Unit dose article for packing personal care product

Abstract

To provide a unit dose article for packing a personal care product.SOLUTION: There is disclosed a unit dose article that includes one or more compartments including nonwoven webs and water-soluble films. As one embodiment of the present disclosure, a unit dose article includes one or more partitions including: a water-soluble film which is in the form of a pouch defining first inner pouch capacity, and includes water-soluble resin; a nonwoven web which is in the form of a pouch enclosing the water-soluble film and defining second inner pouch capacity, and includes a plurality of fibers; and a first composition contained in a first compartment. When the first compartment comes into contact with water, the first composition is discharged. The unit dose article includes the water-soluble film in the form of the pouch, and extends the discharge of the first composition as compared with an identical unit dose article which does not include the nonwoven web in the form of the pouch.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS The benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 62 / 942,369, filed December 2, 2019, is hereby claimed, the disclosure of which is incorporated herein by reference in its entirety.

[0002] FIELD OF THEINVENTION The present disclosure relates generally to unit dose articles having nonwoven webs and water-soluble films and related compositions. More particularly, the present disclosure relates to unit dose articles for packaging personal care products for extended release. [Background technology]

[0003] background Water-soluble packaging materials are commonly used to simplify the dispersion, injection, dissolution, and administration of the material to be delivered. Traditional packaging materials include water-soluble films, and pouches made therefrom are commonly used to package compositions such as laundry detergents, dishwashing detergents, or personal care compositions. Consumers can add the composition in the pouch directly to water. It is advantageous to provide accurate dosing while eliminating the need for consumers to measure the composition. Traditional water-soluble films can be unstable in wet environments such as in a bathroom, which can affect the properties of the film, such as the mechanical properties of the film can deteriorate over time. Furthermore, pouches made from water-soluble films release the contents of the pouch immediately after the pouch dissolves. Thus, water-soluble films cannot provide a slow release of the contained composition while maintaining the mechanical integrity of the film and / or pouch. Furthermore, some current market pouches made from water-soluble polymeric films have an unpleasant rubbery or plastic feel when consumers handle them.

[0004] Thus, there is a need in the art for a unit dose package that is comfortable to handle, can have extended release of the contained composition, and can withstand a moist environment such as a bathroom. Summary of the Invention [Means for solving the problem]

[0005] overview One aspect of the present disclosure provides a unit dose article comprising one or more compartments comprising: a water-soluble film in the form of a pouch defining a first inner pouch volume, the water-soluble film comprising a water-soluble resin; a nonwoven web comprising a plurality of fibers in the form of a pouch defining a second inner pouch volume containing the water-soluble film; and a first composition contained by the first compartment, wherein when the first compartment contacts water, the first composition is released, and the unit dose article comprises a water-soluble film in the form of a pouch, which extends the release of the first composition compared to an identical unit dose article that does not include the nonwoven web in the form of a pouch.

[0006] Another aspect of the present disclosure provides a unit dose article comprising a first compartment, the unit dose article comprising: a water-soluble film comprising a water-soluble resin, the water-soluble film taking the form of a pouch defining a first inner pouch volume; a nonwoven web comprising a plurality of fibers, the nonwoven web taking the form of a pouch defining a second inner pouch volume containing the water-soluble film; and a first composition contained by the first compartment, wherein the nonwoven web has a dissolution time greater than the dissolution time of the water-soluble film by MSTM 205.

[0007] Another aspect of the present disclosure provides a unit dose article comprising a first compartment, the unit dose article comprising: a water-soluble film comprising a water-soluble resin, the water-soluble film being in the form of a pouch defining a first inner pouch volume; a nonwoven web comprising a plurality of fibers, the water-soluble film being in the form of a pouch defining a second inner pouch volume; and a first composition contained by the first compartment, the water-soluble film and the nonwoven web being in the form of a laminate and having a degree of lamination ranging from about 5% to about 100%.

[0008] Another aspect of the present disclosure provides a unit dose article comprising a compartment comprising: a water soluble film comprising a water soluble resin, taking the form of a pouch defining a first inner pouch volume; a nonwoven web taking the form of the pouch containing the water soluble film, comprising a plurality of fibers, the fiber type comprising a blend of PVOH homopolymer fiber forming material and a fiber type comprising a water insoluble biodegradable fiber forming material, wherein the water soluble film and the nonwoven web form a laminate, and a personal care composition is contained by the unit dose article, the unit dose article comprising a surfactant.

[0009] Another aspect of the present disclosure provides a unit dose article comprising two or more compartments comprising: a water-soluble film comprising a water-soluble resin, taking the form of a pouch defining a first inner pouch volume; a nonwoven web taking the form of the pouch containing the water-soluble film, comprising a plurality of fibers comprising a fiber type comprising a water-insoluble biodegradable fiber forming material, wherein the water-soluble film and the nonwoven web form a laminate, and a personal care composition is contained by the unit dose article comprising a surfactant.

[0010] Another aspect of the present disclosure provides a method of preparing a unit dose article according to the present disclosure, the method comprising: forming a water-soluble film into an open pouch defining an open pouch volume; adding a first composition to the open pouch volume; and sealing the film to form a first inner pouch volume.

[0011] For the articles, water-soluble films, nonwoven webs, fibers, and compositions described herein, optional features including, but not limited to, components and their compositional ranges, fiber forming materials, multi-layer construction, fiber geometry, and / or mechanical properties are contemplated to be selected from the various aspects and embodiments provided herein.

[0012] Further aspects and advantages will become apparent to those skilled in the art from a consideration of the following detailed description. While the articles, water-soluble films, nonwoven webs, fibers, and compositions of the present disclosure are susceptible to embodiment in various ways, the following description includes specific embodiments, with the understanding that the disclosure is illustrative and is not limited to the specific embodiments described herein. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a diagram of the wire frame cage (shown open at the top to better reveal the water-soluble pouch contained within) used in the liquid release studies described herein.

[0014] [Diagram 2] FIG. 2 shows an apparatus for conducting liquid release tests that includes a beaker mounted on a stand that holds a rod for lowering a cage within the beaker, the rod being lockable by a collar with a set screw (not shown).

[0015] [Figure 3A] FIG. 3A is a microscope image of a nonwoven web of the present disclosure having a softness ranking of 1.

[0016] [Figure 3B] FIG. 3B is a microscope image of a nonwoven web of the present disclosure having a softness ranking of 5.

[0017] [Figure 4] FIG. 4 is a diagram of a multi-compartment unit dose article of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] Detailed Description In the disclosure presented herein, an aspect provides a unit dose article comprising one or more compartments comprising a water-soluble film and a nonwoven web. In an embodiment, the water-soluble film can be in the form of a pouch defining a first inner pouch volume, and the nonwoven web can be in the form of a pouch defining a second inner pouch volume that encompasses the water-soluble film. In an embodiment, the water-soluble film can comprise a water-soluble resin, the nonwoven web can comprise a plurality of fibers, and the first composition can be contained by the unit dose article. In an embodiment, the water-soluble resin can comprise a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. In an embodiment, the unit dose article comprises a first compartment, the first composition is released when the first compartment is contacted with water, and the unit dose article comprises a water-soluble film in the form of a pouch, which extends the release of the first composition compared to an identical unit dose article that does not comprise a nonwoven web in the form of a pouch.

[0019] Another aspect of the present disclosure provides a unit dose article comprising a first compartment, the unit dose article comprising: a water-soluble film comprising a water-soluble resin, the water-soluble film taking the form of a pouch defining a first inner pouch volume; a nonwoven web comprising a plurality of fibers, the nonwoven web taking the form of a pouch defining a second inner pouch volume containing the water-soluble film; and a first composition contained by the first compartment, wherein the nonwoven web has a dissolution time greater than the dissolution time of the water-soluble film by MSTM 205.

[0020] Another aspect of the present disclosure provides a unit dose article comprising a first compartment, the unit dose article comprising: a water-soluble film comprising a water-soluble resin, the water-soluble film being in the form of a pouch defining a first inner pouch volume; a nonwoven web comprising a plurality of fibers, the water-soluble film being in the form of a pouch defining a second inner pouch volume; and a first composition contained by the first compartment, the water-soluble film and the nonwoven web being in the form of a laminate and having a degree of lamination ranging from about 5% to about 100%.

[0021] Unit dose articles according to the present disclosure can be designed to provide one or more advantages, such as a more "natural" feeling of consumer benefit, stability in a moist environment, enhanced functionality such as exfoliation and delivery of personal care compositions in an aqueous environment, and / or extended release of liquid compositions, while maintaining the mechanical integrity of the article over the period of use.

[0022] As used herein, a "plurality of fibers" can be of a single fiber type or can include two or more different fiber types. In embodiments where the plurality of fibers includes two or more different fiber types, each fiber type can generally be included in any amount, for example, in an amount of about 0.5% to about 99.5% by weight of the total weight of the plurality of fibers. In embodiments where the plurality of fibers includes a single fiber type, the plurality of fibers is substantially free of a second or more fiber type. The plurality of fibers is substantially free of a second or more fiber type when the plurality of fibers includes less than about 0.5% by weight of the second or more fiber type. In general, differences between fiber types can be determined by fiber length to diameter ratio (L / D), toughness, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g ), chemical composition, color, or a combination thereof.

[0023] Without wishing to be bound by theory, the time it takes for the composition to be released from the article using the Liquid Release Test described herein and the liquid composition within or on the article during use conditions are There is believed to be a positive correlation between the residence time of the liquid composition in the article and the liquid release time of the composition. The use conditions generally include wetting and mechanical agitation of the article, such as forming a foam from the composition contained in the article. As used herein and unless otherwise indicated, the residence time of the liquid composition in or on the article during the use conditions refers to the length of time that the composition is present in or on the article, for example as a liquid and / or foam (e.g., soap lather). Thus, the "extended release" of the composition from the article can be characterized by the liquid release time of the article as determined by the liquid release test described herein, and the article provides "extended release" when the article does not begin to release the composition for at least about 1 minute by the liquid release test. For example, the unit dose article may not begin to release the composition in at least about 1 minute, at least about 2 minutes, at least about 3 minutes, or at least about 5 minutes by the liquid release test, for example, in the range of about 1 to about 15 minutes, about 1 to about 10 minutes, about 1 to about 8 minutes, or about 1 to about 5 minutes. Additionally or alternatively, the "extended release" of the composition from the unit dose article of the present disclosure can be characterized by a liquid release time determined by the liquid release test described herein that is at least about 1.3x (1.3 times) longer than the same unit dose article that includes a water-soluble film in the form of a pouch and does not include a nonwoven web in the form of a pouch. For example, the "extended release" of the composition from the unit dose article of the present disclosure can be characterized by a liquid release time that is at least about 1.4x, about 1.5x, about 1.9x, about 2.7x, about 3.0x, about 3.3x, about 3.5x, about 3.6x, about 4.2x, about 4.3x, about 4.7x, about 5.6x, about 6.1x, about 7.1x, about 10.5x, about 11.6x, or about 22.3x longer than the same unit dose article that includes a water-soluble film in the form of a pouch and does not include a nonwoven web in the form of a pouch. Alternatively, or in addition, "extended release" may be characterized by the amount of composition retained within a unit dose article, where the article provides "extended release" when at least 30% of the composition is retained in the unit dose for about 5 minutes after contact of the article with water having a temperature of about 45°C or less.For example, the unit dose article can retain at least about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, or about 90% of the composition after contact with water having a temperature of about 45° C. or lower, e.g., in the range of about 0° C. to about 43° C., about 0° C. to about 40° C., about 10° C. to about 40° C., about 20° C. to about 40° C., about 20° C. to about 30° C., or about 30° C. to about 40° C. As used herein, a composition is "retained" if the composition is present in or on the article, e.g., as a liquid and / or foam (e.g., soap lather). As used herein, the term "contact with water" and variations thereof (e.g., "contacted with water") can refer to a unit dose article that is immersed in water, showered with water, or generally wet with water. In an embodiment, the unit dose article contacts water when showered with water. In embodiments, the unit dose article generally comes into contact with water when it is wetted, for example, when water is applied to the composition surrounding the unit dose article and the water diffuses through the surrounding composition to contact the pouch (e.g., the pouch is buried in wet mud or soil when the mud or soil is watered). Furthermore, the "extended release" of the article can be characterized by the amount of surface area of ​​the article that is retained after 300 seconds when tested by MSTM-205 at 40° C. In embodiments, the unit dose article is considered suitable for extended release of the composition if the article comprises a film, nonwoven web, or combination thereof that retains at least 50% of its original surface area after 300 seconds when tested by MSTM-205 at 40° C. For example, the unit dose article can retain at least about 50%, at least about 60%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, or at least about 95% of its pre-MSTM-205 surface area after 300 seconds when tested with MSTM-205 at 40° C.

[0024] In an embodiment, the first compartment of the unit dose article comprises a water-soluble film in the form of a pouch and extends the release of the first composition after contact with water at a temperature in the range of about 30° C. to about 40° C. for a period of at least about 30 seconds, as compared to an identical unit dose article that does not comprise a nonwoven web in the form of a pouch. In an embodiment, the first compartment of the unit dose article comprises a water-soluble film in the form of a pouch and extends the release of the first composition after contact with water at a temperature in the range of about 30° C. to 40° C. for a period of at least about 1 minute, as compared to an identical unit dose article that does not comprise a nonwoven web in the form of a pouch. In an embodiment, the first compartment of the unit dose article comprises a water-soluble film in the form of a pouch and extends the release of the first composition after contact with water at a temperature in the range of about 30° C. to 40° C. for a period of at least about 2 minutes, as compared to an identical unit dose article that does not comprise a nonwoven web in the form of a pouch. In an embodiment, the first compartment of the unit dose article comprises a water-soluble film in the form of a pouch and extends the release of the first composition after contact with water at a temperature in the range of about 30° C. to 40° C. for a period of at least about 3 minutes, as compared to an identical unit dose article that does not comprise a nonwoven web in the form of a pouch. In an embodiment, the first compartment of the unit dose article comprises a water-soluble film in the form of a pouch and extends the release of the first composition after contact with water at a temperature in the range of about 30° C. to 40° C. for a period of at least about 4 minutes, as compared to an identical unit dose article that does not comprise a nonwoven web in the form of a pouch. In an embodiment, the first compartment of the unit dose article comprises a water-soluble film in the form of a pouch and extends the release of the first composition after contact with water at a temperature in the range of about 30° C. to 40° C. for a period of at least about 5 minutes, as compared to an identical unit dose article that does not comprise a nonwoven web in the form of a pouch. In an embodiment, the first compartment of the unit dose article comprises a water-soluble film in the form of a pouch and extends the release of the first composition after contact with water at a temperature in the range of about 30° C. to 40° C. for a period of at least about 7.5 minutes, as compared to an identical unit dose article that does not comprise a nonwoven web in the form of a pouch. In an embodiment, the first compartment of the unit dose article comprises a water-soluble film in the form of a pouch and extends the release of the first composition after contact with water at a temperature in the range of about 30° C. to 40° C. for a period of at least about 10 minutes, as compared to an identical unit dose article that does not comprise a nonwoven web in the form of a pouch. In an embodiment, the first compartment of the unit dose article comprises a water-soluble film in the form of a pouch and extends the release of the first composition after contact with water at a temperature in the range of about 30° C. to 40° C. for a period of at least about 12 minutes or more, as compared to an identical unit dose article that does not comprise a nonwoven web in the form of a pouch.

[0025] The unit dose article of the present disclosure, in which the nonwoven fabric is laminated to a film, can be designed to provide one or more advantages. For example, without being bound by theory, the unit dose article of the present disclosure can provide extended release of liquid composition only to the water-soluble film pouch by creating a tortuous path for the composition(s) to exit and / or water to enter the unit dose article while maintaining mechanical integrity, the unit dose article can include an increased gas barrier only to the nonwoven web pouch (e.g., to allow vacuum to be applied during the thermoforming process or to prevent the composition contained therein from stale), and / or can include the ability to retain liquid only to the nonwoven web pouch.

[0026] All percentages, parts, and ratios referred to herein are of the total dry weight of the fiber composition, nonwoven web composition, film composition, or, as the case may be, the total weight of the packet content composition of the present disclosure, unless otherwise indicated, and all measurements made are at about 25° C. All percentages, parts, and ratios referred to herein with respect to liquid compositions are of the total weight of the liquid composition. All such weights with respect to listed ingredients are of the active level and thus do not include carriers or by-products that may be included in commercially available materials, unless otherwise specified.

[0027] All ranges stated herein include all possible subsets of ranges and any combination of such subset ranges. By default, ranges include the stated endpoints unless otherwise stated. When a range of values ​​is provided, it is understood that each intervening value between the upper and lower limits of that range, as well as any other stated or intervening values ​​within that stated range, are encompassed by the disclosure. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of those limits, ranges excluding either or both of those included limits are also intended to be part of the disclosure.

[0028] For any numerical values ​​described herein, for example as parameters of the described object or as part of a range related to the described object, alternative examples forming part of this description are expressly contemplated as functionally equivalent ranges surrounding the particular numerical value (e.g., for a dimension disclosed as "40 mm," an alternative embodiment contemplated is "about 40 mm").

[0029] As used herein, unless otherwise indicated, the term "nonwoven web" refers to a web or sheet that includes, consists of, or consists essentially of fibers that are arranged (e.g., by a carding process) and bonded together. Additionally, as used herein, "nonwoven web" includes nonwoven webs or sheets. Methods for preparing nonwoven webs from fibers are described, for example, in Nonwoven Fabrics Handbook, prepared by Ian Butler, edited by Subhash, which is incorporated herein by reference in its entirety. It is well known in the art, as described in Batra et al., Printing by Design, 1999. As used herein, and unless otherwise indicated, the term "film" refers to a continuous film or sheet prepared, for example, by a casting or extrusion process.

[0030] As used herein, and unless otherwise indicated, the term "water soluble" refers to any nonwoven web, film, or laminate that has a dissolution time of 300 seconds or less at the specified temperature as determined by MSTM-205 as described herein, or any fiber that has complete dissolution at a temperature of 40°C by the Method for Determining Single Fiber Solubility. For example, the dissolution time of the film, nonwoven web, or laminate 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 by MSTM-205, as appropriate. In embodiments where no dissolution temperature is specified, the nonwoven web, water soluble film, or laminate has a dissolution time of 300 seconds or less at a temperature of about 80°C or less. In embodiments, a "water soluble film" means that at a thickness of 1.5 mils, the film dissolves in 300 seconds or less in MSTM-205 at a temperature of 80° C. or less. For example, a water soluble film 1.5 mils (about 38 μm) thick 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 in MSTM-205 at a temperature of about 70° C., about 60° C., about 50° C., about 40° C., about 30° C., about 20° C., or about 10° C.

[0031] As used herein and unless otherwise indicated, the term "cold water soluble" refers to any nonwoven web, water soluble film, or laminate having a dissolution time of 300 seconds or less at a temperature ranging from about 10°C to about 20°C as determined by MSTM-205, or a fiber having complete dissolution at a temperature ranging from about 10°C to about 20°C as determined according to the Method for Determining Single Fiber Solubility. For example, the dissolution time of the film, nonwoven web, or laminate can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds at a temperature ranging from about 10°C to about 20°C by MSTM-205, as appropriate. In an embodiment, a "cold water soluble film" refers to a film having a thickness of 1.5 mils and having a dissolution time of 300 seconds or less at a temperature of 20°C or less by MSTM-205. For example, a water-soluble film having a thickness of 1.5 mils (about 38 μm) may have a dissolution time of 300 seconds or less, 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less with MSTM-205 at a temperature of about 20° C. or about 10° C.

[0032] As used herein, and unless otherwise indicated, the term "hot water soluble" refers to any nonwoven web, water soluble film, or laminate that has a dissolution time of 300 seconds or less at temperatures greater than about 20°C, e.g., in the range of about 21°C to about 80°C, as determined by MSTM-205, or fibers that have complete dissolution at temperatures greater than about 20°C, e.g., in the range of about 21°C to about 80°C, as determined by the Method for Determining Single Fiber solubility. For example, the dissolution time of the film, nonwoven web, or laminate can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds with MSTM-205 at a temperature greater than about 20° C., such as from about 21° C. to about 80° C., from about 25° C. to about 80° C., from about 25° C. to about 60° C., from about 30° C. to about 60° C., from about 25° C. to about 45° C., from about 30° C. to about 45° C., or from about 25° C. to about 43° C., from about 30° C. to about 43° C., from about 25° C. to about 40° C., or from about 30° C. to about 40° C., as appropriate. In an embodiment, a “hot water soluble film” means that at a thickness of 1.5 mils, the film dissolves with MSTM-205 in 300 seconds or less at a temperature of about 21° C. or greater. For example, a water-soluble film having a thickness of 1.5 mils (about 38 μm) can have a dissolution time of 300 seconds or less, 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less with MSTM-205 at a temperature of about 80° C., 70° C., about 60° C., about 50° C., about 40° C., about 30° C., about 25° C., or about 21° C.

[0033] As used herein, the terms packet(s) and pouch(s) should be considered synonymous. In certain embodiments, the terms packet(s) and pouch(s) are each used to refer to a container made using a nonwoven web or a water-soluble film or both, and are preferably used to refer to a fully sealed container with a sealed material inside, such as a container in the form of a metered dose delivery system. Sealed pouches can be made from any suitable method, including such processes and features, such as heat sealing, solvent welding, and adhesive sealing (e.g., by using water-soluble adhesives).

[0034] As used herein, the terms resin(s) and polymer(s) should be considered synonymous. In certain embodiments, the terms resin(s) and polymer(s) are used to refer to a polymer optionally combined with one or more additional polymers, and to refer to a single type of polymer, respectively, e.g., a resin can include more than one polymer.

[0035] As used herein, and unless otherwise indicated, the terms "weight percent (wt.%)" and "weight percent (wt%)" shall refer to the composition of an element specified in "dry (anhydrous)" parts by weight of the entire nonwoven web or water-soluble film, including residual moisture in the nonwoven web or water-soluble film, as the case may be, or the composition of an element specified in parts by weight of the entire unit dose article or composition.

[0036] As used herein, and unless otherwise indicated, the term "PHR" ("phr") means 100 parts water-soluble polymeric resin(s) in a nonwoven web or water-soluble film, or in a solution used to make the nonwoven web or water-soluble film. "Component" refers to the composition (in parts) of a specified element per unit (whether PVOH or other polymer resin, unless otherwise specified).

[0037] "Comprising" as used herein means various components, ingredients, or steps that can be used together in the practice of the present disclosure. Thus, the term "comprising" encompasses the more restrictive terms "consisting essentially of" and "consisting of". The compositions of the present invention can include, consist essentially of, or consist of any of the required and optional elements disclosed herein. For example, a thermoformed packet can "consist essentially of" a nonwoven web as described herein that uses its thermoforming properties while including a non-thermoformable nonwoven web (e.g., a lid portion) and an optional mark on the nonwoven web, e.g., 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.

[0038] The unit dose articles, nonwoven webs, water-soluble films, 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, unless otherwise stated.

[0039] In general, the unit dose article can include a nonwoven web and a water-soluble film, where the nonwoven web can include a plurality of fibers including one or more water-soluble fiber types, one or more water-insoluble fiber types, a blend of water-soluble and water-insoluble fiber types, one or more water-soluble fiber forming materials, one or more water-insoluble fiber forming materials, or a blend of water-soluble and water-insoluble fiber forming materials. The water-soluble film can include a water-soluble resin, optionally including one or more water-soluble polymers.

[0040] Water-soluble film and fiber forming materials

[0041] Water-soluble polymers used in the water-soluble fibers, nonwoven webs, and water-soluble films include, but are not limited to, polyvinyl alcohol, polyacrylates, water-soluble acrylate copolymers, polyvinylpyrrolidone, polyethyleneimine, pullulan, water-soluble natural polymers including, but not limited to, guar gum, acacia gum, xanthan gum, carrageenan, and starch, water-soluble polymer derivatives including, but not limited to, modified starch, ethoxylated starch, and hydroxypropylated starch, copolymers of the foregoing, and combinations of any of the foregoing. 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 other, are commercially available from a variety of sources.

[0042] Generally, the fibers and films of the present disclosure can include polyvinyl alcohol. Polyvinyl alcohol is a synthetic polymer that is generally prepared by alcoholysis of polyvinyl acetate, usually referred to as hydrolysis or saponification. Fully hydrolyzed PVOH, in which virtually all acetate groups have been converted to alcohol groups, is It is a strongly hydrogen-bonded, highly crystalline polymer that is soluble only in hot water, above about 140° F. (about 60° C.). If a sufficient number of acetate groups are left behind after hydrolysis of polyvinyl acetate, i.e., the PVOH polymer is partially hydrolyzed, the polymer is more weakly hydrogen-bonded, less crystalline, and is soluble in cold water, generally 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 commonly referred to as PVOH.

[0043] 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 particular 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 limiting case 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.

[0044] In some embodiments, the polyvinyl alcohol comprises a modified polyvinyl alcohol, such as a copolymer. The modified polyvinyl alcohol can comprise a copolymer or higher polymer (e.g., terpolymer) that comprises one or more monomers in addition to the vinyl acetate / vinyl alcohol group. Optionally, the modification is neutral, such as provided by ethylene, propylene, N-vinylpyrrolidone, or other uncharged monomer species. Optionally, the modification is cationic, such as provided by a 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., when not fully hydrolyzed). In some embodiments, the PVOH copolymer can comprise two or more types of anionic monomer units. General classes 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 citraconates, dialkyl citraconates, citraconic anhydride, mesaconic acid, monoalkyl mesaconates, dialkyl mesaconates, glutaconic acid, monoalkyl glutaconates, dialkyl glutaconates, Alkyl acrylates, alkyl alkacrylates, vinyl sulfonic acid, allyl sulfonic acid, ethylene sulfonic acid, 2-acrylamido-1-methylpropanesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, 2-methylacrylamido-2-methylpropanesulfonic acid (AMPS), 2-sulfoethyl acrylate, alkali metal salts of the foregoing (e.g., sodium, potassium, or other alkali metal salts), esters of the foregoing (e.g., methyl, ethyl, or other C1-C4 or C6 aryl). The PVOH copolymers may include vinyl polymerized units corresponding to vinyl anionic monomers, including vinyl alkyl esters, vinyl aryl esters, and combinations of the foregoing (e.g., multiple types of anionic monomers or equivalent forms of the same anionic monomer). In some embodiments, the PVOH copolymers may include two or more types of monomer units selected from neutral, anionic, and cationic monomer units.

[0045] The incorporation level of one or more anionic monomer units in the PVOH copolymer is not particularly limited. In embodiments, the one or more anionic monomer units are present in the PVOH copolymer in an amount ranging from about 1 mol% or 2 mol% to about 6 mol% or 10 mol% (e.g., 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.

[0046] Polyvinyl alcohol can be subject to changes in solubility properties. It is known to those skilled in the art that the acetate groups of co-poly(vinyl acetate vinyl alcohol) polymers (PVOH homopolymers) can be hydrolyzed by either acid or alkaline hydrolysis. As the degree of hydrolysis increases, polymer compositions made from PVOH homopolymers will have high mechanical strength, but will have reduced solubility at low temperatures (e.g., requiring warm water temperatures for complete dissolution). Thus, exposure of PVOH homopolymers to an alkaline environment (e.g., from laundry bleach additives) can transform the polymer from one that dissolves quickly and completely in a given aqueous environment (e.g., cold water medium) to one that dissolves slowly and / or incompletely in the aqueous environment, possibly resulting in insoluble polymer residues.

[0047] The degree of hydrolysis (DH) of the PVOH homopolymers and PVOH copolymers included 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 75% to about 89%, about 80% to about 90%, about 88% to 92%, about 86.5% to about 89%, or about 88%, 90%, or 92%, for cold water soluble compositions; about 90% to about 99.9%, about 90% to about 99%, about 92% to about 99%, about 95% to about 99%, about 98% to about 99%, about 98% to about 99.9%, about 96%, about 98%, about 99%, or more than 99%). As the degree of hydrolysis decreases, the fibers or films made from the polymers will have reduced mechanical strength but will have 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 or fiber made from the polymer and additional components is also affected. In one option, the film and / or fiber is cold water soluble. In a co-poly(vinyl acetate vinyl alcohol) polymer that does not contain any other monomers (e.g., a homopolymer that is not copolymerized with anionic monomers), a cold water soluble fiber or film that is soluble in water at a temperature of less than 10°C can include PVOH with a degree of hydrolysis ranging from about 75% to about 90%, from about 75% to about 89%, or from about 80% to about 90%, or from about 85% to about 90%. In another 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), a hot water soluble fiber or film that is soluble in water at a temperature of at least about 60° C. can include PVOH having a degree of hydrolysis of at least about 98%. In an embodiment, one or more of the plurality of fibers includes a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 75% to about 99.9%.In an embodiment, one or more of the plurality of fibers comprises a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 75% to about 98%. More than one of the fibers comprises a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 75% to about 89%. In an embodiment, one or more of the plurality of fibers comprises a polyvinyl alcohol polymer having a degree of hydrolysis ranging from about 90% to about 99.9%. In an embodiment, the water-soluble film comprises a polyvinyl alcohol homopolymer or a PVOH copolymer having a degree of hydrolysis ranging from about 75% to about 99.9%. In an embodiment, the water-soluble film comprises a polyvinyl alcohol homopolymer or a polyvinyl alcohol copolymer having a degree of hydrolysis ranging from about 75% to about 98%.

[0048] The degree of hydrolysis of the polymer blends is the arithmetically weighted average degree of hydrolysis.

number

number

number

[0049] 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 international convention to refer to the viscosity of a 4% aqueous polyvinyl alcohol solution at 20°C. All viscosities specified herein in centipoise (cP) should be understood to refer to the viscosity of a 4% aqueous polyvinyl alcohol solution at 20°C, unless otherwise specified. Similarly, when a polymer is described as having (or not having) a particular viscosity, unless otherwise specified, the specified viscosity is intended to be the average viscosity of the polymer, inherent with the corresponding molecular weight distribution, i.e., the weighted natural logarithm average viscosity. The viscosity of a PVOH polymer is determined based on the weight average molecular weight of the PVOH polymer.

number

number

[0050] In embodiments, the PVOH resin may have a viscosity of about 1.0 to about 50.0 cP, about 1.0 to about 40.0 cP, or about 1.0 to about 30.0 cP, such as about 4 cP, 8 cP, 15 cP, 18 cP, 23 cP, or 26 cP. The monopolymers and / or copolymers may have a viscosity of about 1.0 to about 40.0 cP, or about 5 cPs 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, 12 cP, 14 cP, 16 cP, 17 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, 36 cP, 37 cP, 38 cP, 39 cP, 40 cP, 41 cP, 42 cP, 43 cP, 44 cP, 45 cP, 46 cP, 47 cP, 48 cP, 49 cP, 50 cP, 51 cP, 52 cP, 53 cP, 54 cP, 55 cP, 56 cP, 57 cP, 58 cP, 59 cP, 60 cP, 61 cP, 62 cP, 63 cP, 64 cP, 65 cP, 66 cP, 67 cP, 68 cP, 69 cP, 70 cP, 71 cP, 7 cP, 11 cP, 12 cP, 13 cP, 14 cP, 15 cP, 17.5 cP, 18 cP, 19 cP, 20 cP, 21 cP, 22 cP, 23 cP, 24 cP, 25 cP, 26 cP, 27 cP, 28 cP, 29 cP, 30 cP, 31 cP, 32 cP, 33 cP, 34 cP, 35 cP, or 40 cP. In embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 21 cP to 26 cP. In embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 5 cP to about 14 cP. In embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 5 cP to about 23 cP.

[0051] 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 (e.g., a PVOH ter (or higher copolymer)) comprising one or more types of anionic monomer units, and a second PVOH polymer ("second PVOH polymer"), which can comprise a PVOH homopolymer or a PVOH copolymer (e.g., a PVOH ter (or higher copolymer)) comprising one or more types of anionic monomer units. In some embodiments, the PVOH polymer blend comprises only a first PVOH polymer and a second PVOH polymer (e.g., a binary blend of two polymers). Alternatively, or in addition, the PVOH polymer blend or a 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%, at least 97%, or at least 99% by weight 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).

[0052] biodegradable

[0053] Polyvinyl alcohol polymers are generally biodegradable since they degrade in the presence of water and enzymes under aerobic, anaerobic, soil, and compost conditions. In general, the biodegradation activity of polyvinyl alcohol polymers increases as the degree of hydrolysis of the polyvinyl alcohol polymer increases up to about 80%. Without being bound by theory, it is believed that increasing the degree of hydrolysis beyond 80% does not appreciably affect biodegradability. Furthermore, the stereoregularity of the hydroxyl groups of the polyvinyl alcohol polymer has a significant effect on the level of biodegradation activity; the more isotactic the hydroxyl groups in the polymer sequence, the higher the degradation activity. Without being bound by theory, it is believed that in soil and / or compost biodegradation, nonwoven webs prepared from polyvinyl alcohol fibers exhibit a higher degree of biodegradation activity than similar polyvinyl alcohol polymers due to the increased polymer surface area provided by the nonwoven web relative to the film. It is believed that the polyvinyl alcohol polymer will have a higher biodegradation activity level relative to the water-soluble film prepared from the polyvinyl alcohol polymer. Furthermore, without being bound by theory, it is believed that the degree of polymerization of the polyvinyl alcohol polymer has little or no effect on the biodegradability of the film or nonwoven web prepared with the polymer, but the polymerization temperature may affect the biodegradability of the film or nonwoven web since it may affect the crystallinity and aggregation state of the polymer. In particular, as the crystallinity decreases, the polymer chain hydroxyl groups become less aligned within the polymer structure, and the polymer chains become more disordered leading to the accumulation of the chains as amorphous aggregates, thereby decreasing the availability of ordered polymer structures and biodegradation activity is predicted to decrease the biodegradation mechanism in soil and / or compost where the polymer does not dissolve. Without being bound by theory, it is believed that the stereoregularity of the hydroxyl groups of polyvinyl alcohol polymers has a large effect on the biodegradability level, and therefore substitution with functional groups other than hydroxyl groups (e.g., anionic AMPS functional groups, carboxylate groups, or lactone groups) is expected to reduce the biodegradability level relative to polyvinyl alcohol homopolymers having the same degree of hydrolysis, unless the functional groups themselves are also biodegradable, in which case the biodegradability of the polymer may be increased by substitution. Furthermore, it is believed that the biodegradability level of substituted polyvinyl alcohols can be lower than that of the corresponding homopolymers, but the substituted polyvinyl alcohols will still be biodegradable.

[0054] 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 (intrinsic biodegradation), OECD 311 (anaerobic), and ASTM D5988 (soil).

[0055] In an embodiment, the fibers described herein can be of standard ready biodegradation or enhanced degradation. As used herein, the term "ready biodegradation" refers to a standard that is met if the material (e.g., fiber) reaches 60% biodegradation (mineralization) within 28 days from the start of the test according to the OECD 301B test as described in ECHA's Annex XV. As used herein, the term "enhanced biodegradation" refers to a standard that is met if the material (e.g., fiber) reaches 60% biodegradation within 60 days from the start of the test according to the OECD 301B test as described in ECHA's Annex XV. In an embodiment, the fibers herein meet the ready biodegradation standard. In an embodiment, the films herein meet the ready biodegradation or enhanced degradation standard. In an embodiment, the laminates (nonwovens and films) used herein meet the ready biodegradation or enhanced biodegradation standard.

[0056] Adjuvants

[0057] In general, the fibers, nonwoven webs, and / or water-soluble films of the present disclosure, along with the film and / or fiber forming materials, may contain additives such as plasticizers, plasticizer compatibilizers, surfactants, lubricants, release agents, fillers, bulking agents, crosslinking agents, antiblocking agents, antioxidants, anti-blocking agents, antifoaming agents, nanoparticles, such as layered silicate-type nanoclays (e.g., sodium montmorillonite), bleaching agents (e.g., sodium metabisulfite, sodium bisulfite, or the like), aversive agents, such as 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 cassinoids. Adjuvants such as, but not limited to, pungent agents (e.g., capsaicin, piperine, allyl isothiocyanate, and resinferratoxin), and pungent flavoring agents (e.g., capsaicin, piperine, allyl isothiocyanate, and resinferratoxin), and other functional ingredients, may be included in amounts suitable for their intended purpose. As used herein, and unless otherwise specified, "adjuvants" includes secondary additives, processing agents, and active agents. Such specific adjuvants may be selected from those suitable for use with water-soluble fibers, water-insoluble fibers, nonwoven webs, or water-soluble films.

[0058] In an embodiment, the fiber and / or film may be free of auxiliary agents. As used herein, and unless otherwise specified, "auxiliary-free" with respect to a 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, and unless otherwise specified, "auxiliary-free" with respect to a film or 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 film or 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.

[0059] A plasticizer is a liquid, solid, or semi-solid that is added to a material (usually a resin or elastomer) to make the material softer, more flexible (by lowering the glass transition temperature of the polymer), or easier to process. Alternatively, a polymer can be plasticized internally by chemically modifying the polymer or monomer. Additionally or alternatively, a polymer can be plasticized externally by the addition of a suitable plasticizer. Water is recognized as a very efficient plasticizer for PVOH and other polymers, including but not limited to water-soluble polymers, however, the volatility of water limits its usefulness since polymer films need to have at least some resistance (robustness) to a variety of ambient conditions, including low and high relative humidity.

[0060] Plasticizers can include, but are not limited to, glycerin, diglycerin, sorbitol, xylitol, maltitol, ethylene glycol, diethylene glycol, triethylene glycol, dipropylene glycol, tetraethylene glycol, propylene glycol, polyethylene glycols up to 1000 MW, neopentyl glycol, trimethylolpropane, polyether polyols, sorbitol, 2-methyl-1,3-propanediol (MPDiol®), ethanolamine, and mixtures thereof.

[0061] Surfactants used in the film are well known in the art and may be suitably used in the fibers, films, and / or compositions of the present disclosure. Optionally, surfactants are included to aid in the dispersion of the fibers during carding. Optionally, surfactants are included as cleaning agents for personal care compositions. Suitable surfactants may include nonionic, cationic, anionic, and zwitterionic classes. Suitable surfactants include, but are not limited to, propylene glycol, diethylene glycol, monoethanolamine, polyoxyethylated polyoxypropylene glycol, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylene glycols, and alkanolamides (nonionic), polyoxyethylated amines, quaternary ammonium salts, and quaternized polyoxyethylated amines (cationic), alkali metal salts of higher fatty acids containing about 8 to 24 carbon atoms, alkyl sulfates, alkylpolyethenes, and alkyl esters of ... Other suitable surfactants include dioctyl sodium sulfosuccinate, lactylated fatty acid esters of glycerin and propylene glycol, lactylic acid esters of fatty acids, sodium alkyl sulfates, polysorbate 20, polysorbate 60, polysorbate 65, polysorbate 80, lecithin, acetylated fatty acid esters of glycerin and propylene glycol, and sodium lauryl sulfate, acetylated esters of fatty acids, myristyl dimethylamine oxide, trimethyl tallow alkyl ammonium chloride, quaternary ammonium compounds. The surfactants include, for example, glycerol ... In various embodiments, the amount of surfactant in the fiber ranges from about 0.01% to about 10%, from about 0.1% to about 5%, from about 1.0% to about 2.5%, from about 0.01% to about 1.5%, from about 0.1% to about 1%, from about 0.01% to 0.25%, or from about 0.10% to 0.20% by weight. In various embodiments, the amount of surfactant in the personal care composition contained within the pouch can range from about 5% to about 50%, from about 10% to about 45%, or from about 10% to about 40% by weight.

[0062] In embodiments, the nonwoven webs and / or films of the present disclosure may further include adjuvants, such as one or more of the following groups: exfoliants (chemical and mechanical exfoliants), fragrance and / or fragrance microcapsules, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiling agents, and cosmetic agents.

[0063] In embodiments, the adjunct is provided in or on one or more of the group of the nonwoven web, the plurality of fibers, and the water-soluble film. In embodiments, the personal care composition is provided on or on one or more of the group of the nonwoven web, the plurality of fibers, and the water-soluble film. In embodiments, the one or more adjuncts can be provided on a surface of the nonwoven web. In embodiments, the one or more adjuncts can be dispersed within the fibers of the nonwoven web. In embodiments, the one or more adjuncts can be dispersed on a face of the nonwoven web. In embodiments, the one or more adjuncts can be dispersed in the fibers. In embodiments, the one or more adjuncts can be dispersed on the fibers. In embodiments, the one or more adjuncts can be provided on a face of the water-soluble film. In some embodiments, the one or more adjuncts can be dispersed within the water-soluble film. In embodiments, the nonwoven web in the form of a pouch has an exterior surface facing outward from the inner pouch volume, and the personal care composition is provided on the exterior surface. In an embodiment, the nonwoven web in the form of a pouch has an outer surface facing outwardly from the inner pouch volume, and one or more adjuncts are provided on the outer surface.

[0064] When present, chemical exfoliants, mechanical exfoliants, fragrance and / or perfume microcapsules, aversive agents, surfactants, colorants, proteins, peptides, enzymes, skin conditioners, degreasing agents, cosmetic agents, or combinations thereof, are present in an amount of at least about 1% by weight based on the weight of the polymer blend (e.g., fiber-forming or film-forming material); Or in an amount ranging from about 1% to about 99% by weight. In embodiments, the chemical exfoliants, mechanical exfoliants, microcapsules of fragrances and / or perfumes, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiler agents, and / or cosmetic agents can be provided in an amount sufficient to provide additional functionality, such as human skin exfoliation, to the fibers and / or films. The chemical exfoliants, mechanical exfoliants, microcapsules of fragrances and / or perfumes, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiler agents, cosmetic agents, or combinations thereof can take any desired form, including solids (e.g., powders, granules, crystals, flakes, or ribbons), liquids, salves, pastes, gases, and the like, and can be encapsulated, such as microcapsules, if desired.

[0065] In certain embodiments, the nonwoven web and / or film can include enzymes. Suitable enzymes include those classified into one of six traditional Enzyme Commission (EC) categories: EC1 oxidoreductases (catalyzes oxidation / reduction reactions), EC2 transferases (transfers functional groups, such as methyl or phosphate groups), EC3 hydrolases (catalyzes hydrolysis of various bonds), EC4 lyases (cleaves various bonds by methods other than hydrolysis and oxidation), EC5 isomerases (catalyzes isomerization changes within a molecule), and EC6 ligases (joins two molecules by a covalent bond). Examples of such enzymes include dehydrogenases and oxidases in EC1, transaminases and kinases in EC2, lipases, cellulases, amylases, mannanases, and peptidases (also known as proteases or proteolytic enzymes) in EC3, decarboxylases in EC4, isomerases and mutases in EC5, and synthetases and synthases in EC6. Suitable enzymes from each category are described, for example, in U.S. Pat. No. 9,394,092, the disclosure of which is incorporated herein by reference in its entirety. In certain embodiments, the enzymes can include bromelain (pineapple extract), papain (papaya), ficin (fig), actinidin (kiwi), hyaluronidase, lipase, peroxidase, superoxide dismutase, tyrosinase, alkaline phosphatase, or combinations thereof. In embodiments, the enzymes can be encapsulated, for example, in the form of a nanoemulsion, nanocapsule, granule, or combinations thereof.

[0066] Enzymes used in laundry and dishwashing applications can include one or more of proteases, amylases, lipases, dehydrogenases, transaminase, kinases, cellulases, mannases, peptidases, decarboxylases, isomerases, mutases, synthetases, synthases, and oxido-reductase enzymes, including oxido-reductase enzymes that catalyze the formation of bleach.

[0067] 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 will come from at least two different types of sources.For example, the mixture of protease and lipase can be obtained from bacterial (protease) and fungal (lipase) sources.

[0068] Optionally, the enzymes used herein, including but not limited to any of the enzyme types or members described herein, are those that operate under alkaline pH conditions, for example, at a pH ranging from about 8 to about 11. Optionally, the enzymes used herein, including but not limited to any of the enzyme types or members described herein, are those that operate at a temperature ranging from about 5° C. to about 45° C.

[0069] In an embodiment, the nonwoven web and / or film may comprise a protein and / or peptide Suitable proteins and / or peptides can include, but are not limited to, collagen and / or collagen peptides, or amino acids such as aspartic acid, glutamic acid, serine, histidine, glycine, threonine, arginine, alanine, tyrosine, cysteine, valine, methionine, phenylalanine, isoleucine, leucine, lysine, hydroxyproline, or proline.

[0070] In embodiments, the nonwoven web and / or film may include a colorant. Suitable colorants may include indicator dyes, such as pH indicators (e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), moisture / water indicators (e.g., hydrochromic inks or leuco dyes), or thermochromic inks, which change color when the temperature increases and / or decreases. Suitable colorants include, but are not limited to, triphenylmethane dyes, azo dyes, anthraquinone dyes, perylene dyes, indigoid dyes, Food, Drug, and Cosmetics (FD&C) colorants, organic pigments, inorganic pigments, or combinations thereof. Examples of colorants include, but are not limited to, FD&C Red #40; Red #3; FD&C Black #3; Black #2; mica-based pearlescent pigments; FD&C Yellow #6; Green. Examples of suitable colorants include: Blue #3; Blue #1; Blue #2; Titanium Dioxide (Food Grade); Brilliant Black; and combinations thereof. Other examples of suitable colorants can be found in U.S. Patent No. 5,002,789, which is incorporated herein by reference in its entirety.

[0071] Another type of embodiment may include one or more fragrances in the nonwoven web and / or film of the present disclosure. As used herein, the term fragrance refers to any applicable material that is volatile enough to produce a scent. The embodiments that include a fragrance may include fragrances that are pleasant to humans or, alternatively, fragrances that are unpleasant to humans, animals, and / or insects. Suitable fragrances include, but are not limited to, fruit scents, including but not limited to lemon, apple, cherry, grape, pear, pineapple, orange, strawberry, raspberry, musk, and floral scents, including but not limited to lavender-like, rose-like, iris-like, and carnation-like. Optionally, the fragrance is also not a flavoring. Other fragrances include herbal scents, including but not limited to rosemary, thyme, and sage; and woodland scents derived from pine, spruce, and other woodland scents. Fragrances may be derived from a variety of oils, including but not limited to essential oils, or from botanical materials, including but not limited to peppermint, spearmint, and the like. Suitable fragrant oils can be found in U.S. Patent No. 6,458,754, which is incorporated herein by reference in its entirety.Suitable fragrant oils include, but are not limited to, 4-(2,2,6-trimethylcyclohex-1-enyl)-2-en-4-one, acetaldehyde phenylethyl propyl acetal, 2,6,10-trimethyl-9-undecanal, hexanoic acid 2-propenyl ester, 1-octen-3-ol, trans-anethole, isobutyl (z)-2-methyl-2-butenoate, anisaldehyde diethyl acetal, 3-methyl-5-propyl-cyclohexen-1-one, 2,4-dimethyl-3-cyclohexene ... The fragrances include 1-carbaldehyde, trans-4-decenal, decanal, 2-pentylcyclopentanone, ethyl anthranilate, eugenol, 3-(3-isopropylphenyl)butanoal, methyl 2-octanoate, isoeugenol, cis-3-hexenylmethylcarbonate, 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 include those described in U.S. Patent Nos. 4,534,981, 5,112,688, 5,145,842, 6,844, all of which are incorporated herein by reference in their entirety. 4,302, and in Perfumes Cosmetics and Soaps, Second Edition, edited by WA Poucher, 1959. These fragrances include acacia, goldenrod, chypre, cyclamen, fern, gardenia, hawthorn, heliotrope, honeysuckle, hyacinth, jasmine, lilac, lily, magnolia, mimosa, daffodil, fresh-cut hay, orange blossom, orchid, mignonette, sweet pea, trefle, tuberose, vanilla, violet, wallflower, and the like.

[0072] The fragrance may include a fragrance. The fragrance may include a neat fragrance, an encapsulated fragrance, or a mixture thereof. Preferably, the fragrance includes a neat fragrance. A portion of the fragrance may be encapsulated in the core-shell encapsulation. In another type of embodiment, the fragrance is not encapsulated in the core / shell encapsulation.

[0073] The term "perfume" as used herein encompasses perfume raw materials (PRMs) and perfume accords. The term "perfume raw materials" as used herein refers to compounds having a molecular weight of at least about 100 g / mol and useful for imparting an odor, fragrance, essence, or smell, either alone or together with other perfume raw materials. As used herein, the terms "perfume ingredient" and "perfume raw materials" are synonymous. The term "accord" as used herein refers to a mixture of two or more PRMs. In embodiments, any of the perfume accords, perfume raw materials, or fragrances can be encapsulated in microcapsules, referred to as "perfume microcapsules" as used herein.

[0074] Typical PRMs include, inter alia, alcohols, ketones, aldehydes, esters, ethers, nitrites, and alkenes, such as terpenes. Lists of common PRMs can be found in various references, e.g., "Perfume and Flavor Chemicals", Vols. I and II; Steffen Arctander Allured Pub. Co. (1994), and "Perfumes: Art, Science and Technology", Miller, P.M. and Lamparsky, D., Blackie Academic and Professional (1994). PRMs are characterized by their boiling point (BP), measured at atmospheric pressure (760 mmHg), and their octanol / water partition coefficient (P). Based on these characteristics, PRMS may be classified as Quadrant I, II, III, or IV fragrances.

[0075] In embodiments, the nonwoven web and / or film may include an exfoliant. In embodiments, the exfoliant may include a chemical exfoliant or a mechanical exfoliant. Suitable mechanical exfoliants for use herein may include, but are not limited to, apricot shells, sugar, oatmeal, salt, silica, diatomaceous earth, clay, aluminum hydroxide, PVOH microbeads, pumice, or combinations thereof. Suitable chemical exfoliants for use herein may include, but are not limited to, alpha hydroxyl acids, beta hydroxyl acids, enzymes, salicylic acid, glycolic acid, citric acid, malic acid, or combinations thereof.

[0076] In certain embodiments, the aversive agents, surfactants, colorants, enzymes, skin conditioners, degreasing agents, cosmetic agents, or combinations thereof are encapsulated and allow for controlled release. Suitable microcapsules include those made of melamine formaldehyde, polyurethane, urea formaldehyde, chitosan, polymethylmethacrylate, polystyrene, polysulfone, polytetrahydrofuran, gelatin, gum arabic, starch, polyvinylpyrrolidone, carboxymethylcellulose, hydroxyethylcellulose, methylcellulose, arabinogalactan, polyvinyl alcohol, polyacrylic acid, ethylcellulose, polyethylene, polymethacrylate, polyamide, poly(ethylene vinyl acetate), cellulose nitrate, silicone, poly(lactideco-glycolide), paraffin, carnauba, spermaceti, beeswax, stearin, etc. The microcapsules may comprise or be made from one or more of the following: glyceryl stearate, 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 in the range of, for example, about 0.1 microns to about 200 microns. In an alternative embodiment, the microcapsules may form aggregates of individual particles, for example, the individual particles have an average particle size of at least about 0.1 microns, or in the range of, for example, about 0.1 microns to about 200 microns.

[0077] Soluble Fiber

[0078] Water-soluble fibers generally include fibers and / or fiber-forming materials made of any material that, when provided as the sole resin in a film or the sole fiber-forming material in a nonwoven, dissolves in 300 seconds or less at 80° C. or less, as determined by MSTM-205. Water-soluble fibers can include a single water-soluble polymer or a blend of water-soluble polymers. Suitable water-soluble polymers include, but are not limited to, polyvinyl alcohol homopolymers, polyvinyl alcohol copolymers, polyacrylates, water-soluble acrylate copolymers, polyvinylpyrrolidone, polyethyleneimine, pullulan, water-soluble natural polymers including, but not limited to, guar gum, acacia gum, xanthan gum, carrageenan, and starch, water-soluble polymer derivatives including, but not limited to, modified starch, ethoxylated starch, and hydroxypropylated starch, copolymers of the foregoing, and combinations of any of the foregoing. Still other water-soluble fibers can include polyalkylene oxides, polyacrylamides, polyacrylic acids and their salts, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and their salts, polyamino acids, polyamides, gelatin, methylcellulose, carboxymethylcellulose and its salts, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, maltodextrin, polymethacrylates, and combinations of any of the foregoing. In an embodiment, the water-soluble fiber can include a PVOH homopolymer fiber-forming material, a PVOH copolymer fiber-forming material, or a combination thereof. In an embodiment, the water-soluble fiber can include a single PVOH homopolymer fiber-forming material or a blend of PVOH homopolymer fiber-forming materials. In an embodiment, the water-soluble fiber can include a hot water soluble PVOH homopolymer fiber-forming material. In a further embodiment, the water-soluble fiber can include a PVOH homopolymer fiber-forming material having a viscosity in the range of 5 cP to 23 cP and a degree of hydrolysis in the range of 86% to 92%.

[0079] In an embodiment, the water-soluble fiber may include the above-mentioned auxiliary agent. In an embodiment, the water-soluble fiber may be substantially free of the above-mentioned auxiliary agent. In an embodiment, the water-soluble fiber may include the above-mentioned plasticizer. The total amount of non-aqueous plasticizer provided in the water-soluble fiber may range from about 1% to about 45% by weight, or from about 5% to about 45% by weight, or from about 10% to about 40% by weight, or from about 20% to about 30% by weight, from about 1% to about 4% by weight, or from about 1.5% to about 3.5% by weight, or from about 2.0% to about 3.0% by weight, for example, about 1% by weight, about 2.5% by weight, about 5% by weight, about 10% by weight, about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, or about 40% by weight. In an embodiment, the water-soluble fiber includes glycerin, sorbitol, or a combination thereof. In an embodiment, the water-soluble fiber includes glycerin. In embodiments, the water soluble fiber includes sorbitol. In certain embodiments, the water soluble fiber can include glycerin, e.g., at about 10% by weight based on the total fiber weight, and sorbitol, e.g., at about 5% by weight based on the total fiber weight.

[0080] In an embodiment, the water-soluble fiber can include the above-mentioned surfactant. In various embodiments, the amount of surfactant in the water-soluble fiber is in the range of about 0.01% to about 2.5% by weight, about 0.1% to about 2.5% by weight, about 1.0% to about 2.0% by weight, about 0.01% to 0.25% by weight, or about 0.10% to 0.20% by weight. The water-soluble fiber can include one or more surfactants such as cocamides, for example cocamide ethanolamine. In an embodiment, the cocamides can include cocamide diethanolamine, cocamide monoethanolamine, or combinations thereof. Cocamides can be used in cosmetic personal care unit dose articles and can provide various benefits, such as a long-term dissolution profile due to the fatty acid chain of the molecule.

[0081] In an embodiment, any of the auxiliary agents disclosed herein can be added to the fibers of the present disclosure. In a refinement of the above embodiment, the auxiliary agent can be added to the fiber-forming material before the formation of the fiber, so that the auxiliary agent is dispersed in the fiber. Additionally and / or alternatively, the auxiliary agent can be added to the surface of the fiber after the fiber is formed (e.g., dispersed on the fiber).

[0082] When included in the water soluble fibers, the colorant can be provided in an amount of 0.01% to 25% by weight of the polymer mixture, for example 0.02%, 0.05%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, and 24% by weight of the polymer mixture.

[0083] Insoluble Fiber

[0084] Water insoluble fibers generally include fibers and / or fiber forming materials made of any material which, when provided in a film as the sole film forming material or in a nonwoven web as the sole fiber forming material, does not cause the film and / or nonwoven web to dissolve in 300 seconds or less at temperatures of 80° C. or less as determined by MSTM-205. Water insoluble fibers can include the sole water insoluble polymeric fiber forming material or a blend of water insoluble polymeric fiber forming materials. Suitable water insoluble fibers and / or water insoluble fiber forming materials include, but are not limited to, cotton, polyester, polyethylene (e.g., high density polyethylene and low density polyethylene), polypropylene, wood pulp, fluff pulp, abaca, viscose, polylactic acid, polyester, nylon 6, insoluble cellulose, insoluble starch, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, lace bark, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, Dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, and combinations thereof. In embodiments, the water insoluble fiber forming materials and / or fibers include one or more of the group: cotton, hemp, jute, flax, ramie, sisal, bagasse, banana, lacebark, silk, sinew, catgut, wool, seasilk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo, modal, diacetate fibers, triacetate fibers, polyvinyl alcohol homopolymer, polyvinyl alcohol copolymer, or combinations thereof.

[0085] In embodiments, the water-insoluble fiber may include the above-mentioned auxiliary agents. In embodiments, the water-insoluble fiber may be substantially free of the above-mentioned auxiliary agents. In embodiments, the water-insoluble fiber may include the above-mentioned plasticizers. The total amount of non-water-insoluble plasticizer provided in the water-insoluble fiber may range from about 1% to about 45% by weight, or from about 5% to about 45% by weight, based on the total fiber weight. , or about 10% to about 40% by weight, or about 20% to about 30% by weight, about 1% to about 4% by weight, or about 1.5% to about 3.5% by weight, or about 2.0% to about 3.0% by weight, such as about 1%, about 2.5%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, or about 40% by weight. In an embodiment, the water-insoluble fiber comprises glycerin, sorbitol, or a combination thereof. In an embodiment, the water-insoluble fiber comprises glycerin. In an embodiment, the water-insoluble fiber comprises sorbitol. In a particular embodiment, the water-insoluble fiber can comprise a plasticizer such as glycerin, for example about 10% by weight based on the total fiber weight, and sorbitol, for example about 5% by weight based on the total fiber weight.

[0086] In an embodiment, the water-insoluble fiber can include the above-mentioned surfactant. In various embodiments, the amount of surfactant in the water-soluble fiber is in the range of about 0.01% to about 2.5% by weight, about 0.1% to about 2.5% by weight, about 1.0% to about 2.0% by weight, about 0.01% to 0.25% by weight, or about 0.10% to 0.20% by weight. The water-insoluble fiber can include one or more surfactants such as cocamides, for example cocamide ethanolamine. In an embodiment, the cocamides can include cocamide diethanolamine, cocamide monoethanolamine, or combinations thereof. Cocamides can be used in cosmetic personal care unit dose articles and can provide various benefits, such as a prolonged dissolution profile due to the fatty acid chains on the molecule.

[0087] In an embodiment, any of the adjuncts disclosed herein can be added to the fibers of the present disclosure. In a refinement of the above embodiment, it can be added to the fiber-forming material prior to the formation of the fiber, so that the adjunct can be added to the surface of the fiber after the fiber is formed. In a refinement of the above embodiment, the adjunct can be added to the surface of the fiber after the fiber is formed.

[0088] When included in the water insoluble fibers, the colorant can be provided in an amount of 0.01% to 25% by weight of the polymer mixture, for example 0.02%, 0.05%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, and 24% by weight of the polymer mixture.

[0089] Non-woven web

[0090] The nonwoven webs of the present disclosure can be water soluble, water insoluble, or at least partially water insoluble. The unit dose articles of the present disclosure can include a nonwoven web, at least a portion of which is soluble in water at temperatures ranging from about 0° C. to about 20° C. by MSTM 205, or at least a portion of which is not soluble in water at temperatures at or below 20° C. by MSTM 205, or the nonwoven web ... 205 in water at temperatures ranging from about 0° C. to about 20° C. It will be understood that "at least a portion" of the nonwoven web means that if the nonwoven web comprises a plurality of fibers and that fiber type is provided in the nonwoven fabric as the sole fiber type, then the fiber type is soluble (or not soluble) at a given temperature, and the nonwoven web made of that fiber type is soluble (or not soluble) at a given temperature by MSTM-205.

[0091] Nonwoven webs of the present disclosure generally include a plurality of fibers. Nonwoven webs generally refer to an arrangement of fibers that are bonded together, and the fibers are not woven or knitted. Generally, the plurality of fibers can be arranged in any orientation. In embodiments, the plurality of fibers is arranged randomly. In embodiments, the fibers are arranged in one direction. In embodiments, the fibers are arranged in two directions. In some embodiments, the fibers are multidirectional and have different arrangements in different regions of the nonwoven web.

[0092] In general, the fibers in any given nonwoven web can comprise any of the fiber-forming materials disclosed herein. The nonwoven web can comprise (1) a monofilament type that includes a monofilament forming material, (2) a monofilament type that includes a blend of fiber-forming materials, (3) a blend of fiber types where each fiber type includes a monofilament forming material, (4) a blend of fiber types where each fiber type includes a blend of fiber-forming materials, or (5) a blend of fiber types where each fiber type includes a monofilament forming material or a blend of fiber-forming materials. In embodiments that include a blend of fiber types, the various fiber types can be characterized by their length to diameter ratio (L / D), toughness, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g ), the chemical nature of the fiber-forming material, and color group. In certain embodiments, the plurality of fibers can include two or more types of water-soluble fibers. In embodiments, the plurality of fibers can include at least one fiber type that includes at least one type of water-soluble fiber-forming material, and at least one fiber type that includes at least one type of water-insoluble fiber. In embodiments, the plurality of fibers can include two or more types that include at least one type of water-insoluble fiber-forming material.

[0093] In embodiments, the nonwoven web may further comprise any of the adjuncts disclosed herein with respect to the fibers and / or films. In embodiments, the adjuncts may be added to the fibers themselves, to the nonwoven web during carding of the nonwoven web, to the nonwoven web prior to bonding (e.g., after carding), to the nonwoven web following bonding, or combinations thereof. Adjuncts added to the fibers during carding may be distributed throughout the nonwoven web. Adjuncts added to the nonwoven web after carding but prior to bonding may be selectively added to one or both sides of the nonwoven web.

[0094] The adjuvant may be applied by any suitable means to one or more surfaces of the nonwoven web or to an article containing it, such as a packet. In an embodiment, the adjuvant is in powder form. In a refinement of the above embodiment, one or more stationary powder spray guns are used to direct a powder stream towards the web or packet from one or more directions while the web or packet is transported through a coating zone using a belt conveyor. In an embodiment, the web or packet is conveyed through a suspension of powder in air. In an embodiment, the web or packet is tumble mixed with the powder in a trough-like device. In an embodiment that can be combined with any other embodiment, electrostatic forces are used to enhance the attraction between the powder and the packet or web. This type of process is typically based on negatively charging the powder particles and directing these charged particles towards a grounded packet or web. In other alternative embodiments, the powder is applied to the web or packet by a secondary transfer tool, including but not limited to a rotating brush in contact with the powder, or by a powdered glove that can transfer the powder from a container to the web or packet. In yet another embodiment, the powder is applied by dissolving or suspending the powder in a non-aqueous solvent or carrier, which is then atomized and sprayed onto the web or packet. In one type of embodiment, the solvent or carrier subsequently evaporates, leaving behind the activator powder. In one class of embodiments, the powder is applied to the web or packet in precise doses. This class of embodiments is accomplished using a closed system dry lubricant application machine, such as PekuTECH's Powder Applicator PM 700. In this process, the powder is fed into the feed trough of an application machine, batchwise or continuously as required. The web or packet is then fed into a standard rotating drum powder feeder. From the output belt of the powder applicator, the powder is transferred onto a conveyor belt of a powder applicator, which deposits controlled doses of powder into webs or packets that can then be transported to a suitable secondary packaging process.

[0095] In embodiments where the adjuvant is in liquid form or in solution, the foregoing can be dispersed within the fibers, dispersed onto the surface of the nonwoven web, or combinations thereof, for example, by spin casting, spraying a solution such as an aerosolized solution, roll coating, flow coating, curtain coating, extrusion, knife coating, and combinations thereof.

[0096] Adjuncts, such as chemical exfoliants, mechanical exfoliants, microcapsules of fragrances and / or flavors, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiler agents, cosmetic agents, or combinations thereof, when present in the nonwoven web, are in an amount of at least about 1% by weight, or in a range of about 1% to about 99% by weight, and provide additional functionality to the nonwoven web. The chemical exfoliants, mechanical exfoliants, microcapsules of fragrances and / or flavors, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiler agents, cosmetic agents, or combinations thereof can be in any desired form, including solids (e.g., powders, granules, crystals, flakes, or ribbons), liquids, spreaders, pastes, gases, and the like, and can be encapsulated as needed.

[0097] In embodiments, the nonwoven web can be colored, pigmented, and / or dyed to provide improved aesthetic effects compared to water-soluble films. Suitable colorants for use in the nonwoven web can include indicator dyes, such as pH indicators (e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), moisture / water indicators (e.g., hydrochromic inks or leuco dyes), or thermochromic inks, which change color when the temperature increases and / or decreases. Suitable colorants include, but are not limited to, triphenylmethane dyes, azo dyes, anthraquinone dyes, perylene dyes, indigo dyes, Food, Drug, and Cosmetics (FD&C) colorants, organic pigments, inorganic pigments, or combinations thereof. Examples of colorants include, but are not limited to, FD&C Red #40; Red #3; FD&C Black #3; Black #2; mica-based pearlescent pigments; FD&C Yellow #6; Green #3; Blue #1; Blue #2; titanium dioxide (food grade); brilliant black; and combinations thereof.

[0098] In embodiments, the nonwoven web can include any of the surfactants disclosed herein. In embodiments, the nonwoven web can include one or more of the group: sodium cocoyl isethionate, glucotein, phenamide, cola lipids, cocamides such as cocamide ethanolamine, ethylene oxide based surfactants, and saponified avocado and palm oils.

[0099] 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 100 μm, or about 40 to about 90 μm, or about 50 to 80 μm, or about or about 60 to 65 μm, such as 50 μm, 65 μm, 76 μm, or 88 μm. The nonwoven web of the present disclosure can be characterized as high loft or low loft. Loft 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 thickness to mass per unit area. As used herein, "high loft" refers to a nonwoven web 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 ASTM D5729-97, ASTM D5736, and and / or according to ISO 9073-2:1995, which 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, for example, cross-wrapping, using a cross wrapper to fold the unbonded web on itself to build loft and basis weight. Without wishing to be bound by theory, in contrast to water-soluble films, where the solubility of the film may depend on the thickness of the film; the solubility of 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, the parameter that limits the approach of water to the fibers, and thus the dissolution of the fibers, is believed to be the basis weight (i.e., fiber density in the nonwoven), regardless of the thickness of the nonwoven web.

[0100] In general, the dynamic coefficient of friction and the ratio of the static coefficient of friction to the dynamic coefficient of friction for the nonwoven web of the present disclosure are lower than the dynamic coefficient of friction and the ratio of the static coefficient of friction to the dynamic coefficient of friction for the water-soluble film due to the increased surface roughness of the nonwoven web relative to the water-soluble film, resulting in reduced surface contact with the nonwoven web. Advantageously, this surface roughness can provide improved consumer feel (i.e., cloth-like hand instead of rubber-like hand), improved aesthetics (i.e., less gloss than water-soluble films), and / or ease of processability for thermoformed and / or vertically formed, filled and sealed, and / or multi-chambered packets that require the web to be pulled along the surface of a processing tool / mold. Thus, the water-soluble and / or water-insoluble fibers should be sufficiently rough to provide surface roughness to the resulting nonwoven web without being so rough that it causes drag.

[0101] The water solubility of the nonwoven web of the present disclosure is generally a function of the type of fiber(s) used to prepare the web as well as the basis weight of the web. Without wishing to be bound by theory, it is believed that the solubility profile of the nonwoven web follows the same solubility profile of the fiber(s) used to prepare the nonwoven web, and the solubility profile of the fiber generally follows the same solubility profile of the polymer(s) from which the fiber is prepared. For example, in a nonwoven web comprising PVOH fibers, the degree of hydrolysis of the PVOH polymer can be selected such that the water solubility of the nonwoven web is also affected. In general, at a given temperature, as the degree of hydrolysis of the PVOH polymer increases from partial hydrolysis (88% DH) to full hydrolysis (≧98% DH), the water solubility of the polymer generally decreases. Thus, in 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 of less than 10°C can include fibers of PVOH with a degree of hydrolysis ranging from about 75% to about 90%, or from about 75% to about 89%, or from about 80% to about 90%, or from about 85% to about 90%, or from about 90% to about 99.5%. Alternatively, the nonwoven web can be hot water soluble. For example, for co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., not copolymerized with anionic monomers), a hot water soluble web can be soluble in water at a temperature of at least about 60°C by including fibers of PVOH with a degree of hydrolysis of at least about 98%.

[0102] Modification of PVOH generally increases the solubility of the PVOH polymer. Thus, at a given temperature, the solubility of a nonwoven web or film prepared from a PVOH copolymer is expected to be higher than that of a nonwoven web or film prepared from a PVOH homopolymer having the same degree of hydrolysis as the PVOH copolymer. Following these trends, nonwoven webs with specific solubility characteristics can be engineered by blending polymers into the fibers and / or by blending fibers into the nonwoven web. Additionally, as described herein, nonwoven webs may include a plurality of fibers, and in some cases, may be engineered to have a solubility of 100%. It may contain two or more different fiber types.

[0103] The inclusion of water-insoluble fibers and / or water-insoluble fiber-forming materials in the fibers of the nonwoven web can also be used to design a nonwoven web with a particular solubility and / or extended release characteristics. Without wishing to be bound by theory, it is believed that as the weight percentage of water-insoluble fibers in the nonwoven web increases (relative to the total weight of the nonwoven web), the solubility of the nonwoven web generally decreases and the extended release characteristics of the pouch containing the nonwoven web generally increase. When contacted with water at or above the solubility temperature of the water-soluble fibers, the nonwoven web containing water-soluble and water-insoluble fibers will begin to disperse as the water-soluble fibers dissolve, thereby disrupting the web structure and / or increasing the pore size of the pores in the nonwoven web. In general, the greater the disruption of the web structure or the larger the pore size, the faster water can access the pouch contents and the faster the pouch contents will be released. Similarly, extended release of the pouch contents containing the nonwoven web of the present disclosure can be achieved by using a blend of water-soluble fibers with different solubility characteristics and / or different solubility temperatures. As the faster dissolving fibers dissolve, the web is disrupted, and the less soluble fibers have a larger exposed surface area, facilitating dissolution of the less soluble fibers and release of the pouch contents. In embodiments in which the nonwoven web comprises water soluble and water insoluble fibers, the ratio of soluble fibers to water insoluble fibers is not particularly limited. The water soluble fibers can comprise about 1% to about 99%, about 20% to about 80%, about 40% to about 90%, about 50% to about 90%, or about 60% to about 90% by weight of the total weight of the plurality of fibers, and the water insoluble fibers can comprise about 1% to about 99%, about 20% to about 80%, about 10% to about 60%, about 10% to about 50%, or about 10% to about 40% by weight of the total weight of the fibers. In an embodiment, the plurality of fibers comprises about 10% to about 80% water soluble fibers by weight, based on the total weight of the fibers, with the remainder being water insoluble fibers.

[0104] In an embodiment, the nonwoven web, the plurality of fibers, the water-soluble film, or a combination thereof disclosed herein can include a biodegradable polymer. In certain embodiments, the plurality of fibers can include water-insoluble fibers that form a material that is biodegradable. In an embodiment, the plurality of fibers can include a first fiber that is a water-insoluble biodegradable fiber and a second fiber that is soluble in water at a temperature of about 10° C. to about 20° C. by MSTM 205 or is not soluble in water at a temperature of about 30° C. or less by MSTM 205. In an embodiment, the nonwoven web is water-insoluble and biodegradable.

[0105] In embodiments, the nonwoven web is biodegradable. As used herein, when a nonwoven web is said to be biodegradable, at least 50% of the nonwoven web is biodegradable, such as at least 60%, at least 70%, at least 80%, at least 90%, or 100% of the nonwoven web is biodegradable.

[0106] The nonwoven webs disclosed herein can include a plurality of fibers including a first fiber type and a second fiber type, where the first fiber type and the second fiber type have characteristics such as diameter, length, tenacity, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g ), chemical composition, color, or combinations thereof. In embodiments, the first fiber type may comprise a PVOH homopolymer fiber forming material, a PVOH copolymer fiber forming material, or a combination thereof. In embodiments, the first fiber type may comprise two or more PVOH homopolymer fiber forming materials, two or more PVOH copolymer fiber forming materials, or a combination thereof. In embodiments, the second fiber type may comprise a PVOH homopolymer fiber forming material, a PVOH copolymer fiber forming material, or a combination thereof. In embodiments, the second fiber type may comprise two or more PVOH homopolymer fiber forming materials, a PVOH copolymer fiber forming material, or a combination thereof. The nonwoven web may comprise a PVOH homopolymer fiber-forming material, two or more PVOH copolymer fiber-forming materials, or a combination thereof. In an embodiment, the first fiber type and / or the second fiber type are water insoluble fiber-forming materials. In an embodiment, the first fiber type may comprise a water insoluble polymeric fiber-forming material and the second fiber type may comprise a polyvinyl alcohol fiber-forming material that, when provided as the sole fiber-forming material of the nonwoven web or as a film, the resulting web or film is soluble by MSTM 205 in water at temperatures ranging from about 0° C. to about 20° C. In an embodiment, the first fiber type may comprise a water insoluble polymeric fiber-forming material and the second fiber type may comprise a PVOH homopolymer or copolymer fiber-forming material that, when provided as the sole fiber-forming material of the nonwoven web or as a film, the resulting web or film is soluble by MSTM 205 in water at temperatures ranging from about 20° C. or less. In an embodiment, the first fiber type comprises two or more polyvinyl alcohol homopolymer fiber forming materials, two or more polyvinyl alcohol copolymer fiber forming materials, or a combination of polyvinyl alcohol homopolymer fiber forming materials and polyvinyl alcohol copolymer fiber forming materials. In an embodiment, the second fiber type comprises two or more polyvinyl alcohol homopolymer fiber forming materials, two or more polyvinyl alcohol copolymer fiber forming materials, or a combination of polyvinyl alcohol homopolymer fiber forming materials and polyvinyl alcohol copolymer fiber forming materials.

[0107] The fibers included in the nonwoven web of the present disclosure can generally have any tenacity. The tenacity of the fiber correlates with the coarseness of the fiber. As the tenacity of the fiber decreases, the coarseness of the fiber increases. The fibers used to prepare the nonwoven web of the present disclosure can have a tenacity of about 1 to about 100 cN / dtex, or about 1 to about 75 cN / dtex, or about 1 to about 50 cN / dtex, or about 1 to about 45 cN / dtex, or about 1 to about 40 cN / dtex, or about 1 to about 35 cN / dtex, or about 1 to about 30 cN / dtex, or about 1 to about 25 cN / dtex, or about 1 to about 20 cN / dtex, or about 1 to about 15 cN / dtex, or about 1 to about 10 cN / dtex, or about 3 to about 8 cN / dtex, or about 4 to about 8 cN / dtex. tex, or from about 6 to about 8 cN / dtex, or from about 4 to about 7 cN / dtex, or from about 10 to about 20, or from about 10 to about 18, or from about 10 to about 16, or about 1 cN / dtex, about 2 cN / dtex, about 3 cN / dtex, about 4 cN / dtex, about 5 cN / dtex, about 6 cN / dtex, about 7 cN / dtex, about 8 cN / dtex, about 9 cN / dtex, about 10 cN / dtex, about 11 cN / dtex, about 12 cN / dtex, about 13 cN / dtex, about 14 cN / dtex, or about 15 cN / dtex. In embodiments, the plurality of fibers may have a tenacity ranging from about 3 cN / dtex to about 15 cN / dtex, or from about 5 cN / dtex to about 12 cN / dtex, or from about 5 cN / dtex to about 10 cN / dtex.

[0108] The toughness of the nonwoven web can be the same or different from the toughness of the fibers used to prepare the web. Without being bound by theory, it is believed that the toughness of the nonwoven web is related to the strength of the nonwoven web, with higher toughness providing the nonwoven web with higher strength. In general, the toughness of the nonwoven web can be modified by using fibers with different toughness. The toughness of the nonwoven web can also be affected by processing. In general, the nonwoven web of the present disclosure has a relatively high toughness, i.e., the nonwoven web is a self-supporting web that can be used as the sole material to prepare an article and / or pouch. In contrast, nonwoven webs prepared by meltblowing, electrospinning, and / or rotary spinning processes typically have low toughness and may not be self-supporting or can not be used as the sole web to form an article or pouch.

[0109] 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 can be measured by measuring the linear mass density, the ratio of fiber mass per unit length. The main physical unit of linear mass density is 1 tex, which is equal to 1000m of fibers weighing 1g. The unit dtex is typically used, which represents 1g / 10,000m of fibers. The linear mass density can be selected to provide a nonwoven web with suitable stiffness / handle, torsional stiffness, light reflection and interaction, absorption of dyes and / or other actives / additives, ease of fiber spinning in the manufacturing process, and uniformity of the finished article. Generally, as the linear mass density of the fibers increases, the nonwoven fabrics 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 relative to density. Further, without being bound by theory, when a blend of fiber types is used, the average linear mass density can be determined using a weighted average of the individual fiber types. The fibers can be characterized as very fine (dtex≦1.22), fine (1.22≦dtex≦1.54), medium (1.54≦dtex≦1.93), slightly coarse (1.93≦dtex≦2.32), and coarse (dtex≧2.32). The nonwoven webs of the present disclosure can include fibers that are very fine, fine, medium, slightly coarse, or combinations thereof. In an embodiment, the nonwoven web has an average linear mass density ranging from about 1 dtex to about 5 dtex, or from about 1 dtex to about 3 dtex, or from about 1.5 dtex to about 2.5 dtex. In an embodiment, the nonwoven web comprises a blend of fibers, where a first fiber comprises an average linear mass density of 1.7 dtex and a second fiber comprises an average linear mass density of 2.2 tex.

[0110] The fibers used to prepare the 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 fibers used to prepare the nonwoven web of the present disclosure can have a diameter of more than 100 microns to about 300 microns. In an embodiment, the diameter of the fibers used to prepare the nonwoven web of the present disclosure has a substantially uniform diameter. In an embodiment, one or more fiber types can have an average diameter in the range of about 10 microns to about 300 microns, or about 50 microns to 200 microns, or about 50 microns to about 100 microns.

[0111] The fibers used to prepare the nonwoven web of the present disclosure can generally be of any length. In embodiments, the length of the 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 plurality of fibers can be less than about 30 mm, or in a range of about 0.25 mm to less than about 30 mm, such as at least about 0.25 mm, at least about 0.5 mm, at least about 0.75 mm, at least about 1 mm, at least about 2.5 mm, at least about 5 mm, at least about 7.5 mm, or at least about 10 mm, and up to about 29 mm, up to about 28 mm, up to about 27 mm, up to about 26 mm, up to about 25 mm, up to about 20 mm, or up to about 15 mm. In embodiments, the plurality of fibers has an average length of about 30 mm to about 100 mm, or about 30 mm to about 60 mm. In embodiments, the nonwoven web comprises a first fiber type having a length of about 38 mm and a second fiber type having a length of about 54 mm. Includes blends of fiber types, including

[0112] The fibers used to prepare the nonwoven web of the present disclosure can generally have any length to diameter (L / D) ratio. Advantageously, the toughness of the nonwoven web of the present disclosure can be controlled using the L / D ratio of the fibers and the respective amounts of fibers with various L / D ratios in the nonwoven composition. Generally, as the L / D of the fibers decreases, the stiffness and resistance to bending increases, providing a rougher hand. The fibers of the present disclosure generally impart a rougher hand to the nonwoven web comprising them when the fibers have a low L / D in the range of about 0.5 to about 15, or about 0.5 to about 25, or about 1 to about 5. Such low L / D fibers can be provided in the nonwoven web in an amount ranging from about 0 to about 50% by weight, for example, from about 0.5 to about 25% by weight, or from about 1 to about 15% by weight, based on the total weight of the fibers in the nonwoven web. If the amount of low L / D fibers in a nonwoven web is unknown, the amount can be estimated by visual inspection of a photomicrograph of the nonwoven web. Figure 3A is a photomicrograph of a nonwoven web having 0% low L / D fibers and a softness rating of 1, while Figure 3B is a photomicrograph of a nonwoven web having 25% low L / D fibers and a softness rating of 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.

[0113] 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.

[0114] Nonwoven webs can be characterized by their basis weight. The basis weight of a nonwoven web is the mass per unit area of ​​the nonwoven web. The basis weight can be modified by varying manufacturing conditions, as known in the art. The nonwoven web can have the same basis weight before and after bonding. Alternatively, the bonding method can change the basis weight of the nonwoven web. For example, when bonding occurs through the application of heat and pressure, the thickness of the nonwoven web (and therefore the area of ​​the nonwoven web) can be reduced, thereby increasing the basis weight. Thus, as used herein and unless otherwise specified, the basis weight of a nonwoven web refers to the basis weight of the nonwoven web after bonding.

[0115] The nonwoven webs of the present disclosure generally have a fiber density of about 0.1 g / m 2 to about 700g / m 2 , about 0.5g / m 2 to about 600g / m 2 , about 1g / m 2 to about 500g / m 2 , about 1g / m 2 to about 400g / m 2 , about 1g / m 2 to about 300g / m 2 , about 1g / m 2 to about 200 g / m 2 , about 1g / m 2 to about 100g / m 2 , about 30g / m 2 to about 100g / m 2 , about 20g / m 2 to about 100g / m 2 , about 20g / m 2 From about 80g / m 2 , or about 25 g / m 2 From about 70g / m 2 The sheet may have any basis weight in the range of 1000 to 15000 grammage.

[0116] Furthermore, assuming the fiber composition and web thickness remain constant, as the basis weight of the web increases, the dissolution rate of the web decreases because more material is dissolved. For example, at a given temperature, a web containing PVOH polymer(s) and having a basis weight of, for example, 40 g / m 2A water-soluble web prepared from fibers having a basis weight of, for example, 30 g / m 2 and is predicted to dissolve slower than an otherwise identical water-soluble web having a basis weight of about 1 g / m. Basis weight can therefore also be used to modify the solubility characteristics of the nonwoven web. 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 10g / m 2 to about 100g / m 2 , about 30g / m 2 to about 100g / m 2 , about 20g / m 2 From about 100g / m 2 , about 20g / m 2 From about 80g / m 2 , about 25g / m 2 From about 70g / m 2 , or about 40 g / m 2 From about 60g / m 2 The sheet may have any basis weight in the range of 1000 to 15000 grammage.

[0117] The nonwoven web of the present disclosure can be used as a single layer, can be layered with other nonwoven webs, or can be in the form of a laminate with a water-soluble film. In some embodiments, the nonwoven web comprises a single layer of nonwoven web. In some embodiments, the nonwoven web is a multi-layer nonwoven web comprising two or more layers of nonwoven web. The two or more layers can be laminated together. In refinements of the above-mentioned embodiments, the two or more layers can be the same (e.g., can be prepared from the same fibers and basis weights). In refinements of the above-mentioned embodiments, the two or more layers can be different (e.g., can be prepared from different types of fibers, fiber chemistries, and / or have different basis weights).

[0118] Generally, a multi-layer nonwoven web can have a basis weight that is the sum of the basis weights of the individual layers, and thus the multi-layer nonwoven web will take longer to dissolve than either of the individual layers provided as a single layer.

[0119] Water-soluble film

[0120] The water-soluble films described herein generally comprise any of the water-soluble polymers disclosed herein. In an embodiment, the water-soluble films of the present disclosure comprise a polyvinyl alcohol (PVOH) resin, a modified polyvinyl alcohol resin, or a combination thereof. In an embodiment, the water-soluble film comprises a PVOH resin selected from the group consisting of a PVOH homopolymer, a PVOH copolymer with an anionic modification, and a combination of the foregoing. In an embodiment, the water-soluble film can comprise a single PVOH polymer or a blend of PVOH polymers. In an embodiment, the water-soluble film comprises a PVOH homopolymer. In an embodiment, the water-soluble film comprises a hot water soluble PVOH homopolymer. In an embodiment, the water-soluble film can comprise a PVOH copolymer with an anionic modification in an embodiment where the nonwoven web comprises a surfactant and / or an exfoliant. In an embodiment, the water-soluble film can comprise a water-soluble polyvinyl alcohol homopolymer or copolymer, which when provided in the film as the sole film-forming material, said film is soluble in water at a temperature ranging from about 0° C. to about 20° C. by MSTM 205. In an embodiment, the water-soluble film can include a water-soluble polyvinyl alcohol homopolymer or copolymer that, when provided in the film as the sole film-forming material, is not water-soluble at temperatures of 20° C. or less in water by MSTM 205.

[0121] The water-soluble film may include other film-forming polymers, including but not limited to polyvinyl alcohol, water-soluble acrylate copolymers, polyethyleneimine, pullulan, water-soluble natural polymers including but not limited to guar gum, acacia gum, xanthan gum, carrageenan, and starch, water-soluble polymer modified starch, copolymers of the foregoing, or combinations of any of the foregoing. Still other water-soluble polymers may include polyalkylene oxides, polyacrylamides, 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, or combinations of any of the foregoing. Such water-soluble polymers are commercially available from a variety of sources. In an embodiment, the water-soluble film may include PVOH homopolymers, PVOH copolymers, or combinations thereof. In an embodiment, the water-soluble film may include water-soluble PVOH homopolymers, PVOH copolymers, or combinations thereof. The film comprises a single PVOH homopolymer or a blend of PVOH homopolymers. In a further embodiment, the water-soluble film comprises a PVOH homopolymer having a viscosity in the range of 5 cP to 23 cP and a degree of hydrolysis in the range of 86% to 92%.

[0122] The film can have any suitable thickness, with a film thickness of about 76 microns (μm) being typical and specifically contemplated. Other values ​​and ranges contemplated include a range of about 5 to about 200 μm, or a range of about 20 to about 100 μm, or a range of about 40 to about 90 μm, or a range of about 50 to 80 μm, or about or about 60 to 65 μm, such as values ​​of 65 μm, 76 μm, or 88 μm.

[0123] In an embodiment, the water-soluble film can include the above-mentioned auxiliary. In an embodiment, the water-soluble film can be substantially free of the above-mentioned auxiliary. In an embodiment, the water-soluble film can include the above-mentioned plasticizer. The total amount of non-aqueous plasticizer provided in the water-soluble film can be in the range of about 1% to about 45% by weight, or about 5% to about 45% by weight, or about 10% to about 40% by weight, or about 20% to about 30% by weight, about 1% to about 4% by weight, or about 1.5% to about 3.5% by weight, or about 2.0% to about 3.0% by weight, for example, about 1% by weight, about 2.5% by weight, about 5% by weight, about 10% by weight, about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, or about 40% by weight. In embodiments, the water-soluble film comprises one or more of propylene glycol, glycerol, diglycerol, sorbitol, xylitol, maltitol, trimethylolpropane (TMP) and polyethylene glycol (100-1000 molecular weight).

[0124] In embodiments, the water-soluble film can include the above-mentioned surfactant. In various embodiments, the amount of surfactant in the water-soluble film is in the range of about 0.01% to about 2.5% by weight, about 0.1% to about 2.5% by weight, about 1.0% to about 2.0% by weight, about 0.01% to 0.25% by weight, or about 0.10% to 0.20% by weight. In embodiments, the water-soluble film includes one or more of polysorbate 80, lecithin from various plant sources, and sodium lauryl sulfate (SLS), and the like.

[0125] In embodiments, the water-soluble film adjuvants may include fillers / bulking agents / antiblocking agents / antiblocking agents. Suitable fillers / bulking agents / antiblocking agents include, but are not limited to, crosslinked polyvinylpyrrolidone, crosslinked cellulose, microcrystalline cellulose, silica, metal oxides, calcium carbonate, talc, mica, stearic acid and its metal salts, such as magnesium stearate. If desired, additional unmodified or modified starches can be included in the water-soluble form in addition to one of the specific starch components mentioned above, such as hydroxypropylated starches present in an amount ranging from about 5 phr to about 30 phr, or modified starches with a degree of modification greater than about 2% and present in an amount ranging from about 2.5 phr to about 30 phr, or unmodified starches with an amylose content ranging from about 20% to about 80%, or hydroxypropyl-modified starches with an amylose content ranging from about 23% to about 95%, where the polyvinyl alcohol comprises unmodified polyvinyl alcohol or an anionic modified polyvinyl alcohol copolymer, and provided that the anionic modifier is not an acrylate. Preferred materials are starch, modified starch, and silica. In one type of embodiment, the amount of filler / bulking agent / antiblocking agent / antisticking agent in the water-soluble film can range, for example, from about 1% to about 6% by weight, or from about 1% to about 4% by weight, or from about 2% to about 4% by weight, or from about 1 phr to about 6 phr, or from about 1 phr to about 4 phr, or from about 2 phr to about 4 phr. In an embodiment, when starch or modified starch is included in the water-soluble film in addition to one of the specific starch components described above, The additional starch component will be provided in an amount of less than about 50% by weight based on the total weight of all starches included in the film. Without being bound by theory, it is believed that any benefits provided to the water-soluble films of the present disclosure from the inclusion of the above-mentioned starch components are not affected by the inclusion of additional starch components that provide less benefit or no benefit to the water-soluble film.

[0126] The water-soluble film may further have a residual moisture content of at least 4% by weight, such as in the range of about 4 to about 10% by weight, as measured by Karl Fischer titration.

[0127] Method for preparing fibers

[0128] Wet-cooled gel spinning

[0129] In an embodiment, the plurality of water soluble fibers may include water soluble fibers prepared according to a wet cryogel spinning process, the wet cryogel spinning process comprising: (a) dissolving a water-soluble polymer (or polymers) in solution to form a polymer mixture, optionally including an adjuvant; (b) extruding the polymer mixture through a spinneret nozzle into a coagulation bath to form an extruded polymer mixture; (c) passing the extruded polymer mixture through a solvent exchange bath; (d) optionally wet drawing the extruded polymer mixture; and (e) finishing the extruded polymer mixture to provide water soluble fibers. Includes.

[0130] The solvent in which the water-soluble polymer is dissolved can suitably be any solvent in which the water-soluble polymer is soluble. In an embodiment, the solvent in which the water-soluble polymer is dissolved comprises a polar aprotic solvent. In an embodiment, the solvent in which the water-soluble polymer is dissolved comprises dimethylsulfoxide (DMSO).

[0131] 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. The coagulation bath can be a mixture that includes a solvent in which the polymer is soluble and a solvent in which the polymer is not soluble. The solvent in which the polymer is not soluble is typically the primary solvent, and the solvent in which the polymer is not soluble comprises greater than 50% by volume of the mixture.

[0132] After passing through the coagulation bath, the extruded polymer mixture gel can pass through one or more solvent exchange baths. The solvent exchange baths are provided to replace the solvent in which the water-soluble polymer is soluble with a solvent in which the water-soluble polymer is not soluble to further coagulate the extruded polymer mixture, and to replace the solvent in which the water-soluble polymer is soluble with a solvent that will evaporate more easily, thereby shortening the drying time. The solvent exchange baths can include a series of solvent exchange baths with a gradient of the solvent in which the water-soluble polymer is soluble as well as the solvent in which the water-soluble polymer is not soluble, a series of solvent exchange baths with only the solvent in which the water-soluble polymer is not soluble, or a single solvent exchange bath with only the solvent in which the water-soluble polymer is not soluble. In an embodiment, at least one solvent exchange bath can consist essentially of the solvent in which the water-soluble polymer is not soluble.

[0133] The finished fibers may also be referred to as staple 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. and Wet stretching of the extruded polymer mixture can provide a substantially uniform diameter to the extruded polymer mixture from which fibers are cut. Stretching is quite different from extrusion as is known in the art. In particular, extrusion refers to the act of forcing a resin mixture through a spinneret head to create fibers, whereas stretching refers to mechanically pulling the fibers in the machine direction to promote polymer chain orientation and crystallinity, thereby increasing fiber strength and toughness.

[0134] In embodiments in which the water soluble fibers are prepared from a wet cryogel spinning process, the water soluble polymer can generally be any water soluble polymer or blend thereof, such as two or more different polymers, as generally described herein. In refinements of the foregoing embodiments, the polymer(s) can be any degree of polymerization (DP), such as in the range of 10 to 10,000,000, such as at least 10, at least 20, at least 50, at least 100, at least 200, at least 300, at least 400, at least 500, at least 750, or at least 1000, and up to 10,000,000, up to 5,000,000, up to 2,500,000, up to 1,000,000, up to 900,000, up to 750,000, up to 500,000, up to 250,000, up to 100,000, up to 90,000, up to 10,0 ... 75,000, up to 50,000, up to 25,000, up to 12,000, up to 10,000, up to 5,000, or up to 2,500, for example, 1000 to about 50,000, 1000 to about 25,000, 1000 to about 12,000, 1000 to about 5,000, 1000 to about 2,500, about 50 to about 12,000, about 50 to about 10,000, about 50 to about 5,000, about 50 to about 2,500, about 50 to about 1000, about 50 to about 900, about 100 to about 800, about 150 to about 700, about 200 to about 600, or about 250 to about 500. In an embodiment, the DP is at least 1,000. The above mentioned adjuvants can be added to the fibers themselves or to the nonwoven web during the carding and / or bonding process.

[0135] Thermoplastic Fiber Spinning

[0136] Thermoplastic fiber spinning is well known in the art. Briefly, thermoplastic fiber spinning involves the steps of: (a) preparing a polymer mixture including a fiber-forming polymer, optionally including an adjuvant; (b) extruding the polymer mixture through a spinneret nozzle to form an extruded polymer mixture; (c) optionally stretching the extruded polymer mixture; and (d) finishing the extruded polymer mixture to obtain fibers. Includes.

[0137] The complete staple fibers of the thermoplastic fiber spinning process can be finished by drying, cutting, and / or crimping as individual fibers are formed. Stretching the extruded polymer mixture mechanically pulls the fiber in the machine direction, promoting polymer chain orientation and crystallinity, increasing fiber strength and toughness. Preparation of the polymer mixture for thermoplastic fiber spinning typically involves (a) preparing a solution of fiber-forming material and a readily volatile solvent, extruding the solution through a spinneret, where the solvent readily evaporates when the solution contacts a stream of hot air, leaving behind a solid fiber, or (b) melting the polymer, where the polymer solidifies by extruding the hot polymer through a spinneret, where the polymer solidifies by quenching with cold air. Thermoplastic fiber spinning processes include at least: (a) in thermoplastic fiber spinning, the extruded fiber is solidified by evaporation of the solvent rather than by use of a coagulation bath, or by quenching the hot solid fiber with cold air; and (b) in wet-cooled gel spinning, optional stretching is performed while the fiber is in a gel state rather than a solid state. This method is clearly different from the wet-cooled gel spinning method in that it is carried out in a 30-minute cycle.

[0138] The fiber-forming material for preparing fibers from a thermoplastic fiber spinning process can generally be any fiber-forming polymer or blend thereof, for example, two or more different polymers, provided that the polymer or blend thereof has a suitable solubility in a readily volatile solvent and / or has a significantly different melting point below its decomposition temperature. Furthermore, when a blend of fiber-forming polymers is used to make fibers, the fiber-forming material must have a similar solubility in a readily volatile solvent and / or have a similar thermal profile such that the two or more fiber-forming materials melt at similar temperatures. In contrast, the fiber-forming material for preparing fibers from a wet-cooled gel spinning process is not limited, and the fibers can be prepared from a blend of any two or more polymers that are soluble in the same solvent system, and the solvent system does not have to be a single solvent or even a volatile solvent.

[0139] The fiber-forming polymer(s) for preparing thermoplastic fiber spun fibers can have a degree of polymerization (DP) ranging, for example, from 10 to 10,000, such as at least 10, at least 20, at least 50, at least 100, at least 200, at least 300, at least 400, at least 500, at least 750, or at least 1000, and up to 10,000, up to 5,000, up to 2,500, up to 1,000, up to 900, up to 750, up to 500, or up to 250. In an embodiment, the DP is less than 1,000.

[0140] Melt Spinning

[0141] Melt spinning is well known in the art and is understood to refer to both spunbonding and meltblowing processes. Melt spinning is a continuous process that directly prepares a nonwoven web following fiber formation. Thus, the melt-spun forming fibers are not completed and cut to any consistent length (e.g., staple fibers are not prepared by these processes). Furthermore, melt spinning does not include a drawing step, and therefore the only control of the diameter of the resulting melt-spun fibers is the size of the hole through which the fiber-forming materials are extruded, and the polymer chains are typically not oriented in any particular direction.

[0142] Simply put, melt spinning is: (a) preparing a polymer mixture comprising a fiber-forming polymer, optionally including an adjuvant; (b) extruding the polymer mixture into a die assembly to form an extruded polymer mixture; (c) quenching the extruded polymer mixture; (d) depositing the quenched extruded polymer mixture onto a belt to form a nonwoven web; and (e) bonding the nonwoven web Includes.

[0143] In the spunbond process, the extruded polymer mixture is pumped into a die assembly as a molten polymer and quenched with cold air as it passes through the die assembly. In the meltblown process, the extruded polymer mixture is pumped into a die assembly with hot air blown into it and quenched as it exits the die assembly and comes into contact with air at ambient temperature. In both processes, the fibers are continuously lowered onto a belt or drum, usually facilitated by drawing a vacuum under the belt or drum.

[0144] The diameter of the melt spun fibers generally ranges from about 0.1 to about 50 microns, e.g., at least about 0.1 micron, at least about 1 micron, at least about 2 microns, at least about 5 microns, at least about 10 microns, at least about 15 microns, or at least about 20 microns, and up to about 50 microns, up to about 40 microns, up to about 30 microns, up to about 25 microns, up to about 20 microns, up to about 15 microns, up to about 10 microns, from about 0.1 micron to about 50 microns, from about 0.1 micron to about 40 microns, from about 0.1 micron to about 30 microns. from about 0.1 microns to about 25 microns, from about 0.1 microns to about 20 microns, from about 0.1 microns to about 15 microns, from about 0.1 microns to about 10 microns, from about 0.1 microns to about 9 microns, from about 0.1 microns to about 8 microns, from about 0.1 microns to about 7 microns, from about 0.1 microns to about 6 microns, from about 0.1 microns to about 6 microns, from about 5 microns to about 35 microns, from about 5 microns to about 30 microns, from about 7.5 microns to about 25 microns, from about 10 microns to about 25 microns, or from about 15 microns to about 25 microns. The meltblowing process can provide microfine fibers having an average diameter in the range of about 1 to 10 microns, however, it is known in the art that meltblowing processes have a very large variation in fiber-to-fiber diameter, for example, a variation of 100-300%. Additionally, spunbond fibers can have larger average fiber diameters, e.g., typically from about 15 to about 25 microns, but are known in the art to have improved uniformity from fiber to fiber, e.g., about 10% variation.

[0145] Fiber-forming materials for thermal extrusion processes (e.g., melt spinning, thermoplastic fiber spinning) are more limited than those for wet-cooled gel spinning processes. Generally, the degree of polymerization for thermal extrusion processes is limited to a range of about 200 to about 500. As the degree of polymerization decreases below 200, the viscosity of the fiber-forming material also becomes too low, and the individual fibers prepared by pumping the material through the die assembly do not maintain proper separation after exiting the die assembly. Similarly, as the degree of polymerization increases above 500, the viscosity becomes too high to efficiently pump the material through small enough holes in the die assembly to run the process at high speeds, thus losing the efficiency of the process and the uniformity of the fibers and / or nonwovens. Furthermore, processes that require heating of the fiber-forming material are not suitable for polyvinyl alcohol homopolymers, since homopolymers generally do not have the necessary thermal stability.

[0146] The wet chill gel spinning process advantageously provides one or more benefits, such as providing fibers containing a blend of water-soluble polymers, controlling the diameter of the fiber, providing relatively large diameter fibers, controlling the length of the fiber, controlling the tenacity of the fiber, providing high tenacity fibers, providing fibers from polymers with a high degree of polymerization, and / or providing fibers that can be used to provide a self-supporting nonwoven web. Continuous processes such as spunbonding, meltblowing, electrospinning, and rotary spinning generally do not allow blends of water-soluble polymers (e.g., due to the difficulty of matching the melt index of various polymers), forming fibers with large diameters (e.g., greater than 50 microns), controlling the length of the fiber, providing high tenacity fibers, and using polymers with a high degree of polymerization. Furthermore, the wet chill gel spinning process advantageously is not limited to polymers that are only melt processable, and therefore can utilize fibers made from fiber-forming materials with very high molecular weights, high melting points, low melt flow indexes, or combinations thereof, providing fibers with stronger physical properties and various chemical functionalities compared to fibers prepared by thermal extrusion processes. Still further, advantageously, the wet-cooled gel spinning process is not limited by the viscosity of the polymer. In contrast, processes requiring melting of the fiber-forming material are known in the art to be limited to fiber-forming materials with viscosities of 5 cP or less. Thus, polyvinyl alcohols having viscosities greater than 5 cP are preferred. Fibers containing polymers including coal homopolymers and copolymers are only available by wet chill gel spinning.

[0147] Method for preparing a nonwoven web

[0148] The nonwoven web of the present disclosure is generally a sheet-like structure having two outer surfaces, the nonwoven web comprising a plurality of fibers. The nonwoven web of the present disclosure can be prepared from fibers using any method known in the art. As known in the art, when fibers are spunbonded or meltblown, the fibers are laid continuously side by side to form a nonwoven web, and then the fibers are bonded.

[0149] The staple fibers are carded or airlaid and bonded to provide a nonwoven web. Carding and airlaid methods are well known in the art.

[0150] Methods of bonding nonwoven webs are well known in the art. In general, bonding can include thermal, mechanical, and / or chemical bonding. Thermal bonding can include, but is not limited to, calendaring, embossing, air-through, and ultrasonic. Mechanical bonding can include, but is not limited to, hydroentanglement (spunlace), needle punching, and stitch bonding. Chemical bonding can include, but is not limited to, solvent bonding and resin bonding.

[0151] Thermal bonding is achieved by applying heat and pressure, typically maintaining the pore size, shape, and alignment created by the carding process. Thermal bonding conditions can be easily determined by one skilled in the art. In general, if too little heat and / or pressure is applied, the fibers will not bond sufficiently to form a freestanding web, and if too much heat and / or pressure is applied, the fibers will begin to blend together. The chemical nature of the fibers determines the upper and lower limits of heat and / or pressure for thermal bonding. Without wishing to be bound by theory, it is believed that at temperatures above 235°C, polyvinyl alcohol-based fibers decompose. Embossing methods for thermal bonding of fibers are known. Embossing can be single-sided embossing or double-sided embossing. 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 the embossing increases (e.g., as surface features are imparted to the web), the surface area of ​​the web increases. Without wishing to be bound by theory, as the surface area of ​​the web increases, the solubility of the web increases, and therefore the solubility characteristics of a nonwoven web can be advantageously tailored by varying the surface area through embossing.

[0152] Air-through bonding generally requires a high thermoplastic content in the nonwoven web and two different melting point materials. In air-through bonding, the unbonded nonwoven web circulates around a drum while hot air flows from the outside of the drum toward the center of the drum. Air-through bonding is suitable for low density and higher basis weight (e.g., 20 to about 2000 g / m2). 2 It is possible to provide a nonwoven fabric having a thickness greater than 1 mm. Airbonded nonwoven fabrics are typically very soft.

[0153] Chemical bonding generally includes solvent bonding and resin bonding. In particular, chemical bonding typically uses a binder solution of solvent and resin (e.g., latex, or waste polymers left over from fiber preparation). The nonwoven web can be coated with the binder solution and heat and pressure can be applied to cure the binder and bond the nonwoven. The binder solution can be applied by dipping the nonwoven in a bath of binder solution, spraying the binder solution onto the nonwoven, extruding the binder solution onto the web (foam bonding), and / or applying the binder solution as a print or gravure. By putting it on, it can be attached.

[0154] Chemical bonding can result in smaller, less ordered pores versus carded / melt spun pores. Without wishing to be bound by theory, it is believed that if the resin solution used for chemical bonding is concentrated enough and / or sufficient pressure is applied, a non-porous nonwoven web can be formed. The solvent used for chemical bonding induces partial solubilization of existing fibers in the web to weld and bond the fibers together. Thus, in general, the solvent for chemical bonding can be any solvent that can at least partially solubilize one or more fiber-forming materials of the fibers of the nonwoven. In an embodiment, the solvent is selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof. In an embodiment, the solvent is selected from the group consisting of water, glycerin, and combinations thereof. In an embodiment, the binder solution comprises a solvent selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof, and further comprises a resin selected from the group consisting of polyvinyl alcohol, latex, and polyvinylpyrrolidone. The binder provided in the solution aids in the welding process to provide a more mechanically robust web. The temperature of the polymer solution is not particularly limited and can be provided at room temperature (about 23° C.). In some embodiments, a second layer of fibers can be used to bond the nonwoven web. In embodiments, the nonwoven web layers can be bonded using thermal, mechanical, or chemical bonds, either alone or in addition to bonding using additional layers of nonwoven web / fibers.

[0155] Method for Laminating Films to Nonwoven Webs

[0156] Methods for preparing laminates (eg, water-soluble films and nonwovens) can include, but are not limited to, calendar lamination (heat and pressure) or melt bonding.

[0157] Calender lamination is achieved by applying heat and pressure. The conditions of calender lamination can be easily determined by those skilled in the art. In general, if the applied heat and / or pressure is too low, the fibers will not bond well to the water-soluble film forming the laminate, and if the heat and / or pressure is too high, the fibers will begin to melt with each other and with the film. Fiber chemistry and film chemistry determine the upper and lower limits of heat and / or pressure for calender lamination. Without wishing to be bound by theory, it is believed that at temperatures higher than 235°C, polyvinyl alcohol-based fibers decompose. In an embodiment, the heat applied to the overlay nonwoven and water-soluble film is about 50°C to about 200°C, for example, about 100°C to about 200°C, about 110°C to about 190°C, about 120°C to about 180°C, or about 130°C to about 160°C. In an embodiment, the pressure applied to the overlay nonwoven and water-soluble film is about 5 psi to about 50 psi, such as about 10 psi to about 40 psi, about 15 psi to about 30 psi, or about 20 psi to about 30 psi. In an embodiment, the heat applied to the overlay nonwoven and water-soluble film is about 150° C. and the pressure applied is about 25 psi. In an embodiment, the heat and pressure are applied for about 2-4 seconds. An embossing method for the calender lamination of fibers and / or films is contemplated. The embossing can be single-sided embossing or double-sided embossing. Typically, embossing of water-soluble fibers and / or water-soluble films includes single-sided embossing using a single embossing roll of ordered circular arrays and a steel roll with a flat surface. As the embossing increases (e.g., an increased amount of surface features are imparted to the web and / or film), the surface area of ​​the laminate increases. Without wishing to be bound by theory, it is believed that as the surface area of ​​the article decreases, the solubility of the web and / or film decreases. Thus, the solubility characteristics of the nonwoven web and / or water-soluble film can be advantageously tailored by varying the surface area through embossing. Without wishing to be bound by theory, it is believed that as the degree of lamination of the unit dose article increases, It is believed that the surface area of ​​the laminate is reduced and the bond between the water-soluble film and the nonwoven is increased, resulting in reduced solubility and increased liquid release time.

[0158] Melt bond lamination is achieved by applying an adhesive directly to the water-soluble film, then the nonwoven web is placed on top of the water-soluble film with the applied adhesive and subjected to cold lamination for bonding of the nonwoven web and the water-soluble film. As used herein, the term "cold lamination" refers to a lamination process that requires pressure but no additional heat. The adhesive can be any suitable adhesive to one skilled in the art. In an embodiment, the adhesive is Henkel National adhesive. The application of the adhesive directly to the water-soluble film can be applied by any suitable method to one skilled in the art, such as a hot melt spray process. In an embodiment, the melt bond lamination process is a hot melt spray process at 160°C followed by a 94 N / mm 2 This can include low temperature lamination at a pressure of 1000 .mu.m.

[0159] The laminate of the present disclosure generally comprises a water-soluble film and a nonwoven web. In an embodiment, the laminate can have a lamination degree of about 1% to about 100%, and the lamination degree can range from about 1% to about 90%, or about 25% to about 75%, or about 1% to about 50%, or about 5% to about 25%, or about 25% to about 100%, or about 50% to about 100%. As used herein, "lamination degree" refers to the amount of the total area of ​​the water-soluble film bonded to the nonwoven web. For example, a laminate having a lamination degree of about 25% or less means that about 25% or less of the area of ​​the water-soluble film is bonded to the nonwoven web, e.g., laminated only with a sealant. For example, a laminate having a lamination degree of about 100% means that about 100% of the area of ​​the water-soluble film is bonded to the nonwoven web. In an embodiment with a lamination degree of about 25% or less, the lamination can be achieved during a heat seal process where lamination occurs with each sealant of the unit dose article. In embodiments where the laminate has a lamination degree of about 25% or less, this low lamination degree can be advantageous because it provides internal voids where the water-soluble film and the nonwoven web are not laminated, providing physical separation of compartments with incompatible chemical properties and providing the opportunity for a two-stage delivery system of the composition of the unit dose article. In embodiments, the lamination degree is in the range of about 5% to about 25%. In embodiments, the lamination degree is in the range of about 50% to about 100%.

[0160] Use of unit dose articles

[0161] The unit dose article of the present disclosure is generally suitable for various commercial applications.Suitable commercial applications of the unit dose article of the present disclosure can include pouches and packets for delivering personal care products such as exfoliating materials, shampoos, conditioners, body washes, face washes, skin lotions, skin treatments, hair treatments, bath salts, essential oils, or combinations thereof, where extended release of personal care products is desired to extend the use time of personal care products and prevent products from being washed off immediately.The unit dose article of the present disclosure can be suitable for exfoliating human skin.

[0162] Additional application examples for the unit dose article of the present disclosure can include, but are not limited to, packets and pouches of agricultural compositions for long-term delivery, such as fertilizers to plants. In an embodiment, the unit dose article of the present disclosure includes a water-soluble film comprising a water-soluble and biodegradable polyvinyl alcohol homopolymer in the form of a pouch defining an inner volume within which the agricultural composition is contained, and a water-insoluble or poorly water-soluble biodegradable and / or compostable nonwoven web encompassing the water-soluble film, the nonwoven web being in the form of a pouch defining a second inner pouch volume and optionally containing a second agricultural composition, the nonwoven web comprising a water-insoluble biodegradable and / or compostable fiber-forming material, such as a plurality of fibers, including cotton as a non-limiting example. Advantageously, such a unit dose article can be used in a wide variety of applications, including, but not limited to, ... The dosage allows a home gardener to spread a pre-packed amount of the agricultural composition, such as fertilizer, on a garden, thus allowing the garden to be fertilized continuously and over time by simply watering the garden (whereby the unit dosage comes into contact with water, dissolving the water-soluble film containing the agricultural composition).The agricultural composition can then be diffused from the nonwoven web, which can maintain sufficient structure until the composition diffuses and then decomposes or composts.In an embodiment, the nonwoven web in the form of a pouch has an outer surface facing outward from the inner pouch volume, and the outer surface comprises a personal care composition.

[0163] Additional contemplated applications include those that can include a constant flow of water, such as car washing applications and / or dishwashing applications. Advantageously, in such applications, when at least a portion of the composition is released from the unit dose, the nonwoven web can be used to facilitate lathering and / or hard scrubbing to remove soils without damaging the surface being cleaned, such as the paint on a car or a nonstick cooking surface.

[0164] Additional contemplated applications include those where the active agents need to be kept separate until the point of use. Advantageously, the unit dose article of the present disclosure can contain a first active agent in a first inner pouch volume formed by a water-soluble film, and a second active agent that can be contained in a second inner pouch volume formed by a nonwoven web. The unit dose can be designed to (a) release the second active agent upon exposure to cooler water and the first active agent upon exposure to warmer water, such that the second active agent does not come into contact with the first active agent before the second active agent is released into the water, or (b) release the first active agent from the first inner pouch volume prior to substantial dissolution of the nonwoven web, such that the first active agent and the second active agent come into contact / mix within the second inner pouch before either composition is substantially released from the unit dose.

[0165] Additional contemplated applications may include those in which the composition contained in the unit dose becomes stale or otherwise unsuitable over time, for example when exposed to oxygen, or in which it is otherwise necessary to release the extract of the composition after use. Such applications may include, but are not limited to, tea leaves and pouched tobacco products. Advantageously, the unit dose of the present disclosure may provide a gas barrier to the water-soluble film to maintain freshness, which may dissolve at the time of use (e.g., with hot water, or by placing in the consumer's mouth and contact with saliva), allowing the release of the extract (e.g., caffeine, flavor, and / or tobacco extract) while leaving the solid portion of the composition (e.g., the leaf) contained within a water-insoluble biodegradable or compostable nonwoven web. The nonwoven web may then be discarded as needed and allowed to biodegrade or be composted.

[0166] Aspects of the disclosure herein provide a method of exfoliating human skin using a unit dose article of the present disclosure. In embodiments, the method can include contacting the unit dose article with human skin and then exfoliating the human skin.

[0167] Sealed pouch

[0168] The present disclosure further provides a unit dose article comprising a water-soluble film of the present disclosure in the form of a pouch defining a first inner pouch volume, and a nonwoven web according to the present disclosure in the form of a pouch and containing the water-soluble film. In some embodiments, the pouch can comprise a laminate comprising the water-soluble film and the nonwoven web. The present disclosure further provides a method of preparing a unit dose article of the present disclosure, comprising forming a water-soluble film into an open pouch defining an open pouch volume; adding a first composition into the open pouch volume; and sealing the film to form the first inner pouch volume. In some embodiments, the sealing is performed by: This includes heat sealing, solvent sealing, adhesive sealing, or a combination thereof. In an embodiment, the nonwoven web is laminated to the water-soluble film before forming the water-soluble film into a pouch. In an embodiment, the water-soluble film is formed into a pouch, and then the nonwoven web and water-soluble film are laminated.

[0169] The nonwoven webs and laminates disclosed herein are useful for creating sealed articles in the form of pouches that define an internal pouch volume for containing therein a first composition that is released into an aqueous environment. "Sealed articles" optionally include sealed compartments with vent holes, for example in embodiments where the compartment encapsulates a solid that releases gas, but more commonly will be completely sealed compartments.

[0170] Additionally, auxiliary agents can be added to the surface of the pouch.

[0171] The unit dose article comprises one or more compartments. The unit dose article disclosed herein can be formed from two layers of nonwoven web and two layers of water-soluble film or two layers of laminate sealed at the interface, or by a single nonwoven web and a single water-soluble film or a single laminate folded on itself and sealed. The nonwoven web and water-soluble film or laminate form at least one side wall of the pouch, optionally the entire pouch, preferably the outer surface of at least one side wall. In another type of embodiment, the nonwoven web and water-soluble film or laminate form the inner wall of the packet, for example as a dividing wall between compartments. The nonwoven web and water-soluble film or laminate can 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.

[0172] In an embodiment, the unit dose article of the present disclosure may include two compartments. In an embodiment, the unit dose article of the present disclosure may include three compartments. In an embodiment where the unit dose article includes at least two compartments, at least one nonwoven web pouch is not water soluble. In an embodiment where the unit dose article includes at least two compartments, at least a portion of one nonwoven web pouch is soluble in water at a temperature ranging from about 10°C to about 20°C by MSTM 205. In an embodiment where the unit dose article includes at least two compartments, at least a portion of one nonwoven web pouch is not soluble in water at a temperature of about 30°C or less by MSTM 205. In embodiments where the unit dose article comprises at least two compartments, at least a portion of one nonwoven web pouch is soluble in water by MSTM 205 at temperatures ranging from about 10°C to about 20°C, and at least a portion of one nonwoven web pouch is not soluble in water by MSTM 205 at temperatures of about 30°C or less.

[0173] The composition contained within 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 and / or different compositions. The composition may also be in any suitable form, including, but not limited to, liquids, solids, gels, pastes, salves, compressed solids (tablets), and combinations thereof (e.g., solids suspended in a liquid). In embodiments, each compartment may contain the same and / or different personal care compositions, for example, a unit dose article includes one compartment containing a surfactant and a different compartment containing an enzyme. In embodiments where the composition is a liquid, the liquid is contained by the film and / or laminate.

[0174] In some embodiments, the unit dose article comprises multiple compartments. The outline of the multiple compartments is not particularly limited, and the multiple compartments can be stacked, including but not limited to, such that the compartments share a partition wall inside the pouch or the compartments are side-by-side. The compartments of the multi-compartment pouch may be of the same or different size(s) and / or volume(s). The compartments of the multi-compartment pouch of the present invention can be separated or connected in any manner. In an embodiment, the second and / or third and / or subsequent compartments are superimposed on the first compartment. In one embodiment, the third compartment may be superimposed on the second compartment and further superimposed on the first compartment in a sandwich configuration. Alternatively, the second and third compartments may be superimposed on 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 concentrically. The compartments may be packed in a series, each compartment being individually separable by a tear line. Thus, each compartment may be individually cut from the remainder of the series by an end user. In some embodiments, the first compartment may be surrounded by at least a second compartment, for example in a tire-rim configuration or a pouch-in-pouch configuration. In an embodiment, the unit dose article includes a second compartment comprising one or more of a water-soluble film and a nonwoven web in the form of a pouch defining an inner pouch volume. In an embodiment, the unit dose article includes a third compartment including one or more of the water-soluble films in the form of a pouch defining an inner pouch volume. In an embodiment, at least one compartment is formed by a nonwoven web that is not water-soluble. In an embodiment, at least one compartment is formed by a nonwoven web that is soluble in water at a temperature ranging from about 0° C. to about 20° C. by MSTM 205. In an embodiment, at least one compartment is formed by a nonwoven web, at least a portion of which is not soluble in water at or below 20° C. by MSTM 205. In an embodiment, at least one compartment is formed by a nonwoven web and a water-soluble film in the form of a laminate. In an embodiment, the unit dose article includes two compartments provided in a side-by-side configuration. In an embodiment, the unit dose article includes two compartments superimposed. In an embodiment, the unit dose article includes three compartments superimposed as seen in FIG. 4. FIG. 4 shows a stacked unit dose article 1 in which compartments 3 and 4 are provided in a side-by-side configuration and are stacked on compartment 2.

[0175] The geometries of the sections may be the same or different. In embodiments, each of the third and subsequent sections, as required, has a different geometry and shape compared to the first and second sections. In these embodiments, the third and subsequent sections, as required, are arranged with a design on the first or second section. The design may be decorative, educational, or schematic, and may be used, for example, to show a concept or instruction and / or to show the origin of the product.

[0176] Methods for Making Unit Dose Articles

[0177] Unit dose articles, including pouches and packets, may be made using any suitable equipment and methods. For example, single compartment pouches may be made using vertical form-fill, horizontal form-fill, or rotary drum-fill techniques commonly known in the art. Such processes may be either continuous or intermittent. The layered nonwoven web, film, or laminate structure may be moistened and / or heated to increase its malleability. The method may include the use of a vacuum to draw the layered nonwoven web, film, or laminate structure into a suitable mold. The vacuum to draw the nonwoven web, film, or laminate into the mold may be applied for about 0.2 to about 5 seconds, or about 0.3 to about 3, or about 0.5 to about 1.5 seconds when the layered nonwoven web, film, or laminate structure is on the horizontal portion of the surface. The vacuum may be adapted to provide a pressure, for example, in the range of 10 mbar to 1000 mbar, or in the range of 100 mbar to 600 mbar.

[0178] The present disclosure further provides a method of preparing a unit dose article of the present disclosure, comprising: forming a water-soluble film into an open pouch defining an open pouch volume; adding a first composition into the open pouch volume; and sealing the film to form a first inner pouch volume. In some embodiments, sealing can be by heat sealing, solvent sealing, adhesive sealing, or the like. or combinations thereof. In an embodiment, forming the water-soluble film into an open pouch defining the open pouch volume includes co-thermal forming of the water-soluble film and the nonwoven web, so that the water-soluble film and the nonwoven web form a laminate during pouch formation. In an embodiment, laminating the water-soluble film and the nonwoven web, and then forming the water-soluble film into an open pouch defining the open pouch volume. In an embodiment, sealing the film to form the first inner pouch volume includes positioning a second water-soluble film and a second nonwoven web over the portion of the pouch that is open, and sealing the second water-soluble film and the nonwoven web to the water-soluble film that takes the form of the open pouch, the second water-soluble film and the second nonwoven web being configured such that the second water-soluble film is adjacent to the open pouch volume and the second water-soluble film forms an outer surface of the pouch.

[0179] The mold in which the packet can be made can have any shape, length, width, and depth depending on the required dimensions of the pouch. The mold can vary in size and shape from one to the other as needed. For example, the volume of the final pouch can be from about 5 ml to about 300 ml, or from about 10 ml to 150 ml, or from about 20 ml to about 100 ml, with the mold size adjusted accordingly.

[0180] thermoforming

[0181] A thermoformable nonwoven web, film, or laminate is one that can be shaped by the application of heat and force. Thermoforming of a nonwoven web, film, or laminate structure is a process of heating a nonwoven web, film, or laminate structure, shaping it (e.g., in a mold), and then cooling the resulting nonwoven web, film, or laminate, which will result in the nonwoven web, film, or laminate retaining its shape, e.g., the shape of the mold. Heat may be applied using any suitable means. For example, the nonwoven web, film, or laminate may be directly heated by passing it under a heating element or through hot air before being applied to a surface or after being placed on the surface. Alternatively, it may be indirectly heated, e.g., by heating the surface or by attaching a hot article onto the nonwoven web, film, or laminate. In an embodiment, the nonwoven web, film, or laminate is heated using infrared radiation. The nonwoven web, film, or laminate may be heated to a temperature ranging from about 50 to about 150° C., about 50 to about 120° C., about 60 to about 130° C., about 70 to about 120° C., or about 60 to about 90° C. Thermoforming can be accomplished by any one or more of the following processes: manual draping of a heat-softened nonwoven web, film, or laminate over a mold, or pressure-induced forming (e.g., vacuum forming) of a softened nonwoven web, film, or laminate against a mold, or automated high speed indexing of a freshly extruded sheet having a precisely known temperature into a forming and trimming station, or automated placement, plugging, and / or pneumatic stretching, and pressure forming of the nonwoven web, film, or laminate.

[0182] Alternatively, the nonwoven web, film, or laminate can be wetted by any suitable means, such as directly by spraying the nonwoven web, film, or laminate with a wetting agent (water, a polymeric composition, a plasticizer of the nonwoven web, film, or laminate composition, or any combination of the foregoing) before being applied to the surface or after being placed on the surface, or indirectly by wetting the surface or by depositing a wet article onto the nonwoven web, film, or laminate.

[0183] After the nonwoven web, film, or laminate is heated and / or wetted, it may be drawn into a suitable mold, preferably using a vacuum. Filling of the molded nonwoven web, film, or laminate may be accomplished by utilizing any suitable means. In embodiments, the most preferred method is based on the product morphology and the required fill rate. In an embodiment, the molded nonwoven web, film, or laminate is filled by an in-line filling technique. A second nonwoven web, film, or laminate is then used to close the filled open packet to form a pouch by any suitable method. This may be accomplished with a continuous constant motion while in a horizontal position. Closure may be accomplished by continuously feeding a second nonwoven web, film, or laminate through or onto the open packet, and then sealing the first and second nonwoven webs, films, or laminates together, typically in the area between the dies and therefore between the packets.

[0184] Sealing

[0185] Any suitable method of sealing the packet and / or its individual compartments may be utilized. Non-limiting examples of such means include heat sealing, solvent welding, solvent or wet sealing, and combinations thereof. Typically, only the areas to form the seal are treated with heat or solvent. Heat or solvent can be applied by any method, typically onto the closure material, and typically only onto the areas to form the seal. If solvent or wet sealing or welding is used, it is believed that heat is also applied. A preferred wet or solvent sealing / welding method involves selectively depositing a solvent onto the areas between the dies or onto the closure material, for example by spraying or printing onto these areas, and then applying pressure to these areas to form the seal. Sealing rolls and belts (which also provide heat if necessary) can be used, for example.

[0186] In an embodiment, the inner nonwoven web, film, or laminate is sealed to the outer nonwoven web(s), film(s), or laminate(s) by solvent sealing. The sealing solution is generally an aqueous solution. In an embodiment, the sealing solution comprises water. In an embodiment, the sealing solution comprises water and further comprises one or more diols and / or glycols, such as 1,2-ethanediol (ethylene glycol), 1,3-propanediol, 1,2-propanediol, 1,4-butanediol (tetramethylene glycol), 1,5-pantanediol (pentamethylene glycol), 1,6-hexanediol (hexamethylene glycol), 2,3-butanediol, 1,3-butanediol, 2-methyl-1,3-propanediol, various polyethylene glycols (e.g., diethylene glycol, triethylene glycol), and combinations thereof. In an embodiment, the sealing solution comprises erythritol, threitol, arabitol, xylitol, ribitol, mannitol, sorbitol, galactitol, fucitol, iditol, inositol, volemitol, isomer, maltitol, lactitol. In an embodiment, the sealing solution comprises a water soluble polymer.

[0187] The sealing solution can be applied to the interface area of ​​the inner nonwoven web, film, or laminate in any amount suitable to bond the inner and outer nonwoven webs or laminates. As used herein, the term "coating weight" refers to the amount of sealing solution applied to the nonwoven web, film, or laminate in grams per square meter of the nonwoven web, film, or laminate. In general, if the coating weight of the sealing solvent is too low, the nonwoven web, film, or laminate will not adhere properly and there is a risk of the pouch breaking as the seam increases. Furthermore, if the coating weight of the sealing solvent is too high, there is an increased risk of the solvent migrating from the interface area and an increased likelihood of forming etch holes in any film, including the sides of the pouch. The coating weight window refers to the range of coating weights that can be applied to a given film or laminate while maintaining both good adhesion and avoiding the formation of etch holes. A wide coating weight window is desirable because a wider window results in a robust seal under a wide range of operations. A suitable coating weight window is at least about 3 g / m 2 , or at least about 4 g / m 2 , or at least about 5 g / m 2 , or at least about 6 g / m 2 It is.

[0188] In an embodiment, sealing the pouch to form a sealed article includes positioning a second water-soluble film and a second nonwoven web in the open pouch portion and sealing the second water-soluble film and the nonwoven web to the water-soluble film in the form of a pouch. In an embodiment, the second water-soluble film and the second nonwoven web are configured such that the second water-soluble film is adjacent to the inner pouch volume and the second water-soluble film forms an exterior surface of the pouch.

[0189] Cutting unit dose articles

[0190] The formed pouch may be cut by a cutting device. The cutting may be accomplished using any known method. It is also believed that the cutting is performed continuously, preferably at a constant speed and preferably while in a horizontal position. The cutting device may be, for example, a sharp article, or a laser, whereby in the latter case the hot article or laser "burns through" the film / sealed area.

[0191] Forming and Filling Multi-Compartment Unit Dose Articles

[0192] The various compartments of a multi-compartment unit dose article, including pouches, may be made together in a side-by-side or concentric fashion, and the resulting interlocking pouches may or may not be separated by cutting. Alternatively, the compartments may be made separately.

[0193] In an embodiment, the pouch may be made by a process including the steps of: a) forming a first compartment (as described above); b) forming recesses in or all of the closed compartments formed in step (a) to create a second molded compartment superimposed over the first compartment; c) filling and closing the second compartment 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, films, or laminates to produce the multi-compartment pouch. The recesses formed in step (b) may be achieved by applying a vacuum to the compartments prepared in step (a).

[0194] In embodiments, the second and / or third compartment(s) 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 / 240388(A1) or WO 2009 / 152031.

[0195] In an embodiment, the pouch may be made by a process including: a) forming a first compartment in a first former using a first nonwoven web, film, or laminate, 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 optionally second compartments with or laminating to the first nonwoven web or laminate a second nonwoven web, film, or laminate; and e) cutting the nonwoven web or laminate to produce the multi-compartment pouch.

[0196] In an embodiment, the pouch comprises: a) forming a first compartment in a first former using a first nonwoven web, film, or laminate, optionally with heat and / or vacuum; b) filling the first compartment with a first composition; c) deforming a second nonwoven web, film, or laminate in a second former, optionally with heat and vacuum, to create a second and optionally third molded compartment; d) forming a second and optionally third molded compartment. and optionally a third compartment; e) sealing the second and optionally a third compartment with a third nonwoven web, film, or laminate; f) placing the sealed second and optionally a third compartment onto the first compartment; g) sealing the first, second, and optionally a third compartment; and h) cutting the nonwoven web, film, or laminate to produce a multi-compartment pouch.

[0197] The first and second formers may be selected based on their suitability for carrying out the above process. In an embodiment, the first former is preferably a horizontal former and the second former is preferably a rotary drum former, preferably positioned above the first former.

[0198] It should be understood that by using an appropriate supply 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.

[0199] In embodiments, the nonwoven web, film, or laminate, and / or pouch is sprayed or dusted with a suitable material, such as an activator, lubricant, aversive agent, or mixtures thereof. In embodiments, the nonwoven web, film, or laminate, and / or pouch is printed, for example, with an ink and / or an activator.

[0200] Vertical Form, Fill, and Seal

[0201] In an embodiment, the nonwoven web, film, or laminate of the present disclosure can be formed into a sealed article. In an embodiment, the sealed article is a vertical form filled and sealed article. The vertical form, fill, and seal (VFFS) process is a conventional automated process. The VFFS includes an apparatus such as an assembly machine that wraps a single piece of nonwoven web, film, or laminate around a vertically oriented feed tube. The machine heat seals or otherwise secures the opposing edges of the nonwoven web, film, or laminate together to create a side seal of the nonwoven web, film, or laminate or to form a hollow tube. The machine then heat seals or otherwise creates a bottom seal, thereby defining a container portion with an open top, and a top seal will be formed later. The machine introduces a specified amount of free-flowing product into the container portion through the open top end. Once the container contains a desired amount of product, the machine advances the nonwoven web, film, or laminate to another heat sealing device to, for example, create a top seal. Finally, the machine advances the nonwoven web, film, or laminate to a cutter which cuts the film just above the top seal to provide a filled package.

[0202] In operation, the assembly machine advances the nonwoven web, film, or laminate from a roll to form a package. Thus, the nonwoven web, film, or laminate must be able to be easily advanced through the machine and must not adhere to the machine assembly or be so fragile that it will be destroyed during processing.

[0203] Pouch Contents

[0204] In any embodiment, the pouch can contain (enclose) a first composition in a defined first interior volume of the pouch. The first composition can be selected from a liquid, a solid, or a combination thereof. In an embodiment, the first composition comprises a liquid, a solid, or a combination thereof, the water-soluble film is in the form of a pouch defining a first interior pouch volume, and the nonwoven web is in the form of a pouch defining a second interior pouch volume that encompasses the water-soluble film. and the first composition is contained by the water-soluble film. In an embodiment, the first composition is contained by the water-soluble film and the second composition is disposed in the second inner pouch volume between the water-soluble film pouch and the nonwoven web pouch. In an embodiment, the second composition is liquid and the second composition is disposed in the second inner pouch volume between the water-soluble film pouch and the nonwoven web pouch, and the nonwoven web can be a nonporous nonwoven web or a laminate. In an embodiment where the second composition is solid and the second composition is disposed between the water-soluble film pouch and the nonwoven web pouch, the nonwoven web can be a porous nonwoven web. In an embodiment where the nonwoven web pouch is porous, the porous nonwoven web can have a porosity of about 20% to about 95%, or about 30% to about 90%, or about 40% to about 80%, according to the Porosity Test Method.

[0205] In an embodiment, the sealed unit dose article of the present disclosure can encapsulate a first composition and / or a second composition in a first inner pouch volume, a second inner pouch volume, or both. The first and / or second compositions of the present disclosure are not particularly limited, and can be, for example, a personal care composition, a dishwashing composition, an automotive composition, an agricultural composition, an edible composition, and / or a surface cleaning composition. In general, the first and / or second compositions of the present disclosure can include chemical exfoliants, mechanical exfoliants, fragrance microcapsules, aversive agents, surfactants, colorants, enzymes, skin conditioners, degreasing agents, cosmetic agents, fertilizers, ingestible compositions, or combinations thereof. In an embodiment, the first and / or second compositions include personal care compositions. The personal care composition may include a shampoo, a conditioner, a body wash, a face wash, a skin lotion, a skin treatment, a body oil, a fragrance, a hair treatment, a chemical exfoliant, a mechanical exfoliant, a bath salt, an essential oil, a bath bomb, an enzyme, or a combination thereof.

[0206] In further embodiments, the personal care composition may be provided as part of a plurality of fibers dispersed within the nonwoven pouch, provided on a surface of the nonwoven pouch, or a combination thereof.

[0207] As used herein, "liquid" includes free-flowing fluids, as well as pastes, gels, foams, and mousses.

[0208] The unit dose article and / or nonwoven fabric of the present disclosure can advantageously extend the release of the composition contained in the unit dose article and / or nonwoven fabric after contacting with water. The extended release of the composition contained in the unit dose article and / or nonwoven fabric can be advantageous, for example, in the shower when the unit dose article and / or nonwoven fabric is used with the body wash composition contained by the unit dose article and / or nonwoven fabric, since the user of the unit dose article and / or nonwoven fabric may desire a slow release of the composition. The extended release of the composition allows the user to have an improved experience, for example, in the shower, unlike traditional bulk liquid body wash, shampoo, or conditioner that foams and rinses quickly without staying long enough to properly cleanse the skin / hair, the unit dose article and / or nonwoven fabric can provide the foaming, cleansing, and soapy permanence that removes dirt, oil, and other foreign undesirable materials from the skin or hair. The unit dose article and / or nonwoven of the present disclosure provides the composition to the user for an extended period of time, unlike traditional personal care product delivery systems such as bulk liquids. Such improved user experience cannot be provided by simply providing bulk soap in a conventional water-soluble unit dose pod, since the soap is freely rinsed off as soon as the pod is burst. In contrast, with the unit dose article and / or nonwoven of the present disclosure, the foaming action, cleaning, and soap can last for a long time until the article does not dissolve, allowing the consumer to more thoroughly cleanse the skin or hair with a single dose of cleanser.

[0209] In an embodiment, the first and / or second compositions within the unit dose article and / or nonwoven fabric can have an extended release from the unit dose article and / or nonwoven fabric after contact with water when the unit dose article and / or nonwoven fabric comprises a water soluble film and a nonwoven web, the water soluble film is soluble in water at a temperature ranging from about 0° C. to about 20° C. by MSTM 205, and at least a portion of the nonwoven web is not soluble in water at a temperature below 20° C. by MSTM 205. In an embodiment, the first and / or second compositions within the unit dose article and / or nonwoven fabric can have an extended release from the unit dose article and / or nonwoven fabric after contact with water when the unit dose article and / or nonwoven fabric comprises a water soluble film and a nonwoven web, the water soluble film is not soluble in water at a temperature below 20° C. by MSTM 205, and at least a portion of the nonwoven web is not soluble in water at a temperature below 20° C. by MSTM 205. In an embodiment, the first and / or second compositions within the unit dose article and / or nonwoven fabric can have an extended release from the unit dose article and / or nonwoven fabric after contact with water when the unit dose article and / or nonwoven fabric comprises a water soluble film and a nonwoven web, the water soluble film is soluble in water at a temperature ranging from about 0° C. to about 20° C. by MSTM 205, and at least a portion of the nonwoven web is soluble in water at a temperature ranging from about 0° C. to about 20° C. by MSTM 205. In an embodiment, the first and / or second compositions within the unit dose article and / or nonwoven fabric can have an extended release from the unit dose article and / or nonwoven fabric after contact with water when the unit dose article and / or nonwoven fabric comprises a water soluble film and a nonwoven web, the water soluble film is soluble in water at a temperature ranging from about 0° C. to about 20° C. by MSTM 205, and at least a portion of the nonwoven web is not water soluble and / or biodegradable.In an embodiment, the first and / or second compositions in the unit dose article and / or nonwoven may have an extended release from the unit dose article after contact with water when the unit dose article and / or nonwoven web comprises a water soluble film and a nonwoven web, where the water soluble film is not soluble in water at or below 20° C. by MSTM 205, and at least a portion of the nonwoven web is not water soluble and / or biodegradable. In a refinement of the above embodiment, the water soluble film and the nonwoven web are laminated.

[0210] In an embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition after contact with water at a temperature ranging from greater than 20° C. to about 45° C. for a period of about 30 seconds by Long Term Release Test Method A, Long Term Release Test Method B, or Long Term Release Test Method C. In a refinement of the above embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition for a period of about 30 seconds by Long Term Release Test Method A. In an embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition after contact with water at a temperature ranging from greater than 20° C. to about 45° C. for a period of about 1 minute by Long Term Release Test Method A, Long Term Release Test Method B, or Long Term Release Test Method C. In a refinement of the above embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition for a period of about 1 minute by Long Term Release Test Method A. In an embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition for at least about 1 minute when the unit dose article and / or nonwoven fabric does not begin to release the first composition by the Liquid Release Test. In an embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition after contact with water at a temperature ranging from greater than 20° C. to about 45° C. for a period of about 2 minutes by Long-Term Release Test Method A, Long-Term Release Test Method B, or Long-Term Release Test Method C. In a refinement of the above embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition for a period of about 2 minutes by Long-Term Release Test Method A. In an embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition for at least about 2 minutes when the unit dose article and / or nonwoven fabric does not begin to release the first composition by the Liquid Release Test. In embodiments, the unit dose article and / or nonwoven fabric extends the release of the first composition after contact with water at a temperature ranging from greater than 20° C. to about 45° C. for a period of about 3 minutes according to Extended Release Test Method A, Extended Release Test Method B, or Extended Release Test Method C. In a refinement of the form, the unit dose article and / or nonwoven extends the release of the first composition over a period of about 3 minutes by Extended Release Test Method A. In an embodiment, the unit dose article and / or nonwoven extends the release of the first composition when the unit dose article and / or nonwoven does not begin to release the first composition for at least about 3 minutes by Liquid Release Test. In an embodiment, the unit dose article and / or nonwoven extends the release of the first composition after contact with water at a temperature ranging from greater than 20° C. to about 45° C. over a period of about 4 minutes by Extended Release Test Method A, Extended Release Test Method B, or Extended Release Test Method C. In a refinement of the above embodiment, the unit dose article and / or nonwoven extends the release of the first composition over a period of about 4 minutes by Extended Release Test Method A. In an embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition when the unit dose article and / or nonwoven fabric does not begin to release the first composition for at least about 4 minutes by the Liquid Release Test. In an embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition after contact with water at a temperature ranging from greater than 20° C. to about 45° C. for a period of about 5 minutes by Long-Term Release Test Method A, Long-Term Release Test Method B, or Long-Term Release Test Method C. In a refinement of the above embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition for a period of about 5 minutes by Long-Term Release Test Method A. In an embodiment, the unit dose article and / or nonwoven fabric extends the release of the first composition when the unit dose article and / or nonwoven fabric does not begin to release the first composition for at least about 5 minutes by the Liquid Release Test. In an embodiment, the unit dose article and / or nonwoven extends the release of the first composition after contact with water at a temperature ranging from greater than 20° C. to about 45° C. over a period of about 10 minutes by Long Term Release Test Method A, Long Term Release Test Method B, or Long Term Release Test Method C. In a refinement of the above embodiment, the unit dose article and / or nonwoven extends the release of the first composition over a period of about 10 minutes by Long Term Release Test Method A. In an embodiment, the unit dose article and / or nonwoven extends the release of the first composition when the unit dose article and / or nonwoven does not begin to release the first composition for at least about 10 minutes by the Liquid Release Test.In an embodiment, the unit dose article and / or the first section of the nonwoven fabric extends the release of the first composition when the unit dose article has a liquid release time determined by a Liquid Release Test that is at least about 1.3x (1.3 times) longer than an identical unit dose article that includes a water-soluble film in the form of a pouch but does not include a nonwoven web in the form of a pouch. In an embodiment, the unit dose article and / or the first section of the nonwoven fabric extends the release of the first composition when the unit dose article has a liquid release time determined by a Liquid Release Test that is at least about 1.4x (1.4 times) longer than an identical unit dose article that includes a water-soluble film in the form of a pouch but does not include a nonwoven web in the form of a pouch. In an embodiment, the unit dose article and / or the first section of the nonwoven fabric extends the release of the first composition when the unit dose article has a liquid release time as determined by liquid release testing that is at least about 2× (2 times) longer than an identical unit dose article that includes a water-soluble film in the form of a pouch but does not include a nonwoven web in the form of a pouch.

[0211] Further provided herein is a unit dose article comprising a compartment comprising: a water-soluble film of the present disclosure in the form of a pouch defining a first inner pouch volume, the water-soluble resin comprising a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a mixture of polyvinyl alcohol homopolymer and polyvinyl alcohol copolymer; and a nonwoven web in the form of a pouch defining a second inner pouch volume encompassing the water-soluble film in the form of a pouch, the nonwoven web comprising a plurality of fibers comprising a first fiber type comprising a polyvinyl alcohol homopolymer fiber forming material having a degree of hydrolysis of about 75% to about 91% and a second fiber type comprising one or both of a water insoluble polyester and a polylactic acid fiber forming material, wherein the water-soluble film and the nonwoven web are in the form of a laminate; and a personal care composition disposed within the first inner pouch volume.

[0212] Further provided herein is a water-soluble film of the present disclosure in the form of a pouch defining a first inner pouch volume, the water-soluble resin being a polyvinyl alcohol homopolymer. and a nonwoven web in the form of a pouch defining a second inner pouch volume containing the water-soluble film in the form of a pouch, the nonwoven web comprising a plurality of fibers comprising a first fiber type comprising a polyvinyl alcohol homopolymer having a degree of hydrolysis of about 92% to about 99.9% and a second fiber type comprising one or both of a water insoluble polyester and a polylactic acid fiber forming material, the water-soluble film and the nonwoven web being in the form of a laminate; and a personal care composition disposed within the first pouch volume, the personal care composition comprising a surfactant.

[0213] Particularly contemplated non-limiting embodiments are presented in the table below, where "MA PVOH" refers to methyl acrylate polyvinyl alcohol copolymer, "MMM PVOH" refers to monomethyl maleate polyvinyl alcohol copolymer, "PET" refers to polyethylene terephthalate, "PLA" refers to polylactic acid, "DL" refers to degree of lamination, and the remaining compositions identified by viscosity and degree of hydrolysis (DH) are polyvinyl alcohol homopolymers. [Table 1A-1] [Table 1A-2] Dissolution and Disintegration Time-MSTM-205

[0214] The nonwoven web, water-soluble film, or laminate structure can be characterized by or tested for dissolution time and disintegration time according to MonoSol Test Method 205 (MSTM 205), a method known in the art. See, for example, U.S. Patent No. 7,022,656. The description provided below refers to a nonwoven web, but is equally applicable to a water-soluble film or laminate structure. Apparatus and method: 600mL beaker Magnetic stir bar (Labline Model No. 1250 or equivalent) Magnetic stirring bar (5cm) Thermometer (0 to 100°C ±1°C) Template, stainless steel (3.8cm x 3.2cm) Timer (0-300 seconds, accurate to the second) Polaroid 35mm slide mount (or equivalent) MonoSol 35mm Slide Mount Holder (or equivalent) Distilled water

[0215] For each nonwoven web, water-soluble film, or laminate structure being tested, three test specimens, 3.8 cm x 3.2 cm specimens, are cut from the nonwoven web, water-soluble film, or laminate structure sample. 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.

[0216] Each specimen is mounted on an individual 35 mm slide mount.

[0217] Fill a beaker with 500 mL of distilled water. Measure the water temperature with a thermometer and heat or cool the water as necessary to maintain a temperature at which dissolution is determined, e.g., 20° C. (about 68° F.).

[0218] Mark the height of the water column. Place a magnetic stir bar at the base of the holder. Place the beaker on the magnetic stir bar, add the magnetic stir bar to the beaker, turn the stir bar, and adjust the stirring speed until a vortex is created at approximately one-fifth of the height of the water column. Mark the depth of the vortex.

[0219] Secure the 35mm slide mount into the alligator clamp of the 35mm slide mount holder with the long side of the slide mount parallel to the water surface. The holder's depth adjustment should be set so that when lowered, the end of the clamp is 0.6 cm below the surface of the water. One of the short pieces of the slide mount should be adjacent to the side of the beaker and the other positioned directly above the center of the stir bar so that the surface of the nonwoven web is perpendicular to the water flow.

[0220] In one motion, the secured slide and clamp are lowered into the water and a timer is started. Disintegration occurs when the nonwoven web tears. When all visible nonwoven web has been released from the slide mount, the slide is raised out of the water while continuing to monitor the solution for undissolved nonwoven web fragments. Dissolution occurs when all nonwoven web fragments are no longer visible and the solution becomes clear.

[0221] Results should include: complete sample identification; individual and average disintegration and dissolution times; and the water temperature in which the samples were tested.

[0222] Method for determining single fiber solubility The solubility of a single fiber is characterized by its water breakage temperature. The fiber breakage temperature can be determined as follows: A load of 2 mg / dtex is applied to a fiber of fixed length 100 mm. The water temperature starts at 1.5°C and then increases by 1.5°C every 2 minutes until the fiber breaks. The temperature at which the fiber breaks is called the water breakage temperature.

[0223] The solubility of a single fiber can also be characterized by the temperature of complete dissolution. The temperature of complete dissolution can be determined as follows: 0.2 g of fiber with a fixed length of 2 mm is added to 100 mL of water. The water temperature starts at 1.5°C and then is increased by 1.5°C every 2 minutes until the fiber is completely dissolved. The sample is stirred at each temperature. The temperature at which the fiber is completely dissolved is designated the complete dissolution temperature.

[0224] Diameter Test Method The diameter of individual fibers or fibers within a nonwoven web is determined by using a scanning electron microscope (SEM) or optical microscope and image analysis software. A magnification of 200 to 10,000 times is selected so that the fibers are adequately magnified for measurement. When using an SEM, the sample is sputtered with gold or palladium compounds to avoid charging and vibration of the fibers in the electron beam. A manual procedure for determining fiber diameter is used from an image (on a monitor screen) taken with an SEM or optical microscope. The mouse and cursor tools are used to locate a randomly selected edge of the fiber and then measure both ends of its width (i.e., perpendicular to the fiber direction at that point) to the other edge of the fiber. Scaling and calibration image analysis tools provide scaling to obtain an actual reading in microns. For fibers within a nonwoven web, a number of fibers are randomly selected throughout a sample of the nonwoven web using an SEM or optical microscope. At least two portions of the nonwoven web have material cut and tested with this technique. In total, at least 100 such measurements are made and all data is then recorded for statistical analysis. The recorded data is used to determine the average (mean) of the fibers, the standard deviation of the fibers, and and the median fiber diameter are calculated.

[0225] Tensile Strength, Modulus, and Elongation Testing Nonwoven webs, water-soluble films, or laminate structures characterized by or tested for tensile strength by the Tensile Strength (TS) Test, modulus (or tensile stress) by the Modulus (MOD) Test, and elongation by the Elongation Test are analyzed as follows. The description provided below refers to nonwoven webs, but is equally applicable to water-soluble films or laminate structures. The procedure involves the determination of tensile strength and modulus at 10% elongation by ASTM D 882 ("Standard Test Method for Tensile Properties of Thin Plastic Sheet Formings") or equivalent. Nonwoven web data is collected using an INSTRON tensile testing device (Model 5544 Tensile Tester or equivalent). A minimum of three specimens, each cut with a reliable cutting tool to ensure dimensional stability and repeatability, are tested in the machine direction (MD) (where applicable) for each measurement. The experiments were carried out in a standard laboratory atmosphere of 23±2.0° C. and 35±5% relative humidity. For the determination of tensile strength or modulus, a 1" wide (2.54 cm) sample of the nonwoven web is prepared. The sample is then transferred to an INSTRON tensile tester for testing with minimal exposure to a 35% relative humidity environment. The tensile tester is equipped with a 500N load cell and is prepared and calibrated according to the manufacturer's instructions. The correct grips and faces are fitted (INSTRON grips with model number 2702-032 faces, rubber coated, 25 mm wide, or equivalent). The sample is placed in the tensile tester and analyzed to determine the 100% modulus (i.e., the stress required to achieve 100% film elongation), tensile strength (i.e., the stress required to break the film), and the % elongation (the length of the sample at break relative to the initial sample length). In general, the higher the % elongation of the sample, the better the processability properties of the nonwoven web (e.g., increased formability into a packet or pouch).

[0226] Determining Basis Weight Basis weight is determined in accordance with ASTM D3776 / D3776M-09a(2017). Briefly, it must be at least 130 cm2 Obtained from various locations on a test piece or specimen having an area of ​​at least 130 cm 2 Cut several smaller die cut specimens having a total area of ​​100 mm. Weigh the specimen(s) to determine mass on a top-loading analytical balance with a resolution of ±0.001 g. Protect the balance from air currents and other disturbances using a draft shield. Fabric specimens may be weighed together. Calculate mass as ounces per square yard, ounces per linear yard, linear yards per pound, or grams per square meter to three significant figures.

[0227] The foregoing description is given merely for clarity of understanding, and no unnecessary limitations are to be understood therefrom, so that modifications within the scope of the invention may be apparent to those skilled in the art.

[0228] 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.

[0229] Long-term Release Test Method A Conductivity measurement: The unit dose article is placed in a wire cage and immersed in water (stirred or unstirred) in a beaker for a specified time and temperature. The time when the unit dose article is immersed in the water is recorded. The conductivity of the water is constantly monitored while the unit dose article is immersed. As the composition is released from the unit dose article, the conductivity of the water will be constantly changing. When the conductivity of the water reaches a plateau, the time is recorded. The time taken from the initial unit dose article immersion to the beginning of the conductivity plateau correlates with the time taken for the unit dose article and composition to start dissolving and reach an end point where dissolution stops due to all possible dissolution having occurred, respectively. A longer time to reach this plateau of conductivity change may indicate a unit dose article with extended release compared to a unit dose article that takes less time to reach such a plateau. The individual levels of conductivity in this method do not necessarily indicate any significant factor of extended release, since the conductivity will be affected by the ingredients contained in the unit dose article and the composition therein.

[0230] Long-term Release Test Method B Weight Loss After Unit Dose Burst: The unit dose article is placed in a wire cage and immersed in a beaker of water (stirred or unstirred) of the specified volume and temperature. The time when the unit dose article is immersed in the water is recorded. The time taken for the first observed leakage of the contained composition from the article is again recorded. At this point, a timer is started and the cage containing the article is removed from the water and suspended above the beaker, allowing the composition to release and fall into the water below. The cage can be hung from a pressure gauge and the cage and article weighed to determine the weight loss of the article due to composition loss over time. This measurement can be performed to record the time it takes for the article to lose a particular amount of weight (e.g., a percentage such as 50% of a known amount of composition contained in the article) or alternatively, to record how much weight the article has lost in a particular length of time, such as 2 minutes.

[0231] Long-term Release Test Method C Corrected Liquid Release Time Visual Observation: The unit dose article is placed in a wire cage and immersed in a beaker of water (stirred or unstirred) of the specified volume and temperature. The time when the unit dose article is immersed in the water is recorded. The time taken for the contained composition to first be observed to leak out of the article is recorded. The time taken for the entirety of the composition to be released is also recorded.

[0232] Porosity Test Method The method for determining the porosity of a particular nonwoven utilizes the liquid saturation method and is carried out as follows: A 1 inch by 1 inch specimen is cut from the nonwoven web. The mass of the specimen is determined and recorded using an analytical balance. The specimen is immersed in a liquid that will not swell or dissolve the fibers in the nonwoven specimen. The liquid sample along with the immersed nonwoven specimen is then sonicated for 5 minutes to ensure complete penetration of the liquid throughout all available voids of the nonwoven specimen. After 5 minutes, the liquid sample is removed from the sonicator and the nonwoven specimen is removed from the liquid with tweezers and hung to dry (time needs to be verified here). After hanging to dry completely, the nonwoven surface is tapped with a chemwipe to remove excess surface liquid. Care must be taken not to absorb liquid from the bulk of the nonwoven specimen, so a very light tap on each side is sufficient. Once finished, the mass of the specimen is again determined and recorded and the difference between the initial and final mass is calculated, i.e., the mass of absorbed liquid. From this mass, and using the known density of the liquid, calculate the volume of absorbed liquid (L V ). Using the initial mass of the nonwoven and its known density, calculate the nonvoid volume of the nonwoven (N V Using the two calculated volume values, the percent porosity of the nonwoven fabric is calculated using the following equation: Porosity (%)=[L V / (L V +N V )] x 100 Determined via.

[0233] Softness rating 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. A tester performing the softness evaluation uses clean hands to touch the sample in any manner or manner of the individual's choice to determine the softness rank of the nonwoven web and article of the present disclosure, as compared to a control material comprising a nonwoven web of fibers made of 88% polyvinyl alcohol homopolymer hydrolysis, having a 2.2 dtex / 51 mm cut, and a softness rank of 1 (softest), and a control material comprising a nonwoven web of 75% fibers made of 88% polyvinyl alcohol homopolymer hydrolysis, having a 2.2 / 51 mm cut, and 25% PET fibers of 22 dtex / 38 mm, and a softness rank of 5 (coarsest / most roughened). The hand panel was performed in a blind test to ensure that the evaluator was not influenced by the name of the sample by knowing it. The samples were ranked from 1 to 5.

[0234] Liquid Release Test FIG. 1 is a diagram of the wire frame cage (shown with the top open to better reveal the water-soluble pouch contained within) used in the liquid release studies described herein.

[0235] FIG. 2 shows an apparatus for conducting liquid release tests, including a beaker mounted on a stand, the stand holding a rod for lowering a cage into the beaker, and the rod being fixable by a collar with a set screw (not shown).

[0236] The method generally follows ASTM D4332-13, Standard Practice for Conditioning Containers, Packages, or Packaging Components for Testing; however, control of 50±2% relative humidity is not maintained in the liquid release test.

[0237] In accordance with the Liquid Release Test, water-soluble films, nonwoven webs, and / or pouches to be characterized by or tested for delayed solubility are analyzed as follows using the following materials: 2L beaker and 6L of deionized (DI) water (enough to repeat the test 5 times) · The water-soluble pouches on which the tests are made; the pouches are preconditioned for at least 24 hours for 2 weeks at 23±1°C and 50±4% relative humidity; in order to compare results, all films tested should have the same thickness, e.g. 88μm or 76μm; all nonwovens should have the same basis weight, e.g. 50gsm. ·Thermometer Wire cage ·timer

[0238] Prior to running the experiment, ensure that enough DI water is available to repeat the experiment five times and ensure that the wire cage, beaker, and clamps are clean and dry.

[0239] The wire frame cage is a plastic coated wire cage (10 cm x 8.9 cm x 6.4 cm) or equivalent with no sharp edges. The gauge of the wire should be approximately 1.25 mm and the wire should have openings 0.5 inches (1.27 cm) square in size. An exemplary image of the cage 28 with test pouch 30 is shown in FIG. 1.

[0240] To prepare for testing, the water-soluble pouch is carefully placed in the cage, allowing free space for the pouch to move without scratching the pouch on the cage. The pouch is not tightly bonded to the wire cage, yet is still securely attached and will not move 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 permitted (i.e., the side of the pouch that will float to the top should be oriented towards the top). If the pouch is symmetrical, the orientation of the pouch generally does not matter.

[0241] Next, fill a 2 L beaker with 1200 milliliters of 20° C. DI water.

[0242] The wire frame cage with the contained 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 all sides of the pouch are completely submerged. Ensure that the cage is stable and does not move or start a timer once the pouch is lowered into the water. 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 secured above the beaker and a rod attached to the top of the cage. The clamp can engage the rod to fix the position of the cage, reducing tension on the clamp to allow the cage to be lowered into the water. Other means of frictional engagement can be used in place of the clamp, for example, as shown in FIG. 2 (setscrew not shown). 2 shows a beaker 30 mounted on a stand 40, which holds a rod 50 for lowering a cage 10 (not shown) into the beaker 30, the rod 50 being capable of being held in a fixed vertical position by the use of a collar 60 having a set screw (not shown) which engages the rod 50, for example, by friction or by engaging a hole (not shown) in the rod 50.

[0243] The release of liquid content is defined as the first physical evidence of liquid leaving the immersed pouch. The liquid release time can generally be correlated with the extended release time of liquid content from the pouch of the present disclosure. Generally, as the liquid release time increases, the extended release time also increases. For pouches containing compositions such as cleaning compositions and detergents that contain surfactants that can create foam, without wishing to be bound by theory, it is believed that the liquid release time correlates with the foam formation / lathering time; for example, the longer the liquid release time, the longer the resulting foam / foam will last. EXAMPLES

[0244] Example 1 Preparation of unit dose articles

[0245] The following example unit dose articles were prepared by the following heat sealing process with the following parameters:

[0246] [Table 1]

[0247] The film, nonwoven web, or laminate to be thermoformed is laid down in the intended cavity. If the material to be thermoformed is a laminate, the nonwoven web is laid down in contact with the mold with the water-soluble film facing up. In this study, the cavity is fixed at 50 mm x 50 mm x 12 mm and thermoforming is performed under the conditions described in Table 1. Liquid laundry detergent (LLD) is added to the thermoformed cavity (nominal 15 mL). Liquid laundry detergent (LLD) suitable for testing the compatibility of the water-soluble films described herein with liquid laundry detergent is described in Tables 2 and 3 below. Without wishing to be bound by theory, it is believed that low molecular weight polyols, such as propylene glycol, in the liquid laundry detergent can migrate into the film or fiber and interact with the polymer therein to reduce the crystallinity of the polymer and increase the solubility of the unit dose article in water. Generally, as the amount of low molecular weight polyol in the liquid laundry detergent increases, the unit dose article containing the liquid laundry detergent becomes more readily soluble (i.e., the solubility temperature decreases and / or the solubility time decreases). A cap material is then placed over the filled thermoformed unit dose article. If the thermoformed material is a laminate, the water-soluble film side is placed in contact with the encapsulated composition and the nonwoven web side is placed on the outer surface of the unit dose article, facing away from the encapsulated composition. The unit dose article is then sealed using heat and pressure as described in Table 1.

[0248] [Table 2]

[0249] [Table 3]

[0250] Example 2

[0251] Materials and Methods: The nonwoven web of the pouch of this example was fixed at about 40 to 50 gsm, and the water-soluble film of the pouch of this example was fixed at about 3 mil. The nonwoven web was composed of a 50 / 50 blend of 1.7 dtex / 38 mm cut filament and 2.2 dtex / 51 mm cut filament. All samples were unit dose articles as made by the process of Example 1. The water-soluble film with 2 mol% methyl acrylate (MA) PVOH further contained a plasticizer amount of about 43 phr. The water-soluble film with 1.7% monomethyl maleate (MMM) PVOH further contained a plasticizer amount of about 20 phr. The water-soluble film with PVOH homopolymer with a viscosity of 23 cPs and a DH of 88% further contained a plasticizer amount of about 26 PHR. The water-soluble film with PVOH homopolymer with a viscosity of 8 cPs and a DH of 88% further contained a plasticizer amount of about 15 phr. The pouches are described below in Table 4. The pouches were tested for liquid release time and softness and the results obtained are presented in Table 4.

[0252] [Table 4-1] [Table 4-2]

[0253] The unit dose articles of Table 4 were tested for their dissolution, softness, and liquid release time. The unit dose articles containing the laminate were compared to unit dose articles containing only the water-soluble film or only the nonwoven web to determine the effect of the laminate on the liquid release time, dissolution, and softness. The results are shown in Table 4.

[0254] In general, it has been found that the calendar laminated unit dose article with DL of 25% advantageously exhibits increased release time compared to its water-soluble film only unit dose article counterpart.For example, comparing Samples 1, 3, and 6, where Sample 1 is a unit dose article with only water-soluble film, Sample 3 is a unit dose article with 25% calendar laminated laminate, which laminate contains the same water-soluble film as Sample 1, and Sample 6 is a unit dose article with 25% calendar laminated laminate, which laminate contains the same water-soluble film as Sample 1 and 3, but with a different nonwoven fabric laminated thereon compared to Sample 3, demonstrates that adding a nonwoven fabric to the film to form the laminate increases the liquid release time, and furthermore, the type of fiber used to form the nonwoven fabric of the laminate also affects the liquid release time.In particular, Samples 3 and 6 have been found to advantageously have about 1.9 times and 2.7 times longer liquid release time than the pouch with only water-soluble film, respectively.In addition, Samples 3 and 6 are different in the nonwoven fibers used in each independent laminate. In particular, Sample 6 contained fibers having a higher degree of hydrolysis than the fibers of Sample 3. The liquid release time of Sample 6 was longer than Sample 3 (3.3 times longer than the comparative film pouch and 2.7 times longer than the comparative film pouch, respectively). This difference demonstrates that the selection of fibers in the nonwoven web can advantageously provide tunable liquid release times.

[0255] More generally, it was found that the calendered unit dose articles with a DL of 100% demonstrated increased release times compared to both the calendered unit dose articles with a DL of 25% and the unit dose article counterparts with only water-soluble film. For example, a comparison of Samples 8-10, where Sample 8 is a unit dose article with only water-soluble film, Sample 9 is a unit dose article with a 25% calendered nonwoven web, and Sample 10 is a unit dose article with a 100% calendered nonwoven web, which is the same as Sample 9 but calendered at 100%, demonstrated increased liquid release times with increasing lamination. Sample 10 was found to have an increased liquid release time 4.7 times longer than the film-only pouch compared to Sample 9, which had an increased liquid release time 3.7 times longer than the film-only pouch. This difference demonstrates that the selection of lamination degree can be advantageously used to provide a tunable liquid release time.

[0256] It has further been found that the softness of the unit dose article comprising the laminate can be adjusted based on the nonwoven fiber used and / or the lamination degree. For example, both sample 17 and 18 are unit dose articles comprising the laminate of the same water-soluble film and nonwoven web but with different lamination degrees. Sample 17 had a lamination degree of 25%, which resulted in a softness rank of 2, whereas sample 18 had a lamination degree of 100%, which resulted in a softness rank of 3. Thus, it is demonstrated that the softness value increases with increasing lamination degree (higher softness value indicates a less soft article). This difference demonstrates that the selection of lamination degree can be advantageously used to provide adjustable softness. It has further been found that the softness can be adjusted based on the selection of fiber. For example, unit dose article samples that were laminates with a lamination degree of 25% containing only nonwoven fibers of 23 cPs and 96% DH as monofilaments had a softness ranking of 2 (e.g., Samples 6, 11, and 17). However, when fibers with shorter lengths and wider diameters were included, the softness value of the resulting article increased. For example, Samples 27 and 30 contained 75% of the same fiber type used in Samples 6, 11, and 17, but also contained 25% polyester fiber that was 6 dpf×51 mm or 25% polylactic acid fiber that was 6.6 dtex×60 mm, respectively. This resulted in Samples 27 and 30 having increased softness rankings of 4 and 5, respectively. Articles with such softness rankings can be advantageously used in personal care articles where a rougher surface can exert a mechanical exfoliating effect. This difference indicates that the selection of fibers, particularly the L / D ratio of the fibers, can advantageously provide tunable softness to the article. Demonstrate that it can bring

[0257] The unit dose articles in Table 4, Samples 26 to 31, containing water-soluble and water-insoluble fibers, showed similar trends to the unit dose articles with single fiber type. The liquid release time can be advantageously adjusted based on the lamination degree. In general, the higher the lamination degree, the longer the liquid release time for the laminated samples. For example, Samples 28 and 31 were calendered at 100% lamination degree and had liquid release times of 116 and 121, respectively. Samples 27 and 30 were calendered at 25% lamination degree and had liquid release times of 89 and 43, respectively. Articles in which the nonwoven web contains water-soluble and water-insoluble fibers are also expected to follow the above trends with respect to (a) increased release times as the degree of hydrolysis of the water-soluble fibers increases, and (b) softness values ​​increasing with increasing lamination degree. In one embodiment, for example, the following items are provided: (Item 1) 1. A unit dose article comprising a first compartment, a water-soluble film in the form of a pouch defining a first inner pouch volume, the water-soluble film including a water-soluble resin; a nonwoven web in the form of a pouch defining a second inner pouch volume containing said water-soluble film, said nonwoven web comprising a plurality of fibers; a first composition contained by said first compartment; Including, A unit dose article, wherein the first composition is released when the first compartment contacts water, and the unit dose article includes a water-soluble film in the form of a pouch, which extends the release of the first composition compared to an identical unit dose article that does not include a nonwoven web in the form of a pouch. (Item 2) 1. A unit dose article comprising a first compartment, a water-soluble film in the form of a pouch defining a first inner pouch volume, the water-soluble film including a water-soluble resin; a nonwoven web in the form of a pouch defining a second inner pouch volume containing said water-soluble film, said nonwoven web comprising a plurality of fibers; a first composition contained by said first compartment; Including, A unit dose article, wherein the nonwoven web has a dissolution time greater than the dissolution time of the water-soluble film by MSTM 205. (Item 3) 1. A unit dose article comprising a first compartment, a water-soluble film in the form of a pouch defining a first inner pouch volume, the water-soluble film including a water-soluble resin; a nonwoven web in the form of a pouch defining a second inner pouch volume containing said water-soluble film, said nonwoven web comprising a plurality of fibers; a first composition contained by said first compartment; Including, The unit dose article, wherein the water-soluble film and the nonwoven web are in the form of a laminate, the degree of lamination being in the range of about 5% to about 100%. (Item 4) 3. The unit dose article of claim 1 or 2, wherein the nonwoven web and the water-soluble film are in the form of a laminate. (Item 5) 5. The unit dose article of claim 3 or 4, wherein the laminate has a degree of lamination in the range of about 5% to about 25%. (Item 6) 5. The unit dose article of claim 3 or 4, wherein the laminate has a degree of lamination ranging from about 50% to about 100%. (Item 7) 2. The unit dose article of any one of the preceding claims, wherein at least a portion of the nonwoven web is not water soluble. (Item 8) The unit dose article of any one of the preceding items, wherein at least a portion of the nonwoven web is soluble in water at a temperature ranging from about 0° C. to about 20° C. by MSTM 205. (Item 9) 2. The unit dose article of any one of the preceding claims, wherein at least a portion of the nonwoven web is not water soluble by MSTM 205 at or below 20° C. (Item 10) 20. The unit dose article of any one of the preceding claims, wherein the plurality of fibers comprises a fiber type that includes a water insoluble fiber forming material. (Item 11) 20. The unit dose article of any one of the preceding claims, wherein the plurality of fibers comprises a fiber type that includes a water soluble fiber-forming material. (Item 12) 20. The unit dose article of any one of the preceding claims, wherein the plurality of fibers comprises a fiber type including a polyvinyl alcohol homopolymer fiber forming material, a polyvinyl alcohol copolymer fiber forming material, or a combination thereof. (Item 13) 13. The unit dose article of claim 12, wherein the polyvinyl alcohol homopolymer or polyvinyl alcohol copolymer has a degree of hydrolysis ranging from about 75% to about 89%. (Item 14) 14. The unit dose article of claim 12 or 13, wherein the polyvinyl alcohol homopolymer or polyvinyl alcohol copolymer has a degree of hydrolysis ranging from about 90% to about 99.9%. (Item 15) 20. The unit dose article of any one of the preceding claims, wherein the plurality of fibers includes a fiber type that includes a water soluble fiber forming material and a fiber type that includes a water insoluble fiber forming material. (Item 16) 20. The unit dose article of any one of the preceding claims, wherein the plurality of fibers comprises about 10% to about 80% water soluble fiber by weight, based on the total weight of the fibers and the remainder being water insoluble fiber. (Item 17) The plurality of fibers are A first fiber type; The second fiber type wherein the first fiber type and the second fiber type have characteristics similar to each other, such as length to diameter (L / D) ratio, tenacity, shape, stiffness, elasticity, solubility in water, melting point, glass transition temperature (T g ), fiber chemical composition, and color. (Item 18) 18. The unit dose article of claim 17, wherein the first fiber type comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. (Item 19) Item 17. The method of claim 17, wherein the first fiber type comprises two or more polyvinyl alcohol homopolymers, two or more polyvinyl alcohol copolymers, or a combination of polyvinyl alcohol homopolymers and polyvinyl alcohol copolymers. Or the unit dose article described in 18. (Item 20) 20. The unit dose article of any one of items 17 to 19, wherein the second fiber type comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. (Item 21) 21. The unit dose article of any one of items 17 to 20, wherein the second fiber type comprises two or more polyvinyl alcohol homopolymers, two or more polyvinyl alcohol copolymers, or a combination of polyvinyl alcohol homopolymers and polyvinyl alcohol copolymers. (Item 22) 22. The unit dose article of any one of items 17 to 21, wherein the first fiber type comprises a water insoluble polymer. (Item 23) 23. The unit dose article of any one of items 17 to 22, wherein the second fiber type comprises polyvinyl alcohol having a degree of hydrolysis ranging from about 75% to about 89%. (Item 24) 24. The unit dose article of any one of items 17 to 23, wherein the second fiber type comprises polyvinyl alcohol having a degree of hydrolysis ranging from about 90% to about 99.5%. (Item 25) 25. The unit dose article of any one of items 17 to 24, wherein the second fiber type comprises a water insoluble polymeric fiber forming material. (Item 26) 26. The unit dose article of any one of items 7 or 22 to 25, wherein the water insoluble fiber forming material comprises one or more materials in the group of cotton, hemp, jute, flax, ramie, sisal, bagasse, banana, lacebark, silk, sinew, catgut, wool, seasilk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo, modal, cellulose diacetate, cellulose triacetate, polyvinyl alcohol homopolymer, and polyvinyl alcohol copolymer. (Item 27) 2. The unit dose article of any one of the preceding claims, wherein the nonwoven web has a linear mass density in the range of about 1 dtex to about 5 dtex, or about 1 dtex to about 3 dtex, or about 1.5 dtex to about 2.5 dtex. (Item 28) 2. The unit dose article of any one of the preceding claims, wherein the nonwoven web is biodegradable. (Item 29) 20. The unit dose article of any one of the preceding claims, wherein the water-soluble resin comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. (Item 30) The unit dose article of any one of the preceding items, wherein the nonwoven web further comprises one or more of the following group: chemical exfoliants, mechanical exfoliants, fragrance microcapsules, aversive agents, surfactants, colorants, enzymes, skin conditioners, deoiling agents, and cosmetic agents dispersed within the fibers, dispersed on the surface of the nonwoven web, or combinations thereof. (Item 31) The unit dose article of any one of the preceding items, wherein the plurality of fibers further comprises one or more of the group of chemical exfoliants, mechanical exfoliants, fragrance microcapsules, aversive agents, surfactants, colorants, enzymes, skin conditioners, de-oiling agents, and cosmetic agents dispersed within the fibers, dispersed on the fibers, or combinations thereof. (Item 32) the first composition comprising a chemical exfoliant, a mechanical exfoliant, fragrance microcapsules, The unit dose article of any one of the preceding items, comprising one or more of the group of aversive agents, surfactants, colorants, enzymes, skin conditioners, degreasing agents, cosmetic agents, ingestible ingredients, and fertilizers. (Item 33) 33. The unit dose article of any one of items 30 to 32, wherein the mechanical exfoliant comprises one or more of the group of exfoliants: apricot shell, sugar, oatmeal, salt, silica, diatomaceous earth, clay, aluminum hydrate, polyvinyl alcohol microbeads, and pumice. (Item 34) 34. The unit dose article of any one of items 30 to 33, wherein the chemical exfoliant comprises one or more exfoliants from the group of alpha hydroxyl acids, beta hydroxyl acids, enzymes, salicylic acid, glycolic acid, citric acid, and malic acid. (Item 35) 2. The unit dose article of any one of the preceding items, further comprising a second composition contained by the unit dose article. (Item 36) The unit dose article of any one of the preceding items, wherein the first composition is contained by the water-soluble film. (Item 37) 37. The unit dose article of claim 35 or 36, wherein the second composition is disposed within the second inner pouch volume between the water-soluble film and the nonwoven web. (Item 38) 40. The unit dose article of any one of the preceding claims, wherein the first composition is disposed within the second inner pouch volume between the water-soluble film and the nonwoven web. (Item 39) 39. The unit dose article of any one of the preceding claims, wherein the first composition comprises a liquid. (Item 40) The unit dose article of any one of the preceding items, wherein the first composition comprises a personal care composition. (Item 41) 41. The unit dose article of any one of items 35 to 40, wherein the second composition comprises a personal care composition. (Item 42) The unit dose article of any one of the preceding items, wherein a personal care composition is provided on or in one or more of the group of the plurality of fibers, the nonwoven web, and the water-soluble film. (Item 43) 20. The unit dose article of any one of the preceding claims, wherein the nonwoven web in the form of a pouch has an outer surface facing away from the inner pouch volume, and a personal care composition is provided on the outer surface. (Item 44) 44. The unit dose article of any one of items 40 to 43, wherein the personal care composition comprises one or more compositions of the group of shampoos, conditioners, body washes, face washes, skin lotions, skin treatments, body oils, fragrances, hair treatments, bath salts, essential oils, bath bombs, and enzymes. (Item 45) The unit dose article is a water-soluble film and a nonwoven web defining an inner pouch volume. 2. The unit dose article of any one of the preceding claims, comprising a second compartment comprising one or more of the in the form of a pouch. (Item 46) 2. The unit dose article of any one of the preceding claims, wherein the unit dose article includes a third compartment comprising one or more water-soluble films in the form of a pouch defining an inner pouch volume. (Item 47) 47. The unit dose article of item 45 or 46, wherein at least one compartment is formed by a nonwoven web that is not water soluble. (Item 48) 48. The unit dose article of any one of items 45 to 47, wherein at least one compartment is formed by a nonwoven web that is soluble in water at a temperature ranging from about 0° C. to about 20° C. by MSTM 205. (Item 49) 49. The unit dose article of any one of items 45 to 48, wherein at least one compartment is formed by a nonwoven web, at least a portion of said nonwoven web is not soluble in water at or below 20° C. by MSTM 205. (Item 50) 50. The unit dose article of any one of items 45 to 49, wherein at least one compartment is formed by the nonwoven web and the water-soluble film in the form of a laminate. (Item 51) 51. The unit dose article of item 50, wherein the laminate has a degree of lamination of about 25% or less. (Item 52) 51. The unit dose article of claim 50, wherein the laminate has a degree of lamination ranging from about 50% to about 100%. (Item 53) 53. The unit dose article of any one of items 45 to 52, wherein the two compartments are provided in a side-by-side configuration. (Item 54) 54. The unit dose article of any one of items 45 to 53, wherein the two compartments overlap. (Item 55) 55. The unit dose article of any one of items 45 to 54, wherein one compartment comprises the first composition, the first composition comprising a surfactant, and a second compartment comprises a second composition comprising an enzyme. (Item 56) 2. The unit dose article of any one of the preceding items, wherein the plurality of fibers comprises at least one fiber type having a tenacity in the range of about 3 cN / dtex to about 15 cN / dtex, or about 5 cN / dtex to about 12 cN / dtex, or about 5 cN / dtex to about 10 cN / dtex. (Item 57) 2. The unit dose article of any one of the preceding items, wherein the plurality of fibers comprises at least one fiber type having an average diameter in the range of about 10 microns to about 300 microns, or about 50 microns to 200 microns, or about 50 microns to about 100 microns. (Item 58) 2. The unit dose article of any one of the preceding claims, wherein the plurality of fibers comprises at least one fiber type having a substantially uniform average diameter. (Item 59) Any of the preceding items, wherein the plurality of fibers comprises at least one fiber type having an average length in the range of about 30 mm to about 100 mm, or in the range of about 30 mm to about 60 mm. 2. The unit dose article of claim 1. (Item 60) 2. The unit dose article of any one of the preceding claims, wherein the nonwoven web is porous. (Item 61) 61. The unit dose article of claim 60, wherein the nonwoven web has a porosity of about 30% to about 90%. (Item 62) 11. The unit dose article of any one of the preceding claims, wherein the water soluble resin comprises a polyvinyl alcohol resin selected from the group of polyvinyl alcohol homopolymer, polyvinyl alcohol copolymer, and a mixture of polyvinyl alcohol homopolymer and polyvinyl alcohol copolymer, the polyvinyl alcohol resin having a degree of hydrolysis ranging from about 75% to about 99.9%. (Item 63) 2. The unit dose article of any one of the preceding claims, wherein the water soluble resin comprises a polyvinyl alcohol resin selected from the group of polyvinyl alcohol homopolymer, polyvinyl alcohol copolymer, or a mixture of polyvinyl alcohol homopolymer and polyvinyl alcohol copolymer, the polyvinyl alcohol resin having a degree of hydrolysis ranging from about 75% to about 98%. (Item 64) 20. The unit dose article of any one of the preceding claims, wherein a plasticizer is included in the water-soluble film, the fibers of the plurality of fibers, or both. (Item 65) 20. The unit dose article of any one of the preceding items, wherein the unit dose article does not begin to release the first composition for at least about 1 minute according to a liquid release test. (Item 66) 20. The unit dose article of any one of the preceding items, wherein the unit dose article does not begin to release the first composition for at least about 2 minutes according to a liquid release test. (Item 67) 20. The unit dose article of any one of the preceding items, wherein the unit dose article does not begin to release the first composition for at least about 3 minutes according to a liquid release test. (Item 68) a water-soluble film in the form of a pouch defining a first inner pouch volume, the water-soluble film comprising a water-soluble resin comprising a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a mixture of a polyvinyl alcohol homopolymer and a polyvinyl alcohol copolymer; a nonwoven web in the form of a pouch defining a second inner pouch volume containing said water-soluble film in the form of a pouch, said nonwoven web comprising a plurality of fibers comprising a first fiber type comprising a polyvinyl alcohol homopolymer fiber forming material having a degree of hydrolysis of about 75% to about 91%, and a second fiber type comprising one or both of a water-insoluble polyester and a polylactic acid fiber forming material, said water-soluble film and said nonwoven web being in the form of a laminate; a compartment comprising a personal care composition, the personal care composition comprising a surfactant, the compartment being disposed within the first inner pouch volume. (Item 69) a water-soluble film in the form of a pouch defining a first inner pouch volume, the water-soluble film comprising a water-soluble resin comprising a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a mixture of a polyvinyl alcohol homopolymer and a polyvinyl alcohol copolymer; a nonwoven web in the form of a pouch defining a second inner pouch volume containing said water-soluble film in the form of a pouch, said nonwoven web comprising a polypropylene having a degree of hydrolysis of about 92% to about 99.9%; a nonwoven web comprising a plurality of fibers comprising a first fiber type comprising a vinyl alcohol homopolymer and a second fiber type comprising one or both of a water insoluble polyester and a polylactic acid fiber forming material, said water soluble film and said nonwoven web being in the form of a laminate; a compartment comprising a personal care composition, the personal care composition comprising a surfactant, the compartment being disposed within the first inner pouch volume. (Item 70) 20. A method for preparing a unit dose article according to any one of the preceding claims, the method comprising: forming said water-soluble film into an open pouch defining an open pouch volume; adding said first composition into said open pouch volume and sealing said film to form said first inner pouch volume. A method comprising: (Item 71) Item 71. The method of item 70, wherein forming the water-soluble film into the open pouch defining the open pouch volume comprises co-thermal forming the water-soluble film and the nonwoven web, such that the water-soluble film and the nonwoven web form a laminate during pouch formation. (Item 72) 71. The method of claim 70, further comprising laminating the water-soluble film and a nonwoven web prior to forming the water-soluble film into the open pouch defining the open pouch volume. (Item 73) 73. The method of any one of items 71 to 72, wherein sealing the film to form the first inner pouch volume comprises positioning a second water-soluble film and a second nonwoven web over a portion of the pouch that is open and sealing the second water-soluble film and nonwoven web to the water-soluble film that takes the form of the open pouch, the second water-soluble film and the second nonwoven web being configured such that the second water-soluble film is adjacent the open pouch volume and such that the second water-soluble film forms an outer surface of the pouch. (Item 74) 74. The method of any one of items 71 to 73, wherein the sealing comprises heat sealing. (Item 75) 75. The method of any one of items 71 to 74, wherein the sealing comprises solvent sealing. (Item 76) 70. A method of exfoliating human skin comprising contacting the human skin with the unit dose article of any one of the preceding items.

Claims

[Claim 1] The invention described in the specification.

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