Nonwoven water dispersible article for unit dose packaging

Abstract

To provide nonwoven water dispersible article for unit dose packaging.SOLUTION: The disclosure provides a nonwoven web, the nonwoven web includes a plurality of fibers including a blend of fiber forming materials, and the blend of fiber forming materials includes a first polyvinyl alcohol polymer. The blend of fiber forming materials further comprises a second polyvinyl alcohol polymer or does not include carboxymethyl cellulose, hydroxypropyl methylcellulose or starch. The nonwoven web can be water-dispersible, optionally water-soluble, and / or flushable. The disclosure further provides a pouch including a nonwoven web including a plurality of fibers according to the disclosure. In some embodiments, the water dispersible pouch can include a laminate comprising a water-soluble film and a nonwoven web of the disclosure.SELECTED DRAWING: None

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 62 / 838,282, filed April 24, 2019, and No. 62 / 908,287, filed September 30, 2019, the disclosures of which are incorporated herein by reference in their entireties.

[0002] FIELD OF THEINVENTION The present disclosure relates generally to nonwoven water-dispersible articles. More particularly, the present disclosure relates to nonwoven water-dispersible articles comprising water-soluble fibers and unit dose packages comprising the same. [Background technology]

[0003] background Water-soluble polymeric films are commonly used as packaging materials that simplify the dispersion, pouring, dissolving, and dosing of materials to be delivered. For example, pouches made from water-soluble films are commonly used to package household product compositions, such as laundry and dish detergents. Consumers can add the pouched composition directly to a mixing tank, such as a bucket, sink, or washing machine. Advantageously, this provides accurate dosing while eliminating the need for consumers to measure the composition. Pouched compositions can also (i) reduce the hassle that may be associated with dispensing similar compositions from a tank, such as pouring liquid laundry detergent from a bottle, (ii) reduce the waste that may be associated with dispensing similar compositions from a tank, such as pouring liquid laundry detergent from a bottle, and / or (iii) provide a safer dispensing option that may be associated with dispensing chemicals that may be harmful to humans, such as pesticides or undiluted pool cleaning chemicals. In short, soluble pre-measured polymeric film pouches provide convenience of consumer use in a variety of applications.

[0004] Some water-soluble polymeric films used to make currently marketed pouches may interact with pouch components (e.g., detergents) or moisture in the environment, affecting the properties of the pouch, for example, the solubility of the film may decrease over time when in contact with the contents therein, resulting in undesirable residues left after washing and / or the mechanical properties of the film may deteriorate over time. In another type of problem, water-soluble films prepared from water-soluble polymers may stick to processing equipment and / or other water-soluble films. Such problems may occur especially when the films are formed into pouches and the pouches are stored together in secondary packaging. Furthermore, some currently marketed pouches made with water-soluble polymeric films have an unpleasant rubbery or plastic feel when handled by consumers. In another type of problem, when the water-soluble pouch is provided, for example, in bulk water, it may release its contents in such a way that it provides a local concentration of the contents, rather than providing a more homogeneous distribution of the contents throughout the bulk solution. Summary of the Invention [Problem to be solved by the invention]

[0005] Thus, there is a need in the art for a water-dispersible package that is comfortable to handle, quickly releases the pouch contents to provide a more uniform distribution, and retains water solubility after storage in contact with the pouch contents while having a reduced tendency to stick to other water-soluble packages. [Means for solving the problem]

[0006] Disclosure Summary One aspect of the present disclosure provides a nonwoven web having a plurality of fibers, the plurality of fibers comprising a first fiber comprising a blend of fiber-forming materials comprising a first polyvinyl alcohol fiber-forming material and a second polyvinyl alcohol fiber-forming material, or the blend of fiber-forming materials does not comprise carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), or starch. The polyvinyl alcohol fiber-forming material may comprise a polyvinyl alcohol homopolymer and / or a polyvinyl alcohol copolymer. In an embodiment, the nonwoven web is water dispersible. In an embodiment, the nonwoven web is water soluble. In an embodiment, the nonwoven web is flushable. In an embodiment, the first fiber of the nonwoven web is spinned by a wet chill gel spinning process. It is prepared by

[0007] Another aspect of the present disclosure provides a multi-layer nonwoven web comprising a first nonwoven web according to the present disclosure. In an embodiment, the multi-layer nonwoven web comprises a second nonwoven web according to the present disclosure. In an embodiment, the multi-layer nonwoven web comprises a first nonwoven web and a second nonwoven web in the form of a laminate. In an embodiment, the multi-layer nonwoven web comprises a film, optionally a water-soluble film, laminated to the first nonwoven web. In an embodiment, the multi-layer nonwoven web is water-dispersible. In an embodiment, the multi-layer nonwoven web is water-soluble. In an embodiment, the multi-layer nonwoven web is water-flushable.

[0008] Another aspect of the present disclosure provides a fiber comprising a blend of fiber-forming materials, the blend of fiber-forming materials comprising a first polyvinyl alcohol polymer and a second polyvinyl alcohol polymer, or the blend of fiber-forming materials does not comprise CMC, HPMC, or starch. The polyvinyl alcohol fiber-forming material may comprise a polyvinyl alcohol homopolymer and / or a polyvinyl alcohol copolymer. In an embodiment, the fiber is water dispersible. In an embodiment, the fiber is water soluble. In an embodiment, the fiber is water flushable.

[0009] Another aspect of the present disclosure provides a nonwoven web comprising a plurality of fibers of the present disclosure. In embodiments, the nonwoven web is water dispersible. In embodiments, the nonwoven web is water soluble. In embodiments, the nonwoven web is water flushable.

[0010] Another aspect of the present disclosure provides a multi-layer nonwoven web comprising a first layer nonwoven web comprising a plurality of fibers of the present disclosure. In an embodiment, the multi-layer nonwoven web is water dispersible. In an embodiment, the multi-layer nonwoven web is water soluble. In an embodiment, the multi-layer nonwoven web is water flushable.

[0011] Another aspect of the present disclosure provides a pouch comprising a nonwoven web of the present disclosure or a multi-layer nonwoven web of the present disclosure in the form of a pouch. In embodiments, the pouch is water dispersible. In embodiments, the pouch is water soluble. In embodiments, the pouch is flushable.

[0012] Another aspect of the present disclosure provides a sealed article comprising the pouch of the present disclosure. In an embodiment, the sealed article comprises a composition enclosed in the internal pouch volume.

[0013] Another aspect of the present disclosure provides a method of preparing a sealed article according to the present disclosure, comprising forming a nonwoven web of the present disclosure into the shape of a pouch, filling the pouch with a composition to be encapsulated therein, and sealing the pouch to form the sealed article.

[0014] Another aspect of the present disclosure provides a method of preparing a fiber of the present disclosure using a wet chill gel spinning process, the wet chill gel spinning process comprising the steps of: a) dissolving a fiber-forming material in a solution to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle and into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide a fiber.

[0015] Another aspect of the present disclosure provides a method of controlling the hand of a pouch or packet comprising preparing a pouch or packet from a water-dispersible nonwoven web, the water-dispersible nonwoven web comprising a plurality of water-soluble fibers comprising a water-soluble fiber-forming material.

[0016] Other aspects and advantages will become apparent to those skilled in the art upon review of the following detailed description. While the fibers, nonwoven webs, pouches, sealed articles, and methods of making the same can be embodied in a variety of forms, the following description includes specific embodiments, with the understanding that the disclosure is illustrative and is not intended to limit the invention to the specific embodiments described herein. [Brief description of the drawings]

[0017] [Figure 1A] FIG. 1A is a microscope image of Sample 1 of the example.

[0018] [Figure 1B] FIG. 1B is a microscope image of Sample 2 of the example.

[0019] [Figure 1C] FIG. 1C is a microscope image of Example Sample 3.

[0020] [Figure 1D] FIG. 1D is a microscope image of Example Sample 5.

[0021] [Figure 1E] FIG. 1E is a microscope image of Example Sample 6.

[0022] [Figure 1F] FIG. 1F is a microscope image of Example Sample 4.

[0023] [Diagram 2] FIG. 2 is a schematic diagram of an exemplary method for preparing the soluble fiber of the present disclosure.

[0024] [Diagram 3] FIG. 3 is an illustration of a wire frame cage (shown open at the top to better illustrate the water-soluble pouch contained therein) for use in the liquid release testing described herein.

[0025] [Figure 4] FIG. 4 shows an apparatus for conducting liquid release testing that includes a beaker resting on a stand, which holds a rod for lowering a cage into the beaker, the rod being fixable by a collar having a set screw (not shown).

[0026] [Figure 5A] FIG. 5A is a microscope image of a nonwoven web of the present disclosure having a softness rating of 1.

[0027] [Figure 5B] FIG. 5B is a microscope image of a nonwoven web of the present disclosure having a softness rating of 5. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] Detailed Description Provided herein is a nonwoven web comprising a plurality of fibers, the plurality of fibers comprising a first fiber prepared from a blend of fiber-forming materials. The blend of fiber-forming materials can comprise a) a first polyvinyl alcohol fiber-forming material and a second polyvinyl alcohol fiber-forming material, or b) a first polyvinyl alcohol fiber-forming material and a second fiber-forming material that is not carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), or starch. In some embodiments, the plurality of water-soluble fibers comprises one or more polyvinyl alcohol fiber-forming materials and / or polyvinyl pyrrolidone fiber-forming materials. Optionally, the nonwoven web can comprise fibers prepared from a water-insoluble fiber-forming material. Generally, the nonwoven web is water-dispersible. Optionally, the nonwoven web can be water-soluble. Optionally, the nonwoven web can be water-flushable.

[0029] Water-dispersible nonwoven webs and pouches made therefrom can offer one or more advantages over water-soluble films and pouches, such as improved user or consumer feel (e.g., a cloth-like feel rather than a rubbery or plastic-like feel), reduced pouch-to-pouch sticking (e.g., reduced chance of pouches sticking together during pouch production or in secondary packaging resulting in reduced chance of pouch bursting after separation), reduced coefficient of friction (e.g., reduced chance of sticking to processing equipment and / or improved ability to conform to mold shapes), increased heat or water shrinkage, increased chemical resistance to harsh chemicals packaged within the nonwoven web, improved or retention of mechanical properties after storage in higher moisture and higher temperature environments, and / or improved solubility and dissolution.

[0030] As used herein, unless otherwise indicated, the term "water-soluble" refers to any nonwoven web or film having a dissolution time of 300 seconds or less at a specified temperature as determined according to MSTM-205 described herein, or any fiber having a complete dissolution time of less than 30 seconds at a specified temperature according to the method for determining single fiber solubility disclosed herein. For example, the solubility parameter can be characterized for a nonwoven web or laminate structure having a thickness of 6 mils (about 152 μm), or a pouch made therefrom. As used herein, a fiber is "insoluble", "water-insoluble", or "water-insoluble" when the fiber has a complete dissolution time of more than 30 seconds at a specified temperature according to the method for determining single fiber solubility disclosed herein. For example, the dissolution time of the nonwoven web or film can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less, as appropriate, at temperatures of about 100° C., about 90° C., about 80° C., about 70° C., about 60° C., about 50° C., about 40° C., about 20° C., or about 10° C. In embodiments where no dissolution temperature is specified, the water-soluble nonwoven web or film has a dissolution time of 300 seconds or less at temperatures of about 100° C. or less. The fibers can have a complete dissolution time of 30 seconds or less at temperatures of about 100° C., about 90° C., about 80° C., about 70° C., about 60° C., about 50° C., about 40° C., about 20° C., or about 10° C. In embodiments where no complete dissolution temperature is specified, water soluble fibers have a complete dissolution time of 30 seconds or less at temperatures of about 100° C. or less, and water insoluble fibers have a complete dissolution time of more than 30 seconds at temperatures of about 100° C. or less. As used herein, unless otherwise indicated, the term "cold water soluble" refers to any nonwoven web or film that has a dissolution time of 300 seconds or less at 10° C. as determined according to MSTM-205. For example, the dissolution time can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less at 10° C., as desired.As used herein, unless otherwise indicated, the term "cold water soluble" in reference to a fiber refers to a fiber that has a complete dissolution time of 30 seconds or less at 10° C. or less according to the method for determining single fiber solubility disclosed herein. In embodiments, a "water soluble film" means that at a thickness of 1.5 mils, the film dissolves in 300 seconds or less at a temperature of 100° C. or less. For example, a water soluble film of 1.5 mils (about 38 μm) thickness 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 70° C., about 60° C., about 50° C., about 40° C., about 30° C., about 20° C., or about 10° C. according to MSTM-205.

[0031] As used herein, unless otherwise indicated, the term "water-dispersible" refers to a nonwoven web, laminate structure, or pouch that physically dissociates into smaller constituent pieces after immersion in water at a specified temperature. 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 embodiments where a dispersion temperature is not specified, the nonwoven web or pouch will disintegrate in 300 seconds or less at a temperature of about 100°C or less according to MSTM-205. For example, the disintegration time can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less at temperatures of about 80°C, about 70°C, about 60°C, about 50°C, about 40°C, about 20°C, or about 10°C, as appropriate, according to MSTM-205. For example, such dispersion parameters may be characteristic of a nonwoven web or laminate structure having a thickness of 6 mils (about 152 μm), or a pouch made therefrom.

[0032] The term "flushable" as used herein refers to an article, such as a nonwoven web, laminate structure, or pouch, that is dispersible in an aqueous environment, such as a liquid sludge system, such that disposal of the web(s), laminate(s), or pouch(es) will not result in such article being trapped in the pipes of a piping system or accumulating over time to clog such pipes. The INDA / EDANA standard for flushability requires that after 60 minutes of a slosh box test using 28 RPM and an 18° tilt angle, more than 95% of the starting material must pass through a 12.5 mm sieve. The flushability test described herein provides a more stringent flushability test. A commercially available nonwoven web in the form of a flushable wipe, referred to herein as Commercial Wipe A, is certified to be flushable. Thus, as used herein, unless otherwise indicated, the term "flushable" refers to an article such as a nonwoven web, laminate, or pouch that has a percent disintegration that meets or exceeds the percent disintegration of Commercial Wipe A as measured by the Flushability Test described herein. Flushable nonwoven webs, laminate structures, and pouches have the advantage that they are more processable in recycling processes, or can be easily flushed, for example, in septic and municipal wastewater treatment systems, thus eliminating the need to landfill, incinerate, or otherwise dispose of the web, structure, or pouch after use.

[0033] 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 and bonded together (e.g., by a weaving process). Thus, the term nonwoven web can be considered a shorthand for a nonwoven fiber-based web. Additionally, as used herein, "nonwoven web" includes any structure that includes a nonwoven web or sheet, including, for example, a nonwoven web or sheet having a film laminated to its surface. Methods for preparing nonwoven webs from fibers can be found, for example, in Nonwoven Fabrics Handbook, prepared by As described in Ian Butler, edited by Subhash Batra et al., Printing by Design, 1999, and well known in the art. As used herein, unless otherwise indicated, Unless otherwise noted, the term "film" refers to a continuous film or sheet prepared, for example, by a casting or extrusion process.

[0034] "Comprising" as used herein means various components, ingredients, or steps that can be used in conjunction together in carrying out 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 include, consist essentially of, or consist of any of the required and optional elements disclosed herein. For example, a thermoforming packet can "consist essentially of" a nonwoven web as described herein for use in its thermoforming properties, including a non-thermoforming film or nonwoven web (e.g., a lid portion), and optional markings on the film, for example, by inkjet printing. The present disclosure as illustratively disclosed herein may be practiced in the absence of any element or step not specifically disclosed herein.

[0035] All percentages, parts, and ratios referred to herein are based on the total dry weight of the nonwoven web or film compositions of the present disclosure or the total weight of the packet content compositions, as the case may be, and all measurements made are made at about 25° C. unless otherwise indicated. All weights as they pertain to listed ingredients are based on the active level and thus do not include carriers or by-products that may be included in commercially available materials, unless otherwise indicated.

[0036] All ranges described herein include all possible subsets of the ranges and any combination of such subset ranges. By default, ranges include the stated endpoints unless otherwise stated. When a range of values ​​is provided, it is understood that each value between the upper and lower limits of the range, and any other stated or intermediate values ​​of the stated range, are included within the scope of the disclosure. The upper and lower limits of these smaller ranges may be independently included in the smaller ranges, and are also included within the scope of the disclosure, subject to any explicit exclusion limits of the stated range. When a stated range includes one or both of the limits, ranges excluding either or both of those included limits are also intended to be part of the disclosure.

[0037] For example, for any numerical values ​​described herein as parameters of the described subject matter or as part of a range related to the described subject matter, alternative examples forming part of this description are expressly contemplated as functionally equivalent ranges surrounding the particular numerical value (e.g., for a dimension disclosed as "40 mm," an alternative embodiment contemplated is "about 40 mm").

[0038] As used herein, the terms packet(s) and pouch(s) should be considered interchangeable. In certain embodiments, the terms packet(s) and pouch(s) are each used to refer to a container made using nonwoven webs and / or films, preferably a fully sealed container with a sealed material inside, such as a system that delivers a measured dose. Sealed pouches can be made from any suitable method, including such processes and features as heat sealing, solvent welding, and adhesive sealing (e.g., by using water-soluble adhesives).

[0039] As used herein, unless otherwise indicated, the terms "wt.%" and "wt%" shall refer to the composition of the identified element in "dry" (anhydrous) parts by weight of the total article or composition, which may refer to, for example, a nonwoven web or film (if applicable) or a nonwoven web or film including residual moisture in a laminate structure, or in parts by weight of the composition enclosed in a pouch (if applicable).

[0040] As used herein, unless otherwise indicated, the term "PHR" ("phr") refers to the composition of a specified element in parts per 100 parts water-soluble polymer (whether PVOH or other polymer, unless otherwise indicated) in a polymer-containing article, which may refer to, for example, a water-soluble film, fiber, or nonwoven web, or a solution used to make a fiber or film.

[0041] The nonwoven webs, pouches, and related methods of making and using are intended to include embodiments including any combination of one or more of the additional optional elements, features, and steps further described below (including those shown in the examples and figures), unless otherwise stated.

[0042] Water-soluble film and fiber forming materials

[0043] In general, the nonwoven web of the present disclosure can include a plurality of fibers. In an embodiment, the nonwoven web can be a water-dispersible or water-soluble nonwoven web and can include a plurality of water-soluble fibers, including a single fiber-forming material or a blend of fiber-forming materials. In an embodiment, the nonwoven web can be a water-dispersible or water-soluble nonwoven web and can include a plurality of water-soluble fibers, including, for example, a single water-soluble fiber-forming material or a blend of water-soluble fiber-forming materials. In an embodiment, the nonwoven web can be a water-dispersible nonwoven web and can include a plurality of water-dispersible fibers, including water-soluble and / or water-insoluble fiber-forming materials. As used herein, a water-dispersible nonwoven web that includes fibers having a single fiber-forming material means that all the fibers are prepared from the same fiber-forming material (e.g., polymer(s)).

[0044] The material forming the water-soluble fiber and water-soluble film can be a water-soluble polymer. The water-soluble polymers used in the water-soluble fiber, water-dispersible nonwoven web, and water-soluble film can include, but are not limited to, polyvinyl alcohol, polyacrylate, water-soluble acrylate copolymer, 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 polymers 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. Such water soluble polymers, whether PVOH or not, are commercially available from a variety of sources.

[0045] In general, the fibers and films of the present disclosure can include polyvinyl alcohol. Polyvinyl alcohol is a synthetic polymer that is generally prepared by alcoholysis, usually called hydrolysis or saponification, of polyvinyl acetate. Fully hydrolyzed PVOH is a strongly hydrogen-bonded, highly crystalline polymer in which virtually all acetate groups have been converted to alcohol groups and is soluble only in hot water above about 140°F (about 60°C). If a sufficient number of acetate groups remain after hydrolysis of polyvinyl acetate, i.e., the PVOH polymer is partially hydrolyzed, the polymer is less hydrogen-bonded and less crystalline, and is 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.

[0046] The fibers and / or films described herein may include one or more polyvinyl alcohol (PVOH) homopolymers, one or more polyvinyl alcohol copolymers, or a combination 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 "homopolymer" (or "PVOH homopolymer") 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 limit of 100% hydrolysis, a PVOH homopolymer may include a true homopolymer having only vinyl alcohol units. In some embodiments, the fibers and / or films of the present disclosure include a polyvinyl alcohol homopolymer. In some embodiments, the fibers and / or films of the present disclosure include a hot water soluble polyvinyl alcohol homopolymer.

[0047] In some embodiments, the polyvinyl alcohol comprises a modified polyvinyl alcohol, e.g., a copolymer. The modified polyvinyl alcohol can comprise a copolymer or higher polymer (e.g., a terpolymer) that comprises one or more monomers in addition to the vinyl acetate / vinyl alcohol groups. Optionally, the modification is neutral, e.g., provided by ethylene, propylene, N-vinylpyrrolidone, or other uncharged monomer species. Optionally, the modification is cationic, e.g., provided by positively charged monomer species. Optionally, the modification is anionic. Thus, in some embodiments, the polyvinyl alcohol comprises an anionically modified polyvinyl alcohol. An anionically modified polyvinyl alcohol can comprise a partially or fully hydrolyzed PVOH copolymer that comprises anionic monomer units, vinyl alcohol monomer units, and optionally vinyl acetate monomer units (i.e., if not fully hydrolyzed). In some embodiments, the PVOH copolymer can comprise two or more types of anionic monomer units. Common types of anionic monomer units that can be used in the PVOH copolymers include vinyl polymerized units corresponding to vinyl sulfonic acid monomers and their esters, vinyl monocarboxylic acid monomers, their esters, and anhydrides, dicarboxylic acid monomers having a polymerizable double bond, their esters, and anhydrides, and 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 citraconic acids, dialkyl citraconic acids, citraconic anhydride, mesaconic acid, monoalkyl mesaconic acids, dialkyl mesaconic acids, glutaconic acid, monoalkyl glutaconic acids, dialkyl glutaconic acids, glutaconic anhydride, alkyl acrylates, alkyl alkacrylates, vinyl sulfonic acid, allyl sulfonic acid, ethylene The polymerized vinyl units correspond to vinyl anionic monomers including sulfonic acid, 2-acrylamido-1-methylpropanesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, 2-methylacrylamido-2-methylpropanesulfonic acid, 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 thereof). In some embodiments, the PVOH copolymers can include two or more types of monomer units selected from neutral, anionic, and cationic monomer units.

[0048] The incorporation level / modification level of one or more monomer units in the PVOH copolymer is not particularly limited. In embodiments, the one or more monomer units / modifications 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., 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.%) in various embodiments. In embodiments, the modification is anionic, and the 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.%).

[0049] Polyvinyl alcohol can undergo 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 homopolymers) can be hydrolyzed by either acid or alkaline hydrolysis. As the degree of hydrolysis increases, the polymer composition made from PVOH homopolymer will have increased mechanical strength, but will have reduced solubility at lower temperatures (e.g., requiring hot water temperatures for dissolution). Thus, exposure of PVOH homopolymer to an alkaline environment (e.g., obtained from laundry bleach additives) can transform the polymer from one that dissolves quickly and entirely in a given aqueous environment (e.g., cold water medium) to one that dissolves slowly and / or incompletely in the aqueous environment, which may result in undissolved polymer residue at the end of the wash cycle.

[0050] PVOH copolymers with pendant carboxyl groups, such as vinyl alcohol / hydrolyzed sodium methyl acrylate polymers, can form lactone rings between adjacent pendant carboxyl and alcohol groups, thus reducing the water solubility of the PVOH copolymer. In the presence of strong base, the lactone rings can open over a period of weeks in relatively warm (ambient) and humid conditions (e.g., via lactone ring-opening reactions to form corresponding pendant carboxyl and alcohol groups with increased water solubility). Thus, in contrast to the effects observed with PVOH homopolymers, it is believed that such PVOH copolymers can become more soluble during storage due to chemical interactions between the polymer and the alkaline composition in the pouch. As a result, over time, the packets are believed to be more prone to dissolution more and more quickly during high temperature wash cycles (usually 40° C.), thus potentially reducing the efficacy of certain laundry actives due to the presence of bleach and the resulting decrease in pH.

[0051] Certain sulfonic acids and their derivatives with polymerizable vinyl bonds can be copolymerized with vinyl acetate to provide cold water soluble PVOH polymers that are stable in the presence of strong base. The base catalyzed alcoholysis products of these copolymers, used in the formulation of water soluble films, are fast dissolving vinyl alcohol-sulfonate copolymers. The sulfonic acid groups in the PVOH copolymers can revert back to sulfonic acid groups in the presence of hydrogen ions, but the sulfonic acid groups still provide excellent cold water solubility of the polymer. In embodiments, the vinyl alcohol-sulfonate copolymers do not contain residual acetate groups (i.e., are fully hydrolyzed) and therefore are not further hydrolyzable by either acid or alkali hydrolysis. In general, water solubility increases with increasing amount of modification, so sufficient modification via sulfonate or sulfonic acid groups inhibits hydrogen bonding and crystallinity, allowing dissolution in cold water. In the presence of acidic or basic species, the copolymers are generally unaffected except for the sulfonate or sulfonic acid groups, maintaining excellent cold water solubility even in the presence of acidic or basic species. Examples of suitable sulfonic acid comonomers (and / or their alkali metal salt derivatives) include vinyl sulfonic acid, allyl sulfonic acid, ethylene sulfonic acid, 2-acrylamido-1-methylpropanesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, 2-methacrylamido-2-methylpropanesulfonic acid, and 2-sulfoethyl acrylate, with the sodium salt of 2-acrylamido-2-methylpropanesulfonic acid (AMPS) being the preferred comonomer.

[0052] 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 homopolymer or a PVOH copolymer that comprises one or more types of anionic monomer units (e.g., a PVOH ter (or higher co-) polymer), and a second PVOH polymer ("second PVOH polymer"), which can comprise a PVOH homopolymer or a PVOH copolymer that comprises one or more types of anionic monomer units (e.g., a PVOH ter (or higher co-) polymer). In some embodiments, the PVOH polymer blend comprises only the first PVOH polymer and the second PVOH polymer (e.g., a two-component blend of the two polymers). Alternatively or additionally, the PVOH polymer blend or the fiber 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 wt.%, at least 97 wt.%, or at least 99 wt.% of the total amount of water-soluble polymers in the water-soluble fiber or film. In other embodiments, the water-soluble fiber 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 homopolymers or 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 a PVOH polymer (e.g., other than a PVOH homopolymer or PVOH copolymer, with or without anionic monomer units).

[0053] The degree of hydrolysis (DH) of the PVOH homopolymers and PVOH copolymers contained in the water-soluble fibers and films of the present disclosure can range from about 75% to about 99.9% (e.g., about 79% to about 92%, about 80% to about 90%, about 88% to 92%, about 86.5% to about 89%, or about 88%, 90%, or 92%, for example, cold water soluble compositions; 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 higher than 99%). As the degree of hydrolysis decreases, the fibers or films made from the polymers will have reduced mechanical strength but faster solubility at temperatures below about 20°C. As the degree of hydrolysis increases, fibers or films made from the polymer 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 made from the polymer and additional components is also affected. In one option, the film is cold water soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., homopolymers that are not copolymerized with anionic monomers), cold water soluble fibers 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%, or ranging from about 80% to about 90%, or ranging from about 85% to about 90%. In another option, the fiber or film is hot water soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., homopolymers that are not copolymerized with anionic monomers), hot water soluble fibers or films that are soluble in water at temperatures of at least about 60° C. can include PVOH having a degree of hydrolysis of at least about 98%.

[0054] The degree of hydrolysis of the polymer blends is the arithmetically weighted average degree of hydrolysis.

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[0055] The viscosity of PVOH polymers (μ) is based on British Standard EN ISO 15023-2:2006 It is determined by measuring the freshly made solution using a Brookfield LV type viscometer with a UL adapter as described in Annex E Brookfield test method. It is an international convention to refer to the viscosity of a 4% aqueous polyvinyl alcohol solution at 20°C. It should be understood that all viscosities specified herein in centipoise (cP) refer to the viscosity of a 4% aqueous polyvinyl alcohol solution at 20°C, unless otherwise indicated. Similarly, when a polymer is described as having (or not having) a particular viscosity, unless otherwise indicated, the specified viscosity is intended to be the average viscosity for a polymer originally having the corresponding molecular weight distribution, i.e., the weighted natural log average viscosity as described below. The viscosity of a PVOH polymer is determined by the weighted average molecular weight of the PVOH polymer.

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[0056] In embodiments, the PVOH resin can 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 can 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, 9.5 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 can have a viscosity of about 21 cP to 26 cP. In embodiments, the PVOH homopolymer and / or copolymer can have a viscosity of about 5 cP to about 14 cP. In embodiments, the PVOH homopolymer and / or copolymer can have a viscosity of about 5 cP to about 23 cP.

[0057] For reference, in the polymer blend, a first PVOH polymer is designated as having a first 4% solution viscosity (μ1) at 20° C. and a second PVOH polymer is designated as having a second 4% solution viscosity (μ2) at 20° C. In various embodiments, the first viscosity μ1 can be in the range of about 4 cP to about 70 cP (e.g., at least about 4, 8, 10, 12, or 16 cP, and / or at most about 12, 16, 20, 24, 28, 30, 32, 35, 37, 40, 45, 48, 50, 56, 60, or 70 cP, e.g., about 4 cP to about 70 cP, about 4 cP to about 60 cP, about 4 cP to about 46 cP, about 4 cP to about 24 cP, about 10 cP to about 16 cP, or about 10 cP to about 20 cP, or about 20 cP to about 30 cP). Alternatively, or in addition, the second viscosity μ2 can be in the range of about 4 cP to about 70 cP (e.g., at least about 4, 8, 10, 12, or 16 cP, and / or at most about 12, 16, 20, 24, 28, 30, 32, 35, 37, 40, 45, 48, 50, 56, 60, or 70 cP, such as about 12 cP to about 30 cP, about 10 cP to about 16 cP, or about 10 cP to about 20 cP, or about 20 cP to about 30 cP). When the PVOH polymer blend comprises three or more PVOH polymers selected from PVOH polymers and PVOH copolymers, the aforementioned viscosity values ​​can be applied to each PVOH polymer or PVOH copolymer individually. Thus, the weight average molecular weight of the water-soluble polymers, including the first PVOH copolymer and the second PVOH copolymer, can be, for example, in the range of about 30,000 to about 175,000, or about 30,000 to about 100,000, or about 55,000 to about 80,000. When referring to the average viscosity of a PVOH polymer blend, the weighted natural log average viscosity is

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[0058] Soluble Fiber

[0059] The fibers of the nonwoven web of the present disclosure can include water-soluble fibers. The water-soluble fibers can include any of the water-soluble fiber-forming materials disclosed herein. The water-soluble fibers can include a single water-soluble polymer or a blend of water-soluble polymers. Suitable water-soluble fibers include, but are not limited to, polyvinyl alcohol homopolymers, 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 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. In an embodiment, the water-soluble fiber can include a polyvinyl alcohol fiber-forming material. In a refinement of the foregoing embodiment, the water-soluble fiber can include a PVOH homopolymer fiber-forming material. In another refinement of the foregoing embodiment, the water-soluble fiber can include a PVOH copolymer fiber-forming material. In an embodiment, the water-soluble fiber can include a blend of polyvinyl alcohol polymer fiber-forming materials. In a refinement of the foregoing embodiment, the water-soluble fiber can include one or more PVOH homopolymers. In another refinement of the foregoing embodiment, the water-soluble fiber can include one or more PVOH copolymers. In yet another refinement of the above embodiment, the water soluble polymer may comprise one or more PVOH homopolymers and one or more PVOH copolymers.In embodiments, the water soluble fibers may include a blend of polyvinyl alcohol fiber forming materials and non-polyvinyl alcohol based water soluble fiber forming materials.

[0060] In an embodiment in which the water-soluble fiber comprises a blend of polyvinyl alcohol homopolymer and polyvinyl alcohol copolymer, the relative amount of homopolymer and copolymer is not particularly limited. The polyvinyl alcohol homopolymer can comprise about 15wt.% to about 70wt.% of the total weight of the water-soluble polymer blend, for example, at least about 15wt.%, at least about 20wt.%, at least about 25wt.%, at least about 30wt.%, at least about 40wt.%, at least about 50wt.%, or at least about 60wt.%, and up to about 70wt.%, up to about 60wt.%, up to about 50wt.%, up to about 40wt.%, or up to about 30wt.%, based on the total weight of the water-soluble polymer blend, and can be a single homopolymer or a blend of one or more homopolymers (e.g., with differences in viscosity and / or degree of hydrolysis). The remainder of the water-soluble polymer blend can be water-soluble polyvinyl alcohol copolymer. Without wishing to be bound by theory, it is believed that the ability of the blend of polyvinyl alcohol homopolymers and copolymers to form fibers decreases as the amount of homopolymer decreases below about 15 wt.%. The water-soluble polyvinyl alcohol copolymer can comprise about 30 wt.% to about 85 wt.% of the total weight of the water-soluble polymer blend, for example at least about 30 wt.%, at least about 40 wt.%, at least about 50 wt.%, at least about 60 wt.%, at least about 70 wt.%, at least about 75 wt.%, or at least about 80 wt.%, and up to about 85 wt.%, up to about 80 wt.%, up to about 70 wt.%, up to about 60 wt.%, up to about 50 wt.%, or up to about 40 wt.%, based on the total weight of the water-soluble polymer blend, and can be a single copolymer or a blend of one or more copolymers. The blend can consist of a polyvinyl alcohol homopolymer and a polyvinyl alcohol copolymer. The blend may consist of a polyvinyl alcohol homopolymer and multiple polyvinyl alcohol copolymers.The blend may consist of multiple polyvinyl alcohol homopolymers and multiple polyvinyl alcohol copolymers.

[0061] In an embodiment, the nonwoven web can include a plurality of fibers, the plurality of fibers including a first fiber including a first water-soluble polyvinyl alcohol fiber-forming material and a blend of fiber-forming materials including (a) a second polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not include carboxymethylcellulose, hydroxypropylmethylcellulose, or starch. In an embodiment, the nonwoven web can be a water-dispersible nonwoven web including a plurality of fibers, the plurality of fibers including a first water-dispersible fiber including a first water-soluble polyvinyl alcohol fiber-forming material and a blend of fiber-forming materials including (a) a second polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not include carboxymethylcellulose, hydroxypropylmethylcellulose, or starch. In an embodiment, the nonwoven web can include a plurality of fibers including first fibers and second fibers, the first fibers include a first polyvinyl alcohol and (a) a blend of fiber-forming materials including a second polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not include carboxymethyl cellulose, hydroxypropyl methyl cellulose, or starch, and the first and second fibers have a length to diameter (L / D) ratio, tenacity, shape, stiffness, elasticity, solubility in water, melting point, glass transition temperature (T g ), water soluble polymer, color, or combinations thereof. In embodiments, the nonwoven web may be a water dispersible nonwoven web and may include a plurality of fibers including a first water soluble fiber and a second fiber, the first water soluble fiber includes a first polyvinyl alcohol and (a) a blend of fiber forming materials including a second polyvinyl alcohol fiber forming material, or (b) the blend of fiber forming materials does not include carboxymethylcellulose, hydroxypropylmethylcellulose, or starch, and the first and second fibers may have differences in length to diameter (L / D) ratio, tenacity, shape, stiffness, elasticity, solubility in water, melting point, glass transition temperature (T g ), water soluble polymer, color, or a combination thereof.

[0062] Water-insoluble fiber

[0063] The nonwoven web of the present disclosure can also include water-insoluble fibers. Water-insoluble fibers generally include fibers made of fiber-forming materials that, when provided as the sole fiber in the nonwoven web, do not dissolve in the nonwoven web at 80° C. or less in 300 seconds or less, as determined by MSTM-205. Generally, water-insoluble fibers can include a single water-insoluble polymeric fiber-forming material or a blend of water-insoluble polymeric fiber-forming materials. Suitable water-insoluble fiber-forming materials include, but are not limited to, cotton, polyester, copolyester, polyethylene, (e.g., high density polyethylene and low density polyethylene), polypropylene, wood pulp, fluff pulp, abaca, viscose, insoluble cellulose, insoluble starch, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polyester, copolyester, polylactide (PLA), polyethylene terephthalate (PET), polypropylene (PP), or combinations thereof. In an embodiment, the water-insoluble fiber does not include cotton or rayon. In an embodiment, the water-insoluble fiber includes wool, diacetate, triacetate, nylon, PLA, PET, PP, or combinations thereof.

[0064] Non-woven web

[0065] The nonwoven webs of the present disclosure are generally water dispersible, optionally water soluble, and optionally flushable. The nonwoven webs of the present disclosure generally include a plurality of water soluble fibers, and optionally water insoluble fibers. Nonwoven webs generally refer to an arrangement of fibers bonded together, the fibers being neither woven nor knitted. Generally, the plurality of fibers can be arranged in any orientation. In embodiments, the plurality of fibers are arranged randomly (i.e., have no orientation). In embodiments, the plurality of fibers are arranged in a unidirectional orientation. In embodiments, the plurality of fibers are arranged in a bidirectional orientation. In some embodiments, the plurality of fibers are multidirectional and have different arrangements in different regions of the nonwoven web.

[0066] In general, the fibers of any given nonwoven web can comprise any of the fiber-forming materials disclosed herein. The nonwoven web can comprise (1) a monofilament type comprising a monofilament forming material, (2) a monofilament type comprising a blend of fiber-forming materials, (3) a blend of fiber types where each fiber type comprises a monofilament forming material, (4) a blend of fiber types where each fiber type comprises a blend of fiber-forming materials, or (5) a blend of fiber types where each fiber type comprises a monofilament forming material or a blend of fiber-forming materials. In embodiments comprising a blend of fiber types, the different fiber types can be characterized by different length to diameter (L / D) ratios, tenacity, shape, cross-sectional surface area, stiffness, elasticity, solubility, melting point, glass transition temperature (T g), the chemical nature of the fiber-forming material, color, or a combination thereof. In an embodiment, the plurality of fibers comprises a plurality of water-soluble fibers. The plurality of water-soluble fibers can comprise a single type of water-soluble fiber. In an embodiment, the plurality of water-soluble fibers can comprise at least two different types of water-soluble fiber. In an embodiment, the water-dispersible nonwoven web can further comprise a plurality of water-insoluble fibers. In an embodiment, the water-dispersible nonwoven web can comprise a single type of water-soluble fiber and one or more different types of water-insoluble fiber. In an embodiment, the water-dispersible nonwoven web can comprise one or more different types of water-soluble fiber and one or more different types of water-insoluble fiber. In an embodiment, the water-dispersible nonwoven web consists of or consists essentially of one or more types of water-soluble fiber. For example, the fiber components in the water-dispersible nonwoven web can all be water-soluble fibers.

[0067] In an embodiment, the nonwoven web comprises a plurality of fibers, the plurality of fibers comprising a first fiber type comprising a first polyvinyl alcohol fiber forming material and a blend of fiber forming materials comprising (a) a second polyvinyl alcohol fiber forming material, or (b) the blend does not comprise CMC, HPMC, or starch. In an embodiment, the nonwoven web is water dispersible and comprises a plurality of water soluble fibers, the plurality of water soluble fibers comprising a first water soluble fiber type comprising a first water soluble polyvinyl alcohol fiber forming material and a blend of fiber forming materials comprising (a) a second polyvinyl alcohol fiber forming material, or (b) the blend does not comprise CMC, HPMC, or starch.

[0068] In an embodiment, the first polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer or a polyvinyl alcohol copolymer. In an embodiment, the second polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer or a polyvinyl alcohol copolymer. In an embodiment, the first and / or second polyvinyl alcohol may comprise a modified polyvinyl alcohol copolymer. In a refinement of the previous embodiment, the modified polyvinyl alcohol copolymer may be an anionically modified polyvinyl alcohol copolymer. In an embodiment, the first polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer and the second polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol copolymer, optionally an anionically modified copolymer.

[0069] In an embodiment, the first polyvinyl alcohol fiber forming material has a degree of hydrolysis in the range of about 75% to about 99.9%, optionally in the range of about 80% to about 90%, optionally in the range of about 92% to about 99%, optionally in the range of about 98% to about 99%, optionally in the range of about 98% to about 99.9%. In an embodiment, the second first polyvinyl alcohol fiber forming material has a degree of hydrolysis in the range of about 75% to about 99.9%, optionally in the range of about 80% to about 90%, optionally in the range of about 92% to about 99%, optionally in the range of about 98% to about 99%, optionally in the range of about 98% to about 99.9%.

[0070] In an embodiment, the plurality of fibers comprises a first fiber type and a second fiber type. Optionally, the first fiber type and / or the second fiber type are water-soluble fibers. Generally, the first and second fiber types have characteristics that are similar to each other, such as length to distance (L / D) ratio, tenacity, shape, cross-sectional area, stiffness, elasticity, solubility in water, melting point, glass transition temperature (T g ), fiber chemistry, color, or a combination thereof. In an embodiment, the first and second fiber types have differences in length to distance (L / D) ratio, tenacity, shape, water solubility, glass transition temperature (T g ), fiber chemistry, or a combination of these.

[0071] In an embodiment, the plurality of fibers further comprises a water insoluble fiber. In an embodiment, the water insoluble fiber comprises about 20% to about 80% by weight of the total weight of the plurality of fibers. In an embodiment, the water insoluble fiber comprises cotton, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polyester, copolyester, viscose, polylactide, polyethylene terephthalate, polypropylene, or combinations thereof.

[0072] Flushable nonwoven webs and flushability

[0073] The nonwoven webs, laminate materials, and pouches described herein can be waterflushable. The waterflushable nonwoven webs include a plurality of fibers, and the plurality of fibers can include water soluble fibers and water insoluble fibers.

[0074] The water soluble fibers of the flushable nonwoven web may comprise any of the water soluble fiber forming materials disclosed herein. In an embodiment, the water soluble fibers comprise polyvinyl alcohol fiber forming materials. In a refinement of the foregoing embodiment, the water soluble fibers comprise PVOH homopolymers. In another refinement of the foregoing embodiment, the water soluble fibers comprise PVOH copolymers. In an embodiment, the water soluble fibers comprise a blend of polyvinyl alcohol fiber forming materials. In a refinement of the foregoing embodiment, the water soluble fibers comprise one or more PVOH homopolymers. In another refinement of the foregoing embodiment, the water soluble fibers comprise one or more PVOH copolymers.

[0075] In an embodiment, the water-soluble fiber comprises a blend of water-soluble fiber-forming materials. In a refinement of the above embodiment, the blend of water-soluble fiber-forming materials can comprise a polyvinyl alcohol polymer, or a blend of polyvinyl alcohol polymers, including polyvinyl alcohol homopolymers, polyvinyl alcohol copolymers, or combinations thereof. In another refinement, the water-soluble fiber can comprise a blend of water-soluble polymers, including polyvinyl alcohol homopolymers and polyvinyl alcohol copolymers. In yet another refinement of the above embodiment, the water-soluble polymer comprises one or more PVOH homopolymers and one or more PVOH copolymers. In some embodiments, the water-soluble fiber comprises a blend of fiber-forming materials, including a first polyvinyl alcohol fiber-forming material and (a) a second polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not include CMC, HPMC, or starch.

[0076] In an embodiment, the water-soluble nonwoven web can include a plurality of water-soluble fibers including a first water-soluble fiber and a second water-soluble fiber, the first and second water-soluble fibers having a L / D ratio, length, tenacity, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g ), fiber chemistry, color, or a combination thereof.

[0077] Suitable water-insoluble fiber-forming materials for the flushable fibers, nonwoven webs, laminates, and / or pouches of the present disclosure include, but are not limited to, cotton, polyester, copolyester, polyethylene (e.g., high density polyethylene and low density polyethylene), polypropylene, wood pulp, fluff pulp, abaca, viscose, insoluble cellulose, insoluble starch, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polyester, copolyester, viscose, polylactide, polyethylene terephthalate, polypropylene, and combinations thereof. In embodiments, the water-insoluble fiber-forming material does not include cotton or rayon.

[0078] The amount of water soluble fibers in the waterflushable nonwoven web can range from at least about 20, 25, 30, 40, 50, or 60 wt.% and / or up to about 100, 95, 90, 85, 80, 75, 70, 60, 50, or 40 wt.%, based on the total weight of fibers in the waterflushable nonwoven web, e.g., about 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100 wt.%, based on the total weight of fibers in the waterflushable nonwoven web, with the remainder of the fibers being water insoluble fibers.

[0079] The amount of water-insoluble fibers in the waterflushable nonwoven web can range from about 0, 5, 10, 15, 20, 40, 50, or 60 wt.%, and / or up to about 75, 70, 60, 50, 40, 30, or 25 wt.%, based on the total weight of fibers in the waterflushable nonwoven web, for example, about 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, or 75 wt.%, based on the total weight of fibers in the waterflushable nonwoven web, with the remainder of the fibers being water-soluble fibers.

[0080] The ratio of water insoluble fibers to water soluble fibers in the flushable nonwoven web can range from about 1:18 to about 4:1, about 1:10 to about 3:1, about 1:5 to about 2:1, or about 1:2 to about 2:1, e.g., about 1:18, 1:16, 1:14, 1:12, 1:10, 1:5, 1:3, 1:2, 1:1, 2:1, 3:1, or 4:1.

[0081] Without wishing to be bound by theory, for nonwoven webs containing only polyvinyl alcohol fibers, the mechanical stability decreases as the water washability increases (i.e., the disintegration value increases as determined by the Water Washability Test herein). Thus, the inventors have discovered that by incorporating water insoluble fibers into the nonwoven web, the water washability can be further increased without compromising the mechanical stability of the web.

[0082] In the water-washable nonwoven film containing polyvinyl alcohol, water-washability increases with increasing water solubility, but water solubility and mechanical stability generally have an inverse relationship.Therefore, the selection of a specific polyvinyl alcohol, as well as the selection of any additional water-soluble and / or water-insoluble fibers, can be important to maintain the mechanical integrity of the web while also having suitable water-washability properties.For example, parameters such as the DH and modification percentage of polyvinyl alcohol homopolymer or copolymer can affect the water-washability and mechanical properties of the fiber.

[0083] Adjuvants

[0084] The water soluble fibers, water insoluble fibers, nonwoven webs, laminates, and / or water soluble films may contain other auxiliary and processing agents, such as, but not limited to, plasticizers, plasticizer compatibilizers, surfactants, lubricants, release agents, fillers, extenders, crosslinking agents, antiblocking agents, antioxidants, antiblocking agents, defoamers, nanoparticles, such as layered silicate-type nanoclays (e.g., sodium montmorillonite), bleaching agents (e.g., sodium metabisulfite, sodium bisulfite, or others), aversive agents, For example, bittering agents (e.g., denatonium salts, such as denatonium benzoate, denatonium saccharides, and denatonium chloride; sucrose octaacetate; quinines; flavonoids, such as quercetin and naringen; and quassinoids, such as quassin and brucine), and pungent agents (e.g., capsaicin, piperine, allyl isothiocyanate, and resinferratoxin), and other functional ingredients, may be included in amounts appropriate for their intended purpose. As used herein, unless otherwise indicated, "auxiliary agents" include secondary additives, processing agents, and active agents. Certain such auxiliary agents and processing agents may be selected from those suitable for use with water-soluble fibers, water-insoluble fibers, nonwoven webs, or those suitable for use with water-soluble films.

[0085] In an embodiment, the water-soluble fiber, the water-insoluble fiber, the nonwoven web, and / or the water-soluble film are free of auxiliary agents. As used herein, unless otherwise indicated, "free of auxiliary agents" with respect to the fiber means that the fiber contains less than about 0.01 wt.%, less than about 0.005 wt.%, or less than about 0.001 wt.% of auxiliary agents based on the total weight of the fiber. As used herein, unless otherwise indicated, "free of auxiliary agents" with respect to the nonwoven web 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 auxiliary agents based on the total weight of the nonwoven web. In an embodiment, the water-soluble fiber contains a plasticizer. In an embodiment, the water-soluble fiber contains a surfactant. In an embodiment, the water-insoluble fiber contains a plasticizer. In an embodiment, the water-insoluble fiber contains a surfactant. In an embodiment, the nonwoven web contains a plasticizer. In an embodiment, the nonwoven web contains a surfactant. In embodiments where the first fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber further comprises a plasticizer, a surfactant, or a combination thereof. In embodiments where the first fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber further comprises a plasticizer. In embodiments where the first fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber further comprises a surfactant.

[0086] A plasticizer is a liquid, solid, or semi-solid that is added to a material (usually a resin or elastomer) to make it softer, more pliable (by lowering the glass transition temperature of the polymer), and easier to process. Alternatively, a polymer can be plasticized internally by chemically modifying the polymer or monomer. In addition to the alternative, a polymer can be plasticized externally by adding a suitable plasticizer. Water is recognized as a very efficient plasticizer for PVOH; and other polymers, including but not limited to water-soluble polymers; however, water's volatility limits its usefulness, since the polymer film must have at least some resistance (robustness) to a variety of ambient conditions, including low and high relative humidity.

[0087] Plasticizers can include, but are not limited to, glycerin, diglycerin, sorbitol, ethylene glycol, diethylene glycol, triethylene glycol, dipropylene glycol, tetraethylene glycol, propylene glycol, polyethylene glycols up to 400 MW, neopentyl glycol, trimethylolpropane, polyether polyols, sorbitol, 2-methyl-1,3-propanediol (MPDiol®), ethanolamine, and mixtures thereof. The total amount of non-aqueous plasticizer provided to the fibers can range from about 1 wt.% to about 45 wt.%, or about 5 wt.% to about 45 wt.%, or about 10 wt.% to about 40 wt.%, or about 20 wt.% to about 30 wt.%, about 1 wt.% to about 4 wt.%, or about 1.5 wt.% to about 3.5 wt.%, or about 2.0 wt.% to about 3.0 wt.%, for example about 1 wt.%, about 2.5 wt.%, about 5 wt.%, about 10 wt.%, about 15 wt.%, about 20 wt.%, about 25 wt.%, about 30 wt.%, about 35 wt.%, or about 40 wt.% based on the total fiber weight.

[0088] Surfactants for use in fibers are well known in the art. Surfactants for use in films are also well known in the art and may be suitably used in the fibers, films, and / or nonwoven webs of the present disclosure. If desired, a surfactant is included to aid in the dispersion of the fibers in the web. Suitable surfactants for the fibers of the present disclosure include, but are not limited to, dialkyl sulfosuccinates, lactylated fatty acid esters of glycerol and propylene glycol, lactic acid esters of fatty acids, sodium alkyl sulfates, polysorbate 20, polysorbate 60, polysorbate 65, polysorbate 80, alkyl polyethylene glycol ethers, lecithin, acetylated fatty acid esters of glycerol and propylene glycol, 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 from about 8 to 24 carbon atoms, alkyl sulfates, alkyl polyethoxylate sulfates, alkyl benzene sulfonates, monoethanolamines, lauryl alcohol ethoxylates, propylene glycol, diethylene glycol, salts thereof, and combinations of any of the foregoing.

[0089] Suitable surfactants can include nonionic, cationic, anionic, and zwitterionic classes.Suitable surfactants include, but are not limited to, propylene glycol, diethylene glycol, monoethanolamine, polyoxyethylated polyoxypropylene glycol, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylenic glycols and alkanolamides (nonionic), polyoxyethylated amines, quaternary ammonium salts and quaternized polyoxyethylated amines (cationic), alkali metal salts of higher fatty acids containing about 8 to 24 carbon atoms, alkyl sulfates, alkyl polyethoxylate sulfates and alkylbenzene 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, lactic 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 acetylated esters of fatty acids, and combinations thereof. In various embodiments, the amount of surfactant in the fiber ranges from about 0.01 wt.% to about 2.5 wt.%, from about 0.1 wt.% to about 2.5 wt.%, from about 1.0 wt.% to about 2.0 wt.%, from about 0.01 wt.% to 0.25 wt.%, or from about 0.10 wt.% to 0.20 wt.%.

[0090] In embodiments, the nonwoven web can be colored, pigmented, and / or dyed to provide improved aesthetic effects over water-soluble films. Suitable colorants can include indicator dyes, such as pH indicators (e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), moisture / water indicators (e.g., hydrochromic inks or leuco dyes), or thermochromic inks, which change color when the temperature increases and / or decreases. Suitable colorants include, but are not limited to, triphenylmethane dyes, azo dyes, anthraquinone dyes, perylene dyes, indigoid dyes, Food, Drug, and 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.

[0091] When included in the fiber, the colorant can be provided in an amount of 0.01% to 25% by weight of the water soluble 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 water soluble polymer mixture.

[0092] In embodiments, the nonwoven web of the present disclosure may include an active agent. The active agent may be added to the fibers themselves, or during the filling of the nonwoven web, and / or may be added to the nonwoven web prior to bonding. An active agent added to the fibers during filling may be distributed throughout the nonwoven web. An active agent added to the nonwoven web after filling but prior to bonding may be selectively added to one or both sides of the nonwoven web. Additionally, the active agent may be added to the surface of a pouch or other article prepared from the nonwoven web. In embodiments, the active agent is provided as part of a plurality of fibers, dispersed within the nonwoven web, provided on one side of the nonwoven web, or a combination thereof.

[0093] The active agent provides additional functionality to the nonwoven web when present in the nonwoven web in an amount of at least about 1 wt%, or in a range of about 1 wt% to about 99 wt%. In embodiments, the active agent can include one or more components including, but not limited to, enzymes, oils, flavors, colorants, odor absorbents, fragrances, pesticides, fertilizers, activators, acid catalysts, metal catalysts, ion scavengers, cleaning agents, disinfectants, surfactants, bleaching agents, bleaching components, fabric softeners, or combinations thereof. In embodiments, the active agent can include colorants, surfactants, or combinations thereof. The active agent can take any desired form including solids (e.g., powders, granules, crystals, flakes, or ribbons), liquids, mulls, pastes, gases, and the like, and can be encapsulated as needed.

[0094] In certain embodiments, the active agent may comprise an enzyme. Suitable enzymes include enzymes classified into one of the six traditional Enzyme Commission (EC) classifications: EC1 oxidoreductases (catalyzing oxidation / reduction reactions), EC2 transferases (transferring functional groups, e.g., methyl or phosphate groups), EC3 hydrolases (catalyzing the hydrolysis of various bonds), EC4 lyases (cleaving various bonds using methods other than hydrolysis and oxidation), EC5 isomerases (catalyzing isomeric changes within a molecule), and EC6 ligases (covalently joining two molecules together). Examples of such enzymes include EC1 dehydrogenases and oxidases, EC2 transaminases and kinases, EC3 lipases, cellulases, amylases, mannanases, and peptidases (also known as proteases or proteolytic enzymes), EC4 decarboxylases, EC5 isomerases and mutases, and EC6 synthetases and synthases. Suitable enzymes from each class are described, for example, in US Pat. No. 9,394,092, the disclosure of which is incorporated herein by reference in its entirety.

[0095] Enzymes used in laundry and dishwashing applications can include one or more of proteases, amylases, lipases, dehydrogenases, transaminases, kinases, cellulases, mannanases, peptidases, decarboxylases, isomerases, mutases, synthetases, synthases, and oxido-reductase enzymes, including oxidoreductase enzymes that catalyze the formation of bleach.

[0096] 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 type of embodiment, the mixture of two or more enzymes is obtained 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.

[0097] Optionally, enzymes as used herein, including but not limited to any of the classes or members of enzymes described herein, are enzymes that operate at alkaline pH conditions, e.g., at a pH ranging from about 8 to about 11, as used in cleaning applications, including, for example, laundry detergents and / or dish detergents. Optionally, enzymes as used herein, including but not limited to any of the classes or members of enzymes described herein, are enzymes that operate at temperatures ranging from about 5°C to about 45°C.

[0098] Non-fragrance oils may include flavoring and coloring agents.

[0099] In one type of embodiment, the active agent comprises a flavor or combination of flavors. Suitable flavors include, but are not limited to, spearmint oil, cinnamon oil, oil of wintergreen (methyl salicylate), peppermint oil, and synthetic and natural fruit flavors, including citrus oils.

[0100] In some embodiments, the active agent may be a colorant or a combination of colorants. Examples of suitable colorants include food coloring, caramel, paprika, cinnamon, and saffron. Other examples of suitable colorants can be found in U.S. Patent No. 5,002,789, the entirety of which is incorporated herein by reference.

[0101] Another class of embodiments includes one or more odor absorbents as active agents.Odor absorbents suitable for use as active agents according to the present disclosure include, but are not limited to, zeolites and complex zinc salts of ricinoleic acid.Odor absorbent active agents can also include fixatives known in the art as primarily odor neutralizing fragrances, including, but not limited to, extracts of labdanum, styrax, and derivatives of abietic acid.

[0102] Another class of embodiments includes one or more fragrances as active agents. As used herein, the term fragrance refers to any applicable material that is sufficiently volatile to produce an aroma. The embodiments that include fragrances as active agents can include fragrances that are pleasant to humans or fragrances that are unpleasant to humans, animals, and / or insects. Suitable fragrances include, but are not limited to, fruity scents, including but not limited to lemon, apple, cherry, grape, pear, pineapple, orange, strawberry, raspberry, musk, and floral scents, including but not limited to lavender-like, rose-like, iris-like, and carnation-like. Optionally, the fragrance is not a flavoring agent. Other fragrances include herbal scents, including but not limited to rosemary, thyme, and sage; and woodland scents derived from pine, spruce, and other forest odors. Fragrances may be derived from a variety of oils, including but not limited to essential oils, or from botanical materials, including but not limited to peppermint, spearmint, and the like. Suitable fragrance oils can be found in U.S. Patent No. 6,458,754, which is incorporated herein by reference in its entirety.Suitable fragrance oils include, but are not limited to, 4-(2,2,6-trimethylcyclohex-1-enyl)-2-en-4-one, acetaldehyde phenylethyl propyl acetal, 2,6,10-trimethyl-9-undecenal, hexanoic acid 2-propenyl ester, 1-octen-3-ol, trans-anethole, isobutyl (z)-2-methyl-2-butenoate, anisaldehyde diethyl acetal, 3-methyl-5-propyl-cyclohexen-1-one, 2,4-dimethyl-3-cyclohexene, 2,5-dimethyl-3-cyclohexene, 2,6,10-trimethyl-9-undecenal, 2,5 ... These include xene-1-carbaldehyde, trans-4-decenal, decanal, 2-pentylcyclopentanone, ethyl anthranilate, eugenol, 3-(3-isopropylphenyl)butanoal, methyl 2-octynoate, 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. Applicable 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, cassia, chypre, cyclamen, fern, gardenia, hawthorn, heliotrope, honeysuckle, hyacinth, jasmine, lilac, lily, magnolia, mimosa, daffodil, fresh-cut hay, orange blossom, orchid, mignonette, sweet pea, clover, tuberose, vanilla, violet, wallflower, and the like.

[0103] The fragrance can include a perfume. The perfume can include a natural perfume, an encapsulated perfume, or a mixture thereof. Preferably, the perfume includes a natural perfume. A part of the perfume can be encapsulated in a core-shell encapsulation. In another type of embodiment, the perfume is no longer encapsulated in a core / shell encapsulation.

[0104] The term "perfume" as used herein includes perfume raw materials (PRMs) and perfume matches. 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 scent, alone or with other perfume raw materials. As used herein, the terms "perfume ingredient" and "perfume raw materials" are interchangeable. The term "matches" as used herein refers to a mixture of two or more PRMs.

[0105] Typical PRMs include, among others, alcohols, ketones, aldehydes, esters, ethers, nitrites, and alkenes, such as terpenes. Lists of common PRMs can be found in various reference sources, 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 measured at standard pressure (760 mmHg). PRMS are characterized by their boiling points (BP), which are determined by their octanol / water partition coefficients (P). Based on these characteristics, PRMS can be classified as Quadrant I, II, III, or IV fragrances.

[0106] Applicable insect repellent fragrances include one or more of dichlorovos, pyrethrin, allethrin, naled and / or fenthion pesticides disclosed in U.S. Patent No. 4,664,064, the entirety of which is incorporated herein by reference.Suitable insect repellents are citronellal (3,7-dimethyl-6-octanal), N,N-diethyl-3-methylbenzamide (DEET), vanillin, and volatile oils extracted from turmeric (Curcuma longa), kaffir lime (Citrus hystrix), citronella (Cymbopogon winterianus), and Thai basil (Ocimum americanum).Furthermore, applicable insect repellents can be mixtures of insect repellents.

[0107] In one type of embodiment, the active agent according to the present disclosure can include one or more pesticides. Suitable pesticides can include, but are not limited to, insecticides, herbicides, miticides, fungicides, and larvicides.

[0108] Another type of embodiment includes one or more fertilizers as active agents. As used herein, the term fertilizer applies to any applicable material that releases one or more of nitrogen, phosphorus, potassium, calcium, magnesium, sulfur, boron, chlorine, copper, iron, manganese, molybdenum, or zinc. Suitable fertilizers include, but are not limited to, zeolites. For example, clinoptilolite is a zeolite that releases potassium and can also release nitrogen if ammonium is preloaded.

[0109] One type of embodiment includes an acid catalyst as an activator. As used herein, the term acid catalyst refers to any chemical species that acts as a proton source, thereby facilitating a chemical reaction. In one type of embodiment, the acid catalyst will be a non-oxidizing organic acid. A suitable organic acid is para-toluenesulfonic acid. In some embodiments, the acid catalyst activator facilitates reactions including, but not limited to, acetalization, esterification, or transesterification. Additional acid-catalyzed reactions are well known in the art.

[0110] In one type of embodiment, the activator will include a metal catalyst. These catalysts mediate reactions including, but not limited to, oxidation or reduction, hydrogenation, carbonylation, C-H bond activation, and bleaching. Suitable metals for use as metal catalysts include, but are not limited to, VIIIA and IB transition metals, such as iron, cobalt, nickel, copper, platinum, rhodium, ruthenium, silver, osmium, gold, and iridium. The metal mediating the catalyst can be in any suitable oxidation state.

[0111] In an alternative embodiment, the active agent may optionally be an ion scavenger. Suitable ion scavengers include, but are not limited to, zeolites. Optionally, zeolites can be added to water-soluble packets containing laundry or dishwashing detergents as water softeners.

[0112] Inorganic and organic bleaching agents are suitable cleaning actives for use herein. Inorganic bleaching agents include perhydrate salts, including but not limited to perborates, percarbonates, perphosphates, persulfates, and persilicates. Inorganic perhydrate salts are typically alkali metal salts. Alkali metal percarbonates, particularly sodium percarbonate, are suitable perhydrates for use herein. Organic bleaching agents include diacyl and tetraacyl peroxides, particularly but not limited to diperoxydodecanedioc acid, diperoxytetradecanedioc acid, and diperoxyhexanoic acid. Organic peroxyacids including diperoxyhexadecanedioc acid can be included. Dibenzoyl peroxide is a suitable organic peroxyacid according to the present disclosure. Other organic bleaching agents include peroxyacids, specific examples being alkylperoxyacids and arylperoxyacids.

[0113] In one type of embodiment, the activator may include a bleach activator including an organic peracid precursor that enhances bleaching action during cleaning at temperatures of 60° C. and below. Bleach activators suitable for use herein include compounds that under perhydrolysis conditions provide aliphatic peroxycarboxylic acids and / or optionally substituted perbenzoic acids having 1 to 10 carbon atoms or 2 to 4 carbon atoms. Suitable materials retain O-acyl and / or N-acyl groups of the specified number of carbon atoms, and / or optionally substituted benzoyl groups. Suitable materials also include, but are not limited to, polyacylated alkylenediamines, particularly tetraacetylethylenediamine (TAED), acylated triazine derivatives, particularly 1,5-diacetyl-2,4-dioxohexahydro-1,3,5-triazine (DADHT), acylated glycolurils, particularly tetraacetylglycoluril (TAGU), N-acylimides, particularly N-nonanoylsuccinimide (NOSI), acylated phenolsulfonates, particularly n-nonanoyl- or isononanoyloxybenzenesulfonate (n- or iso-NOBS), carboxylic anhydrides, particularly phthalic anhydride, acylated polyhydric alcohols, particularly triacetin, ethylene glycol diacetate, and 2,5-diacetoxy-2,5-dihydrofuran, and triethylacetyl citrate (TEAC).

[0114] In embodiments including fabric softeners as active agents, various in-wash fabric softeners, particularly the fine textured smectic clays of U.S. Patent No. 4,062,647, which is incorporated herein by reference in its entirety, as well as other softener clays known in the art, can be used to obtain the benefits of fabric softening simultaneously with fabric cleaning, if desired. Clay softeners can be used in combination with amines and cationic softeners, for example, as disclosed in U.S. Patent Nos. 4,375,416 and 4,291,071, which are incorporated herein by reference in their entireties.

[0115] In embodiments, the active agent may include a disinfectant. Disinfectants suitable for use herein may include, but are not limited to, hydrogen peroxide, inorganic peroxides and their precursors, sodium metabisulfite, quaternary ammonium cation-based compounds, chlorine, activated charcoal, and hypochlorite.

[0116] In embodiments, the active agent may include a surfactant. Surfactants suitable for use herein include, but are not limited to, propylene glycol, diethylene glycol, monoethanolamine, polyoxyethylated polyoxypropylene glycol, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylenic glycols and alkanolamides (non-ionic), polyoxyethylated amines, quaternary ammonium salts and quaternized polyoxyethylated amines (cationic), alkali metal salts of higher fatty acids containing about 8 to 24 carbon atoms, alkyl sulfates, alkylpolyethoxylate ... These may include sylate sulfates, and alkylbenzene sulfonates (anionic), amine oxides, N-alkyl betaines and sulfobetaines (zwitterionic), dioctyl sodium sulfosuccinate, lactylated fatty acid esters of glycerin and propylene glycol, lactic 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 acetylated esters of fatty acids, and combinations thereof.

[0117] The active agent may be solid or liquid. The active agent that is solid may have an average particle size (e.g., Dv50) of at least about 0.01 μm, or a size ranging from about 0.01 μm to about 2 mm, for example. The liquid active agent may be directly applied to the nonwoven web, mixed with a carrier powder, or microencapsulated. In embodiments that include a carrier powder, the average particle size of the carrier powder may be at least about 0.01 μm, or a size ranging from about 0.01 μm to about 2 mm, for example.

[0118] In one type of embodiment, the active agent is encapsulated, allowing the controlled release of the active agent.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(lactide-co-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 have an average particle size of at least about 0.1 microns, or, for example, in the range of about 0.1 microns to about 200 microns.

[0119] In embodiments where the activator is applied to one or more surfaces of the nonwoven web or to the packets, the activator can be applied by any suitable means. In one embodiment, one or more stationary powder spray guns are used to direct a stream of activator powder from one or more directions toward the web or packets, while the web or packets are transported in a coating zone using a belt conveyor. In an alternative embodiment, the pouches are conveyed in a suspension of activator in air. In yet another alternative embodiment, the packets are tumble mixed with the activator powder in a trough-like device. In another embodiment, which can be combined with any other embodiment, electrostatic forces are used to enhance the attraction between the activator powder and the packets. This type of process is typically based on negatively charging the powder particles and directing these charged particles toward a grounded packet. In other alternative embodiments, the activator powder is applied to the packets by a secondary transfer tool, including but not limited to a rotating brush that contacts the powder, or by a powdered glove that can transfer the powder from a container to the packets. In yet another embodiment, the active agent powder is applied by dissolving or suspending the powder in a non-aqueous solvent or carrier, which is then atomized and sprayed onto the packet. In one type of embodiment, the solvent or carrier subsequently evaporates, leaving the active agent powder behind. In one type of embodiment, the active agent powder is applied to the packet in precise doses. This type of embodiment utilizes a closed system dry lubricated application machine, such as PekuTECH's Powder Applicator PM 700D. In this process, the active agent powder is fed into the feed trough of the application machine, batchwise or continuously as needed. The packets are transferred from the output belt of a standard rotating drum pouch machine onto the conveyor belt of a powder application machine, where a controlled dosage of active agent is applied to the packet. The packets are then transported to a suitable secondary packaging process.

[0120] The liquid active agent can be applied to the nonwoven web or packet by, for example, spin casting, spraying a solution such as an aerosolized solution, roll coating, flow coating, curtain coating, extrusion, knife coating, and combinations thereof.

[0121] Fiber and nonwoven web formation

[0122] The multiple fibers can be prepared by any process known in the art, such as wet chill gel spinning, meltblowing, spunbonding, electrospinning, rotary spinning, continuous filament producing operations, tow fiber producing operations, and combinations thereof.

[0123] In an embodiment, the plurality of fibers comprises fibers, such as water-soluble fibers, prepared by a wet cryogel spinning process, the wet cryogel spinning process comprising: (a) dissolving a fiber-forming material(s) (e.g., a water-soluble polymer(s)) in a solvent to form a polymer mixture, optionally including an adjuvant; (b) extruding the polymer mixture through a spinning nozzle and 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 fibers. Includes.

[0124] The solvent in which the water-soluble polymer is dissolved can suitably be any solvent in which the polymer is soluble. In embodiments in which the polymer is water-soluble, the solvent in which the water-soluble polymer is dissolved comprises a polar aprotic solvent. In embodiments, the solvent in which the water-soluble polymer is dissolved comprises dimethylsulfoxide (DMSO).

[0125] Typically, the coagulation bath includes 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. Suitable coagulation bath temperatures can be about 15°C or lower, about 10°C or lower, about 5°C or lower, or 0°C or lower, for example, in the range of about 15°C to about -20°C, about 12°C to about -15°C, about 10°C to about -10°C, about 10°C to about 0°C, about 6°C to about 0°C, about 6°C to about 2°C, about 5°C to about 0°C, or about 5°C to about 2°C. In an embodiment, the coagulation bath can have a temperature of about 5°C. The coagulation bath can include a mixture of a solvent in which the fiber-forming material is soluble and a solvent in which the fiber-forming material is not soluble. The solvent in which the fiber-forming material is not soluble is generally the primary solvent, and the solvent in which the fiber-forming material is not soluble constitutes more than 50% of the mixture. The solvent in which the fiber-forming material is not soluble and the solvent in which the fiber-forming material is soluble can be provided in a ratio of about 95:5 to about 55:45 by volume, for example, about 95:5, about 90:10, about 85:15, about 80:20, about 75:25, about 70:30, about 65:45, about 60:40, or about 55:45 by volume. In embodiments in which the polymer is water-soluble, the solvent in which the water-soluble polymer is not soluble comprises methanol, acetone, mineral spirits, mineral oil, or combinations thereof. In embodiments, the solvent in which the water-soluble polymer is not soluble comprises methanol, acetone, or combinations thereof. In embodiments, the solvent in which the water-soluble polymer is not soluble comprises methanol. In embodiments, the solvent in which the water-soluble polymer is not soluble comprises acetone. In embodiments, the coagulation bath comprises a mixture of methanol and DMSO in a volume ratio of about 80:20.

[0126] After passing through the coagulation bath, the extruded polymer mixture gel can pass through one or more solvent replacement baths. The solvent replacement baths are provided to replace the solvent in which the fiber-forming material is soluble with a solvent in which the fiber-forming material is not soluble to further coagulate the extruded polymer mixture and to replace the solvent in which the fiber-forming material is soluble with a solvent that will evaporate more easily, thereby reducing drying time. The solvent replacement baths can include a series of solvent replacement baths with a gradient of solvents in which the fiber-forming material is soluble, including a solvent in which the fiber-forming material is not soluble, a series of solvent replacement baths with only a solvent in which the fiber-forming material is not soluble, or a single solvent replacement bath with only a solvent in which the fiber-forming material is not soluble. In an embodiment, at least one solvent replacement bath can consist essentially of a solvent in which the fiber-forming material is not soluble. A representative process for preparing the water-soluble fibers of the present disclosure is shown in FIG. 2.

[0127] The finished fibers may be referred to as stabilized fibers, short cut fibers, 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 provides a substantially uniform diameter to the extruded polymer mixture from which the fibers are cut. Drawing differs from extrusion as is known in the art. In particular, extrusion refers to the act of making fibers by forcing a resin mixture through a spinneret head, whereas drawing refers to mechanically pulling the fibers in the machine direction to promote polymer chain orientation and crystallinity, thereby increasing the strength and tenacity of the fibers. As used herein, fiber diameters are "substantially uniform" when the variance in diameter between fibers is less than 10%, for example 8% or less, 5% or less, 2% or less, or 1% or less. Wet drawing of the extruded polymer mixture may be suitably carried out before the extruded polymer mixture passes through the solvent exchange bath, after the extruded polymer mixture passes through the solvent exchange bath, or while the extruded polymer mixture passes through the first and second solvent exchange baths.

[0128] In embodiments in which the fibers are prepared from a wet cryogel spinning process, the fiber-forming material 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 above embodiment, the polymer(s) can have any degree of polymerization (DP), such as within 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, The molecular weight can range from up to 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, from 1000 to about 50,000, from 1000 to about 25,000, from 1000 to about 12,000, from 1000 to about 5,000, from 1000 to about 2,500, from about 50 to about 12,000, from about 50 to about 10,000, from about 50 to about 5,000, from about 50 to about 2,500, from about 50 to about 1000, from about 50 to about 900, from about 100 to about 800, from about 150 to about 700, from about 200 to about 600, or from about 250 to about 500. In an embodiment, the DP is at least 1,000. As is known in the art, nonwoven webs can be prepared by mixing and bonding staple fibers. Alternatively, nonwoven webs can be prepared from continuous fibers. The above-mentioned adjuvants can be added to the fibers themselves or to the nonwoven web during the mixing and / or bonding process.

[0129] Methods for preparing staple and continuous fibers are well known in the art. After the staple or continuous fibers are spun, the nonwoven web is bonded. Methods for bonding staple fibers are well known in the art and can include through-air bonding (heat), calendar bonding (heat with pressure), and chemical bonding. The nonwoven web of the present disclosure can be thermally or chemically bonded. Nonwoven webs can generally be porous, with various pore sizes, morphologies, and web nonuniformities, as shown in FIG. 1. The physical properties of the fibers and the type of bonding can affect the porosity of the resulting nonwoven web. Calendar bonding is achieved by applying heat and pressure, and typically maintains the pore size, shape, and alignment created by the spun process. The conditions for calendar bonding can be easily determined by one skilled in the art. In general, if the applied heat and / or pressure is too low, the fibers will not bond sufficiently to form a self-supporting web, and if the heat and / or pressure is too high, the fibers will begin to melt together. The chemical nature of the fiber governs the upper and lower limits of heat and / or pressure for calendar bonding. Without wishing to be bound by theory, it is believed that at temperatures above 235°C, polyvinyl alcohol-based fibers degrade. Methods of embossing for calendar bonding of fibers are known. Embossing can be single-sided embossing or double-sided embossing. Typically, 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 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, it is expected that as the surface area of ​​the web increases, the solubility of the web increases. Thus, the solubility properties of nonwoven webs can be advantageously tailored by varying the surface area through embossing. As shown in Figures 1A, 1B, 1C, 1D, and 1E, embossing during calendar bonding can impart observable divots to the nonwoven web.

[0130] In contrast to calendar bonding, chemical bonding typically uses a binder solution of waste polymers left over after fiber preparation to coat the surface fibers under pressure, resulting in pores that are smaller and less ordered than the surfaced pores. In general, the solvent can be any solvent that solubilizes the binder. Typically, the solvent for the chemical bonding solution is water. Without wishing to be bound by theory, it is believed that if the polymer solution used in chemical bonding is sufficiently concentrated and / or sufficient pressure is applied, a non-porous water-dispersible nonwoven web can be formed. The solvent used in chemical bonding induces partial solubilization of existing fibers in the web to weld and bond the fibers together. The polyvinyl alcohol binder provided in the solution aids 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).

[0131] In some embodiments, a second fibrous layer can be used to bond the nonwoven web. Without wishing to be bound by theory, it is believed that fibers prepared by melt-blowing process, such as water-soluble fibers, can be used to bond the nonwoven web using an in-line process. In particular, the nonwoven web can be passed under a melt-blowing process station so that the melt-blown fibers are deposited after melt extrusion, and as the melt-blown fibers cool and solidify, they bond to each other and to the nonwoven web on which they are deposited. The melt-blown fibers can be micro to nano-scale in length and can be provided on the nonwoven web such that the melt-blown fibers constitute about 15% by weight, about 12% by weight, about 10% by weight, about 8% by weight, about 6% by weight, or about 5% by weight of the final nonwoven web relative to the total weight of the fibers of the final nonwoven web. Without wishing to be bound by theory, it is believed that the inclusion of about 5% to about 15% melt-blown fibers can increase the mechanical integrity of the nonwoven web without substantially changing the solubility characteristics of the nonwoven web. Generally, when polyvinyl alcohol fiber forming materials are used to prepare meltblown fibers, the polyvinyl alcohol polymer will be a homopolymer because the meltblowing process requires a polymer with low viscosity and high melt flow index.

[0132] Pore ​​size can be determined using high magnification and high order surface analytical techniques, including but not limited to Brunauer-Emmett-Teller theory (BET), small angle X-ray scattering (SAXS), and molecular adsorption.

[0133] The nonwoven web of the present disclosure can generally have any thickness. Suitable thicknesses can include, but are not limited to, about 5 to about 10,000 μm (1 cm), about 5 to about 5,000 μm, about 5 to about 1,000 μm, about 5 to about 500 μm, about 200 to about 500 μm, about 5 to about 200 μm, about 20 to about 150 μm, about 20 to about 100 μm, or about 40 to about 90 μm, or about 50 to 80 μm, or about 60 to 65 μm, such as 50 μm, 65 μm, 76 μm, 88 μm, or 152 μm. The nonwoven web of the present disclosure can be characterized as high loft or low loft. Loft generally 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 caliper 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 caliper greater than 200 μm. The caliper of the nonwoven web is measured according to the ASTM D5729-97, ASTM D5736, and ISO 9073-2:1995, and may include, for example, subjecting the nonwoven web to a load of 2N and measuring the thickness. High loft materials may be used according to methods known in the art, such as by cross-wrapping, using a cross-wrap to fold the unbonded web on itself to build loft and basis weight, or through air bonding. Without wishing to be bound by theory, in contrast to water-soluble films, whose solubility may depend on the thickness of the film; the solubility of nonwoven webs is not believed to depend on the thickness of the web. In this regard, since individual fibers provide a higher surface area than water-soluble films, it is believed that the parameter that limits water access to the fibers and thereby the dissolution of the fibers is the basis weight (i.e., fiber density in nonwovens), regardless of the thickness of the film and nonwoven web.

[0134] The solubility of the nonwoven web of the present disclosure is generally a function of the type of fiber(s) used to prepare the web as well as the basis weight of the water-dispersible web. Without wishing to be bound by theory, it is believed that in nonwoven webs that include a single fiber type that includes a single fiber-forming material, the solubility profile of the nonwoven web follows the same solubility profile as the fiber(s) used to prepare the nonwoven web, and the solubility profile of the fiber generally follows the same solubility profile as the fiber-forming polymer(s) from which the fiber is formed. For example, in the case of a nonwoven web that includes PVOH fibers, the degree of hydrolysis of the PVOH polymer can be selected so that the water solubility of the nonwoven web is also affected. Generally, 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 one option, 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 below 10° C. can include fibers of PVOH having a degree of hydrolysis ranging from about 75% to about 90%, or from about 80% to about 90%, or from about 85% to about 90%. Alternatively, the nonwoven web can be hot 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 hot water soluble web that is soluble in water at a temperature of at least about 60° C. can include fibers of PVOH having a degree of hydrolysis of at least about 98%.

[0135] The modification of PVOH generally increases the solubility of the PVOH polymer. Therefore, it is expected that at a given temperature, the solubility of a water-dispersible nonwoven web prepared from a PVOH copolymer may be higher than that of a nonwoven web prepared from a PVOH homopolymer having the same degree of hydrolysis as the PVOH copolymer. According to these trends, a water-dispersible nonwoven web with a specific solubility characteristic can be designed.

[0136] Surprisingly, as demonstrated in Example 8 herein, for nonwoven webs containing a blend of fiber types, each fiber type having a single fiber-forming material, the solubility of the nonwoven web was found not to follow the rule of mixtures, as might be expected for blends of fiber types. Rather, for nonwoven webs containing a blend of two fiber types, when the two fiber types were provided in a ratio other than 1:1, the solubility of the nonwoven web tended toward the solubility of the less soluble fiber (i.e., required a higher temperature to completely dissolve and dissolved more slowly at temperatures below the complete dissolution temperature). For nonwoven webs containing a 1:1 blend of fibers, the solubility of the nonwoven web was generally lower than that of nonwoven webs containing blends other than the 1:1 blend (i.e., at a given temperature, the nonwoven web containing the 1:1 blend took longer to break, disintegrate, and dissolve than nonwoven webs containing fiber types in ratios of, for example, 3:1 and 1:3). This trend was particularly evident at temperatures below the complete dissolution temperature of the less soluble fiber.

[0137] The inclusion of water-insoluble fibers in a water-dispersible nonwoven web can also be used to design the nonwoven web with a particular solubility and / or delayed release characteristics (e.g., when the nonwoven web is included in a water-dispersible pouch). Without being bound by theory, it is believed that as the weight percentage of water-insoluble fibers included in the nonwoven web increases (relative to the total weight of the nonwoven web), the solubility of the nonwoven web generally decreases and the delayed release characteristics of the pouch including the nonwoven web generally increase. After contacting with water at or above the solubility temperature of the water-soluble fibers, the nonwoven web including water-soluble and water-insoluble fibers will begin to thin as the water-soluble fibers dissolve, thereby destroying the web structure and / or increasing the pore size of the pores in the nonwoven web. In general, the greater the destruction of the web structure or the larger the pore size, the faster water can contact the pouch contents and the faster the pouch contents will be released. Similarly, delayed release of the contents of the pouch containing the water-dispersible 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. In general, for nonwoven webs containing water-soluble fibers containing polyvinyl alcohol fiber-forming materials, at a water temperature of 50% or higher than the complete dissolution temperature of the water-soluble fibers (e.g., 40°C for fibers with a complete dissolution temperature of 70°C), the fibers will undergo swelling and softening of the polymer network, but the overall structure will remain intact. In embodiments in which the water-dispersible nonwoven web contains water-soluble fibers and water-insoluble fibers, the ratio of soluble fibers to 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 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.

[0138] Further, as shown in Example 7, since there is more material to dissolve, the dissolution rate of the web decreases as the basis weight of the web increases, assuming the fiber composition and bonding parameters remain constant. For example, at a given temperature, a web containing PVOH polymer(s) and having, for example, 40 g / m 2 A water-soluble web prepared from fibers having a basis weight of, for example, 30 g / m 2 The water-dispersible nonwoven web is expected to dissolve more slowly than an otherwise identical water-soluble web having a basis weight of about 1 g / m. This relationship was particularly evident when the temperature of the water for dissolution was lower than the complete dissolution temperature of the fibers that make up the nonwoven web. Thus, basis weight can also be used to modify the solubility characteristics of the water-dispersible nonwoven web. Water-dispersible nonwoven webs generally 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 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 , about 25g / m 2 From about 70g / m 2 , or about 30 g / m 2 From about 70g / m 2 The sheet may have any basis weight in the range of 1000 to 15000 grammage.

[0139] Additionally, the calendar settings generally have a secondary effect on the solubility profile of the nonwoven webs of the present disclosure. As shown in Example 7, for nonwoven webs with the same fiber chemistry and similar basis weight, at a given calendar pressure, the solubility time of the nonwoven web generally increases with increasing calendar temperature. This relationship is particularly evident when the temperature of the water at dissolution is lower than the complete dissolution temperature of the fibers that make up the nonwoven web.

[0140] Without wishing to be bound by theory, it is believed that the solubility (e.g., in terms of time to dissolution by MSTM-205) of a water-soluble nonwoven web is expected to exceed that of a water-soluble film of the same size (L×W) and / or mass prepared from the same PVOH polymer. This is due to the higher surface area found in the nonwoven compared to the film, leading to faster solubilization. As shown in the examples below, a nonwoven web prepared from a PVOH homopolymer with a degree of hydrolysis of 88% dissolves in 14 seconds, while a water-soluble film of similar size prepared from the same PVOH homopolymer with a degree of hydrolysis of 88% dissolves in about 100 seconds.

[0141] The water-soluble and water-insoluble fibers used to prepare the water-dispersible nonwoven webs of the present disclosure can generally 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 water-dispersible nonwoven webs 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 including a first fiber having a blend of fiber forming materials including a first polyvinyl alcohol fiber forming material, the first fiber can have a tenacity in the range of about 3 cN / dtex to about 10 cN / dtex, optionally about 7 cN / dtex to about 10 cN / dtex, optionally about 4 cN / dtex to about 8 cN / dtex, or optionally about 6 cN / dtex to about 8 cN / dtex.

[0142] In embodiments where the water-soluble fibers are prepared from a wet cryogel spinning process, the resulting fibers can generally have any tenacity as described herein. In refinements of the foregoing embodiments, the fibers can have a tenacity ranging from about 3 to about 15, about 3 to about 13, about 3 cN / dtex to about 10 cN / dtex, about 5 cN / dtex to about 10 cN / dtex, or about 6 cN / dtex to about 10 cN / dtex, about 7 cN / dtex to about 10 cN / dtex, about 4 cN / dtex to about 8 cN / dtex, or about 6 cN / dtex to about 8 cN / dtex. In embodiments including a first fiber having a blend of fiber forming materials including a first polyvinyl alcohol fiber forming material, where the first fiber is prepared from a wet chill gel spinning process, the first fiber can have a tenacity in the range of about 3 cN / dtex to about 10 cN / dtex, optionally about 7 cN / dtex to about 10 cN / dtex, optionally about 4 cN / dtex to about 8 cN / dtex, or optionally about 6 cN / dtex to about 8 cN / dtex.

[0143] The tenacity of the nonwoven web can be the same or different from the tenacity of the fibers used to prepare the web. Without being bound by theory, it is believed that the tenacity of the nonwoven web is related to the strength of the nonwoven web, with higher tenacity imparting higher strength to the nonwoven web. In general, the tenacity of the nonwoven web can be modified by using fibers with different tenacities. The tenacity of the nonwoven web can also be affected by processing. In general, the water-dispersible webs of the present disclosure can have a relatively high tenacity, i.e., the water-dispersible nonwoven web is a self-supporting web that can be used as a single material to prepare an article and / or pouch. In contrast, nonwoven webs prepared by meltblowing, electrospinning, and / or rotary spinning processes typically have a low tenacity and may not be self-supporting or can be used as a single web to form an article or pouch.

[0144] In general, the ratio of the dynamic coefficient of friction and the static coefficient of friction to the dynamic coefficient of friction for the nonwoven web of the present disclosure will be lower than that for the water-soluble film due to the increased surface roughness of the nonwoven web compared to the water-soluble film, resulting in reduced surface contact for the nonwoven web. Advantageously, this surface roughness can provide improved feel to the consumer (i.e., cloth-like hand instead of rubbery hand), improved aesthetics (i.e., less shine than water-soluble films), and / or facilitate processability in preparing thermoformed and / or vertically formed, filled and sealed, and / or multi-chamber packets that require pulling the web along the surface of a processing tool / mold. Thus, the fibers should be sufficiently rough to provide surface roughness to the resulting nonwoven web without being so rough as to generate drag.

[0145] The fibers used to prepare the nonwoven webs of the present disclosure can generally 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 is the ratio of the mass of the fibers to the length. The main physical unit of fiber fineness is 1 tex, which is equal to 1000m of fibers weighing 1g. Typically, the unit dtex is used, which represents 1g / 10,000m of fibers. The fineness of the fibers can be selected to obtain a nonwoven web having suitable stiffness / hand of the nonwoven web, torsional stiffness, light reflection and interaction, absorption of dyes and / or other activators / additives, ease of fiber spinning in the manufacturing process, and uniformity of the finished product. Generally, as the fineness of the fibers increases, the nonwovens obtained therefrom demonstrate higher uniformity, improved tensile strength, extensibility, and luster. Further, without being bound by theory, it is believed that finer fibers will result in slower dissolution times compared to larger fibers based on density. Further, without being bound by theory, when a blend of fibers is used, the average fineness of the fibers can be determined using a weighted average of the individual fiber components. 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.

[0146] The shape of the fibers used to prepare the nonwoven webs of the present disclosure is not particularly limited and can have a cross-sectional shape including, but not limited to, round, elliptical (also called ribbon), triangular (also called delta), trilobal, and / or other multilobal shapes. It will be understood that the shape of the fibers need not be perfectly geometric, for example, a fiber having a round cross-sectional shape does not necessarily have a perfect circle as a cross-sectional area, and a fiber having a triangular cross-sectional shape will generally have rounded corners.

[0147] It will be understood that the diameter of a fiber refers to the cross-sectional diameter of the fiber along its longest cross-sectional axis. When a fiber is described as having (or not having) a particular diameter, unless otherwise indicated, the specified diameter is intended to be the average diameter for the particular fiber type being referred to, i.e., a plurality of fibers prepared from a polyvinyl alcohol fiber-forming material has an arithmetic average fiber diameter across the plurality of fibers. In the case of shapes that are not typically considered to have a "diameter", such as triangular or multi-lobal shapes, the diameter refers to the diameter of a circle circumscribing the fiber shape.

[0148] The water-soluble and water-insoluble fibers used to prepare the water-dispersible nonwoven web of the present disclosure typically have a diameter in the range of 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 water-soluble fibers used to prepare the nonwoven web of the present disclosure can have a diameter of greater than 100 microns to about 300 microns. In an embodiment, the fibers of the present disclosure can have a diameter in the range of about 10 to about 300 microns, about 25 to about 300 microns, about 50 to about 300 microns, greater than 100 microns to about 300 microns, or about 75 to about 100 microns. In an embodiment, the diameter of the water-soluble fibers used to prepare the nonwoven web of the present disclosure has a substantially uniform diameter. Without wishing to be bound by theory, it is believed that drawing the water-soluble polymer mixture during the wet cryogel spinning process can be used to control the diameter of the resulting fiber as well as the uniformity of the diameter size of the resulting fiber. In an embodiment in which the first fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber has a diameter ranging from about 10 microns to about 300 microns, about 50 microns to about 300 microns, or greater than 100 microns to about 300 microns. In an embodiment in which the first fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber has a substantially uniform diameter.

[0149] The water-soluble and water-insoluble fibers used to prepare the nonwoven web of the present disclosure can generally be of any length. In embodiments, the length of the water-soluble fibers can be in the range of about 30 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 embodiments, the length of the water soluble 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 embodiments where the first fiber comprises a blend of fiber forming materials that includes a first polyvinyl alcohol fiber forming material, the first fiber has a length in a range of about 30 mm to about 100 mm, or about 30 mm to about 60 mm, or less than about 30 mm, or about 0.25 mm to less than 30 mm. Water-soluble fibers can be prepared to any length by cutting and / or crimping the extruded water-soluble polymer mixture prepared using the wet-cooled gel spinning process. In contrast, processes such as spunbonding, meltblowing, electrospinning, and rotary spinning are continuous processes in which continuous filaments are prepared and directly provided in web form. Thus, such processes do not provide the opportunity to cut the filaments to the desired fiber length.

[0150] The water soluble and water insoluble fibers used to prepare the nonwoven webs of the present disclosure can generally have any length to diameter (L / D) ratio. Advantageously, the tactility of the nonwoven webs of the present disclosure varies with the L / D ratio of the fibers and with the various L / D ratios in the nonwoven composition. The amount of each of the fibers having a L / D ratio of about 0.5 to about 15, or about 0.5 to about 25, or about 1 to about 5, can be used to control the amount of each of the fibers having a L / D ratio of about 0.5 to about 15, or about 0.5 to about 25, or about 1 to about 5, respectively. Generally, as the L / D of the fiber decreases, the stiffness and resistance to bending increases, resulting in a rougher hand. The fibers of the present disclosure generally impart a rougher feel to the nonwoven web comprising the fibers when the fibers have a low L / D ratio 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 wt.% based on the total weight of the fibers in the nonwoven web, for example, in the range of about 0.5 wt.% to about 25 wt.% or about 1 wt.% to about 15 wt.%. If the amount of low L / D fibers in the nonwoven web is unknown, the amount can be estimated by visual inspection of a micrograph of the nonwoven web. As shown in FIG. 3, a collection of fibers having a visibly larger diameter and a shorter cut ratio relative to the total fiber collection can be observed. Figure 5A is a micrograph of a nonwoven web having 0% low L / D fibers and a softness ranked as 1, while Figure 5B is a micrograph of a nonwoven web having 25% low L / D fibers and a softness ranked as 5. In embodiments in which the first fibers comprise a blend of fiber forming materials that includes a first polyvinyl alcohol fiber forming material, at least a portion of the first fibers can have an L / D ratio of from about 0.5 to about 25, or from about 0.5 to about 15, or from about 1 to about 5.

[0151] The wet-cooled gel spinning process advantageously provides one or more benefits, such as providing fibers comprising 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 having a high degree of polymerization, providing fibers that can be used to provide free-standing nonwoven webs, and / or providing fibers from a wider range of materials than can be used with traditional thermal extrusion techniques (e.g., meltblowing and spunbonding), for example, using polymers with higher molecular weights and / or higher melting points / melt viscosities than can be used with traditional thermal extrusion techniques. Continuous processes such as spunbonding, meltblowing, electrospinning, and rotary spinning generally do not allow blending of water-soluble polymers (e.g., due to the difficulty of matching the melt index of various polymers), do not allow the formation of large diameter fibers (e.g., greater than 50 microns), do not allow control of the length of the fiber, do not allow the provision of high tenacity fibers, and do not allow the use of polymers with a high degree of polymerization. A comparison of the various processes is provided in the following table: [Table 15-1] [Table 15-2]

[0152] In an embodiment, the nonwoven web of the present disclosure can include a plurality of water-soluble fibers prepared by a wet chill gel spinning process in combination with a continuous filament prepared by a continuous process selected from the group consisting of meltblowing, spunbonding, electrospinning, rotary spinning, continuous filament production operation, tow fiber production operation, and a combination of one or more of the aforementioned processes. A water-dispersible nonwoven web comprising a plurality of water-soluble fibers prepared by a wet chill gel spinning process and filaments prepared by a continuous process can be formed using an in-line process. For example, a first nonwoven web of fibers can be prepared, and then the prepared web can proceed under a second station where filaments are prepared by a continuous process and then deposited on the nonwoven web prepared from the fibers. The first nonwoven web prepared from the fibers can be bonded before or after the filaments are provided on the first nonwoven web. As used herein, "filament" refers to an extruded product of a water-soluble polymer mixture prepared from a continuous process, and the extruded product does not have a defined length range. The use of filament on fiber does not convey any information regarding a specific length. For example, fibers can have any length, theoretically up to or greater than the length of filaments prepared from a continuous process. Thus, as used herein, filaments and fibers are intended to distinguish products having a defined length range (i.e., fibers) from products that do not have a defined length range (i.e., filaments).

[0153] Water-dispersible nonwoven webs comprising a plurality of water-soluble fibers prepared by wet chill gel spinning process and filaments / fibers prepared by continuous process can also be formed using indirect process. Meltblown fibers prepared at nano or micro scale are prepared and mixed with a plurality of water-soluble fibers prepared by wet chill gel spinning process, and then combined with the fibers prepared by wet chill gel spinning process. Such fiber blends can provide water-dispersible nonwoven webs with improved mechanical strength (relative to a comparable water-dispersible nonwoven web prepared with water-soluble fibers prepared only by wet chill gel spinning process) and stability, which can be advantageous for preparing wipes (e.g., cleaning wipes, personal care wipes, and the like). Generally, blends of water-soluble fibers and meltblown fibers prepared by a wet chill gel spinning process can include meltblown fibers in an amount of about 50 wt.% or less based on the total weight of all fibers, for example, in a range of about 1 wt.% to about 50 wt.%, about 5 wt.% to about 50 wt.%, about 10 wt.% to about 40 wt.%, about 15 wt.% to about 30 wt.%, about 20 wt.% to about 30 wt.%, for example about 1 wt.%, about 5 wt.%, about 10 wt.%, about 15 wt.%, about 20 wt.%, about 25 wt.%, about 30 wt.%, about 40 wt.%, or about 50 wt.% based on the total weight of all fibers. The blend of water-soluble and meltblown fibers prepared by the wet cryogel spinning process can be bonded using any suitable bonding method known in the art, such as the physical and chemical bonding processes described herein.

[0154] Water-soluble fibers can be characterized by water-breaking temperature. "Water-breaking temperature" refers to the minimum temperature required for complete dissolution in practical applications, as estimated using the following method: a 100 mm length of water-soluble fiber is placed in an aqueous solution with an initial temperature of 1.5°C under a load of 1 mg / dtex; the temperature of the aqueous solution is systematically increased as a function of time (1.5°C every 2.5 minutes until the breaking temperature is reached); the water temperature is recorded after fiber breakage under a load of 2 mg / dtex and reported as water-breaking temperature. Water-soluble fibers can also be characterized by complete dissolution temperature, as described in the Method for Determining Single Fiber Solubility described herein.

[0155] Advantageously, the nonwoven web of the present disclosure can demonstrate preferential shrinkage in the presence of heat and / or water (e.g., humidity). Thus, the nonwoven web can be heat and / or water shrinkable when formed into a packet. Even more advantageously, the nonwoven web of the present disclosure can demonstrate increased robustness (i.e., mechanical properties) and improved solubility performance after storage in high heat and moisture environments (e.g., 38°C and 80% relative humidity (RH)). Such increased robustness and improved solubility performance is surprising, since predictions based on water-soluble films of similar composition would suggest that robustness and solubility performance would not be affected by storage in high heat and moisture conditions. In particular, after removal of a comparable water-soluble film from the conditioning conditions, the water-soluble film re-equilibrates with the surrounding environment, resulting in no long-term or permanent change in the performance characteristics of the film.

[0156] The nonwoven web of the present disclosure can be used as a monolayer or can be layered with other nonwoven webs and / or water-soluble films. In some embodiments, the water-dispersible nonwoven web comprises a monolayer of a water-dispersible nonwoven web. In some embodiments, the water-dispersible nonwoven web is a multi-layer water-dispersible nonwoven web comprising two or more layers of a water-dispersible nonwoven web. One or more layers can be layered with each other. In refinements of the foregoing embodiment, the two or more layers can be the same (e.g., can be prepared from the same fibers and basis weight). In refinements of the foregoing embodiment, the two or more layers can be different (e.g., can be prepared from different types of fibers and / or can have different basis weights). In an embodiment, the nonwoven web can be layered to a water-soluble film. In refinements of the foregoing embodiment, the nonwoven web and the water-soluble film can be prepared from the same polymer (e.g., a PVOH polymer having a specific viscosity, degree of hydrolysis, and amount of modification in the case of modified polymers). In refinements of the foregoing embodiment, the nonwoven web and water-soluble film can be prepared from different polymers (e.g., the polymer used to prepare the fibers of the nonwoven web can have a different fiber chemistry (e.g., modification), viscosity, degree of polymerization, degree of hydrolysis, and / or solubility than the polymer that makes up the water-soluble film). Advantageously, the multi-layered nonwoven webs and laminates can be used to tailor the moisture vapor transmission rate (MVTR) of pouches or packets made therefrom. Multi-layered materials can be prepared by a variety of processes known in the art, such as melt extrusion, coating (e.g., solvent coating, aqueous coating, or solid coating), spray bonding, material transfer, high temperature lamination, low temperature lamination, and combinations thereof.

[0157] In an embodiment, the nonwoven web can be a multi-layer nonwoven web comprising a first nonwoven web comprising a plurality of fibers, the plurality of fibers comprising a first fiber comprising a first polyvinyl alcohol fiber-forming material and a blend of fiber-forming materials comprising (a) a second polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not comprise carboxymethylcellulose, hydroxypropylmethylcellulose, or starch. In a refinement of the aforementioned embodiment, the multi-layer nonwoven web can comprise a second nonwoven web comprising a plurality of fibers, the plurality of fibers comprising a second fiber comprising a third polyvinyl alcohol fiber-forming material and a blend of fiber-forming materials comprising (a) a fourth polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not comprise carboxymethylcellulose, hydroxypropylmethylcellulose, or starch. In a refinement of the aforementioned embodiment, the first and second nonwoven webs can comprise the same fibers and have the same basis weight. In an alternative refinement of the aforementioned embodiment, the first and second nonwoven webs can comprise different fibers and have the same basis weight. In an alternative refinement of the aforementioned embodiment, the first and second nonwoven webs can include different fibers and can have different basis weights. In a refinement of the aforementioned embodiment, the first and second nonwoven webs can be layered with each other. In a refinement of the aforementioned embodiment, the first nonwoven web can have a water-soluble film laminated thereto. In a refinement of the aforementioned embodiment, the fiber-forming material of the first fibers of the first nonwoven web can be the same material as the film-forming material of the water-soluble film. In an alternative embodiment, the fiber-forming material of the first fibers of the first nonwoven web can be a different material than the film-forming material of the water-soluble film.

[0158] Generally, a multi-layer nonwoven web can have a basis weight that is the sum of the basis weights of the individual layers. Thus, the multi-layer nonwoven web will take longer to dissolve than either of the individual layers provided as a single layer. In an embodiment, the multi-layer nonwoven web has a basis weight of about 1 g / m 2 to about 100g / m 2The nonwoven web may have a basis weight ranging from 0.1 to 1.0. Additionally, without being bound by theory, it is believed that if the pore size and pore arrangement is non-uniform from layer to layer, the pores of each layer will not line up, thereby providing a multi-layer nonwoven web having smaller pores than the individual layers. Thus, a non-porous water-dispersible nonwoven web can be prepared by layering multiple porous water-dispersible nonwoven webs.

[0159] The nonwoven web can also be laminated to a water-soluble film. The laminate can be formed using any method known in the art, including but not limited to heat and pressure, chemical bonding, and / or solvent welding. Chemical bonding can include ionically or covalently functionalizing the surface of the nonwoven web and / or the surface of the water-soluble film so that when the surface of the nonwoven web comes into contact with the surface of the water-soluble film, a chemical reaction occurs and covalently bonds the nonwoven web and the water-soluble film together. The multilayer nonwoven web can include three or more layers. In an embodiment, the multilayer nonwoven web can include a first layer including a water-soluble film, a second layer including a nonwoven web, and a third layer including a water-soluble film. In an embodiment, the multilayer nonwoven web can include a first layer including a nonwoven web, a second layer including a water-soluble film, and a third layer including a nonwoven web.

[0160] Advantageously, the laminate can be prepared simultaneously with pouch formation, for example, using heat applied during thermoforming to bond the nonwoven web and the water-soluble film layer together. The water-soluble film can have the same solubility and / or chemical compatibility properties as the nonwoven web, or the water-soluble film can have a different solubility and / or chemical compatibility properties than the nonwoven web. In embodiments, the water-soluble film has the same solubility and / or chemical compatibility properties as the nonwoven web. In some embodiments, the water-soluble film has a different solubility and / or chemical compatibility properties than the nonwoven web. Advantageously, when the water-soluble film has a different solubility and / or chemical compatibility properties than the nonwoven web, the laminate can be used to form a pouch having an inner surface with a first solubility and / or chemical compatibility and an outer surface with a second solubility and / or chemical compatibility.

[0161] The water-soluble film used for the laminate can generally be any water-soluble film, such as those already known in the art. The polymer used to form the water-soluble film can be any water-soluble polymer, or combinations thereof, such as those described herein. The water-soluble film can contain at least about 50wt.%, 55wt.%, 60wt.%, 65wt.%, 70wt.%, 75wt.%, 80wt.%, 85wt.%, or 90wt.%, and / or up to about 60wt.%, 70wt.%, 80wt.%, 90wt.%, 95wt.%, or 99wt.% water-soluble polymer, such as PVOH polymer or polymer blend.

[0162] The water-soluble films can contain other auxiliary and processing agents, such as, but not limited to, plasticizers, plasticizer compatibilizers, surfactants, lubricants, release agents, fillers, extenders, crosslinkers, antiblocking agents, antioxidants, anti-adherents, defoamers, nanoparticles, such as layered silicate-type nanoclays (e.g., sodium montmorillonite), bleaching agents (e.g., sodium metabisulfite, sodium bisulfite, or others), aversive agents, such as bitter agents (e.g., denatonium salts, such as denatonium benzoate, denatonium saccharide, and denatonium chloride; sucrose octaacetate; quinines; flavonoids, such as quercetin and naringenin; and quassinoids, such as quassin and brucine), and pungent agents (e.g., capsaicin, piperine, allyl isothiocyanate, and resinferratoxin), and other functional ingredients, in amounts appropriate for their intended purpose. Preferred are embodiments that include plasticizers. The amount of such agents, individually or collectively, can be up to about 50 wt.%, 20 wt.%, 15 wt.%, 10 wt.%, 5 wt.%, 4 wt.%, and / or at least 0.01 wt.%, 0.1 wt.%, 1 wt.%, or 5 wt.% of the film.

[0163] The plasticizer can include any of the plasticizers disclosed herein, including, but not limited to, glycerin, diglycerin, sorbitol, ethylene glycol, diethylene glycol, triethylene glycol, dipropylene glycol, tetraethylene glycol, propylene glycol, polyethylene glycols up to 400 MW, neopentyl glycol, trimethylolpropane, polyether polyols, sorbitol, 2-methyl-1,3-propanediol (MPDiol®), ethanolamine, and mixtures thereof. Preferred plasticizers are glycerin, sorbitol, triethylene glycol, propylene glycol, dipropylene glycol, 2-methyl-1,3-propanediol, trimethylolpropane, or combinations thereof. The total amount of non-aqueous plasticizer can range from about 10 wt.% to about 40 wt.%, or from about 15 wt.% to about 35 wt.%, or from about 20 wt.% to about 30 wt.%, for example about 25 wt.%, based on the total film weight.

[0164] Suitable surfactants can include nonionic, cationic, anionic, zwitterionic classes. Suitable surfactants include any surfactants described herein. In various embodiments, the amount of surfactant in the water-soluble film is in the range of about 0.1 wt% to 2.5 wt%, and optionally in the range of about 1.0 wt% to 2.0 wt%. In embodiments, the amount of surfactant in the water-soluble film is expressed in parts per 100 parts of total water-soluble polymer in the water-soluble film (phr), and is present in the range of about 0.5 phr to about 4 phr, about 0.75 phr to about 3.0 phr, about 1.0 phr to about 2.5 phr, about 1.0 phr to about 2.0 phr, or about 1.5 phr.

[0165] Suitable lubricants / release agents can include, but are not limited to, fatty acids and their salts, fatty alcohols, fatty esters, fatty amines, fatty amine acetates, and fatty amides.Preferred lubricants / release agents are fatty acids, fatty acid salts, and fatty amine acetates.In one type of embodiment, the amount of lubricant / release agent in the water-soluble film ranges from about 0.02wt% to about 1.5wt%, optionally from about 0.1wt% to about 1wt%.

[0166] Fillers can be included in the water-soluble film and can include bulking agents, extenders, antiblocking agents, antiblocking agents, and combinations thereof. Suitable fillers / bulking agents / extenders / antiblocking agents / antiblocking agents include, but are not limited to, starch, modified starch, crosslinked polyvinylpyrrolidone, crosslinked cellulose, microcrystalline cellulose, silica, metal oxides, calcium carbonate, talc, mica, stearic acid, and metal salts thereof, such as magnesium stearate. Preferred materials are starch, modified starch, and silica. In one type of embodiment, the amount of fillers / extenders / antiblocking agents / antiblocking agents in the water-soluble film can range, for example, from about 1 wt.% to about 6 wt.%, or from about 1 wt.% to about 4 wt.%, or from about 2 wt.% to about 4 wt.%, 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.

[0167] In some embodiments, the water-soluble film can include 2 phr or more (e.g., 2 phr to 6 phr or 2 phr to 4 phr) of filler. In some embodiments, the film can include 2 phr or more (e.g., 2 phr to 6 phr or 2 phr to 4 phr) of filler, including bulking agents, antiblocking agents, or combinations thereof. Without wishing to be bound by theory, it is believed that including 2 phr or more (e.g., 2 phr to 6 phr or 2 phr to 4 phr) of filler can help prevent plasticizer from flowing or migrating out of the film when the plasticizer is included in an amount greater than or equal to 30 phr, for example in the range of 30 phr to 50 phr.

[0168] The antiblocking agent (e.g., SiO2 and / or stearic acid) can be present in the film in an amount ranging from at least 0.1 PHR, or at least 0.5 PHR, or at least 1 PHR, or from about 0.1 to 5.0 PHR, or from about 0.1 to about 3.0 PHR, or from about 0.4 to 1.0 PHR, or from about 0.5 to about 0.9 PHR, or from about 0.5 to about 2 PHR, or from about 0.5 to about 1.5 PHR, or from 0.1 to 1.2 PHR, or from 0.1 to 2.7 PHR, such as 0.5 PHR, 0.6 PHR, 0.7 PHR, 0.8 PHR, or 0.9 PHR.

[0169] Suitable median particle sizes for the antiblocking agent include ranges of about 3 to about 11 microns, or about 4 microns to about 11 microns, or about 4 to about 8 microns, or about 5 to about 6 microns, such as a median size (e.g., Dv50) of 5, 6, 7, 8, or 9 microns. Suitable SiO2 is an untreated synthetic amorphous silica designed for use in aqueous systems.

[0170] The water-soluble film may further have a residual moisture content of at least 4 wt.%, such as in the range of about 4 to about 10 wt.%, as measured by Karl Fischer titration.

[0171] Water-dispersible nonwoven webs may be prepared using methods described in Nonwoven Fabrics Handbook, prepared by Ian Butler, edited by Subhash Batra et al., incorporated herein by reference in its entirety. As described in Printing by Design, 1999, the present invention is also applicable to the use of other known methods including those described in the art. It can be made by any suitable method. The water-soluble film can be made by any suitable method, including solution casting. The water-dispersible nonwoven web and / or laminate can be used to form a container (pouch) by any suitable process, including vertical form, fill, and seal (VFFS), or thermoforming. The water-dispersible nonwoven web and / or laminate can be sealed by any suitable process, including, for example, solvent sealing or heat sealing of the water-dispersible nonwoven web and / or laminate layers along the perimeter of the container. The pouch can be used to administer materials that are delivered in bulk water, for example.

[0172] biodegradable

[0173] Polyvinyl alcohol polymers are generally biodegradable since they degrade under aerobic, anaerobic, soil, and compost conditions (in the presence of water) in the presence of water and enzymes. 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 above 80% does not appreciably affect biodegradation. Furthermore, the stereoregularity of the hydroxyl groups of the polyvinyl alcohol polymer has a significant effect on the biodegradation activity level, the more isotactic the hydroxyl groups of the polymer sequence, 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 to the film. Furthermore, without wishing to be bound by theory, it is believed that the degree of polymerization of a polyvinyl alcohol polymer has little or no effect on the biodegradability of a film or nonwoven web prepared with that polymer, but the polymerization temperature may affect the biodegradability of the film or nonwoven, as the polymerization temperature may affect the crystallinity and aggregation state of the polymer. In particular, as the crystallinity decreases, the hydroxyl groups of the polymer chains become less aligned within the polymer structure, and the polymer chains become more disordered, leading to the chains accumulating as amorphous aggregates, thereby decreasing the availability of ordered polymer structures and biodegradation activity, as would be expected if the polymer were to become insoluble, reducing the biodegradation mechanism in soil and / or compost.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, and therefore substitution of 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 homopolymers having the same degree of hydrolysis, unless the functional groups themselves are also biodegradable and the biodegradability of the polymer cannot be increased by substitution.Furthermore, it is believed that although the biodegradability activity level of substituted polyvinyl alcohols can be lower than that of the corresponding homopolymers, the substituted polyvinyl alcohols will still exhibit biodegradability.

[0174] 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. Appropriate standards include OECD 301B (ready biodegradation), OECD 301B (enhanced biodegradation), OECD 302B (native biodegradation), OECD 311 (anaerobic), and ASTM D5988 (soil).

[0175] In an embodiment, the fibers and nonwoven webs of the present disclosure can be readily biodegradable, enhanced biodegradable, or native biodegradable. As used herein, the term "ready biodegradable" refers to a standard met by a material (e.g., fiber) according to the OECD 301B test described in ECHA's Annex XV, where the material (e.g., fiber) reaches 60% biodegradation (mineralization) within 28 days from the start of the test. As used herein, the term "enhanced biodegradable" refers to a standard met by a material (e.g., fiber) according to the OECD 301B test described in ECHA's Annex XV, where the material (e.g., fiber) reaches 60% biodegradation within 60 days from the start of the test. In an embodiment, the fibers and nonwoven webs of the present disclosure meet the readily biodegradable standard. In an embodiment, the fibers and nonwoven webs of the present disclosure meet the readily biodegradable or enhanced degradation standard. In an embodiment, the fibers and nonwoven webs of the present disclosure meet the native biodegradable standard. In an embodiment, the fibers and nonwoven webs of the present disclosure meet the enhanced degradation standard. In embodiments, the fibers and nonwoven webs of the present disclosure meet the specifications for natural, enhanced, or facile biodegradation. In embodiments, the laminates (nonwovens and films) of the present disclosure meet the specifications for facile or enhanced biodegradation.

[0176] Purpose The nonwoven web of the present disclosure is generally suitable for various commercial applications.Suitable commercial applications of the nonwoven web of the present disclosure include, but are not limited to, water-dispersible or flushable pouches and packets; medical uses such as surgical masks, medical packaging, shoe covers, wound dressings and drug delivery; filtration systems for gasoline and oil, mineral processing, vacuum bags, air filters and allergen membranes or laminates; personal care products such as baby wipes, makeup remover wipes, exfoliating cloths and makeup applicators; office products such as shopping bags or envelopes; and others such as lens cleaning wipes, cleanroom wipes, plant potting materials, antibacterial wipes, agricultural seed strips, fabric softener sheets, clothing / laundry bags, food packaging materials, floor care wipes, pet care wipes, scouring tools, powder removal and hand washing detergents.

[0177] Sealed pouch The present disclosure further provides a pouch comprising a nonwoven web according to the present disclosure. In some embodiments, the pouch comprises a laminate comprising a water-soluble film and a water-dispersible nonwoven web of the present disclosure. The pouch can be a water-dispersible pouch, and optionally a water-soluble pouch and / or a flushable pouch. The present disclosure further provides a method of preparing a packet comprising a nonwoven web of the present disclosure, comprising forming the nonwoven web into a pouch, filling the pouch with a composition to be encapsulated therein, and sealing the pouch to form a packet. In some embodiments, the sealing comprises heat sealing, solvent welding, adhesive sealing, or a combination thereof.

[0178] The nonwoven webs and laminates disclosed herein are useful for making sealed articles in the form of pouches that define an interior pouch volume containing a composition therein for release to an aqueous environment. In embodiments, a "sealed article" optionally includes a sealed compartment with a vent, for example, if the compartment encloses a solid that outgasss, but would more commonly be a completely sealed compartment.

[0179] The pouch may contain a single compartment or multiple compartments. The water-dispersible pouch may be formed from two layers of water-dispersible nonwoven webs or laminates sealed at the borders, or by a single nonwoven web or laminate folded over itself and sealed. The nonwoven web or laminate forms the outer surface of at least one sidewall of the pouch, optionally of the entire pouch, and preferably of at least one sidewall. In another type of embodiment, the nonwoven web or laminate forms the inner wall of the packet, for example as a dividing wall between both compartments. The nonwoven web or laminate may also be used in combination with a water-soluble film, for example as an outer wall, an inner wall and / or a lid of a compartment.

[0180] The composition enclosed in the pouch is not particularly limited, and may include, for example, any of the various compositions described herein.In embodiments that include multiple compartments, each compartment may contain the same composition and / or different compositions.In turn, the composition may take any suitable form, including, but not limited to, liquid, solid, gel, paste, mul, compressed solid (tablet), and combinations thereof (e.g., solid suspended in liquid).

[0181] In some embodiments, the pouch includes multiple compartments. The multiple compartments are generally stacked such that the compartments share a dividing wall inside the pouch. The compartments of the multi-compartment pouch may be of the same or different size and / or volume. The compartments of the multi-compartment pouch of the present invention may be isolated or connected in any suitable manner. In an embodiment, the second and / or third and / or subsequent compartments are stacked on top of the first compartment. In one embodiment, the third compartment may be stacked on top of the second compartment, which is then stacked on top of the first compartment in a sandwich configuration. Alternatively, the second and third compartments may be stacked on top of the first compartment. However, it is equally conceivable that the first, second and / or third and / or subsequent compartments are oriented side-by-side or in a concentric orientation. The compartments may be wrapped with a string, with each compartment being individually separable by a line of perforation, such that each compartment may be individually torn away from the remainder of the string by an end user. In some embodiments, the first compartment may be surrounded by at least a second compartment, for example, in a tire and rim configuration, or in a pouch-in-pouch configuration.

[0182] The geometries of the compartments may be the same or different. In embodiments, the third and subsequent compartments have different geometries and shapes compared to the first and second compartments, respectively, as needed. In these embodiments, the third and subsequent compartments are arranged in a design on the first or second compartments as needed. The design may be decorative, educational, or illustrative, for example, to illustrate a concept or instruction, and / or may be used to indicate the origin of the product.

[0183] How to make a pouch

[0184] The pouches and packets can be made using any suitable equipment and methods. For example, single compartment pouches can be made using vertical, horizontal or rotary drum filling techniques commonly known in the art. Such methods can be either continuous or intermittent. The nonwoven web, layered nonwoven web and film, or laminate structure can be moistened and / or heated to increase its malleability. The method can also include the use of a vacuum to draw the nonwoven web, layered nonwoven web and film, or laminate structure into a suitable mold. The vacuum to draw the nonwoven web or laminate into the mold can be applied for about 0.2 to about 5 seconds, or about 0.3 to about 3 seconds, or about 0.5 to about 1.5 seconds once the nonwoven web, layered nonwoven web and film, or laminate structure is on the horizontal portion of the surface. This vacuum may for example be such as to result in an overpressure in the range of 10 mbar to 1000 mbar, or in the range of 100 mbar to 600 mbar.

[0185] The mold from 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 also vary in size and shape from one another, if desired. For example, the volume of the final pouch can be about 5ml to about 300ml, or about 10ml to 150ml, or about 20ml to about 100ml, and the size of the mold is adjusted accordingly.

[0186] thermoforming

[0187] A thermoformable nonwoven web or laminate is one that can be shaped by the application of heat and force. Thermoforming of nonwoven webs, layered nonwoven webs and films or laminate structures is the process of heating the nonwoven webs, layered nonwoven webs and films, or laminate structures, shaping them (e.g., in a mold), and then cooling the resulting nonwoven web or laminate, at which point it retains its shape, e.g., the shape of the mold. Heat may be applied using any suitable means. For example, the nonwoven web or laminate may be heated directly before it is fed onto a surface, or at some point on the surface, by passing it under a heating element or through hot air. Alternatively, it may be heated indirectly, for example, by heating the surface of the nonwoven web or laminate or by applying a heat item to the surface. In an embodiment, the nonwoven web or laminate is heated using infrared light. The nonwoven web or laminate may be heated to a temperature ranging from about 50° C. to about 200° C., about 50° C. to about 170° C., 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 may be performed by any one or more of the following processes: manual draping of the thermally softened nonwoven web or laminate over a mold, or pressure induced forming (e.g., vacuum forming) of the softened nonwoven web or laminate onto a mold, or automatic high speed indexing of a fresh extruded sheet having a precise known temperature to forming and trimming stations, or automatic placement, plug forming, and / or pneumatic stretch forming and pressure forming of the nonwoven web or laminate.

[0188] Alternatively, the nonwoven web or laminate can be wetted directly by any suitable means, such as by spraying a wetting agent (including water, a polymeric composition, a plasticizer for the nonwoven web or laminate composition, or any combination of the foregoing) onto the nonwoven web or laminate before it is delivered to the surface or once on the surface, or indirectly by wetting the surface of the nonwoven web or laminate or by applying a wetting article to the surface of the nonwoven web or laminate.

[0189] Once the nonwoven web or laminate is heated and / or wetted, it can be drawn into a suitable mold, preferably using a vacuum. Filling of the nonwoven web or laminate after molding can be done by utilizing any suitable means. In an embodiment, the most preferred method depends on the product form and the required filling speed. In an embodiment, the nonwoven web or laminate after molding is filled by an in-line filling technique. The filled open packet is then closed using a second nonwoven web or laminate by any suitable method to form a pouch. This can be done in a horizontal position and with a continuous constant motion. Closing can be done by continuously feeding a second nonwoven web or laminate, preferably a water-soluble nonwoven web or laminate, onto and on the surface of the open packet, and then sealing the first and second nonwoven webs or laminates together, preferably in the area between the molds and therefore between both packets.

[0190] Pouch sealing

[0191] Any suitable method of sealing the pouch and / or its individual compartments may be utilized. Non-limiting examples of such means include heat sealing, solvent welding, solvent or wet sealing, or combinations thereof. Usually, only the areas that will form the seal are treated with heat or solvent. Heat or solvent can be applied by any method, usually only to the sealing material and usually only to the areas that will form the seal. When using solvent or wet sealing or solvent or wet welding, it may be preferred that heat is also applied. A preferred wet or solvent sealing / welding method includes selectively applying a solvent to areas between the mold or on the surface of the closing material, for example, by spraying or printing the solvent on these areas, and then applying pressure to these areas to form the seal. For example, sealing rolls and belts (which also provide heat, if necessary) can be used.

[0192] In an embodiment, the inner nonwoven web or laminate is sealed to the outer nonwoven web 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 solvent comprises water and further comprises one or more of polyols, diols and / or glycols, such as 1,2-ethanediol (ethylene glycol), 1,3-propanediol, 1,2-propanediol, 1,4-butanediol (tetramethylene glycol), 1,5-pentanediol (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, isomal, maltitol, lactitol. In an embodiment, the sealing solution comprises a water soluble polymer.

[0193] The sealing solution may be applied to the interface area of ​​the inner nonwoven web or laminate in any suitable amount 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 or laminate in grams of solution per square meter of nonwoven web or laminate. In general, if the coating weight of the sealing solvent is too low, the nonwoven web or laminate will not adhere well and there is an increased risk of pouch failure at the seam. Furthermore, if the coating weight of the sealing solvent is too high, there is an increased risk of solvent migration from the border area and an increased likelihood that etching holes may form in the sides of the pouch. The coating weight window refers to the range of coating weights that can be applied to a given film while maintaining both good adhesion and avoiding the formation of etching holes. A wider coating weight window is desirable because it results in a robust seal under a wider 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.

[0194] Packet Drop

[0195] The formed packets can be cut by a cutting device. The cutting can be done using any known method. It may also be preferred that the cutting is done continuously, preferably at a constant speed, preferably while in a horizontal position. The cutting device can be, for example, a sharp article, or a warm article, or a laser, whereby, in the latter case, the warm article or laser passes through and "burns" the film / sealed area.

[0196] Forming and filling multi-compartment pouches

[0197] The various compartments of the multi-compartment pouch may be made together in a side-by-side or concentric style, in which case the resulting tethered pouch may or may not be separated by cutting. Alternatively, the compartments may be made individually.

[0198] In an embodiment, a pouch may be made according to a method comprising the steps of: a) forming a first compartment (as described above), b) forming a recess in or all of the closed compartment formed in step (a) to produce a second molded compartment overlying the first compartment, c) filling the second compartment and closing it with a third nonwoven web, laminate or film, d) sealing the first, second and third nonwoven webs, laminates or films, and e) cutting the nonwoven webs or laminates to produce a multi-compartment pouch. The recess formed in step (b) may be achieved by applying a vacuum to the compartment prepared in step (a).

[0199] In embodiments, the second and / or third compartment may be made in separate steps and then combined with the first compartment, as described in European Patent Application No. 08101442.5, or U.S. Patent Application Publication No. 2013 / 240388A1, or WO2009 / 152031.

[0200] In embodiments, pouches may be made according to a method comprising the steps of: a) forming a first compartment using a first nonwoven web or laminate in a first forming device, optionally using heat and / or vacuum; b) filling the first compartment with a first composition; c) optionally filling the second compartment with a second composition; d) sealing the first and optional second compartments to the first nonwoven web or laminate with a second nonwoven web or laminate; and e) cutting the nonwoven web or laminate to produce the multi-compartment pouch.

[0201] In an embodiment, a pouch may be made according to a method comprising the steps of: a) forming a first compartment with a first nonwoven web or laminate in a first forming device, optionally using heat and / or vacuum; b) filling the first compartment with a first composition; c) deforming a second nonwoven web or laminate in a second forming device, optionally using heat and vacuum to create a second and optionally third shaped compartment; d) filling the second and optionally third compartment; e) sealing the second and optionally third compartment with a third nonwoven web or laminate; f) placing the sealed second and optionally third compartment over the first compartment; g) sealing the first, second and optionally third compartments; and h) cutting the nonwoven web or laminate to produce a multi-compartment pouch.

[0202] The first and second forming machines may be selected based on their suitability for carrying out the above method. In an embodiment, the first forming machine is preferably a horizontal forming machine, and the second forming machine is preferably a rotary drum forming machine, preferably located above the first forming machine.

[0203] It should be appreciated that by use of an appropriate feed station it may be possible to produce multi-compartment pouches incorporating several different or distinct compositions, and / or different or distinct liquid, gel or paste compositions.

[0204] In embodiments, the nonwoven web or laminate and / or pouch is sprayed or dusted with a suitable substance, such as an active agent, a lubricant, a repellent, or mixtures thereof. In embodiments, the nonwoven web or laminate and / or pouch is printed on its surface, for example with an ink and / or an active agent.

[0205] Vertical Form, Fill and Seal

[0206] In an embodiment, the nonwoven web or laminate of the present disclosure can be used to make 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 or laminate around a feed tube in a longitudinal direction. The machine heat seals or otherwise fastens the opposing edges of the nonwoven web or laminate together to make a side seal of the nonwoven web or laminate to form a hollow tube. The machine then heat seals or otherwise makes a bottom seal, thereby defining an open-topped container portion where a top seal is later formed. The machine introduces a specified amount of flowable product into the container portion through the open top end. Once the container contains a desired amount of product, the machine sends the nonwoven web or laminate to another heat sealing device, for example, to make a top seal. Finally, the machine feeds the nonwoven web or laminate to a cutter which cuts the film just above the top seal to provide a filled package.

[0207] During operation, the assembly equipment feeds the nonwoven web or laminate from the rolls to form the package, therefore the nonwoven web or laminate must be able to easily advance through the equipment and not be so fragile that it will not adhere to the assembly equipment or break during processing.

[0208] Pouch Contents In any embodiment, the pouch can contain (enclose) the composition in the defined internal volume of the pouch. The composition can be selected from a liquid, a solid, or a combination thereof. In an embodiment in which the composition is a liquid, the nonwoven web can be a nonporous nonwoven web or a porous nonwoven web laminated with a water-soluble film, the water-soluble film forming the inner surface of the pouch. In an embodiment in which the composition is a solid, the pouch can be a nonporous nonwoven web, a porous nonwoven web, or a porous nonwoven web laminated with a water-soluble film. In an embodiment in which the pouch comprises a porous nonwoven web, the particle size of the solid composition is smaller than the pore size of the nonwoven web.

[0209] In an embodiment, the sealed article of the present disclosure can enclose within its internal pouch volume a composition comprising a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, a food nutritional composition, an industrial cleaning composition, a pharmaceutical composition, a disinfectant composition, a pet composition, an office composition, a livestock composition, an industrial composition, a marine composition, a commercial composition, a military composition, a recreational composition, or a combination thereof. In an embodiment, the water-dispersible sealed article of the present disclosure can enclose within its internal pouch volume a composition comprising a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, a food nutritional composition, an industrial cleaning composition, or a combination thereof. In an embodiment, the water-dispersible sealed article of the present disclosure can enclose within its internal pouch volume a composition comprising a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, or a combination thereof. In an embodiment, the water-dispersible sealed article of the present disclosure can enclose within its internal pouch volume a composition comprising an agricultural composition or a water treatment composition.

[0210] As used herein, "liquid" includes free-flowing liquids, as well as pastes, gels, foams, and mousses. Non-limiting examples of liquids include light-duty and heavy-duty liquid detergent compositions, dish detergents for hand and / or machine washing; hard surface cleaning compositions, fabric enhancers, gel detergents commonly used in laundry, bleaches and laundry additives, shaving creams, skin care, hair care compositions (shampoos and conditioners), and body washes. Such detergent compositions can include surfactants, bleaches, enzymes, fragrances, dyes or colorants, solvents, and combinations thereof. Optionally, the detergent composition is selected from the group consisting of laundry detergents, dish washing detergents, hard surface cleaning compositions, fabric enhancer compositions, shaving creams, skin care, hair care compositions (shampoos and conditioners), and body washes, and combinations thereof.

[0211] Non-limiting examples of liquids include agricultural compositions, automotive compositions, aviation compositions, food and nutritional compositions, industrial compositions, livestock compositions, marine compositions, pharmaceutical compositions, commercial compositions, military and paramilitary compositions, office compositions, recreational and park compositions, pet compositions, and water treatment compositions, including cleaning and detergent compositions applicable to any such use.

[0212] Gas, e.g., suspended bubbles, or solids, e.g., particles, may be contained within the liquid. "Solids," as used herein, include, but are not limited to, powders, agglomerates, and mixtures thereof. Non-limiting examples of solids include granules, microcapsules, beads, noodles, glaze balls. Solid compositions may provide technical benefits, including, but not limited to, cleaning benefits, pre-treatment benefits, and / or aesthetic effects.

[0213] The composition may be a non-household care composition.For example, the non-household care composition can be selected from agricultural compositions, aviation compositions, food nutrition compositions, industrial compositions, livestock compositions, marine compositions, pharmaceutical compositions, commercial compositions, military and paramilitary compositions, office compositions, recreational and park compositions, pet compositions, and water treatment compositions, including cleaning compositions and detergent compositions applicable to any such use, but excluding fabric and household care compositions.

[0214] In one type of embodiment, the composition is an agricultural chemical, such as a pesticide, fungicide, herbicide, pesticide, miticide, repellent, attractant, defoliament, plant growth regulator, or the like. The additives may include one or more of the following: nociceptors, fertilizers, bactericides, micronutrients and trace elements. Suitable pesticides and adjuvants are described in US Patent Nos. 6,204,223 and 4,681,228 and EP0989803A1. For example, suitable herbicides include paraquat salts (e.g., paraquat dichloride or paraquat bis(methyl sulfate)), diquat salts (e.g., diquat dibromide or diquat alginate), and glyphosate or its salts or esters (also known as sulfosates, such as glyphosate isopropylammonium, glyphosate sesquisodium or glyphosate trimesium). A pair of incompatible crop protection chemicals can be used in separate chambers, for example, as described in US Patent No. 5,558,228. Pairs of incompatible crop protection chemicals that may be used include, for example, bensulfuron methyl and molinate; 2,4-D and thifensulfuron methyl; 2,4-D and methyl 2-[[[[N-4-methoxy-6-methyl-1,3,5-triazin-2-yl]-N-methylamino]carbonyl]amino]-sulfonyl]benzoate; 2,4-D and metsulfuron methyl; maneb or mancozeb and benomyl; glyphosate and metsulfuron methyl; tralomethrin and any organophosphate (such as monocrotophos or dimethoate). ); bromoxynil and N-[[4,6-dimethoxypyrimidin-2-yl]-amino]carbonyl]-3-(ethylsulfonyl)-2-pyridine-sulfonamide; bromoxynil and methyl 2-[[[[(4-methyl-6-methoxy)-1,3,5-triazin-2-yl)amino]carbonyl]amino]sulfonyl]-benzoate, bromoxynil and methyl 2-[[[[N-(4-methoxy-6-methyl-1,3,5-triazin-2-yl)-N-methylamino]carbonyl]amino]sulfonyl]benzoate.In another related type of embodiment, the composition can include one or more seeds, optionally together with soil, including, for example, the type of embodiments described in U.S. Pat. No. 8,333,033, and optionally together with one or more additional components selected from mulch, sand, peat moss, water jelly crystals, and fertilizer.

[0215] In another type of embodiment, the composition is a water treatment agent. Such agents may include harsh chemicals, such as aggressive oxidizing chemicals, as described, for example, in US Patent Application Publication No. 2014 / 0110301 and US Patent No. 8,728,593. For example, disinfectants may include hypochlorites, such as sodium hypochlorite, calcium hypochlorite and lithium hypochlorite, chlorinated isocyanurates, such as dichloroisocyanuric acid (also called "dichlor" or dichloro-s-triazinetrione, 1,3-dichloro-1,3,5-triazinane-2,4,6-trione) and trichloroisocyanuric acid (also called "trichlor" or 1,3,5-trichloro-1,3,5-triazinane-2,4,6-trione). Salts and hydrates of disinfectant compounds are also contemplated. For example, dichloroisocyanuric acid may be provided as sodium dichloroisocyanurate, sodium dichloroisocyanurate dihydrate, among others. Bromine-containing disinfectants, such as 1,3-dibromo-5,5-dimethylhydantoin (DBDMH), 2,2-dibromo-3-nitrilopropionamide (DBNPA), dibromocyanoacetamide, 1-bromo-3-chloro-5,5-dimethylhydantoin and 2-bromo-2-nitro-1,3-propanediol, among others, may also be suitable for use in unit dose packaging applications. The oxidizing agent may be one described in U.S. Pat. No. 7,476,325, for example, potassium hydrogen peroxymonosulfate. The composition may be a pH-adjusting chemical, for example, one described in U.S. Patent Application Publication No. 2008 / 0185347, including, for example, an acidic component and an alkaline component, such that the composition is effervescent upon contact with water and can adjust the pH of the water. Suitable components include sodium bicarbonate, sodium bicarbonate, potassium hydroxide, sulfamic acid, organic carboxylic acids, sulfonic acids, and potassium dihydrogen phosphate. The buffer blend can include, for example, boric acid, sodium carbonate, glycolic acid and oxone monopersulfate.

[0216] The water treatment agent can be or can include a flocculant, for example, as described in U.S. Patent Application Publication No. 2014 / 0124454. The flocculant can include a polymer flocculant, such as polyacrylamide, polyacrylamide copolymers (such as acrylamide copolymers of diallydimethylammonium chloride (DADMAC), dimethylaminoethyl acrylate (DMAEA), dimethylaminoethyl methacrylate (DMAEM), 3-methylamidopropyltrimethylammonium chloride (MAPTAC)) or acrylic acid; cationic polyacrylamide; anionic polyacrylamide; neutral polyacrylamide; polyamine; polyvinylamine; polyethyleneimine; polydimethyldiallylammonium chloride; polyoxyethylene; polyvinyl alcohol; polyvinylpyrrolidone; polyacrylic acid; polyphosphoric acid; polystyrene sulfonic acid; or any combination thereof. The flocculant can be selected from chitosan acetate, chitosan lactate, chitosan adipate, chitosan glutamate, chitosan succinate, chitosan malate, chitosan citrate, chitosan fumarate, chitosan hydrochloride, and combinations thereof. The water treatment composition can include one or more phosphate removing substances selected from, for example, zirconium compounds, rare earth lanthanide salts, aluminum compounds, iron compounds, or any combination thereof.

[0217] The composition may be, for example, a limescale removing composition as described in US Patent Application Publication No. 2006 / 0172910, such as citric acid or maleic acid or their sulfates, or any mixture thereof.

[0218] Various other types of compositions are contemplated for use in the packets described herein, including particulates such as down feathers as described in US RE29059E, superabsorbent polymers as described in US Patent Publication Nos. 2004 / 0144682 and 2006 / 0173430, pigments and stains as described in US Patent Nos. 3,580,390 and 2011 / 0054111, brazing fluxes (e.g., alkali metal fluoroaluminates, alkali metal fluorosilicates and alkali metal fluorozincates) as described in US Patent No. 8,163,104, food products (e.g., coffee powder or dried soups) as described in US Patent Publication No. 2007 / 0003719, and wound dressings as described in US Patent No. 4,466,431.

[0219] In pouches containing laundry, laundry additive and / or softener booster compositions, the compositions may be formulated with the following non-limiting list of ingredients: fabric care benefit agents; detersive enzymes; precipitation aids; rheology modifiers; builders; bleach; bleaching agents; bleach precursors; bleach boosters; bleach catalysts; perfume and / or perfume microencapsulations (see, e.g., U.S. Pat. No. 5,137,646); perfume loaded zeolites; starch encapsulated accords; accord); polyglycerol esters; whitening agents; pearlescent agents; enzyme stabilizing systems; scavenging agents including anionic dye fixing agents, anionic surfactant complexing agents and mixtures thereof; optical brighteners or fluorescent agents; polymers including, but not limited to, soil releasing polymers and / or soil suspending polymers; dispersants; defoamers; non-aqueous solvents; fatty acids; foam suppressors, such as silicone foam suppressors (see U.S. Publication No. 2003 / 0060390 A1, ¶65-77). cationic starch (see US2004 / 0204337A1 and US2007 / 0219111A1); dross dispersants (see US2003 / 0126282A1, ¶89-90); direct dyes; hueing dyes (see US2014 / 0162929A1); colorants; opacifiers; antioxidants; hydrotropes such as toluenesulfonates, cumenesulfonates and naphthalenesulfonates; color speckles; colored beads, spheres or extrudates; clay softeners; and antibacterial agents. Any one or more of these ingredients are further described in U.S. Patent Application Publication No. 2010 / 305020A1, U.S. Patent Application Publication No. 2003 / 0139312A1 and U.S. Patent Application Publication No. 2011 / 0023240A1. Additionally or alternatively, the composition may include a surfactant, a quaternary ammonium compound, and / or a solvent system. The quaternary ammonium compound may be present in a softening booster composition, such as a fabric softener, and may have the structure NR4 + and R is an alkyl or aryl group.

[0220] Dissolution and disintegration test (MSTM-205) The nonwoven web, water-soluble film or laminate structure can be characterized or tested by dissolution time and disintegration time according to MonoSol Test Method 205 (MSTM205), 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. Equipment and materials: 600mL beaker Magnetic stirrer (Labline model number 1250 or equivalent) Magnetic stirring rod (5cm) Thermometer (0 to 100°C ±1°C) Mold, stainless steel (3.8cm x 3.2cm) Timer (0 to 300 seconds, accurate to the nearest second) Polaroid 35mm slide mount (or equivalent) MonoSol 35mm Slide Mount Holder (or equivalent) Distilled water

[0221] For each nonwoven web to be tested, three test specimens are cut from the nonwoven web sample resulting in a 3.8 cm by 3.2 cm test specimen. 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.

[0222] Each specimen is mounted on an individual 35 mm slide mount.

[0223] Fill a beaker with 500 mL of distilled water. Measure the temperature of the water with a thermometer and, if necessary, heat or cool the water to maintain the temperature at which dissolution will be determined, e.g., 20° C. (about 68° F.).

[0224] Mark the height of the water column. Place a magnetic stirrer in the bottom of the holder. Place a beaker on the magnetic stirrer, add a magnetic stirring rod to the beaker, turn on the stirrer, and adjust the stirring speed until a vortex is created that is approximately one-fifth the height of the water column. Mark the depth of the vortex.

[0225] Secure the 35mm slide mount in the alligator clamp of the 35mm slide mount holder so that the long end of the slide mount is parallel to the surface of the water. The depth adjuster on the holder should be set so that the end of the clamp drops 0.6 cm below the surface of the water. One of the short sides of the slide mount should be next to the side of the beaker with the other positioned directly over the center of the stirring rod so that the surface of the nonwoven web is perpendicular to the water flow.

[0226] In one motion, drop the clamped slide and clamp into the water and start the timer. Rupture occurs when the sample becomes compromised within the slide, e.g., a hole is created. Disintegration occurs when the nonwoven web breaks away and no sample material remains within the slide. When all of the visible nonwoven web is released from the slide mount, lift the slide out of the water while continuing to monitor the solution for undissolved nonwoven web fragments. Dissolution has occurred when all of the nonwoven web fragments are no longer visible and the solution is no longer cloudy. Rupture and dissolution can occur simultaneously in nonwoven samples, in which case the fibers are prepared from polyvinyl alcohol with a low degree of hydrolysis (e.g., about 65-88%). If the difference between rupture and dissolution is 5 seconds or longer, the dissolution time is recorded, independent of the rupture time.

[0227] 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 the opacity of the nonwoven web or an increase in its transparency. The change from opaque to gradually transparent can be observed visually. During MSTM-205, the opacity / transparency of the nonwoven web is monitored after the fixed slide and clamp are dropped into water. At the time point where no change in opacity / transparency is observed (i.e., the web does not decrease in opacity or increases in transparency), the time is recorded as the thinning time.

[0228] Results should include: complete sample identification; individual and average disintegration and dissolution times; and the water temperature in which the samples were tested.

[0229] Method for determining single fiber solubility Single fiber solubility can be characterized by the water breaking temperature. The fiber breaking temperature can be determined as follows: A load of 2 mg / dtex is placed on a fiber with a fixed length of 100 mm. The water temperature starts at 1.5° C. and then increases in 1.5° C. increments every 2 minutes until the fiber breaks. The temperature at which the fiber breaks is expressed as the water breaking temperature.

[0230] Single fiber solubility can be characterized by the temperature at which dissolution is complete. The temperature at which dissolution is complete 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 increases in 1.5° C. increments every 2 minutes until the fiber is completely dissolved. The sample is stirred at each temperature. The temperature at which the fiber is completely dissolved in less than 30 seconds is designated as the complete dissolution temperature.

[0231] Diameter Test Method The diameter of discrete fibers or fibers in 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 to provide a suitable magnification for measuring the fibers. 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 the image (on the monitor screen) obtained with the SEM or optical microscope. A mouse and cursor instrument is used to find the edge of a randomly selected fiber and then measure along its width (i.e. perpendicular to the fiber direction at that point) to the other edge of the fiber. A calibrated image analysis tool with a magnified scale is used to scale and provide an actual reading in microns. For fibers in a nonwoven web, a number of fibers are randomly selected along a sample of the nonwoven web using the SEM or optical microscope. At least two portions of the nonwoven web material are cut and tested in this manner. A total of at least 100 such measurements are made and then all data is recorded for statistical analysis. The recorded data is used to determine the average (mean) of the fibers, the standard deviation of the fibers, and the fiber distribution. The median diameter of the fibers is calculated.

[0232] Tensile Strength, Modulus and Elongation Tests Nonwoven webs, water-soluble films or laminate structures characterized or tested for tensile strength according to the Tensile Strength (TS) Test, modulus (or tensile stress) according to the Modulus (MOD) Test, and elongation according to 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 includes the determination of tensile strength and the determination of modulus at 10% elongation according to ASTM D882 ("Standard Test Method for Tensile Properties of Thin Plastic Sheets") or equivalent. An INSTRON tensile testing device (Model 5544 Tensile Tester or equivalent) is used to collect the nonwoven web data. A minimum of three specimens (each cut with a reliable cutting device to ensure dimensional stability and repeatability) are tested in the machine direction (MD) (as required) for each measurement. Testing is performed at a standard laboratory atmosphere of 23±2.0°C and 35±5% relative humidity. For tensile strength or modulus determination, a 1 inch (2.54 cm) wide 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 prepared according to the manufacturer's instructions, equipped with a 500N load cell, and calibrated. The correct grips and faces are installed (INSTRON grips with rubber coated, 25 mm wide, model number 2702-032 faces, or equivalent). The sample is mounted 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 (sample length at break relative to the initial sample length). In general, the higher the % elongation of the sample, the better the processing characteristics of the nonwoven web (e.g., improved formability into packets or pouches).

[0233] Determining Basis Weight Basis weight is determined in accordance with ASTM D3776 / D3776M-09a (2017). Briefly, it should be at least 130 cm 2A test piece having an area of ​​at least 130 cm, or several smaller die-cut test pieces taken from different locations in the sample. 2 The specimen is cut into die cut specimens having a total area of ​​1.5 mm. The specimens are weighed and mass determined on a top-loading analytical balance with a resolution of ±0.001 g. The balance is protected from air currents and other obstructions with a draft shield. A fabric specimen may also be weighed. Mass is calculated in ounces / square yard, ounces / linear yard, linear yard / pound, or grams / square meter to three significant figures.

[0234] Determination of water vapor transmission rate Moisture Vapor Transmission Rate (MVTR) is determined in accordance with MSTM-136. MVTR defines how much moisture will migrate through a film sample per day. The description provided below refers to nonwoven webs, but is equally applicable to water-soluble films or laminate structures. Equipment and materials: Permatran-W Model 3 / 34 (or equivalent) Compressed gas cylinder of nitrogen (99.7% or higher) T-shaped regulator (part number 027-343) Main Line Supply Regulator HPLC grade water (or equivalent) 10cc syringe with Luerlok tip (part number 800-020) powder-free gloves High Vacuum Grease (Part Number 930-022) (2) Test cell Cutting mold Cutting Board Razor blade with handle cut resistant gloves

[0235] Prepare the Permatran W-Model 3 / 34: Ensure that the nitrogen pressure level is greater than 300 psi, that the carrier gas T-regulator pressure indicates 29 psi (must not exceed 32 psi), and that the main line supply regulator pressure is set to 35 psi. Open the instrument panel door and approach the humidifier to check the water level. If the water level is low, fill a syringe with HPLC grade water and insert the luer fitting of the syringe into the reservoir's "fill port". Open the "fill valve" by rotating it counterclockwise 2-3 times, then push on the syringe plunger to force the water into the reservoir. Close the "fill valve" and remove the syringe. Note: The water level should not exceed the line marked adjacent to the reservoir.

[0236] Sample Preparation and Testing: For each nonwoven web to be tested, take the sample web and lay it flat on the cutting board. Place the mold on top of the web and use the razor blade with handle to cut the sample. Be sure to wear cut resistant gloves when cutting the sample. Set the sample aside. Grease the perimeter sealing surface of the top piece of the test cell with high vacuum grease. Mount the film sample on top of the top piece of the sample cell. NOTE: Orientation can be important. For homogenous materials, orientation is not important. For multi-layered and laminated materials, place the multi-layered film or laminate with the barrier coating or laminate up against the top of the cell. For example, one side of a wax coated PVOH web should be mounted wax side up and placed with the wax facing in the direction of the carrier gas (nitrogen). Place the top piece of the test cell on top of the bottom piece of the test cell. Make sure the test cell is securely clamped together with a good seal. Press the cell load / unload button and open the cell tray. Grasp the test cell by the leading and trailing edges and lower straight down. Close the cell tray completely by gently pushing straight down towards the panel. Press the Cell Load / Unload button to clamp the cell. NOTE: A click should be heard. Repeat with the second sample.

[0237] After the specimens are loaded and the instrument is ready, the test parameters must be set. NOTE: There are two types of test parameters: Cell parameters and Instrument parameters. Cell parameters are specific to each cell while Instrument parameters are common for all cells. Touch the "Test button" on the screen. Under "Auto Test", select "Tab A". Touch the "Cell Tab". Enter the following by touching each bubble: ID, Area (cm'2), Thickness (mils). NOTE: The mold area is 50 cm 2 Repeat "Tab B". Touch "Instrument Tab". Enter the following by touching each bubble: Cell Temperature (°C) and Test Gas RH (%). Note: Make sure 100% RH is set to OFF. Cell Temperature can be set from a minimum of 10°C to a maximum of 40°C. Test Gas RH can be set from a minimum of 5% to a maximum of 90%. If 100% RH is required a different method is required. ... Repeat step B. Once the test parameters are set, select "Start Selected" or "Start All" depending on the number of samples. Note: The indicator lights for each cell on the front panel will be green indicating that the test has started.

[0238] Surface resistivity measurement The surface resistivity of nonwoven webs and films can be measured according to ASTM D257.

[0239] Flexibility Score The hand feel of the nonwoven web, laminate or pouch of the present disclosure relates to the softness of the sample and can be evaluated using a relative test method. The softness evaluation tester, whatever the manner or method chosen by the individual, used clean hands to feel the sample and determined the softness rating for the nonwoven web and article of the present disclosure in comparison with a control material comprising a nonwoven web of fibers made of polyvinyl alcohol homopolymer with a degree of hydrolysis of 88% and having a cut piece of 2.2 dtex / 51 mm with a softness rating of 1 (softest), and a control material comprising a nonwoven web of fibers made of 75% polyvinyl alcohol homopolymer with a degree of hydrolysis of 88% and having a cut piece of 2.2 / 51 mm and 25% PET fiber of 22 dtex / 38 mm with a softness rating of 5 (coarsest / coarsest). The hand panel was blinded to ensure that the evaluators were not influenced by the name of the sample. The samples were scored from 1 to 5.

[0240] Flushability Test The ability of the nonwoven webs and / or laminates of the present disclosure to be flushed into a septic tank or municipal wastewater treatment system can be determined in accordance with the modified INDA / EDANA-Flushable Product Certification Criteria, as set forth below. Although the following tests refer to nonwoven web samples, it is understood that the methods can also be used on laminate structures.

[0241] Device: Rocking Digital Platform Shaker Two clear plastic 12 x 5 x 3.9 inch containers 2 sieves (12.5mm gap) Dry nonwoven web samples 100℃ oven

[0242] parameter: Set the rocking platform to 18 RPM and a tilt period of 11°. 1L tap water per container 30 minute test period

[0243] Test procedure: 1. Place two containers on the rocking platform. This method tests two samples at a time. 2. Measure 1L of tap water into a beaker and pour it into one plastic container. Repeat with the other container. Ensure the tap water in the container is at 15°C ± 1°C before starting the test. 3. Record the weight of the initial dry test sample (initial sample mass (g)) and the weight of the sieve (initial sieve mass (g)) and record separately. 4. Setting appropriate parameters for the digital locking platform. 5. Place each test sample into its corresponding container and immediately begin the agitation process (platform agitation). 6. Once the process is complete (after 30 minutes), take each container and pour into their corresponding sieve. Pour to a height of 10 cm above the sieve plate. 7. Rinse the container through the sieve to ensure all remaining test sample is removed. 8. Place the sieve in a 100°C oven for 45 minutes to ensure all water has evaporated. 9. Record the weight of the sieve and the remaining test sample together (total final mass (g)). 10. Calculate the total mass of the sample retained (final sample mass (g)): Final sample mass (g) = total final mass (g) - initial sieve mass (g) 10. Calculate the decay rate (%): % disintegration = [1-(final sample mass (g) / initial sample mass (g))] x 100 11. Ensure that the sieve is clean, dry and reweighed before starting the next test. 12. Repeat the test until N=3 replicates have been completed for each designated test sample.

[0244] If a sample has a disintegration rate equal to or greater than at least 20%, the sample is sufficiently flushable to be disposed of by flushing in a septic tank or municipal wastewater treatment system. In embodiments, the nonwoven webs, laminates, and pouches of the present disclosure can have a disintegration rate of at least 20%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% as measured by the flushability test.

[0245] Liquid Release Test FIG. 3 is an illustration of a wire frame cage (shown open at the top to better illustrate the water-soluble pouch contained therein) for use in the liquid release testing described herein.

[0246] FIG. 4 shows an apparatus for conducting liquid release testing that includes a beaker resting on a stand, which holds a rod for lowering a cage into the beaker, the rod being fixable by a collar having a set screw (not shown).

[0247] Water-soluble films and / or pouches characterized or tested for delayed solubility according to the Liquid Release Test are analyzed as follows using the following materials: 2 L beaker and 1.2 L deionized (DI) water · Water-soluble pouches to be tested; pouches are pre-conditioned for 2 weeks at 38°C; for results to be comparable, all films tested should have the same thickness, e.g. 88μm or 76μm. · Thermometer Wire cage · timer

[0248] Prior to conducting the experiment, ensure that sufficient DI water is available for five experimental replicates and ensure that the wire cage and beaker are clean and dry.

[0249] The wire frame cage is a plastic coated wire cage (4" x 3.5" x 2.5") or similar with no sharp edges. The wire gauge should be approximately 1.25 mm and the wire should have an opening sized 0.5 inch (1.27 cm) square. An example image of a cage 28 containing a test pouch 30 is shown in FIG. 3.

[0250] To set up the test, carefully place the water-soluble pouch into the cage while not damaging the pouch on the cage and allowing the pouch to move in free space. Do not tie the pouch tightly with the wire cage, again making sure the pouch is secured and does not come out of the cage. The orientation of the pouch within the cage should be such that the natural buoyancy of the pouch, if any, is allowed for (i.e., the side of the pouch that floats to the top should be placed facing up). If the pouch is asymmetrical, the orientation of the pouch is generally not critical.

[0251] Next, fill a 2 L beaker with 1200 mL of 20° C. DI water.

[0252] The wire frame cage containing the sealed pouch is then lowered into the water. Ensure that the cage is 1 inch (2.54 cm) from the bottom of the beaker. Ensure that the pouch is fully submerged on all sides. Ensure that the cage is stable and does not move, and start the timer as soon as the pouch is submerged. The position of the cage relative to the water in the beaker can be adjusted and maintained by any suitable means, for example, by using a clamp fixed on the beaker and a rod attached to the top of the cage. The clamp can engage with the rod to fix the position of the cage, and tension can be applied to the clamp to submerge the cage. Other means of frictional engagement can be used in place of the clamp, for example, a collar with a set screw as shown in FIG. 4 (set screw not shown). FIG. 4 shows beaker 30 resting on stand 40, which holds rod 50 for lowering cage 10 (not shown) into beaker 30, and rod 50 can be held in a vertically fixed position by the use of a collar 60 having a set screw (not shown) that engages rod 50, for example, by friction or by engagement with a hole (not shown) in rod 50.

[0253] Release of liquid contents is defined as the first visual evidence of liquid leaving the pouch submerged.

[0254] The following embodiments are specifically contemplated:

[0255] In some embodiments, the nonwoven web comprises a polymer blend. The polymer blend can comprise a first anionic group-modified polyvinyl alcohol polymer in an amount ranging from about 30 wt% to about 85 wt% or from about 50 wt% to about 85 wt% by weight of the nonwoven web, and a second polyvinyl alcohol homopolymer in an amount ranging from about 15 wt% to about 70 wt% or from about 15 wt% to about 50 wt% by weight of the nonwoven web. The basis weight of the nonwoven web comprising the polymer blend is about 10 g / m 2 From about 80g / m 2, about 20g / m 2 From about 70g / m 2 , about 30g / m 2 From about 60g / m 2 or about 40 g / m 2 From about 50g / m 2 For example, about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75 or 80 g / m 2The static coefficient of friction of the nonwoven web comprising the polymer blend can be less than about 0.90, less than about 0.85, or less than about 0.80, such as about 0.10, 0.25, 0.50, 0.60, 0.70, 0.71, 0.72, 0.73, 0.74, 0.75, 0.76, 0.77, 0.78, 0.79, 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, or 0.90. The ratio of the static coefficient of friction to the kinetic coefficient of friction of the nonwoven web comprising the polymer blend can range from about 0.90 to about 1.10 or from about 0.95 to about 1.05, such as about 0.90, 0.95, 0.98, 0.99, 1.00, 1.01, 1.02, 1.05, or 1.10. The yellowness of the nonwoven web comprising the polymer blend can be less than about 5, less than about 4, or less than about 3, as measured using ASTM E313. For example, the yellowness of the nonwoven web comprising the polymer blend can be about 2.50, 2.75, 3.00, 3.10, 3.15, 3.20, 3.25, 3.30, 3.40, 3.50, 3.75, 4.00, 4.25, 4.50, 4.75, or 5.00. The whiteness of the nonwoven web comprising the polymer blend can range from about 40 to about 70, about 45 to about 65, or about 50 to about 60, as measured using ASTM E313. For example, the whiteness of the nonwoven web comprising the polymer blend can be about 40, 42, 45, 48, 49, 50, 52, 55, 56, 58, 60, 62, 65, 67, or 70. The brightness of the nonwoven webs comprising the polymer blends can range from about 40 to about 70, from about 45 to about 65, or from about 50 to about 60, as measured using a TAPPI 452. For example, the brightness of the nonwoven webs comprising the polymer blends can be about 40, 42, 45, 47, 49, 50, 52, 54, 55, 56, 58, 60, 62, 65, 67, or 70.

[0256] In some embodiments, the nonwoven web comprises a single polyvinyl alcohol homopolymer. The degree of hydrolysis of the PVOH homopolymer can range from about 85% to about 99%, for example, about 85%, 88%, 90%, 92%, 94%, 96%, 98% or 99%. The basis weight of the nonwoven web comprising a single PVOH homopolymer is about 10 g / m 2 From about 60g / m 2 , about 20g / m 2 From about 50g / m 2 or about 30 g / m 2 From about 40g / m 2 For example, about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55 or 60 g / m 2 The static coefficient of friction of the nonwoven web comprising a single PVOH homopolymer can be less than about 0.90, less than about 0.70, or less than about 0.40, such as about 0.10, 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, or 0.90. The ratio of static to kinetic coefficient of friction of the nonwoven web comprising a single PVOH homopolymer can range from about 0.90 to about 1.10 or from about 0.95 to about 1.05, such as about 0.90, 0.95, 0.98, 0.99, 1.00, 1.01, 1.02, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, or 1.10. The yellowness index of nonwoven webs comprising the polymer blends can be less than about 5, less than about 4, or less than about 3, as measured using ASTM E313. For example, the yellowness index of nonwoven webs comprising a single PVOH homopolymer can be about 1.00, 1.25, 1.50, 1.75, 2.00, 2.50, 2.55, 2.60, 2.75, 3.00, 3.25, 3.30, 3.40, 3.50, 3.75, 4.00, 4.25, 4.50, 4.75, or 5.00. The whiteness of nonwoven webs comprising a single PVOH homopolymer can be less than about 5, less than about 4, or less than about 3, as measured using ASTM E313. The brightness of the nonwoven webs comprising the polymer blends can range from about 40 to about 70, about 45 to about 65, or about 50 to about 60, as measured using E313. For example, the brightness of the nonwoven webs comprising the polymer blends can be about 40, 42, 45, 48, 49, 50, 51, 52, 54, 55, 56, 58, 60, 62, 65, 67, or 70. The brightness of the nonwoven webs comprising a single PVOH homopolymer can range from about 40 to about 70, about 45 to about 65, or about 50 to about 60, as measured using TAPPI 452. For example, the brightness of the nonwoven webs comprising the polymer blends can be about 40, 42, 45, 47, 49, 50, 52, 54, 55, 56, 58, 59, 60, 62, 65, 67, or 70.

[0257] One or more optional features that can be used individually or in combination are described in the following paragraphs. Optionally, the fibers of the present disclosure are comprised of a monofilament forming material. Optionally, the fibers of the present disclosure are comprised of a polyvinyl alcohol homopolymer. Optionally, the polyvinyl alcohol homopolymer can have a degree of hydrolysis ranging from 85% to 99.9%, for example, 88%, 96%, 98% or 99.9%. Optionally, the fibers of the present disclosure can include a blend of fiber forming materials. Optionally, the blend of fiber forming materials can include a polyvinyl alcohol homopolymer in combination with a polyvinyl alcohol copolymer or a second polyvinyl alcohol homopolymer. Optionally, the polyvinyl alcohol homopolymer can have a degree of hydrolysis ranging from 85% to 99.9%, for example, 88%, 96%, 98% or 99.9%. Optionally, the polyvinyl alcohol copolymer can be an anionically modified polyvinyl alcohol copolymer. Optionally, the anionically modified polyvinyl alcohol copolymer can be an AMPS copolymer having a degree of modification of about 2 mol.% to about 10 mol.%, for example 2 mol.%. Optionally, the fiber comprising a blend of fiber-forming materials can comprise a homopolymer in an amount of 30 wt.%, and a copolymer in an amount of 70 wt.%, based on the total weight of the fiber-forming material. Optionally, the fiber comprising a blend of polyvinyl alcohol homopolymers can comprise a first polyvinyl alcohol homopolymer in an amount of about 25 wt.% to 75 wt.%, for example about 25 wt.%, 50 wt.% or 75 wt.%, based on the total weight of the fiber-forming material, and a second polyvinyl alcohol homopolymer in an amount of about 75 wt.% to about 25 wt.%, for example about 75 wt.%, 50 wt.% or 25 wt.%, based on the total weight of the fiber-forming material. Optionally, the fiber can have a complete melt temperature in the range of about 20°C to about 90°C, for example about 20°C, about 40°C, about 70°C or about 90°C. Optionally, the nonwoven web can be a multi-layer nonwoven web. Optionally, the multi-layer nonwoven web can include a first nonwoven web that includes only one fiber type and a second nonwoven web that includes only one fiber type.Optionally, the multi-layer nonwoven web can include a first nonwoven web that includes a blend of fiber types and a second nonwoven web that includes only one fiber type. Optionally, the carded web can be calendered. Optionally, the carded web can be needle-perforated prior to calendering.

[0258] Optionally, the nonwoven web can have a dynamic coefficient of friction in the range of about 0.30 to about 0.90, e.g., 0.31, 0.62, 0.77, 0.78, 0.82, or 0.86. Optionally, the nonwoven web can have a static coefficient of friction in the range of about 0.30 to about 0.90, e.g., 0.34, 0.65, 0.78, 0.79, 0.83, or 0.90. Optionally, the nonwoven web can have a ratio of static to kinetic coefficient of friction in the range of about 1.00 to about 1.10, e.g., 1.01, 1.02, 1.04, 1.05, or 1.09. Optionally, the nonwoven web can have a ratio of static to kinetic coefficient of friction in the range of about 1.00 to about 11.2 N / mm in the machine direction. 2 For example, about 1.00 N / mm 2 , 1.53N / mm 2 , 1.64N / mm 2 , 5.99N / mm 2 , 7.36N / mm 2 or 11.11N / mm 2 Optionally, the nonwoven web can have a maximum stress of about 0.20 to about 5.90 N / mm in the cross direction. 2 , for example, about 0.22 N / mm 2 , 0.42N / mm 2 , 0.51N / mm 2 , 2.76N / mm 2 , 4.28N / mm 2 or 5.86N / mm 2Optionally, the nonwoven web can have a ratio of maximum stress in the machine direction to maximum stress in the cross direction of about 1.4 to about 4.7, e.g., 1.40, 1.90, 2.67, 3.02, 3.91, or 4.64. Optionally, the nonwoven web can have a breaking strain in the machine direction of about 6.80 to 359.00%, e.g., 6.83%, 58.19%, 59.91%, 129.73%, 144.39%, and 358.84%. Optionally, the nonwoven web can have a breaking strain in the cross direction of about 130.00 to about 300.00%, e.g., about 130.17%, 163.84%, 173.75%, 195.34%, 250.02%, or 299.42%. Optionally, the nonwoven web can have a longitudinal breaking strain relative to a transverse breaking strain of about 0.04 to about 1.9, e.g., about 0.04, 0.20, 0.23, 0.79, 1.11, or 1.85. Optionally, the nonwoven web can have a yellowness value ranging from about 2.5 to about 3.255, e.g., about 2.56, 2.58, 3.2, 3.21, and 3.52. Optionally, the nonwoven web can have a whiteness value ranging from about 42.00 to about 57.00, e.g., about 42.36, 48.90, 51.24, 51.74, 54.41, or 56.90. Optionally, the nonwoven web can have a brightness value ranging from about 47.80 to about 62.4, e.g., about 47.88, 54.67, 56.01, 56.50, 59.42 or 62.35. Optionally, the nonwoven web can have a brightness value ranging from about 1×10 10 From 1×10 12 Ω range, e.g. 1×10 10 Ω, 1×10 11 Ω or 1×10 12 It may have a surface resistivity of Ω.

[0259] Optionally, the nonwoven web can be a single layer nonwoven web made of a monofilament type of monofilament forming material and have a basis weight in the range of about 15 to about 50 GSM, e.g., 15.5 GSM, 16.8 GSM, 17 GSM, 17.5 GSM, 18.9 GSM, 19.3 GSM, 19.5 GSM, 19.6 GSM, 19.7 GSM, 21.0 GSM, 22.2 GSM, 22.9 GSM, 23.1 GSM, 23.5 GSM, 25.1 GSM, 27.7 GSM, 32.4 GSM, 33.4 GSM, 38.0 GSM, 39.7 GSM, 40.0 GSM, 40.1 GSM, 41.8 GSM, 42.5 GSM, 43.8 GSM, 45.3 GSM or 44.7 GSM. Optionally, the nonwoven web can be a single layer nonwoven web made of a monofilament type, the monofilament type being a single polyvinyl alcohol fiber forming material having a degree of hydrolysis ranging from 88% to 96% and having a hydrolysis time ranging from about 5.00 seconds to about 140.00 seconds at 23° C., e.g., 8.00 seconds, 8.67 seconds, 10.33 seconds, 13.33 seconds, 13.67 seconds, 15.67 seconds, 16.67 seconds, and having a time to rupture of 18.33 seconds, 20.67 seconds, 21.33 seconds, 22.33 seconds, 24.67 seconds, 68.33 seconds, 73.67 seconds, 85.33 seconds, 90.00 seconds, 90.33 seconds, 92.33 seconds, 97.00 seconds, 128.33 seconds, 131.00 seconds, 133.67 seconds, 136.33 seconds, 138.67 seconds or 140.00 seconds. Optionally, the nonwoven web can be a monolayer nonwoven web comprised of a monofilament type comprising a single polyvinyl alcohol fiber forming material having a degree of hydrolysis ranging from 88% to 96% and having a disintegration time at 23° C. ranging from about 19.00 seconds to about 209.00 seconds, e.g., 19.00 seconds, 21.33 seconds, 23.00 seconds, 24.00 seconds, 28.00 seconds, 28.67 seconds, 29.00 seconds, 34.67 seconds, 35.00 seconds, 30.67 seconds, 31.33 seconds, 42.67 seconds, 127.50 seconds, 134.50 seconds, 140.50 seconds, 175.67 seconds, 189.00 seconds, 191.67 seconds, 193.33 seconds or 209.00 seconds.Optionally, the nonwoven web can be a monolayer nonwoven web comprised of a monofilament type consisting of a single polyvinyl alcohol fiber forming material having a degree of hydrolysis ranging from 88% to 96% and having a time to rupture at 40° C. ranging from about 1.30 seconds to about 11.00 seconds, e.g., 1.22 seconds, 1.33 seconds, 2.00 seconds, 2.33 seconds, 2.67 seconds, 3.00 seconds, 3.33 seconds, 4.33 seconds, 5.00 seconds, 5.33 seconds, 5.67 seconds, 6.33 seconds, 6.67 seconds, 8.67 seconds, 9.00 seconds or 11.00 seconds. Optionally, the nonwoven web can be a monolayer nonwoven web comprised of a monofilament type consisting of a single polyvinyl alcohol fiber forming material having a degree of hydrolysis ranging from 88% to 96% and having a disintegration time at 40° C. ranging from about 3.00 seconds to about 27.00 seconds, e.g., 3.00 seconds, 3.33 seconds, 3.67 seconds, 4.00 seconds, 4.67 seconds, 5.00 seconds, 5.33 seconds, 6.67 seconds, 7.00 seconds, 7.67 seconds, 8.33 seconds, 9.67 seconds, 10.67 seconds, 13.33 seconds, 14.33 seconds, 15.33 seconds, 15.67 seconds, 16.00 seconds, 20.33 seconds or 26.67 seconds. Optionally, the nonwoven web can be a single layer nonwoven web made of a single fiber type, the single fiber type being made of a single polyvinyl alcohol fiber forming material having a degree of hydrolysis of 98% and having a time to burst in the range of about 2.00 seconds to about 7.00 seconds, for example, 2.33 seconds, 2.67 seconds, 3.33 seconds, 4.33 seconds, or 7.00 seconds, at 80° C. Optionally, the nonwoven web can be a single layer nonwoven web made of a single fiber type, the single fiber type being made of a single polyvinyl alcohol fiber forming material having a degree of hydrolysis of 98% and having a disintegration time in the range of about 5.00 seconds to about 34.00 seconds, for example, 5.33 seconds, 7.67 seconds, 9.00 seconds, 10.33 seconds, 15.33 seconds, or 33.67 seconds, at 80° C.Optionally, the nonwoven web can be a single layer nonwoven web made of a single fiber type, the single fiber type being made of a single polyvinyl alcohol fiber forming material having a degree of hydrolysis of 99.9% and having a time to burst in the range of 5.00 seconds to about 90.00 seconds, e.g., 5.33 seconds, 7.67 seconds, 9.33 seconds, or 89.67 seconds, at 90° C. Optionally, the nonwoven web can be a single layer nonwoven web made of a single fiber type, the single fiber type being made of a single polyvinyl alcohol fiber forming material having a degree of hydrolysis of 99.9% and having a disintegration time in the range of about 9.5 seconds to about 180.00 seconds, e.g., 9.67 seconds, 15.67 seconds, 36.00 seconds, or 179.5 seconds, at 90° C.

[0260] Optionally, the nonwoven web can be a monolayer nonwoven web comprising a blend of fiber types, including a first fiber comprising a PVOH homopolymer having a DH of 88% and a second fiber comprising a PVOH homopolymer having a DH of 96%, where the first fiber type is provided in a range of 25% to 75% by weight of the total fibers, e.g., 25%, 50% or 75% by weight, and the second fiber type is provided in a range of 75% to 25% by weight of the total fibers, e.g., 25%, 50% or 75% by weight. Optionally, a nonwoven web comprising a blend of fiber types having a first fiber comprising a PVOH homopolymer having a DH of 88% and a second fiber comprising a PVOH homopolymer having a DH of 96% can have a basis weight ranging from about 32.5 GSM to about 50.0 GSM, e.g., 32.9 GSM, 40.2 GSM, 43.7 GSM, 43.8 GSM, 43.9 GSM, 41.6 GSM, 44.5 GSM, 44.9 GSM, 45.3 GSM, 45.9 GSM or 47.9 GSM. Optionally, a nonwoven web comprising a blend of fiber types having a first fiber comprising a PVOH homopolymer having a DH of 88% and a second fiber comprising a PVOH homopolymer having a DH of 96% can have a time to rupture at 23° C. in the range of about 69.00 seconds to about 122.00 seconds, e.g., 69.00 seconds, 76.33 seconds, 78.33 seconds, 87.00 seconds, 93.33 seconds, 93.67 seconds, 99.00 seconds, 101.00 seconds, 102.67 seconds, 107.67 seconds, 108.67 seconds or 121.33 seconds. Optionally, a nonwoven web comprising a blend of fiber types having a first fiber comprising a PVOH homopolymer having a DH of 88% and a second fiber comprising a PVOH homopolymer having a DH of 96% can have a disintegration time in the range of about 121.00 seconds to about 164.00 seconds, e.g., 121.00 seconds, 122.67 seconds, 134.67 seconds, 145.00 seconds, 146.67 seconds, 154.33 seconds, 156.00 seconds, 161.33 seconds or 164.00 seconds.Optionally, a nonwoven web comprising a blend of fiber types having a first fiber comprising a PVOH homopolymer having a DH of 88% and a second fiber comprising a PVOH homopolymer having a DH of 96% can have a time to rupture at 43° C. in the range of about 4.00 seconds to about 8.00 seconds, e.g., about 4.33 seconds, 5.00 seconds, 5.33 seconds, 5.67 seconds, 6.00 seconds, 7.00 seconds, or 7.67 seconds. Optionally, a nonwoven web comprising a blend of fiber types having a first fiber comprising a PVOH homopolymer having a DH of 88% and a second fiber comprising a PVOH homopolymer having a DH of 96% can have a disintegration time at 40° C. in the range of about 9.5 seconds to about 19.00 seconds, e.g., about 9.67 seconds, 10.00 seconds, 11.00 seconds, 12.00 seconds, 12.67 seconds, 13.00 seconds, 18.00 seconds, or 19.00 seconds.

[0261] Optionally, the nonwoven web can be a multi-layer nonwoven web comprising one or more layers of a nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% and one or more layers of a second nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 96% and a basis weight of 40 GSM. Optionally, the multi-layer nonwoven comprises two layers of a nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88%. Optionally, the multi-layer nonwoven comprises two layers of a nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 96%. Optionally, the multi-layer nonwoven comprises one layer of a nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% and one layer of a nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 96%. Optionally, a multi-layer nonwoven web comprising one or more layers of a nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% and one or more layers of a second nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 96% can have a time to rupture at 23° C. ranging from about 18.5 seconds to about 108.5 seconds, e.g., about 18.67 seconds, 23.00 seconds, 94.67 seconds, 101.00 seconds, 103.33 seconds or 108.33 seconds. Optionally, a multi-layer nonwoven web comprising two layers of nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% can have a disintegration time at 23° C. ranging from about 38.5 seconds to about 47.00 seconds, e.g., 38.67 seconds or 46.67 seconds.Optionally, a multi-layer nonwoven web comprising one or more layers of a nonwoven comprising only fibers having a sole fiber-forming material comprising PVOH homopolymer having a DH of 88% and one or more layers of a second nonwoven comprising only a fiber-forming material comprising PVOH homopolymer having a DH of 96% can have a time to rupture at 40° C. of about 2.00 seconds to about 7.5 seconds, e.g., about 2.33 seconds, about 3.33 seconds, about 5.00 seconds, about 5.67 seconds, about 6.33 seconds or about 7.33 seconds. Optionally, a multi-layer nonwoven web comprising one or more layers of a nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% and one or more layers of a second nonwoven comprising only a fiber-forming material comprising a PVOH homopolymer having a DH of 96% can have a disintegration time at 40° C. of about 4.00 seconds to about 17.00 seconds, e.g., 4.00 seconds, 14.33 seconds, 15.67 seconds, 16.00 seconds or 17.00 seconds.

[0262] Optionally, the nonwoven web can be a monolayer nonwoven web comprising a blend of fibers having a first PVOH fiber comprising a fiber-forming material comprising a PVOH homopolymer having a DH of 96% and a second non-PVOH fiber comprising a fiber-forming material selected from the group consisting of polyethylene terephthalate, polylactide, viscose, cellulose and cotton, the nonwoven web having a basis weight of 50 GSM. Optionally, the monolayer nonwoven web comprising a blend of fibers comprising a first PVOH fiber and a second non-PVOH fiber can have a time to rupture at 23° C. in the range of about 123.00 seconds to about 158.00 seconds, e.g., 123.33 seconds, 130.67 seconds, 134.33 seconds, 144.67 seconds or 158.00 seconds. Optionally, the monolayer nonwoven web comprising a blend of fibers comprising a first PVOH fiber and a second non-PVOH fiber can have a time to rupture ranging from about 2.00 seconds to about 7.5 seconds, e.g., 2.33 seconds, 3.33 seconds, 5.00 seconds, 5.67 seconds, 6.33 seconds or 7.33 seconds at 40° C. Optionally, the monolayer nonwoven web comprising a blend of fibers comprising a first PVOH fiber and a second non-PVOH fiber can have a softness value ranging from 2 to 4, e.g., 2, 3 or 4.

[0263] Optionally, the nonwoven web can be a monolayer nonwoven web comprising a blend of two fibers, each fiber comprising only one PVOH homopolymer fiber-forming material having a DH selected from the group consisting of 88%, 96%, 98% and 99.9%, with at least one fiber having a PVOH homopolymer fiber-forming material having a DH of 98% or 99.9%. Optionally, the monolayer nonwoven web comprising a blend of two fibers, comprising at least one fiber having a PVOH homopolymer fiber-forming material having a DH of 98% or 99.9%, can have a basis weight of 40 GSM. Optionally, a single layer nonwoven web comprising a blend of two fibers includes at least one fiber having a PVOH homopolymer having a DH of 98% and a second PVOH homopolymer fiber having a DH of 88% or 96%, and the nonwoven web can have a time to rupture at 80° C. in the range of about 1.50 seconds to about 10.5 seconds, e.g., 1.67 seconds, 2.00 seconds, 2.33 seconds, 2.67 seconds, 3.00 seconds, 3.33 seconds, 4.33 seconds, 4.67 seconds, 5.00 seconds or 10.33 seconds. Optionally, a single layer nonwoven web comprising a blend of two fibers includes at least one fiber having a PVOH homopolymer having a DH of 98% and a second PVOH homopolymer fiber having a DH of 88% or 96%, and the nonwoven web can have a disintegration time at 80° C. in the range of about 4.00 seconds to about 32.00 seconds, e.g., 4.00 seconds, 4.33 seconds, 5.00 seconds, 5.33 seconds, 6.00 seconds, 6.67 seconds, 7.67 seconds, 9.33 seconds, 10.00 seconds, 13.67 seconds, 21.00 seconds, 21.33 seconds or 32.00 seconds.Optionally, a monolayer nonwoven web comprising a blend of two fibers includes at least one fiber having a PVOH homopolymer having a DH of 99.9% and a second PVOH homopolymer fiber having a DH of 88%, 96% or 98%, and the nonwoven web can have a time to rupture at 90° C. in the range of about 2.00 seconds to about 93.5 seconds, e.g., 2.00 seconds, 3.00 seconds, 3.33 seconds, 4.33 seconds, 5.33 seconds, 6.67 seconds, 7.00 seconds, 7.33 seconds, 7.67 seconds, 8.00 seconds, 11.67 seconds, 13.67 seconds, 15.00 seconds, 16.33 seconds, 17.00 seconds, 18.33 seconds, 23.33 seconds or 93.33 seconds. Optionally, a single layer nonwoven web comprising a blend of two fibers includes at least one fiber having a PVOH homopolymer having a DH of 99.9% and a second PVOH homopolymer fiber having a DH of 88%, 96% or 98%, and the nonwoven web can have a disintegration time at 90° C. in the range of about 5.00 seconds to about 168.5 seconds, e.g., 5.33 seconds, 6.33 seconds, 6.67 seconds, 7.00 seconds, 8.33 seconds, 9.33 seconds, 10.33 seconds, 13.00 seconds, 13.33 seconds, 16.67 seconds, 18.33 seconds, 21.33 seconds, 21.67 seconds, 39.00 seconds, 41.00 seconds, 42.33 seconds, 19.33 seconds, 54.67 seconds, 64 seconds, 74.00 seconds or 168.5 seconds.

[0264] Optionally, the nonwoven web can be a monolayer nonwoven web comprising a blend of two fibers, each fiber comprising only one PVOH homopolymer fiber-forming material having a DH selected from the group consisting of 88%, 96%, 98% and 99.9%, with at least one fiber comprising a PVOH homopolymer fiber-forming material having a DH of 98%. Optionally, the monolayer nonwoven web comprising a blend of two fibers, comprising at least one fiber comprising a PVOH homopolymer fiber-forming material having a DH of 98%, can have a basis weight of 50 GSM. Optionally, the monolayer nonwoven web comprising a blend of two fibers comprises at least one fiber comprising a PVOH homopolymer fiber-forming material having a DH of 98%, with the second PVOH homopolymer fiber having a DH of 88% or 96%, and the nonwoven web can have a thinning time at 40° C. ranging from about 5.00 seconds to about 18.5 seconds, for example, 5.33 seconds, 7.33 seconds, 10.00 seconds or 18.33 seconds.

[0265] Optionally, the nonwoven web can be a multi-layer nonwoven web comprising two layers of nonwoven webs, each layer comprising only fibers having a DH of 88%, 96%, 98% or 99.9% and having a basis weight of 100 GSM or 60 GSM. Optionally, the multi-layer nonwoven fabric comprises one layer of a nonwoven web comprising only fibers having a DH of 88% and one layer comprising only fibers having a DH of 96%, 98% or 99.9%. Optionally, the multi-layer nonwoven fabric comprises one layer of a nonwoven web comprising only fibers having a DH of 96% and one layer comprising only fibers having a DH of 88%, 98% or 99.9%. Optionally, the multi-layer nonwoven fabric comprises one layer of a nonwoven web comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 98% and one layer comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% or 96%. Optionally, the multi-layer nonwoven fabric comprises one layer of a nonwoven web comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 99.9% and one layer comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% or 96%. Optionally, the multi-layer nonwoven fabric includes one layer of a nonwoven web including only fibers having a sole fiber-forming material including a PVOH homopolymer having a DH of 88% and one layer including only fibers having a sole fiber-forming material including a PVOH homopolymer having a DH of 98%, the multi-layer nonwoven fabric having a total basis weight of up to 100 GSM and a thinning time at 40° C. in the range of 98.00 seconds to 134.00 seconds, e.g., 98.00 seconds or 133.67 seconds.Optionally, a multi-layer nonwoven web comprising two layers of nonwoven webs, each layer having a DH of 88%, 96%, 98% or 99.9% and containing only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a basis weight of 60 GSM, can have a thinning time at 40° C. in the range of about 6.00 seconds to about 140.5 seconds, e.g., 6.00 seconds, 7.00 seconds, 29.67 seconds, 44.33 seconds, 46.33 seconds, 63.33 seconds, 73.67 seconds, 94.67 seconds, 133.67 seconds or 140.33 seconds.

[0266] Optionally, the nonwoven web can be a monolayer nonwoven having only fibers with only a fiber-forming material comprising a PVOH homopolymer having a degree of hydrolysis of 99.9%, the nonwoven having a basis weight of 40 GSM and having at least 20% degradation as determined by the flushability test herein. Optionally, the nonwoven web can be (a) a monolayer nonwoven having only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a degree of hydrolysis of 88%, 96% or 98% and a basis weight of about 20 to about 40 GSM, or (b) a multilayer nonwoven web having a basis weight in the range of about 30 GSM to about 50 GSM, both layers comprising only fibers having a sole fiber-forming material that is a PVOH homopolymer, the layers having PVOH homopolymer having degrees of hydrolysis of (i) 88% and 96%; (ii) 88% and 98%; (iii) 88% and 99.9%; or (iv) 96% and 98%, and the multilayer nonwoven web has at least 40% disintegration as determined by the flushability test herein.

[0267] The following types of embodiments are specifically contemplated: [Table 16]

[0268] Generally, all water-dispersible webs that are water-soluble can be flushable, provided that any additives added to the web are suitable for disposal in liquid sewerage.The water-dispersible webs of the present disclosure can also be flushable, for example, if the web contains water-soluble fibers in an amount that allows sufficient disintegration of the web compared to any water-insoluble fibers, and / or if the water-insoluble fibers contain a sufficient amount of water-soluble resin in the fibers to allow sufficient disintegration of the web, i.e., at least 20% disintegration, as determined by the flushability test disclosed herein.The following types of embodiments are specifically contemplated: [Table 17-1] [Table 17-2] [Table 17-3] [Table 17-4] [Table 17-5] [Table 17-6] [Table 17-7] [Table 17-8] [Table 17-9] [Table 17-10]

[0269] In the above embodiments involving blends of water-soluble fiber-forming materials in the water-soluble fiber, the water-soluble fiber-forming materials can include one or more PVOH homopolymers, one or more PVOH copolymers, one or more non-PVOH polymers, or combinations thereof. The following types of refinements of the above-described embodiments are contemplated, where refinements where only one type of polymer is specified are intended to refer to a blend of the specified polymer types: [Table 18-1] [Table 18-2] [Table 18-3] [Table 18-4] [Table 18-5] [Table 18-6] [Table 18-7] [Table 18-8] [Table 18-9]

[0270] In the above embodiments involving blends of fiber-forming materials in a water-insoluble fiber, the fiber-forming materials can include one or more water-insoluble polymers and, optionally, one or more water-soluble polymers, where the one or more water-soluble polymers can include one or more PVOH homopolymers, one or more PVOH copolymers, one or more non-PVOH polymers, or combinations thereof. The following types of refinements of the above-described embodiments are contemplated, where refinements where only one type of polymer is specified are intended to refer to a blend of the specified polymer types: [Table 19-1] [Table 19-2] [Table 19-3] [Table 19-4] [Table 19-5] [Table 19-6] [Table 19-7] [Table 19-8] [Table 19-9] [Table 19-10] [Table 19-11]

[0271] Particularly contemplated embodiments of the present disclosure are described herein in the following numbered paragraphs, which are intended to be illustrative and not limiting in nature.

[0272] Paragraph 1. A water-dispersible nonwoven web comprising a plurality of water-soluble fibers.

[0273] Paragraph 2. The water-dispersible nonwoven web of paragraph 1, wherein the plurality of water-soluble fibers comprises a blend of water-soluble polymers.

[0274] Paragraph 3. The water-dispersible nonwoven web of paragraph 1 or paragraph 2, wherein the plurality of water-soluble fibers comprises fibers comprising a polyvinyl alcohol polymer fiber-forming material.

[0275] Paragraph 4. The water-dispersible nonwoven web of paragraph 3, wherein the polyvinyl alcohol polymer comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

[0276] Paragraph 5. The water-dispersible nonwoven web of paragraphs 3 or 4, wherein the polyvinyl alcohol copolymer comprises an anionically modified polyvinyl alcohol copolymer.

[0277] Paragraph 6. The water-dispersible nonwoven web of paragraph 5, wherein the anionically modified polyvinyl alcohol copolymer has a degree of modification in the range of about 1 mol.% to about 10 mol.%.

[0278] Paragraph 7. The water-dispersible nonwoven web of any one of paragraphs 3 through 6, wherein the polyvinyl alcohol polymer comprises a polyvinyl alcohol homopolymer and a polyvinyl alcohol copolymer.

[0279] Paragraph 8. The water-dispersible nonwoven web of paragraph 7, wherein the polyvinyl alcohol homopolymer comprises from about 15 wt.% to about 70 wt.%, based on the total weight of the polyvinyl alcohol polymers, and the copolymer comprises from about 30 wt.% to about 85 wt.%, based on the total weight of the polyvinyl alcohol polymers.

[0280] Paragraph 9. The water-dispersible nonwoven web of any one of paragraphs 3 through 8, wherein the polyvinyl alcohol polymer has a degree of hydrolysis ranging from about 75% to about 99.9%.

[0281] Paragraph 10. The water-dispersible nonwoven web of paragraph 9, wherein the polyvinyl alcohol polymer has a degree of hydrolysis ranging from about 80% to about 90%.

[0282] Paragraph 11. The water-dispersible nonwoven web of paragraph 9, wherein the polyvinyl alcohol polymer has a degree of hydrolysis ranging from about 92% to about 99%, optionally from about 98% to about 99%, optionally from about 98% to about 99.9%.

[0283] Paragraph 12. Multiple soluble fibers are A first soluble fiber; The second soluble fiber The first and second water-soluble fibers have a diameter, length, tenacity, shape, stiffness, elasticity, water solubility, melting point, glass transition temperature (T g 12. The water-dispersible nonwoven web of any one of paragraphs 1 to 11, having differences in fiber chemistry, color, or combinations thereof.

[0284] Paragraph 13. The water-dispersible nonwoven web of any one of Paragraphs 1 to 12, further comprising a plurality of water-insoluble fibers.

[0285] Paragraph 14. The water-dispersible nonwoven web of Paragraph 13, wherein the plurality of water-soluble fibers constitutes from about 20% to about 80% by weight of the total weight of the fibers, and the plurality of water-insoluble fibers constitutes from about 20% to about 80% by weight of the total weight of the fibers.

[0286] Paragraph 15. The water-dispersible nonwoven web of Paragraph 13 or Paragraph 14, wherein the plurality of water-insoluble fibers comprises cotton, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, seasilk, mohair, angora, cashmere, collagen, actin, nylon, Dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polylactide, polyethylene terephthalate, or combinations thereof.

[0287] Paragraph 16. The water-dispersible nonwoven web of any one of Paragraphs 1 to 15, wherein the water-dispersible nonwoven web is biodegradable.

[0288] Paragraph 17. The water-dispersible nonwoven web of any one of Paragraphs 1 to 16, wherein the plurality of water-soluble fibers have a tenacity ranging from about 3 cN / dtex to about 10 cN / dtex, optionally from about 7 cN / dtex to about 10 cN / dtex.

[0289] Paragraph 18. The water-dispersible nonwoven web of Paragraph 17, wherein the plurality of water-soluble fibers have a tenacity ranging from about 4 cN / dtex to about 8 cN / dtex, optionally from about 6 cN / dtex to about 8 cN / dtex.

[0290] Paragraph 19. The water-dispersible nonwoven web of any one of Paragraphs 1 to 18, wherein the plurality of water-soluble fibers comprises water-soluble fibers that include a plasticizer.

[0291] Paragraph 20. The water-dispersible nonwoven web of any one of Paragraphs 1 to 19, further comprising an active agent.

[0292] Paragraph 21. The water-dispersible nonwoven web of Paragraph 20, wherein the active agent is provided as part of the water-soluble fibers, dispersed within the nonwoven web, provided on a surface of the nonwoven web, or a combination thereof.

[0293] Paragraph 22. The water-dispersible nonwoven web of Paragraph 20 or Paragraph 21, wherein the active agent is selected from an enzyme, an oil, a flavor, a colorant, an odor absorber, a fragrance, a pesticide, a fertilizer, an activator, an acid catalyst, a metal catalyst, an ion scavenger, a cleaning agent, a disinfectant, a surfactant, a bleaching agent, a bleaching component, a fabric softener, or a combination thereof.

[0294] Paragraph 23. The water-dispersible nonwoven web of any one of Paragraphs 1 to 22, wherein the plurality of water-soluble fibers have a diameter ranging from about 10 microns to about 300 microns, optionally from about 50 microns to about 300 microns, optionally from greater than 100 microns to about 300 microns.

[0295] Paragraph 24. The water-dispersible nonwoven web of any one of Paragraphs 1 to 23, wherein the plurality of water-soluble fibers have a substantially uniform diameter.

[0296] Paragraph 25. The water-dispersible nonwoven web of any one of Paragraphs 1 to 24, wherein the plurality of water-soluble fibers have a length in the range of about 30 mm to about 100 mm, or about 30 mm to about 60 mm.

[0297] Paragraph 26. The water-dispersible nonwoven web of any one of Paragraphs 1 to 24, wherein the plurality of water-soluble fibers have a length less than about 30 mm, or in a range of from about 0.25 mm to less than 30 mm.

[0298] Paragraph 27. The water-dispersible nonwoven web of any one of Paragraphs 1 to 26, wherein the nonwoven web is porous.

[0299] Paragraph 26. The water-dispersible nonwoven web of any one of Paragraphs 1 through 20, wherein the nonwoven web is nonporous.

[0300] Paragraph 27. The water-dispersible nonwoven web of any one of Paragraphs 1 through 26, wherein the nonwoven web is colored, dyed, pigmented, or a combination thereof.

[0301] Paragraph 28. The nonwoven web has a thickness of about 1 g / m 2 to about 100g / m 2 , about 20g / m2 From about 80g / m 2 , about 30g / m 2 to about 100g / m 2 , or about 25 g / m 2 From about 70g / m 2 28. The nonwoven web of any one of paragraphs 1 through 27, having a basis weight of.

[0302] Paragraph 29. The water-dispersible nonwoven web of any one of paragraphs 1 to 28, wherein at a given temperature, the water-dispersible nonwoven web dissolves at least about 5 times faster than a water-soluble film prepared from the same water-soluble polymer as the water-soluble fibers of the water-dispersible nonwoven web.

[0303] Paragraph 30. The plurality of water-soluble fibers comprises water-soluble fibers prepared by a wet cryogel spinning process, the wet cryogel spinning process comprising: a) dissolving a polymer in a solution to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle and into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide water soluble fibers. 30. The water-dispersible nonwoven web of any one of paragraphs 1 to 29.

[0304] Paragraph 31. The water-dispersible nonwoven web of Paragraph 30, wherein finishing comprises cutting or crimping the extruded polymer mixture to provide water soluble fibers.

[0305] Paragraph 32. The water-dispersible nonwoven web of paragraphs 30 or 31, wherein the coagulation bath comprises a mixture of solvents including a first solvent in which the water-soluble polymer is soluble and a second solvent in which the water-soluble polymer is not soluble.

[0306] Paragraph 33. The water-dispersible nonwoven web of any one of Paragraphs 30 through 32, wherein the solvent exchange bath consists essentially of a solvent in which the water-soluble polymer is not soluble.

[0307] Paragraph 34. The water-dispersible nonwoven web of any one of Paragraphs 30 through 33, wherein the water-soluble polymer comprises a blend of two or more different polymers.

[0308] Paragraph 35. The water-dispersible nonwoven web of any one of paragraphs 30 to 34, wherein the water-soluble polymer has a degree of polymerization of at least 1000.

[0309] Paragraph 36. The water-dispersible nonwoven web of any one of paragraphs 30 to 35, wherein the water-soluble fibers have fiber diameters in the range of 10 to 300 microns, 25 to 300 microns, 50 to 300 microns, or 75 to 100 microns.

[0310] Paragraph 37. The water-dispersible nonwoven web of any one of Paragraphs 30 to 36, wherein the water-soluble fibers have a tenacity in the range of about 5 cN / dtex to about 10 cN / dtex, or about 6 cN / dtex to about 10 cN / dtex, or about 7 cN / dtex to about 10 cN / dtex.

[0311] Paragraph 38. The water-dispersible nonwoven web of any one of Paragraphs 30 through 37, further comprising filaments prepared by a process selected from the group consisting of meltblowing, spunbonding, electrospinning, rotary spinning, continuous filament producing operations, tow fiber producing operations, and combinations thereof.

[0312] Paragraph 39. The water-dispersible nonwoven web of any one of paragraphs 1 to 38, wherein the water-dispersible nonwoven web is water-flushable.

[0313] Paragraph 40. A multi-layer water-dispersible nonwoven web comprising a first water-dispersible nonwoven web according to any one of paragraphs 1 to 39.

[0314] Paragraph 41. The multi-layer water-dispersible nonwoven web of Paragraph 40, further comprising a second water-dispersible nonwoven web of any one of Paragraphs 1 to 39.

[0315] Paragraph 42. The multi-layer water-dispersible nonwoven web of Paragraph 41, wherein the first water-dispersible nonwoven web and the second water-dispersible nonwoven web comprise the same fibers and have the same basis weight.

[0316] Paragraph 43. The multi-layer water-dispersible nonwoven web of Paragraph 41, wherein the first water-dispersible nonwoven web and the second water-dispersible nonwoven web comprise different fibers and have the same basis weight.

[0317] Paragraph 44. The multi-layer water-dispersible nonwoven web of Paragraph 41, wherein the first water-dispersible nonwoven web and the second water-dispersible nonwoven web comprise different fibers and have different basis weights.

[0318] Paragraph 45. The multi-layer water-dispersible nonwoven web of any one of Paragraphs 41 to 43, wherein the first water-dispersible nonwoven web and the second water-dispersible nonwoven web are laminated to one another.

[0319] Paragraph 46. The multi-layer water-dispersible nonwoven web of any one of Paragraphs 40 to 45, further comprising a film laminated to the first water-dispersible nonwoven web.

[0320] Paragraph 47. The multi-layer water-dispersible nonwoven web of Paragraph 46, wherein the fibers and the water-soluble film of the first water-dispersible nonwoven web comprise the same water-soluble polymer.

[0321] Paragraph 48. The multi-layer water-dispersible nonwoven web of Paragraph 46, wherein the fibers and the water-soluble film of the first water-dispersible nonwoven web comprise different water-soluble polymers.

[0322] Paragraph 49. The multi-layer water-dispersible nonwoven web has a fiber density of about 1 g / m 2 to about 100g / m 2 49. The multi-layer water-dispersible nonwoven web of any one of paragraphs 40 to 48, having a basis weight of

[0323] Paragraph 50. The multi-layer water-dispersible nonwoven web of any one of Paragraphs 40 to 48, wherein the first multi-layer water-dispersible nonwoven web is porous.

[0324] Paragraph 51. The multi-layer water-dispersible nonwoven web of any one of Paragraphs 40 to 48, wherein the multi-layer water-dispersible nonwoven web is non-porous.

[0325] Paragraph 52. The multi-layer water-dispersible nonwoven web of any one of Paragraphs 40 to 51, wherein the multi-layer water-dispersible nonwoven web is waterflushable.

[0326] Paragraph 53. A water-dispersible pouch comprising the water-dispersible nonwoven web of any one of Paragraphs 1 to 39 in the form of a pouch defining an interior pouch volume.

[0327] Paragraph 54. A water-dispersible pouch comprising the multi-layer water-dispersible nonwoven web of any one of Paragraphs 40 to 51 in the form of a pouch defining an interior pouch volume.

[0328] Paragraph 55. The water-dispersible pouch of Paragraph 54, wherein the multi-layer water-dispersible nonwoven web comprises a first water-dispersible nonwoven web and a water-soluble film, the water-soluble film forming an interior surface of the pouch.

[0329] Paragraph 56. A water-dispersible sealed article comprising the water-dispersible pouch of any one of Paragraphs 53 to 55.

[0330] Paragraph 57. The water-dispersible sealed article of Paragraph 56, further comprising a composition enclosed in the interior pouch volume.

[0331] Paragraph 58. The water-dispersible sealed article of Paragraph 56, wherein the composition enclosed in the inner pouch volume comprises a solid, a liquid, or a combination thereof.

[0332] Paragraph 59. The water-dispersible sealed article of Paragraph 58, wherein the composition enclosed in the inner pouch volume comprises a liquid.

[0333] Paragraph 60. The water-dispersible sealed article of Paragraph 58, wherein the composition enclosed in the inner pouch volume comprises a solid.

[0334] Paragraph 61. The water-dispersible sealed article of any one of Paragraphs 57 to 60, wherein the composition enclosed in the inner pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, a food nutritional composition, a pharmaceutical composition, an industrial cleaning composition, a disinfecting composition, a pet composition, an office composition, a livestock composition, an industrial composition, a marine composition, a commercial composition, a military composition, a recreational composition, or a combination thereof.

[0335] Paragraph 62. The water-dispersible sealed article of Paragraph 61, wherein the composition enclosed in the interior pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, a food nutritional composition, an industrial cleaning composition, or a combination thereof.

[0336] Paragraph 63. Forming the water-dispersible nonwoven web into the shape of a pouch; filling the pouch with a composition to be enclosed therein; and Sealing the pouch to form a sealed article. 63. A method for preparing the water-dispersible sealing article of any one of paragraphs 57 to 62, comprising:

[0337] Paragraph 64. The method of Paragraph 63, wherein sealing the pouch comprises heat sealing, solvent welding, adhesive sealing, or a combination thereof.

[0338] Paragraph 65. The multi-layer water-dispersible nonwoven web of Paragraph 46 or Paragraph 47, wherein the water-soluble fibers of the first water-dispersible nonwoven web comprise a first polyvinyl alcohol homopolymer and the water-soluble film comprises a second polyvinyl alcohol homopolymer, the first and second polyvinyl alcohol homopolymers have the same degree of hydrolysis, the multi-layer water-dispersible nonwoven web has a dissolution time at 10°C similar to or faster than a water-soluble film comprising an anionically modified polyvinyl alcohol copolymer having the same degree of hydrolysis as the first and second polyvinyl alcohol homopolymers, and the water-dispersible nonwoven web has greater biodegradability than a water-soluble film comprising an anionically modified polyvinyl alcohol.

[0339] Paragraph 66. Water-soluble fibers, including blends of water-soluble polymers.

[0340] Paragraph 67. The water-soluble fiber of Paragraph 66, wherein the blend of water-soluble polymers includes a polyvinyl alcohol polymer.

[0341] Paragraph 68. The water-soluble fibers are prepared by a wet chill gel spinning process, the wet chill gel spinning process comprising: a) dissolving two or more polymers in a solution to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle and into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide water soluble fibers. Soluble fiber of paragraph 66 or 67, including:

[0342] Paragraph 69. The water-soluble fiber of any one of Paragraphs 67 to 68, wherein the polyvinyl alcohol polymer has a degree of polymerization of at least 1000.

[0343] Paragraph 70. The water-soluble fiber of any one of Paragraphs 66 to 69, wherein the blend of water-soluble polymers comprises a blend of polyvinyl alcohol polymers.

[0344] Paragraph 71. The water-soluble fiber of Paragraph 70, wherein the blend of polyvinyl alcohol polymers comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

[0345] Paragraph 72. The water soluble fiber of any one of Paragraphs 66 to 71, wherein the water soluble fiber has a fiber diameter in the range of about 10 to about 300 microns, about 25 to about 300 microns, about 50 to about 300 microns, or at least about 100 to about 300 microns.

[0346] Paragraph 73. The water-soluble fiber of any one of Paragraphs 66 to 71, having a tenacity in the range of about 5 cN / dtex to about 10 cN / dtex, about 6 cN / dtex to about 10 cN / dtex, or about 7 cN / dtex to about 10 cN / dtex.

[0347] Paragraph 74. A water-dispersible nonwoven web comprising a plurality of water-soluble fibers of any one of Paragraphs 67 to 73.

[0348] Paragraph 75. A first layer comprising the water-soluble web of Paragraph 74; and (a) a second layer comprising a water-soluble web according to paragraph 74; or (b) a second layer comprising a water-soluble film; 1. A multi-layer water-dispersible nonwoven web comprising:

[0349] Paragraph 76. A water-dispersible pouch comprising the water-dispersible nonwoven web of Paragraph 74 in the form of a pouch defining an interior pouch volume.

[0350] Paragraph 77. A water-dispersible pouch comprising the multi-layer water-dispersible nonwoven web of Paragraph 75 in the form of a pouch defining an interior pouch volume.

[0351] Paragraph 78. A water-dispersible sealed article, including a water-dispersible pouch of paragraph 76 or paragraph 77.

[0352] Paragraph 79. The water-dispersible sealed article of Paragraph 78, further comprising a composition enclosed in the interior pouch volume.

[0353] Paragraph 80. The water-dispersible sealed article of Paragraph 79, wherein the composition enclosed in the inner pouch volume comprises a solid, a liquid, or a combination thereof.

[0354] Paragraph 81. The water-dispersible sealed article of Paragraph 79 or Paragraph 80, wherein the composition enclosed in the inner pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a water treatment composition, a personal care composition, a food nutritional composition, a pharmaceutical composition, a pet composition, an office composition, a livestock composition, an industrial composition, a marine composition, a commercial composition, a military composition, a recreational composition, or a combination thereof.

[0355] Paragraph 82. The water-dispersible sealed article of Paragraph 81, wherein the composition enclosed in the interior pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a water treatment composition, a personal care composition, a food nutritional composition, or a combination thereof.

[0356] Paragraph 83. Forming the water-dispersible nonwoven web into the shape of a pouch; filling the pouch with a composition to be enclosed therein; and Sealing the pouch to form a sealed article. 82. A method for preparing the water-dispersible sealing article of any one of paragraphs 78 to 81, comprising:

[0357] Paragraph 84. The method of Paragraph 83, wherein sealing the pouch comprises heat sealing, solvent welding, adhesive sealing, or a combination thereof.

[0358] Paragraph 85. A wet chill gel spinning process, comprising: a) dissolving a water soluble polymer in a solution to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle and into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide water soluble fibers. 74. A method for preparing a soluble fiber of any one of paragraphs 66, 67, or 69 through 73, comprising:

[0359] Paragraph 86. The method of Paragraph 85, wherein finishing includes cutting or crimping the extruded polymer mixture to provide water soluble fibers.

[0360] Paragraph 87. The method of Paragraph 85 or Paragraph 86, wherein the coagulation bath comprises a mixture comprising a first solvent in which the water-soluble polymer is soluble and a second solvent in which the water-soluble polymer is not soluble.

[0361] Paragraph 88. The method of any one of Paragraphs 85 to 87, wherein the solvent exchange bath consists essentially of a solvent in which the water-soluble polymer is not soluble.

[0362] Paragraph 89. A method of controlling the hand of a water-dispersible pouch or packet, comprising preparing a pouch or packet from a water-dispersible nonwoven web, the water-dispersible nonwoven web comprising a plurality of water-soluble fibers that comprise a water-soluble polymer.

[0363] While the above embodiments are specifically contemplated, they are not intended to limit the scope of water-dispersible nonwoven webs according to the present disclosure in any way.

[0364] Water-dispersible nonwoven webs according to the present disclosure can be better understood in light of the following examples, which are intended merely to illustrate water-dispersible nonwoven webs and are in no way intended to limit their scope. EXAMPLES

[0365] Example 1: Preparation of Nonwoven Web Single layer nonwoven webs were prepared from various water soluble fibers as listed in Table 1 below. Briefly, water soluble staple fibers were carded and then calendered or chemically bonded. Calendering was performed at temperatures between 160°C and 190°C and at a loading of approximately 2 kg / m 2The bonding was performed using an embossing roll with a pressure of approximately 2 kg / m2. Conventional heated calender rolls made from cast iron or steel were used. Chemical bonding was performed as follows: An aqueous polyvinyl alcohol solution is prepared using the same polyvinyl alcohol used to prepare the fibers. A sponge roller coated with the polyvinyl alcohol solution from a dip pan is then used to bond the fibers with approximately 2 kg / m2 of pressure. 2 The polyvinyl alcohol solution was coated onto the unbonded nonwoven web surface using a pressure of 1000 g. [Table 1]

[0366] Thus, Example 1 illustrates the formation of a water-dispersible nonwoven web of the present disclosure.

[0367] Example 2: Nonwoven Web Properties The nonwoven web prepared according to Example 1 was tested for various mechanical and physical properties according to the methods described herein. The results are presented in Table 2. Table 2 also includes the mechanical and physical properties for a water-soluble film having a thickness of 3 mils and prepared from a polyvinyl alcohol homopolymer having a degree of hydrolysis of 88. The water-soluble film further includes about 26.5 PHR of a plasticizer, about 0.4 PHR of a surfactant, and about 0.2 PHR of other adjuvants. [Table 2]

[0368] Thus, Example 2 demonstrates that the water-dispersible webs of the present disclosure have lower static CoF and static to dynamic CoF ratios (Sample 6 compared to Film 1, both prepared from a PVOH homopolymer having a degree of hydrolysis of 88), significantly higher slip, improved hand, and ease of processing, for example, into pouches, compared to water-soluble films prepared with similar PVOH polymers. Example 2 further demonstrates that there is a general trend toward higher CoF values ​​for nonwoven webs prepared from fibers having lower tenacity (Samples 1, 2, 3, and 6 compared to Samples 4 and 5).

[0369] (Example 3) Color Index The color index of the nonwoven web prepared according to Example 1 was tested according to procedures commonly used in the art: ASTM E313 (yellowness and whiteness) and TAPPI 452 (brightness). [Table 3]

[0370] Thus, Table 3 shows that the nonwoven webs of the present disclosure have suitable Yellowness Index, Whiteness and Brightness values. Example 3 further shows that the use of copolymers with higher substituent numbers as fibers results in improved Yellowness values ​​compared to fibers containing homopolymers, which is expected when the functionality of the substituents on the PVOH backbone is increased.

[0371] (Example 4) Surface resistivity The surface resistivity of the nonwoven webs prepared according to Example 1 was tested as described above. [Table 4]

[0372] Thus, Example 4 shows that nonwoven fabrics according to the present disclosure generally exhibit higher surface resistivity compared to water-soluble films. Example 4 further shows that the use of fibers containing an anionically modified polyvinyl alcohol copolymer can result in nonwoven fabrics with slightly lower surface resistivity compared to nonwoven fabrics made from polyvinyl alcohol homopolymer fibers.

[0373] Example 5: Aging and Conditioning Water-dispersible nonwoven web samples prepared according to Example 1 were exposed to various temperature and humidity environments for 24 hours as described in Table 5. All samples were then conditioned in an ambient environment (i.e., 23°C, 35% RH) for 24 hours prior to testing. Mechanical properties of the conditioned samples were obtained as described above and the results are presented in Table 5. [Table 5]

[0374] Table 5 shows that, as expected, Samples 4 and 5 prepared from fibers containing PVOH homopolymer with 98% and 96% hydrolysis degree, respectively, were not soluble in cold water. In contrast, Sample 6 prepared from fibers containing PVOH homopolymer with 88% hydrolysis degree was soluble in cold water even after exposure to high temperature and high humidity conditions. Comparison of Samples 5 and 7 shows that mechanical properties and the effect of humidity and temperature conditioning environment on mechanical properties can be controlled by simply changing the applied bonding technique. Table 5 further shows that the mechanical properties of the water-dispersible nonwoven web of the present disclosure are maintained and / or positively affected when exposed to high temperature and high humidity environment.

[0375] (Example 6) ATR Crystallinity Ratio The crystallinity of water-dispersible nonwoven web samples prepared according to Example 1 was tested using FTIR-ATR and the results are presented in Table 6. The absorbance of the shoulder / peak at 1141 is an indication of crystallinity, and the ratio of the peak height at 1141 to the peak height of the reference peak 1420 provides the relative crystallinity between samples. Polyvinyl alcohol has a peak absorbance of 1141 cm when measured by FTIR (including FTIR-ATR). -1 It is well known in the art that the absorbance of this peak is related to the degree of crystallinity. The ratio of the absorbance of this peak to the absorbance of a reference peak, usually between 1420 and 1430 cm -1 Peak maxima in the range of 0.01 to 0.15 μm (associated with the CH2 bending absorption expected to be present in all polyvinyl alcohol homopolymers) allow for comparison of the relative differences in crystallinity between the various samples. [Table 6]

[0376] Table 6 shows the expected trend of increasing crystallinity with increasing degree of hydrolysis of the PVOH polymer used to prepare the fibers that were subsequently used to prepare the water-dispersible nonwoven webs of the present disclosure. A comparison of Tables 6A and 6B further shows the improved crystallinity ratio after heat sealing.

[0377] (Example 7) Single-layer nonwoven fabric containing a single fiber type containing a single fiber forming material Single layer nonwoven webs were prepared from various water soluble fibers as listed in Table 7A below. Briefly, water soluble staple fibers were carded and then calender bonded. Calender bonding was performed using an embossing roll at a temperature between 120°C and 140°C and a pressure of about 25 to 50 PSI. Conventional heated calender rolls made from cast iron or steel were used. Calender speeds were between about 1 and 5 FPM. Fibers formed from PVOH homopolymers with a degree of hydrolysis of 88% have a complete melt temperature of 20°C, and fibers formed from PVOH homopolymers with a degree of hydrolysis of 96% have a complete melt temperature of 40°C. [Table 7A]

[0378] The solubility of the nonwoven webs was tested at 23° C. and 40° C. In particular, the time to burst and disintegration of the nonwoven webs was determined according to MSTM-205, as described herein. The solubility reported as time to burst is presented below in Table 7B. [Table 7B]

[0379] Thus, Example 7 shows that the solubility of nonwoven webs generally follows the same water solubility profile as that of the PVOH fiber-forming material from which they are constructed. In particular, for PVOH homopolymer fiber-forming materials, as the degree of hydrolysis increases (e.g., from 88% to 96%), the solubility of the fibers and nonwoven webs improves (e.g., requires higher temperatures or takes longer to burst / disintegrate). Example 7 further shows that for a given calender temperature and pressure, the dissolution time of nonwoven webs generally improves as the basis weight increases. This relationship is particularly evident when the temperature of the dissolving water is lower than the complete dissolution temperature of the fibers that make up the nonwoven web. For example, compare Samples 12 and 18, and 13 and 19, each of which is prepared from a water-soluble fiber having a complete dissolution temperature of 40°C. At 23°C, Samples 12 and 13, with basis weights of 39.7 and 41.8, respectively (90 seconds and 90.33 seconds, respectively), are slower to burst than Samples 18 and 19, with basis weights of 21 and 23.1, respectively (73.67 seconds and 85.33 seconds, respectively). Example 7 further shows that for nonwoven webs with the same fiber chemistry and similar basis weights, at a given calendering pressure, the dissolution time of the nonwoven web generally increases with increasing calendering temperature. This relationship is particularly evident when the temperature of the dissolving water is lower than the complete dissolution temperature of the fibers that make up the nonwoven web. For example, compare Samples 11 and 23, and 17 and 53, each of which was prepared from a water-soluble fiber with a complete dissolution temperature of 40°C. At 40°C, the samples calendered at 140°C have a longer dissolution time than the samples calendered at 120°C (11 seconds compared to 6.67 seconds for samples with basis weights of 42.5 and 44.7, respectively; 6.67 seconds compared to 4.33 seconds for samples with basis weights of 19.3 and 19.5, respectively).The same trend was even more pronounced at 23°C, where samples calendered at 140°C had dissolution times of 138.67 seconds and 92.33 seconds (for nonwovens having basis weights of 42.5 and 19.3, respectively) compared to dissolution times of 97 seconds and 68.33 seconds (for nonwovens having basis weights of 44.7 and 19.5, respectively) for nonwovens calendered at 120°C.

[0380] Example 8: Single layer nonwoven fabric containing a blend of fiber types, each fiber type containing a monofilament forming material Single layer nonwoven webs were prepared from various blends of water soluble fibers as listed in Table 8A below. Briefly, water soluble staple fibers were carded and then calender bonded. Calender bonding was performed using an embossing roll at a temperature of 140° C. and a pressure of about 40 to 50 PSI. Conventional heated calender rolls made from cast iron or steel were used. Calender speeds were between about 1 and 2 FPM. [Table 8A]

[0381] The nonwoven webs were tested for solubility at 23° C. and 40° C. In particular, the time to burst and disintegration of the nonwoven webs was determined according to MSTM-205 described herein. The solubility is presented in Table 8B below. [Table 8B]

[0382] Example 8 illustrates a nonwoven web of the present disclosure that includes a blend of fibers that includes a first fiber that includes a first water-soluble fiber-forming material and a second fiber that includes a second water-soluble fiber-forming composition. Specifically, Example 8 in combination with Samples 20 and 23 of Example 7 illustrates that when a blend of fibers is used in a nonwoven web, the solubility of the nonwoven web does not follow the rule of mixtures (compare Samples 63-65 with Samples 20 and 23). Example 8 further illustrates that for samples having similar basis weights and prepared using the same calendering conditions at a temperature lower than the complete dissolution temperature of the less soluble fiber (e.g., 23°C for a blend including a fiber with a complete dissolution temperature of 40°C), the burst time of the nonwoven fabric is substantially the same for a blend of two fibers having a molar ratio of 25:75 and a blend of two fibers having a molar ratio of 75:25 (compare Samples 63 and 65; 55 and 61; and 56 and 62). Unexpectedly, at all temperatures, nonwoven webs having a 50:50 blend of the two fibers demonstrated different burst times than the 25:75 and 75:25 blends, and surprisingly demonstrated longer times to burst than the 25:75 and 75:25 blends (compare Sample 64 with Samples 63 and 65; 58 with 55 and 61; and 59 with 56 and 62).

[0383] Example 9: Multilayer nonwoven fabric Multi-layer nonwoven webs were prepared from various water-soluble fibers as described in Table 9A below. In particular, each nonwoven web included a first layer (L1) and a second layer (L2). Each layer included a monofilament type, including monofilament forming materials. Briefly, the water-soluble staple fibers were carded and then calender bonded. The two carded webs were then placed on top and passed through calender rollers at the specified conditions. If necessary, the placed nonwoven web was passed through a needle punch bonding station before passing through the calender rollers. Calender bonding was performed using an embossing roll at a temperature of 140° C. and a pressure of about 40 PSI. Conventional heated calender rolls made of cast iron or steel were used. The calender speed was about 2 FPM. [Table 9A]

[0384] The nonwoven webs were tested for solubility at 23° C. and 40° C. In particular, the time to burst and disintegration of the nonwoven webs was determined according to MSTM-205 as described herein. The solubility is presented in Table 9B below. [Table 9B]

[0385] Thus, Example 9 shows a multi-layer nonwoven web according to the present disclosure. Example 9 further shows that when the multi-layer nonwoven web and the single-layer nonwoven web have similar basis weights, the multi-layer nonwoven web having two layers of the same nonwoven web generally has the same dissolution characteristics as the single nonwoven web of the same material (compare Samples 66 and 67 with Sample 20 in Example 7; Samples 68 and 69 with Sample 23 in Example 7). Example 9 further shows that when the multi-layer nonwoven web has two different layers, the solubility characteristics of the multi-layer nonwoven web do not follow the rule of mixtures (compare Samples 70 and 71 with Samples 20 and 23 in Example 7). Instead, at temperatures below the complete dissolution temperature of the fibers of the less soluble nonwoven web, the solubility of the multilayer nonwoven web generally behaves more similarly to the dissolution of the less soluble nonwoven web (compare Samples 70, 71, 20 and 23: the less soluble nonwoven sample (23) contains fibers having a complete dissolution temperature of 40°C, and at temperatures below 40°C (e.g., 23°C), multilayer nonwoven webs containing a layer of Sample 23 and a layer of Sample 20 (i.e., Samples 70 and 71) have increased solubility compared to Sample 23, but not to the extent of a weighted average (i.e., do not follow the rule of mixtures)).

[0386] Example 10: Single layer nonwoven fabric containing a blend of fiber types, each fiber type containing a monofilament forming material Single layer nonwoven webs were prepared from various blends of water soluble fibers as listed in Table 8A below. Briefly, water soluble staple fibers were carded and then calender bonded. Calender bonding was performed using an embossing roll at a temperature of 140° C. and a pressure of about 40 to 50 PSI. Conventional heated calender rolls made from cast iron or steel were used. Calender speeds were between about 1 to 2 FPM. The nonwoven webs include first fibers comprising a water soluble polyvinyl alcohol film forming material and second fibers comprising a non-polyvinyl alcohol water insoluble fiber forming material. The water-insoluble fiber-forming material was one of Trevira 298, 1.6 dtex × 38 mm polyethylene terephthalate fiber ("PET"); 6.6 dtex × 60 mm polylactide fiber ("PLA"); 5.5 dtex × 78 mm viscose (rayon) fiber ("Viscose"), 22 dtex × 38 mm PET fiber ("High PET"); and Lenzing Lyocell, 1.65 dtex × 38 mm cellulose fiber ("Cellulose"). [Table 10A]

[0387] The nonwoven webs were tested for solubility and flexibility at 23° C. and 40° C. In particular, the burst and disintegration times of the nonwoven webs were determined according to MSTM-205 as described herein. The solubility is presented in Table 10B below. [Table 10B]

[0388] Thus, Example 10 shows a water-dispersible nonwoven fabric of the present disclosure that includes a blend of water-soluble and water-insoluble fibers. Example 10 further shows that fiber selection can advantageously control the feel (e.g., softness) of nonwoven webs. In particular, for a given fiber type, lowering the L / D ratio reduces softness (i.e., has a higher softness rating), as can be seen in the cases of Samples 72 and 75, where PVOH has an L / D ratio of 23.18 and PET has an L / D ratio of 23.75, a mixture of PVOH / PET fibers results in a nonwoven web with a softness rating of 2 (Sample 72), and when PVOH has the same L / D ratio of 23.18 but PET has a lower L / D ratio of 1.72, a mixture of PVOH / PET fibers results in a nonwoven web with a softness rating of 4 (Sample 75).

[0389] Example 11: Single layer nonwoven fabric containing a blend of fiber-forming materials Single layer nonwoven webs were prepared from various blends of water soluble fibers as described below in Table 11A. Briefly, water soluble staple fibers were carded and then calender bonded using an embossing roll under the conditions described in Table 11A. [Table 11A-1] [Table 11A-2]

[0390] The nonwoven webs were tested for solubility at 23° C., 40° C. and 80° C. In particular, the time to burst and disintegration of the nonwoven webs were determined according to MSTM-205 as described herein.

[0391] According to MSTM-205, none of the samples burst, disintegrated or dissolved within 300 seconds at temperatures of 23° C. or 40° C. Samples containing any amount of fiber containing fully hydrolyzed (99.9% DH) PVOH fiber-forming material did not burst, disintegrate or dissolve at temperatures at or below 80° C. Solubility data for samples that burst and / or disintegrated at temperatures of 80° C. and 90° C. are presented below in Table 11B. [Table 11B-1] [Table 11B-2]

[0392] Thus, Example 11 illustrates a warm water soluble nonwoven web of the present disclosure comprising a blend of fibers comprising a first fiber comprising a water soluble polyvinyl alcohol fiber forming material and a second fiber comprising a water soluble polyvinyl alcohol fiber forming material.

[0393] Example 12: Multi-layer nonwoven webs with different fiber chemistries Multi-layer nonwoven webs were prepared from various water-soluble fibers as set forth in Table 12A below. In particular, each nonwoven web contained two layers, each layer containing a monofilament type, which contained a monofilament forming material. Briefly, the water-soluble staple fibers were carded, and the two carded webs were stacked and calender bonded. Some samples were needle-perforated after stacking the two carded webs and before calendering, as set forth in Table 12A. Calender bonding was performed using an embossing roll under the conditions set forth in Table 12A. Samples 156-159 were single layer nonwoven webs containing a blend of fiber types, including the amount of each fiber type specified in Table 12A. [Table 12A]

[0394] The multi-layer nonwoven web was tested for solubility at 23° C. and 40° C. The thinning times were determined according to MSTM-205 and are presented below in Table 12B. [Table 12B]

[0395] Thus, Example 12 shows that for multi-layer nonwoven webs of the present disclosure having the same fiber chemistry and bonding conditions, the thinning time generally decreases as the total basis weight of the multi-layer nonwoven decreases (compare Samples 144 and 146, and Samples 145 and 147). Example 12 further shows that for multi-layer nonwoven webs of the present disclosure having the same total basis weight and bonding conditions, the thinning time generally increases as the fiber solubility of one layer decreases (compare Samples 146 and 150, Samples 147 and 151, Samples 148 and 152, and Samples 149 and 153). Example 12 further shows that for single layer nonwoven webs comprising a blend of fibers and similar basis weights, the thinning time generally increases as the overall fiber solubility decreases (compare Samples 156 and 157, and Samples 158 and 159; also compare Samples 159 and 157 and Samples 158 and 156).

[0396] (Example 13) Possibility of flushing The waterflushability of various nonwoven webs prepared in the previous examples was tested using the waterflushability test described herein. Two commercially available waterflushable nonwoven wipes were also tested according to the waterflushability test. The commercially available waterflushable nonwoven wipes meet the INDA / EDANA requirements for waterflushability. Thus, the degradation rates of the commercially available waterflushable wipes using the waterflushability test are considered the threshold at which the nonwoven webs of the present disclosure are considered waterflushable, because the INDA / EDNA standards are not as stringent as the waterflushability test, these nonwoven webs would also be expected to meet the INDA / EDANA standards for waterflushability. Nonwoven webs of the present disclosure that meet or exceed the degradation rates determined for commercial wipe A are indicated in Table 13 with "(+)". Nonwoven webs of the present disclosure that had a degradation rate at least twice that of Commercial Wipe A are designated in Table 13 with a "(++)". [Table 13]

[0397] Thus, Example 13 shows that the nonwoven webs of the present disclosure meet or exceed the flushability demonstrated by commercially available flushable wipes.In particular, Example 13 shows that the monolayer nonwoven webs of the present disclosure that contain only one fiber type with only one fiber forming material, the monolayer nonwoven webs of the present disclosure that contain a blend of fiber types, each fiber type with a monolayer forming material, and the multilayer nonwoven webs of the present disclosure (each layer contains only one fiber type with only one fiber forming material) all meet or exceed the flushability demonstrated by commercially available flushable nonwoven wipes.Example 13 further shows that for most nonwoven webs of the present disclosure, the flushability is significantly improved over commercially available options, demonstrating at least twice the degradation of commercially available samples.

[0398] Example 14 Preparation of Pouches and Sealed Articles The pouches and sealed articles were prepared as follows: A four-sided nonwoven web according to Sample 21 was folded in half on itself and the two unfolded sides were heat sealed at a temperature of 175°C to obtain a pouch having an opening and an internal pouch volume. The powder composition was dispensed through the opening into the internal pouch volume. The opening was heat sealed at a temperature of 175°C to obtain a sealed article.

[0399] Two four-sided nonwoven webs according to Sample 21 were placed one on top of the other and folded in half, resulting in an article having one folded side and three unfolded sides. Two of the unfolded sides were heat sealed at a temperature of 175°C to obtain a pouch having an opening and an internal pouch volume. A powder composition was dispensed through the opening into the internal pouch volume. The opening was heat sealed at a temperature of 175°C to obtain a sealed article comprising a laminate of two nonwoven webs.

[0400] A four-sided nonwoven web conforming to Sample 21 was placed over the water-soluble film and folded in half, resulting in an article having one folded side and three unfolded sides with the water-soluble film therein. Two of the unfolded sides were heat sealed at a temperature of 175° C. to provide a pouch having an opening and an interior pouch volume defined by the water-soluble film. A liquid and / or powder composition was delivered through the opening into the interior pouch volume. The opening was heat sealed at a temperature of 175° C. to provide a sealed article comprising a laminate of the nonwoven web and the water-soluble film.

[0401] The pouches and sealed products containing the laminate of nonwoven web and water-soluble film are as follows: The nonwoven web used conformed to sample 21. Four different pouches were prepared using four different polyvinyl alcohol water-soluble films. The water-soluble film on the walls of the pouches was the same as that on the top seal. The nonwoven web was placed over the thermoformable cavity, and the water-soluble film was placed over the nonwoven web. A vacuum pressure of 400 mbar and heat of 120°C were applied to draw the nonwoven web and water-soluble film inside the cavity. The cavity was then filled with a liquid and / or solid composition. A second water-soluble film was placed over the top of the filled cavity, and a second nonwoven web according to sample 21 was placed over the water-soluble film. The cavity was then heat sealed at a temperature of 175°C to form a sealed article comprising a laminate of nonwoven web and water-soluble film.

[0402] The release of the contents of the thermoformed sealed articles was determined according to the Liquid Release Test described herein and compared to the release of the same contents from a thermoformed pouch prepared with only a water-soluble film, and the results are shown in Table 14. [Table 14]

[0403] Thus, Example 14 shows that the nonwoven web of the present disclosure was used to prepare pouches and sealed articles of the present disclosure. Example 14 further shows that the sealed articles prepared from the laminates of the present disclosure, including the nonwoven web and the water-soluble film, when immersed in water, maintain the contents of the pouch for a longer period of time than sealed articles prepared from only the water-soluble film, and advantageously achieve a delayed release profile compared to articles prepared from only the water-soluble film.

[0404] The above description is set forth merely for clarity of understanding, and no unnecessary limitations should be understood therefrom, since modifications within the scope of the invention may be apparent to those skilled in the art.

[0405] All patents, publications and references cited herein are hereby incorporated by reference in their entirety. In the event of a conflict between this disclosure and the incorporated patents, publications and references, this disclosure shall control. The present invention provides, for example, the following items. (Item 1) A nonwoven web comprising a plurality of fibers, the plurality of fibers being comprised of a first polyvinyl alcohol fiber forming material and (a) Second polyvinyl alcohol fiber-forming material or (b) the blend of fiber-forming materials does not include carboxymethylcellulose, hydroxypropylmethylcellulose, or starch; Nonwoven web. (Item 2) 2. The nonwoven web of claim 1, wherein the first polyvinyl alcohol fiber forming material comprises a polyvinyl alcohol homopolymer or a polyvinyl alcohol copolymer. (Item 3) 3. The nonwoven web of claim 1 or 2, wherein the second polyvinyl alcohol fiber forming material comprises a polyvinyl alcohol homopolymer or a polyvinyl alcohol copolymer. (Item 4) 4. The nonwoven web of claim 2 or 3, wherein the polyvinyl alcohol copolymer comprises a modified polyvinyl alcohol copolymer. (Item 5) 5. The nonwoven web of claim 4, wherein the modified polyvinyl alcohol copolymer comprises an anionically modified polyvinyl alcohol copolymer. (Item 6) Item 6. The nonwoven web of item 4 or item 5, wherein the modified polyvinyl alcohol copolymer has a degree of modification ranging from about 1 mol.% to about 10 mol.%. (Item 7) 2. The nonwoven web of any one of the preceding claims, wherein the first fibers comprise the first and second polyvinyl alcohol fiber forming materials, the first polyvinyl alcohol fiber forming material comprises a polyvinyl alcohol homopolymer and the second polyvinyl alcohol fiber forming material comprises a polyvinyl alcohol copolymer. (Item 8) 8. The nonwoven web of claim 7, wherein the polyvinyl alcohol homopolymer comprises about 15 wt.% to about 70 wt.%, based on the total weight of the polyvinyl alcohol fiber forming material, and the copolymer comprises the remainder of the polyvinyl alcohol fiber forming material. (Item 9) 2. The nonwoven web of any one of the previous claims, wherein the first polyvinyl alcohol fiber forming material has a degree of hydrolysis ranging from about 75% to about 99.9%. (Item 10) 10. The nonwoven web of claim 9, wherein the first polyvinyl alcohol fiber forming material has a degree of hydrolysis ranging from about 80% to about 90%. (Item 11) 10. The nonwoven web of claim 9, wherein the first polyvinyl alcohol fiber forming material has a degree of hydrolysis in the range of about 92% to about 99%, optionally about 98% to about 99%, optionally about 98% to about 99.9%. (Item 12) 2. The nonwoven web of any one of the preceding claims, wherein the second polyvinyl alcohol fiber forming material has a degree of hydrolysis ranging from about 75% to about 99.9%. (Item 13) 13. The nonwoven web of claim 12, wherein the second polyvinyl alcohol fiber forming material has a degree of hydrolysis ranging from about 80% to about 90%. (Item 14) 13. The nonwoven web of claim 12, wherein the second polyvinyl alcohol fiber forming material has a degree of hydrolysis in the range of about 92% to about 99%, optionally about 98% to about 99%, optionally about 98% to about 99.9%. (Item 15) The plurality of fibers are The first fibers; The second fiber The first and second fibers have a length to distance (L / D) ratio, tenacity, shape, stiffness, elasticity, water solubility, melting point, glass transition temperature (T g ), fiber chemistry, color, or a combination thereof. (Item 16) 2. The nonwoven web of any one of the preceding claims, wherein the plurality of fibers comprises water insoluble fibers. (Item 17) 17. The nonwoven web of claim 16, wherein the water insoluble fibers comprise from about 20% to about 80% by weight of the total weight of the plurality of fibers. (Item 18) Item 18. The nonwoven web of item 16 or item 17, wherein the plurality of water insoluble fibers comprises cotton, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polyester, copolyester, viscose, polylactide, polyethylene terephthalate, polypropylene, or combinations thereof. (Item 19) 2. The nonwoven web of any one of the preceding claims, which is biodegradable. (Item 20) 2. The nonwoven web of any one of the preceding claims, wherein the first fibers have a tenacity in the range of about 3 cN / dtex to about 10 cN / dtex, optionally about 7 cN / dtex to about 10 cN / dtex. (Item 21) 21. The nonwoven web of claim 20, wherein the first fibers have a tenacity in the range of about 4 cN / dtex to about 8 cN / dtex, optionally about 6 cN / dtex to about 8 cN / dtex. (Item 22) 2. The nonwoven web of any one of the preceding claims, wherein the first fibers further comprise a plasticizer. (Item 23) 2. The nonwoven web of any preceding claim, further comprising an active agent. (Item 24) 24. The nonwoven web of claim 23, wherein the active agent is provided as part of a plurality of fibers, dispersed within the nonwoven web, provided on a surface of the nonwoven web, or a combination thereof. (Item 25) 25. The nonwoven web of claim 23 or 24, wherein the active agent is selected from an enzyme, an oil, a flavor, a colorant, an odor absorber, a fragrance, a pesticide, a fertilizer, an activator, an acid catalyst, a metal catalyst, an ion scavenger, a cleaning agent, a disinfectant, a surfactant, a bleaching agent, a bleaching component, a fabric softener, or a combination thereof. (Item 26) 2. The nonwoven web of any one of the preceding claims, wherein the first fibers have a diameter ranging from about 10 microns to about 300 microns, optionally from about 50 microns to about 300 microns, optionally from greater than 100 microns to about 300 microns. (Item 27) 2. The nonwoven web of any one of the preceding claims, wherein the first fibers have a substantially uniform diameter. (Item 28) 2. The nonwoven web of any one of the preceding claims, wherein the first fibers have a length in the range of about 30 mm to about 100 mm, or about 30 mm to about 60 mm. (Item 29) 28. The nonwoven web of any one of the previous claims, wherein the first fibers have a length less than about 30 mm, or in the range of about 0.25 mm to less than 30 mm. (Item 30) 30. The nonwoven web of any one of the previous items, wherein the first fibers have a length to diameter (L / D) ratio of about 0.5 to 15, about 0.75 to about 10, or about 1 to about 5. (Item 31) 2. The nonwoven web of any one of the preceding claims, which is porous. (Item 32) 31. The nonwoven web of any one of the preceding claims, which is nonporous. (Item 33) Item 11. The nonwoven web of any one of the preceding items, which is colored, dyed, pigmented, or a combination thereof. (Item 34) Approximately 1g / m 2 to about 100g / m 2 , about 20g / m 2 From about 80g / m 2 , about 30g / m 2 to about 100g / m 2 , or about 25 g / m 2 From about 70g / m 2 2. The nonwoven web of claim 1, having a basis weight of (Item 35) The nonwoven web of any one of the preceding claims, which dissolves at a given temperature at least about 5 times faster than a film prepared from the same polymer as the first fibers of the nonwoven web. (Item 36) The first fiber is prepared by a wet chill gel spinning process, the wet chill gel spinning process comprising: a) dissolving said fiber-forming material in a solvent to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle and into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing said extruded polymer mixture to provide said first fibers. 2. The nonwoven web of any one of the preceding claims, comprising: (Item 37) The second fiber is prepared by a wet chill gel spinning process, the wet chill gel spinning process comprising: a) dissolving said fiber-forming material in a solvent to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle and into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing said extruded polymer mixture to provide said second fibers. 37. The nonwoven web of any one of items 15 to 36, comprising: (Item 38) 38. The nonwoven web of any one of claims 36 or 37, wherein the finishing comprises cutting or crimping the extruded polymer mixture to obtain the first or second fibers. (Item 39) 39. The nonwoven web of any one of claims 36 to 38, wherein the coagulation bath comprises a mixture of solvents comprising a first solvent in which the fiber-forming material is soluble and a second solvent in which the fiber-forming material is not soluble. (Item 40) 40. The nonwoven web of any one of claims 36 to 39, wherein the solvent exchange bath consists essentially of a solvent in which the fiber-forming material is not soluble. (Item 41) 41. The nonwoven web of any one of claims 36 to 40, wherein the degree of polymerization of the fiber-forming material is at least 1000. (Item 42) 42. The nonwoven web of any one of items 36 to 41, wherein the first fibers have a fiber diameter in the range of 10 to 300 microns, 25 to 300 microns, 50 to 300 microns, or 75 to 100 microns. (Item 43) 43. The nonwoven web of any one of items 36 to 42, wherein the first fibers have a tenacity in the range of about 5 cN / dtex to about 10 cN / dtex, or about 6 cN / dtex to about 10 cN / dtex, or about 7 cN / dtex to about 10 cN / dtex. (Item 44) 44. The nonwoven web of any one of items 36 to 43, further comprising filaments prepared by a process selected from the group consisting of meltblowing, spunbonding, electrospinning, rotary spinning, continuous filament producing operations, tow fiber producing operations, and combinations thereof. (Item 45) 2. The nonwoven web of any one of the preceding claims, which is flushable. (Item 46) 2. The nonwoven web of any one of the preceding claims, which is water-dispersible. (Item 47) 47. A multi-layer nonwoven web comprising the first nonwoven web of any one of the preceding claims. (Item 48) Item 48. The multi-layer nonwoven web of item 47, further comprising a second nonwoven web of any one of items 1 to 47. (Item 49) Item 49. The multi-layer nonwoven web of item 48, wherein the first nonwoven web and the second nonwoven web comprise the same fibers and have the same basis weight. (Item 50) Item 49. The multi-layer nonwoven web of item 48, wherein the first nonwoven web and the second nonwoven web comprise different fibers and have the same basis weight. (Item 51) Item 49. The multi-layer nonwoven web of item 48, wherein the first nonwoven web and the second nonwoven web comprise different fibers and have different basis weights. (Item 52) 52. The multi-layer nonwoven web of any one of items 48 to 51, wherein the first nonwoven web and the second nonwoven web are laminated to one another. (Item 53) 53. The multilayer nonwoven web of any one of items 47 to 52, further comprising a film laminated to the first nonwoven web. (Item 54) 54. The multi-layer nonwoven web of claim 53, wherein the plurality of fibers of the first nonwoven web and the film comprise the same water soluble polymer. (Item 55) 54. The multi-layer nonwoven web of claim 53, wherein the plurality of fibers of the first nonwoven web and the film comprise different polymers. (Item 56) Approximately 1g / m 2 to about 100g / m 2 56....

Claims

[Claim 1] The invention described in the specification.

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