Water-soluble unit dose article comprising a water-soluble core construct

Abstract

The single unit dose article comprises a water-soluble core substrate comprising a water-soluble resin. The water-soluble core substrate comprises a carrier solvent comprising an active cleaning formulation, and the water-soluble core substrate exhibits shrinkage or swelling when the water-soluble core substrate and the carrier solvent are in contact with each other. Also disclosed is a method for making the single unit dose article. The single unit dose article is a unit dose article having a structure that is comfortable to handle and dissolves quickly without leaving undesirable residue when intended to be used, for example, when the unit dose article is placed in a washing machine.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 185,592, filed May 7, 2021, the entirety of which is expressly incorporated by reference herein.

[0002] Field The present disclosure relates generally to water-soluble unit dose articles comprising a water-soluble core construct. More particularly, the present disclosure relates to water-soluble unit dose articles configured to contain a cleaning formulation. [Background technology]

[0003] background Water-soluble packaging materials are commonly used to simplify the dispersion, injection, dissolution and administration of the delivered material. Traditional packaging materials include water-soluble films, and pouches made from water-soluble films are commonly used to package formulations such as laundry detergents, dish detergents, or personal care formulations. Consumers can add the formulation in the pouch directly to water. It would be advantageous to provide accurate dosing while eliminating the need for consumers to measure the formulation. However, some current market pouches made from water-soluble polymer films have, for example, an unpleasant rubbery or plastic feel when handled by consumers. In addition, bulk or concentrated detergents are not always stable and may contain relatively incompatible ingredients that become unstable when in contact with other ingredients. For example, enzymes can become unstable in various solvents and affect the properties of the film, such as the mechanical properties of the film, which may deteriorate over time. As a result, traditional pouches, such as detergent pouches, contain a limited number of cavities or compartments. In addition, traditional water-soluble film-based unit dose constructions are complex and expensive, requiring separate creation of films, detergents, and pods. Summary of the Invention [Problem to be solved by the invention]

[0004] Thus, there is a need in the art for unit dose articles that have a construction that is easily manufacturable, provides chemical stability during shipping and storage, yet is comfortable to handle, and dissolves quickly upon intended use without leaving behind undesirable residue, for example, when the unit dose article is placed in a washing machine. [Brief description of the drawings]

[0005] [Figure 1] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Diagram 2] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Diagram 3] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Figure 4] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Diagram 5] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Figure 6] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Figure 7] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Figure 8] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Figure 9] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Figure 10]1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Figure 11] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Figure 12] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Figure 13] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments. [Figure 14] 1-14 are cross-sectional schematic diagrams of exemplary single unit dose (SUD) articles containing active cleaning formulations, according to example embodiments.

[0006] [Figure 15] FIG. 15 illustrates an example method of making a SUD article, according to an example embodiment.

[0007] [Figure 16] FIG. 16 shows shrinkage results (in a detergent formulation with 20% water at 45° C.) of 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%.

[0008] [Figure 17] FIG. 17 shows shrinkage results (in a detergent formulation with 35% water at 20° C., 35° C., and 45° C.) of 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%.

[0009] [Figure 18] FIG. 18 shows the shrinkage results of example samples as shown in FIG. 17 (in a detergent formulation containing 50% water at 20° C., 35° C., and 45° C.).

[0010] [Figure 19] FIG. 19 shows the shrinkage results of example samples as shown in FIG. 17 (in a detergent formulation containing 65% water at 20° C., 35° C., and 45° C.).

[0011] [Figure 20] FIG. 20 shows shrinkage results (in a detergent formulation with 35% water at 20° C.) of an exemplary sample including at least one nonwoven layer having multiple fibers (fiber F1) with different basis weights.

[0012] [Figure 21] FIG. 21 shows shrinkage results (in a detergent formulation with 35% water at 20° C.) of an example sample including at least one nonwoven layer having a plurality of fibers (fiber F1) having a basis weight of 50 gsm with different bonding styles (including a point bonding style and a daisy bonding style that includes a higher density of bond points than the point bonding style).

[0013] [Figure 22] FIG. 22 shows disintegration time results (at 20° C., 35° C., 45° C.) of an exemplary sample including a core substrate including at least one nonwoven layer or sheet (50 gsm, point bond) 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%.

[0014] [Diagram 23] FIG. 23 shows the burst time results (at 20° C., 35° C., and 45° C.) of exemplary samples as shown in FIG.

[0015] [Figure 24]FIG. 24 shows disintegration time results (at 20° C., 35° C., 45° C.) of example samples including a core substrate including at least one nonwoven layer or sheet (daisy bond, having different basis weights) having a plurality of fibers (including a first type of fiber ("F1") comprising a polyvinyl alcohol copolymer having a degree of hydrolysis of 88%).

[0016] [Diagram 25] FIG. 25 shows the burst time results (at 20° C., 35° C., and 45° C.) of exemplary samples as shown in FIG.

[0017] [Figure 26] FIG. 26 shows burst time results (in water at 20° C., 35° C., and 45° C.) for an exemplary sample including at least one nonwoven layer having a plurality of fibers (fiber F1) having a basis weight of 50 gsm (including one of two different bond styles including a point bond style and a daisy bond style that includes a higher density of bond points than the point bond style).

[0018] [Figure 27] FIG. 27 shows the disintegration time results (in water at 20° C., 35° C., and 45° C.) of exemplary samples as shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Detailed Description In the exemplary embodiments described herein, the single unit dose (SUD) article includes one or more core substrates, e.g., one or more open or closed cell core substrates with precision dosing to deliver cleaning agents for washing clothes, or one or more nonwoven web core substrates. In the exemplary embodiments, the substrate includes water-soluble polymers, e.g., polyvinyl alcohol (PVOH)-based polymers and / or starch derivatives, or blends thereof with water-dispersible polymers that otherwise have a high degree of biodegradation activity or can be composted or recycled. In the exemplary embodiments, the core substrate is contained within a water-soluble material, such as a water-soluble nonwoven material, a water-soluble foam material, and / or a water-soluble film material. As a result, the consumer simply inserts the SUD article containing the activated substrate, which is pre-dosed with one or more active cleaning formulations for chemical and mechanical cleaning action that disperses, dissolves, and / or biodegrades without leaving undesirable residues during the wash cycle.

[0020] In the SUD article, particularly in the exemplary embodiment, the water-soluble core substrate is configured to contain a carrier solvent containing one or more active cleaning formulations, such as a laundry detergent formulation. In the exemplary embodiment, the carrier solvent containing the active cleaning formulation is disposed on or coated on one or more surfaces of the water-soluble core substrate, or embedded and / or adhered to the water-soluble core substrate. For example, the water-soluble core substrate may include a single layer, e.g., a single layer of nonwoven or foam core substrate, or may include multiple layers, e.g., a sheet of nonwoven or foam core substrate folded in a serpentine arrangement, or overlapped, e.g., to form a layer containing a carrier solvent containing the active cleaning formulation disposed between adjacent layers of the water-soluble nonwoven core substrate. By way of example, the active cleaning formulation may include, but is not limited to, a laundry detergent, a soap, a fabric softener, a bleaching agent, a laundry enhancer, a stain remover, an optical brightener, or a water softener. Other examples include dish detergent, soap or cleaner, shampoo, conditioner, body wash, face wash, skin lotion, skin treatment, body oil, fragrance, hair treatment, bath salts, essential oil, bath bomb, or enzymes. In certain exemplary embodiments, the water-soluble core substrate is encapsulated by a water-soluble nonwoven material, a water-soluble foam material, and / or a water-soluble film material. Additionally, the carrier solvent may include, but is not limited to, any suitable polar solvent, water, glycerin, polyols such as DPG, or any combination thereof. In exemplary embodiments, the water-soluble core substrate includes a plurality of fibers including a water-soluble resin. Upon contact of an appropriate amount, e.g., a saturating amount, of the carrier solvent with at least one fiber of the plurality of fibers, the at least one fiber exhibits a shrinkage of 0.5% to 65%. The exemplary process disclosed herein of incorporating an active cleaning formulation into the water-soluble core substrate facilitates preservation of active agents such as enzymes and improves the overall performance of the SUD article.

[0021] 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 an exemplary embodiment 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 with MSTM-205. For example, the disintegration time may be 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. For example, such dispersion parameters may be characterized for a nonwoven substrate, foam substrate, film or laminate structure having a thickness of 6 mils (about 152 μm).In an exemplary embodiment, the water-dispersible core substrate has a dispersion time of 300 seconds or less.

[0022] As used herein and unless otherwise indicated, the term "water soluble" refers to any nonwoven web, foam, film, or laminate that has a dissolution time of 300 seconds or less at a specified temperature as determined by MSTM-205 as described herein. For example, the dissolution time of the nonwoven web, foam, film, or laminate can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less at a temperature of about 80°C, about 70°C, about 60°C, about 50°C, about 40°C, about 20°C, or about 10°C as appropriate according to MSTM-205. In embodiments where no dissolution temperature is specified, the water soluble nonwoven web, foam, film, or laminate has a dissolution time of 300 seconds or less at a temperature of about 80°C or less. In an exemplary embodiment, "water soluble film" means that at a thickness of 1.5 mils, the film dissolves in 300 seconds or less at a temperature of 80°C or less according to MSTM-205. For example, a water-soluble film 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 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.

[0023] As used herein and unless otherwise indicated, the term "cold water soluble" refers to any water soluble nonwoven web, foam, 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 the nonwoven web, foam, film, or laminate can 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 embodiment, a "cold water soluble film" means that at a thickness of 1.5 mils (about 38 μm), the film dissolves in 300 seconds or less at a temperature of 20° C. or less according to MSTM-205. For example, a water-soluble film 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 or less at a temperature of about 20° C., or about 10° C. with MSTM-205.

[0024] As used herein and unless otherwise indicated, the term "hot water soluble" refers to any water soluble nonwoven web, foam, 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 the nonwoven web, foam, film, or laminate can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds, as appropriate, at temperatures in the range of greater than about 20° C., e.g., 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. In an exemplary embodiment, a “hot water soluble film” means that at a thickness of 1.5 mils (about 38 μm), the film dissolves in 300 seconds or less at a temperature of about 21° C. or greater according to MSTM-205. For example, a water-soluble film having a thickness of 1.5 mils (about 38 μm) 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 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 a “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., when contacted with water having a suitable dissolution time, e.g., 300 seconds or less, having a temperature equal to its hot water solubility temperature.

[0025] 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.

[0026] As used herein, a "plurality of fibers" can be of a single fiber type or can include two or more different fiber types. In exemplary embodiments in which the plurality of fibers includes two or more different fiber types, each fiber type can generally be included in any amount, for example, from about 0.5% to about 99.5% by weight of the total weight of the plurality of fibers. In embodiments in which the plurality of fibers includes a single fiber type, the plurality of fibers is substantially free of the second or more fiber types. The plurality of fibers is substantially free of the second or more fiber types when the plurality of fibers includes less than about 0.5% by weight of the second or more fiber types. In general, the differences between fiber types can be differences in fiber length to diameter ratio (L / D), toughness, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (Tg), chemical composition, color, or combinations thereof.

[0027] The terms "packet" and "pouch" used herein should be considered interchangeable. In certain embodiments, the terms "packet" and "pouch" are each used to refer to a single unit dose article that contains a water-soluble core substrate that contains one or more active cleaning formulations. In certain embodiments, the pouch is sealed with an outer water-soluble material to enclose and contain the water-soluble core substrate that contains one or more active cleaning formulations. The sealed pouch can be made using any suitable method, including such processes and features, such as heat sealing, solvent welding or sealing, and / or adhesive sealing (e.g., by using a water-soluble adhesive).

[0028] 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.

[0029] 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.

[0030] As used herein, and unless otherwise indicated, the term "PHR" ("phr") shall refer to the composition of a specified element per 100 parts water-soluble polymeric resin (whether PVOH or other polymeric resin, unless otherwise specified) in the water-soluble film or in the solution used to make the water-soluble film.

[0031] 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.

[0032] When values ​​are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. As used herein, "about X," where X is a numerical value, refers in exemplary embodiments to ±10% (e.g., ±5%) of the stated value, inclusive.

[0033] The SUD articles, water soluble nonwoven materials, water soluble foam materials and water soluble film materials, and related methods of making and using the SUD articles, water soluble nonwoven materials, water soluble foam materials and water soluble film materials, unless otherwise noted, are intended to include embodiments that include any combination of one or more of the additional optional elements, features and steps further described below.

[0034] In an exemplary embodiment, the single unit dose article comprises a water-soluble core substrate comprising a water-soluble resin. In an exemplary embodiment, the water-soluble core substrate comprises one or more of a water-soluble nonwoven core substrate, a water-soluble foam core substrate, or a water-soluble film core substrate, or any suitable combination of a water-soluble nonwoven core substrate, a water-soluble foam core substrate, and / or a water-soluble film core substrate. The water-soluble core substrate comprises a carrier solvent comprising an active cleaning formulation. Upon contact with an appropriate amount, e.g., a saturating amount, of the carrier solvent, the water-soluble core substrate exhibits a shrinkage rate of 0.5% to 65%. In an exemplary embodiment, when the water-soluble core substrate comprises a water-soluble nonwoven substrate comprising a plurality of fibers, at least one of the fibers or the core substrate exhibits a shrinkage rate of 0.5% to 65% upon contact with an appropriate amount of the carrier solvent. 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 cleaning formulation. In an exemplary embodiment, when the core substrate contacts water having a temperature higher than 20°C, the water-soluble core substrate becomes soluble, i.e., dissolves and releases the active cleaning formulation. In exemplary embodiments, the active cleaning formulation is in the form of at least one solid, such as a powder, a plurality of granules or particles, a gel, a liquid or a slurry form, or any suitable combination thereof.In certain embodiments, the water-soluble core substrate is saturated with the active cleaning formulation.In other embodiments, the active cleaning formulation is embedded, coated or attached to the water-soluble core substrate, for example, the active cleaning 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 cleaning formulation or impregnated with the active cleaning formulation.In exemplary embodiments, the active cleaning formulation is present in the water-soluble core substrate, for example, in the fiber-forming composition, the foam-forming composition, or the film-forming composition.

[0035] In an exemplary embodiment, the single unit dose article comprises a water-soluble nonwoven material, a water-soluble foam material, or a water-soluble film material, or a composite water-soluble material, including combinations thereof, such as a water-soluble film material laminated to a water-soluble nonwoven material or a water-soluble foam material, and encapsulating a water-soluble core substrate and / or an active cleaning composition. In an exemplary embodiment, the water-soluble outer material defines an inner volume in which the water-soluble core substrate and the active cleaning composition are contained. The bond interface is configured to create a seal that encapsulates the water-soluble core substrate and the active cleaning composition in the inner volume. In a particular embodiment, the water-soluble film is laminated to the water-soluble nonwoven material. For example, the water-soluble film is disposed on a first surface, such as the inner surface of the water-soluble nonwoven material.

[0036] Referring now to the figures and initially to Figures 1-3, the single unit dose article 20 includes a water-soluble nonwoven substrate 22 that includes a plurality of fibers that include a water-soluble resin. In an exemplary embodiment, the water-soluble nonwoven substrate 22 includes any suitable fiber chemistry, including but not limited to PVOH fibers or PVOH fibers blended with up to 90% by weight 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 22 has a basis weight of 15 gsm (grams per square meter) to 150 gsm, and more specifically, 30 gsm to 65 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of the water-soluble nonwoven substrate 22 may be bonded using any suitable method, including but not limited to, heat, thermal, chemical, water or solution bonding, or any suitable bonding method known in the art for nonwoven fiber bonding. As described below and shown in Figures 1-3, the water-soluble nonwoven substrate 22 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 22 may be porous or non-porous and may be cold water soluble or hot water soluble. The water-soluble nonwoven substrate 22 may be formed using any suitable manufacturing process known in the nonwoven 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, stacked layers or plies, or rolled layers or plies.

[0037] 1-3, in an exemplary embodiment, the water soluble nonwoven substrate 22 includes a plurality of layers 24. For example, the water soluble nonwoven substrate 22 includes layers 24. n ,twenty four n+1 ,twenty four n+2 ,twenty four n+3and the like. In an exemplary embodiment, the water soluble nonwoven substrate 22 is a continuous sheet of a water soluble nonwoven web that is folded into a serpentine construction to form the multiple layers 24. In an alternative exemplary embodiment, the water soluble nonwoven substrate 22 comprises a plurality of separate water soluble nonwoven substrate sheets that are stacked, laminated or layered to form the multiple layers 24. In an exemplary embodiment, each layer 24 may include the same active cleaning formulation 26, or each layer 24 may contain a different cleaning formulation 26 than one or more of the other layers 24. For example, in certain embodiments, a first layer 24 may include a plurality of separate active cleaning formulations 26. n contains a protease, and the second layer 24 n+1 contains amylase, and the third layer 24 n+2 contains lipase, and the fourth layer 24 n+3 The fifth layer 24 includes a surfactant. n+4 contains a chelating agent, and the sixth layer 24 n+5 contains a builder.

[0038] In an exemplary embodiment, the water-soluble nonwoven substrate 22 contains a carrier solvent 25 that includes an active cleaning formulation 26. In an exemplary embodiment, the active cleaning formulation 26 is a liquid formulation. In an exemplary embodiment, upon contact of an appropriate amount, e.g., a saturation amount, of the carrier solvent 25 with the water-soluble nonwoven substrate 22, e.g., one or more fibers of the plurality of fibers forming the water-soluble nonwoven substrate 22, the one or more fibers exhibit at least one fiber or the nonwoven substrate exhibits a shrinkage percentage of 0.5% to 65%. In an exemplary embodiment, the fibers have a crystallinity of at least 25%, more particularly between 30% and 35%. In an exemplary embodiment, the carrier solvent 25 includes any suitable polar solvent, and may include, but is not limited to, water, glycerin, polyols such as DPG (dipropylene glycol), or any combination thereof. In other exemplary embodiments, the carrier solvent 25 is first disposed on the water-soluble nonwoven substrate 22, e.g., coated or applied to shrink or swell the fibers of the water-soluble nonwoven substrate 22, and then the active cleaning formulation 26 is applied to the water-soluble nonwoven substrate 22. In an exemplary embodiment, the carrier solvent 25 containing the active cleaning formulation 26 facilitates containing the active cleaning in a core substrate, such as a water-soluble nonwoven substrate 22, creating stability for the SUD article while maintaining acceptable cleaning and solubility.

[0039] In an exemplary embodiment, when the water soluble nonwoven substrate 22 is contacted with water having a temperature of at least 10° C., the water soluble nonwoven substrate 22 becomes soluble and releases the active cleaning formulation 26 from the water soluble nonwoven substrate 22. Furthermore, when the water soluble nonwoven substrate 22 is contacted with water having a temperature of at least 10° C. for 300 seconds or less, the active cleaning formulation 26 is substantially released from the water soluble nonwoven substrate 22. In an alternative embodiment, when the water dispersible nonwoven substrate is contacted with water having a temperature less than 10° C., the water dispersible nonwoven substrate becomes dispersible and releases the active cleaning formulation from the water dispersible nonwoven substrate. When the water dispersible nonwoven substrate is contacted with water having a temperature less than 10° C. for 300 seconds or less, the active cleaning formulation is substantially released from the water dispersible nonwoven substrate.

[0040] The active cleaning formulation 26 may be in the form of a solid, e.g., a powder or multiple granules or particles, a gel, a liquid, or a slurry formulation, or any suitable combination of, e.g., powder, solid, gel, liquid, or slurry formulations. In an exemplary embodiment, the active cleaning formulation 26 is in any suitable phase, including, e.g., a solid phase, a liquid phase, a slurry phase (a liquid containing solids and multiple phases), and any suitable combination of phases. For example, the active cleaning formulation 26 may include a fine powder or granules, a gel, one or more liquids, or a slurry (e.g., a liquid containing solids and multiple phases), or multiple phases. The active cleaning formulation may include, but is not limited to, detergents, surfactants, emulsifiers, chelating agents, soil suspending agents, stain release agents, enzymes, pH adjusters, builders, soil release polymers, structuring agents, free fragrances, encapsulated perfumes, preservatives, solvents, minerals, and / or any ingredients suitable for personal care, laundry detergents, dish detergents, and / or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article 20 includes an active cleaning formulation having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In embodiments where the active cleaning formulation 26 is in a solid phase, the particles or granules may have a size of 1 micron to 100 microns or may be in the form of tablets.

[0041] In an exemplary embodiment, the cleaning composition may be applied to the matrix of the water soluble nonwoven substrate 22 by saturating the water soluble nonwoven substrate 22 with a carrier solvent 25 containing an active cleaning formulation 26, e.g., as shown in FIGS. 1 and 2, by embedding the carrier solvent 25 containing the active cleaning formulation 26 in one or more layers 24 of the water soluble nonwoven substrate 22, e.g., as shown in FIG. 3, and / or by disposing the carrier solvent 25 containing the active cleaning formulation 26 between adjacent layers 24 of the water soluble nonwoven substrate 22, e.g., between layers 24. n one or more surfaces of layer 24 n+1 one or more surfaces and / or layers 24 of n+2The carrier solvent 25 containing the active cleaning formulation 26 is contained in the water soluble nonwoven substrate 22, for example, by coating one or more surfaces of the water soluble nonwoven substrate 22 with the carrier solvent 25 containing the active cleaning formulation 26. The carrier solvent 25 containing the active cleaning formulation 26 may be adsorbed and / or adhered or bonded to the surface of the water soluble nonwoven substrate 22, for example. In an exemplary embodiment as shown in FIG. 1, the single unit dose article 20 includes a multi-layer water soluble nonwoven substrate 22, a carrier solvent 25 containing the active cleaning formulation 26 in a liquid phase surrounding the water soluble nonwoven substrate 22, and a water soluble nonwoven material 28 that encapsulates and contains the water soluble nonwoven substrate 22, the carrier solvent 25, and the active cleaning formulation 26. In an exemplary embodiment as shown in FIG. 2, the single unit dose article 20 includes a multi-layer water soluble nonwoven substrate 22 that contains the carrier solvent 25 containing the active cleaning formulation 26 in a liquid phase, and a water soluble nonwoven material 28 that encapsulates and contains the water soluble nonwoven substrate 22 and the carrier solvent 25 containing the active cleaning formulation 26. In an exemplary embodiment as shown in FIG. 3, single unit dose article 20 includes a multi-layer water soluble nonwoven substrate 22 containing active cleaning formulation 26 in a solid phase, and a water soluble nonwoven material 28 that encapsulates and contains carrier solvent 25 that includes water soluble nonwoven substrate 22 and active cleaning formulation 26.

[0042] 1-3, in an exemplary embodiment, water soluble nonwoven substrate 22 comprises a plurality of fibers (the detailed structure of the fibers is not shown in FIGS. 1-3). In an exemplary embodiment, one or more fibers of the plurality of fibers are saturated with carrier solvent 25 comprising active cleaning formulation 26. Carrier solvent 25 comprising active cleaning formulation 26 may be embedded into one or more fibers of the plurality of fibers, or carrier solvent 25 comprising active cleaning formulation 26 may be disposed, e.g., coated, on a surface of one or more fibers of the plurality of fibers.

[0043] In an exemplary embodiment, as shown in Figures 1-3, the water-soluble nonwoven material 28, and / or, for example, a water-soluble film (see, for example, Figures 13 and 14), at least partially encapsulates the water-soluble nonwoven substrate 22 and defines an interior volume 32 in which the water-soluble nonwoven substrate 22 and the carrier solvent 25 containing the active cleaning formulation 26 are contained. For example, in certain embodiments, a water-soluble film (such as described in Figures 13 and 14) is laminated to a first surface, for example, an interior surface, of the water-soluble nonwoven material 28. In an exemplary embodiment, the water-soluble nonwoven material 28 comprises any suitable fiber chemistry, including, but not limited to, PVOH fibers or PVOH fibers blended with up to 90% by weight of cellulosic type fibers. In an alternative embodiment, the nonwoven material is made of water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material 28 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of the water soluble nonwoven material 28 may be bonded using any suitable method, including but not limited to, thermal, chemical, water or solution bonding, or any suitable bonding method known in the art for nonwoven fiber bonding. The water soluble nonwoven material 28 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 material 28 may be porous or non-porous and may be cold water soluble or hot water soluble. The water soluble nonwoven material 28 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 material 28 may include, for example, folded layers or plies, stacked layers or plies, or rolled layers or plies. In an exemplary embodiment, a first side or surface may have a fibrous appearance, and a second side or surface, for example, the opposite first side or surface, may be smooth or coated with water to create a continuous layer using heat and / or water. The first surface is an interior surface and the second surface is, in one particular embodiment, an exterior surface.

[0044] 1-3, the bond interface 34 is formed or configured to create a seal 36 that encapsulates the water soluble nonwoven substrate 22 and the carrier solvent 25 with the active cleaning formulation 26 within the interior volume 32. A suitable bond interface or seal 36 may be formed using liquid, solvent, heat, chemical, air-permeable, or mechanical entanglement (needle-pierced) bonds or seals 36. For example, as shown in FIG. 1, the carrier solvent 25 with the liquid active cleaning formulation 26 is contained inside the interior volume 32.

[0045] 4 and 5, the single unit dose article 120 includes a water-soluble nonwoven substrate 122 that includes a water-soluble resin. In an exemplary embodiment, the water-soluble nonwoven substrate 122 includes any suitable fiber chemistry, including, but not limited to, PVOH fibers or PVOH 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 122 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of the water-soluble nonwoven substrate 122 may be bonded using any suitable method, including, but not limited to, thermal, thermal, chemical, water or solution bonding, or any suitable bonding method known in the art for nonwoven fiber bonding. In an exemplary embodiment, the water-soluble nonwoven substrate 122 may include any suitable number of layers or plies, for example, 1 layer or ply to 50 layers or plies, or more in certain embodiments. The water soluble nonwoven substrate 122 may be porous or non-porous, and may be cold water soluble or hot water soluble. The water soluble nonwoven substrate 122 may be formed using any suitable manufacturing process known in the nonwoven manufacturing art, including, but not limited to, carded processes. The construction of the water soluble nonwoven substrate 122 may include, for example, folded layers or plies, stacked layers or plies, rolled layers or plies, or high loft nonwoven substrates.

[0046] In an exemplary embodiment, the water soluble nonwoven substrate 122 contains a carrier solvent 125 that includes an active cleaning formulation 126. In an exemplary embodiment, when the water soluble nonwoven substrate 122 contacts water having a temperature greater than 20° C., the water soluble nonwoven substrate 122 becomes soluble and releases the active cleaning formulation 126. The active cleaning formulation 126 may be in the form of, for example, a solid, gel, liquid, or slurry formulation, or any suitable combination of solid, gel, liquid, or slurry formulations. In an exemplary embodiment as shown in FIGS. 4 and 5, the active cleaning formulation 126 is in a solid phase, for example, a tablet, solid particles, granules, fine powder. The active cleaning formulation 126 may include, but is not limited to, actives, detergents, surfactants, emulsifiers, chelating agents, soil suspending agents, stain release agents, enzymes, pH adjusters, builders, soil release polymers, structuring agents, free fragrance, encapsulated fragrance, preservatives, solvents, minerals, and / or any ingredients suitable for personal care, laundry detergents, dish detergents, and / or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article 120 includes an active cleaning formulation having a mass of 0.5 grams (g) to 250 grams, a volume of 1.0 milliliters (ml) to 250 ml, and a particle or granule size of 1.0 microns to 100 microns. In an exemplary embodiment, the carrier solvent 125 with the active cleaning formulation 126 is contained in the water soluble nonwoven substrate 122, for example, in solid particles or granules of the active cleaning formulation 126 embedded or adsorbed or bound to the surface of the water soluble nonwoven substrate 122 as shown in FIG. 4, and / or in solid particles or granules of the active cleaning formulation 126 embedded or adsorbed or bound within the matrix of the water soluble nonwoven substrate 122 as shown in FIG. 5. An exemplary single unit dose article 120 is shown in FIGS. 4 and 5 for demonstration purposes only. The water soluble nonwoven substrate 122, carrier solvent 125, and active cleaning formulation 126 may be exemplary of or may be the same as the water soluble nonwoven substrate 22, carrier solvent 25, and active cleaning formulation 26, respectively, described in FIGS. 1-3. The single unit dose article 120 shown in FIGS. 4 and 5 may be a portion of the single unit dose article 20 shown in FIGS. 1-3.

[0047] 6-9, in an exemplary embodiment, the single unit dose article 220 includes a water-soluble foam substrate 222 that includes a water-soluble resin. In an exemplary embodiment, the water-soluble foam substrate 222 includes any suitable resin chemistry, such as PVOH homopolymer; PVOH copolymer; modified PVOH copolymer, such as maleic anhydride (MA) modified PVOH copolymer, monomethyl maleate (MMM) modified PVOH copolymer, 2-acrylamido-2-methylpropanesulfonic acid (AMPS) modified PVOH copolymer, cellulose and cellulose derivatives, polyvinylpyrrolidone (PVP), protein, casein, soy, or any water dispersible or water soluble resin. In certain embodiments, the water-soluble foam substrate 222 has a thickness of 3 microns to 3000 microns and can be formed using any suitable manufacturing process known in the foam manufacturing art, including, 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 222 may be porous or non-porous and may be cold water soluble or hot water soluble. The construction of the water-soluble foam substrate 222 may include, for example, folded layers or plies, laminated layers or plies, or rolled layers or plies.

[0048] The water-soluble foam substrate 222 is configured to contain a carrier solvent 225 that includes an active cleaning formulation 226. In an exemplary embodiment, upon contact of the carrier solvent 25 with the water-soluble foam substrate 222, the water-soluble foam substrate 222 exhibits a carrier solvent absorption capacity of 1% to 1300%. Furthermore, when the water-soluble foam substrate 222 contacts water having a temperature greater than 20° C., the water-soluble foam substrate 222 becomes soluble and releases the active cleaning formulation 226. In certain embodiments, as shown in FIGS. 6-8, the water-soluble nonwoven material 228 at least partially encapsulates and contains the water-soluble foam substrate 222 and the carrier solvent 225 that includes the active cleaning formulation 226. The active cleaning formulation 226 may be in the form of, for example, a solid, liquid, gel, or slurry formulation, or any suitable combination of solid, liquid, gel, or slurry formulations. In the exemplary embodiment as shown in Figures 6-9, the active cleaning formulation 226 is in a solid phase, but in certain embodiments, it may be in any suitable phase including, for example, a liquid phase, a slurry phase (a liquid containing solids and multiple phases), and any suitable combination of phases. The active cleaning formulation may include, but is not limited to, actives, detergents, surfactants, emulsifiers, chelating agents, soil suspending agents, stain release agents, enzymes, pH adjusters, builders, soil release polymers, structuring agents, free fragrances, encapsulated fragrances, preservatives, solvents, minerals, and / or any ingredients suitable for personal care, laundry detergents, dish detergents, and / or household surface cleaners or cleansers. In the exemplary embodiment, the single unit dose article 220 includes a structuring agent or adhesive material to hold the active cleaning formulation 226 in a solid, liquid, or gel form, bonded to a water-soluble foam substrate 222 to provide a barrier against the consumer's hands. In an exemplary embodiment, the single unit dose article 220 includes an active cleaning formulation 226 having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In an exemplary embodiment as shown in Figures 7-9, the active cleaning formulation 226 includes a solid active cleaning formulation 226 in the form of a fine powder or granules, or a tablet, having a particle size of 1 micron to 100 microns.

[0049] In an exemplary embodiment, the carrier solvent 225 containing the active cleaning formulation 226 is contained in the water soluble foam substrate 222, for example, by saturating the water soluble foam substrate 222 with the carrier solvent 225 containing the active cleaning formulation 226 as shown in FIG. 6, or by adhering, adsorbing or bonding a solid, e.g., powder or granule, carrier solvent 225 containing the active cleaning formulation 226 to a surface of the water soluble foam substrate 222 as shown in FIGS. 7-9, or by disposing or embedding the carrier solvent 225 containing the active cleaning formulation 226 in one or more layers or surfaces or matrices of the water soluble foam substrate 222, for example, by coating one or more surfaces with the solid carrier solvent 225 containing the active cleaning formulation 226. In an exemplary embodiment as shown in Figure 6, the single unit dose article 20 includes a water soluble foam substrate 222, a carrier solvent 225 with an active cleaning formulation 226 contained within the water soluble foam substrate 222, and a water soluble nonwoven material 228 that encapsulates and contains the water soluble foam substrate 222 and the carrier solvent 225 with the active cleaning formulation 226. In an exemplary embodiment as shown in Figures 7 and 8, the single unit dose article 220 includes a water soluble foam substrate 222 containing a carrier solvent 225 with an active cleaning formulation 226 in a solid phase, e.g., powder or granular form, and a water soluble nonwoven material 228 that at least partially encapsulates and contains the water soluble foam substrate 222 and the carrier solvent 225 with the active cleaning formulation 226. In the example shown in Figure 7, the bond interface 234 is formed or configured to create a seal 236 that encapsulates the water soluble foam substrate 222 and the carrier solvent 225 with the active cleaning formulation 226 within the interior volume 232 of the water soluble nonwoven material 228. In an exemplary embodiment as shown in Figure 9, single unit dose article 220 includes a water-soluble foam substrate 222 containing a carrier solvent 225 with an active cleaning formulation 226 in a solid phase, e.g., powder or granular form, adhered or bonded to a surface of the water-soluble foam substrate 222, and does not include a water-soluble nonwoven material 228 that encapsulates the water-soluble foam substrate 222 and the carrier solvent 225 with the active cleaning formulation 226. The exemplary single unit dose article 220 is shown in Figures 6-9 for demonstration purposes only.Water soluble nonwoven substrate 222, carrier solvent 225, active cleaning formulation 226, and water soluble nonwoven material 228 may be made of the same materials as water soluble nonwoven substrate 22, carrier solvent 25, active cleaning formulation 26, and water soluble nonwoven material 28, respectively, described in Figures 1-3. Bond interface 234 and seal 236 may be the same as bond interface 34 and seal 36, respectively, shown in Figures 1-3.

[0050] In an exemplary embodiment, as shown, for example, in Figures 6-8, a water-soluble nonwoven material 228 and / or a water-soluble film (see, for example, Figures 13 and 14) at least partially encapsulates the water-soluble foam substrate 222 defining an interior volume 232 in which the water-soluble foam substrate 222 and the carrier solvent 225 containing the active cleaning formulation 226 are contained. For example, in certain embodiments, the water-soluble film is laminated to a first surface, for example, an interior surface, of the water-soluble nonwoven material 228. In an exemplary embodiment, the water-soluble nonwoven material 228 includes any suitable fiber chemistry, such as PVOH fibers or PVOH fibers blended with up to 90% by weight of cellulosic type fibers. In an alternative embodiment, the nonwoven material is made of water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material 28 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of the water soluble nonwoven material 228 may be bonded using any suitable method, including, but not limited to, heat, thermal, chemical, water or solution bonding, or any suitable bonding method known in the art for nonwoven fiber bonding. The water soluble nonwoven material 228 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 material 228 may be porous or non-porous and may be cold water soluble or hot water soluble. The water soluble nonwoven material 228 may be formed using any suitable manufacturing process known in the nonwoven manufacturing art, including, but not limited to, carded processes. The construction of the water soluble material 228 may include, for example, folded layers or plies, stacked layers or plies, or rolled layers or plies. In an exemplary embodiment, a first side or surface may have a fibrous appearance and a second side or surface, e.g., the opposite first side or surface, may be smooth or may be coated with water to create a continuous layer using heat and / or water.

[0051] For example, in the exemplary embodiment shown in Figures 8 and 9, a disposable laundry bag or basket liner includes a water-soluble foam substrate alone or in combination with a water-soluble film substrate and / or a water-soluble nonwoven substrate containing one or more active cleaning formulations in an appropriate amount for cleaning a large amount of laundry. The active cleaning formulations may be embedded or contained in the polymer matrix of the water-soluble foam substrate and / or disposed on one or more surfaces of the water-soluble foam substrate. The consumer simply places the laundry bag or basket liner containing the soiled laundry into the washing machine and starts the wash cycle. In the exemplary embodiment, the water-soluble disposable laundry bag or basket liner completely dissolves or otherwise disperses to release the active cleaning formulations that clean the soiled laundry. In other exemplary embodiments, the single unit dose article, for example in the form of a tag or sticker, may be sewn or otherwise attached to the article of clothing to be cleaned. The consumer can benefit from the high-performance cleaning ability, the natural or more sustainable appearance, and the convenience of isolating otherwise incompatible cleaning agents or actives.

[0052] 10, in an exemplary embodiment, a single unit dose article 320 includes a carrier solvent 325 that includes an active cleaning formulation 326. The active cleaning formulation 326 may be in the form of, for example, a solid, a powder or granules, a gel, a liquid, or a slurry formulation, or any suitable combination of a powder, solid, liquid, or slurry formulation. In the exemplary embodiment as shown in FIG. 10, the active cleaning formulation 326 is in a solid phase that includes a plurality of solid particles or granules, however, in certain embodiments, the active cleaning formulation 326 may be in any suitable phase including, for example, a liquid phase, a slurry phase (a liquid containing a solid and multiple phases), any suitable combination of phases. The active cleaning formulation may include, but is not limited to, actives, detergents, surfactants, emulsifiers, chelating agents, soil suspending agents, stain release agents, enzymes, pH adjusters, builders, soil release polymers, structuring agents, free fragrances, encapsulated fragrances, preservatives, solvents, minerals, and / or any ingredients suitable for personal care, laundry detergents, dish detergents, and / or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article 20 includes an active cleaning formulation having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In an exemplary embodiment, the active cleaning formulation 326 includes a plurality of fine powder particles or granules having a particle size of 1 micron to 100 microns, or in tablet form. The particles, granules, or tablets in the active cleaning formulation 326 may have different particle sizes, for example, a unimodal or bimodal particle size distribution.

[0053] In an exemplary embodiment, as shown in FIG. 10, for example, the water-soluble nonwoven material 328 and / or water-soluble film (see, for example, FIGS. 13 and 14) defines an interior volume 332 containing a carrier solvent 325 with an active cleaning formulation 326. In an exemplary embodiment, the water-soluble nonwoven material 328 includes any suitable fiber chemistry, for example, PVOH fibers or PVOH fibers blended with up to 90% by weight of cellulosic type fibers. In an alternative embodiment, the nonwoven material is made of water dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material 328 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of the water-soluble nonwoven material 328 may be bonded using any suitable method, including, but not limited to, heat, thermal, chemical, water or solution bonding, or any suitable bonding method known in the art for nonwoven fiber bonding. The water soluble nonwoven material 328 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 material 328 may be porous or non-porous and may be cold water soluble or hot water soluble. The water soluble nonwoven material 328 may be formed using any suitable manufacturing process known in the nonwoven manufacturing art, including, but not limited to, carded processes. The construction of the water soluble material 328 may include, for example, folded layers or plies, stacked layers or plies, or rolled layers or plies. In an exemplary embodiment, a first side or surface may have a fibrous appearance and a second side or surface, for example, the opposite first side or surface, may be smooth or may be coated with water to create a continuous layer using heat and / or water.

[0054] As shown in FIG. 10, the bond interface 334 is formed or configured to create a seal 336 that encapsulates the carrier solvent 325 containing the active cleaning formulation 326 within the interior volume 332. A suitable bond interface 334 or seal 336 may be formed using liquid, solvent, heat, chemical, air-through, or mechanical entanglement (needle-punch) bonds or seals 336. In an exemplary embodiment, when the water-soluble nonwoven material 328 contacts water having a temperature greater than 20° C., the water-soluble nonwoven material 328 becomes soluble and releases the active cleaning formulation 326. An exemplary single unit dose article 320 is shown in FIG. 10 for demonstration purposes only. The carrier solvent 325, active cleaning formulation 326, and water-soluble nonwoven material 328 may be made of the same materials as the carrier solvent 25, active cleaning formulation 26, and water-soluble nonwoven material 28, respectively, described in FIGS. 1-3. Bonding interface 334 and seal 336 may be the same as bonding interface 34 and seal 36, respectively, shown in Figures 1-3. Particles, granules or tablets in active cleaning formulation 326 having different particle sizes, for example, unimodal or bimodal particle size distribution, are also applicable to single unit dose article 20 shown in Figures 1-3.

[0055] As shown in Figures 11 and 12, the single unit dose article 420 includes a water-soluble nonwoven material 428 having a first water-soluble nonwoven web 428a containing a first water-soluble resin and an opposing second water-soluble nonwoven web 428b containing a second water-soluble resin, the same or different from the first water-soluble nonwoven web. An active cleaning formulation 426 is disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web, and when the first water-soluble nonwoven web and / or the second water-soluble nonwoven web contacts water having a temperature higher than 20°C, the first water-soluble nonwoven web and / or the second water-soluble nonwoven web becomes soluble and releases the active cleaning formulation. A water-soluble film substrate 422 is disposed between the first water-soluble nonwoven web 428a and the second water-soluble nonwoven web 428b, and a carrier solvent 425 containing the active cleaning formulation 426 is disposed, e.g., embedded or bonded, to a surface of the water-soluble film substrate 422.

[0056] In an exemplary embodiment, the water-soluble film substrate 422 comprises a water-soluble resin. In an exemplary embodiment, the water-soluble film substrate 422 comprises any suitable chemistry, such as PVOH homopolymer, PVOH copolymer, MA-modified PVOH copolymer, MMM-modified PVOH copolymer, AMPS-modified PVOH copolymer, cellulose and cellulose derivatives, PVP, protein, casein, soy, or any water-dispersible or water-soluble resin. The water-soluble film substrate 422 has a thickness of 3 microns to 3000 microns and can be formed using any suitable manufacturing process known in the foam manufacturing art, including, but not limited to, casting, extrusion, melt processing, and coating processes. The water-soluble film substrate 422 can be cold water soluble or hot water soluble. In an exemplary embodiment, the water-soluble film substrate 422 comprises a structuring agent or adhesive material suitable for holding or bonding the solid, liquid, and / or gel active cleaning formulation 426 to the water-soluble film substrate 422.

[0057] In an exemplary embodiment, the water-soluble film substrate 422 contains a carrier solvent 425 that includes an active cleaning formulation 426. In an exemplary embodiment, when the water-soluble film substrate 422 contacts water having a temperature greater than 20° C., the water-soluble film substrate 422 becomes soluble and releases the active cleaning formulation 426. The active cleaning formulation 426 may be in the form of, for example, a solid, such as a fine powder or granules, a powder, a liquid, or a slurry formulation, or any suitable combination of solids, such as fine powders, granules, liquids, and slurry formulations. In the exemplary embodiment as shown in FIGS. 11 and 12, the active cleaning formulation 426 is in a solid phase, but may also be in any suitable phase including, for example, a liquid phase, a slurry phase (a liquid containing a solid and multiple phases), and any suitable combination of phases. The active cleaning formulation may include, but is not limited to, actives, detergents, surfactants, emulsifiers, chelating agents, soil suspending agents, stain release agents, enzymes, pH adjusters, builders, soil release polymers, structuring agents, free fragrances, encapsulated fragrances, preservatives, solvents, minerals, and / or any ingredients suitable for personal care, laundry detergents, dish detergents, and / or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article 20 includes an active cleaning formulation having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In an exemplary embodiment, the active cleaning formulation 426 includes a fine powder or granules having a particle size of 1 micron to 100 microns, or a tablet form. The powder or granules may have different sizes, including, for example, a particle size distribution or a bimodal particle size distribution.

[0058] 11 and 12, single unit dose article 420 includes water soluble film substrate 422, carrier solvent 425 with active cleaning formulation 426 adhered, adsorbed or bound to the surface of water soluble film substrate 422 in a solid phase, and water soluble nonwoven material 428 at least partially encapsulating and containing water soluble film substrate 422 and carrier solvent 425 with active cleaning formulation 426. In the exemplary embodiment as shown in FIG. 11, single unit dose article 420 includes water soluble film substrate 422 containing carrier solvent 425 with active cleaning formulation 426 in a solid phase, and water soluble nonwoven material 428 encapsulating and containing water soluble film substrate 422 with carrier solvent 425 with active cleaning formulation 426. In an exemplary embodiment as shown in Figure 12, a single unit dose article 420 includes a water soluble film substrate 422 containing a carrier solvent 425 with an active cleaning formulation 426 in a solid phase, and a water soluble nonwoven material 428 partially encapsulating and containing the water soluble film substrate 422 with the carrier solvent 425 with the active cleaning formulation 426. An exemplary single unit dose article 420 is shown in Figure 10 for demonstration purposes only. The carrier solvent 425, active cleaning formulation 426, and water soluble nonwoven material 428 may be made of the same materials as the carrier solvent 25, active cleaning formulation 26, and water soluble nonwoven material 28, respectively, described with respect to Figures 1-3.

[0059] In an exemplary embodiment, the water-soluble nonwoven material 428 includes any suitable fiber chemistry, such as PVOH fibers or PVOH fibers blended with up to 90% by weight cellulosic type fibers. In an alternative embodiment, the nonwoven material is made of water dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material 428 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of the water-soluble nonwoven material 428 may be bonded using any suitable method, including but not limited to, thermal, thermal, chemical, water or solution bonding, or any suitable bonding method known in the art for nonwoven fiber bonding. The water-soluble nonwoven material 428 may include any suitable number of layers or plies, such as from 1 layer or ply to 50 layers or plies, or more in certain embodiments. The water-soluble nonwoven material 428 may be porous or non-porous and may be cold water soluble or hot water soluble. The water soluble nonwoven material 428 may be formed using any suitable manufacturing process known in the nonwoven manufacturing art, including, but not limited to, carded processes. The construction of the water soluble nonwoven material 428 may include, for example, folded layers or plies, stacked layers or plies, or rolled layers or plies. In an exemplary embodiment, a first side or surface may have a fibrous appearance, and a second side or surface, e.g., the opposite first side or surface, may be smooth or coated with water to create a continuous layer using heat and / or water. The first surface may be an interior surface, and the second surface may be an exterior surface of the single unit dose article 420 in certain embodiments.

[0060] 11, bond interface 434 is formed or configured to create a seal 436 that encapsulates water-soluble film substrate 422 and carrier solvent 425 containing active cleaning formulation 426 within interior volume 432 defined by water-soluble nonwoven material 428. A suitable bond interface or seal 436 may be formed using liquid, solvent, heat, chemical, air-permeable, or mechanical intertwining (needle-pierced) bonds or seals 436. Bond interface 434 and seal 436 may be the same as bond interface 34 and seal 36, respectively, shown in FIGS. 1-3.

[0061] 13 and 14, a single unit dose article 520 includes a water-soluble composite 528 including a water-soluble film 522 material made with a water-soluble resin as described herein coupled, bonded or laminated to a water-soluble nonwoven material 527 as described herein or a water-soluble foam material 529 made with a water-soluble resin. For example, as shown in FIG. 13, the water-soluble composite 528 includes a water-soluble nonwoven web 527 having a first surface 527a facing an interior volume 532 and an opposing second surface 527b, e.g., an outer surface including a water-soluble film material 522 disposed on the first surface. The water-soluble composite 528 is bonded at a bond interface 534 along the edges of the water-soluble materials that define the interior volume 532 of the single unit dose article 520. A seal 536 is also formed. An active cleaning formulation 526 is disposed in the interior volume 532. In an exemplary embodiment, when the water soluble composite material 528 comes into contact with water having a temperature greater than 20° C., at least a portion of the water soluble composite material 528 becomes soluble and releases the active cleaning formulation 526 .

[0062] In an exemplary embodiment, as shown in FIG. 13, for example, the water-soluble nonwoven material 527 of the water-soluble composite 528 includes any suitable fiber chemistry, such as PVOH fibers or PVOH fibers blended with up to 90% by weight of cellulosic type fibers. In an alternative embodiment, the nonwoven material 527 is made of water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material 527 has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of the water-soluble nonwoven material 527 may be bonded using any suitable method, including but not limited to, thermal, chemical, water or solution bonding, or any suitable bonding method known in the art for nonwoven fiber bonding. The water-soluble nonwoven material 527 may include any suitable number of layers or plies, such as 1 layer or ply to 50 layers or plies, or more in certain embodiments. The water-soluble nonwoven material 527 may be porous or non-porous and may be cold water soluble or hot water soluble. The water-soluble nonwoven material may be formed using any suitable manufacturing process known in the nonwoven manufacturing art, including, but not limited to, carded processes. The construction of the water-soluble nonwoven material may include, for example, folded layers or plies, stacked layers or plies, or rolled layers or plies. In an exemplary embodiment, a first side or surface may have a fibrous appearance, and a second side or surface, e.g., the opposite first side or surface, may be smooth or coated with water to create a continuous layer using heat and / or water.

[0063] In an exemplary embodiment, as shown in FIG. 14, the water-soluble foam substrate 529 of the water-soluble composite material 528, for example, comprises any suitable resin chemistry, such as homopolymer, MA-modified PVOH copolymer, MMM-modified PVOH copolymer, AMPS-modified PVOH copolymer, cellulose and cellulose derivatives, PVP, protein, casein, soy, or any water-dispersible or water-soluble resin. The water-soluble foam material 529 has a thickness of 3 microns to 3000 microns and can be formed using any suitable manufacturing process known in the foam manufacturing art, including, but not limited to, casting, extrusion, melt processing, coating, chemical blowing, mechanical air entrapment, air injection, and turbulent extrusion processes. The water-soluble foam material 529 can be porous or non-porous and can be cold water soluble or hot water soluble. The construction of the water-soluble foam material 529 can include, for example, folded layers or plies, laminated layers or plies, or rolled layers or plies.

[0064] In exemplary embodiments, the carrier solvent 525 containing the active cleaning formulation 526 may be in the form of a solid, e.g., a powder or granule, a liquid, or a slurry formulation, or may be any suitable combination of solids, liquids, or slurry formulations, for example. In the exemplary embodiments as shown in Figures 13 and 14, the active cleaning formulation 526 is in a liquid phase, but in certain embodiments, it may be in any suitable phase, including, for example, a liquid phase, a slurry phase (a liquid containing solids and multiple phases), a solid phase, and any suitable combination of phases. The active cleaning formulation may include, but is not limited to, actives, detergents, surfactants, emulsifiers, chelating agents, soil suspending agents, stain release agents, enzymes, pH adjusters, builders, soil release polymers, structuring agents, free fragrances, encapsulated fragrances, preservatives, solvents, minerals, and / or any ingredients suitable for personal care, laundry detergents, dish detergents, and / or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article 520 includes an active cleaning formulation 526 having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In an exemplary embodiment, the active cleaning formulation 526 includes a fine powder or granules having a particle size of 1 micron to 100 microns, or a tablet form.

[0065] In an exemplary embodiment as shown in FIG. 13, the single unit dose article 520 comprises a carrier solvent 525 with an active cleaning formulation 526 in a liquid phase contained within a water soluble composite 528 comprising a water soluble film material laminated to a water soluble nonwoven material that encapsulates and contains the carrier solvent 525 with the active cleaning formulation 526. In an exemplary embodiment as shown in FIG. 14, the single unit dose article 520 comprises a carrier solvent 525 with an active cleaning formulation 526 in a liquid phase contained within a water soluble composite 528 comprising a water soluble film material laminated to a water soluble foam material that encapsulates and contains the carrier solvent 525 with the active cleaning formulation 526. FIGS. 13 and 14 are shown for demonstration purposes. The carrier solvent 525 and the active cleaning formulation 526 may be the same as described with respect to FIGS. 2-12. The carrier solvent 525 and active cleaning formulation 526 may also be adsorbed, embedded or loaded between, coated or layered on the inside of the pouch with one or more layers of a water-soluble core substrate, such as a nonwoven foam and / or film, having one of the configurations described with respect to Figures 2-12.

[0066] In an exemplary embodiment, the single unit dose article includes, for example, a water-soluble nonwoven material and / or a water-soluble film defining an interior volume that contains an active cleaning formulation. In an exemplary embodiment, the water-soluble nonwoven material includes any suitable fiber chemistry, for example, PVOH fibers or PVOH fibers blended with up to 90% by weight of cellulosic type fibers. In an alternative embodiment, the nonwoven material is made of water-dispersible fibers. In an exemplary embodiment, the water-soluble nonwoven material has a basis weight of 15 gsm to 150 gsm, a fiber length of 10.0 millimeters (mm) to 150 mm, and a suitable fiber diameter. The fibers of the water-soluble nonwoven material may be bonded using any suitable method, including but not limited to, thermal, thermal, chemical, water or solution bonding, or any suitable bonding method known in the art for nonwoven fiber bonding. The water-soluble nonwoven material may include any suitable number of layers or plies, for example, 1 layer or ply to 50 layers or plies, or more in certain embodiments. The water-soluble nonwoven material may be porous or non-porous, and may be cold water-soluble or hot water-soluble. The water-soluble nonwoven material 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 material may include, for example, folded layers or plies, stacked layers or plies, or rolled layers or plies. In an exemplary embodiment, a first side or surface may have a fibrous appearance, and a second side or surface, e.g., the opposite first side or surface, may be smooth or coated with water to create a continuous layer using heat and / or water.

[0067] In an exemplary embodiment, the active cleaning formulation is in the form of a solid, e.g., a powder, although the active cleaning formulation may be in the form of a gel, liquid, or slurry formulation, or any suitable combination of, e.g., solid, liquid, or slurry formulations. The active cleaning formulation may include, but is not limited to, actives, detergents, surfactants, emulsifiers, chelating agents, soil suspending agents, stain release agents, enzymes, pH adjusters, builders, soil release polymers, structuring agents, free fragrances, encapsulated fragrances, preservatives, solvents, minerals, and / or any ingredients suitable for personal care, laundry detergents, dish detergents, and / or household surface cleaners or cleansers. In an exemplary embodiment, the single unit dose article includes an active cleaning formulation having a mass of 0.5 grams (g) to 250 grams and a volume of 1.0 milliliters (ml) to 250 ml. In an exemplary embodiment, the active cleaning formulation includes a plurality of fine powder particles or granules having a particle size of 1 micron to 100 microns, or a tablet form.

[0068] The bond interface 534 is formed or configured to create a seal 536 that encapsulates the active cleaning formulation within the interior volume. A suitable bond interface or seal may be formed using liquid, solvent, heat, chemical, air-through, or mechanical entanglement (needle-piercing) bonds or seals. In an exemplary embodiment, when the water soluble nonwoven material comes into contact with water having a temperature greater than 20° C., the water soluble nonwoven material becomes soluble and releases the active cleaning formulation from the interior volume.

[0069] A consumer can place one or more single unit dose articles, e.g., single unit dose articles 20, 120, 220, 320, 420 or 520, into a laundry vessel, e.g., a washer or basin, to deliver or introduce an active cleaning formulation, e.g., active cleaning formulation 26, 126, 226, 326, 426, 526, into the laundry vessel to wash a person or an article, including, but not limited to, clothes, dishes and / or surfaces. In exemplary embodiments, the material of the single unit dose article completely or substantially completely dissolves or otherwise disperses without negatively affecting the perceived appearance of cleanliness by the consumer. In certain exemplary embodiments, the single unit dose article is connected or attached, e.g., sewn or glued, to an article, such as a piece of clothing, to be washed. Other examples include the single unit dose article in the form of a tag attached to the clothing or a sticker adhesively connected to the surface to be washed.

[0070] Additionally, the single unit dose article 520 may be configured as a bag or container for soiled articles for unit washing and an overall simplified washing process, such as a laundry bag containing an active cleaning formulation. The laundry bag containing the soiled articles can be placed in a washing machine and will completely or substantially completely dissolve or otherwise disperse when the soiled articles are washed. Consumer-perceived benefits of the single unit dose article include, for example, high performance cleaning, the ability to physically separate otherwise incompatible cleaning agents, a natural and more sustainable appearance, convenience, and / or product differentiation and novelty.

[0071] 15, in an exemplary embodiment, a method 600 of making a single unit dose article containing a carrier solvent with an active cleaning formulation includes any or all of steps 602, 604, 606, and 608. In step 602, a water-soluble core substrate is formed that includes a water-soluble resin. In an exemplary embodiment, the step of forming a water-soluble core substrate containing a carrier solvent with an active cleaning formulation with a water-soluble resin includes forming one of a water-soluble nonwoven substrate, a water-soluble foam substrate, or a water-soluble film substrate. In an exemplary embodiment, the water-soluble nonwoven substrate is formed into a plurality of layers that includes a carrier solvent with an active cleaning formulation disposed between adjacent layers of the plurality of layers. The plurality of layers may be formed by folding a continuous sheet of a water-soluble nonwoven web into a serpentine construction, or by laminating a plurality of separate substrate sheets into a layered construction, for example.

[0072] The water-soluble core substrate contains a carrier solvent with an active cleaning formulation as described herein. In exemplary embodiments, the water-soluble core substrate is saturated with the carrier solvent with the active cleaning formulation, the carrier solvent with the active cleaning formulation is disposed on the surface of the water-soluble core substrate, the surface of the water-soluble core substrate is coated with the carrier solvent with the active cleaning formulation, the carrier solvent with the active cleaning formulation is embedded in the water-soluble core substrate, and / or the water-soluble core substrate is impregnated with the carrier solvent with the active cleaning formulation.

[0073] In an exemplary embodiment, the method 600 includes applying a carrier solvent containing an active cleaning formulation to a surface of a water-soluble nonwoven sheet, for example a 30 gsm water-soluble nonwoven sheet, up to a maximum coating weight of 120 gsm as a carrier solvent containing an active cleaning formulation, which limits the amount of active cleaning formulation that can be applied to each water-soluble nonwoven sheet and determines the number of plies of water-soluble nonwoven sheets required to make up the water-soluble core substrate. The carrier solvent containing the active cleaning formulation, for example the maximum amount of glycerin solvent, is applied to the surface of the water-soluble nonwoven substrate until the single unit dose article contains 55% by weight of the active cleaning formulation. In an exemplary embodiment, the water-soluble nonwoven substrate is formed into a number of layers such that the single unit dose article contains 55% by weight of the active cleaning formulation.

[0074] In an exemplary embodiment, the method 600 includes forming a water-soluble core substrate including a plurality of fibers including a water-soluble resin. The water-soluble core substrate contains a carrier solvent including an active cleaning formulation. At least one of the fibers or the water-soluble core substrate exhibits a shrinkage rate of 0.5% to 65% when the carrier solvent contacts at least one fiber of the plurality of fibers. In an exemplary embodiment, the method 600 includes contacting the carrier solvent with a water-soluble solid substrate, and at least one of the fibers or substrate exhibits a shrinkage rate of 0.5% to 65% when contacted with the carrier solvent. In an exemplary embodiment, when the water-soluble core substrate contacts with water having a temperature greater than 10° C., the water-soluble core substrate becomes soluble and releases the active cleaning formulation from the water-soluble core substrate. Furthermore, when the water-soluble core substrate contacts with water having a temperature of at least 10° C. for 300 seconds or less, the active cleaning formulation is substantially released from the water-soluble core substrate.

[0075] At step 604, the outer water-soluble material is formed into an open pouch defining an interior volume configured to contain the water-soluble core substrate and the carrier solvent with the active cleaning formulation. The outer water-soluble material includes a water-soluble nonwoven material, a water-soluble foam material, a water-soluble film material, or a composite material including a water-soluble nonwoven material, a water-soluble foam material, and / or a water-soluble film material. In an exemplary embodiment, the outer water-soluble material includes a dispersive barrier coating layer on the inner surface of the outer water-soluble material facing the water-soluble core substrate, formed, for example, with a film layer, formed by bonding the inner surfaces of the outer water-soluble material to form a substantially continuous smooth surface, or formed by applying a wax coating or hydrophobic material to the inner surface of the outer water-soluble material. Any suitable dispersive barrier coating is applied to the outer water-soluble material to facilitate reducing the transfer of the active cleaning formulation, e.g., laundry detergent, to the user's hands. At step 606, the water-soluble core substrate and the carrier solvent with the active cleaning formulation are introduced into the interior volume. In an exemplary embodiment, at step 608, the outer water-soluble material is sealed to enclose the interior volume. For example, a seal may be formed at the bond interface to enclose the water-soluble core substrate and the active cleaning formulation in the interior volume.

[0076] In an exemplary embodiment, the step of forming a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin includes forming the water-soluble nonwoven substrate into a plurality of layers and disposing a carrier solvent and an active cleaning formulation between adjacent layers of the plurality of layers. In an exemplary embodiment, a continuous sheet of the water-soluble nonwoven web is folded into a serpentine construction to form a plurality of layers, or a plurality of separate substrate sheets are laminated into a stacked construction. A carrier solvent comprising glycerin containing an active cleaning formulation is applied to the surface of the water-soluble nonwoven substrate to a maximum coating weight of 120 gsm as a carrier solvent containing an active cleaning formulation, for example, until the single unit dose article contains 55% by weight of the active cleaning formulation. In an exemplary embodiment, the water-soluble nonwoven substrate is formed into 25 to 110 layers.

[0077] In an exemplary embodiment, a method of making a single unit dose article containing a carrier solvent with an active cleaning formulation includes forming a water-soluble foam substrate containing a water-soluble resin. The water-soluble foam substrate contains a carrier solvent with an active cleaning formulation, and upon contact of the carrier solvent with the water-soluble foam substrate, the water-soluble foam substrate exhibits a carrier solvent absorption capacity of 1% to 1300%. For example, the water-soluble foam substrate exhibits a carrier solvent absorption capacity in the range of 10% to 1000%, 10% to 500%, 10% to 200%, or 10% to 100%. In an exemplary embodiment, an outer water-soluble material, including at least one of a water-soluble nonwoven material, a water-soluble foam material, a water-soluble film material, or a composite thereof, is formed into an open pouch defining an interior volume configured to contain the water-soluble foam substrate and the carrier solvent with the active cleaning formulation. The water-soluble foam substrate and the carrier solvent with the active cleaning formulation are introduced into the interior volume, and in an exemplary embodiment, the outer water-soluble material is sealed to enclose the interior volume. Water-soluble film and fiber forming materials

[0078] Water-soluble polymers used in the water-soluble fibers, water-soluble nonwoven webs, water-soluble foams, and water-soluble films include, but are not limited to, polyvinyl alcohol (PVOH) polymers, 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.

[0079] 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 above about 140°F (about 60°C). If a sufficient number of acetate groups are left 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 below about 50°F (about 10°C). Thus, the partially hydrolyzed polymer is a vinyl alcohol-vinyl acetate copolymer, which is a PVOH copolymer, but is generally referred to as PVOH.

[0080] In certain 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, in some embodiments, is 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 generally 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. The term "PVOH fiber" as used herein refers to a fiber that includes a PVOH polymer.

[0081] 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.

[0082] 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 may be considered as 0, while the degree of hydrolysis of a polyvinyl alcohol homopolymer may be considered as 100%. The degree of hydrolysis of a copolymer of vinyl acetate and vinyl alcohol is equal to the percentage of vinyl alcohol moieties among the sum of vinyl acetate and vinyl alcohol moieties, which is between 0 and 100%.

[0083] 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 polymer comprises an anionically modified polyvinyl alcohol.

[0084] 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.

[0085] 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%).

[0086] 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.

[0087] The degree of hydrolysis (DH) of the PVOH homopolymers and PVOH copolymers (including modified PVOH copolymers) included in the water soluble fibers, foams, and films of the present disclosure can 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 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 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%.

[0088] The degree of hydrolysis of the polymer blends was calculated as the arithmetically weighted average degree of hydrolysis (

number

number

number

[0089] 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

[0090] In embodiments, the PVOH resin may have a viscosity of about 1.0 to about 50.0 cP, about 1.0 to about 40.0 cP, or about 1.0 to about 30.0 cP, such as about 4 cP, 8 cP, 15 cP, 18 cP, 23 cP, or 26 cP. In 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. The PVOH homopolymer and / or copolymer may have a viscosity of 5 cP, 10 cP, 11 cP, 12 cP, 13 cP, 14 cP, 15 cP, 17.5 cP, 18 cP, 19 cP, 20 cP, 21 cP, 22 cP, 23 cP, 24 cP, 25 cP, 26 cP, 27 cP, 28 cP, 29 cP, 30 cP, 31 cP, 32 cP, 33 cP, 34 cP, 35 cP, or 40 cP. In embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 21 cP to 26 cP. In embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 5 cP to about 14 cP. In embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 5 cP to about 23 cP.

[0091] 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)) that comprises one or more types of anionic monomer units, and a second PVOH polymer ("second PVOH polymer"), which can comprise a PVOH copolymer or a modified PVOH copolymer (e.g., a PVOH ter (or higher copolymer) that comprises 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 and second PVOH polymers 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 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. biodegradable

[0092] 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 in the polymer sequence, the higher the degradation activity. Without being bound by theory, it is believed that in soil and / or compost biodegradation, nonwoven webs prepared from polyvinyl alcohol fibers will have a higher biodegradation activity level relative to water-soluble films prepared from similar polyvinyl alcohol polymers due to the increased polymer surface area provided by the nonwoven web relative to the film. Furthermore, without wishing to be bound by theory, it is believed that while the degree of polymerization of a polyvinyl alcohol polymer has little or no effect on the biodegradability of a film, foam or nonwoven web prepared with the polymer, the polymerization temperature may affect the biodegradability of the film, foam or nonwoven 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 leading to the accumulation of the chains as amorphous aggregates, thereby decreasing the availability of ordered polymer structures and biodegradation activity would be predicted to decrease the soil and / or compost biodegradation mechanisms 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.

[0093] 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).

[0094] In an exemplary embodiment, 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 an exemplary embodiment, the fibers meet the ready biodegradation standard. In an exemplary embodiment, the films herein meet the ready biodegradation or enhanced degradation standard. In an exemplary embodiment, the laminates (nonwoven and film, or foam and film) used herein meet the ready biodegradation or enhanced biodegradation standard. Carrier Solvent

[0095] In an exemplary embodiment, the carrier solvent comprises a polar solvent. In an exemplary embodiment, the solvent comprises octanol, heptanol, hexanol, pentanol, butanol, propanol, tetrahydrofuran, dichloromethane, acetone, ethanol, N-methylpyrrolidone, methanol, acetonitrile, ethylene glycol, N,N-dimethylformamide, glycerin, dimethylsulfoxide, formic acid, water, or a combination thereof. In an exemplary embodiment, the carrier solvent comprises n-octanol, n-heptanol, n-hexanol, n-pentanol, n-butanol, isobutanol, sec-butanol, tert-butanol, n-propanol, isopropanol, acetone, ethanol, N-methylpyrrolidone, methanol, acetonitrile, N,N-dimethylformamide, dimethylsulfoxide, formic acid, water, or a combination thereof. In an exemplary embodiment, the carrier solvent comprises n-propanol, acetone, ethanol, N-methylpyrrolidone, methanol, acetonitrile, N,N-dimethylformamide, dimethylsulfoxide, formic acid, water, or a combination thereof. In an exemplary embodiment, the carrier solvent comprises an alcohol that is liquid under the mixed conditions. In an exemplary embodiment, the carrier solvent comprises methanol. In an exemplary embodiment, the carrier solvent comprises methanol and at least one additional solvent. In an embodiment, the carrier solvent comprises methanol and water. In an exemplary embodiment, the carrier solvent comprises at least one of butanol, pentanol, hexanol, heptanol, and octanol in combination with water. In an exemplary embodiment, the carrier solvent comprises DMSO and water. In an exemplary embodiment, the carrier solvent comprises DMSO and water, the DMSO and water being provided in a weight ratio of about 40 / 60 to 80 / 20. Without wishing to be bound by theory, it is believed that as the amount of water is increased above 60% or the amount of DMSO is increased above about 80%, the interaction of the respective solvents with polyvinyl alcohol increases, resulting in increased swelling and gelling of the polymer.

[0096] In an exemplary embodiment, the carrier solvent comprises a non-polar solvent, hi an exemplary embodiment, the carrier solvent comprises hexane, cyclohexane, methylpentane, pentane, cyclopropane, dioxane, benzene, pyridine, xylene, toluene, diethyl ether, chloroform, or a combination thereof.

[0097] In an exemplary embodiment, the carrier solvent comprises a mixture of a first carrier solvent and a second carrier solvent. In an exemplary embodiment, the first carrier solvent comprises a polar solvent and the second carrier solvent comprises a non-polar solvent. In an exemplary embodiment, the first carrier solvent has a first dielectric constant and the second carrier solvent has a second dielectric constant, the dielectric constant of the first carrier solvent being different, e.g., higher, than the dielectric constant of the second carrier solvent. In an exemplary embodiment, the first dielectric constant is 5 or less, 4 or less, 3 or less, or 2 or less. In an exemplary embodiment, the second dielectric constant is greater than 5, greater than 7.5, greater than 10, greater than 15, greater than 18, greater than 20, greater than 25, or greater than 30. In an exemplary embodiment, the difference between the first dielectric constant and the second dielectric constant is at least 3, at least 5, at least 8, or at least 10. In exemplary embodiments, when the carrier solvent comprises a mixture of a first carrier solvent and a second carrier solvent, the first carrier solvent and the second carrier solvent can be provided in any ratio, provided that the fibers are not soluble in the mixture before, during, and after treatment. In exemplary embodiments, the first carrier solvent and the second carrier solvent can be provided in a weight ratio of about 99 / 1 to about 1 / 99, about 95 / 5 to about 5 / 95, about 90 / 10 to 10 / 90, about 85 / 15 to about 15 / 85, about 80 / 20 to about 20 / 80, about 75 / 25 to about 25 / 75, about 70 / 30 to about 30 / 70, about 65 / 35 to about 35 / 65, about 60 / 40 to about 40 / 60, about 55 / 45 to about 45 / 55, or about 50 / 50. Active Cleansing Formula

[0098] In an exemplary embodiment, the SUD article, particularly the water-soluble core substrate, is configured to contain one or more active cleaning formulations, such as laundry detergent formulations. In an exemplary embodiment, the active cleaning formulations are disposed or coated on one or more surfaces of the water-soluble core substrate, or embedded and / or adhered to the water-soluble core substrate. The water-soluble core substrate may comprise a single layer, such as a single layer foam core substrate, or may comprise multiple layers, such as a sheet of nonwoven core substrate folded or stacked in a serpentine arrangement, to form a layer containing the active cleaning formulation disposed between adjacent layers of the water-soluble nonwoven core substrate. By way of example, the active cleaning formulation may comprise, but is not limited to, an active, laundry detergent, soap, fabric softener, bleach, laundry enhancer, stain remover, optical brightener, or water softener. Other examples include dish detergent, soap or cleaner, shampoo, conditioner, body wash, face wash, skin lotion, skin treatment, body oil, fragrance, hair treatment, bath salts, essential oil, bath bomb, or enzymes. In certain exemplary embodiments, the water-soluble core substrate is encapsulated by a water-soluble nonwoven material, a water-soluble foam material, and / or a water-soluble film material. Adjuvants

[0099] In general, the fibers, nonwoven webs, foams and / or water-soluble films of the present disclosure, along with the film, foam 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 bittering agents (e.g., sodium bisulfite, sodium bisulfite, or the like), and the like. For example, the composition may include adjuvants such as, but not limited to, denatonium salts, e.g., denatonium benzoate, denatonium saccharides, and denatonium chloride; sucrose octaacetate; quinines; flavonoids, e.g., quercetin and naringen; and cassinoids, e.g., cassine and brucine; and pungent agents, e.g., capsaicin, piperine, allyl isothiocyanate, and resinferratoxin, and other functional ingredients, 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.

[0100] In embodiments, the fibers, foams and / or films may be free of adjuvants. As used herein and unless otherwise specified, "free of adjuvants" with respect to fibers means that the fibers contain less than about 0.01 wt.%, less than about 0.005 wt.%, or less than about 0.001 wt.% of adjuvants based on the total weight of the fibers. As used herein and unless otherwise specified, "free of adjuvants" with respect to films or nonwoven webs means that the nonwoven web contains less than about 0.01 wt.%, less than about 0.005 wt.%, or less than about 0.001 wt.% of adjuvants based on the total weight of the film, foam or nonwoven web. In embodiments, the water-soluble fibers contain a plasticizer. In embodiments, the water-soluble fibers contain a surfactant. In embodiments, the water-insoluble fibers contain a plasticizer. In embodiments, the water-insoluble fibers contain a surfactant. In embodiments, the nonwoven web contains a plasticizer. In embodiments, the nonwoven web contains a surfactant.

[0101] 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 polymers 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.

[0102] 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.

[0103] Surfactants for use in films are well known in the art and may 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 cleaning aids. Suitable surfactants may include nonionic, cationic, anionic, and zwitterionic classes. Suitable surfactants include, but are not limited to, sodium alkyl sulfates (sodium dodecyl sulfate) and other surfactants suitable for laundry applications as cleaning aids, propylene glycol, diethylene glycol, monoethanolamines, polyoxyethylated polyoxypropylene glycols, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylenic glycols, and alkanolamides (nonionic), polyoxyethylated amines, quaternary ammonium salts, and quaternized polyoxyethylated amines (cationic), alkali metal salts of higher fatty acids containing from 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, alkali metal salts of higher fatty acids containing about 8 to 24 carbon atoms, alkyl sulfates, alkyl polyethoxylate sulfates, alkyl benzene sulfonates, monoethanolamines, lauryl alcohol ethoxylates, propylene glycol, diethylene glycol, sodium cocoyl isethionate, sodium lauryl sulfate, glucotaine, phenamides, cola lipids, cocamides, such as cocamide ethanolamine, ethylene oxide-based surfactants, saponified avocado and palm oils, their salts, and any combination of the above.In an embodiment, the surfactant comprises cocamides.Without being bound by theory, it is believed that cocamides can aid in foam formation and enhance the foaming experience of articles containing personal care compositions. In various embodiments, the amount of surfactant in the fiber ranges from about 0.01% to about 10%, from about 0.1% to about 5%, from about 1.0% to about 2.5%, from about 0.01% to about 1.5%, from about 0.1% to about 1%, from about 0.01% to 0.25%, or from about 0.10% to 0.20% by weight. In various embodiments, the amount of surfactant in the personal care composition contained within the pouch can range from about 5% to about 50%, from about 10% to about 45%, or from about 10% to about 40% by weight.

[0104] In embodiments, the nonwoven webs, foams and / or films of the present disclosure may further comprise adjuvants, such as one or more of the following groups: exfoliants (chemical and mechanical exfoliants), microcapsules of fragrance and / or perfume, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiling agents, and cosmetic agents.

[0105] In embodiments, the adjunct is provided in or on one or more of the nonwoven web, foam, fibers, and water-soluble film. In embodiments, the active cleaning formulation is provided on or in one or more of the group of the nonwoven web, fibers, and water-soluble film. In embodiments, the one or more adjuncts can be provided on the surface of the nonwoven web. In embodiments, the one or more adjuncts can be dispersed within the fibers of the nonwoven web. In embodiments, the one or more adjuncts can be dispersed on the surface of the nonwoven web. In embodiments, the one or more adjuncts can be dispersed in the fibers. In embodiments, the one or more adjuncts can be dispersed on the fibers. In embodiments, the one or more adjuncts can be provided on the surface of the water-soluble film. In some embodiments, the one or more adjuncts can be dispersed within the water-soluble film. In embodiments, the nonwoven web in the form of a pouch has an outer surface facing outward from the inner volume, and the active cleaning formulation is provided on the outer surface. In embodiments, the nonwoven web in the form of a pouch has an outer surface facing outward from the inner volume, and the one or more adjuncts are provided on the outer surface.

[0106] 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 may be provided in an amount of at least about 0.1% by weight, or in a range of about 0.1% to about 99% by weight, based on the weight of the polymer mixture (e.g., fiber-forming or film-forming material). In embodiments, the chemical exfoliants, mechanical exfoliants, fragrance and / or perfume microcapsules, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiler agents, and / or cosmetic agents may 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.

[0107] 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 embodiments, the enzymes can be encapsulated, for example, in the form of a nanoemulsion, nanocapsule, granule, or combinations thereof.

[0108] Enzymes for use in laundry and dishwashing applications can include one or more of proteases, amylases, lipases, dehydrogenases, transaminase, kinases, cellulases, mannases, peptidases, decarboxylases, isomerases, mutases, synthetases, synthases, and oxido-reductase enzymes, including oxido-reductase enzymes that catalyze the formation of bleach.

[0109] 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.

[0110] 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.

[0111] In embodiments, the nonwoven webs, foams, and / or films 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.

[0112] In embodiments, the nonwoven web, foam and / or film may include a colorant. Suitable colorants may 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.

[0113] Other embodiments may include one or more fragrances in the nonwoven webs, foams, and / or films of the present disclosure. As used herein, the term "fragrance" refers to any impartable material that is volatile enough to produce a scent. 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 also 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, or any combination thereof. 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 phenyletheyl 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-cyclohexen-1-one, 2,5-dimethyl-3-cyclohexen-1-one, 2,6,10-trimethyl-9-undecanal, 2-propenyl ester of hexanoic acid, 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-cyclohexen-1-one, 2,5 ... These include hexene-1-carbaldehyde, trans-4-decenal, decanal, 2-pentyl cyclopentanone, ethyl anthranilate, eugenol, 3-(3-isopropylphenyl)butanoal, methyl 2-octinoate, isoeugenol, cis-3-hexenylmethyl carbonate, linalool, methyl-2-nonynonate, benzoic acid 2-hydroxymethyl ester, nonal, octanal, 2-nonenenitrile, 4-nonanolide, 9-decen-1-ol, and 10-undecen-1-al. 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.

[0114] 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.

[0115] 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 embodiments, any of the perfume accords, perfume raw materials, or fragrances can be encapsulated in microcapsules, referred to as "perfume microcapsules" as used herein.

[0116] 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.

[0117] In embodiments, the nonwoven web, foam, and / or film may include an exfoliant. In embodiments, the exfoliant may include a chemical exfoliant or a mechanical exfoliant. Suitable mechanical exfoliants for use herein may 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 may include, but are not limited to, alpha hydroxyl acids, beta hydroxyl acids, enzymes, salicylic acid, glycolic acid, citric acid, malic acid, or combinations thereof.

[0118] 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

[0119] 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 an embodiment, the water-soluble fiber can include a PVOH copolymer fiber-forming material, a modified PVOH copolymer fiber-forming material, or a combination thereof. In an embodiment, the water-soluble fiber can include a single PVOH copolymer fiber-forming material or a blend of PVOH copolymer fiber-forming materials. In an embodiment, the water-soluble fiber can include a hot water soluble PVOH homopolymer fiber-forming material. In a further embodiment, the water-soluble fiber can include a PVOH copolymer fiber-forming material having a viscosity in the range of 5 cP to 23 cP and a degree of hydrolysis in the range of 86% to 92%.

[0120] In an embodiment, the water-soluble fiber may include the above-mentioned auxiliary agent. In an embodiment, the water-soluble fiber may be substantially free of the above-mentioned auxiliary agent. In an embodiment, the water-soluble fiber may include the above-mentioned plasticizer. The total amount of non-aqueous plasticizer provided in the water-soluble fiber 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% 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 embodiment, the water-soluble fiber includes glycerin, sorbitol, or a combination thereof. In an embodiment, the water-soluble fiber includes glycerin. In embodiments, the water soluble fiber includes sorbitol. In certain embodiments, the water soluble fiber can include glycerin, e.g., at about 10% by weight based on the total fiber weight, and sorbitol, e.g., at about 5% by weight based on the total fiber weight.

[0121] In 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.

[0122] In an embodiment, any of the auxiliary agents disclosed herein can be added to the fibers of the present disclosure. In a refinement of the above embodiment, the auxiliary agent can be added to the fiber-forming material before the formation of the fiber, so that the auxiliary agent is dispersed in the fiber. Additionally and / or alternatively, the auxiliary agent can be added to the surface of the fiber after the fiber is formed (e.g., dispersed on the fiber).

[0123] 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

[0124] 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 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.

[0125] In an embodiment, the water-insoluble fiber can include the above-mentioned auxiliary agent. In an embodiment, the water-insoluble fiber can be substantially free of the above-mentioned auxiliary agent. In an embodiment, the water-insoluble fiber can include the above-mentioned plasticizer. The total amount of non-water-soluble 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 embodiment, the water-insoluble fiber includes glycerin, sorbitol, or a combination thereof. In embodiments, the water insoluble fiber includes glycerin. In embodiments, the water insoluble fiber includes sorbitol. In certain embodiments, 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.

[0126] In 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.

[0127] In an embodiment, any of the adjuncts disclosed herein can be added to the fibers of the present disclosure. In a refinement of the above embodiment, it can be added to the fiber-forming material prior to the formation of the fiber, so that the adjunct can be added to the surface of the fiber after the fiber is formed. In a refinement of the above embodiment, the adjunct can be added to the surface of the fiber after the fiber is formed.

[0128] 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

[0129] The nonwoven web or nonwoven substrate of the present disclosure may be water soluble, water insoluble, or at least partially water insoluble. The unit dose article of the present disclosure may include a nonwoven web, at least a portion of which is soluble in water at a temperature ranging from about 0° C. to about 20° C. according to MSTM-205, or at least a portion of which is not soluble in water at or below 20° C. according to MSTM-205, or the nonwoven web is not soluble in water at or below 20° C. according to MSTM-205, or the nonwoven web is soluble in water at a temperature ranging from about 0° C. to about 20° C. according to MSTM-205. It is understood that "at least a portion" of the nonwoven web refers to the fiber type that is soluble (or not soluble) at a given temperature when the nonwoven web comprises a plurality of fibers and that fiber type is provided in the nonwoven as the sole fiber type, and the nonwoven web made of that fiber type is soluble (or not soluble) at a given temperature according to MSTM-205.

[0130] 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 embodiments, the plurality of fibers are randomly arranged (i.e., have no orientation). In embodiments, the plurality of fibers are arranged in one direction. In 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.

[0131] 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 embodiments that include 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 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 embodiments, the plurality of fibers can include two or more types that include at least one type of water-insoluble fiber-forming material.

[0132] In embodiments, the nonwoven web may further comprise any of the adjuncts disclosed herein with respect to the fibers and / or films. In embodiments, the adjuncts 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 combinations thereof. Adjuncts added to the fibers during carding may be distributed throughout the nonwoven web. Adjuncts added to the nonwoven web after carding but before bonding may be selectively added to one or both sides of the nonwoven web.

[0133] The adjuvant may be applied by any suitable means to one or more surfaces of the nonwoven web or to the article containing it, such as a packet. In an embodiment, the adjuvant is in powder form. In a refinement of the previous embodiment, one or more stationary powder spray guns are used to direct a powder stream towards the web or packet from one or more directions while the web or packet is transported through the coating zone using a belt conveyor. In an embodiment, the web or packet is conveyed through a suspension of powder in air. In an embodiment, the web or packet is tumble mixed with the powder in a trough-like device. In an embodiment that can be combined with any other embodiment, electrostatic forces are used to enhance the attraction between the powder and the packet or web. This type of process may be based on negatively charging the powder particles and directing these charged particles towards a grounded packet or web. In other alternative embodiments, the powder is applied to the web 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 web or packet. In yet another embodiment, the powder is applied by dissolving or suspending the powder in a non-aqueous solvent or carrier, which is then atomized and sprayed onto the web or packet. In one embodiment, the solvent or carrier subsequently evaporates, leaving behind the active agent powder. In certain embodiments, the powder is applied to the web 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, batchwise or continuously as needed. The web or packet 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 dosage of the powder to the web or packet. The web or packet can then be transported to an appropriate secondary packaging process.

[0134] In embodiments where the adjuvant is in liquid form or in solution, the foregoing can be dispersed within the fibers, dispersed onto the surface of the nonwoven web, 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 nonwoven web, are in an amount of at least about 0.1% by weight, or in a range of about 0.1% to about 99% by weight, and provide additional functionality to the nonwoven web. 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 be in 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 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.

[0137] In embodiments, the nonwoven web can include any of the surfactants disclosed herein. In embodiments, 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.

[0138] The nonwoven web 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 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, for example, 50 μm, 65 μm, 76 μm, 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, for example, 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, the solubility of the nonwoven web is not believed to be dependent on the thickness of the web, in contrast to water-soluble films, where the solubility of the film may depend on the thickness of the film. 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.

[0139] 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 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 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 rubber-like hand), improved aesthetics (i.e., less gloss than water-soluble films), and / or ease of processability for thermoformed and / or vertically formed, filled and sealed, and / or multi-chambered packets that require the web to be pulled along the surface of a processing tool / mold. Thus, the water-soluble and / or water-insoluble fibers should be sufficiently rough to provide surface roughness to the resulting nonwoven web without being so rough that it causes drag.

[0140] The water solubility of the nonwoven web of the present disclosure is a function of the type of fiber(s) used to prepare the web as well as the basis weight of the web. Without 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%.

[0141] The modification of the PVOH polymer 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 copolymer 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 by blending fibers into the nonwoven web. Furthermore, as described herein, nonwoven webs may contain multiple fibers, and in some cases, may contain two or more fiber types with different solubilities.

[0142] 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 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 disrupting the web structure and / or increasing the pore size of the pores in the nonwoven web. The greater the disruption of the web structure or the larger the pore size, the faster water can access the pouch contents and the faster the pouch contents will be released. Similarly, extended release of the pouch contents containing 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 disrupted, and the less soluble fibers have a larger exposed surface area, facilitating dissolution of the less soluble fibers and release of the pouch contents. In embodiments in which the nonwoven web comprises water soluble and water insoluble fibers, the ratio of soluble 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 embodiments, the plurality of fibers comprises about 10% to about 80% water soluble fibers, with the remainder being water insoluble fibers, based on the total weight of the fibers.

[0143] In an 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 a particular embodiment, the plurality of fibers can include water-insoluble fibers that form a material that is biodegradable. In an 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 embodiment, the nonwoven web is water-insoluble and biodegradable.

[0144] In 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.

[0145] The nonwoven webs disclosed herein can include composite materials including 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 an embodiment, the first fiber type may comprise a composite material comprising a PVOH homopolymer fiber-forming material, a PVOH copolymer fiber-forming material, a modified PVOH copolymer fiber-forming material, or a combination thereof. In an embodiment, 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 an embodiment, 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 an embodiment, 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 an embodiment, the first fiber type and / or the second fiber type are water-insoluble fiber-forming materials. In an 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 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 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 PVOH copolymer fiber forming materials and modified PVOH copolymer fiber forming materials.In an embodiment, the second fiber type comprises two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a combination of a PVOH copolymer fiber-forming material and a modified PVOH copolymer fiber-forming material.

[0146] 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 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 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.

[0148] 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 an embodiment, 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 an embodiment, 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.

[0149] 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 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 embodiment, the diameter of the fibers used to prepare the nonwoven web of the present disclosure has a substantially uniform diameter. In an 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.

[0150] The fibers used to prepare the nonwoven web of the present disclosure can be of any length. In embodiments, the length of the fibers can be in the range of about 30 millimeters (mm) to about 100 mm, about 10 mm to about 60 mm, or 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 an embodiment, 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 an embodiment, the fibers have an average length of about 30 mm to about 100 mm, or about 30 mm to about 60 mm. In an embodiment, 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.

[0151] 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 embodiments where 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.

[0152] Pore ​​size can be determined using high magnification and high order surface analytical techniques, including, but not limited to, Brunauer-Emmett-Teller theory (BET), and molecular adsorption.

[0153] 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.

[0154] 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.

[0155] 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 / m2 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.

[0156] 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).

[0157] 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

[0158] In an exemplary embodiment, suitable water-soluble foams include any suitable resin chemistry, such as PVOH homopolymers; PVOH copolymers; modified PVOH copolymers, such as maleic anhydride (MA) modified PVOH copolymers, monomethyl maleate (MMM) modified PVOH copolymers, and AMPS (2-methylacrylamido-2-methylpropanesulfonic acid) modified PVOH copolymers; cellulose and cellulose derivatives; PVP; proteins; casein; soy; or any water dispersible or water soluble resin. In certain embodiments, the water-soluble foam substrate has a thickness of 3 microns to 3000 microns and can be formed using any suitable manufacturing process known in the foam manufacturing art, including, 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.

[0159] 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 embodiment, the auxiliary agent is in the form of a powder. In a refinement of the above 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 a coating zone using a belt conveyor. In an embodiment, the water-soluble foam substrate or packet is conveyed through a suspension of powder in air. In an embodiment, the water-soluble foam substrate or packet is tumble mixed with the powder in a trough-like device. In an embodiment that can 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.

[0160] In embodiments where the adjuvant is in liquid form or in solution, the foregoing can be dispersed into the water-soluble foam substrate, dispersed onto 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.

[0161] Adjuncts, such as chemical exfoliants, mechanical exfoliants, microcapsules of fragrances and / or perfumes, 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 0.1% by weight, or in a range of about 0.1% 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 perfumes, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiler agents, cosmetic agents, or combinations thereof can be in 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.

[0162] In embodiments, 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 with 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.

[0163] In embodiments, the water-soluble foam base can include any of the surfactants disclosed herein. In embodiments, 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.

[0164] 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.

[0165] 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 for thermoformed and / or vertically formed, filled and sealed, and / or multi-chambered packets that require the water-soluble foam substrate to be pulled along the surface of a processing tool / mold. Thus, the water-soluble and / or non-water-soluble fibers should be sufficiently rough to provide surface roughness to the resulting water-soluble foam substrate without being so rough that it causes dragging.

[0166] 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%.

[0167] The modification of the PVOH polymer 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.

[0168] The inclusion of water-insoluble fibers and / or water-insoluble fiber-forming materials in the fibers of the water-soluble foam substrate can also be used to design a water-soluble foam substrate 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 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 fibers, the water-soluble foam substrate containing water-soluble fibers and water-insoluble fibers will begin to disperse as the water-soluble fibers dissolve, 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 access the pouch contents and the faster the pouch contents will be released. Similarly, the extended release of the contents of the pouch containing the water-soluble foam substrate 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, and the less soluble fibers have a larger exposed surface area, facilitating the dissolution of the less soluble fibers and the release of the pouch contents. In embodiments in which the foam substrate comprises water soluble fibers 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 embodiments, the plurality of fibers comprises about 10% to about 80% water soluble fibers by weight of the total weight of the fibers, with the remainder being water insoluble fibers.

[0169] In an 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 a particular embodiment, the plurality of fibers can include water-insoluble fibers that form a material that is biodegradable. In an 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 embodiment, the nonwoven web is water-insoluble and biodegradable.

[0170] In 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.

[0171] In an exemplary embodiment, the water-soluble foam substrate 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 an embodiment, 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 an embodiment, 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 an embodiment, 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 an embodiment, 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 an embodiment, the first fiber type and / or the second fiber type are water-insoluble fiber-forming materials. In an embodiment, the first fiber type may comprise a water insoluble polymeric fiber forming material and the second fiber type may comprise a polyvinyl alcohol fiber forming material that, when provided as the sole fiber forming material of a nonwoven web or as a film, the resulting web or film is soluble by MSTM 205 in water at temperatures ranging from about 0° C. to about 20° C. In an embodiment, the first fiber type may comprise a water insoluble polymeric fiber forming material and the second fiber type may comprise a PVOH copolymer or modified copolymer fiber forming material that, when provided as the sole fiber forming material of a water soluble foam substrate, the resulting water soluble foam substrate is not soluble by MSTM 205 in water at temperatures of 20° C. or less. In an embodiment, the first fiber type comprises two or more PVOH copolymer fiber forming materials, two or more modified PVOH copolymer fiber forming materials, or a combination of a PVOH copolymer fiber forming material and a modified PVOH copolymer fiber forming material.In an embodiment, the second fiber type comprises two or more PVOH copolymer fiber-forming materials, two or more modified PVOH copolymer fiber-forming materials, or a combination of a copolymer fiber-forming material and a modified PVOH copolymer fiber-forming material.

[0172] 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 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.

[0173] 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.

[0174] 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.

[0175] 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.

[0176] 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.

[0177] 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).

[0178] 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

[0179] The water-soluble films described herein include any of the water-soluble polymers disclosed herein. In an embodiment, the water-soluble films of the present disclosure include polyvinyl alcohol (PVOH) resins, modified polyvinyl alcohol resins, or combinations thereof. In an 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 embodiment, the water-soluble films can include a single PVOH polymer or a blend of PVOH polymers. In an embodiment, the water-soluble films include a PVOH copolymer. In an embodiment, the water-soluble films include a hot water soluble PVOH copolymer. In an embodiment, the nonwoven web includes a surfactant and / or an exfoliant, the water-soluble films can include a PVOH copolymer with anionic modifications. In an embodiment, the water-soluble films can include a water-soluble polyvinyl alcohol copolymer or modified copolymer that, when provided in the film as the sole film-forming material, is soluble in water at temperatures ranging from about 0° C. to about 20° C. by MSTM 205. In an 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 lower by MSTM 205.

[0180] 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 embodiment, the water-soluble film can include PVOH homopolymers, PVOH copolymers, modified PVOH copolymers, or combinations thereof. In an 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%.

[0181] 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.

[0182] In an embodiment, the water-soluble film can include the above-mentioned auxiliary. In an embodiment, the water-soluble film can be substantially free of the above-mentioned auxiliary. In an embodiment, the water-soluble film can include the above-mentioned plasticizer. The total amount of non-aqueous plasticizer provided in the water-soluble film 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 embodiments, 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).

[0183] In embodiments, the water-soluble film can include the above-mentioned surfactant. In various embodiments, the amount of surfactant in the water-soluble film is in the range of about 0.01% to about 2.5% by weight, about 0.1% to about 2.5% by weight, about 1.0% to about 2.0% by weight, about 0.01% to 0.25% by weight, or about 0.10% to 0.20% by weight. In 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, or any combination thereof.

[0184] In embodiments, the water-soluble film adjuvants may include fillers / bulking agents / antiblocking agents / antiblocking agents. 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 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 above-mentioned starch components is not affected by including additional starch components that provide less benefit or no benefit to the water-soluble film.

[0185] 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

[0186] Wet-cooled gel spinning

[0187] In an embodiment, the plurality of water soluble fibers may 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.

[0188] The solvent in which the water-soluble polymer is dissolved can suitably be any solvent in which the water-soluble polymer is soluble. In an embodiment, the solvent in which the water-soluble polymer is dissolved comprises a polar aprotic solvent. In an embodiment, the solvent in which the water-soluble polymer is dissolved comprises dimethylsulfoxide (DMSO).

[0189] 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.

[0190] 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 shortening the 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 embodiment, at least one solvent exchange bath can consist essentially of the solvent in which the water-soluble polymer is not soluble.

[0191] The finished fiber may also be referred to as staple fiber, short cut fiber, or pulp. In an embodiment, finishing includes drying the extruded polymer mixture. In an 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.

[0192] In 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 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.

[0193] Thermoplastic Fiber Spinning

[0194] 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.

[0195] 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.

[0196] 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.

[0197] 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 an embodiment, the DP is less than 1,000.

[0198] Melt Spinning

[0199] Melt spinning is well known in the art and is understood to refer to both 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.

[0200] 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.

[0201] 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.

[0202] 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 uniformity from fiber to fiber, e.g., about 10% variation.

[0203] 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.

[0204] 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

[0205] 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.

[0206] The staple fibers are carded or airlaid and bonded to provide a nonwoven web. Carding and airlaid methods are well known in the art.

[0207] Methods of bonding nonwoven webs are well known in the art. For example, bonding can include thermal, mechanical, and / or chemical bonding. Thermal bonding can include, but is not limited to, 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.

[0208] 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.

[0209] 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.

[0210] 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.

[0211] 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 embodiment, the solvent is selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof. In an embodiment, the solvent is selected from the group consisting of water, glycerin, and combinations thereof. In an embodiment, the binder solution comprises a solvent selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof, and further comprises 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.).

[0212] In some embodiments, a second layer of fibers can be used to bond the nonwoven web. In 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

[0213] 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.

[0214] Calender lamination is achieved by applying heat and pressure. The conditions of calender lamination can be easily determined by those skilled in the art. 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 applied 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 higher than 235°C, polyvinyl alcohol-based fibers decompose. In an 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 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 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 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. 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.

[0215] 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 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 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.

[0216] The laminate of the present disclosure generally comprises a water-soluble film and a nonwoven web. In an 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 having 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 having 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 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 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 the 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 embodiments, the lamination degree is in the range of about 5% to about 25%. In embodiments, the lamination degree is in the range of about 50% to about 100%. Dissolution and Disintegration Test (Modified MSTM-205)

[0217] 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.

[0218] 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

[0219] 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.

[0220] 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.

[0221] Results should include: complete sample identification; individual and average disintegration and dissolution times; and the water temperature in which the samples were tested. I 補正 =I 測定 x (reference thickness / measured thickness) 1.93 [1] S 補正 =S 測定 x (reference thickness / measured thickness) 1.83 [2] Method for determining single fiber solubility

[0222] 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.

[0223] The solubility of a single fiber can also be characterized by the temperature of complete dissolution. The temperature of complete dissolution can be determined as follows: 0.2 g of 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

[0224] 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

[0225] 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)

[0226] 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.

[0227] 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

[0228] 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.

[0229] 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.

[0230] 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.

[0231] Shrinkage Percentage Calculation: Contracted length = initial length - final length [3] Fiber shrinkage (%) = (shrinkage length / initial length) × 100% [4] Nonwoven Shrinkage Percentage Test (MSTM)

[0232] The percent shrinkage of a nonwoven sheet when contacted with an appropriate amount of carrier solvent can be determined according to the percent shrinkage test for nonwovens under the MonoSol standard operating procedure.

[0233] The samples are prepared as follows: 1. Using a Cricut Maker machine, cut out a 2 inch x 2 inch (5.08 cm x 5.08 cm) square nonwoven sample. 2. Each nonwoven square was weighed. Prior to testing, the density (gsm) of each nonwoven square was calculated. 3. Cleaning formulations were made and diluted to different moisture concentrations. 4. The camera was set at a height of approximately 11.25 in (28.6 cm) to record the contraction of the WSNW.

[0234] Shrinkage testing was performed on the nonwoven samples as follows: 5. A square of the nonwoven (5.08 cm x 5.08 cm) was placed into a 100 x 1 mm Petri dish. 6. Heat the cleaning solution to the set temperature. 7. The Petri dish containing the sample was placed under the camera. To achieve a higher temperature, a hot plate was placed directly under the Petri dish to apply heat to maintain a constant temperature. 8. Once the cleaning solution had reached the ideal temperature, the camera was started to record. 9. 10 mL of cleaning solution was injected onto the nonwoven square. Once the cleaning solution covered the square, a 5 minute timer was started. 10. After 5 minutes, the final contraction was recorded along with any observations. 11. The initial and final areas of the squares were used to calculate the percentage of shrinkage. 12. Each set was repeated three times. 13. For shrinkage at 1 hour, nonwoven samples were measured 1 hour after initial exposure to the cleaning composition. To achieve a higher temperature, the exposed samples were placed in an oven at a set temperature and then removed after 1 hour for shrinkage measurement. Use of Single Unit Dose Articles

[0235] The single unit dose article of the present disclosure is suitable for various commercial applications. Commercial applications suitable for the single unit dose article of the present disclosure may include, but are not limited to, pouches and packets for delivering cleaning formulations including laundry detergents, soaps, fabric softeners, bleaches, laundry enhancers, stain removers, optical brighteners, or water softeners. In exemplary embodiments, the active cleaning formulation may include, but is not limited to, actives, detergents, surfactants, emulsifiers, chelating agents, soil suspension agents, stain release agents, enzymes, pH adjusters, builders, soil release polymers, structuring agents, free fragrances, encapsulated fragrances, preservatives, solvents, minerals, and / or any ingredients suitable for personal care, laundry detergents, dishwashing detergents, and / or household surface cleaners or cleansers. Other examples include dish detergents, soaps or cleaners, shampoos, conditioners, body washes, face washes, skin lotions, skin treatments, body oils, fragrances, hair treatments, bath salts, essential oils, bath bombs, or enzymes. The active cleaning formulation may be, for example, in the form of a solid, e.g., a powder or a plurality of granules or particles, a gel, a liquid, or a slurry formulation, or any suitable combination of a powder, solid, gel, liquid, or slurry formulation.

[0236] Additional applications of the unit dose articles of the present disclosure can include pouches and packets for delivering personal care products such as exfoliating materials, shampoos, conditioners, body washes, face washes, skin lotions, skin treatments, hair treatments, bath salts, essential oils, or combinations thereof.

[0237] Additional contemplated applications include those that can include a constant flow of water, such as car washing applications and / or dishwashing applications. Advantageously, in such applications, when at least a portion of the composition is released from the unit dose, the nonwoven web can be used to facilitate lathering and / or hard scrubbing to remove soils without damaging the surface being cleaned, such as the paint on a car or a nonstick cooking surface.

[0238] Additional contemplated applications include those where the active agents need to be kept separate until the point of use. Advantageously, the unit dose article of the present disclosure can contain a first active agent in a first interior volume formed by the water-soluble film, and a second active agent that can be contained in a second interior volume formed by the nonwoven web. The unit dose can be designed to (a) release the second active agent upon exposure to cooler water and the first active agent upon exposure to warmer water, such that the second active agent does not come into contact with the first active agent before the second active agent is released into the water, or (b) release the first active agent from the first interior volume prior to substantial dissolution of the nonwoven web, such that the first active agent and the second active agent come into contact / mix within the second interior volume before either composition is substantially released from the unit dose.

[0239] Additional contemplated applications may include those where the composition contained in the unit dose becomes stale or otherwise unsuitable over time, for example when exposed to oxygen, or where it is otherwise necessary to release the extract of the composition after use. Such applications may include, but are not limited to, tea leaves and pouched tobacco products. Advantageously, the unit dose of the present disclosure may provide a gas barrier to the water-soluble film to maintain freshness, which may dissolve at the time of use (e.g., with hot water, or by placing in the consumer's mouth and contact with saliva), allowing the release of the extract (e.g., caffeine, flavor, and / or tobacco extract) while leaving the solid portion of the composition (e.g., the leaf) contained within a water-insoluble, biodegradable or compostable nonwoven web. The nonwoven web may then be discarded as needed and allowed to biodegrade or be composted. Methods for Making Unit Dose Articles

[0240] Unit dose articles, including pouches and packets, may be made using any suitable equipment and methods. For example, single compartment pouches may be made using vertical form-fill, horizontal form-fill, or rotary drum-fill techniques commonly known in the art. Such processes may be either continuous or intermittent. The layered nonwoven web, film, or laminate structure may be moistened and / or heated to increase its malleability. The method may include the use of a vacuum to draw the layered nonwoven web, film, or laminate structure into a suitable mold. The vacuum to draw the nonwoven web, film, or laminate into the mold may be applied for about 0.2 to about 5 seconds, or about 0.3 to about 3, or about 0.5 to about 1.5 seconds when the layered nonwoven web, film, or laminate structure is on the horizontal portion of the surface. The vacuum may be adapted to provide a pressure, for example, in the range of 10 mbar to 1000 mbar, or in the range of 100 mbar to 600 mbar.

[0241] The mold in which the packet can be made can have any shape, length, width, and depth depending on the required dimensions of the pouch. The mold can vary in size and shape from one to the other as needed. For example, the volume of the final pouch can be from about 5 ml to about 300 ml, or from about 10 ml to 150 ml, or from about 20 ml to about 100 ml, with the mold size adjusted accordingly.

[0242] thermoforming

[0243] A thermoformable nonwoven web, film, or laminate is one that can be shaped by the application of heat and force. Thermoforming of a nonwoven web, film, or laminate structure is a process of heating a nonwoven web, film, or laminate structure, shaping it (e.g., in a mold), and then cooling the resulting nonwoven web, film, or laminate, which will result in the nonwoven web, film, or laminate retaining its shape, e.g., the shape of the mold. Heat may be applied using any suitable means. For example, the nonwoven web, film, or laminate may be directly heated by passing it under a heating element or through hot air before being applied to a surface or after being placed on the surface. Alternatively, it may be indirectly heated, e.g., by heating the surface or by attaching a hot article onto the nonwoven web, film, or laminate. In an embodiment, the nonwoven web, film, or laminate is heated using infrared radiation. The nonwoven web, film, or laminate may be heated to a temperature ranging from about 50° C. to about 150° C., about 50° C. to about 120° C., about 60° C. to about 130° C., about 70° C. to about 120° C., or about 60° C. to about 90° C. Thermoforming can be accomplished by any one or more of the following processes: manual draping of a heat-softened nonwoven web, film, or laminate over a mold, or pressure-induced forming (e.g., vacuum forming) of a softened nonwoven web, film, or laminate against a mold, or automatic high speed indexing of a freshly extruded sheet having a precisely known temperature into a forming and trimming station, or automatic placement, plugging, and / or pneumatic stretching, and pressure forming of the nonwoven web, film, or laminate.

[0244] Alternatively, the nonwoven web, film, or laminate can be wetted by any suitable means, such as directly by spraying the nonwoven web, film, or laminate with a wetting agent (including water, a polymeric composition, a plasticizer of the nonwoven web, film, or laminate composition, or any combination of the foregoing) before being applied to the surface or after being placed on the surface, or indirectly by wetting the surface or by depositing a wet article onto the nonwoven web, film, or laminate.

[0245] After the nonwoven web, film, or laminate is heated and / or wetted, it may be drawn into a suitable mold, preferably using a vacuum. Filling of the molded nonwoven web, film, or laminate may be accomplished by utilizing any suitable means. In an embodiment, the most preferred method will depend on the product form and the required filling speed. In an embodiment, the molded nonwoven web, film, or laminate is filled by an in-line filling technique. A second nonwoven web, film, or laminate is then used to close the filled open packet to form a pouch by any suitable method. This may be accomplished in a continuous constant motion while in a horizontal position. Closure may be accomplished by continuously feeding a second nonwoven web, film, or laminate through or onto the open packet, and then sealing the first and second nonwoven webs, films, or laminates together, typically in the area between the molds and therefore in the area between the packets.

[0246] Sealing

[0247] Any suitable method of sealing the packet and / or its individual compartments may be utilized. Non-limiting examples of such means include heat sealing, solvent welding, solvent or wet sealing, and combinations thereof. Typically, only the areas to form the seal are treated with heat or solvent. Heat or solvent can be applied by any method, typically onto the closure material, and typically only onto the areas to form the seal. If solvent or wet sealing or welding is used, it is believed that heat is also applied. A preferred wet or solvent sealing / welding method involves selectively depositing a solvent onto the areas between the dies or onto the closure material, for example by spraying or printing onto these areas, and then applying pressure to these areas to form the seal. Sealing rolls and belts (which also provide heat if necessary) can be used, for example.

[0248] In an embodiment, the inner nonwoven web, foam, film, or laminate is sealed to the outer nonwoven web, film, or laminate by solvent sealing. The sealing solution is generally an aqueous solution. In an embodiment, the sealing solution comprises water. In an embodiment, the sealing solution comprises water and further comprises one or more diols and / or glycols, such as 1,2-ethanediol (ethylene glycol), 1,3-propanediol, 1,2-propanediol, 1,4-butanediol (tetramethylene glycol), 1,5-pantanediol (pentamethylene glycol), 1,6-hexanediol (hexamethylene glycol), 2,3-butanediol, 1,3-butanediol, 2-methyl-1,3-propanediol, various polyethylene glycols (e.g., diethylene glycol, triethylene glycol), and combinations thereof. In an embodiment, the sealing solution comprises erythritol, threitol, arabitol, xylitol, ribitol, mannitol, sorbitol, galactitol, fucitol, iditol, inositol, volemitol, isomer, maltitol, lactitol. In an embodiment, the sealing solution comprises a water soluble polymer.

[0249] The sealing solution can be applied to the interface area of ​​the inner nonwoven web, foam, film, or laminate in any amount suitable to bond the inner and outer nonwoven webs or laminates. As used herein, the term "coating weight" refers to the amount of sealing solution applied to the nonwoven web, foam, film, or laminate in grams of solution per square meter of nonwoven web, foam, film, or laminate. In general, if the coating weight of the sealing solvent is too low, the nonwoven web, foam, film, or laminate will not adhere properly and there is a risk of the pouch breaking as the seam increases. Furthermore, if the coating weight of the sealing solvent is too high, there is an increased risk of the solvent migrating from the interface area and an increased likelihood of forming etch holes in any film, including the sides of the pouch. The coating weight window refers to the range of coating weights that can be applied to a given film or laminate while maintaining both good adhesion and avoiding the formation of etch holes. A wide coating weight window is desirable because a wider window results in a robust seal under a wide range of operations. A suitable coating weight window is at least about 3 g / m 2 , or at least about 4 g / m 2 , or at least about 5 g / m 2 , or at least about 6 g / m 2 It is.

[0250] Cutting unit dose articles

[0251] The formed pouch may be cut by a cutting device. The cutting may be accomplished using any known method. It is also believed to be preferred that the cutting is performed continuously, preferably at a constant speed and preferably while in a horizontal position. The cutting device may be, for example, a sharp article, or a hot article, or a laser, whereby in the latter case the hot article or laser "burns through" the film / sealed area.

[0252] Vertical Form, Fill and Seal

[0253] In an embodiment, the nonwoven web, foam, film, or laminate of the present disclosure can be formed into a sealed article. In an embodiment, the sealed article is a vertical form filled and sealed article. The vertical form, fill, and seal (VFFS) process is a conventional automated process. The VFFS includes an apparatus such as an assembly machine that wraps a single piece of nonwoven web, foam, film, or laminate around a vertically oriented feed tube. The machine heat seals or otherwise secures the opposing edges of the nonwoven web, foam, film, or laminate together to create a side seal of the nonwoven web, foam, film, or laminate or to form a hollow tube. The machine then heat seals or otherwise creates a bottom seal, thereby defining a container portion with an open top, and a top seal will be formed later. The machine introduces a specified amount of free-flowing product, e.g., an active cleaning formulation, into the container portion through the open top end. Once the container contains a desired amount of product, the machine advances the nonwoven web, foam, film, or laminate to another heat sealing device to, e.g., create a top seal. Finally, the machine advances the nonwoven web, film, or laminate to a cutter which cuts the film just above the top seal to provide a filled package.

[0254] In operation, the assembly machine advances the nonwoven web, foam, film, or laminate from a roll to form a package. Thus, the nonwoven web, foam, film, or laminate must be able to advance easily through the machine and must not adhere to the machine assembly or be so fragile that it will break during processing. EXAMPLES

[0255] As described herein, a single unit dose article may include one of the following constructs: (a) a disposable cold water soluble nonwoven sheet is folded or laminated into a layered construction and saturated with an active cleaning formulation, and in certain embodiments, the nonwoven sheet is encased in a water soluble nonwoven web or a water soluble foam or film material layer to act as a barrier and transport the active cleaning formulation to the consumer's hands or body, or to a surface; (b) a disposable cold water soluble cleaning sachet comprising a water soluble nonwoven substrate containing a bulk or loose active cleaning formulation in liquid, slurry or solid, e.g., powder form; (c) foam sheets, e.g., open cell or closed cell foam sheets, folded or laminated into a layered construction and saturated with an active cleaning formulation, and in certain embodiments, the foam sheets are encased in, for example, a water soluble nonwoven web or a water soluble foam or film material layer to act as a barrier and transport the active cleaning formulation to the consumer's hands or body, or to a surface; (d) a disposable water soluble nonwoven sheet containing an active cleaning formulation or having an active cleaning formulation adhered to a surface of the nonwoven sheet; (e) the water soluble nonwoven sheet is folded or laminated into a layered construction and saturated with the active cleaning formulation, and in certain embodiments, the nonwoven sheet is encased in a water soluble nonwoven web or a water soluble foam or film material layer that does not contain an active agent, for example, to act as a barrier and transport the active cleaning formulation to the consumer's hands or body, or to a surface; (f) disposable cold water soluble foam substrates (open or closed cell) having low or substantially no moisture laundry detergent on the surface of the foam substrate for cleaning garments, the foam substrate being dissolvable upon contact with cold water to deliver one or more cleaning agents to a water soluble nonwoven fabric for a "plastic free" or "natural" aesthetic, the outer surface of the foam substrate may be at least partially covered or encapsulated as the garment wash cycle is completed; (g) disposable cold water soluble foam substrates (open or closed cell) having a low moisture or substantially no moisture laundry detergent in the core or matrix of the foam substrate for cleaning garments, the foam substrate being dissolvable upon contact with cold water to deliver one or more cleaning agents, the exterior surface of the foam substrate may be at least partially covered or encapsulated in a water soluble nonwoven fabric for a "plastic free" or "natural" aesthetic upon completion of the garment wash cycle; (h) a disposable cold water soluble foam substrate (open or closed cell) having a low moisture or substantially no moisture laundry detergent on the surface of the foam substrate for cleaning garments, the foam substrate becoming dissolvable upon contact with cold water that delivers one or more cleaning agents as the garment wash cycle is completed; (i) a disposable cold water soluble foam substrate (open or closed cell) having a low moisture or substantially no moisture laundry detergent in the core or matrix of the foam substrate for cleaning garments, the foam substrate becoming dissolvable upon contact with cold water that delivers one or more cleaning agents as the garment wash cycle is completed; and (j) A core substrate comprising a water-soluble nonwoven web or sheet, a water-soluble foam substrate, or a water-soluble film substrate having an active cleaning formulation in the form of a solid, liquid, or slurry disposed or coated on the surface of the core substrate, adhered to the surface of the core substrate, embedded in the core substrate, or dispersed in the matrix of the core substrate, or any suitable combination thereof.

[0256] 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.

[0257] In an exemplary embodiment, the single unit dose article includes a water-soluble core substrate that includes a water-soluble resin. The water-soluble core substrate contains an active cleaning formulation. When the water-soluble core substrate contacts water having a temperature higher than 20° C., the water-soluble core substrate becomes soluble and releases the active cleaning formulation. In an exemplary embodiment, the water-soluble nonwoven material and / or the water-soluble film encapsulates the water-soluble nonwoven substrate. In certain embodiments, the water-soluble film is laminated to the water-soluble nonwoven material. The bond interface is configured to create a seal that encapsulates the water-soluble core substrate. The active cleaning formulation is in at least one of a powder, solid, liquid, gel, or slurry form. In an exemplary embodiment, the active cleaning formulation is disposed or embedded in the water-soluble core substrate. In an exemplary embodiment, the water-soluble core substrate is at least one of saturated with, coated with, or impregnated with the active cleaning formulation. In an exemplary embodiment, the active cleaning formulation is present in the water-soluble core substrate.

[0258] In an exemplary embodiment, the single unit dose article includes a water-soluble nonwoven substrate that includes a water-soluble resin. The water-soluble nonwoven substrate contains an active cleaning formulation. When the water-soluble nonwoven substrate contacts water having a temperature greater than 20° C., the water-soluble nonwoven substrate becomes soluble and releases the active cleaning formulation. In an exemplary embodiment, the water-soluble nonwoven material and / or the water-soluble film encapsulates the water-soluble nonwoven substrate. In an exemplary embodiment, the water-soluble film is laminated to the water-soluble nonwoven material. In certain embodiments, the bond interface is configured to create a seal that encapsulates the water-soluble nonwoven substrate and the active cleaning formulation. The active cleaning formulation is in at least one of the form of a powder, a solid, a liquid, a gel, or a slurry formulation. In an exemplary embodiment, the water-soluble nonwoven substrate includes a plurality of fibers saturated with the active cleaning formulation, an active cleaning formulation embedded in a plurality of fibers, and / or an active cleaning formulation disposed between adjacent layers of a plurality of layers. In an exemplary embodiment, the water-soluble nonwoven substrate is a continuous sheet of a water-soluble nonwoven web that is folded into a serpentine construction to form a plurality of layers. In other embodiments, the water soluble nonwoven substrate comprises a plurality of separate substrate sheets in a stacked construction. The plurality of fibers may be saturated with the active cleaning formulation, the active cleaning formulation may be embedded in the plurality of fibers, or the active cleaning formulation may be disposed, e.g., coated, on the surface of the water soluble nonwoven substrate or disposed, e.g., coated, on the surface of the plurality of fibers. In an exemplary embodiment, the water soluble nonwoven material defines an interior volume that encapsulates and contains the water soluble nonwoven substrate and the active cleaning formulation, e.g., a liquid active cleaning formulation.

[0259] In an exemplary embodiment, the single unit dose article includes a water-soluble foam substrate that includes a water-soluble resin. The water-soluble foam substrate contains an active cleaning formulation. When the water-soluble foam substrate contacts water having a temperature higher than 20° C., the water-soluble foam substrate becomes soluble and releases the active cleaning formulation. In an exemplary embodiment, the water-soluble nonwoven material and / or the water-soluble film at least partially encapsulates the water-soluble foam substrate. In certain embodiments, the water-soluble film is laminated to the water-soluble nonwoven material. In certain embodiments, the bonding interface is configured to create a seal that encapsulates the water-soluble core substrate. The active cleaning formulation may be in at least one of the following forms: powder, solid, liquid, gel, or slurry form. In certain embodiments, the water-soluble foam substrate is saturated with the active cleaning formulation, and the active cleaning formulation may be embedded in the water-soluble foam substrate, or the active cleaning formulation may be disposed, for example, coated, on the surface of the water-soluble foam substrate.

[0260] In an exemplary embodiment, the single unit dose article includes a first water-soluble nonwoven web comprising a first water-soluble resin and an opposing second water-soluble nonwoven web comprising a second water-soluble resin. An active cleaning formulation is disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web. When at least one of the first water-soluble nonwoven web or the second water-soluble nonwoven web contacts water having a temperature higher than 20°C, at least one of the first water-soluble nonwoven web or the second water-soluble nonwoven web becomes soluble and releases the active cleaning formulation. The active cleaning formulation may be in at least one of a powder, solid, liquid, gel, or slurry form. In certain embodiments, the bonded interface is configured to create a seal between the first water-soluble nonwoven web and the second water-soluble nonwoven web that defines an interior volume and encapsulates the active cleaning formulation within the interior volume. In an exemplary embodiment, a water-soluble film substrate is disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web. The active cleaning formulation may be embedded in the water-soluble film substrate or the active cleaning formulation is disposed, eg, coated, on the surface of the water-soluble film substrate.

[0261] In an exemplary embodiment, the single unit dose article includes a water-soluble material including a water-soluble resin. The water-soluble material is bonded at a bond interface along the edge of the water-soluble material that defines the interior volume of the single unit dose article. The active cleaning formulation is disposed in the interior volume. When the water-soluble material contacts water having a temperature higher than 20°C, the water-soluble material becomes soluble and releases the active cleaning formulation. In an exemplary embodiment, the water-soluble material includes one of a water-soluble nonwoven web or a water-soluble foam material. The active cleaning formulation may be in at least one of a powder, solid, liquid, gel, or slurry form. In an exemplary embodiment, the water-soluble material has a first surface facing the interior volume and an opposing second surface. The single unit dose article further includes a water-soluble film disposed on the first surface. In an exemplary embodiment, the water-soluble material includes a water-soluble composite material including a water-soluble film material made of a first water-soluble resin or a water-soluble foam material made of a second water-soluble resin that is coupled to one of the water-soluble nonwoven materials.

[0262] In an exemplary embodiment, a method for making a single unit dose article containing an active cleaning formulation includes the steps of forming a water-soluble core substrate, the water-soluble core substrate comprising a water-soluble resin and containing an active cleaning formulation, and when the water-soluble core substrate contacts with water having a temperature higher than 20°C, the water-soluble core substrate becomes soluble and releases the active cleaning formulation; forming an outer water-soluble material comprising at least one of a water-soluble nonwoven material, a water-soluble foam material, a water-soluble film material, or a composite material thereof into an open pouch defining an inner volume configured to contain the water-soluble core substrate and the active cleaning formulation; introducing the water-soluble core substrate and the active cleaning formulation into the inner volume; and sealing the outer water-soluble material to enclose the inner volume. In an exemplary embodiment, forming the water-soluble core substrate comprising a water-soluble resin and the water-soluble core substrate containing the active cleaning formulation includes forming one of a water-soluble nonwoven substrate, a water-soluble foam substrate, or a water-soluble film substrate. In an exemplary embodiment, forming the water-soluble core substrate includes forming the water-soluble nonwoven substrate into a plurality of layers and disposing the active cleaning formulation between adjacent layers of the plurality of layers. A continuous sheet of water-soluble nonwoven web may be folded into a serpentine construction to form a water-soluble nonwoven substrate with multiple layers, or multiple separate substrate sheets may be laminated, for example, into a stacked construction to form a water-soluble nonwoven substrate. In an exemplary embodiment, forming a water-soluble core substrate comprising a water-soluble resin, a water-soluble core substrate containing an active cleaning composition includes at least one of saturating the water-soluble core with the active cleaning composition, disposing the active cleaning composition on a surface of the water-soluble core substrate, coating the surface of the water-soluble core substrate with the active cleaning composition, embedding the active cleaning composition in the water-soluble core substrate, or impregnating the water-soluble core substrate with the active cleaning composition. In an exemplary embodiment, sealing the outer water-soluble material includes forming a seal at the bond interface that encapsulates the water-soluble core substrate and the active cleaning composition in the interior volume.

[0263] In the examples, the nonwoven substrate containing the active cleaning formulation and / or carrier solvent is described for illustrative purposes only as one example of the core substrate. The core substrate and the active cleaning formulation can have any composition and / or form described herein. For example, the core substrate can include a water-soluble nonwoven foam, and / or a film substrate or layer, or any combination thereof. One or more additional water-soluble nonwoven foams, or film substrates or layers, or any combination thereof, can be disposed thereon and used to seal the core substrate containing the cleaning formulation. Such a core substrate can include one or more PVOH polymers, such as vinyl alcohol-vinyl acetate copolymers. For example, in certain embodiments, the core substrate includes at least one nonwoven substrate 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 1:99 to about 75:25, about 5:95 to about 75:25, about 1:99 to about 50:50, about 5:95 to about 50:50, about 10:90 to about 50:50 by weight. In some embodiments, the first type of fiber and the second type of fiber are mixed together in at least one nonwoven. In some embodiments, at least one nonwoven substrate or layer comprises 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. The two types of fibers are in different nonwoven sheets.

[0264] In the single unit dose article described herein, the water-soluble core substrate may comprise multiple layers selected from nonwoven sheets, foam layers, films, or any combination thereof. The multiple layers may comprise separate sheets, such as nonwoven sheets in a stacked construction, or continuous layers, such as one nonwoven sheet folded into a serpentine construction. The active cleaning formulation may be disposed and / or embedded in the water-soluble core substrate. For example, upon contact with a carrier solvent at 20° C. for a period of 5 minutes or longer, the single dose article described herein or the core substrate therein exhibits a shrinkage rate in the range of 0.5% to 65%, for example, in the range of 0.5% to 25%.

[0265] In the single unit dose article described herein, the water-soluble core substrate may or may not contain the carrier solvent described. In certain embodiments, the carrier solvent may be used during the manufacturing process. The carrier solvent may be dried, and the resulting single unit dose article may not contain the carrier solvent. In alternative embodiments, the carrier solvent may be used during the manufacturing process and may also be present in the resulting single unit dose article. Fibers used

[0266] Two types of fibers, namely 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 1, were used as starting materials. These fibers have a uniform composition and additional properties shown in Table 1. In the examples described herein, fiber F1 contained a 50:50 mixture of fibers having finenesses of 1.7 dtex, 38 mm, and 2.2 dtex, 51 mm length, respectively, and fiber F2 contained a 50:50 mixture of fibers having finenesses of 1.4 dtex, 38 mm, and 2.2 dtex, 51 mm length, respectively. 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."

[0267] [Table 1]

[0268] Nonwoven core substrates were made using two types of fibers under different bonding conditions, such as calendar point bonding, as shown in Table 2. The two types of fibers were also mixed to make one type of nonwoven as the core substrate (referred to as a "blended nonwoven"). Unless otherwise noted, the samples have a point bond style.

[0269] [Table 2]

[0270] As shown in Table 1, the fibers F1 and F2 used in the experimental samples, for example, Example 1, Example 2, Example 3, Example 4 and Example 5 as shown in Table 2, are a first type fiber and a second type fiber, respectively, containing polyvinyl alcohol copolymer with a degree of hydrolysis of 88% and 96%. These two fibers were mixed and bonded to form a nonwoven sheet as a core substrate for the single unit dose article described herein. In Figures 16-19 and 23-24, the term "wt% of fiber F2" represents the weight content of fiber F2 in the total weight of fiber F1 and fiber 2 in the nonwoven sheet. Detergent formulations with a weight percentage of water ("xx") are represented in the format of "MS-LLD-xx". For example, detergent formulation MS-LLD-20 means that such detergent contains 20% by weight of water. Thus, the detergent formulation is miscible with water as formulated or during use and includes the active cleaning formulation of the present disclosure and surfactants, such as lauryl alcohol ethoxylate, alkali metal salts of higher fatty acids containing from about 8 to 24 carbon atoms, and propylene glycol. The detergent may also include a carrier solvent of the present disclosure, such as glycerin.

[0271] The dielectric constants of the detergent compositions used, containing 5%, 20%, 35%, 50% and 65% water by weight, were also measured at 25°C using a frequency of 100 kHz. The detergent composition containing 50% water was a gel and was difficult to place in the test cell for holding the liquid sample unless it was heated to 45°C. The dielectric constants of such detergent compositions were measured at both 45°C and 25°C. The measured dielectric constant values ​​of the detergent compositions used were 38.7, 395.0, 2016, 6458 and 7320, corresponding to water contents of 5%, 20%, 35%, 50% and 65% by weight, respectively. The dielectric constant increases linearly with the water content. For the experimental samples, their shrinkage in the detergent composition increases with the dielectric constant (i.e., polarity) of the detergent composition. The range of dielectric constants also illustrates the range of carrier solvents that can be used.

[0272] The samples did not show shrinkage at 45°C in detergent formulations with 5% by weight water. Shrinkage of these samples was observed in detergent formulations containing 20% ​​or more by weight water. Figure 16 shows the shrinkage results of these samples at 45°C in detergent formulations with 20% water. The test time was 5 minutes. As shown in Figure 16, increasing the fiber F2 content to 90% reduces the shrinkage at 5 minutes. The sample with a ratio of fibers F1:F2 of 10:90 (i.e., Example 4) has the lowest shrinkage. The nonwoven sample with only fiber F1 (i.e., Example 5) has a shrinkage about 6 times higher than that of the Example 4 sample. The nonwoven sample with only fiber F2 (i.e., Example 1) has a shrinkage about 1.9 times that of the Example 4 sample. These nonwoven samples continued to shrink after 5 minutes (albeit at a much slower rate). For example, the nonwoven sample having only fiber F1 (ie, Example 5) exhibited an additional 7.8% shrinkage over 1 hour.

[0273] FIG. 17 shows the shrinkage results in detergent formulations containing 35% water at 20° C., 35° C., and 45° C. for experimental samples including Example 1, Example 2, Example 3, Example 4, and Example 5, respectively. FIG. 17 shows the effect of the content (wt %) of fiber F2 in the total mass of fibers F1 and F2 on the shrinkage of the nonwoven samples. For all samples, shrinkage was observed at three temperatures in detergent formulations containing 35% water. As shown in FIG. 16, increasing the fiber F2 content to 90% reduces the shrinkage at 5 minutes. Samples with a content of fiber F2 ranging from about 75% to 90% have the lowest shrinkage. As the temperature increases, the shrinkage of the samples increases, but the shrinkage difference between samples containing fibers F1 and F2 decreases. At 45° C., the shrinkage of these nonwoven samples did not change after 5 minutes, but continued to increase at lower temperatures.

[0274] Similar to FIG. 17, FIG. 18 shows the shrinkage results of the experimental samples at 20° C., 35° C. and 45° C., respectively, in a detergent formulation containing 50% water. Such detergent formulation is a gel at 20° C., but fluid at 35° C. and 45° C. For all samples, shrinkage was observed in this detergent formulation at three temperatures. Similar to what was shown in FIG. 17, increasing the fiber F2 content to 90% reduces the shrinkage at 5 minutes. The sample containing 90% fiber F2 has the lowest shrinkage. At 45° C., the nonwoven samples showed similar shrinkage. The shrinkage of these nonwoven samples after 5 minutes did not continue to increase at 30° C. and 45° C., but continued to increase at 20° C.

[0275] Similar to FIG. 17, FIG. 19 shows the shrinkage results of the experimental samples in a detergent formulation containing 65% water at 20° C., 35° C., and 45° C., respectively. Shrinkage was observed for all samples in this detergent formulation at the three temperatures. Similar to those shown in FIGS. 17 and 18, increasing fiber F2 content to 90% reduces shrinkage within 5 minutes. Samples containing 90% of fiber F2 have the lowest shrinkage. In such detergent formulations, shrinkage is not very dependent on the test temperature, but most samples have shrinkage in the range of 78% to 86%. At 45° C., these nonwoven samples showed similar shrinkage. The shrinkage of these nonwoven samples after 5 minutes did not continue to increase at any of the three temperatures in such detergent formulations.

[0276] Figure 20 shows the shrinkage results of an exemplary sample including at least one nonwoven layer having multiple fibers (only fiber F1) with different basis weights in a detergent formulation with 35% water at 20°C. As shown in Figure 20, the shrinkage of the sample is independent of basis weight. This means that if the nonwoven layers have the same fiber content with the same bonding style, a denser water-soluble nonwoven layer will shrink at the same rate as a thinner water-soluble nonwoven layer. The same trend was observed for the solubility of the samples.

[0277] FIG. 21 shows shrinkage results (in a detergent formulation with 35% water at 20° C.) of example samples including at least one nonwoven layer having a plurality of fibers (only fiber F1) having a basis weight of 50 gsm including different bond styles including a point bond style and a daisy bond style that includes a higher density of bond points than the point bond style. The point bonded nonwoven layer shrinks 32.5% more under the same test conditions than a daisy bonded nonwoven layer having the same composition. The daisy bond is significantly denser than the point bond, resulting in a lower surface area in the detergent formulation and reduced shrinkage. A similar trend was observed for the solubility of these samples.

[0278] FIG. 22 shows disintegration time results in water at 20° C., 35° C. and 45° C. for experimental samples including Example 1, Example 2, Example 3, Example 4 and Example 5 with point bond style. FIG. 23 shows burst time results for the same exemplary samples at 20° C., 35° C. and 45° C. Burst time is defined as when the water soluble nonwoven sample develops holes in its structure. Disintegration time is when the water soluble nonwoven sample completely escapes from the sides and dissolves. As shown in FIG. 22, disintegration (solubility) time increased with increasing content of fiber F2 in F1 and F2 blend nonwovens. Dissolution time decreased with increasing temperature. At 20° C., samples containing 75% or more fiber F2 did not disintegrate within the maximum test time of 5 minutes.

[0279] FIG. 24 shows the disintegration time results (at 20° C., 35° C., 45° C.) of an exemplary sample including a core substrate including at least one nonwoven layer or sheet (including daisy binding, different basis weights) having a plurality of fibers including a first type of fiber ("F1") including a polyvinyl alcohol copolymer having a degree of hydrolysis of 88%. FIG. 25 shows the burst time results for the same exemplary sample at 20° C., 35° C., and 45° C. At 20° C., samples including 75% or more of fiber F2 do not disintegrate within the maximum test time of 5 minutes. The dissolution time decreases with increasing test temperature. The dissolution time is about 16 times shorter than that at 20° C.

[0280] Figures 26 and 27 compare burst and disintegration (solubility) time results for samples with the same composition but different bond styles in water at 20°C, 35°C and 45°C. The example sample included one nonwoven layer with multiple fibers (only fiber F1) having a basis weight of 50 gsm. The two different bond styles included a point bond style and a daisy bond style, which has a higher density of bond points than the point bond style. The nonwoven layer with point bonds dissolves much faster than its daisy bonded counterpart. For example, the dissolution time of the daisy bonded nonwoven layer sample is 67% longer at 20°C than the point bonded nonwoven layer sample. Such differences between the daisy and point bonded samples decrease with increasing temperature.

[0281] The following paragraphs further describe aspects of the present disclosure: 1. A single unit dose article comprising a water-soluble core substrate, The water-soluble core substrate comprises a plurality of fibers comprising a water-soluble resin and contains a carrier solvent comprising an active cleaning formulation; the core substrate exhibits a shrinkage percentage of 0.5% to 65% upon contact of at least one fiber of the plurality of fibers with a carrier solvent at a temperature in the range of 10° C. to 20° C. for a period of 5 minutes or longer; A single unit dose article in which the active cleaning formulation is disposed or embedded in a water-soluble core substrate. 2. The single unit dose article of clause 1, further comprising a water soluble nonwoven material encapsulating the water soluble core substrate. 3. The single unit dose article of clause 2, further comprising a water-soluble film encapsulating the water-soluble nonwoven substrate. 4. The single unit dose article of clause 3, wherein the water-soluble film is laminated to a water-soluble nonwoven material. 5. The single unit dose article of clause 2, further comprising a bonding interface configured to create a seal that encapsulates the water-soluble core substrate. 6. The single unit dose article of any of clauses 1-5, wherein the active cleaning formulation is in at least one of a solid, gel, liquid, gel or slurry form. 7. The single unit dose article of any of clauses 1-6, wherein the water-soluble core substrate is at least one of saturated with, coated with, or impregnated with the active cleaning formulation. 8. The single unit dose article of any of clauses 1-7, wherein the active cleaning formulation is present in a water-soluble core substrate. 9. The single unit dose article of any of clauses 1-8, wherein when the water-soluble core substrate is contacted with water having a temperature of at least 10° C., the water-soluble core substrate becomes soluble with MSTM-205 and releases the active cleaning formulation. 10. The single unit dose article of any of clauses 1-9, wherein the active cleaning formulation is substantially released from the water-soluble core substrate after contact with water having a temperature of at least 10° C. for 300 seconds or less. 11. The single unit dose article of any of clauses 1-10, wherein the resin is a polymer that includes vinyl alcohol moieties. 12. The single unit dose article of clause 11, wherein the polymer comprising a vinyl alcohol moiety comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. 13. The single unit dose article of clause 12, wherein the polyvinyl alcohol copolymer is a copolymer or an anionically modified copolymer of vinyl acetate and vinyl alcohol. 14. The single unit dose article of clause 13, wherein the anionically modified copolymer comprises a carboxylate, a sulfonate, or a combination thereof. 15. The single unit dose article of any of clauses 11-14, wherein the plurality of fibers comprises a polyvinyl alcohol copolymer having a degree of hydrolysis in the range of about 75% to about 89%. 16. The single unit dose article of any of clauses 11-14, wherein the plurality of fibers comprises two types of fibers comprising a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%, and the two types of fibers have differences in diameter, length, toughness, shape, stiffness, elasticity, solubility, color, or combinations thereof. 17. The single unit dose article of any of clauses 11-14, 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%. 18. The single unit dose article of clause 17, wherein the ratio of the first type of fibers to the second type of fibers ranges from about 1:99 to about 75:25 by weight. 19. The single unit dose article of clause 17, wherein the ratio of the first type of fibers to the second type of fibers ranges from about 5:95 to about 50:50 by weight. 20. The single unit dose article of any of clauses 17-19, wherein the water-soluble core substrate comprises at least one nonwoven sheet comprising a mixture of a first type of fiber and a second type of fiber. 21. The single unit dose article of any of clauses 17-19, wherein the water-soluble core substrate comprises multiple layers selected from nonwoven sheets, foam layers, films, or any combination thereof. 22. The single unit dose article of clause 21, wherein the multiple layers comprise separate sheets in a stacked construction or a continuous sheet folded into a serpentine construction. 23. A single unit dose article comprising a water soluble nonwoven substrate, The water-soluble nonwoven substrate comprises a plurality of fibers comprising a water-soluble resin and contains a carrier solvent comprising an active cleaning formulation; the nonwoven substrate exhibits a shrinkage percentage of 0.5% to 65% upon contact of at least one fiber of the plurality of fibers with a carrier solvent at a temperature in the range of 10° C. to 20° C. for a period of 5 minutes or longer; A single unit dose article in which the active cleaning formulation is disposed or embedded in a water-soluble core substrate. 24. The single unit dose article of clause 23, further comprising a water soluble nonwoven material encapsulating the water soluble nonwoven substrate. 25. The single unit dose article of clause 24, further comprising a water-soluble film encapsulating the water-soluble nonwoven substrate. 26. The single unit dose article of clause 25, wherein the water-soluble film is laminated to a water-soluble nonwoven material. 27. The single unit dose article of any of clauses 24-26, further comprising a bonding interface configured to create a seal that encapsulates the water soluble nonwoven substrate. 28. The single unit dose article of any of clauses 23-27, wherein the active cleaning formulation is in at least one of a solid, gel, liquid or slurry form. 29. The single unit dose article of any of clauses 23-28, wherein a plurality of fibers are saturated with the active cleaning formulation. 30. The single unit dose article of any of clauses 23-29, wherein the active cleaning formulation is embedded in a plurality of fibers. 31. The single unit dose article of any of clauses 23-30, wherein the water soluble nonwoven substrate comprises multiple layers and the active cleaning formulation is disposed between adjacent layers of the multiple layers. 32. The single unit dose article of clause 31, wherein the water soluble nonwoven substrate is a continuous sheet of a water soluble nonwoven web folded into a serpentine construction to form a plurality of layers. 33. The single unit dose article of clause 31, wherein the water soluble nonwoven substrate comprises a plurality of separate substrate sheets in a stacked construction. 34. The single unit dose article of any of clauses 31-33, wherein a plurality of fibers are saturated with the active cleaning formulation. 35. The single unit dose article of any of clauses 31-33, wherein the active cleaning formulation is embedded in a plurality of fibers. 36. The single unit dose article of clause 32, wherein the active cleaning formulation is disposed on a surface of the water-soluble nonwoven substrate and / or on a surface of the plurality of fibers. 37. The single unit dose article of any of clauses 31-36, further comprising a water soluble nonwoven material encapsulating the water soluble nonwoven substrate. 38. The single unit dose article of any of clauses 23-37, further comprising a water soluble nonwoven material defining an interior volume, the active cleaning formulation being a liquid active cleaning formulation contained within the interior volume. 39. The single unit dose article of any of clauses 23-38, wherein when the water soluble nonwoven substrate is contacted with water having a temperature of at least 10° C., the water soluble nonwoven substrate becomes soluble with MSTM-205 and releases the active cleaning formulation. 40. The single unit dose article of clause 39, wherein the active cleaning formulation is substantially released from the water soluble nonwoven substrate when the water soluble nonwoven substrate is contacted with water having a temperature of at least 10° C. for 300 seconds or less. 41. The single unit dose article of any of clauses 23-40, wherein the water soluble resin is a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. 42. The single unit dose article of clause 41, wherein the polyvinyl alcohol copolymer is a copolymer of vinyl acetate and vinyl alcohol or an anionically modified copolymer of vinyl acetate and vinyl alcohol. 43. The single unit dose article of clause 23, 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%. 44. The single unit dose article of clause 43, wherein the ratio of the first type of fibers to the second type of fibers ranges from about 1:99 to about 75:25 by weight. 45. A first water-soluble nonwoven web comprising a first water-soluble resin, and a second water-soluble nonwoven web comprising a second water-soluble resin; and a carrier solvent containing an active cleaning formulation disposed between a first water-soluble nonwoven web and a second water-soluble nonwoven web; 1. A single unit dose article comprising: A single unit dose article, wherein when at least one of the first water soluble nonwoven web or the second water soluble nonwoven web contacts water having a temperature greater than 10°C, at least one of the first water soluble nonwoven web or the second water soluble nonwoven web becomes soluble with MSTM-205 to release an active cleaning formulation disposed between the first water soluble nonwoven web and the second water soluble nonwoven web. 46. ​​The single unit dose article of clause 45, wherein the first water-soluble nonwoven web comprises a plurality of fibers comprising a first water-soluble resin, and the first water-soluble nonwoven web exhibits a shrinkage percentage of 0.5% to 65% upon contact of at least one fiber of the plurality of fibers with a carrier solvent at 20° C. for a period of 5 minutes or longer. 47. The single unit dose article of any of clauses 45-46, wherein the active cleaning formulation is in at least one of a solid, gel, liquid or slurry form. 48. The single unit dose article of any of clauses 45-47, further comprising a bonding interface configured to create a seal between the first water soluble nonwoven web and the second water soluble nonwoven web, defining an interior volume and enclosing the active cleaning formulation within the interior volume. 49. The single unit dose article of any of clauses 45-48, further comprising a water-soluble film substrate disposed between the first water-soluble nonwoven web and the second water-soluble nonwoven web. 50. The single unit dose article of clause 49, wherein the active cleaning formulation is embedded in a water-soluble film substrate. 51. The single unit dose article of any of clauses 49-50, wherein the active cleaning formulation is disposed on a surface of a water-soluble film substrate. 52. The single unit dose article of any of clauses 45-51, wherein the active cleaning formulation is substantially released from between the first water soluble nonwoven web and the second water soluble nonwoven web when at least one of the first water soluble nonwoven web or the second water soluble nonwoven web is contacted with water having a temperature of at least 10°C for 300 seconds or less. 53. A water-soluble material comprising a plurality of fibers, the fibers comprising a water-soluble resin, bonded at a bond interface along an edge of the water-soluble material, the fibers defining an interior volume of the single unit dose article; and A carrier solvent comprising an active cleaning formulation disposed in the interior volume. 1. A single unit dose article comprising: A single unit dose article, wherein when the water-soluble material comes into contact with water having a temperature greater than 10° C., the water-soluble material becomes soluble with MSTM-205 and releases the active cleaning formulation from the interior volume. 54. The single unit dose article of clause 53, wherein at least one fiber exhibits a shrinkage percentage of 0.5% to 65% upon contact of at least one fiber of the plurality of fibers with a carrier solvent. 55. The single unit dose article of any of clauses 53-54, wherein the water-soluble material comprises one of a water-...

Claims

1. 1. A single unit dose article comprising a water soluble core substrate, The water-soluble core substrate comprises a plurality of fibers comprising a water-soluble resin and contains a carrier solvent comprising an active cleaning formulation; the core substrate exhibits a shrinkage of 0.5% to 65% upon contact of at least one fiber of the plurality of fibers with the carrier solvent at a temperature in the range of 10° C. to 20° C. for a period of 5 minutes or longer; the active cleaning formulation is disposed or embedded in the water-soluble core substrate; the single unit dose article further comprises a water soluble nonwoven material encapsulating the water soluble core substrate or a water soluble film encapsulating the water soluble nonwoven substrate; A single unit dose article, wherein the water-soluble resin is a polymer that includes vinyl alcohol moieties.

2. the water-soluble film is laminated to the water-soluble nonwoven material; or 10. The single unit dose article of claim 1, wherein the unit dose article comprises a bonding interface configured to create a seal that encapsulates the water-soluble core substrate.

3. 10. The single unit dose article of claim 1, wherein the active cleaning formulation is in the form of a solid, gel, liquid, gel, or slurry.

4. the water-soluble core substrate is at least one of saturated with, coated with, or impregnated with the active cleaning formulation; or the active cleaning formulation is present in the water-soluble core substrate; or 10. The single unit dose article of claim 1, wherein the water-soluble core substrate becomes soluble according to MSTM-205 and releases the active cleaning formulation when the water-soluble core substrate contacts water having a temperature of at least 10°C.

5. 10. The single unit dose article of claim 1, wherein the active cleaning formulation is substantially released from the water-soluble core substrate after contact with water having a temperature of at least 10[deg.] C. for 300 seconds or less.

6. the polymer comprising a vinyl alcohol moiety comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof; or the polymer is a polyvinyl alcohol copolymer or an anionically modified copolymer of vinyl acetate and vinyl alcohol, or the polymer is an anionically modified copolymer and comprises a carboxylate, a sulfonate, or a combination thereof; or the plurality of fibers comprises a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%, or 10. The single unit dose article of claim 1, wherein the plurality of fibers comprises two types of fibers comprising a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 89%, and the two types of fibers have differences in diameter, length, tenacity, shape, stiffness, elasticity, solubility, color, or combinations thereof.

7. the plurality of fibers includes 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%, the ratio of the first type of fibers to the second type of fibers is in the range of about 1:99 to about 75:25 by weight; or the ratio of the first type of fibers to the second type of fibers is in the range of about 5:95 to about 50:50 by weight; or 10. The single unit dose article of claim 1, wherein the water soluble core substrate comprises at least one nonwoven sheet comprising a mixture of the first type of fibers and the second type of fibers.

8. the water-soluble core substrate comprises a plurality of layers selected from nonwoven sheets, foam layers, films, or any combination thereof; 8. The single unit dose article of claim 7, wherein the multiple layers comprise separate sheets in a stacked construction or a continuous sheet folded into a serpentine construction.

9. 1. A single unit dose article comprising a water soluble nonwoven substrate, The water-soluble nonwoven substrate comprises a plurality of fibers comprising a water-soluble resin and contains a carrier solvent comprising an active cleaning formulation; the nonwoven substrate exhibits a shrinkage of 0.5% to 65% upon contact of at least one fiber of the plurality of fibers with the carrier solvent at a temperature in the range of 10° C. to 20° C. for a period of 5 minutes or longer; said active cleaning formulation being disposed or embedded in a water-soluble core substrate; the unit dose article further comprises a water-soluble nonwoven material or a water-soluble film encapsulating the water-soluble nonwoven substrate; or the unit dose article is laminated to the water-soluble nonwoven material; or the unit dose article further comprises a bonding interface configured to create a seal that encapsulates the water soluble nonwoven substrate; The single unit dose article, wherein the water soluble resin is a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

10. 10. The single unit dose article of claim 9, wherein the active cleaning formulation is in the form of a solid, gel, liquid or slurry.

11. the plurality of fibers is saturated with the active cleaning formulation; or the active cleaning formulation is embedded in the plurality of fibers; or the water soluble nonwoven substrate comprises a plurality of layers, the active cleaning formulation being disposed between adjacent layers of the plurality of layers; or the water soluble nonwoven substrate is a continuous sheet of a water soluble nonwoven web that is folded into a serpentine construction to form the plurality of layers; or the water-soluble nonwoven substrate comprises a plurality of separate substrate sheets in a stacked construction; the plurality of fibers are saturated with the active cleaning formulation; or the active cleaning formulation is embedded in the plurality of fibers; or 10. The single unit dose article of claim 9, wherein the active cleaning formulation is disposed on a surface of the water soluble nonwoven substrate and / or on a surface of the plurality of fibers.

12. or further comprising a water soluble nonwoven material defining an interior volume, said active cleaning formulation being a liquid active cleaning formulation contained within said interior volume; When the water soluble nonwoven substrate is contacted with water having a temperature of at least 10° C., the water soluble nonwoven substrate becomes soluble according to MSTM-205 and releases the active cleaning formulation; or 10. The single unit dose article of claim 9, wherein the active cleaning formulation is substantially released from the water soluble nonwoven substrate when the water soluble nonwoven substrate is contacted with water having a temperature of at least 10°C for 300 seconds or less.

13. the polyvinyl alcohol copolymer is a copolymer of vinyl acetate and vinyl alcohol or an anionically modified copolymer of vinyl acetate and vinyl alcohol, or 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%, or 10. The single unit dose article of claim 9, wherein the ratio of the first type of fibers to the second type of fibers ranges from about 1:99 to about 75:25 by weight.

14. a first water-soluble nonwoven web comprising a first water-soluble resin, and a second water-soluble nonwoven web comprising a second water-soluble resin; and a carrier solvent containing an active cleaning formulation disposed between said first water soluble nonwoven web and said second water soluble nonwoven web; 1. A single unit dose article comprising: when at least one of said first water soluble nonwoven web or said second water soluble nonwoven web is contacted with water having a temperature greater than 10° C., said at least one of said first water soluble nonwoven web or said second water soluble nonwoven web becomes soluble with MSTM-205 and releases said active cleaning formulation disposed between said first water soluble nonwoven web and said second water soluble nonwoven web; A single unit dose article, wherein a water-soluble film substrate is disposed between said first water-soluble nonwoven web and said second water-soluble nonwoven web.

15. the first water-soluble nonwoven web comprises a plurality of fibers comprising the first water-soluble resin, and the first water-soluble nonwoven web exhibits a shrinkage percentage of 0.5% to 65% upon contact of at least one fiber of the plurality of fibers with the carrier solvent at 20° C. for a period of 5 minutes or longer; or the active cleaning formulation is in the form of a solid, gel, liquid or slurry, or the article further comprises a bonding interface configured to create a seal between the first water soluble nonwoven web and the second water soluble nonwoven web that defines an interior volume and encapsulates the active cleaning formulation within the interior volume; or the active cleaning formulation is embedded in the water-soluble film substrate; or 15. The single unit dose article of claim 14, wherein the active cleaning formulation is disposed on a surface of the water-soluble film substrate.

16. 15. The single unit dose article of claim 14, wherein the active cleaning formulation is substantially released from between the first water soluble nonwoven web and the second water soluble nonwoven web when the at least one of the first water soluble nonwoven web or the second water soluble nonwoven web is contacted with water having a temperature of at least 10°C for 300 seconds or less.

17. a water-soluble material comprising a plurality of fibers, the fibers comprising a water-soluble resin, bonded at a bond interface along an edge of the water-soluble material, the fiber defining an interior volume of the single unit dose article; and a carrier solvent comprising an active cleaning formulation disposed in said interior volume; 1. A single unit dose article comprising: when said water-soluble material comes into contact with water having a temperature greater than 10° C., said water-soluble material becomes soluble with MSTM-205 and releases said active cleaning formulation from said internal volume; The single unit dose article, wherein the water soluble resin is a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

18. the at least one fiber exhibits a shrinkage percentage of between 0.5% and 65% upon contact of at least one fiber of the plurality of fibers with the carrier solvent; or the water-soluble material comprises one of a water-soluble nonwoven web, a water-soluble foam material, or a water-soluble film material; or the active cleaning formulation is in the form of a solid, gel, liquid or slurry, or the water-soluble material has a first surface facing the interior volume and an opposing second surface, the single unit dose article further comprising a water-soluble film disposed on the first surface; or the water-soluble material comprises a water-soluble composite material comprising a water-soluble film material made with a first water-soluble resin linked to one of a water-soluble nonwoven material made with a second water-soluble resin or a water-soluble foam material; or the polyvinyl alcohol copolymer is a copolymer of vinyl acetate and vinyl alcohol or an anionically modified copolymer of vinyl acetate and vinyl alcohol, or the plurality of fibers includes 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%, 20. The single unit dose article of claim 17, wherein the ratio of the first type of fibers to the second type of fibers ranges from about 1:99 to about 75:25 by weight.

19. 1. A method of making a single unit dose article containing a carrier solvent with an active cleaning formulation, comprising: forming a water soluble core substrate, the water soluble core substrate comprising a plurality of fibers comprising a water soluble resin and containing a carrier solvent comprising an active cleaning formulation, the water soluble core substrate exhibiting a shrinkage of 0.5% to 65% upon contact of the carrier solvent with at least one fiber of the plurality of fibers at a temperature in the range of 10° C. to 20° C. for a period of 5 minutes or longer; forming an outer water-soluble material comprising at least one of a water-soluble nonwoven material, a water-soluble foam material, a water-soluble film material, or a composite thereof, into an open pouch defining an interior volume configured to contain said water-soluble core substrate and said carrier solvent comprising said active cleaning formulation; introducing the water-soluble core substrate and the carrier solvent containing the active cleaning formulation into the interior volume; and sealing the outer water-soluble material enclosing the interior volume. The method includes:

20. a water-soluble core substrate comprising a plurality of fibers comprising a water-soluble resin and containing an active cleaning formulation; and A water-soluble nonwoven material encapsulating said water-soluble core substrate.

1. A single unit dose article comprising: the active cleaning formulation is disposed or embedded in the water-soluble core substrate; The single unit dose article further comprises a water soluble film laminated to and encapsulating the water soluble nonwoven substrate, or the water soluble core substrate further comprises a carrier solvent comprising the active cleaning formulation.

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