, e.g., water having a temperature equal to or higher than 40°C, for a period of 30 to 300 seconds (or 30 to 600 seconds or 30 to 900 seconds), the water-soluble core substrate becomes soluble.

[0020] Although the water-dispersible or water-soluble skin cleansing article is described herein as a water-dispersible or water-soluble nonwoven substrate in the form of a facial mask configured to contain one or more active cleansing formulations in one or more areas or regions of the facial mask for delivering, for example, releasing, the active cleansing formulation to a desired location on the skin of a user's face, in other exemplary embodiments, the water-dispersible or water-soluble skin cleansing article described herein is suitable for delivering active cleansing formulations or other skin wellness formulations to other locations on the skin of a user's body, for example.Furthermore, the water-dispersible or water-soluble skin cleansing article may take other forms than a facial mask, including, but not limited to, for example, a wipe, a sheet, a pad, a sachet or a strip.

[0021] In an exemplary embodiment, the water-dispersible or water-soluble skin cleansing article is in the form of a water-dispersible or water-soluble facial mask made of a suitable water-dispersible or water-soluble core substrate, such as a water-dispersible or water-soluble nonwoven substrate. Before use, the water-dispersible or water-soluble nonwoven substrate is substantially flat, but can be formed to the contours of the user's body, e.g., can be formed to the contours of the skin surface of the user's face when wetted with water before or during use. The water-dispersible or water-soluble nonwoven substrate includes openings for alignment with the user's eyes, nose, and mouth, respectively, to facilitate proper positioning of the facial mask on the user's face. In certain embodiments, a first active cleansing formulation, for example, for treating wrinkles, is contained on or within a first region of the water-dispersible or water-soluble nonwoven substrate, which is positioned against the user's eyes, e.g., so that the user's skin contacts around and / or under each eye. Similarly, the second region of the water-dispersible or water-soluble nonwoven substrate may be positioned against the user's forehead, for example, to contact the user's skin on the user's forehead and / or the user's nose bridge, and may contain a first active cleansing formulation, for example, to treat wrinkles, and / or a second active cleansing formulation, for example, to treat acne. Additionally or alternatively, the third region of the water-dispersible or water-soluble nonwoven substrate may be positioned against one or both of the user's cheeks or the user's chin, for example, to contact the user's skin around the user's cheekbones and / or chin, and may contain a second active cleansing formulation, for example, to treat acne, and / or a different active cleansing formulation that provides additional skin wellness formulations to the user's skin. In an exemplary embodiment, each of the first region, the second region, and the third region forms at least a portion of a facial mask. In certain embodiments, one or more of the first region, the second region, or the third region may be separated from other regions of the facial mask before or during use.

[0022] In an exemplary embodiment, due to its high hygroscopicity, the water-dispersible or water-soluble core substrate exists as a gel-like composition during use to provide high hydration and comfort, softening benefits. Furthermore, the gel-like composition effectively maintains the structure and proper positioning of the facial mask on the user's face while maintaining the active cleansing composition in the proper position to contact the desired location on the user's face during use. Furthermore, in an exemplary embodiment in which the water-soluble core substrate is made of PVOH resin, the chemistry of the water-soluble core substrate, particularly the presence of PVOH, provides a soothing effect or benefit to the skin cleansing process.

[0023] In an exemplary embodiment, when the water-soluble core substrate comes into contact with water having a temperature greater than 10° C. or having a temperature between 30° C. and 40° C., the water-soluble core substrate becomes soluble and releases the active cleansing formulation. In an exemplary embodiment, the water-soluble core substrate comprises a water-soluble polymer, such as a polyvinyl alcohol (PVOH) copolymer and / or a starch derivative, such as a blend thereof with a water-dispersible polymer that otherwise has a high degree of biodegradable activity or is compostable or recyclable.

[0024] In an exemplary embodiment, the water-soluble core substrate is a water-soluble nonwoven substrate made of a PVOH resin, such as a PVOH polymer. During use, the water-soluble nonwoven substrate dissolves into a gel-like substrate that provides a soft and comfortable feel while maintaining the structure and integrity of the nonwoven substrate to facilitate keeping the facial mask precisely positioned on the user's face. In an exemplary embodiment, the degree of hydrolysis of the PVOH copolymer and / or the stretching or drawing of the fibers can be adjusted, for example, to achieve fiber swelling and adsorption that enhances the gel-like substrate.

[0025] The water-dispersible skin cleansing article, in particular, in an exemplary embodiment, the water-dispersible or water-soluble core substrate is configured to contain one or more active cleansing formulations for delivering cosmetic or skin treatment agents to the skin of a user.By way of example, the active cleansing formulations may include, but are not limited to, hyaluronic acid, aloe, chamomile extract, lactic acid, citric acid, hydrolyzed collagen, polysaccharides, peptides, surfactants, such as surfactants made from polysaccharides, or foaming agents, or any suitable combination thereof.Other suitable active cleansing formulations may include ceramides, glycolic acid and other alpha hydroxy acids, amino acids, peptides, activated charcoal, chemical and physical sunscreen ingredients, minerals (e.g., Zn), avobenzone, etc., antioxidants, activators, such as caffeine, ginseng, taurine, etc., retinol, retinoic acid, niacinamide, salicylic acid, lactic acid, and / or aseliaic acid. In exemplary embodiments, the active cleansing formulation is disposed or coated on one or more surfaces of, or embedded and / or adhered to, the water-soluble core substrate. The water-soluble core substrate may comprise a single layer, e.g., a single layer of nonwoven core substrate, or may comprise multiple layers, e.g., a sheet of nonwoven core substrate folded in a serpentine arrangement, or cut and overlapped, e.g., to form one or more layers of the water-soluble nonwoven core substrate, e.g., layers including the active cleansing formulation disposed between adjacent layers.

[0026] In an exemplary embodiment, the water-soluble core substrate contains an active cleansing formulation, and when contacted with water having a moderate temperature, the water-soluble core substrate exhibits a shrinkage of 0.5% to 65%. In an exemplary embodiment, when the core substrate contacts water having a temperature as low as 5° C. to 10° C., the core substrate becomes dispersible, i.e., disintegrates and releases the active cleansing formulation. In an exemplary embodiment, when the core substrate contacts water having a temperature greater than 40° C., the water-soluble core substrate becomes soluble, i.e., dissolves and releases the active cleansing formulation.

[0027] As used herein and unless otherwise indicated, the term "water-dispersible" refers to any nonwoven substrate (or nonwoven web), foam substrate, film, or laminate that, upon immersion in water at a specified temperature, physically dissociates the nonwoven substrate, foam substrate, film, or laminate into smaller constituent pieces. The smaller pieces may or may not be visible to the naked eye, may or may not remain suspended in water, and may or may not ultimately dissolve. In exemplary embodiments, such nonwoven substrate (or nonwoven web), foam substrate, film, or laminate has a disintegration time of 900 seconds or less, or particularly 600 seconds or less, or especially 300 seconds or less, at a specified temperature as determined by MSTM-205 as described herein. In exemplary embodiments where no dispersion temperature is specified, the nonwoven substrate, foam substrate, film, or laminate disintegrates in 300 seconds or less at a temperature of about 100°C or less by MSTM-205. The disintegration time may be 200 seconds or more, 100 seconds or more, 60 seconds or more, or 30 seconds or more at temperatures of about 80° C., about 70° C., about 60° C., about 50° C., about 40° C., about 20° C., or about 10° C., as appropriate, with MSTM-205. In an alternative exemplary embodiment where the dispersion temperature is not specified, the nonwoven substrate, foam substrate, film, or laminate disintegrates in 300 seconds or less at temperatures of about 100° C. or less with MSTM-205. The disintegration time may be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less at temperatures of about 80° C., about 70° C., about 60° C., about 50° C., about 40° C., about 20° C., or about 10° C., as appropriate, with MSTM-205. For example, such dispersion parameters may be characteristic of a nonwoven substrate, a foam substrate, a film or a laminate structure having a thickness of 6 millimeters (mm or mils) (about 152 microns (μm)).As described herein, in exemplary embodiments, the disintegration time of the nonwoven substrate, foam substrate, film or laminate may exceed a minimum limit, such as 30 seconds, so that the article, e.g., a facial mask, can be accurately applied to the user's face, such that there is a suitable amount of time between application of the article, e.g., contacting the article with water to perform its intended function, e.g., delivering one or more active cleansing formulations to the user's skin, to provide the desired application benefit. In exemplary embodiments, the nonwoven substrate (or nonwoven web), foam substrate, film or laminate may have a disintegration time within a range suitable for MSTM-205, e.g., between 30 seconds and 900 seconds, between 30 seconds and 600 seconds, between 30 seconds and 300 seconds, between 60 seconds and 900 seconds, between 60 seconds and 600 seconds, or between 60 seconds and 300 seconds, at temperatures of, e.g., about 80°C, about 70°C, about 60°C, about 50°C, about 40°C, about 20°C, or about 10°C.

[0028] As used herein and unless otherwise indicated, the term "water soluble" refers to any nonwoven substrate (or nonwoven web), foam substrate, film, or laminate that, in exemplary embodiments, has a dissolution time of 900 seconds or less, or particularly 600 seconds or less, or especially 300 seconds or less, at the specified temperature as determined by MSTM-205 as described herein. The dissolution time may depend, at least in part, on the active cleansing formulation or formulations used in the substrate, film, laminate, or article described herein and / or the desired application process. Further, in exemplary embodiments, the nonwoven substrate (or nonwoven web), foam substrate, film, or laminate can have a dissolution time within a suitable range, e.g., between 30 seconds and 900 seconds, between 30 seconds and 600 seconds, between 30 seconds and 300 seconds, between 60 seconds and 900 seconds, between 60 seconds and 600 seconds, or between 60 seconds and 300 seconds, at a temperature of, e.g., about 80°C, about 70°C, about 60°C, about 50°C, about 40°C, about 20°C, or about 10°C, per MSTM-205. In exemplary embodiments, the dissolution time of the nonwoven substrate, foam substrate, film, or laminate may be 900 seconds or less, 600 seconds or less, 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less with MSTM-205 at temperatures of about 80° C., about 70° C., about 60° C., about 50° C., about 40° C., about 20° C., or about 10° C., as appropriate. As described herein, in exemplary embodiments, the dissolution time of the nonwoven substrate, foam substrate, film, or laminate may exceed a minimum limit, such as 30 seconds, such that the article, e.g., a facial mask, can be accurately applied to a user's face, e.g., there is an appropriate amount of time between contacting the article with water and doing its intended job, e.g., delivering one or more active cleansing formulations to the user's skin, to provide the desired application benefit. In exemplary embodiments where no dissolution temperature is specified, the water soluble nonwoven substrate, foam substrate, film or laminate has a dissolution time of 300 seconds or less at a temperature of about 80° C. or less.In exemplary embodiments, a "water soluble nonwoven substrate" or "water soluble nonwoven web" means that at a thickness of 1.5 mils (about 38 μm), the nonwoven substrate dissolves in 300 seconds or less with MSTM-205 at a temperature of 80° C. or less. For example, a water soluble nonwoven substrate having a thickness of 1.5 mils (about 38 μm) can have a dissolution time of 300 seconds or less, 200 seconds or less, 100 seconds or less, or 60 seconds or less with MSTM-205 at a temperature of about 70° C., about 60° C., about 50° C., about 40° C., about 30° C., about 20° C., or about 10° C.

[0029] As used herein and unless otherwise indicated, the term "cold water soluble" refers to any water soluble nonwoven substrate, foam substrate, film, or laminate that has a dissolution time of 300 seconds or less at a temperature ranging from about 10° C. to about 20° C. as determined by MSTM-205. For example, the dissolution time of a cold water soluble nonwoven substrate, foam substrate, film, or laminate may be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds at a temperature ranging from about 10° C. to about 20° C. as appropriate by MSTM-205. In an exemplary embodiment, a "cold water soluble nonwoven substrate" or a "cold water soluble nonwoven web" means that a nonwoven substrate at a thickness of 1.5 mils (about 38 μm) dissolves in 300 seconds or less at a temperature of 20° C. or less by MSTM-205. For example, a 1.5 mil (about 38 μm) thick cold water soluble nonwoven substrate may have a dissolution time of 300 seconds or less, 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less with MSTM-205 at a temperature of about 20° C. or about 10° C.

[0030] As used herein and unless otherwise indicated, the term "hot water soluble" refers to any water soluble nonwoven substrate, foam substrate, film or laminate that has a dissolution time of 300 seconds or less at temperatures greater than about 20°C, e.g., in the range of about 21°C to about 80°C, as determined by MSTM-205. For example, the dissolution time of a hot water soluble nonwoven substrate, foam substrate, film or laminate, optionally with MSTM-205, at a temperature above about 20° C., such as from about 21° C. to about 80° C., from about 25° C. to about 80° C., from about 25° C. to about 60° C., from about 30° C. to about 60° C., from about 25° C. to about 45° C., from about 30° C. to about 45° C., or from about 25° C. to about 43° C., from about 30° C. to about 43° C., from about 25° C. to about 40° C., or from about 30° C. to about 40° C., may be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds. In exemplary embodiments, a "hot water soluble nonwoven substrate" or "hot water soluble nonwoven web" means that at a thickness of 1.5 mils (about 38 μm), the nonwoven substrate dissolves in 300 seconds or more with MSTM-205 at a temperature of about 21° C. or greater. For example, a water soluble nonwoven substrate having a thickness of 1.5 mils (about 38 μm) can have a dissolution time of 300 seconds or less, 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds with MSTM-205 at a temperature of about 80° C., 70° C., about 60° C., about 50° C., about 40° C., about 30° C., about 25° C., or about 21° C. In an exemplary embodiment, a hot water soluble substrate, such as a "hot water soluble nonwoven substrate" or "hot water soluble nonwoven web," remains stable, e.g., does not dissolve, when contacted with water having a temperature below its hot water solubility temperature, but becomes soluble, e.g., dissolves, when contacted with water having a temperature equal to its hot water solubility temperature for a suitable dissolution time, e.g., between 30 seconds and about 300 seconds.For example, in exemplary embodiments, MSTM-205 causes a hot water soluble nonwoven substrate in contact with water at a temperature of 40° C. for 300 seconds or less (or 600 seconds or less, or 900 seconds or less) to become soluble, but the hot water soluble nonwoven substrate is stable when in contact with water having a temperature less than 40° C., or when in contact with water having a temperature of 40° C. for less than 300 seconds.

[0031] As used herein, unless otherwise indicated, the term "nonwoven web" refers to a web or sheet that includes, consists of, or consists essentially of fibers that are arranged (e.g., carding process) and bonded to each other. Thus, the term "nonwoven web" can be considered an abbreviation for a web based on nonwoven fibers. Furthermore, as used herein, "nonwoven web" includes any structure that includes a nonwoven web or sheet, including, for example, a nonwoven web or sheet that has a film laminated to its surface. Methods for preparing nonwoven webs from fibers are well known in the art, for example, as described in Nonwoven Fabrics Handbook, prepared by Ian Butler, edited by Subhash Batra et al., Printing by Design, 1999, which is incorporated herein by reference in its entirety. As used herein, and unless otherwise indicated, the term "film" refers to a continuous film or sheet prepared, for example, by a casting or extrusion process.

[0032] As used herein, a "plurality of fibers" can include a single fiber type, or can include two or more different fiber types. In exemplary embodiments where the plurality of fibers includes two or more different fiber types, each fiber type can generally be included in any amount, for example, in an amount of about 0.5% to about 99.5% by weight of the total weight of the plurality of fibers. In exemplary embodiments where the plurality of fibers consists of a single fiber type, the plurality of fibers is substantially free of a second or more fiber type. The plurality of fibers is substantially free of a second or more fiber type when the plurality of fibers includes less than about 0.5% by weight of the second or more fiber type. In general, differences between fiber types can be determined by fiber length to diameter ratio (L / D), toughness, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g ), chemical composition, color, or a combination thereof.

[0033] As used herein, the terms "resin(s)" and "polymer(s)" should be considered synonymous. In certain embodiments, the terms resin(s) and polymer(s) are used to refer to a polymer optionally combined with one or more additional polymers, and to refer to a single type of polymer, respectively, e.g., a resin can include more than one polymer.

[0034] As used herein, and unless otherwise indicated, the terms "weight percent (wt.%)" and "weight percent (wt%)" shall refer to the composition of an element specified in "dry" (anhydrous) parts by weight of the entire water-soluble film, including, for example, residual moisture in the water-soluble film, or the composition of an element specified in parts by weight of the entire composition, as appropriate to the context.

[0035] As used herein and unless otherwise indicated, the term "PHR" ("phr") shall refer to the composition of the specified element per 100 parts water soluble polymeric resin(s) in the water soluble nonwoven substrate, foam substrate or film, or in the solution used to make the water soluble nonwoven substrate, foam substrate or film (whether PVOH or other polymeric resin, unless otherwise specified).

[0036] As used herein and unless otherwise indicated, the term "comprising" means that various components, ingredients, or steps can be used together in the practice of the present disclosure. Thus, the term "comprising" encompasses the more restrictive terms "consisting essentially of" and "consisting of". The compositions of the present invention can comprise, consist essentially of, or consist of any of the required and optional elements disclosed herein. Suitably, the present disclosure as illustratively disclosed herein may be practiced in the absence of any element or step not specifically disclosed herein.

[0037] When values ​​are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. As used herein, "about X," where X is a numerical value, refers in exemplary embodiments to ±10% (e.g., ±5%) of the stated value, inclusive.

[0038] The water-dispersible or water-soluble skin cleansing articles, water-dispersible or water-soluble nonwoven materials, water-dispersible or water-soluble foam materials, and water-dispersible or water-soluble film materials, and related methods of making and using the water-dispersible or water-soluble skin cleansing articles, water-dispersible or water-soluble nonwoven materials, water-dispersible or water-soluble foam materials, and water-dispersible or water-soluble film materials, are intended to include embodiments that include any combination of one or more of the additional optional elements, features, and steps further described below, unless otherwise noted.

[0039] In an exemplary embodiment, the water-dispersible skin cleansing article comprises a water-soluble core substrate comprising a water-soluble resin. In an exemplary embodiment, the water-soluble core substrate comprises one of the more water-soluble nonwoven core substrates. The water-soluble core substrate contains an active cleansing formulation that dissolves and releases the active cleansing formulation when the water-soluble core substrate contacts with water having a temperature higher than 10°C or with water having a temperature between 30°C and 40°C. In an exemplary embodiment, the water-soluble core substrate becomes dispersible at 10°C in 300 seconds, dissolvable at 20°C in more than 15 seconds and less than 300 seconds, dissolvable at 40°C in more than 15 seconds and less than 300 seconds, and dissolvable at 80°C in less than 300 seconds.

[0040] In exemplary embodiments, the active cleansing formulation is in the form of at least one of a solid, such as a powder or a plurality of granules or particles, a gel, a liquid, or a slurry form, or any suitable combination thereof. In certain embodiments, the water-soluble core substrate is saturated with the active cleansing formulation. In other embodiments, the active cleansing formulation is embedded, applied, disposed, coated, and / or adhered to the water-soluble core substrate, for example, the active cleansing formulation is disposed on the surface of the water-soluble core substrate. In exemplary embodiments, the water-soluble core substrate is at least one of coated with the active cleansing formulation or impregnated with the active cleansing formulation. In exemplary embodiments, the active cleansing formulation is present in the water-soluble core substrate, for example, in a fiber-forming composition, a foam-forming composition, or a film-forming composition.

[0041] Referring now to the figures and initially to FIG. 1, in an exemplary embodiment, a water-soluble skin cleansing article 20 takes the form of a water-soluble facial mask 22 made of a suitable water-soluble core substrate, such as a water-soluble nonwoven substrate 24. Although each of the skin cleansing article 20, facial mask 22, core substrate, and nonwoven substrate 24 are described with reference to FIGS. 1-4 as being water-soluble, each of the skin cleansing article 20, facial mask 22, core substrate, and nonwoven substrate 24 may comprise water-dispersible and / or water-soluble materials, such as a plurality of water-dispersible fibers, a plurality of water-soluble fibers, or a blend of water-dispersible and water-soluble fibers. The facial mask 22, such as the water-soluble nonwoven substrate 24, has a first surface 26 configured to contact the skin of a user, and an opposing second surface 28. Before or during use, the facial mask 22 is positioned on the user's face such that the first surface 26 contacts the surface of the skin of the user's face. In exemplary embodiments, the water soluble nonwoven substrate 24 is substantially flat, but when wetted, for example, with water, the water soluble nonwoven substrate 24 is formable to conform or form to the contours of a user's body, for example, formable to conform to the contours of the skin surface of the user's face. In other exemplary embodiments, the water soluble nonwoven substrate 24 is not flat, having a surface contour configured or shaped to conform to the contours of the skin surface of the user's face, for example, around the user's eyes, along the user's forehead, and / or along the user's cheekbones and / or chin.

[0042] As shown in FIG. 1, the facial mask 22, e.g., a water-soluble nonwoven substrate 24, includes a plurality of openings in alignment with the user's eyes, nose, and mouth, respectively, to facilitate proper positioning of the facial mask on the user's face. For example, as shown in FIG. 1, the nonwoven substrate 24 forms a first or right eye opening 30 and a second or left eye opening 32 in alignment with the user's right eye and left eye, respectively. Additionally, the nonwoven substrate 24 forms a third opening 34 in alignment with the user's nose, and a fourth opening 36 in alignment with the user's mouth. In an exemplary embodiment, the nonwoven substrate 24 includes one or more regions, e.g., a plurality of regions, such as a first region 40, a second region 42, a third region 44, and a fourth region 46. Each region of the plurality of regions is configured to contain one or more active cleansing formulations 50.

[0043] For example, in an exemplary embodiment, a first active cleansing formulation, for example, treating wrinkles, may be contained on or within the first region 40 and / or may be contained on or within the second region 42 of the water-soluble nonwoven substrate 24 and positioned against the user's eyes, for example, to contact the user's skin around the right or left eye, respectively, and / or the user's skin under the eye, respectively. Additionally or alternatively, a third region 44 of the water-soluble nonwoven substrate 24 may be positioned against the user's forehead, for example, to contact the user's skin on the user's forehead and / or the bridge of the user's nose. For example, the third region 44 may be configured to contain a first active cleansing formulation, for example, treating wrinkles, and / or a second cleansing formulation, for example, treating acne. Additionally or alternatively, a fourth region 46 of the water-soluble nonwoven substrate 24 may be positioned against one or both of the user's cheeks and / or the user's chin, for example, to contact the user's skin around the user's cheekbones and / or chin. The fourth region 46 is configured to contain a second active cleansing formulation, for example to treat acne, and / or a different active cleansing formulation that provides an additional skin wellness formulation to the user's skin.

[0044] In an exemplary embodiment, each of the first region 40, the second region 42, the third region 44, and the fourth region 46 forms at least a portion of the water-soluble facial mask 22. In an exemplary embodiment, each of the first region 40, the second region 42, the third region 44, and / or the fourth region 46 has suitable dimensions to effectively deliver, e.g., release, the active cleansing formulation 50 to a desired location on the skin of a user. In certain embodiments, one or more of the first region 40, the second region 42, the third region 44, or the fourth region 46 may have adjacent overlapping areas. Additionally, one or more of the first region 40, the second region 42, the third region 44, or the fourth region 46 may be separated from the water-soluble facial mask 22 before or during use.

[0045] In an exemplary embodiment, a skin cleansing article, such as, for example, a facial mask, wipe, sheet, pad, sachet, or strip, is configured to deliver cosmetics and / or skin treatments to the skin of a user. The skin cleansing article includes a first nonwoven substrate including a plurality of fibers including a water-soluble resin. The first nonwoven substrate has at least one first region including a first active cleansing formulation contained in the first region. A second nonwoven substrate is connected to the first nonwoven substrate. The second nonwoven substrate includes a plurality of fibers including a water-dispersible resin and / or a water-soluble resin. The second nonwoven substrate has at least one second region including a second active cleansing formulation contained in the second region. In an exemplary embodiment, when the first nonwoven substrate is contacted with water having a temperature higher than 10° C. for 300 seconds or less (e.g., 30 seconds to 300 seconds), the first nonwoven substrate becomes soluble with MSTM-205 and releases the first active cleansing formulation from the first nonwoven substrate. In certain embodiments, the second nonwoven substrate comprises a plurality of fibers comprising a water-dispersible resin, and when the second nonwoven substrate is contacted with water having a temperature greater than 10° C. for 300 seconds or less (e.g., 30 to 300 seconds), the second nonwoven substrate becomes dispersible by MSTM-205 and releases the second active cleansing formulation from the second nonwoven substrate. In certain embodiments, the second nonwoven substrate comprises a plurality of fibers comprising a water-soluble resin, and when the second nonwoven substrate is contacted with water having a temperature greater than 10° C. for 300 seconds or less (e.g., 30 to 300 seconds), the second nonwoven substrate becomes soluble by MSTM-205 and releases the second active cleansing formulation from the second nonwoven substrate. In exemplary embodiments, the water-soluble film, water-dispersible film, and / or biodegradable film are coupled, e.g., laminated, to the first nonwoven substrate and / or the second nonwoven substrate.

[0046] In an exemplary embodiment, a skin cleansing article, such as, for example, a facial mask, wipe, sheet, pad, sachet or strip, is configured to deliver cosmetics and / or skin treatments to the skin of a user. The skin cleansing article includes a first nonwoven substrate including a plurality of fibers including a water-dispersible resin. The first nonwoven substrate has at least one first region including a first active cleansing formulation contained in the first region. A second nonwoven substrate is connected to the first nonwoven substrate. The second nonwoven substrate includes a plurality of fibers including a water-dispersible resin and / or a water-soluble resin. The second nonwoven substrate has a second region including a second active cleansing formulation contained in the second region. When the first nonwoven substrate is contacted with water having a temperature higher than 10° C. for 300 seconds or less (e.g., 30 seconds to 300 seconds), the first nonwoven substrate becomes dispersible by MSTM-205 and releases the first active cleansing formulation from the first nonwoven substrate. In certain embodiments, the second nonwoven substrate comprises a plurality of fibers comprising a water-dispersible resin, and when the second nonwoven substrate is contacted with water having a temperature greater than 10° C. for 300 seconds or less (e.g., 30 to 300 seconds), the MSTM-205 causes the second nonwoven substrate to become dispersible and release the second active cleansing formulation from the second nonwoven substrate. In certain embodiments, the second nonwoven substrate comprises a plurality of fibers comprising a water-soluble resin, and when the second nonwoven substrate is contacted with water having a temperature greater than 10° C. for 300 seconds or less (e.g., 30 to 300 seconds), the MSTM-205 causes the second nonwoven substrate to become soluble and release the second active cleansing formulation from the second nonwoven substrate. In exemplary embodiments, the water-soluble film, water-dispersible film, and / or biodegradable film are coupled, e.g., laminated, to the first nonwoven substrate and / or the second nonwoven substrate.

[0047] 1-3, the water-soluble skin cleansing article 20 includes a water-soluble nonwoven substrate 24 that includes a water-soluble resin. In an exemplary embodiment, the water-soluble nonwoven substrate 24 includes any suitable fiber chemistry, including, but not limited to, PVOH polymer fibers or PVOH polymer fibers blended with up to 90% by weight of cellulosic type fibers. In an alternative embodiment, the nonwoven substrate is made of water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven substrate 24 has a basis weight of 10 gsm (grams per square meter) to 120 gsm, particularly 15 gsm to 100 gsm, more particularly 30 gsm to 80 gsm, and more particularly 30 gsm to 40 gsm; a fiber length of 10 millimeters (mm) to 100 mm; and a suitable fiber diameter of 5 microns to 100 microns. In other exemplary embodiments, the water-soluble nonwoven substrate 24 has any suitable basis weight, fiber length, and / or fiber diameter. For example, in an exemplary embodiment, the fiber diameter is less than 5 microns or greater than 100 microns. The fibers of the water-soluble nonwoven substrate 24 may be created using any suitable method, including, but not limited to, carding and calendaring processes or any suitable process of making water-soluble nonwoven fibers. Additionally, the fibers of the water-soluble nonwoven substrate 24 are bonded together using any suitable bonding process or method, including, but not limited to, heat, thermal, chemical, water, and / or solution bonding methods, or any suitable bonding method known in the art of nonwoven fiber bonding. As described herein, the water-soluble nonwoven substrate 24 may include any suitable number of layers or plies, for example, from 1 layer or ply to 50 layers or plies, or more in certain embodiments. The water-soluble nonwoven substrate 24 may be porous or non-porous and may be cold water soluble, warm water soluble, or hot water soluble. The water-soluble nonwoven substrate 24 may be formed using any suitable manufacturing process known in the nonwoven fabric manufacturing art, including, but not limited to, carded processes. The construction of the water-soluble substrate 22 may include, for example, folded layers or plies, laminated layers or plies, and / or rolled layers or plies.

[0048] In an exemplary embodiment, the water-soluble nonwoven substrate 24 is configured to contain an active cleansing formulation 50. When the water-soluble nonwoven substrate 24 comes into contact with water having a temperature greater than 20° C. or between 30° C. and 40° C., the water-soluble nonwoven substrate 24 becomes soluble and releases the active cleansing formulation 50, delivering the active cleansing formulation 50 to the desired location on the user's face. The active cleansing formulation 50 may take the form of a solid, e.g., a powder, a plurality of granules or particles, a gel, a liquid or a slurry formulation, or any suitable combination of, e.g., a solid, gel, liquid or slurry formulation. In an exemplary embodiment, the active cleansing formulation 50 is of any suitable phase, including, e.g., a solid phase, a liquid phase, a slurry phase (a liquid containing a solid and multiple phases), or any suitable combination of phases. For example, the active cleansing formulation 50 may include fine powder particles or granules, a gel, one or more liquids, or a slurry, or multiple phases. In an exemplary embodiment, the active cleansing formulation 50 includes one or more of the following, including but not limited to, hyaluronic acid, aloe, chamomile extract, lactic acid, citric acid, hydrolyzed collagen, polysaccharides, peptides, surfactants or foaming agents, detergents, surfactants, emulsifiers, chelating agents, enzymes, pH adjusters, builders, structuring agents, free fragrance, encapsulated fragrance, preservatives, solvents, minerals, and / or any ingredient suitable for inclusion in a skin cleansing, skin wellness, or personal care formulation. In an exemplary embodiment, the skin cleansing article 20 includes an active cleansing formulation 50 having a mass of 0.5 grams (g) to 250 grams, specifically 3.0 grams to 8.0 grams, and more specifically 0.1 g to 3.0 g for selected ingredients, and a volume of 1.0 milliliters (ml) to 250 ml. In exemplary embodiments where the active cleansing formulation 50 is in a solid phase, the particles or granules may have a size of, for example, 1 micron to 100 microns, or may be in the form of a tablet.

[0049] In exemplary embodiments, the active cleansing formulation 50 is contained in, on or by the water soluble nonwoven substrate 24, for example, by saturating the water soluble nonwoven substrate 24 with the active cleansing formulation 50, by disposing the active cleansing formulation 50 on one or more surfaces, for example, the first surface 26 and / or the second surface 28 of the water soluble nonwoven substrate 24 as shown in Figure 2, by embedding the active cleansing formulation 50 in a matrix 52 of the water soluble nonwoven substrate 24, for example, in one or more layers of the water soluble nonwoven substrate 24 as shown in Figure 3, and / or by disposing the active cleansing formulation 50 between different layers, for example, adjacent layers of the water soluble nonwoven substrate 24, for example, by coating one or more surfaces of one or more layers with the active cleansing formulation 50. The active cleansing formulation 50 may be impregnated, adsorbed and / or adhered or bonded to the surface of the water soluble nonwoven substrate 24, for example.

[0050] In an exemplary embodiment as shown in Figure 2, the skin cleansing article 20 includes one or more layers of water soluble nonwoven substrate 24 in the form of a nonwoven sheet 54 and a solid phase active cleansing formulation 50 disposed on a first surface 26 and / or an opposing second surface 28 of the water soluble nonwoven substrate 24. In an exemplary embodiment as shown in Figure 3, the skin cleansing article 20 includes one or more layers of water soluble nonwoven substrate 24 forming a nonwoven sheet 54 containing a solid phase active cleansing formulation 50 embedded within a matrix 52 of the water soluble nonwoven substrate 24.

[0051] 1-3, in an exemplary embodiment, the water soluble nonwoven substrate 24 includes a plurality of fibers, not explicitly shown in FIGS. 1-3 but as described herein. In an exemplary embodiment, one or more fibers of the plurality of fibers are saturated or impregnated with an active cleansing formulation 50. The active cleansing formulation 50 may be embedded in one or more fibers of the plurality of fibers or between one or more adjacent fibers of the plurality of fibers, or the active cleansing formulation 50 may be disposed, e.g., coated, on a surface of one or more fibers of the plurality of fibers.

[0052] As shown in Figure 4, a sustainable package 60 made of suitable reusable materials, such as cardboard, paperboard, coated paper, barrier paper, repulpable packaging, reusable plastic, or other paper-based materials, is configured to contain or store one or more facial masks 22, e.g., a plurality of facial masks 22. Prior to use, a user opens the tab 62 and removes one facial mask 22 from the interior of the package 60 for use. The tab 62 then closes and seals the package 60. In an exemplary embodiment, the facial mask is initially provided dry and water is added to the facial mask prior to or during use.

[0053] In the exemplary embodiment, an exemplary water-soluble skin cleansing article 20 is provided that can be positioned on an area of ​​a user's skin. For example, the water-soluble skin cleansing article 20 in the form of a facial mask 22 can be positioned on the user's face to contact at least a portion of the skin surface of the user's face. For example, the first opening 30 is positioned in line with and around the user's right eye, the second opening 32 is positioned in line with and around the user's left eye. Furthermore, the third opening 34 is positioned in line with and around the user's nose, and the fourth opening 36 is positioned in line with and around the user's mouth. With the facial mask 22 accurately positioned on the user's face, one or more regions, e.g., multiple regions, such as the first region 40, the second region 42, the third region 44, and the fourth region 46 of the facial mask 22 containing one or more active cleansing formulations 50, are accurately positioned to contact the respective regions of the skin surface of the user's face. A first active cleansing formulation, for example, for treating wrinkles, is contained on or within the first region 40 of the water-soluble nonwoven substrate 24, and / or is contained on or within the second region 42, and is positioned against the user's eyes, for example, to contact the user's skin around the right or left eye, respectively, and / or under the respective eye. A third region 44 of the water-soluble nonwoven substrate 24 is positioned against the user's forehead, for example, to contact the user's skin on the user's forehead and / or the bridge of the user's nose. For example, the third region 44 is configured to contain a first active cleansing formulation, for example, for treating wrinkles, and / or a second cleansing formulation, for example, for treating acne. A fourth region 46 of the water-soluble nonwoven substrate 24 is positioned against one or both of the user's cheeks and / or the user's chin, for example, to contact the user's skin around the user's cheekbones and / or chin. The fourth region 46 is configured to contain a second active cleansing formulation, for example to treat acne, and / or a different active cleansing formulation that provides an additional skin wellness formulation to the user's skin.Any suitable skin care ingredients that provide various desired effects, including but not limited to hydrating, moisturizing, brightening, firming, and / or pore-cleansing effects, or fragrances or naturally scented essential oils or extracts, may be included in the active cleansing formulation or formulations in the exemplary embodiment. When the water-soluble skin cleansing article 20, e.g., the facial mask 22, comes into contact with water having a temperature higher than 20° C. or water having a temperature between 30° C. and 40° C., the water-soluble skin cleansing article 20 becomes soluble and releases one or more active cleansing formulations 50 in one or more regions of the facial mask 22. After use, any remaining portions of the facial mask 22 are also removed from the user's face and discarded. Alternatively, in the exemplary embodiment, the remaining portions of the facial mask 22 and / or any remaining active skin formulations 50 form a foam that the user can massage into his or her skin using his or her wet hands or fingers. In an exemplary embodiment, the user can use all of the active skin formulation 50 and he or she does not feel as if he or she is not utilizing the entire amount of the active skin formulation 50. In certain exemplary embodiments, two or more of the multiple regions, e.g., the first region 40, the second region 42, the third region 44 and / or the fourth region 46 of the facial mask 22, may also include the same or substantially the same cleansing formulation 50.

[0054] 5, in an exemplary embodiment, an exemplary method 100 of making a skin cleansing article containing an active cleansing formulation includes steps 102, 104, and / or 106. In step 102, a water-soluble core substrate is formed that includes a water-soluble resin. In an exemplary embodiment, the water-soluble nonwoven substrate has a first region configured to contain a first active cleansing formulation and a second region configured to contain a second active cleansing formulation. In step 104, the first active cleansing formulation is contained in the first region. In step 106, the second active cleansing formulation is contained in the second region. When the water-soluble nonwoven substrate contacts water having a temperature greater than 20° C., the water-soluble nonwoven substrate becomes soluble with MSTM-205 and releases at least one of the first active cleansing formulation and the second active cleansing formulation.

[0055] In an exemplary embodiment, the step 102 of forming a water-soluble core substrate containing a water-soluble resin includes forming one or more layers of a water-soluble nonwoven substrate. In an exemplary embodiment, the water-soluble core substrate, e.g., a water-soluble nonwoven substrate, is configured to contain one or more active cleansing formulations as described herein. In an exemplary embodiment, the active cleansing formulation 50 is contained in or by the water-soluble nonwoven substrate 24, for example, by saturating the water-soluble nonwoven substrate 24 with the active cleansing formulation 50, by disposing the active cleansing formulation 50 on one or more surfaces, e.g., on the first surface 28 and / or the second surface 30 of the water-soluble nonwoven substrate 24 as shown in FIG. 2, by embedding the active cleansing formulation 50 in the matrix 52 of the water-soluble nonwoven substrate 24, for example, in one or more layers of the water-soluble nonwoven substrate 24 as shown in FIG. 3, and / or by disposing the active cleansing formulation 50 between different layers, e.g., adjacent layers of the water-soluble nonwoven substrate 24, for example, by coating one or more surfaces of one or more layers with the active cleansing formulation 50. The active cleansing formulation 50 may be, for example, adsorbed and / or adhered or bonded to the surface of the water-soluble nonwoven substrate 24. When the water-soluble core substrate contacts water having a temperature greater than 20° C. or between 30° C. and 40° C., the water-soluble core substrate becomes soluble and releases the active cleansing formulation. Water-soluble film and fiber forming materials

[0056] Water-soluble polymers used in the water-soluble fibers, water-soluble nonwoven substrates, water-soluble foam substrates, and water-soluble films include, but are not limited to, polyvinyl alcohol, polyacrylates, water-soluble acrylate copolymers, polyvinylpyrrolidone, polyethyleneimine, pullulan, water-soluble natural polymers including, but not limited to, guar gum, acacia gum, xanthan gum, carrageenan, and starch, water-soluble polymer derivatives including, but not limited to, modified starch, ethoxylated starch, and hydroxypropylated starch, copolymers of the foregoing, and combinations of any of the foregoing. Other water-soluble polymers include polyalkylene oxides, polyacrylamides, polyacrylic acids and salts thereof, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and salts thereof, polyamino acids, polyamides, gelatin, methylcellulose, carboxymethylcellulose and salts thereof, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, maltodextrin, polymethacrylates, and combinations of any of the foregoing. Such water soluble polymers, whether PVOH polymers or others, are commercially available from a variety of sources.

[0057] In general, the fibers, foams and films described herein include polyvinyl alcohol. Polyvinyl alcohol is a synthetic polymer that is generally prepared by alcoholysis of polyvinyl acetate, usually referred to as "hydrolysis" or "saponification". Fully hydrolyzed PVOH, in which virtually all acetate groups have been converted to alcohol groups, is a strongly hydrogen-bonded, highly crystalline polymer that is soluble only in hot water, e.g., water having a temperature higher than about 140°F (about 60°C). If a sufficient number of acetate groups remain after hydrolysis of polyvinyl acetate, i.e., the PVOH polymer is partially hydrolyzed, the polymer is more weakly hydrogen-bonded, less crystalline, and generally soluble in cold water, e.g., water having a temperature lower than about 50°F (about 10°C). Thus, the partially hydrolyzed polymer is generally referred to as PVOH, although it is a vinyl alcohol-vinyl acetate copolymer, which is a PVOH copolymer.

[0058] In certain exemplary embodiments, suitable examples of such polymers include, but are not limited to, polyvinyl alcohol homopolymers, polyvinyl alcohol copolymers, modified polyvinyl alcohol copolymers, and combinations thereof. For example, the polyvinyl alcohol copolymer is, in certain embodiments, a copolymer of vinyl acetate and vinyl alcohol. For example, in some embodiments, the modified polyvinyl alcohol copolymer includes an anionically modified copolymer, which may be a copolymer of vinyl acetate and vinyl alcohol, further comprising additional groups such as carboxylate, sulfonate, or combinations thereof. Thus, the partially hydrolyzed polymer is a vinyl alcohol-vinyl acetate copolymer, which is a PVOH copolymer, but is commonly referred to as "polyvinyl alcohol (PVOH)" or "PVOH polymer." For simplicity, the term "PVOH polymer" as used herein is understood to encompass homopolymers, copolymers, and modified copolymers that include vinyl alcohol moieties, for example, 50% or more vinyl alcohol moieties.

[0059] The fibers, foams and / or films described herein may comprise one or more polyvinyl alcohol (PVOH) homopolymers, one or more polyvinyl alcohol copolymers, one or more modified polyvinyl alcohol copolymers, or combinations thereof. As used herein, the term "homopolymer" generally includes polymers having a single type of monomer repeat unit (e.g., a polymer chain consisting of or consisting essentially of a single monomer repeat unit). In the specific case of PVOH, the term "PVOH polymer" further includes copolymers consisting of a distribution of vinyl alcohol monomer units and vinyl acetate monomer units depending on the degree of hydrolysis (e.g., a polymer chain consisting of or consisting essentially of vinyl alcohol and vinyl acetate monomer units). In the limiting case of 100% hydrolysis, a PVOH homopolymer may include a true homopolymer having only vinyl alcohol units. In some embodiments, the fibers, foams and / or films of the present disclosure comprise polyvinyl alcohol copolymers. In some embodiments, the fibers, foams and / or films of the present disclosure comprise cold water soluble or hot water soluble polyvinyl alcohol copolymers.

[0060] Unless expressly indicated otherwise, the term "degree of hydrolysis" is understood as the percentage (e.g., mole percentage) of hydrolyzed moieties among all hydrolyzable moieties of the initial polymer. For example, for a polymer containing at least one vinyl acetate moiety or vinyl alcohol moiety, partial replacement of ester groups in the vinyl acetate moiety with hydroxyl groups occurs during hydrolysis, and the vinyl acetate moiety becomes a vinyl alcohol moiety. The degree of hydrolysis of a polyvinyl acetate homopolymer is considered to be 0, while the degree of hydrolysis of a polyvinyl alcohol homopolymer is considered to be 100%. The degree of hydrolysis of a copolymer of vinyl acetate and vinyl alcohol is considered to be between 0 and 100%, equal to the percentage of vinyl alcohol moieties among the sum of vinyl acetate and vinyl alcohol moieties.

[0061] In some embodiments, the polyvinyl alcohol polymer comprises a modified polyvinyl alcohol, e.g., a copolymer. The modified polyvinyl alcohol can comprise a copolymer or a higher polymer (e.g., a terpolymer) that comprises one or more monomers in addition to the vinyl acetate / vinyl alcohol group. Optionally, the modification is neutral, e.g., provided by ethylene, propylene, N-vinylpyrrolidone, or other uncharged monomer species. Optionally, the modification is cationic, e.g., provided by positively charged monomer species. Optionally, the modification is anionic. Thus, in some embodiments, the polyvinyl alcohol comprises an anionically modified polyvinyl alcohol.

[0062] Anionically modified polyvinyl alcohol can include partially or fully hydrolyzed PVOH copolymers that include anionic monomer units, vinyl alcohol monomer units, and optionally vinyl acetate monomer units (i.e., when not fully hydrolyzed). In some embodiments, modified PVOH copolymers can include two or more types of anionic monomer units. General classes of anionic monomer units that can be used in PVOH copolymers include vinyl sulfonate monomers and their esters, vinyl monocarboxylic acid monomers and their esters and anhydrides, dicarboxylic acid monomers with polymerizable double bonds and their esters and anhydrides, and vinyl polymerized units corresponding to the alkali metal salts of any of the foregoing. Examples of suitable anionic monomer units include vinyl acetate, maleic acid, monoalkyl maleates, dialkyl maleates, maleic anhydride, fumaric acid, monoalkyl fumarates, dialkyl fumarates, itaconic acid, monoalkyl itaconates, dialkyl itaconates, citraconic acid, monoalkyl citraconates, dialkyl citraconates, citraconic anhydride, mesaconic acid, monoalkyl mesaconates, dialkyl mesaconates, glutaconic acid, monoalkyl glutaconates, dialkyl glutaconates, alkyl acrylates, alkyl alkacrylates, vinyl sulfonic acid, allyl sulfonic acid, ethyl acrylates, alkyl alkacrylates, vinyl sulfonic acid, allyl sulfonic acid, ethyl acrylates, alkyl alkacrylates, alkyl ... The polymerized units include vinyl anionic monomers, including acrylate, 2-acrylamido-1-methylpropanesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, 2-methylacrylamido-2-methylpropanesulfonic acid (AMPS), 2-sulfoethyl acrylate, alkali metal salts of the foregoing (e.g., sodium, potassium, or other alkali metal salts), esters of the foregoing (e.g., methyl, ethyl, or other C1-C4 or C6 alkyl esters), and combinations of the foregoing (e.g., multiple types of anionic monomers or equivalent forms of the same anionic monomer). In some embodiments, the modified PVOH copolymers can include two or more types of monomer units selected from neutral, anionic, and cationic monomer units.

[0063] The incorporation level of one or more anionic monomer units in the PVOH copolymer is not particularly limited. In certain embodiments, the one or more anionic monomer units are present in the PVOH copolymer in an amount ranging from about 1 mol% or 2 mol% to about 6 mol% or 10 mol% (e.g., in various embodiments, at least 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, or 4.0 mol%, and / or up to about 3.0, 4.0, 4.5, 5.0, 6.0, 8.0, or 10 mol%).

[0064] Polyvinyl alcohol can be subject to changes in solubility properties. It is known to those skilled in the art that the acetate groups of co-poly(vinyl acetate vinyl alcohol) polymers (PVOH copolymers) can be hydrolyzed by either acid or alkaline hydrolysis. As the degree of hydrolysis increases, polymer compositions made from PVOH copolymers will have high mechanical strength, but will have reduced solubility at low temperatures (e.g., requiring warm water temperatures for complete dissolution). Thus, exposure of PVOH copolymers to an alkaline environment (e.g., from laundry bleach additives) can transform the polymer from one that dissolves quickly and completely in a given aqueous environment (e.g., cold water medium) to one that dissolves slowly and / or incompletely in the aqueous environment, possibly resulting in insoluble polymer residues.

[0065] The degree of hydrolysis (DH) of the PVOH homopolymers and PVOH copolymers (including modified PVOH copolymers) included in the water soluble fibers, foams, and films of the present disclosure can range from about 75% to about 99.9% (e.g., about 79% to about 92%, about 75% to about 89%, about 80% to about 90%, about 88% to 92%, about 86.5% to about 89%, or about 88%, 90%, or 92%, for cold water soluble compositions; about 90% to about 99.9%, about 90% to about 99%, about 92% to about 99%, about 95% to about 99%, about 98% to about 99%, about 98% to about 99.9%, about 96%, about 98%, about 99%, or greater than 99%). As the degree of hydrolysis decreases, fibers, foams, or films made from the polymer will have reduced mechanical strength, but will have faster solubility at temperatures below about 20° C. As the degree of hydrolysis increases, fibers, foams, or films made from the polymer will tend to be mechanically stronger and less thermoformable. The degree of hydrolysis of the PVOH can be selected such that the water solubility of the polymer is temperature dependent, and thus the solubility of the film, foam, or fiber made from the polymer and additional components will also be affected. In certain embodiments, the film, foam, and / or fiber is cold water soluble. In co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., copolymers that are not copolymerized with anionic monomers), cold water soluble fibers, foams, or films that are soluble in water at temperatures below 10° C. can include PVOH with a degree of hydrolysis ranging from about 75% to about 90%, from about 75% to about 89%, or from about 80% to about 90%, or from about 85% to about 90%. In another embodiment, the fiber, foam, or film is hot water soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., copolymers that are not copolymerized with anionic monomers), a hot water soluble fiber, foam, or film that is soluble in water at a temperature of at least about 60° C. can include PVOH with a degree of hydrolysis of at least about 98%.In an exemplary embodiment, one or more of the plurality of fibers comprises a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 75% to about 99.9%. In an exemplary embodiment, one or more of the plurality of fibers comprises a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 75% to about 98%. In an exemplary embodiment, one or more of the plurality of fibers comprises a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 75% to about 89%. In an exemplary embodiment, one or more of the plurality of fibers comprises a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 90% to about 99.9%. In an exemplary embodiment, the water-soluble film comprises a polyvinyl alcohol copolymer or modified PVOH copolymer having a degree of hydrolysis ranging from about 75% to about 99.9%. In an exemplary embodiment, the water-soluble film comprises a polyvinyl alcohol homopolymer or polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 98%.

[0066] The degree of hydrolysis of the polymer blends was calculated as the arithmetically weighted average degree of hydrolysis (

number

number

number

[0067] The viscosity of PVOH polymers (μ) is determined by measuring freshly made solutions using a Brookfield LV type viscometer with UL adapter as described in British Standard EN ISO 15023-2:2006 Annex E Brookfield test method. It is international convention to refer to the viscosity of a 4% aqueous polyvinyl alcohol solution at 20°C. All viscosities specified herein in centipoise (cP) should be understood to refer to the viscosity of a 4% aqueous polyvinyl alcohol solution at 20°C, unless otherwise specified. Similarly, when a polymer is described as having (or not having) a particular viscosity, unless otherwise specified, the specified viscosity is intended to be the average viscosity of the polymer, inherent with the corresponding molecular weight distribution, i.e., the weighted natural logarithm average viscosity. The viscosity of a PVOH polymer is determined by the weight average molecular weight (

number

number

[0068] In exemplary embodiments, the PVOH resin may have a viscosity of about 1.0 to about 50.0 cP, about 1.0 to about 40.0 cP, or about 1.0 to about 30.0 cP, such as about 4 cP, 8 cP, 15 cP, 18 cP, 23 cP, or 26 cP. In exemplary embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 1.0 to about 40.0 cP, or about 5 cP to about 23 cP, such as about 1 cP, 1.5 cP, 2 cP, 2.5 cP, 3 cP, 3.5 cP, 4 cP, 4.5 cP, 5 cP, 5.5 cP, 6 cP, 6.5 cP, 7 cP, 7.5 cP, 8 cP, 8.5 cP, 9 cP, 9 cP, 10 cP, 12 cP, 14 cP, 15 cP, 16 cP, 17 cP, 18 cP, 19 cP, 22 cP, 23 cP, 24 cP, 25 cP, 26 cP, 27 cP, 28 cP, 29 cP, 30 cP, 31 cP, 32 cP, 33 cP, 34 cP, 35 cP, 36 cP, 37 cP, 38 cP, 39 cP, 40 cP, 41 cP, 42 cP, 43 cP, 44 cP, 45 cP, 46 cP, 47 cP, 48 cP, 49 cP, 50 cP, 51 cP, 52 cP, 53 cP, 54 cP, 55 cP, 56 c The PVOH homopolymer and / or copolymer may have a viscosity of about 0.5 cP, 10 cP, 11 cP, 12 cP, 13 cP, 14 cP, 15 cP, 17.5 cP, 18 cP, 19 cP, 20 cP, 21 cP, 22 cP, 23 cP, 24 cP, 25 cP, 26 cP, 27 cP, 28 cP, 29 cP, 30 cP, 31 cP, 32 cP, 33 cP, 34 cP, 35 cP, or 40 cP. In exemplary embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 21 cP to 26 cP. In exemplary embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 5 cP to about 14 cP. In exemplary embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 5 cP to about 23 cP.

[0069] Water-soluble polymers can be blended, whether or not they are polyvinyl alcohol polymers. When the polymer blend comprises a blend of polyvinyl alcohol polymers, the PVOH polymer blend can comprise a first PVOH polymer ("first PVOH polymer"), which can comprise a PVOH copolymer or a modified PVOH copolymer (e.g., a PVOH ter (or higher copolymer)) containing one or more types of anionic monomer units, and a second PVOH polymer ("second PVOH polymer"), which can comprise a PVOH copolymer or a PVOH modified copolymer (e.g., a PVOH ter (or higher copolymer)) containing one or more types of anionic monomer units. In some embodiments, the PVOH polymer blend comprises only a first PVOH polymer and a second PVOH polymer (e.g., a binary blend of two polymers). Alternatively, or in addition, the PVOH polymer blend or the fiber, foam or film made therefrom can be characterized as being free or substantially free of other polymers (e.g., other water-soluble polymers in general, other PVOH-based polymers in particular, or both). As used herein, "substantially free" means that the first PVOH polymer and the second PVOH polymer constitute at least 95%, at least 97%, or at least 99% by weight of the total amount of water-soluble polymers in the water-soluble fiber, foam, or film. In other embodiments, the water-soluble fiber, foam, or film can include one or more additional water-soluble polymers. For example, the PVOH polymer blend can include a third PVOH polymer, a fourth PVOH polymer, a fifth PVOH polymer, etc. (e.g., one or more additional PVOH copolymers or modified PVOH copolymers with or without anionic monomer units). For example, the water-soluble fiber or film can include at least a third (or fourth, fifth, etc.) water-soluble polymer other than the PVOH polymer (e.g., other than the PVOH copolymer or modified PVOH copolymer with or without anionic monomer units). A PVOH homopolymer may also be included in each blend. Biodegradability

[0070] Polyvinyl alcohol polymers are generally biodegradable since they degrade in the presence of water and enzymes under aerobic, anaerobic, soil, and compost conditions. In general, the biodegradation activity of polyvinyl alcohol polymers increases as the degree of hydrolysis of the polyvinyl alcohol polymer increases up to about 80%. Without being bound by theory, it is believed that increasing the degree of hydrolysis beyond 80% does not appreciably affect biodegradability. Furthermore, the stereoregularity of the hydroxyl groups of the polyvinyl alcohol polymer has a significant effect on the biodegradation activity level, the more isotactic the hydroxyl groups of the polymer sequence are, the higher the degradation activity. Without being bound by theory, it is believed that in soil and / or compost biodegradation, a nonwoven substrate or web prepared from polyvinyl alcohol fibers will have a higher biodegradation activity level relative to a water-soluble film prepared from a similar polyvinyl alcohol polymer due to the increased polymer surface area provided by the nonwoven substrate or web relative to the film. Furthermore, without wishing to be bound by theory, it is believed that the degree of polymerization of a polyvinyl alcohol polymer has little or no effect on the biodegradability of a film, foam or nonwoven substrate or web prepared with the polymer, but the polymerization temperature may affect the biodegradability of the film, foam substrate or nonwoven substrate, since it may affect the crystallinity and aggregation state of the polymer. As the crystallinity decreases, the polymer chain hydroxyl groups become less aligned within the polymer structure, and the polymer chains become more disordered, causing the chains to accumulate as amorphous aggregates, thereby reducing the availability of ordered polymer structures and biodegradation activity is predicted to decrease the soil and / or compost biodegradation mechanism in which the polymer does not dissolve.Without being bound by theory, it is believed that the stereoregularity of the hydroxyl groups of polyvinyl alcohol polymers has a large effect on the biodegradability activity level, so that substitution with functional groups other than hydroxyl groups (e.g., anionic AMPS functional groups, carboxylate groups, or lactone groups) is expected to reduce the biodegradability activity level relative to polyvinyl alcohol copolymers having the same degree of hydrolysis, unless the functional groups themselves are also biodegradable, in which case the biodegradability of the polymer may be increased by substitution. Furthermore, it is believed that the biodegradability activity level of substituted polyvinyl alcohols can be lower than that of the corresponding homopolymers or copolymers, but the substituted polyvinyl alcohols will still be biodegradable.

[0071] Methods for determining biodegradation activity are known in the art, for example, as described in Chiellini et al., Progress in Polymer Science, Volume 28, Issue 6, 2003, pp. 963-1014, which is incorporated herein by reference in its entirety. Other methods and standards can be found in ECHA's Annex XV Restriction Report - Microplastics, Version number 1, January 11, 2019, which is incorporated herein by reference in its entirety. Suitable standards include OECD 301B (ready biodegradation), OECD 301B (enhanced biodegradation), OECD 302B (intrinsic biodegradation), OECD 311 (anaerobic), and ASTM D5988 (soil).

[0072] In exemplary embodiments, the fibers described herein can be of standard ready biodegradation or enhanced degradation. As used herein, the term "ready biodegradation" refers to a standard that is met if the material (e.g., fiber) reaches 60% biodegradation (mineralization) within 28 days from the start of testing according to OECD 301B testing as described in ECHA's Annex XV. As used herein, the term "enhanced biodegradation" refers to a standard that is met if the material (e.g., fiber) reaches 60% biodegradation within 60 days from the start of testing according to OECD 301B testing as described in ECHA's Annex XV. In exemplary embodiments, the fibers meet the ready biodegradation standard. Active Cleansing Formula

[0073] In an exemplary embodiment, the water-soluble skin cleansing article, particularly the water-soluble core substrate, is configured to contain one or more active cleansing formulations, such as the skin cleansing formulations or skin wellness formulations described herein, and / or one or more adjuvants. Suitable examples generally include skin cleansing agents, acne treatment agents, emollients, moisturizers, conditioners, wrinkle removers, sunscreens (SPF), rinse aids, and alpha hydroxyl acids neutralized in situ or in the formulation to achieve a specific pH. In an exemplary embodiment, the active cleansing formulations are disposed or coated on one or more surfaces of the water-soluble core substrate, or embedded and / or attached to the water-soluble core substrate. The water-soluble core substrate may comprise a single layer, for example, a single layer of nonwoven core substrate, or may comprise multiple layers, for example, a sheet of nonwoven core substrate folded in a serpentine arrangement, or, for example, overlapped, to form a layer containing the active cleansing formulation disposed between adjacent layers of the water-soluble nonwoven core substrate. By way of example, the active cleansing formulation may include, but is not limited to, one or more of hyaluronic acid, aloe, chamomile extract, lactic acid, citric acid, hydrolyzed collagen, polysaccharides, peptides, surfactants, foaming agents, shampoos, conditioners, body washes, face washes, skin lotions, skin treatments, body oils, fragrances, hair treatments, bath salts, essential oils, bath bombs, enzymes, detergents, surfactants, emulsifiers, chelating agents, pH adjusters, builders, structuring agents, free fragrances, encapsulated fragrances, preservatives, solvents, or minerals, and / or any ingredient suitable for inclusion in a skin cleansing formulation, skin wellness formulation, or personal care formulation. Adjuvants

[0074] In general, the fibers, nonwoven substrates or webs, foam substrates, and / or water-soluble films of the present disclosure, along with film-forming, foam-forming, and / or fiber-forming materials, may contain additives such as plasticizers, plasticizer compatibilizers, surfactants, lubricants, release agents, fillers, extenders, crosslinking agents, antiblocking agents, antioxidants, anti-blocking agents, defoamers, nanoparticles, such as layered silicate-type nanoclays (e.g., sodium montmorillonite), bleaching agents (e.g., sodium metabisulfite, sodium bisulfite, or the like), aversive agents, such as glycerides, ... Adjuvants such as, but not limited to, bittering agents (e.g., denatonium salts, such as denatonium benzoate, denatonium saccharides, and denatonium chloride; sucrose octaacetate; quinines; flavonoids, such as quercetin and naringen; and cassinoids, such as cassine and brucine), and pungent agents (e.g., capsaicin, piperine, allyl isothiocyanate, and resinferratoxin), and other functional ingredients, may be included in amounts suitable for their intended purpose. As used herein, and unless otherwise specified, "adjuvants" includes secondary additives, processing agents, and active agents. Such specific adjuvants may be selected from those suitable for use with water-soluble fibers, water-insoluble fibers, nonwoven webs, foams, or water-soluble films.

[0075] In exemplary embodiments, the fibers, foams, and / or films may be free of adjuvants. As used herein, and unless otherwise specified, "adjuvant-free" with respect to fibers means that the fibers contain less than about 0.01%, less than about 0.005%, or less than about 0.001% by weight of adjuvant based on the total weight of the fibers. As used herein, and unless otherwise specified, "adjuvant-free" with respect to nonwoven substrates or webs means that the nonwoven substrates or webs contain less than about 0.01%, less than about 0.005%, or less than about 0.001% by weight of adjuvant based on the total weight of the nonwoven substrates or webs. In exemplary embodiments, the water-soluble fibers contain a plasticizer. In exemplary embodiments, the water-soluble fibers contain a surfactant. In exemplary embodiments, the water-insoluble fibers contain a plasticizer. In exemplary embodiments, the water-insoluble fibers contain a surfactant. In exemplary embodiments, the nonwoven substrates or webs contain a plasticizer. In exemplary embodiments, the nonwoven substrates or webs contain a surfactant.

[0076] A plasticizer is a liquid, solid, or semi-solid that is added to a material (usually a resin or elastomer) to make the material softer, more flexible (by lowering the glass transition temperature of the polymer), or easier to process. Alternatively, a polymer can be plasticized internally by chemically modifying the polymer or monomer. Additionally or alternatively, a polymer can be plasticized externally by the addition of a suitable plasticizer. Water is recognized as a very efficient plasticizer for PVOH and other polymers, including but not limited to water-soluble polymers, however, the volatility of water limits its usefulness since polymer films need to have at least some resistance (robustness) to a variety of ambient conditions, including low and high relative humidity.

[0077] Plasticizers can include, but are not limited to, glycerin, diglycerin, sorbitol, xylitol, maltitol, ethylene glycol, diethylene glycol, triethylene glycol, dipropylene glycol, tetraethylene glycol, propylene glycol, polyethylene glycols up to 1000 MW, neopentyl glycol, trimethylolpropane, polyether polyols, sorbitol, 2-methyl-1,3-propanediol (MPDiol®), ethanolamine, and mixtures thereof.

[0078] Surfactants used in the film are well known in the art and can be suitably used in the fibers, foams, films, and / or compositions of the present disclosure. Optionally, surfactants are included to aid in the dispersion of fibers during carding. Optionally, surfactants are included as cleansing aids. Suitable surfactants can include nonionic, cationic, anionic, and zwitterionic classes. Suitable surfactants include, but are not limited to, propylene glycol, diethylene glycol, monoethanolamine, polyoxyethylated polyoxypropylene glycol, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylene glycols, and alkanolamides (nonionic), polyoxyethylated amines, quaternary ammonium salts, and quaternized polyoxyethylated amines (cationic), alkali metal salts of higher fatty acids containing about 8 to 24 carbon atoms, alkyl sulfates, alkyl polyethoxylate sulfates, and alkyl benzene sulfonates (anionic), and amine oxides, N-alkyl betaines, and sulfobetaines (zwitterionic).Other suitable surfactants include dioctyl sodium sulfosuccinate, lactylated fatty acid esters of glycerin and propylene glycol, lactylic acid esters of fatty acids, sodium alkyl sulfates, polysorbate 20, polysorbate 60, polysorbate 65, polysorbate 80, lecithin, acetylated fatty acid esters of glycerin and propylene glycol, and sodium lauryl sulfate, acetylated esters of fatty acids, myristyl dimethylamine oxide, trimethyl tallow alkyl ammonium chloride, quaternary ammonium compounds. The surfactants include, for example, glycerol ... In various embodiments, the amount of surfactant in the fibers ranges from about 0.01% to about 10% by weight, from about 0.1% to about 5% by weight, from about 1.0% to about 2.5% by weight, from about 0.01% to about 1.5% by weight, from about 0.1% to about 1% by weight, from about 0.01% to 0.25% by weight, or from about 0.10% to 0.20% by weight.

[0079] In exemplary embodiments, the nonwoven substrates or webs, foams and / or films of the present disclosure may further include adjuvants, such as one or more of the following groups: exfoliants (chemical and mechanical exfoliants), microcapsules of fragrance and / or fragrance, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiling agents, and cosmetic agents.

[0080] In an exemplary embodiment, the adjunct is provided in or on one or more of the nonwoven web, the foam, the plurality of fibers, and the water-soluble film. In an exemplary embodiment, the active cleansing formulation is provided on or in one or more of the group of the nonwoven web, the plurality of fibers, and the water-soluble film. In an exemplary embodiment, the one or more adjuncts can be provided on the surface of the nonwoven web. In an exemplary embodiment, the one or more adjuncts can be dispersed within the fibers of the nonwoven web. In an exemplary embodiment, the one or more adjuncts can be dispersed on the surface of the nonwoven web. In an exemplary embodiment, the one or more adjuncts can be dispersed in the fibers. In an exemplary embodiment, the one or more adjuncts can be dispersed on the fibers. In an exemplary embodiment, the one or more adjuncts can be provided on the surface of the water-soluble film.

[0081] When present, the chemical exfoliants, mechanical exfoliants, fragrance and / or perfume microcapsules, aversive agents, surfactants, colorants, proteins, peptides, enzymes, skin conditioners, deoiler agents, cosmetic agents, or combinations thereof can be provided in an amount of at least about 1% by weight, or in a range of about 1% to about 99% by weight, based on the weight of the polymer mixture (e.g., fiber-forming or film-forming material). In exemplary embodiments, the chemical exfoliants, mechanical exfoliants, fragrance and / or perfume microcapsules, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiler agents, and / or cosmetic agents can be provided in an amount sufficient to provide additional functionality, such as human skin exfoliation, to the fibers and / or films. The chemical exfoliants, mechanical exfoliants, fragrance and / or perfume microcapsules, aversive agents, surfactants, colorants, enzymes, skin conditioners, degreasing agents, cosmetic agents, or combinations thereof can be in any desired form including solids (e.g., powders, granules, crystals, flakes, or ribbons), liquids, ointments, pastes, gases, and the like, and can be encapsulated, such as microcapsules, if desired.

[0082] In certain embodiments, the nonwoven substrate or web, foam and / or film may include an enzyme. Suitable enzymes include those classified into one of the six traditional Enzyme Commission (EC) categories: EC1 oxidoreductases (catalyzes oxidation / reduction reactions), EC2 transferases (transfers functional groups, such as methyl or phosphate groups), EC3 hydrolases (catalyzes hydrolysis of various bonds), EC4 lyases (cleaves various bonds by methods other than hydrolysis and oxidation), EC5 isomerases (catalyzes isomerization changes within a molecule), and EC6 ligases (joins two molecules by a covalent bond). Examples of such enzymes include dehydrogenases and oxidases in EC1, transaminases and kinases in EC2, lipases, cellulases, amylases, mannanases, and peptidases (also known as proteases or proteolytic enzymes) in EC3, decarboxylases in EC4, isomerases and mutases in EC5, and synthetases and synthases in EC6. Suitable enzymes from each category are described, for example, in U.S. Pat. No. 9,394,092, the disclosure of which is incorporated herein by reference in its entirety. In certain embodiments, the enzymes can include bromelain (pineapple extract), papain (papaya), ficin (fig), actinidin (kiwi), hyaluronidase, lipase, peroxidase, superoxide dismutase, tyrosinase, alkaline phosphatase, or combinations thereof. In exemplary embodiments, the enzymes can be encapsulated, for example, in the form of a nanoemulsion, nanocapsule, granule, or combinations thereof.

[0083] It is contemplated that the enzymes used herein can be obtained from any suitable source or combination of sources, such as bacterial, fungal, plant, or animal sources.In one embodiment, the mixture of two or more enzymes will come from at least two different types of sources.For example, the mixture of protease and lipase can be obtained from bacterial (protease) and fungal (lipase) sources.

[0084] Optionally, the enzymes used herein, including but not limited to any of the enzyme types or members described herein, are those that operate under alkaline pH conditions, for example, at a pH ranging from about 8 to about 11. Optionally, the enzymes used herein, including but not limited to any of the enzyme types or members described herein, are those that operate at a temperature ranging from about 5° C. to about 45° C.

[0085] In exemplary embodiments, the nonwoven substrate or web, foam, and / or film can include proteins and / or peptides. Suitable proteins and / or peptides can include, but are not limited to, collagen and / or collagen peptides, or amino acids such as aspartic acid, glutamic acid, serine, histidine, glycine, threonine, arginine, alanine, tyrosine, cysteine, valine, methionine, phenylalanine, isoleucine, leucine, lysine, hydroxyproline, or proline.

[0086] In an exemplary embodiment, the nonwoven substrate or web, foam and / or film can include a colorant. Suitable colorants can include indicator dyes, such as pH indicators (e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), moisture / water indicators (e.g., hydrochromic inks or leuco dyes), or thermochromic inks, which change color when the temperature increases and / or decreases. Suitable colorants include, but are not limited to, triphenylmethane dyes, azo dyes, anthraquinone dyes, perylene dyes, indigoid dyes, Food, Drug, and Cosmetics (FD&C) colorants, organic pigments, inorganic pigments, or combinations thereof. Examples of colorants include, but are not limited to, FD&C Red #40; Red #3; FD&C Black #3; Black #2; mica-based pearlescent pigments; FD&C Yellow #6; Green #3; Blue #1; Blue #2; titanium dioxide (food grade); brilliant black; and combinations thereof. Other examples of suitable colorants can be found in US Pat. No. 5,002,789, which is incorporated herein by reference in its entirety.

[0087] Other embodiments may include one or more fragrances in the nonwoven substrate or web, foam, and / or film of the present disclosure. As used herein, the term "fragrance" refers to any impartable material that is volatile enough to produce a scent. The embodiments that include a fragrance may include fragrances that are pleasant to humans or, alternatively, fragrances that are unpleasant to humans, animals, and / or insects. Suitable fragrances include, but are not limited to, fruit scents, including but not limited to lemon, apple, cherry, grape, pear, pineapple, orange, strawberry, raspberry, musk, and floral scents, including but not limited to lavender-like, rose-like, iris-like, and carnation-like. Optionally, the fragrance is not a flavoring. Other fragrances include herbal scents, including but not limited to rosemary, thyme, and sage; and woodland scents derived from pine, spruce, and other woodland scents. Fragrances may be derived from a variety of oils, including but not limited to essential oils, or from botanical materials, including but not limited to peppermint, spearmint, and the like. Suitable fragrant oils can be found in U.S. Patent No. 6,458,754, which is incorporated herein by reference in its entirety.Suitable fragrant oils include, but are not limited to, 4-(2,2,6-trimethylcyclohex-1-enyl)-2-en-4-one, acetaldehyde phenylethyl propyl acetal, 2,6,10-trimethyl-9-undecanal, hexanoic acid 2-propenyl ester, 1-octen-3-ol, trans-anethole, isobutyl (z)-2-methyl-2-butenoate, anisaldehyde diethyl acetal, 3-methyl-5-propyl-cyclohexen-1-one, 2,4-dimethyl-3-cyclohexene ... These include benzoic acid 2-hydroxymethyl ester, benzoyl ester, ethyl ether ... Possible fragrances can also be found in U.S. Patent Nos. 4,534,981, 5,112,688, 5,145,842, 6,844,302, and Perfumes Cosmetics and Soaps, Second Edition, edited by WA Poucher, 1959, all of which are incorporated herein by reference in their entirety. These fragrances include acacia, goldenrod, chypre, cyclamen, fern, gardenia, hawthorn, heliotrope, honeysuckle, hyacinth, jasmine, lilac, lily, magnolia, mimosa, daffodil, freshly cut hay, orange blossom, orchid, mignonette, sweet pea, trefle, tuberose, vanilla, violet, wallflower, and the like, or any combination thereof.

[0088] The fragrance may include a fragrance. The fragrance may include a neat fragrance, an encapsulated fragrance, or a mixture thereof. In an exemplary embodiment, the fragrance includes a pure fragrance. A portion of the fragrance may be encapsulated in a core-shell encapsulation. In another embodiment, the fragrance is not encapsulated in a core / shell encapsulation.

[0089] The term "perfume" as used herein encompasses perfume raw materials (PRMs) and perfume accords. The term "perfume raw materials" as used herein refers to compounds having a molecular weight of at least about 100 g / mol and useful for imparting an odor, fragrance, essence, or smell, either alone or together with other perfume raw materials. As used herein, the terms "perfume ingredient" and "perfume raw materials" are synonymous. The term "accord" as used herein refers to a mixture of two or more PRMs. In exemplary embodiments, any of the perfume accords, perfume raw materials, or fragrances can be encapsulated in microcapsules, referred to as "perfume microcapsules" as used herein.

[0090] Typical PRMs include alcohols, ketones, aldehydes, esters, ethers, nitrites, and alkenes, such as terpenes, among others. Lists of common PRMs can be found in various references, such as “Perfume and Flavor Chemicals”, Vols. I and II; Steffen Arctander Allured Pub. Co. (1994), and “Perfumes: Art, Science and Technology”, Miller, P. M. and Lamparsky, D., Blackie Academic and Professional (1994). PRMs are characterized by their boiling point (BP), measured at normal pressure (760 mmHg), and their octanol / water partition coefficient (P). Based on these characteristics, PRMS may be classified as quadrant I, II, III, or IV fragrances.

[0091] In exemplary embodiments, the nonwoven web, foam, and / or film may include an exfoliant. In exemplary embodiments, the exfoliant may include a chemical exfoliant or a mechanical exfoliant. Suitable mechanical exfoliants for use herein include, but are not limited to, apricot shells, sugar, oatmeal, salt, silica, diatomaceous earth, clay, aluminum hydroxide, PVOH microbeads, pumice, or combinations thereof. Suitable chemical exfoliants for use herein include, but are not limited to, alpha hydroxyl acids, beta hydroxyl acids, enzymes, salicylic acid, glycolic acid, citric acid, malic acid, or combinations thereof.

[0092] In certain embodiments, the microcapsules encapsulate and allow controlled release of aversive agents, surfactants, colorants, enzymes, skin conditioners, degreasing agents, cosmetic agents, or combinations thereof.Suitable microcapsules can include or be made from one or more of melamine formaldehyde, polyurethane, urea formaldehyde, chitosan, polymethylmethacrylate, polystyrene, polysulfone, polytetrahydrofuran, gelatin, gum arabic, starch, polyvinylpyrrolidone, carboxymethylcellulose, hydroxyethylcellulose, methylcellulose, arabinogalactan, polyvinyl alcohol, polyacrylic acid, ethylcellulose, polyethylene, polymethacrylate, polyamide, poly(ethylene vinyl acetate), cellulose nitrate, silicone, poly(lactideco-glycolide), paraffin, carnauba, spermaceti, beeswax, stearic acid, stearyl alcohol, glyceryl stearate, shellac, cellulose acetate phthalate, zein, and combinations thereof. In one type of embodiment, the microcapsules are characterized by an average particle size (e.g., Dv50) of at least about 0.1 microns, or, for example, in the range of about 0.1 microns to about 200 microns. In alternative embodiments, the microcapsules may form agglomerates of individual particles, for example, the individual particles having an average particle size of at least about 0.1 microns, or in the range of about 0.1 microns to about 200 microns. Soluble Fiber

[0093] Water-soluble fibers include fibers and / or fiber-forming materials made of any material that dissolves in 300 seconds or less at 80°C or less as determined by MSTM-205 when provided as the only resin in a film or foam or the only fiber-forming material in a nonwoven, film, foam or nonwoven. Water-soluble fibers can include a single water-soluble polymer or a blend of water-soluble polymers. Suitable water-soluble polymers include, but are not limited to, polyvinyl alcohol homopolymers, polyvinyl alcohol copolymers, modified polyvinyl alcohol copolymers, polyacrylates, water-soluble acrylate copolymers, polyvinylpyrrolidone, polyethyleneimine, pullulan, water-soluble natural polymers including, but not limited to, guar gum, acacia gum, xanthan gum, carrageenan, and starch, water-soluble polymer derivatives including, but not limited to, modified starch, ethoxylated starch, and hydroxypropylated starch, copolymers of the foregoing, and combinations of any of the foregoing. Still other water-soluble fibers can include polyalkylene oxides, polyacrylamides, polyacrylic acids and their salts, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and their salts, polyamino acids, polyamides, gelatin, methylcellulose, carboxymethylcellulose and its salts, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, maltodextrin, polymethacrylates, and combinations of any of the foregoing. In exemplary embodiments, the water-soluble fibers can include PVOH copolymer fiber-forming materials, modified PVOH copolymer fiber-forming materials, or combinations thereof. In exemplary embodiments, the water-soluble fibers can include a single PVOH homopolymer fiber-forming material or a blend of PVOH copolymer fiber-forming materials. In exemplary embodiments, the water-soluble fibers can include hot water soluble PVOH homopolymer fiber-forming materials. In further embodiments, the water-soluble fibers can include PVOH copolymer fiber-forming materials having a viscosity in the range of 5 cP to 23 cP and a degree of hydrolysis in the range of 86% to 92%.

[0094] In an exemplary embodiment, the water-soluble fiber can include the active cleansing formulation and / or auxiliary agent described above. In an exemplary embodiment, the water-soluble fiber can be substantially free of the active cleansing formulation and / or auxiliary agent described above. In an exemplary embodiment, the water-soluble fiber can include the plasticizer described above. The total amount of non-aqueous plasticizer provided to the water-soluble fiber can be in the range of about 1% to about 45% by weight, or about 5% to about 45% by weight, or about 10% to about 40% by weight, or about 20% to about 30% by weight, about 1% to about 4% by weight, or about 1.5% to about 3.5% by weight, or about 2.0% to about 3.0% by weight, for example, about 1% by weight, about 2.5% by weight, about 5% by weight, about 10% by weight, about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, or about 40% by weight. In an exemplary embodiment, the water soluble fiber includes glycerin, sorbitol, or a combination thereof. In an exemplary embodiment, the water soluble fiber includes glycerin. In an exemplary embodiment, the water soluble fiber includes sorbitol. In one particular embodiment, the water soluble fiber can include glycerin, for example, about 10% by weight based on the total fiber weight, and sorbitol, for example, about 5% by weight based on the total fiber weight.

[0095] In exemplary embodiments, the water-soluble fiber can include a surfactant as described above. In various embodiments, the amount of surfactant in the water-soluble fiber ranges from about 0.01% to about 2.5%, from about 0.1% to about 2.5%, from about 1.0% to about 2.0%, from about 0.01% to 0.25%, or from about 0.10% to 0.20% by weight.

[0096] In an exemplary embodiment, any of the active cleansing formulations and / or adjuncts disclosed herein can be added to the fibers of the present disclosure. In a refinement of the above embodiment, the active cleansing formulations and / or adjuncts can be added to the fiber-forming material before the fibers are formed, such that the adjuncts are dispersed in the fibers. Additionally and / or alternatively, the active cleansing formulations and / or adjuncts can be added to the surface of the fibers (e.g., dispersed in the fibers) after the fibers are formed.

[0097] When included in the water soluble fibers, the colorant can be provided in an amount of 0.01% to 25% by weight of the polymer mixture, such as 0.02%, 0.05%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, and 24% by weight of the polymer mixture. Insoluble Fiber

[0098] Water insoluble fibers include fibers and / or fiber forming materials made of any material which, when provided in a film as the sole film forming material or in a nonwoven web or foam as the sole fiber forming material, does not cause the film, nonwoven web, or foam to dissolve in 300 seconds or less at temperatures of 80° C. or less as determined by MSTM-205. Water insoluble fibers can include the sole water insoluble polymeric fiber forming material or a blend of water insoluble polymeric fiber forming materials. Suitable water insoluble fibers and / or water insoluble fiber forming materials include, but are not limited to, cotton, polyester, polyethylene (e.g., high density polyethylene and low density polyethylene), polypropylene, wood pulp, fluff pulp, abaca, viscose, polylactic acid, polyester, nylon 6, insoluble cellulose, insoluble starch, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, lace bark, silk, tendon, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, Dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, and combinations thereof. In exemplary embodiments, the water insoluble fiber forming materials and / or fibers include one or more of the group: cotton, hemp, jute, flax, ramie, sisal, bagasse, banana, lace bark, silk, tendon, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo, modal, diacetate fibers, triacetate fibers, or combinations thereof.

[0099] In an exemplary embodiment, the water-insoluble fiber can include the above-mentioned auxiliary agent. In an exemplary embodiment, the water-insoluble fiber can be substantially free of the above-mentioned auxiliary agent. In an exemplary embodiment, the water-insoluble fiber can include the above-mentioned plasticizer. The total amount of non-water-insoluble plasticizer provided in the water-insoluble fiber can be in the range of about 1% to about 45% by weight, or about 5% to about 45% by weight, or about 10% to about 40% by weight, or about 20% to about 30% by weight, about 1% to about 4% by weight, or about 1.5% to about 3.5% by weight, or about 2.0% to about 3.0% by weight, for example, about 1% by weight, about 2.5% by weight, about 5% by weight, about 10% by weight, about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, or about 40% by weight. In an exemplary embodiment, the water-insoluble fiber includes glycerin, sorbitol, or a combination thereof. In an exemplary embodiment, the water insoluble fiber includes glycerin. In an exemplary embodiment, the water insoluble fiber includes sorbitol. In one particular embodiment, the water insoluble fiber can include a plasticizer such as glycerin, for example, about 10% by weight based on the total fiber weight, and sorbitol, for example, about 5% by weight based on the total fiber weight.

[0100] In exemplary embodiments, the water insoluble fibers can include a surfactant as described above. In various embodiments, the amount of surfactant in the water soluble fibers ranges from about 0.01% to about 2.5%, from about 0.1% to about 2.5%, from about 1.0% to about 2.0%, from about 0.01% to 0.25%, or from about 0.10% to 0.20% by weight.

[0101] In an exemplary embodiment, any of the adjuncts disclosed herein can be added to the fibers of the present disclosure. In a refinement of the foregoing embodiment, the adjunct can be added to the fiber-forming material prior to the formation of the fiber, such that the adjunct can be added to the surface of the fiber after the fiber is formed. In a refinement of the foregoing embodiment, the adjunct can be added to the surface of the fiber after the fiber is formed.

[0102] When included in the water insoluble fibers, the colorant can be provided in an amount of 0.01% to 25% by weight of the polymer mixture, for example, 0.02%, 0.05%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, and 24% by weight of the polymer mixture. Nonwoven web or substrate

[0103] The nonwoven web or nonwoven substrate of the present disclosure can be water soluble, water insoluble or at least partially water insoluble. The single unit dose article of the present disclosure can include a nonwoven web where at least a portion of the nonwoven web is soluble in water by MSTM-205 at a temperature ranging from about 0° C. to about 20° C., or where at least a portion of the nonwoven web is not soluble in water by MSTM-205 at or below 20° C., or where the nonwoven web is not soluble in water by MSTM-205 at or below 20° C., or where the nonwoven web is soluble in water by MSTM-205 at a temperature ranging from about 0° C. to about 20° C. It will be understood that if a fiber type is provided in the nonwoven as the only fiber type, then a nonwoven web made of that fiber type will be soluble (or not soluble) by MSTM-205 at a given temperature, and if the fiber type is included in a plurality of fibers, then "at least a portion" of the nonwoven web will be soluble (or not soluble) at a given temperature.

[0104] The nonwoven webs of the present disclosure include a plurality of fibers. A nonwoven web refers to an arrangement of fibers that are bonded together, and the fibers are not woven or knitted. The plurality of fibers can be arranged in any orientation. In exemplary embodiments, the plurality of fibers are arranged randomly (i.e., have no orientation). In exemplary embodiments, the plurality of fibers are arranged in one direction. In exemplary embodiments, the plurality of fibers are arranged in two directions. In some embodiments, the plurality of fibers are multidirectional and have different arrangements in different regions of the nonwoven web.

[0105] The fibers in any given nonwoven web can comprise any of the fiber-forming materials disclosed herein. The nonwoven web can comprise (1) a monofilament type that includes a monofilament forming material, (2) a monofilament type that includes a blend of fiber-forming materials, (3) a blend of fiber types where each fiber type includes a monofilament forming material, (4) a blend of fiber types where each fiber type includes a blend of fiber-forming materials, or (5) a blend of fiber types where each fiber type includes a monofilament forming material or a blend of fiber-forming materials. In an exemplary embodiment that includes a blend of fiber types, the various fiber types can be characterized by their length to diameter ratio (L / D), toughness, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g ), the chemical nature of the fiber-forming material, and / or the color group. In certain embodiments, the plurality of fibers can include two or more types of water-soluble fibers. In exemplary embodiments, the plurality of fibers can include at least one fiber type that includes at least one type of water-soluble fiber-forming material, and at least one fiber type that includes at least one type of water-insoluble fiber. In exemplary embodiments, the plurality of fibers can include two or more types that include at least one type of water-insoluble fiber-forming material.

[0106] In exemplary embodiments, the nonwoven web may further comprise any active cleansing formulation and / or adjunct disclosed herein as fibers and / or films. In exemplary embodiments, the active cleansing formulation and / or adjunct may be added to the fibers themselves, to the nonwoven web during carding of the nonwoven web, to the nonwoven web before bonding (e.g., after carding), to the nonwoven web after bonding, or a combination thereof. The active cleansing formulation and / or adjunct added to the fibers during carding may be distributed throughout the nonwoven web. The active cleansing formulation and / or adjunct added to the nonwoven web after carding but before bonding may be selectively added to one or both sides of the nonwoven web.

[0107] The active cleansing formulation and / or adjuncts can be applied by suitable means to one or more faces or surfaces of the nonwoven web or to articles containing them, such as packets. In an exemplary embodiment, the active cleansing formulation and / or adjuncts are in the form of a powder. In a refinement of the previous embodiment, one or more stationary powder spray guns are used to direct a powder stream towards the web from one or more directions while the web is transported through a coating zone using a belt conveyor. In an exemplary embodiment, the web or packets are conveyed through a suspension of powder in air. In an exemplary embodiment, the web is tumble mixed with the powder in a trough-like device. In an exemplary embodiment, which can be combined with any other embodiment, electrostatic forces are used to enhance the attraction between the powder and the web. This type of process may be based on negatively charging the powder particles and directing these charged particles towards a grounded web. In other alternative embodiments, the powder is applied to the web by a secondary transfer tool, including but not limited to a rotating brush in contact with the powder, or by a powdered glove that can transfer the powder from a container to the web. In yet another embodiment, the powder is applied by dissolving or suspending the powder in a non-aqueous solvent or carrier, which is then atomized and sprayed onto the web. In one embodiment, the solvent or carrier subsequently evaporates, leaving behind the active agent powder. In certain embodiments, the powder is applied to the web in precise doses. These embodiments utilize a closed system dry lubricant application machine, such as PekuTECH's Powder Applicator PM 700 D. In this process, the powder is fed into the feed trough of the application machine, batchwise or continuously as needed. The web is transferred from the output belt of a standard rotary drum pouch machine onto the conveyor belt of the powder applicator, which applies a controlled dose of powder to the web. The web can then be transported to a suitable packaging process.

[0108] In exemplary embodiments where the adjuvant is in liquid form or in solution, the foregoing can be dispersed within the fibers, dispersed on the face or surface of the nonwoven web, or combinations thereof, for example, by spin casting, spraying of a solution such as an aerosolized solution, roll coating, flow coating, curtain coating, extrusion, knife coating, and combinations thereof.

[0109] In exemplary embodiments, the active cleansing formulations and / or adjuvants, such as chemical exfoliants, mechanical exfoliants, microcapsules of fragrance and / or perfume, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiler agents, cosmetic agents, or combinations thereof, when present in the nonwoven web, are in an amount of at least about 1% by weight, or in a range of about 1% to about 99% by weight, to provide additional functionality to the nonwoven web. The chemical exfoliants, mechanical exfoliants, microcapsules of fragrance and / or perfume, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiler agents, cosmetic agents, or combinations thereof can take any desired form, including solids (e.g., powders, granules, crystals, flakes, or ribbons), liquids, spreaders, pastes, gases, and the like, and can be encapsulated as needed.

[0110] In an exemplary embodiment, the nonwoven web can be colored, pigmented, and / or dyed to provide improved aesthetic effects compared to water-soluble films. Suitable colorants for use in the nonwoven web can include indicator dyes, such as pH indicators (e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), moisture / water indicators (e.g., hydrochromic inks or leuco dyes), or thermochromic inks, which change color when the temperature increases and / or decreases. Suitable colorants include, but are not limited to, triphenylmethane dyes, azo dyes, anthraquinone dyes, perylene dyes, indigo dyes, Food, Drug, and Cosmetic (FD&C) colorants, organic pigments, inorganic pigments, or combinations thereof. Examples of colorants include, but are not limited to, FD&C Red #40; Red #3; FD&C Black #3; Black #2; mica-based pearlescent pigments; FD&C Yellow #6; Green #3; Blue #1; Blue #2; titanium dioxide (food grade); brilliant black; and combinations thereof.

[0111] In an exemplary embodiment, the nonwoven web can include any of the surfactants disclosed herein. In an exemplary embodiment, the nonwoven web can include one or more of the group: sodium cocoyl isethionate, glucotein, phenamide, cola lipids, cocamides such as cocamide ethanolamine, ethylene oxide based surfactants, and saponified avocado and palm oils.

[0112] The nonwoven web of the present disclosure can generally have any thickness. Suitable thicknesses can include, but are not limited to, about 5 microns (μm) to about 10,000 μm (1 cm), about 5 μm to about 5,000 μm, about 5 μm to about 1,000 μm, about 5 μm to about 500 μm, about 200 μm to about 500 μm, about 5 μm to about 200 μm, about 20 μm to about 100 μm, or about 40 μm to about 90 μm, or about 50 μm to 80 μm, or about 60 μm to 65 μm, such as 50 μm, 65 μm, 76 μm, or 88 μm. The nonwoven web of the present disclosure can be characterized as high loft or low loft. Loft refers to the ratio of thickness to mass per unit area (i.e., basis weight). High loft nonwoven webs can be characterized by a high ratio of thickness to mass per unit area. As used herein, "high loft" refers to nonwoven webs of the present disclosure having a basis weight as defined herein and a thickness greater than 200 μm. The thickness of the nonwoven web can be determined according to ASTM D5729-97, ASTM D5736, and / or ISO 9073-2:1995, and can include, for example, subjecting the nonwoven web to a load of 2N and measuring the thickness. High loft materials can be used according to methods known in the art, such as cross-wrapping, which uses a cross wrapper to fold an unbonded web on itself to build loft and basis weight. Without wishing to be bound by theory, in contrast to water-soluble films, where the solubility of the film may depend on the thickness of the film; the solubility of the nonwoven web is not believed to depend on the thickness of the web. In this regard, since individual fibers offer a higher surface area than water-soluble films, it is believed that the parameter that limits water access to the fibers, and thereby fiber dissolution, is the basis weight (i.e., fiber density in the nonwoven), regardless of the thickness of the nonwoven web.

[0113] In general, the dynamic coefficient of friction and the ratio of the static coefficient of friction to the dynamic coefficient of friction for the nonwoven web of the present disclosure will be lower than the dynamic coefficient of friction and the ratio of the static coefficient of friction to the dynamic coefficient of friction for the water-soluble film due to the increased surface roughness of the nonwoven web relative to the water-soluble film, resulting in reduced surface contact with the nonwoven web. Advantageously, this surface roughness can provide improved consumer feel (i.e., cloth-like hand instead of rubbery hand), improved aesthetics (i.e., less gloss than water-soluble films), and / or ease of processability for those that may need to pull the web along the surface of a processing tool / mold. Thus, in exemplary embodiments, the water-soluble and / or water-insoluble fibers are sufficiently rough to provide surface roughness to the resulting nonwoven web without being so rough that it causes drag.

[0114] The water solubility of the nonwoven web of the present disclosure is generally a function of the type of fiber(s) used to prepare the web as well as the basis weight of the web. Without wishing to be bound by theory, it is believed that the solubility profile of the nonwoven web follows the same solubility profile of the fiber(s) used to prepare the nonwoven web, and the solubility profile of the fiber generally follows the same solubility profile of the polymer(s) from which the fiber is prepared. For example, in a nonwoven web comprising PVOH fibers, the degree of hydrolysis of the PVOH polymer can be selected such that the water solubility of the nonwoven web is also affected. At a given temperature, as the degree of hydrolysis of the PVOH polymer increases from partial hydrolysis (88% DH) to full hydrolysis (≧98% DH), the water solubility of the polymer generally decreases. Thus, in an exemplary embodiment, the nonwoven web can be cold water soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., not copolymerized with anionic monomers), a cold water soluble web that is soluble in water at a temperature of less than 10° C. can include fibers of PVOH with a degree of hydrolysis ranging from about 75% to about 90%, or from about 75% to about 89%, or from about 80% to about 90%, or from about 85% to about 90%, or from about 90% to about 99.5%. In other exemplary embodiments, the nonwoven web can be hot water soluble. For example, for co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., not copolymerized with anionic monomers), a hot water soluble web can be soluble in water at a temperature of at least about 60° C. by including fibers of PVOH with a degree of hydrolysis of at least about 98%.

[0115] Modification of PVOH polymers generally increases the solubility of the PVOH polymer. Thus, at a given temperature, the solubility of a nonwoven web or film prepared from a modified PVOH polymer is expected to be higher than that of a nonwoven web or film prepared from a PVOH copolymer having the same degree of hydrolysis as the modified PVOH copolymer. Following these trends, nonwoven webs with specific solubility characteristics can be designed by blending polymers into fibers and / or blending fibers into nonwoven webs. Furthermore, as described herein, nonwoven webs may contain multiple fibers, and in some cases, may contain two or more fiber types with different solubilities.

[0116] The inclusion of water-insoluble fibers and / or water-insoluble fiber-forming materials in the fibers of the nonwoven web can also be used to design the nonwoven web with a particular solubility and / or extended release characteristics. Without being bound by theory, it is believed that as the weight percentage of water-insoluble fibers contained in the nonwoven web increases (relative to the total weight of the nonwoven web), the solubility of the nonwoven web generally decreases, and the extended release characteristics of the pouch containing the nonwoven web generally increase. When contacted with water at or above the solubility temperature of the water-soluble fibers, the nonwoven web containing water-soluble and water-insoluble fibers will begin to disperse as the water-soluble fibers dissolve, thereby destroying the web structure and / or increasing the pore size of the pores of the nonwoven web. The greater the destruction of the web structure or the larger the pore size, the faster the active cleansing composition will be released. Similarly, the extended release of the active cleansing composition in the nonwoven web of the present disclosure can be achieved by using a blend of water-soluble fibers with different solubility characteristics and / or different solubility temperatures. As the faster dissolving fibers dissolve, the web is broken down, and the less soluble fibers have a larger exposed surface area, facilitating the dissolution of the less soluble fibers and the release of the active cleansing composition. In an exemplary embodiment in which the nonwoven web comprises water-soluble and water-insoluble fibers, the ratio of soluble fibers to water-insoluble fibers is not particularly limited. The water-soluble fibers can comprise about 1% to about 99%, about 20% to about 80%, about 40% to about 90%, about 50% to about 90%, or about 60% to about 90% by weight of the total weight of the plurality of fibers, and the water-insoluble fibers can comprise about 1% to about 99%, about 20% to about 80%, about 10% to about 60%, about 10% to about 50%, or about 10% to about 40% by weight of the total weight of the fibers. In an exemplary embodiment, the plurality of fibers comprises about 10% to about 80% water-soluble fibers by weight of the total weight of the fibers, and the remainder is water-insoluble fibers.

[0117] In an exemplary embodiment, the nonwoven web, the plurality of fibers, the foam, the water-soluble film, or a combination thereof disclosed herein can include a biodegradable polymer. In certain embodiments, the plurality of fibers can include water-insoluble fibers that form a material that is biodegradable. In an exemplary embodiment, the plurality of fibers can include a first fiber that is a water-insoluble biodegradable fiber and a second fiber that is soluble in water at a temperature of about 10° C. to about 20° C. according to MSTM-205 or is not soluble in water at a temperature of about 30° C. or less according to MSTM-205. In an exemplary embodiment, the nonwoven web is water-insoluble and biodegradable.

[0118] In exemplary embodiments, the nonwoven web is biodegradable. As used herein, when a nonwoven web is said to be biodegradable, at least 50% of the nonwoven web is biodegradable, such as at least 60%, at least 70%, at least 80%, at least 90%, or 100% of the nonwoven web is biodegradable.

[0119] The nonwoven webs disclosed herein can include a plurality of fibers including a first fiber type and a second fiber type, where the first and second fiber types have similar characteristics, such as diameter, length, tenacity, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g), chemical composition, color, or combinations thereof. In exemplary embodiments, the first fiber type may comprise a PVOH homopolymer fiber-forming material, a PVOH copolymer fiber-forming material, a modified PVOH copolymer fiber-forming material, or a combination thereof. In exemplary embodiments, the first fiber type may comprise two or more PVOH homopolymer fiber-forming materials, two or more PVOH copolymer fiber-forming materials, a PVOH copolymer fiber-forming material, or a combination thereof. In exemplary embodiments, the second fiber type may comprise a PVOH homopolymer fiber-forming material, a PVOH copolymer fiber-forming material, a PVOH copolymer fiber-forming material, or a combination thereof. In exemplary embodiments, the second fiber type may comprise two or more PVOH homopolymer fiber-forming materials, two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a combination thereof. In exemplary embodiments, the first fiber type and / or the second fiber type are water-insoluble fiber-forming materials. In an exemplary embodiment, the first fiber type can include a water insoluble polymeric fiber forming material and the second fiber type can include a polyvinyl alcohol fiber forming material that, when provided as the sole fiber forming material of a nonwoven web or as a film, the resulting web or film is soluble by MSTM-205 in water at temperatures ranging from about 0° C. to about 20° C. In an exemplary embodiment, the first fiber type can include a water insoluble polymeric fiber forming material and the second fiber type can include a PVOH homopolymer or copolymer fiber forming material that, when provided as the sole fiber forming material of a nonwoven web or as a film, the resulting web or film is not soluble by MSTM-205 in water at temperatures at or below 20° C. In an exemplary embodiment, the first fiber type includes two or more polyvinyl alcohol copolymer fiber forming materials, two or more modified polyvinyl alcohol copolymer fiber forming materials, or a combination of polyvinyl alcohol copolymer fiber forming materials and modified polyvinyl alcohol copolymer fiber forming materials.In exemplary embodiments, the second fiber type includes two or more polyvinyl alcohol copolymer fiber forming materials, two or more modified polyvinyl alcohol copolymer fiber forming materials, or a combination of polyvinyl alcohol copolymer fiber forming materials and modified polyvinyl alcohol copolymer fiber forming materials.

[0120] The fibers included in the nonwoven web of the present disclosure can have any tenacity. The tenacity of the fiber correlates to the coarseness of the fiber. As the tenacity of the fiber decreases, the coarseness of the fiber increases. The fibers used to prepare the nonwoven web of the present disclosure can have a tenacity of about 1 to about 100 cN / dtex, or about 1 to about 75 cN / dtex, or about 1 to about 50 cN / dtex, or about 1 to about 45 cN / dtex, or about 1 to about 40 cN / dtex, or about 1 to about 35 cN / dtex, or about 1 to about 30 cN / dtex, or about 1 to about 25 cN / dtex, or about 1 to about 20 cN / dtex, or about 1 to about 15 cN / dtex, or about 1 to about 10 cN / dtex, or about 3 to about 8 cN / dtex, or about 4 to about 8 cN / dtex. tex, or from about 6 to about 8 cN / dtex, or from about 4 to about 7 cN / dtex, or from about 10 to about 20, or from about 10 to about 18, or from about 10 to about 16, or about 1 cN / dtex, about 2 cN / dtex, about 3 cN / dtex, about 4 cN / dtex, about 5 cN / dtex, about 6 cN / dtex, about 7 cN / dtex, about 8 cN / dtex, about 9 cN / dtex, about 10 cN / dtex, about 11 cN / dtex, about 12 cN / dtex, about 13 cN / dtex, about 14 cN / dtex, or about 15 cN / dtex. In exemplary embodiments, the plurality of fibers may have a tenacity ranging from about 3 cN / dtex to about 15 cN / dtex, or from about 5 cN / dtex to about 12 cN / dtex, or from about 5 cN / dtex to about 10 cN / dtex.

[0121] The toughness of the nonwoven web can be the same or different from the toughness of the fibers used to prepare the web. Without being bound by theory, it is believed that the toughness of the nonwoven web is related to the strength of the nonwoven web, with higher toughness providing the nonwoven web with higher strength. The toughness of the nonwoven web can be modified by using fibers with different toughness. The toughness of the nonwoven web can also be affected by processing. The nonwoven web of the present disclosure has a relatively high toughness, i.e., the nonwoven web is a self-supporting web that can be used as the sole material to prepare an article and / or a pouch. In contrast, nonwoven webs prepared by meltblowing, electrospinning, and / or rotary spinning processes may have low toughness and may not be self-supporting or can not be used as the sole web to form an article or pouch.

[0122] The fibers used to prepare the nonwoven webs of the present disclosure can have any fineness. The fineness of the fibers correlates to how many fibers are present in the cross section of a yarn of a given thickness. The fineness of the fibers can be measured by measuring the linear mass density, the ratio of fiber mass per unit length. The main physical unit of linear mass density is 1 tex, which is equal to 1000m of fibers weighing 1g. The unit dtex is used to represent 1g / 10,000m of fibers. The linear mass density can be selected to provide a nonwoven web with the appropriate stiffness / hand of the nonwoven web, torsional stiffness, light reflection and interaction, absorption of dyes and / or other actives / additives, ease of fiber spinning in the manufacturing process, and uniformity of the finished article. As the linear mass density of the fibers increases, the nonwovens obtained therefrom demonstrate higher uniformity, improved tensile strength, extensibility, and luster. Furthermore, without being bound by theory, it is believed that finer fibers will result in slower dissolution times compared to larger fibers relative to density. Further, without wishing to be bound by theory, when a blend of fiber types is used, the average linear mass density can be determined using a weighted average of the individual fiber types. The fibers can be characterized as very fine (dtex≦1.22), fine (1.22≦dtex≦1.54), medium (1.54≦dtex≦1.93), slightly coarse (1.93≦dtex≦2.32), and coarse (dtex≧2.32). The nonwoven webs of the present disclosure can include fibers that are very fine, fine, medium, slightly coarse, or combinations thereof. In exemplary embodiments, the nonwoven web has an average linear mass density ranging from about 1 dtex to about 5 dtex, or from about 1 dtex to about 3 dtex, or from about 1.5 dtex to about 2.5 dtex. In exemplary embodiments, the nonwoven web includes a blend of fibers, where a first fiber includes an average linear mass density of 1.7 dtex and a second fiber includes an average linear mass density of 2.2 tex.

[0123] The fibers used to prepare the nonwoven web of the present disclosure have a diameter ranging from about 10 microns to 300 microns, such as at least 10 microns, at least 25 microns, at least 50 microns, at least 100 microns, or at least 125 microns, and up to about 300 microns, up to about 275 microns, up to about 250 microns, up to about 225 microns, or up to about 200 microns. In an exemplary embodiment, the fibers used to prepare the nonwoven web of the present disclosure can have a diameter of more than 100 microns to about 300 microns. In an exemplary embodiment, the diameter of the fibers used to prepare the nonwoven web of the present disclosure has a substantially uniform diameter. In an exemplary embodiment, one or more fiber types can have an average diameter ranging from about 10 microns to about 300 microns, or from about 50 microns to 200 microns, or from about 50 microns to about 100 microns.

[0124] The fibers used to prepare the nonwoven web of the present disclosure can be of any length. In exemplary embodiments, the length of the fibers can range from about 30 millimeters (mm) to about 100 mm, from about 10 mm to about 60 mm, or from about 30 mm to about 60 mm, such as at least about 30 mm, at least about 35 mm, at least about 40 mm, at least about 45 mm, or at least about 50 mm, and up to about 100 mm, up to about 95 mm, up to about 90 mm, up to about 80 mm, up to about 70 mm, or up to about 60 mm. In exemplary embodiments, the length of the plurality of fibers can be less than about 30 mm, or in a range of about 0.25 mm to less than about 30 mm, such as at least about 0.25 mm, at least about 0.5 mm, at least about 0.75 mm, at least about 1 mm, at least about 2.5 mm, at least about 5 mm, at least about 7.5 mm, or at least about 10 mm, and up to about 29 mm, up to about 28 mm, up to about 27 mm, up to about 26 mm, up to about 25 mm, up to about 20 mm, or up to about 15 mm. In exemplary embodiments, the fibers have an average length of about 30 mm to about 100 mm, or about 30 mm to about 60 mm. In exemplary embodiments, the nonwoven web comprises a blend of fiber types, where a first fiber type comprises a length of about 38 mm and a second fiber type comprises a length of about 54 mm.

[0125] The fibers used to prepare the nonwoven web of the present disclosure can have any length to diameter (L / D) ratio. Advantageously, the toughness of the nonwoven web of the present disclosure can be controlled using the L / D ratio of the fibers and the respective amounts of fibers with various L / D ratios in the nonwoven composition. As the L / D of the fibers decreases, the stiffness and resistance to bending increases, providing a rougher hand. The fibers of the present disclosure impart a rougher hand to the nonwoven web containing them when the fibers have a low L / D in the range of about 0.5 to about 15, or about 0.5 to about 25, or about 1 to about 5. Such low L / D fibers can be provided in the nonwoven web in an amount ranging from about 0 to about 50% by weight, for example, from about 0.5 to about 25% by weight, or from about 1 to about 15% by weight, based on the total weight of the fibers in the nonwoven web. If the amount of low L / D fibers in a nonwoven web is unknown, the amount can be estimated by visual inspection of a photomicrograph of the nonwoven web. In exemplary embodiments in which the first fibers comprise a blend of fiber forming materials that includes a first polyvinyl alcohol fiber forming material, at least a portion of the first fibers can have an L / D ratio of from about 0.5 to about 25, or from about 0.5 to about 15, or from about 1 to about 5.

[0126] Pore ​​size can be determined using high magnification and high order surface analytical techniques including, but not limited to, Brunauer-Emmett-Teller theory (BET), small angle X-ray scattering (SAXS), and molecular adsorption.

[0127] Nonwoven webs can be characterized by their basis weight. The basis weight of a nonwoven web is the mass per unit area of ​​the nonwoven web. The basis weight can be modified by varying manufacturing conditions, as known in the art. The nonwoven web can have the same basis weight before and after bonding. Alternatively, the bonding method can change the basis weight of the nonwoven web. For example, if bonding occurs through the application of heat and pressure, the thickness of the nonwoven (and therefore the area of ​​the nonwoven) can be reduced, thereby increasing the basis weight. Thus, as used herein and unless otherwise specified, the basis weight of a nonwoven refers to the basis weight of the nonwoven after bonding.

[0128] The nonwoven web of the present disclosure has a viscosity of about 0.1 g / m 2 to about 700g / m 2 , about 0.5g / m 2 to about 600g / m 2 , about 1g / m 2 to about 500g / m 2 , about 1g / m 2 to about 400g / m 2 , about 1g / m 2 to about 300g / m 2 , about 1g / m 2 to about 200 g / m 2 , about 1g / m 2 to about 100g / m 2 , about 30g / m 2 to about 100g / m 2 , about 20g / m 2 to about 100g / m 2 , about 20g / m 2 From about 80g / m 2 , or about 25 g / m 2 From about 70g / m 2 The sheet may have any basis weight in the range of 1000 to 15000 grammage.

[0129] Furthermore, assuming the fiber composition and web thickness remain constant, as the basis weight of the web increases, the dissolution rate of the web decreases because more material is dissolved. For example, at a given temperature, a web containing PVOH polymer(s) and having a basis weight of, for example, 40 g / m 2 A water-soluble web prepared from fibers having a basis weight of, for example, 30 g / m 2 and is predicted to dissolve slower than an otherwise identical water-soluble web having a basis weight of about 1 g / m. Basis weight can therefore also be used to modify the solubility characteristics of the nonwoven web. The nonwoven web has a basis weight of about 1 g / m 2 to about 700g / m 2 , about 1g / m 2 to about 600g / m 2 , about 1g / m 2 to about 500g / m 2 , about 1g / m 2 to about 400g / m 2, about 1g / m 2 to about 300g / m 2 , about 1g / m 2 to about 200 g / m 2 , about 10g / m 2 to about 100g / m 2 , about 30g / m 2 to about 100g / m 2 , about 20g / m 2 to about 100g / m 2 , about 20g / m 2 From about 80g / m 2 , about 25g / m 2 From about 70g / m 2 , or about 40 g / m 2 From about 60g / m 2 The sheet may have any basis weight in the range of 1000 to 15000 grammage.

[0130] The nonwoven web of the present disclosure can be used as a single layer, can be layered with other nonwoven webs, or can be in the form of a laminate with a water-soluble film. In some embodiments, the nonwoven web comprises a single layer of nonwoven web. In some embodiments, the nonwoven web is a multi-layer nonwoven web comprising two or more layers of nonwoven web. The two or more layers can be laminated together. In refinements of the above-mentioned embodiments, the two or more layers can be the same (e.g., can be prepared from the same fibers and basis weights). In refinements of the above-mentioned embodiments, the two or more layers can be different (e.g., can be prepared from different types of fibers, fiber chemistries, and / or have different basis weights).

[0131] A multi-layer nonwoven web can have a basis weight that is the sum of the basis weights of the individual layers, and thus the multi-layer nonwoven web will take longer to dissolve than either of the individual layers provided as a single layer. Water-soluble foam

[0132] In an exemplary embodiment, suitable water-soluble foams include any suitable resin chemistry, such as copolymers, maleic anhydride (MA) modified PVOH polymers, monomethyl maleate (MMM) modified PVOH polymers, 2-methylacrylamido-2-methylpropanesulfonic acid (AMPS) modified PVOH, cellulose and cellulose derivatives, polyvinylpyrrolidone (PVP), proteins, casein, soy, or any water dispersible or water soluble resin. In certain embodiments, the water-soluble foam substrate has a thickness of 3 microns to 3000 microns and can be formed using any suitable manufacturing process known in the foam manufacturing art, including, but not limited to, casting, extrusion, melt processing, coating, chemical blowing, mechanical air entrainment, air injection, and turbulent extrusion processes. The water-soluble foam substrate can be porous or non-porous and can be cold water soluble or hot water soluble. The construction of the water-soluble foam substrate can include, for example, folded layers or plies, laminated layers or plies, or rolled layers or plies.

[0133] In an exemplary embodiment, the water-soluble foam substrate may further include any auxiliary agent as a nonwoven web, fiber and / or film as disclosed herein. The auxiliary agent may be applied by suitable means to one or more surfaces of the water-soluble foam substrate or to the article containing them, e.g., the packet. In an exemplary embodiment, the auxiliary agent is in the form of a powder. In a refinement of the previous embodiment, one or more fixed powder spray guns are used to direct a powder stream from one or more directions toward the water-soluble foam substrate or packet, while the water-soluble foam substrate or packet is transported through the coating zone using a belt conveyor. In an exemplary embodiment, the water-soluble foam substrate or packet is conveyed through a suspension of powder in air. In an exemplary embodiment, the water-soluble foam substrate or packet is tumble mixed with the powder in a trough-like device. In an exemplary embodiment, which may be combined with any other embodiment, electrostatic forces are used to enhance the attraction between the powder and the packet or water-soluble foam substrate. This type of process may be based on negatively charging the powder particles and directing these charged particles toward a grounded packet or water-soluble foam substrate. In other alternative embodiments, the powder is applied to the water-soluble foam substrate or packet by a secondary transfer tool, including but not limited to a rotating brush in contact with the powder, or by a powdered glove that can transfer the powder from a container to the water-soluble foam substrate or packet. In yet another embodiment, the powder is applied by dissolving or suspending the powder in a non-aqueous solvent or carrier, which is then atomized and sprayed onto the water-soluble foam substrate or packet. In one embodiment, the solvent or carrier subsequently evaporates, leaving behind the activator powder. In certain embodiments, the powder is applied to the water-soluble foam substrate or packet in precise doses. These embodiments utilize a closed system dry lubricant application machine, such as PekuTECH's Powder Applicator PM 700 D. In this process, the powder is fed into the feed trough of the application machine in a batch or continuous manner as needed.The water-soluble foam substrate or packet is transferred from the output belt of a standard rotary drum pouch machine onto the conveyor belt of a powder applicator, which applies a controlled dosage of powder to the water-soluble foam substrate or packet, which can then be conveyed to an appropriate secondary packaging process.

[0134] In exemplary embodiments where the adjuvant is in liquid form or in solution, the foregoing can be dispersed in the water-soluble foam substrate, dispersed on the surface of the water-soluble foam substrate, or combinations thereof, for example, by spin casting, spraying a solution such as an aerosolized solution, roll coating, flow coating, curtain coating, extrusion, knife coating, and combinations thereof.

[0135] Adjuncts, such as chemical exfoliants, mechanical exfoliants, microcapsules of fragrances and / or flavors, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiler agents, cosmetic agents, or combinations thereof, when present in the water-soluble foam base, are in an amount of at least about 1% by weight, or in a range of about 1% to about 99% by weight, and provide additional functionality to the water-soluble foam base. The chemical exfoliants, mechanical exfoliants, microcapsules of fragrances and / or flavors, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiler agents, cosmetic agents, or combinations thereof can take any desired form, including solids (e.g., powders, granules, crystals, flakes, or ribbons), liquids, spreaders, pastes, gases, and the like, and can be encapsulated as needed.

[0136] In an exemplary embodiment, the water-soluble foam substrate can be colored, pigmented, and / or dyed to provide improved aesthetic effects compared to water-soluble films. Suitable colorants for use in the water-soluble foam substrate can include indicator dyes, such as pH indicators (e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), moisture / water indicators (e.g., hydrochromic inks or leuco dyes), or thermochromic inks, which change color when the temperature increases and / or decreases. Suitable colorants include, but are not limited to, triphenylmethane dyes, azo dyes, anthraquinone dyes, perylene dyes, indigo dyes, Food, Drug, and Cosmetics (FD&C) colorants, organic pigments, inorganic pigments, or combinations thereof. Examples of colorants include, but are not limited to, FD&C Red #40; Red #3; FD&C Black #3; Black #2; mica-based pearlescent pigments; FD&C Yellow #6; Green #3; Blue #1; Blue #2; titanium dioxide (food grade); brilliant black; and combinations thereof.

[0137] In an exemplary embodiment, the water-soluble foam base can include any of the surfactants disclosed herein. In an exemplary embodiment, the water-soluble foam base can include one or more of the following group: sodium cocoyl isethionate, glucotein, phenamide, cola lipids, cocamides such as cocamide ethanolamine, ethylene oxide based surfactants, and saponified avocado and palm oils.

[0138] The water-soluble foam substrate of the present disclosure can have any thickness. Suitable thicknesses can include, but are not limited to, about 5 microns (μm) to about 10,000 μm (1 cm), about 3 μm to about 5,000 μm, about 5 μm to about 1,000 μm, about 5 μm to about 500 μm, about 200 μm to about 500 μm, about 5 μm to about 200 μm, about 20 μm to about 100 μm, or about 40 μm to about 90 μm, or about 50 μm to 80 μm, or about 60 μm to 65 μm, such as 50 μm, 65 μm, 76 μm, or 88 μm. The water-soluble foam substrate of the present disclosure can be characterized as high loft or low loft. Loft refers to the ratio of thickness to mass per unit area (i.e., basis weight). High loft water-soluble foam substrates can be characterized by a high ratio of thickness to mass per unit area. As used herein, "high loft" refers to water-soluble foam substrates of the present disclosure having a basis weight as defined herein and a thickness greater than 200 μm. The thickness of the water-soluble foam substrate can be determined according to ASTM D5729-97, ASTM D5736, and / or ISO 9073-2:1995, and can include, for example, subjecting the water-soluble foam substrate to a load of 2N and measuring the thickness. High loft materials can be used according to methods known in the art, for example, cross-wrapping, using a cross-wrapper to fold an unbonded web on itself to build loft and basis weight.

[0139] The dynamic coefficient of friction and the ratio of the static coefficient of friction to the dynamic coefficient of friction for the water-soluble foam substrate of the present disclosure are lower than the dynamic coefficient of friction and the ratio of the static coefficient of friction to the dynamic coefficient of friction for the water-soluble film due to the increased surface roughness of the water-soluble foam substrate relative to the water-soluble film, resulting in reduced surface contact with the water-soluble foam substrate. Advantageously, this surface roughness can provide improved consumer feel (i.e., cloth-like hand instead of rubber-like hand), improved aesthetics (i.e., less gloss than water-soluble films), and / or ease of processability that may be required to pull the water-soluble foam substrate along the surface of a processing tool / mold. Thus, in an exemplary embodiment, the water-soluble and / or water-insoluble fibers should be sufficiently rough to provide surface roughness to the resulting water-soluble foam substrate without being so rough that it causes drag.

[0140] The water solubility of the soluble foam substrate of the present disclosure is generally a function of the type of fiber(s) used to prepare the water soluble foam substrate as well as the basis weight of the water soluble foam substrate. Without being bound by theory, it is believed that the solubility profile of the water soluble foam substrate follows the same solubility profile of the fiber(s) used to prepare the water soluble foam substrate, and the solubility profile of the fiber generally follows the same solubility profile of the polymer(s) from which the fiber is prepared. For example, in a water soluble foam substrate comprising PVOH fibers, the degree of hydrolysis of the PVOH polymer can be selected such that the water solubility of the water soluble foam substrate is also affected. In general, at a given temperature, as the degree of hydrolysis of the PVOH polymer increases from partial hydrolysis (88% DH) to full hydrolysis (≧98% DH), the water solubility of the polymer generally decreases. Thus, in an exemplary embodiment, the water soluble foam substrate can be cold water soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., not copolymerized with anionic monomers), the cold water soluble web that is soluble in water at a temperature below 10°C can include fibers of PVOH with a degree of hydrolysis ranging from about 75% to about 90%, or from about 75% to about 89%, or from about 80% to about 90%, or from about 85% to about 90%, or from about 90% to about 99.5%. In other exemplary embodiments, the water-soluble foam substrate can be hot water soluble. For example, for co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., not copolymerized with anionic monomers), the hot water soluble foam substrate can be soluble in water at a temperature of at least about 60°C by including fibers of PVOH with a degree of hydrolysis of at least about 98%.

[0141] The modification of the PVOH copolymer increases the solubility of the PVOH polymer. Thus, at a given temperature, the solubility of a water-soluble foam substrate prepared from a modified PVOH copolymer is expected to be higher than that of a water-soluble foam substrate prepared from a PVOH copolymer having the same degree of hydrolysis as the modified PVOH copolymer. Following these trends, a water-soluble foam substrate with a specific solubility profile can be designed by blending a polymer into a fiber and / or by blending a fiber into a water-soluble foam substrate. Furthermore, as described herein, the water-soluble foam substrate may include multiple fibers, and in some cases, may include two or more fiber types with different solubilities.

[0142] The inclusion of water-insoluble fiber and / or water-insoluble fiber-forming material in the fibers of the water-soluble foam substrate can also be used to design a water-soluble foam substrate with a specific solubility and / or extended release characteristics.Without being bound by theory, it is believed that as the weight percentage of water-insoluble fiber included in the water-soluble foam substrate increases (relative to the total weight of the water-soluble foam substrate), the solubility of the water-soluble foam substrate generally decreases, and the extended release characteristics of the pouch containing the water-soluble foam substrate generally increase.When contacted with water at or above the solubility temperature of the water-soluble fiber, the water-soluble foam substrate containing water-soluble fiber and water-insoluble fiber will begin to disperse as the water-soluble fiber dissolves, thereby destroying the foam structure and / or increasing the pore size of the pores of the water-soluble foam substrate.The greater the destruction of the foam structure or the larger the pore size, the faster water can contact the active cleansing composition, and the faster the active cleansing composition is released. Similarly, the extended release of the active cleansing formulation contained in the water-soluble foam base of the present disclosure can be achieved by using a blend of water-soluble fibers with different solubility characteristics and / or different solubility temperatures.As the faster dissolving fibers dissolve, the foam is broken down, and the less soluble fibers have a larger exposed surface area, facilitating the dissolution of the less soluble fibers and the release of the active cleansing formulation.In exemplary embodiments in which the foam base comprises water-soluble and water-insoluble fibers, the ratio of soluble fibers to water-insoluble fibers is not particularly limited. The water soluble fibers can comprise about 1% to about 99%, about 20% to about 80%, about 40% to about 90%, about 50% to about 90%, or about 60% to about 90% by weight of the total weight of the plurality of fibers, and the water insoluble fibers can comprise about 1% to about 99%, about 20% to about 80%, about 10% to about 60%, about 10% to about 50%, or about 10% to about 40% by weight of the total weight of the fibers. In an exemplary embodiment, the plurality of fibers comprises about 10% to about 80% water soluble fiber by total weight of the fibers, with the remainder being water insoluble fiber.

[0143] In an exemplary embodiment, the nonwoven web, the plurality of fibers, the foam, the water-soluble film, or a combination thereof disclosed herein can include a biodegradable polymer. In certain embodiments, the plurality of fibers can include water-insoluble fibers that form a material that is biodegradable. In an exemplary embodiment, the plurality of fibers can include a first fiber that is a water-insoluble biodegradable fiber and a second fiber that is soluble in water at a temperature of about 10° C. to about 20° C. according to MSTM-205 or is not soluble in water at a temperature of about 30° C. or less according to MSTM-205. In an exemplary embodiment, the nonwoven web is water-insoluble and biodegradable.

[0144] In exemplary embodiments, the water-soluble foam substrate is biodegradable. As used herein, when a water-soluble foam substrate is said to be biodegradable, at least 50% of the water-soluble foam substrate is biodegradable, such as at least 60%, at least 70%, at least 80%, at least 90%, or 100% of the water-soluble foam substrate is biodegradable.

[0145] The water-soluble foam substrates disclosed herein can include a plurality of fibers including a first fiber type and a second fiber type, the first and second fiber types having similar characteristics, such as diameter, length, tenacity, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g), chemical composition, color, or combinations thereof. In exemplary embodiments, the first fiber type may comprise a PVOH homopolymer fiber-forming material, a PVOH copolymer fiber-forming material, a modified PVOH copolymer fiber-forming material, or a combination thereof. In exemplary embodiments, the first fiber type may comprise two or more PVOH homopolymer fiber-forming materials, two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a combination thereof. In exemplary embodiments, the second fiber type may comprise a PVOH homopolymer fiber-forming material, a PVOH copolymer fiber-forming material, a modified PVOH copolymer fiber-forming material, or a combination thereof. In exemplary embodiments, the second fiber type may comprise two or more PVOH homopolymer fiber-forming materials, two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a combination thereof. In exemplary embodiments, the first fiber type and / or the second fiber type are water-insoluble fiber-forming materials. In an exemplary embodiment, the first fiber type can include a water insoluble polymeric fiber forming material and the second fiber type can include a polyvinyl alcohol fiber forming material that, when provided as the sole fiber forming material of a nonwoven web or as a film, the resulting web or film is soluble by MSTM-205 in water at temperatures ranging from about 0° C. to about 20° C. In an exemplary embodiment, the first fiber type can include a water insoluble polymeric fiber forming material and the second fiber type can include a PVOH copolymer or modified copolymer fiber forming material that, when provided as the sole fiber forming material of a water soluble foam substrate, the resulting water soluble foam substrate is not soluble by MSTM-205 in water at temperatures at or below 20° C. In an exemplary embodiment, the first fiber type includes two or more PVOH copolymer fiber forming materials, two or more modified PVOH copolymer fiber forming materials, or a combination of a PVOH homopolymer fiber forming material and a PVOH copolymer fiber forming material.In exemplary embodiments, the second fiber type includes two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a combination of a PVOH copolymer fiber-forming material and a modified PVOH copolymer fiber-forming material.

[0146] The fibers included in the water-soluble foam substrate of the present disclosure can have any tenacity. The tenacity of the fiber correlates with the coarseness of the fiber. As the tenacity of the fiber decreases, the coarseness of the fiber increases. The fibers used to prepare the nonwoven web of the present disclosure can have a tenacity of about 1 to about 100 cN / dtex, or about 1 to about 75 cN / dtex, or about 1 to about 50 cN / dtex, or about 1 to about 45 cN / dtex, or about 1 to about 40 cN / dtex, or about 1 to about 35 cN / dtex, or about 1 to about 30 cN / dtex, or about 1 to about 25 cN / dtex, or about 1 to about 20 cN / dtex, or about 1 to about 15 cN / dtex, or about 1 to about 10 cN / dtex, or about 3 to about 8 cN / dtex, or about 4 to about 8 cN / dtex. tex, or from about 6 to about 8 cN / dtex, or from about 4 to about 7 cN / dtex, or from about 10 to about 20, or from about 10 to about 18, or from about 10 to about 16, or about 1 cN / dtex, about 2 cN / dtex, about 3 cN / dtex, about 4 cN / dtex, about 5 cN / dtex, about 6 cN / dtex, about 7 cN / dtex, about 8 cN / dtex, about 9 cN / dtex, about 10 cN / dtex, about 11 cN / dtex, about 12 cN / dtex, about 13 cN / dtex, about 14 cN / dtex, or about 15 cN / dtex. In exemplary embodiments, the plurality of fibers may have a tenacity ranging from about 3 cN / dtex to about 15 cN / dtex, or from about 5 cN / dtex to about 12 cN / dtex, or from about 5 cN / dtex to about 10 cN / dtex.

[0147] The toughness of the water-soluble foam substrate can be the same or different from the toughness of the fibers used to prepare the web. Without being bound by theory, it is believed that the toughness of the water-soluble foam substrate is related to the strength of the nonwoven web, with higher toughness providing higher strength to the nonwoven web. The toughness of the water-soluble foam substrate can be modified by using fibers with different toughness. The toughness of the water-soluble foam substrate can also be affected by processing. The water-soluble foam substrate of the present disclosure has a relatively high toughness, i.e., the water-soluble foam substrate is a self-supporting substrate that can be used as the sole material to prepare an article and / or a pouch. In contrast, the water-soluble foam substrate prepared by meltblowing, electrospinning, and / or rotary spinning process may have low toughness and may not be self-supporting or can not be used as the sole substrate to form an article or a pouch.

[0148] Water-soluble foam substrates can be characterized by their basis weight. The basis weight of a water-soluble foam substrate is the mass per unit area of ​​the water-soluble foam substrate. The basis weight can be modified by varying manufacturing conditions as known in the art. The water-soluble foam substrate can have the same basis weight before and after bonding. Alternatively, the bonding method can change the basis weight of the water-soluble foam substrate. For example, when bonding occurs through the application of heat and pressure, the thickness of the water-soluble foam substrate (and therefore the area of ​​the water-soluble foam substrate) can be reduced, thereby increasing the basis weight. Thus, as used herein and unless otherwise specified, the basis weight of a water-soluble foam substrate refers to the basis weight of the water-soluble foam substrate after bonding.

[0149] The water-soluble foam substrate of the present disclosure has a viscosity of about 0.1 g / m 2 to about 700g / m 2 , about 0.5g / m 2 to about 600g / m 2 , about 1g / m 2 to about 500g / m 2 , about 1g / m 2 to about 400g / m2 , about 1g / m 2 to about 300g / m 2 , about 1g / m 2 to about 200 g / m 2 , about 1g / m 2 to about 100g / m 2 , about 30g / m 2 to about 100g / m 2 , about 20g / m 2 to about 100g / m 2 , about 20g / m 2 From about 80g / m 2 , or about 25 g / m 2 From about 70g / m 2 The sheet may have any basis weight in the range of 1000 to 15000 grammage.

[0150] Furthermore, assuming the fiber composition and web thickness remain constant, as the basis weight of the water-soluble foam substrate increases, the dissolution rate of the water-soluble foam substrate decreases because more material is dissolved. For example, at a given temperature, a 40 g / m2 water-soluble foam substrate containing PVOH polymer(s) will dissolve at a rate of 100 g / m2 or more. 2 A water-soluble foam substrate prepared from fibers having a basis weight of, for example, 30 g / m 2 and is predicted to dissolve slower than an otherwise identical water-soluble web having a basis weight of about 1 g / m. Basis weight can therefore also be used to modify the solubility characteristics of the water-soluble foam substrate. Water-soluble foam substrates have a basis weight of about 1 g / m. 2 to about 700g / m 2 , about 1g / m 2 to about 600g / m 2 , about 1g / m 2 to about 500g / m 2 , about 1g / m 2 to about 400g / m 2 , about 1g / m 2 to about 300g / m 2 , about 1g / m 2 to about 200 g / m 2 , about 10g / m 2 to about 100g / m 2 , about 30g / m 2 to about 100g / m 2 , about 20g / m 2to about 100g / m 2 , about 20g / m 2 From about 80g / m 2 , about 25g / m 2 From about 70g / m 2 , or about 40 g / m 2 From about 60g / m 2 The sheet may have any basis weight in the range of 1000 to 15000 grammage.

[0151] The water-soluble foam substrate of the present disclosure can be used as a single layer, can be layered with other water-soluble foam substrates, or can be in the form of a laminate with a water-soluble film. In some embodiments, the water-soluble foam substrate comprises a single layer. In some embodiments, the water-soluble foam substrate is a multi-layer water-soluble foam substrate comprising two or more layers. The two or more layers can be laminated together. In refinements of the above-mentioned embodiment, the two or more layers can be the same (e.g., can be prepared from the same fibers and basis weights). In refinements of the above-mentioned embodiment, the two or more layers can be different (e.g., can be prepared from different types of fibers, fiber chemistries, and / or have different basis weights).

[0152] The multi-layer water-soluble foam substrate can have a basis weight that is the sum of the basis weights of the individual layers, and therefore the multi-layer water-soluble foam substrate will take longer to dissolve than either of the individual layers provided as a single layer. Water-soluble film

[0153] The water-soluble films described herein include any of the water-soluble polymers disclosed herein. In an exemplary embodiment, the water-soluble films of the present disclosure include polyvinyl alcohol (PVOH) resins, modified polyvinyl alcohol resins, or combinations thereof. In an exemplary embodiment, the water-soluble films include a PVOH resin selected from the group consisting of PVOH homopolymers, PVOH copolymers, PVOH copolymers with anionic modifications, and combinations of the foregoing. In an exemplary embodiment, the water-soluble films can include a single PVOH polymer or a blend of PVOH polymers. In an exemplary embodiment, the water-soluble films include PVOH copolymers. In an exemplary embodiment, the water-soluble films include hot water soluble PVOH copolymers. In an exemplary embodiment, where the nonwoven web includes a surfactant and / or an exfoliant, the water-soluble films can include PVOH copolymers with anionic modifications. In an exemplary embodiment, the water-soluble films can include water-soluble polyvinyl alcohol copolymers or modified copolymers that, when provided in the film as the sole film-forming material, are soluble in water at temperatures ranging from about 0° C. to about 20° C. by MSTM-205. In an exemplary embodiment, the water-soluble film can include a water-soluble polyvinyl alcohol copolymer or modified copolymer that, when provided in the film as the sole film-forming material, is not water-soluble at water temperatures of 20° C. or less by MSTM-205.

[0154] The water-soluble film can include other film-forming polymers, including but not limited to polyvinyl alcohol, water-soluble acrylate copolymers, polyethyleneimine, pullulan, water-soluble natural polymers including but not limited to guar gum, acacia gum, xanthan gum, carrageenan, and starch, water-soluble polymer modified starch, copolymers of the foregoing, or combinations of any of the foregoing. Other water-soluble polymers can include polyalkylene oxides, polyacrylamides, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and their salts, polyamino acids, polyamides, gelatin, methylcellulose, carboxymethylcellulose and its salts, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, maltodextrin, polymethacrylates, or combinations of any of the foregoing. Such water-soluble polymers are commercially available from a variety of sources. In an exemplary embodiment, the water-soluble film can include a PVOH homopolymer, a PVOH copolymer, a modified PVOH copolymer, or a combination thereof. In an exemplary embodiment, the water-soluble film includes a single PVOH copolymer or a blend of PVOH copolymers. In a further embodiment, the water-soluble film comprises a PVOH copolymer having a viscosity in the range of 5 cP to 23 cP and a degree of hydrolysis in the range of 86% to 92%.

[0155] The film can have any suitable thickness, with a film thickness of about 76 microns (μm) being typical and specifically contemplated. Other values ​​and ranges contemplated include a range of about 5 μm to about 200 μm, or a range of about 20 μm to about 100 μm, or a range of about 40 μm to about 90 μm, or a range of about 50 μm to 80 μm, or about 60 μm to 65 μm, such as values ​​of 65 μm, 76 μm, or 88 μm.

[0156] In an exemplary embodiment, the water-soluble film may include the above-mentioned auxiliary. In an exemplary embodiment, the water-soluble film may be substantially free of the above-mentioned auxiliary. In an exemplary embodiment, the water-soluble film may include the above-mentioned plasticizer. The total amount of non-aqueous plasticizer provided in the water-soluble film may range from about 1% to about 45% by weight, or from about 5% to about 45% by weight, or from about 10% to about 40% by weight, or from about 20% to about 30% by weight, from about 1% to about 4% by weight, or from about 1.5% to about 3.5% by weight, or from about 2.0% to about 3.0% by weight, for example, about 1%, about 2.5%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, or about 40% by weight. In an exemplary embodiment, the water-soluble film comprises one or more of propylene glycol, glycerol, diglycerol, sorbitol, xylitol, maltitol, trimethylolpropane (TMP) and polyethylene glycol (100-1000 molecular weight).

[0157] In exemplary embodiments, the water-soluble film may include the surfactants described above. In various embodiments, the amount of surfactant in the water-soluble film ranges from about 0.01% to about 2.5% by weight, from about 0.1% to about 2.5% by weight, from about 1.0% to about 2.0% by weight, from about 0.01% to 0.25% by weight, or from about 0.10% to 0.20% by weight. In exemplary embodiments, the water-soluble film includes one or more of polysorbate 80, lecithin from various plant sources, and sodium lauryl sulfate (SLS), and the like.

[0158] In an exemplary embodiment, the water-soluble film adjuvant may include a filler / bulking agent / antiblocking agent / antiblocking agent. Suitable fillers / bulking agents / antiblocking agents include, but are not limited to, crosslinked polyvinylpyrrolidone, crosslinked cellulose, microcrystalline cellulose, silica, metal oxides, calcium carbonate, talc, mica, stearic acid and its metal salts, such as magnesium stearate. If desired, additional unmodified or modified starches can be included in the water soluble in addition to one of the specific starch components mentioned above, such as hydroxypropylated starches present in an amount ranging from about 5 phr to about 30 phr, or modified starches having a degree of modification greater than about 2% and present in an amount ranging from about 2.5 phr to about 30 phr, or unmodified starches having an amylose content ranging from about 20% to about 80%, or hydroxypropyl modified starches having an amylose content ranging from about 23% to about 95%, where the polyvinyl alcohol comprises an unmodified polyvinyl alcohol copolymer or an anionic modified polyvinyl alcohol copolymer, and provided that the anionic modifier is not an acrylate. Preferred materials are starch, modified starch, and silica. In one embodiment, the amount of filler / bulking agent / antiblocking agent / antisticking agent in the water-soluble film can range, for example, from about 1% to about 6% by weight, or from about 1% to about 4% by weight, or from about 2% to about 4% by weight, or from about 1 phr to about 6 phr, or from about 1 phr to about 4 phr, or from about 2 phr to about 4 phr. In an exemplary embodiment, when starch or modified starch is included in the water-soluble film in addition to one of the specific starch components described above, the additional starch component will be provided in an amount of less than about 50% by weight based on the total weight of all starches included in the film. Without wishing to be bound by theory, it is believed that any benefit provided to the water-soluble film of the present disclosure from including the starch components described above is not affected by including additional starch components that provide less benefit or no benefit to the water-soluble film.

[0159] The water-soluble film may further have a residual moisture content of at least 4% by weight, such as in the range of about 4% to about 10% by weight, as measured by Karl Fischer titration. Method for preparing fibers

[0160] Wet-cooled gel spinning

[0161] In an exemplary embodiment, the plurality of water soluble fibers can include water soluble fibers prepared according to a wet cryogel spinning process, the wet cryogel spinning process comprising: (a) dissolving a water-soluble polymer (or polymers) in solution to form a polymer mixture, optionally including an adjuvant; (b) extruding the polymer mixture through a spinneret nozzle into a coagulation bath to form an extruded polymer mixture; (c) passing the extruded polymer mixture through a solvent exchange bath; (d) optionally wet drawing the extruded polymer mixture; and (e) finishing the extruded polymer mixture to provide water soluble fibers. Includes.

[0162] The solvent in which the water-soluble polymer is dissolved may suitably be any solvent that the water-soluble polymer is soluble in. In an exemplary embodiment, the solvent in which the water-soluble polymer is dissolved comprises a polar aprotic solvent. In an exemplary embodiment, the solvent in which the water-soluble polymer is dissolved comprises dimethylsulfoxide (DMSO).

[0163] The coagulation bath contains a cooling solvent to gel the extruded polymer mixture. The coagulation bath can generally be at any temperature that facilitates solidification of the extruded polymer mixture. The coagulation bath can be a mixture that includes a solvent in which the polymer is soluble and a solvent in which the polymer is not soluble. The solvent in which the polymer is not soluble is generally the primary solvent, and the solvent in which the polymer is not soluble constitutes greater than 50% by volume of the mixture.

[0164] After passing through the coagulation bath, the extruded polymer mixture gel can pass through one or more solvent exchange baths. The solvent exchange baths are provided to replace the solvent in which the water-soluble polymer is soluble with a solvent in which the water-soluble polymer is not soluble to further coagulate the extruded polymer mixture, and to replace the solvent in which the water-soluble polymer is soluble with a solvent that will evaporate more easily, thereby reducing drying time. The solvent exchange baths can include a series of solvent exchange baths with a gradient of the solvent in which the water-soluble polymer is soluble as well as the solvent in which the water-soluble polymer is not soluble, a series of solvent exchange baths with only the solvent in which the water-soluble polymer is not soluble, or a single solvent exchange bath with only the solvent in which the water-soluble polymer is not soluble. In an exemplary embodiment, at least one solvent exchange bath can consist essentially of the solvent in which the water-soluble polymer is not soluble.

[0165] The finished fiber may also be referred to as staple fiber, short cut fiber, or pulp. In an exemplary embodiment, finishing includes drying the extruded polymer mixture. In an exemplary embodiment, finishing includes cutting or crimping the extruded polymer mixture to form individual fibers. Wet drawing of the extruded polymer mixture can provide a substantially uniform diameter to the extruded polymer mixture from which the fibers are cut. Drawing is quite different from extrusion as is known in the art. In particular, "extrusion" refers to the act of forcing a resin mixture through a spinneret head to create fibers, whereas drawing refers to mechanically pulling the fibers in the machine direction to promote polymer chain orientation and crystallinity, thereby increasing fiber strength and toughness.

[0166] In exemplary embodiments in which the water soluble fibers are prepared from a wet cryogel spinning process, the water soluble polymer can generally be any water soluble polymer or blend thereof, such as two or more different polymers, as generally described herein. In refinements of the foregoing embodiments, the polymer(s) can be any degree of polymerization (DP), such as in the range of 10 to 10,000,000, such as at least 10, at least 20, at least 50, at least 100, at least 200, at least 300, at least 400, at least 500, at least 750, or at least 1000, and up to 10,000,000, up to 5,000,000, up to 2,500,000, up to 1,000,000, up to 900,000, up to 750,000, up to 500,000, up to 250,000, up to 100,000, up to 90,000, up to 10,0 ... 75,000, up to 50,000, up to 25,000, up to 12,000, up to 10,000, up to 5,000, or up to 2,500, for example, 1000 to about 50,000, 1000 to about 25,000, 1000 to about 12,000, 1000 to about 5,000, 1000 to about 2,500, about 50 to about 12,000, about 50 to about 10,000, about 50 to about 5,000, about 50 to about 2,500, about 50 to about 1000, about 50 to about 900, about 100 to about 800, about 150 to about 700, about 200 to about 600, or about 250 to about 500. In an exemplary embodiment, the DP is at least 1,000. The above mentioned adjuvants can be added to the fibers themselves or to the nonwoven web during the carding and / or bonding process.

[0167] Thermoplastic Fiber Spinning

[0168] Thermoplastic fiber spinning is well known in the art. Briefly, thermoplastic fiber spinning involves: (a) preparing a polymer mixture comprising a fiber-forming polymer, optionally including an adjuvant; (b) extruding the polymer mixture through a spinneret nozzle to form an extruded polymer mixture; (c) optionally stretching the extruded polymer mixture; and (d) finishing the extruded polymer mixture to obtain fibers. Includes.

[0169] The full staple fibers of the thermoplastic fiber spinning process can be finished by drying, cutting, and / or crimping to form individual fibers. Stretching the extruded polymer mixture mechanically pulls the fiber in the machine direction, promoting polymer chain orientation and crystallinity to increase fiber strength and toughness. Preparation of the polymer mixture for thermoplastic fiber spinning can include (a) preparing a solution of fiber-forming materials and a readily volatile solvent and extruding the solution through a spinneret, where the solvent readily evaporates when the solution contacts a stream of hot air, leaving behind a solid fiber, or (b) melting the polymer and allowing the polymer to solidify by extruding the hot polymer through a spinneret followed by a quench with cold air. Thermoplastic fiber spinning is distinct from wet chill gel spinning in that at least (a) in thermoplastic fiber spinning, the extruded fiber is solidified by evaporation of a solvent or by quenching the hot solid fiber with cold air rather than by the use of a coagulation bath; and (b) in wet chill gel spinning, any required drawing is accomplished while the fiber is in a gel state rather than a solid state.

[0170] The fiber-forming material for preparing fibers from the thermoplastic fiber spinning process can be any fiber-forming polymer or blend thereof, for example, two or more different polymers, provided that the polymer or blend thereof has a suitable solubility in a readily volatile solvent and / or has a melting point lower than its decomposition temperature and clearly different. Furthermore, when a blend of fiber-forming polymers is used to make fibers, the fiber-forming material must have a similar solubility in a readily volatile solvent and / or have a similar thermal profile so that the two or more fiber-forming materials melt at similar temperatures. In contrast, the fiber-forming material for preparing fibers from the wet-cooled gel spinning process is not limited, and the fibers can be prepared from a blend of any two or more polymers that are soluble in the same solvent system, and the solvent system does not have to be a single solvent or even a volatile solvent.

[0171] The fiber-forming polymer(s) for preparing thermoplastic fiber spun fibers can have a degree of polymerization (DP) ranging, for example, from 10 to 10,000, such as at least 10, at least 20, at least 50, at least 100, at least 200, at least 300, at least 400, at least 500, at least 750, or at least 1000, and up to 10,000, up to 5,000, up to 2,500, up to 1,000, up to 900, up to 750, up to 500, or up to 250. In exemplary embodiments, the DP is less than 1,000.

[0172] Melt Spinning

[0173] Melt spinning is well known in the art and is understood to refer to both spunbonding and meltblowing processes. Melt spinning is a continuous process that directly prepares a nonwoven web following fiber formation. Thus, the melt-spun forming fibers are not completed and cut to any consistent length (e.g., staple fibers are not prepared by these processes). Furthermore, melt spinning does not include a drawing step, and therefore the only control of the diameter of the resulting melt-spun fibers is the size of the hole through which the fiber-forming materials are extruded, and the polymer chains are not oriented in any particular direction.

[0174] In an exemplary embodiment, the melt spinning comprises: (a) preparing a polymer mixture comprising a fiber-forming polymer, optionally including an adjuvant; (b) extruding the polymer mixture into a die assembly to form an extruded polymer mixture; (c) quenching the extruded polymer mixture; (d) depositing the quenched extruded polymer mixture onto a belt to form a nonwoven web; and (e) bonding the nonwoven web Includes.

[0175] In the spunbond process, the extruded polymer mixture is pumped into a die assembly as a molten polymer and quenched with cold air as it passes through the die assembly. In the meltblown process, the extruded polymer mixture is pumped into a die assembly with hot air blown into it and quenched as it exits the die assembly and comes into contact with air at ambient temperature. In both processes, the fibers are continuously lowered onto a belt or drum, usually facilitated by drawing a vacuum under the belt or drum.

[0176] The diameter of the melt spun fibers can range from about 0.1 to about 50 microns, e.g., at least about 0.1 micron, at least about 1 micron, at least about 2 microns, at least about 5 microns, at least about 10 microns, at least about 15 microns, or at least about 20 microns, and up to about 50 microns, up to about 40 microns, up to about 30 microns, up to about 25 microns, up to about 20 microns, up to about 15 microns, up to about 10 microns, from about 0.1 micron to about 50 microns, from about 0.1 micron to about 40 microns, from about 0.1 micron to about 30 microns, From about 0.1 microns to about 25 microns, from about 0.1 microns to about 20 microns, from about 0.1 microns to about 15 microns, from about 0.1 microns to about 10 microns, from about 0.1 microns to about 9 microns, from about 0.1 microns to about 8 microns, from about 0.1 microns to about 7 microns, from about 0.1 microns to about 6 microns, from about 0.1 microns to about 6 microns, from about 5 microns to about 35 microns, from about 5 microns to about 30 microns, from about 7.5 microns to about 25 microns, from about 10 microns to about 25 microns, or from about 15 microns to about 25 microns. Although the meltblowing process can provide microfine fibers having an average diameter in the range of about 1-10 microns, it is known in the art that meltblowing processes have a very large variation in fiber-to-fiber diameter, for example, a variation of 100-300%. Additionally, spunbond fibers can have a larger average fiber diameter, e.g., from about 15 to about 25 microns, but are known in the art to have improved fiber-to-fiber uniformity, e.g., about 10% variation.

[0177] Fiber-forming materials for thermal extrusion processes (e.g., melt spinning, thermoplastic fiber spinning) are more limited than those for wet-cooled gel spinning processes. For example, the degree of polymerization for thermal extrusion processes is limited to a range of about 200 to about 500. As the degree of polymerization decreases below 200, the viscosity of the fiber-forming material also becomes too low, and individual fibers prepared by pumping the material through the die assembly do not maintain proper separation after exiting the die assembly. Similarly, as the degree of polymerization increases above 500, the viscosity becomes too high to efficiently pump the material through small enough holes in the die assembly to run the process at high speeds, thus losing process efficiency and fiber and / or nonwoven uniformity. Furthermore, processes requiring heating of the fiber-forming material are unsuitable for polyvinyl alcohol homopolymers, as homopolymers generally do not have the necessary thermal stability.

[0178] The wet chill gel spinning process advantageously provides one or more benefits, such as providing fibers containing a blend of water-soluble polymers, controlling the diameter of the fiber, providing relatively large diameter fibers, controlling the length of the fiber, controlling the tenacity of the fiber, providing high tenacity fibers, providing fibers from polymers with a high degree of polymerization, and / or providing fibers that can be used to provide a self-supporting nonwoven web. Continuous processes such as spunbonding, meltblowing, electrospinning, and rotary spinning generally do not allow blends of water-soluble polymers (e.g., due to the difficulty of matching the melt index of various polymers), forming fibers with large diameters (e.g., greater than 50 microns), controlling the length of the fiber, providing high tenacity fibers, and using polymers with a high degree of polymerization. Furthermore, the wet chill gel spinning process advantageously is not limited to polymers that are only melt processable, and therefore can utilize fibers made from fiber-forming materials with very high molecular weights, high melting points, low melt flow indexes, or combinations thereof, providing fibers with stronger physical properties and various chemical functionalities compared to fibers prepared by thermal extrusion processes. Further still, advantageously, the wet cryogel spinning process is not limited by the viscosity of the polymer. In contrast, processes requiring melting of the fiber-forming material are known in the art to be limited to fiber-forming materials with viscosities of 5 cP or less. Thus, fibers comprising polymers including polyvinyl alcohol homopolymers and copolymers with viscosities greater than 5 cP are only accessible by wet cryogel spinning. Method for preparing a nonwoven web

[0179] The nonwoven web of the present disclosure is a sheet-like structure having two outer surfaces, the nonwoven web comprising a plurality of fibers. The nonwoven web of the present disclosure can be prepared from fibers using any method known in the art. As known in the art, when fibers are spunbonded or meltblown, the fibers are laid continuously side-by-side to form a nonwoven web, and then the fibers are bonded.

[0180] The staple fibers are carded or airlaid and bonded to provide a nonwoven web. Carding and airlaid methods are well known in the art.

[0181] Methods of bonding nonwoven webs are well known in the art. For example, bonding can include thermal, mechanical, and / or chemical bonding. Thermal bonding can include, but is not limited to, calendaring, embossing, air-through, and ultrasonic. Mechanical bonding can include, but is not limited to, hydroentanglement (spunlace), needle punching, and stitch bonding. Chemical bonding can include, but is not limited to, solvent bonding and resin bonding.

[0182] Thermal bonding is achieved by applying heat and pressure to maintain the pore size, shape, and alignment created by the carding process. Thermal bonding conditions can be easily determined by one skilled in the art. If too little heat and / or pressure is applied, the fibers will not bond sufficiently to form a freestanding web, and if too much heat and / or pressure is applied, the fibers will begin to blend together. The chemical nature of the fibers determines the upper and lower limits of heat and / or pressure for thermal bonding. Without wishing to be bound by theory, it is believed that at temperatures above 235°C, polyvinyl alcohol-based fibers decompose. Embossing methods for thermal bonding of fibers are known. Embossing can be single-sided embossing or double-sided embossing. Embossing of water-soluble fibers includes single-sided embossing using a single embossing roll consisting of an ordered circular array and a steel roll with a flat surface. As the embossing increases (e.g., as surface features are imparted to the web), the surface area of ​​the web increases. Without wishing to be bound by theory, as the surface area of ​​the web increases, the solubility of the web increases, and therefore the solubility characteristics of a nonwoven web can be advantageously tailored by varying the surface area through embossing.

[0183] Air-through bonding requires a high thermoplastic content in the nonwoven web and two different melting point materials. In air-through bonding, the unbonded nonwoven web circulates around a drum while hot air flows from the outside of the drum toward the center of the drum. Air-through bonding is suitable for low density and higher basis weight (e.g., 20 to about 2000 g / m 2 It is possible to provide a nonwoven having a tensile strength (greater than 100%). Airbonded nonwovens are very soft.

[0184] Chemical bonding includes solvent bonding and resin bonding. In particular, chemical bonding may use a binder solution of solvent and resin (e.g., latex, or waste polymers left over from fiber preparation). The nonwoven web can be coated with the binder solution and heat and pressure can be applied to cure the binder and bond the nonwoven. The binder solution can be applied by immersing the nonwoven in a bath of binder solution, spraying the binder solution onto the nonwoven, extruding the binder solution onto the web (foam bonding), and / or applying the binder solution as a print or gravure.

[0185] Chemical bonding can result in smaller, less ordered pores versus carded / melt spun pores. Without wishing to be bound by theory, it is believed that if the resin solution used for chemical bonding is concentrated enough and / or sufficient pressure is applied, a non-porous nonwoven web can be formed. The solvent used for chemical bonding induces partial solubilization of existing fibers in the web to weld and bond the fibers together. Thus, the solvent for chemical bonding can be any solvent that can at least partially solubilize one or more fiber-forming materials of the fibers of the nonwoven. In an exemplary embodiment, the solvent is selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof. In an exemplary embodiment, the solvent is selected from the group consisting of water, glycerin, and combinations thereof. In an exemplary embodiment, the binder solution includes a solvent selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof, and further includes a resin selected from the group consisting of polyvinyl alcohol, latex, and polyvinylpyrrolidone. The binder provided in the solution aids in the welding process to provide a more mechanically robust web. The temperature of the polymer solution is not particularly limited and can be provided at room temperature (about 23° C.).

[0186] In some embodiments, a second layer of fibers can be used to bond the nonwoven web. In exemplary embodiments, the nonwoven web layers can be bonded using thermal, mechanical, or chemical bonds, either alone or in addition to bonding using additional layers of nonwoven web / fibers. Method for Laminating Films to Nonwoven Webs or Foam Substrates

[0187] Methods for preparing laminates (eg, water-soluble films and nonwovens) can include, but are not limited to, calendar lamination (heat and pressure) or melt bonding.

[0188] Calender lamination is achieved by applying heat and pressure. The conditions of calender lamination can be easily determined by those skilled in the art. In general, if the applied heat and / or pressure is too low, the fibers will not bond well to the water-soluble film forming the laminate, and if the heat and / or pressure is too high, the fibers will begin to melt with each other and with the film. Fiber chemistry and film chemistry determine the upper and lower limits of heat and / or pressure for calender lamination. Without wishing to be bound by theory, it is believed that at temperatures above 235°C, polyvinyl alcohol-based fibers decompose. In an exemplary embodiment, the heat applied to the overlay nonwoven and water-soluble film is from about 50°C to about 200°C, for example, from about 100°C to about 200°C, from about 110°C to about 190°C, from about 120°C to about 180°C, or from about 130°C to about 160°C. In an exemplary embodiment, the pressure applied to the overlay nonwoven and water-soluble film is about 5 psi to about 50 psi, such as about 10 psi to about 40 psi, about 15 psi to about 30 psi, or about 20 psi to about 30 psi. In an exemplary embodiment, the heat applied to the overlay nonwoven and water-soluble film is about 150° C. and the pressure applied is about 25 psi. In an exemplary embodiment, the heat and pressure are applied for about 2-4 seconds. An embossing method for the calender lamination of fibers and / or films is contemplated. The embossing can be single-sided embossing or double-sided embossing. For example, embossing of water-soluble fibers and / or water-soluble films includes single-sided embossing using a single embossing roll of ordered circular arrays and a steel roll with a flat surface. As the embossing increases (e.g., an increased amount of surface features are imparted to the web and / or film), the surface area of ​​the laminate increases. Without wishing to be bound by theory, it is believed that as the surface area of ​​the article decreases, the solubility of the web and / or film decreases. Thus, the solubility characteristics of the nonwoven web and / or water-soluble film can be advantageously tailored by varying the surface area through embossing.Without wishing to be bound by theory, it is believed that as the degree of lamination of a unit dose article increases, the surface area of ​​the laminate decreases and the bond between the water-soluble film and the nonwoven increases, resulting in decreased solubility and increased liquid release time.

[0189] Melt bond lamination is achieved by applying an adhesive directly to the water-soluble film, then the nonwoven web is placed on top of the water-soluble film with the applied adhesive and subjected to cold lamination for bonding of the nonwoven web and the water-soluble film. As used herein, the term "cold lamination" refers to a lamination process that requires pressure but no additional heat. The adhesive can be any suitable adhesive to one skilled in the art. In an exemplary embodiment, the adhesive is Henkel National adhesive. The application of the adhesive directly to the water-soluble film can be applied by any suitable method to one skilled in the art, such as a hot melt spray process. In an exemplary embodiment, the melt bond lamination process is a hot melt spray process at 160°C followed by a 94 N / mm 2 This can include low temperature lamination at a pressure of 1000 .mu.m.

[0190] The laminate of the present disclosure generally comprises a water-soluble film and a nonwoven web. In an exemplary embodiment, the laminate can have a lamination degree of about 1% to about 100%, and the lamination degree can range from about 1% to about 90%, or about 25% to about 75%, or about 1% to about 50%, or about 5% to about 25%, or about 25% to about 100%, or about 50% to about 100%. As used herein, "lamination degree" refers to the amount of the total area of ​​the water-soluble film bonded to the nonwoven web. For example, a laminate with a lamination degree of about 25% or less means that about 25% or less of the area of ​​the water-soluble film is bonded to the nonwoven web, e.g., laminated only with a sealant. For example, a laminate with a lamination degree of about 100% means that about 100% of the area of ​​the water-soluble film is bonded to the nonwoven web. In an exemplary embodiment with a lamination degree of about 25% or less, the lamination can be achieved during a heat seal process where lamination occurs with each sealant of the unit dose article. In exemplary embodiments where the laminate has a lamination degree of about 25% or less, this low lamination degree can be advantageous because it provides internal voids where the water-soluble film and nonwoven web are not laminated, providing physical separation of compartments with incompatible chemical properties and providing the opportunity for a two-stage delivery system of the composition of the unit dose article. In exemplary embodiments, the lamination degree is in the range of about 5% to about 25%. In exemplary embodiments, the lamination degree is in the range of about 50% to about 100%. Dissolution and Disintegration Test (Modified MSTM-205)

[0191] The nonwoven web, water-soluble film, or laminate structure can be characterized by or tested for dissolution time and disintegration time according to MonoSol Test Method 205 (MSTM 205), a method known in the art. See, for example, U.S. Patent No. 7,022,656. The description provided below refers to a nonwoven web, but is equally applicable to a water-soluble film or laminate structure.

[0192] Apparatus and method: 600mL beaker Magnetic stir bar (Labline Model No. 1250 or equivalent) Magnetic stirring bar (5cm) Thermometer (0 to 100°C ±1°C) Template, stainless steel (3.8cm x 3.2cm) Timer (0-300 seconds, accurate to the second) Polaroid 35mm slide mount (or equivalent) MonoSol 35mm Slide Mount Holder (or equivalent) Distilled water

[0193] For each nonwoven web to be tested, three test specimens are cut from the nonwoven web sample, being 3.8 cm by 3.2 cm specimens. The test specimens should be cut from areas of the web that are evenly spaced along the cross direction of the web. Each test specimen is then analyzed using the following procedure. Each specimen is mounted on an individual 35 mm slide mount. Fill a beaker with 500 mL of distilled water. Measure the water temperature with a thermometer and heat or cool the water as necessary to maintain a temperature at which dissolution is determined, e.g., 20° C. (about 68° F.). Mark the height of the water column. Place a magnetic stir bar at the base of the holder. Place the beaker on the magnetic stir bar, add the magnetic stir bar to the beaker, turn the stir bar, and adjust the stirring speed until a vortex is created at approximately one-fifth of the height of the water column. Mark the depth of the vortex. Secure the 35mm slide mount into the alligator clamp of the 35mm slide mount holder with the long side of the slide mount parallel to the water surface. The holder's depth adjustment should be set so that when lowered, the end of the clamp is 0.6 cm below the surface of the water. One of the short pieces of the slide mount should be adjacent to the side of the beaker and the other positioned directly above the center of the stir bar so that the surface of the nonwoven web is perpendicular to the water flow. In one motion, drop the clamped slide and clamp into the water and start the timer. Rupture occurs when the sample breaks within the slide, e.g., a hole appears. Disintegration occurs when the nonwoven web tears and no sample material remains in the slide. When all visible nonwoven web is released from the slide mount, the slide is raised out of the water while continuing to monitor the solution for undissolved nonwoven web fragments. Dissolution occurs when all nonwoven web fragments are no longer visible and the solution becomes clear. For nonwoven samples whose fibers are prepared from polyvinyl alcohol polymers with a low degree of hydrolysis (e.g., about 65-88%), rupture and dissolution may occur simultaneously. If the difference between rupture and dissolution is 5 seconds or longer, the dissolution time is recorded independently from the rupture time.

[0194] Thinning time can also be determined using MSTM-205. Thinning of a nonwoven web occurs when some of the fibers that make up the nonwoven web dissolve while other fibers remain intact. Thinning of the web occurs prior to web collapse. Thinning is characterized by a decrease in opacity or an increase in transmittance of the nonwoven web. It is a gradual change from opaque to transparent and can be observed visually. During MSTM-205, the opacity / transmittance of the nonwoven web is monitored after the fixed slide and clamp are lowered into the water. The time at which no change in opacity / transmittance is observed (i.e., the web does not become more opaque or more transparent) is recorded as the thinning time.

[0195] Results should include: complete sample identification; individual and average disintegration and dissolution times; and the water temperature in which the samples were tested. Method for determining single fiber solubility

[0196] The solubility of a single fiber is characterized by its water breakage temperature. The fiber breakage temperature can be determined as follows: A load of 2 mg / dtex is applied to a fiber of fixed length 100 mm. The water temperature starts at 1.5°C and then increases by 1.5°C every 2 minutes until the fiber breaks. The temperature at which the fiber breaks is called the water breakage temperature.

[0197] The solubility of a single fiber can also be characterized by the temperature of complete dissolution. The temperature of complete dissolution can be determined as follows: 0.2 g of fiber with a fixed length of 2 mm is added to 100 mL of water. The water temperature starts at 1.5°C and then is increased by 1.5°C every 2 minutes until the fiber is completely dissolved. The sample is stirred at each temperature. The temperature at which the fiber completely dissolves in less than 30 seconds is designated the temperature of complete dissolution. Diameter Test Method

[0198] The diameter of individual fibers or fibers within a nonwoven web is determined by using a scanning electron microscope (SEM) or optical microscope and image analysis software. A magnification of 200 to 10,000 times is selected so that the fibers are adequately magnified for measurement. When using an SEM, the sample is sputtered with gold or palladium compounds to avoid charging and vibration of the fibers in the electron beam. A manual procedure for determining fiber diameter is used from an image (on a monitor screen) taken with an SEM or optical microscope. The mouse and cursor tools are used to locate a randomly selected edge of the fiber and then measure both ends of its width (i.e., perpendicular to the fiber direction at that point) to the other edge of the fiber. Scaling and calibration image analysis tools provide scaling to obtain an actual reading in microns. For fibers within a nonwoven web, a number of fibers are randomly selected throughout a sample of the nonwoven web using an SEM or optical microscope. At least two portions of the nonwoven web have material cut and tested with this technique. In total, at least 100 such measurements are made and then all data is recorded for statistical analysis. The recorded data is used to calculate the fiber average (mean), fiber standard deviation, and median fiber diameter. Tensile Strength, Modulus, and Elongation Testing

[0199] Nonwoven webs, water-soluble films, or laminate structures characterized by or tested for tensile strength by the Tensile Strength (TS) Test, modulus (or tensile stress) by the Modulus (MOD) Test, and elongation by the Elongation Test are analyzed as follows. The description provided below refers to nonwoven webs, but is equally applicable to water-soluble films or laminate structures. The procedure involves the determination of tensile strength and modulus at 10% elongation by ASTM D 882 ("Standard Test Method for Tensile Properties of Thin Plastic Sheet Formings") or equivalent. Nonwoven web data is collected using an INSTRON tensile testing device (Model 5544 Tensile Tester or equivalent). A minimum of three specimens, each cut with a reliable cutting tool to ensure dimensional stability and repeatability, were tested in the machine direction (MD) (if applicable) for each measurement. Tests were performed at standard laboratory atmosphere of 23±2.0°C and 35±5% relative humidity. For the determination of tensile strength or modulus, a 1" wide (2.54 cm) sample of the nonwoven web is prepared. The sample is then transferred to an INSTRON tensile tester for testing with minimal exposure to a 35% relative humidity environment. The tensile tester is equipped with a 500N load cell and is prepared and calibrated according to the manufacturer's instructions. The correct grips and faces are fitted (INSTRON grips with model number 2702-032 faces, rubber coated, 25 mm wide, or equivalent). The sample is placed in the tensile tester and analyzed to determine the 100% modulus (i.e., the stress required to achieve 100% film elongation), tensile strength (i.e., the stress required to break the film), and the % elongation (the length of the sample at break relative to the initial sample length). In general, the higher the % elongation of the sample, the better the processability properties of the nonwoven web (e.g., increased formability into a packet or pouch). Percent Fiber Shrinkage Test (MSTM)

[0200] The percent shrinkage of a fiber when contacted with an appropriate amount of carrier solvent can be determined according to the Percent Fiber Shrinkage Test under the MonoSol Standard Operating Procedure.

[0201] Equipment and materials: 1. Fiber sample (approximately 3 grams) 2.500mL beaker 3. Chilled deionized water (place in refrigerator) 4. Deionized Water 5. Paper Clip 6. Crocodile clamp (solubility stand) 7. Stir plate 8. Timer

[0202] Prepare the sample as follows: 1. Obtain a small bundle of untangled fibers. Hold securely with a paper clip and alligator clamp. The approximate weight of the fiber bundle is 0.013 grams (g) to 0.015 g. 2. Take a paper clip and pull the end of the fiber through the end of the paper clip. 3. Each unique fiber tested should have N=3 replicates for each test temperature, 23°C and 10°C.

[0203] Equipment setup: 1. Fill a 500ml beaker with 400ml of water at each temperature. Be sure to check the water temperature with a temperature probe before and during the test. 2. Tape a ruler to the top of the alligator clamp so that the ruler hangs parallel to the clamp. 3. Place the beaker on a stir plate and place the solubility stand next to the stir plate and immerse the ruler in the beaker so that the length can then be read.

[0204] Test procedure: 1. Attach the free end of the fiber clipped with paper in a crocodile clamp. 2. Submerge the test sample in the beaker so that it is lined up next to the ruler. 3. Start the timer and record the initial length of the fiber. The test sample fiber length is from the end of the alligator clip to the top of the paper clip. After 4.2 minutes, record the final length of the fiber. 5. Remove the clamps from the water and remove the specimens from the clamps, being sure to thoroughly dry the outside of the clamps and the inside of the clamps between each test.

[0205] Shrinkage Percentage Calculation: Contracted length = initial length - final length [3] Fiber shrinkage (%) = (shrinkage length / initial length) × 100% [4] Use of skin cleansing products

[0206] The skin cleansing article of the present disclosure is suitable for various applications. Applications suitable for water-dispersible or water-soluble skin cleansing articles include the delivery of one or more active cleansing formulations to deliver cosmetics and / or skin treatment agents to the skin of a user. In an exemplary embodiment, the water-soluble core substrate has one or more areas or regions configured to contain one or more active cleansing formulations, such as cosmetics or skin treatment formulations. For example, the water-soluble core substrate may have a first region containing a first active cleansing formulation and a second region containing a second active cleansing formulation that is the same as or different from the first active cleansing formulation. When the water-soluble core substrate contacts with water having a temperature higher than 20°C or a temperature between 30°C and 40°C, the water-soluble core substrate becomes soluble and releases at least one of the one or more active cleansing formulations, such as at least one of the first active cleansing formulation or the second active cleansing formulation. Although the water-dispersible or water-soluble skin cleansing article is described herein as a water-dispersible or water-soluble nonwoven substrate in the form of a facial mask, configured to contain one or more active cleansing formulations in one or more areas or regions of the facial mask, for example, to deliver, for example, release, the active cleansing formulation to a desired location on the skin of the face of a user, the water-dispersible or water-soluble skin cleansing article described herein in other exemplary embodiments is suitable for delivering active cleansing formulations or other skin wellness formulations to other locations on the skin of the body of a user, for example.Furthermore, the water-dispersible or water-soluble skin cleansing article may take other forms than that of a facial mask, including, but not limited to, for example, wipes, sheets, pads, sachets or strips.In exemplary embodiments, the active cleansing formulation may include one or more of the following, but are not limited to, hyaluronic acid, aloe, chamomile extract, lactic acid, citric acid, hydrolyzed collagen, polysaccharides, peptides, surfactants or foaming agents, soaps or cleaners, shampoos, conditioners, body washes, face washes, skin lotions, skin treatments, body oils, fragrances, hair treatments, bath salts, essential oils, bath bombs, enzymes, detergents, surfactants, emulsifiers, chelating agents, pH adjusters, builders, structuring agents, free fragrances, encapsulated fragrances, preservatives, solvents, or minerals, and / or any ingredient suitable for inclusion in a skin cleansing formulation, skin wellness formulation, or personal care formulation.

[0207] The active cleansing formulation may take the form of a solid, e.g., a powder, or a plurality of granules or particles, a gel, liquid, or a slurry formulation, or may be any suitable combination of, e.g., a powder, solid, gel, liquid, or slurry formulation. EXAMPLES

[0208] Example 1 A water-soluble facial mask having respective openings for the user's eyes, nose, and mouth includes a water-soluble nonwoven substrate having a basis weight of 30 gsm to 80 gsm, comprising water-soluble fibers produced by a carding and calendaring process, the water-soluble nonwoven substrate including or containing an active cleansing formulation adjusted to a pH of 3.8 to 4.5 as described in Table 1 below. [Table 1]

[0209] The active cleansing composition is prepared in an aqueous solution. The aqueous solution is coated on at least one flat surface of the water-soluble nonwoven substrate by using any suitable coating technique known to those skilled in the art, such as Mayer roll, slot die, mold, curtain, gravure, kiss roller or dip coating technique. Alternatively, the active cleansing composition can be applied in a dry solid or slurry phase and applied to the water-soluble nonwoven substrate by using any suitable application technique known to those skilled in the art for applying solid compositions, such as air-powered spray, blast or tumble technique.

[0210] The nonwoven substrate containing the active cleansing composition to be applied to at least one surface is then cut into the shape of a facial mask using any suitable cutting technique known to those skilled in the art, such as die cutting technique.The facial mask in a dry state, i.e., does not contain water or does not contain substantially water, for example, does not contain a significant amount of water, is then packaged and placed in a reusable package, for example, as shown in Figure 4.In an exemplary embodiment, a plurality of facial masks, for example, 10 facial masks, 25 facial masks, 50 facial masks, are packaged in a reusable package.

[0211] In an exemplary embodiment, the facial mask is initially provided in a dry and stable state (i.e., requiring significantly reduced secondary packaging) and water is added to the facial mask prior to or during use. Providing the facial mask in a dry state may assist or be beneficial with regulatory and / or product testing concerns regarding, for example, the concentration and / or pH of various materials or ingredients of the active cleansing formulation, such as glycolic acid or sodium hyaluronate, which may be regulated as skin irritants.

[0212] Example 1 described herein is a general example. The active cleansing formulation in Table 1 and the nonwoven substrate as one example of the core substrate are described for illustrative purposes only. The core substrate and the active cleansing formulation can have any suitable composition and / or any suitable form as described herein. For example, the core substrate can include a water-dispersible or water-soluble nonwoven, foam or film, or any combination thereof. Such a core substrate can include one or more PVOH polymers, such as vinyl alcohol-vinyl acetate copolymer. For example, in certain embodiments, the core substrate includes at least one nonwoven web, sheet, or layer including a plurality of fibers. The plurality of fibers includes a first type of fiber including a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%, and a second type of fiber including a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 90% to about 99.5%. The first type of fiber and the second type of fiber are in a suitable ratio, for example, in the range of about 25:75 to about 95:5, or about 25:75 to about 75:25 by weight. In certain embodiments, the first type of fiber and the second type of fiber are mixed together in at least one nonwoven sheet or layer. In certain embodiments, the at least one nonwoven sheet or layer includes a first type of nonwoven sheet or layer made of a first type of fiber and a second type of nonwoven sheet or layer made of a second type of fiber, i.e., the two types of fibers are in different nonwoven sheets. Fibers used

[0213] Two types of fibers, fiber 1 ("F1") and fiber 2 ("F2"), containing copolymers of vinyl acetate and vinyl alcohol with hydrolysis degrees of 88% and 96%, respectively, as shown in Table 2, were used as starting materials. These fibers have a uniform composition and additional properties shown in Table 2. In the examples described herein, the fibers used had a fineness of 2.2 dtex. In the examples, polymers containing vinyl alcohol moieties are referred to as "polyvinyl alcohol polymers" and fibers containing such polymers are referred to as "polyvinyl alcohol fibers." The units of fineness dtex and dpf are close to each other and can be converted using the factor (dtex=dpf / 0.9).

[0214] [Table 2]

[0215] Two types of fibers were used to make the nonwoven core substrate under different bonding conditions, as shown in Table 3. The two types of fibers were used to make separate and different nonwoven layers, which were then used to make the multi-layer nonwoven core substrate. The "multi-layer nonwoven core substrate" sample refers to one with different sheets made with different fiber compositions. Two types of fibers were mixed to make one nonwoven layer as the core substrate (referred to as "blended nonwoven core substrate"). The "blended nonwoven core substrate" refers to a core substrate with the same formulation but different fibers in one sheet. Multiple layers or sheets of blended nonwovens can also be used. Before the calendar bonding process, some samples were first pre-punched with needles to increase bonding.

[0216] [Table 3]

[0217] For each substrate in Table 3, two types of samples were tested for solubility at 23° C. and 40° C., respectively, including an untreated nonwoven and a nonwoven treated (loaded) with the active cleansing formulation ("post-activation nonwoven"). Tables 4 and 5 show the solubility results for the untreated samples (substrate only) and the post-activation samples at 23° C. and 40° C., respectively. Table 5 also shows the tensile test results for these water-soluble substrates. Multiple specimens were tested for each substrate. For simplicity, standard deviations of the data are not shown.

[0218] [Table 4]

[0219] [Table 5]

[0220] FIG. 6 shows the solubility results (at 23° C. with water) of a core substrate including at least one nonwoven layer or sheet having a plurality of fibers, including a first type of fiber ("F1") including a polyvinyl alcohol copolymer having a degree of hydrolysis of 88% and a second type of fiber ("F2") including a polyvinyl alcohol copolymer having a degree of hydrolysis of 96%. FIG. 7 shows the solubility results (at 23° C.) of a sample including the core substrate of FIG. 6 treated with an active cleansing formulation. At 23° C., the multi-layer and blended water-soluble nonwoven sheets or layers have similar burst times. The solubility generally decreases with increasing content of fiber F2, which has a higher degree of hydrolysis. The blended nonwoven tends to disintegrate much faster than the multi-layered nonwoven. For example, when the content of fiber F2 is 50%, the multi-layered nonwoven has a homogenous web made of fiber F2, while the blended nonwoven is more heterogeneous and consequently disintegrates faster. Nonwoven substrate samples containing active cleansing formulations with low moisture content show significantly faster disintegration and solubility after such exposure. Blended nonwovens and multi-layer nonwovens show similar disintegration times after exposure. The active cleansing formulations contain polyol carriers that can loosen the structure of the nonwoven substrate.

[0221] Figures 8 and 9 show the solubility results of the same samples shown in Figures 6 and 7, except that the test temperature is 40°C. The blend nonwoven and multi-layer nonwoven show similar burst and disintegration times. As the content of fiber F2, which has a higher degree of hydrolysis, increases, the solubility decreases, but at a slower rate compared to the data at 23°C. At 40°C, exposure to the active cleansing formulation does not significantly affect the disintegration and solubility of the nonwoven samples.

[0222] Based on the results shown in Figures 6-9, the first type of fiber (F1) and the second type of fiber (F2) may be in a ratio of 25:75 or higher by weight in an exemplary embodiment, for example, in a ratio ranging from about 25:75 to about 95:5, about 25:75 to about 85:15, or about 25:75 to about 75:25. For example, if only fiber F1 is used or the content of fiber F1 is too high, the nonwoven substrate may disintegrate too quickly before the resulting skin cleansing article is applied. If the content of fiber F2 is higher, the resulting skin cleansing article can disintegrate or dissolve in a desired time and can be washed off the skin after application.

[0223] FIG. 10 shows FI-IR curves illustrating the transfer of active cleansing formulation from a water-soluble nonwoven core substrate to the surface of a separate object made of polyester. A nonwoven substrate made of PVOH copolymer was cut into a square of approximately 2.5 cm×2.5 cm, and detergent was poured onto the nonwoven substrate as an example of an active cleansing formulation. After 10 minutes of wetting, the excess detergent was wiped off the surface of the substrate. The nonwoven substrate was then used to wipe the polyester surface. Attenuated total reflectance (ATR) FT-IR was used to scan each sample surface. Three FT-IR curves were obtained from the nonwoven sample with active cleansing formulation, the polyester surface, and the polyester surface after exposure to the nonwoven sample with active formulation, and compared to that of the active cleansing formulation. The FT-IR peaks at 3325 cm, corresponding to hydroxyl and carbonyl groups, were observed. -1 and 1600 cm -1The increase in intensity of each of the peaks indicated the transfer of the active cleansing formulation from the water-soluble nonwoven sample to the polyester surface.

[0224] Exemplary embodiments of the present disclosure are described in the following numbered paragraphs. These exemplary embodiments are intended to be illustrative and not limiting in nature.

[0225] The following paragraphs further describe aspects of the present disclosure. 1. A skin cleansing article configured to deliver a cosmetic or skin treatment to the skin of a user, comprising: A core substrate comprising a resin, the core substrate having a first region containing a first active cleansing formulation and a second region containing a second active cleansing formulation. Including, A skin cleansing article configured such that upon contact with water having a temperature greater than 10°C for a period of time by test method MSTM-205, the skin cleansing article becomes at least water-dispersible or water-soluble and the core substrate becomes at least dispersible or soluble to release at least one of a first active cleansing formulation and a second active cleansing formulation. 2. A skin cleansing article according to clause 1, which is substantially dry or solid containing less than 10% by weight moisture or solvent content prior to contact with water. 3. The skin cleansing article of clause 1 or 2, wherein the time period ranges from about 30 seconds to about 300 seconds, from about 30 seconds to about 600 seconds, or from about 30 seconds to about 900 seconds. 4. A skin cleansing article according to any one of clauses 1 to 3, wherein the core substrate has a dispersion or dissolution time of 300 seconds or less by MSTM-205 at a temperature of 30°C to 40°C. 5. A skin cleansing article according to any one of clauses 1 to 4, wherein the core substrate is substantially flat and formable to conform to the contours of the surface of the user's skin. 6. The skin cleansing article of any of clauses 1-5, wherein the core substrate comprises at least one nonwoven substrate comprising a plurality of fibers comprising a resin selected from at least one of a water-dispersible resin or a water-soluble resin. 7. The skin cleansing article of claim 6, wherein the resin is a polymer that includes vinyl alcohol moieties. 8. The skin cleansing article of clause 7, wherein the vinyl alcohol portion comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. 9. The skin cleansing article of clause 8, wherein the polyvinyl alcohol copolymer is a copolymer of vinyl acetate and vinyl alcohol. 10. The skin cleansing article of clause 8 or 9, wherein the polyvinyl alcohol copolymer comprises an anionically modified copolymer. 11. The cleansing article of clause 10, wherein the anionically modified copolymer comprises a carboxylate, a sulfonate, or a combination thereof. 12. The cleansing article of any of clauses 8-11, wherein the plurality of fibers comprises a first type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis in the range of about 75% to about 89%, and a second type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis in the range of about 90% to about 99.5%. 13. The cleansing article of claim 12, wherein the ratio of the first type of fibers to the second type of fibers ranges from about 25:75 to about 75:25 by weight. 14. The cleansing article of clause 12 or 13, wherein the first type of fibers and the second type of fibers are mixed together in at least one nonwoven sheet. 15. The cleansing article of claim 14, wherein the at least one nonwoven sheet includes a first nonwoven layer made of a first type of fibers and a second nonwoven layer made of a second type of fibers. 16. The skin cleansing article of any of clauses 6-15, wherein the plurality of fibers comprises, based on the total weight of the plurality of fibers, 10% to 80% water-soluble fibers, the remainder being water-insoluble fibers. 17. A skin cleansing article described in any of clauses 1-16, wherein the first area is positionable at a first location on the user's face and the second area is positionable at a second location on the user's face. 18. A skin cleansing article according to any of clauses 8 to 17, wherein the first region is separable from the second region. 19. The skin cleansing article of any of clauses 1-18, wherein each of the first active cleansing formulation and the second active cleansing formulation is in at least one of a solid, liquid, gel, or slurry form. 20. The skin cleansing article of any of clauses 1-19, wherein at least one of the first active cleansing formulation or the second active cleansing formulation is in a solid form having a moisture content of less than 10%. 21. The skin cleansing article of any of clauses 1-20, wherein each of the first active cleansing formulation and the second active cleansing formulation comprises one or more of the following: hyaluronic acid, aloe, chamomile extract, lactic acid, citric acid, hydrolyzed collagen, polysaccharides, peptides, surfactants, foaming agents, ceramides, glycolic acid, alpha hydroxy acids, amino acids, activated charcoal, sunscreens, minerals (Zn), avobenzone, antioxidants, enhancers, caffeine, ginseng, taurine, retinol, retinoic acid, niacinamide, salicylic acid, lactic acid, or azelaic acid, or any combination thereof. 22. A skin cleansing article according to any of clauses 1-21, wherein each of the first active cleansing formulation and the second active cleansing formulation is at least one of disposed on a surface of the core substrate or embedded within the matrix of the core substrate. 23. A skin cleansing article according to any of clauses 1-22, wherein the core substrate is at least one of saturated with, coated with, or impregnated with the active cleansing formulation. 24. A skin cleansing article according to any of clauses 1-23, wherein the core substrate transforms into a hydrogel upon contact with water at a temperature of 10°C or higher for 300 seconds or less. 25. A facial mask configured to deliver a cosmetic or skin therapeutic agent to the skin of a user, comprising: a nonwoven substrate comprising a plurality of fibers comprising a water soluble resin, the fibers being water soluble and having a first region and a second region; a first active cleansing formulation contained in a first region; and A second active cleansing formulation contained in the second region. Including, wherein the nonwoven substrate is soluble upon contact with water having a temperature greater than 10° C. for 300 seconds or less per test method MSTM-205 and releases at least one of a first active cleansing formulation and a second active cleansing formulation from the water soluble nonwoven substrate. 26. The facial mask of clause 25, wherein the nonwoven substrate has a dissolution time of 300 seconds or less according to MSTM-205 at a temperature of 30° C. to 40° C. 27. The facial mask of clause 25 or 26, wherein the nonwoven substrate has a moisture content of less than 10%. 28. The facial mask of any one of clauses 25-27, wherein the nonwoven substrate is substantially flat and formable to conform to the contours of the surface of the user's skin. 29. A facial mask according to any of clauses 25 to 28, wherein the first region is positionable at a first location on the user's face and the second region is positionable at a second location on the user's face, the first region being separated from the second region. 30. A mask according to any of clauses 25-29, wherein each of the first active cleansing formulation and the second active cleansing formulation is in at least one of a solid, liquid, gel or slurry form. 31. The facial mask of any of clauses 25-30, wherein each of the first active cleansing formulation and the second active cleansing formulation comprises one or more of the following: hyaluronic acid, aloe, chamomile extract, lactic acid, citric acid, hydrolyzed collagen, polysaccharides, peptides, surfactants, foaming agents, ceramides, glycolic acid, alpha hydroxy acids, amino acids, activated charcoal, sunscreens, minerals (Zn), avobenzone, antioxidants, enhancers, caffeine, ginseng, taurine, retinol, retinoic acid, niacinamide, salicylic acid, lactic acid or azelaic acid, or any combination thereof. 32. The facial mask of any of clauses 25-31, wherein the plurality of fibers are saturated with one of the first active cleansing formulation or the second active cleansing formulation. 33. The facial mask of any of clauses 25-32, wherein each of the first active cleansing formulation and the second active cleansing formulation is one of disposed on a surface of the plurality of fibers or embedded in the plurality of fibers. 34. The facial mask of any of clauses 25-33, wherein the plurality of fibers comprises a fiber type comprising one or more of the following: polyvinyl alcohol homopolymer, polyvinyl alcohol copolymer, or a combination thereof. 35. The facial mask of clause 34, wherein the polyvinyl alcohol copolymer has a degree of hydrolysis ranging from about 75% to about 89%. 36. The facial mask of clause 34, wherein the polyvinyl alcohol copolymer has a degree of hydrolysis ranging from about 90% to about 99.9%. 37. The facial mask of any one of clauses 34-36, wherein the polyvinyl alcohol copolymer comprises an anionically modified copolymer comprising a carboxylate, a sulfonate, or a combination thereof. 38. The facial mask of any of clauses 25-37, wherein the plurality of fibers comprises a first type of fiber and a second type of fiber, and the first type of fiber and the second type of fiber have differences in one or more of the following characteristics: length to diameter ratio (L / D), toughness, shape, stiffness, elasticity, solubility in water, melting point, glass transition temperature (Tg), chemical composition of the fiber, or color, or any combination thereof. 39. The facial mask of clause 38, wherein each of the first type of fibers and the second type of fibers comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. 40. The facial mask of clause 38 or 39, wherein the first type of fibers comprises a polyvinyl alcohol copolymer having a degree of hydrolysis in the range of 75% to 89%, and the second type of fibers comprises a polyvinyl alcohol copolymer having a degree of hydrolysis in the range of 90% to 99.5%. 41. The facial mask of clause 40, wherein the ratio of the first type of fibers to the second type of fibers ranges from about 25:75 to about 75:25 by weight. 42. The facial mask of clause 40 or 41, wherein the first type of fibers and the second type of fibers are mixed together in the same nonwoven sheet or separated into different nonwoven sheets. 43. The facial mask of any of clauses 38-42, wherein one of the first type of fibers or the second type of fibers comprises a water-insoluble polymeric fiber molding material. 44. The facial mask of clause 43, wherein the water insoluble polymeric fiber forming material comprises one or more of the following materials: cotton, hemp, jute, flax, ramie, sisal, bagasse, banana, lace bark, silk, tendon, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo, modal, cellulose diacetate, cellulose triacetate, or combinations thereof. 45. The facial mask of any one of clauses 25 to 44, wherein the water-soluble nonwoven substrate has a linear mass density in the range of 1 dtex to 5 dtex. 46. ​​The facial mask of any one of clauses 25 to 45, wherein the water-soluble nonwoven substrate is biodegradable. 47. A method for manufacturing a fiber optic cable comprising the steps of: (a) providing a fiber optic cable having a tenacity in the range of 3 cN / dtex to 15 cN / dtex; having an average diameter in the range of 10 microns to 300 microns; having a substantially uniform average diameter; and / or at least one fiber type having an average length in the range of 10 millimeters (mm) to 100 mm. 48. The facial mask of any one of clauses 25-47, wherein the nonwoven substrate has a porosity of 30% to 90%. 49. The facial mask of clause 27, wherein the water-soluble resin comprises a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from 75% to 99.9%. 50. The facial mask of any one of clauses 25-49, wherein the nonwoven substrate exhibits a shrinkage percentage of 0.5% to 65% upon contact with water having a temperature greater than 10°C. 51. A method of making a skin cleansing article, comprising: forming a water soluble nonwoven substrate having a core substrate comprising a water soluble resin, a first region and a second region; and Containing a first active cleansing formulation in the first region and a second active cleansing formulation in the second region. The method includes: 52. The method of claim 51, wherein containing the first active cleansing formulation in the first region comprises at least one of saturating the first region of the core substrate with the first active cleansing formulation, disposing the first active cleansing formulation on a surface of the first region of the core substrate, coating the surface of the first region of the core substrate with the first active cleansing formulation, embedding the first active cleansing formulation in the first region of the core substrate, or impregnating the first region of the core substrate with the first active cleansing formulation. 53. The method of clause 51 or 52, wherein forming a core substrate containing resin comprises recycling the core substrate to produce the resin. 54. The method of any of clauses 51-53, wherein the resin and core substrate are water-soluble and the skin cleansing article is a water-soluble facial mask. 55. A skin cleansing article configured to deliver a cosmetic or skin therapeutic agent to the skin of a user, comprising: a core substrate having a first region containing a resin, a first active cleansing formulation, the skin cleansing article being configured to be substantially dry or solid and at least water dispersible or water soluble; A skin cleansing article configured such that upon contact with water having a temperature greater than 10°C for a period of time, the core substrate becomes at least dispersible or soluble to release a first active cleansing formulation from the water-dispersible core substrate, according to test method MSTM-205. 56. A skin cleansing article according to clause 55, wherein the temperature is greater than 40°C and the duration is between 30 and 300 seconds. 57. A skin cleansing article configured to deliver a cosmetic or skin therapeutic agent to the skin of a user, comprising: A first nonwoven substrate having a first region including a plurality of fibers including a water soluble or water dispersible resin; a first active cleansing formulation contained in the first region; a second nonwoven substrate connected to the first nonwoven substrate, the second nonwoven substrate having a second region and including a plurality of fibers including one of a water-dispersible resin or a water-soluble resin; and A second active cleansing formulation contained in the second region. Including, A skin cleansing article, wherein when the first nonwoven substrate is contacted with water having a temperature greater than 10° C. for 300 seconds or less, the first nonwoven substrate becomes soluble or dispersible by MSTM-205 to release a first active cleansing formulation from the first nonwoven substrate. 58. The skin cleansing article of clause 57, wherein the first nonwoven substrate is water soluble and the second nonwoven substrate comprises a plurality of fibers comprising a water dispersible resin, and when the second nonwoven substrate is contacted with water having a temperature greater than 10° C. for 300 seconds or less, the second nonwoven substrate becomes dispersible with MSTM-205 to release the second active cleansing formulation from the second nonwoven substrate. 59. The skin cleansing article of clause 57 or 58, wherein the first nonwoven is water soluble and the second nonwoven substrate comprises a plurality of fibers comprising a water soluble resin, and when the second nonwoven substrate is contacted with water having a temperature greater than 10° C. for 300 seconds or less, the second nonwoven substrate becomes soluble with MSTM-205 to release the second active cleansing formulation from the second nonwoven substrate. 60. The skin cleansing article of any one of clauses 57-59, further comprising a water-soluble or water-dispersible film coupled to one of the first nonwoven substrate and the second nonwoven substrate.

[0226] All percentages, parts and ratios referred to herein are based on the total dry weight of the fiber composition, film composition, or, as the case may be, the total weight of the packaging material composition of the present disclosure, and all measurements made are at about 25° C. unless otherwise indicated. All percentages, parts and ratios referred to herein with respect to liquid formulations are based on the total weight of the liquid formulation. All such weights with respect to listed ingredients are based on the active level and therefore do not include carriers or by-products that may be included in commercially available materials, unless otherwise specified.

[0227] All ranges described herein include all possible subsets of ranges and any combination of such subset ranges. By default, ranges include the stated endpoints unless otherwise stated. When a range of values ​​is provided, it is understood that each intervening value between the upper and lower limits of the range, as well as any other intervening values ​​stated or within the stated range, are included in the disclosure. The upper and lower limits of these smaller ranges may be independently included in the smaller ranges, and are also included in the disclosure, subject to any specifically excluded limits in the stated range. If the stated range includes one or both of these limits, it is contemplated that ranges excluding either or both of those included limits are also part of the disclosure.

[0228] For any numerical values ​​described herein, for example as parameters of the described object or as part of a range related to the described object, alternative examples forming part of this description are expressly contemplated as functionally equivalent ranges surrounding the particular numerical value (e.g., for a dimension disclosed as "40 millimeters (mm)," an alternative embodiment contemplated is "about 40 mm").

[0229] References to "exemplary embodiment" or "embodiment" throughout this specification may mean that a particular structure, structure or feature described in connection with a particular embodiment may be included in at least one embodiment of the claimed subject matter. Thus, the appearance of the phrase "exemplary embodiment" or "exemplary embodiment" in various places throughout this specification does not necessarily refer to the same embodiment or any one particular embodiment described. Furthermore, it should be understood that the particular structure, structure or feature described may be combined in various ways in one or more embodiments. In general, of course, these and other issues may vary with the particular context of use. Thus, the particular context of the description or use of these terms may provide useful guidance regarding the inference cited as that context.

[0230] Although the subject matter has been described in language specific to structural features and / or methodological acts, it should be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the claims.

[0231] Those skilled in the art will appreciate that a virtually unlimited number of variations are possible to the above description, and that the examples and accompanying figures are only intended to illustrate one or more examples of implementations.

[0232] Those skilled in the art will recognize that various other modifications may be made and equivalents substituted without departing from the claimed subject matter. Additionally, many modifications may be made to adapt a particular situation to the teachings of the claimed subject matter without departing from the central concepts described herein. Therefore, it is not intended that the claimed subject matter be limited to the particular embodiments disclosed, but that such claimed subject matter also includes all embodiments that fall within the scope of the appended claims and their equivalents.

[0233] In the above detailed description, numerous specific details are set forth to provide a thorough understanding of the claimed subject matter. However, it will be understood by those skilled in the art that the claimed subject matter may be practiced without these specific details. In other instances, methods, apparatus or systems that are known to those skilled in the art have not been described in detail so as not to obscure the claimed subject matter.

Claims

1. 1. A skin cleansing article configured to deliver a cosmetic or skin therapeutic agent to the skin of a user, comprising: A core substrate comprising a resin, the core substrate having a first region containing a first active cleansing formulation and a second region containing a second active cleansing formulation, the second active cleansing formulation being different from the first active cleansing formulation. Including, 1. A skin cleansing article, wherein the skin cleansing article is at least water-dispersible or water-soluble, and the core substrate is at least dispersible or soluble to release at least one of the first active cleansing formulation and the second active cleansing formulation, upon contact with water having a temperature greater than 10° C. for a period of time by test method MSTM-205, and wherein the vinyl alcohol portion comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

2. is substantially dry or solid containing less than 10% by weight moisture or solvent content prior to contact with water; or the period of time is in the range of about 30 seconds to about 300 seconds, or about 30 seconds to about 600 seconds, or about 30 seconds to about 900 seconds; or At a temperature of 30° C. to 40° C., said core substrate has a dispersion or dissolution time according to MSTM-205 of 300 seconds or less; or the core substrate is substantially flat and formable to the contours of the surface of the user's skin; or 10. The skin cleansing article of claim 1, wherein said core substrate comprises at least one nonwoven substrate comprising a plurality of fibers comprising said resin selected from at least one of a water-dispersible resin or a water-soluble resin.

3. the polyvinyl alcohol copolymer is a copolymer of vinyl acetate and vinyl alcohol, or the polyvinyl alcohol copolymer comprises an anionically modified copolymer, or the polyvinyl alcohol copolymer comprises an anionically modified copolymer, the anionically modified copolymer comprises a carboxylate, a sulfonate, or a combination thereof; or the polyvinyl alcohol copolymer comprises a plurality of fibers, the plurality of fibers comprising a first type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis in the range of about 75% to about 89% and a second type of fiber comprising a polyvinyl alcohol copolymer having a degree of hydrolysis in the range of about 90% to about 99.5%; or 2. The skin cleansing article of claim 1, wherein the polyvinyl alcohol copolymer comprises a plurality of fibers, the plurality of fibers comprising a first type of fibers comprising the polyvinyl alcohol copolymer and a second type of fibers comprising the polyvinyl alcohol copolymer, and the first type of fibers and the second type of fibers are present in a ratio of the first type of fibers to the second type of fibers in a range of about 25:75 to about 75:25 by weight.

4. the first type of fibers and the second type of fibers are mixed together into at least one nonwoven sheet; The cleansing article of claim 3 , wherein the at least one nonwoven sheet comprises a first nonwoven layer made of the first type of fibers and a second nonwoven layer made of the second type of fibers.

5. the plurality of fibers comprises, based on the total weight of the plurality of fibers, 10% to 80% water soluble fibers, the remainder being water insoluble fibers; or the first region is positionable at a first location on the user's face and the second region is positionable at a second location on the user's face; or the first region can be separate from the second region; or 3. The skin cleansing article of claim 2, wherein each of the first and second active cleansing formulations is in the form of a solid, liquid, gel, or slurry.

6. 10. The skin cleansing article of claim 1, wherein each of the first and second active cleansing formulations comprises one or more of the following: hyaluronic acid, aloe, chamomile extract, lactic acid, citric acid, hydrolyzed collagen, polysaccharides, peptides, surfactants, foaming agents, ceramides, glycolic acid, alpha hydroxy acids, amino acids, activated charcoal, sunscreens, minerals (Zn), avobenzone, antioxidants, enhancers, caffeine, ginseng, taurine, retinol, retinoic acid, niacinamide, salicylic acid, lactic acid, or azelaic acid, or any combination thereof.

7. each of the first active cleansing formulation and the second active cleansing formulation is at least one of disposed on a surface of the core substrate and embedded within a matrix of the core substrate; or 10. The skin cleansing article of claim 1, wherein the core substrate is at least one of saturated with, coated with, or impregnated with an active cleansing formulation.

8. 1. A facial mask configured to deliver a cosmetic or skin therapeutic agent to the skin of a user, the facial mask comprising: a nonwoven substrate comprising a plurality of fibers comprising a water soluble resin, the fibers being water soluble and having a first region and a second region; a first active cleansing formulation contained in said first region; and a second active cleansing formulation contained in said second region Including, wherein said nonwoven substrate becomes soluble upon contact with water having a temperature greater than 10° C. for 300 seconds or less by test method MSTM-205 and releases at least one of said first active cleansing formulation and said second active cleansing formulation from said water-soluble nonwoven substrate; At a temperature of 30° C. to 40° C., the nonwoven substrate has a dissolution time of 300 seconds or less according to MSTM-205; or the nonwoven substrate has a moisture content of less than 10%, or the nonwoven substrate is substantially flat and formable to the contours of the surface of the user's skin; or A facial mask, wherein the first region is positionable at a first location on the user's face and the second region is positionable at a second location on the user's face, the first region being separated from the second region.

9. each of the first active cleansing formulation and the second active cleansing formulation is in the form of a solid, liquid, gel or slurry; or each of the first active cleansing formulation and the second active cleansing formulation comprises one or more of the following: hyaluronic acid, aloe, chamomile extract, lactic acid, citric acid, hydrolyzed collagen, polysaccharides, peptides, surfactants, foaming agents, ceramides, glycolic acid, alpha hydroxy acids, amino acids, activated charcoal, sunscreens, minerals (Zn), avobenzone, antioxidants, enhancers, caffeine, ginseng, taurine, retinol, retinoic acid, niacinamide, salicylic acid, lactic acid, or azelaic acid, or any combination thereof; or the plurality of fibers are saturated with one of the first active cleansing formulation or the second active cleansing formulation; or 10. The facial mask of claim 8, wherein each of the first active cleansing formulation and the second active cleansing formulation is one of disposed on a surface of the plurality of fibers or embedded in the plurality of fibers.

10. the plurality of fibers comprises a fiber type comprising one or more of the following: polyvinyl alcohol homopolymer, polyvinyl alcohol copolymer, or a combination thereof; or the polyvinyl alcohol copolymer has a degree of hydrolysis ranging from about 75% to about 89%, or the polyvinyl alcohol copolymer has a degree of hydrolysis ranging from about 90% to about 99.9%, or 9. The facial mask of claim 8, wherein the polyvinyl alcohol copolymer comprises an anionically modified copolymer comprising a carboxylate, a sulfonate, or a combination thereof.

11. the plurality of fibers comprises a first type of fiber and a second type of fiber, the first type of fiber and the second type of fiber having differences in one or more of the following characteristics: length to diameter ratio (L / D), tenacity, shape, stiffness, elasticity, solubility in water, melting point, glass transition temperature (Tg), fiber chemical composition, or color, or any combination thereof; each of the first type of fibers and the second type of fibers comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof; or the first type of fibers comprises a polyvinyl alcohol copolymer having a degree of hydrolysis in the range of 75% to 89% and the second type of fibers comprises a polyvinyl alcohol copolymer having a degree of hydrolysis in the range of 90% to 99.5%, or the ratio of the first type of fibers to the second type of fibers ranges from about 25:75 to about 75:25 by weight; or 10. The facial mask of claim 8, wherein the first type of fibers and the second type of fibers are mixed together in the same nonwoven sheet or separated into different nonwoven sheets.

12. one of the first type of fibers or the second type of fibers comprises a water insoluble polymeric fiber molding material; 12. The facial mask of claim 11, wherein the water insoluble polymeric fiber forming material comprises one or more of the following materials: cotton, hemp, jute, flax, ramie, sisal, bagasse, banana, lace bark, silk, tendon, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo, modal, cellulose diacetate, cellulose triacetate, or combinations thereof.

13. the water-soluble nonwoven substrate has a linear mass density in the range of 1 dtex to 5 dtex; or the water-soluble nonwoven substrate is biodegradable; or the plurality of fibers comprises at least one fiber type having a tenacity in the range of 3 cN / dtex to 15 cN / dtex, an average diameter in the range of 10 microns to 300 microns, a substantially uniform average diameter, and / or an average length in the range of 10 millimeters (mm) to 100 mm; or the nonwoven substrate has a porosity of 30% to 90%, or the water-soluble resin comprises a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from 75% to 99.9%, or 10. The facial mask of claim 8, wherein the nonwoven substrate exhibits a shrinkage percentage of 0.5% to 65% upon contact with water having a temperature greater than 10°C.

14. 1. A method of making a skin cleansing article, the method comprising: forming a water soluble nonwoven substrate having a core substrate comprising a water soluble resin, a first region and a second region; and containing a first active cleansing formulation in said first region and a second active cleansing formulation in said second region. Contains, or The method, wherein containing a first active cleansing formulation in the first region comprises at least one of saturating the first region of the core substrate with the first active cleansing formulation, disposing the first active cleansing formulation on a surface of the first region of the core substrate, coating the surface of the first region of the core substrate with the first active cleansing formulation, embedding the first active cleansing formulation in the first region of the core substrate, or impregnating the first region of the core substrate with the first active cleansing formulation.

15. 1. A skin cleansing article configured to deliver a cosmetic or skin therapeutic agent to the skin of a user, comprising: a core substrate having a first region containing a resin and a first active cleansing formulation, the skin cleansing article being substantially dry or solid and configured to be at least water dispersible or water soluble; A skin cleansing article configured such that upon contact with water having a temperature greater than 10° C. by test method MSTM-205 for a period of time, said core substrate becomes at least dispersible or soluble to release said first active cleansing formulation from said water-dispersible core substrate.

16. 1. A skin cleansing article configured to deliver a cosmetic or skin therapeutic agent to the skin of a user, comprising: A first nonwoven substrate having a first region comprising a plurality of fibers comprising a water soluble or water dispersible resin; a first active cleansing formulation contained in said first region; a second nonwoven substrate connected to the first nonwoven substrate, the second nonwoven substrate having a second region and including a plurality of fibers including one of a water-dispersible resin or a water-soluble resin; and a second active cleansing formulation contained in said second region Including, A skin cleansing article, wherein when said first nonwoven substrate is contacted with water having a temperature greater than 10° C. for 300 seconds or less, said first nonwoven substrate becomes soluble or dispersible by MSTM-205 to release said first active cleansing formulation from said first nonwoven substrate.

17. 17. The skin cleansing article of claim 16, wherein the first nonwoven substrate is water soluble and the second nonwoven substrate comprises a plurality of fibers comprising a water dispersible resin, and when the second nonwoven substrate is contacted with water having a temperature greater than 10° C. for 300 seconds or less, the second nonwoven substrate becomes dispersible by MSTM-205 to release the second active cleansing formulation from the second nonwoven substrate.

18. 17. The skin cleansing article of claim 16, wherein the first nonwoven is water soluble and the second nonwoven substrate comprises a plurality of fibers comprising a water soluble resin, and when the second nonwoven substrate is contacted with water having a temperature greater than 10° C. for 300 seconds or less, the second nonwoven substrate becomes soluble with MSTM-205 to release the second active cleansing formulation from the second nonwoven substrate.

19. 17. The skin cleansing article of claim 16, further comprising a water-soluble or water-dispersible film coupled to one of the first nonwoven substrate and the second nonwoven substrate.

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