Process for making fibrous water-soluble products

Abstract

1. A method for producing a fibrous water-soluble product having particles, the method comprising: a) providing a first continuous water-soluble fibrous substrate having a first side and moving in a first direction; b) providing a discretization unit including one or more pockets with openings; c) providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket openings to at least partially fill at least one of the one or more pockets; d) delivering the first particles from the pockets through the openings onto a portion of the first side of the first continuous water-soluble fibrous substrate; and e) at least partially covering the first side of the first continuous water-soluble fibrous substrate.

Description

[Technical Field]

[0001] A process for making a fibrous water-soluble product utilizing a discretization unit. [Background technology]

[0002] Fibrous water-soluble products are of increasing interest to consumers, and the technology associated with such articles continues to evolve in terms of providing these articles with the desired active agents that enable the consumer to accomplish the tasks they wish to accomplish in the manner they wish to accomplish them.

[0003] In the consumer goods field, simply delivering the correct active agent is not enough to satisfy the consumer: the appearance and feel of the product is often important to the consumer's perception and can contribute to the desire to purchase the product.

[0004] Fibrous substrates have historically been used in consumer goods, including dryer sheets, toiletries, and wipes. Such products tend to flimsy and gather around the consumer's hands or fingers when the product is used. This can make the product difficult or uncomfortable for consumers to clean. For such products that contain active agents, it may be desirable to limit contact between the consumer's hands and the active agent. Some fibrous substrates have a surface texture that some consumers perceive as tactilely imperfect. Furthermore, when an active agent is carried by a fibrous substrate, consumers may find it uncomfortable to touch the active agent.

[0005] The production of multi-ply articles from fibrous substrates can be challenging because the individual plies of the article must be bonded together to form a coherent product. Bonding and cutting multi-ply articles can be difficult when the caliper of the individual articles varies across the surface of the article, which can easily occur where the article is loaded with particles. In addition, loading particles into a fibrous water-soluble product can also create challenges in dissolving the article. Summary of the Invention [Problem to be solved by the invention]

[0006] Given these limitations, there continues to be an unmet need for a process for making fibrous water-soluble unit dose articles having particles that can be manufactured economically and maintain acceptable dissolution. [Means for solving the problem]

[0007] Included herein is a method of producing a fibrous water-soluble product comprising particles, the method including: a) providing a first continuous water-soluble fibrous substrate having a first side and moving in a first direction; b) providing a discretization unit having one or more pockets with openings; c) providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket openings to at least partially fill at least one of the one or more pockets; d) delivering the first particles from the pockets through the openings onto a portion of the first side of the first continuous water-soluble fibrous substrate; and e) at least partially covering the first side of the first continuous water-soluble fibrous substrate.

[0008] Also included herein is a method of producing a fibrous water soluble product comprising particles, the method including: a) providing a first continuous water soluble fibrous substrate having a first side and moving in a first direction; b) providing a discretization unit having one or more pockets with openings; c) providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket openings; d) intermittently delivering the first particles from the pocket openings onto a portion of the first side of the first continuous water soluble fibrous substrate; e) metering the first particles to a target dose; and f) at least partially covering the first side of the first continuous water soluble fibrous substrate.

[0009] These and other iterations are described in more detail below. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a representation of a discretization unit with pockets. [Figure 2] This is a representation of the stator. [Figure 3] FIG. 1 is an exploded view of a discretization unit and a stator. [Figure 4] This is an expression of the combination of the stator and hopper. [Figure 5] 1 is a schematic representation of a process for making a fibrous water-soluble product. [Figure 6] 1 is a micro-CT image of a fibrous water-soluble product with particles. [Figure 7] 10 is a graph showing dose time versus angle from horizontal at the stator outlet. [Figure 8] FIG. 2 is a cross-sectional view of a discretization unit and a stator. [Figure 9] 1 is a time lapse cross-sectional view of a discretization unit and stator depositing particles onto a fibrous substrate. DETAILED DESCRIPTION OF THE INVENTION

[0011] The production of water-soluble products can be a delicate balance of materials and processes to achieve the desired end product, functionality, and performance, and to meet the economic requirements for mass production. Previous methods for producing water-soluble products with particles have involved incorporating small amounts of particles directly into a substrate, for example, by incorporating the particles into the substrate during the substrate fabrication process or by spraying the particles onto a finished substrate. However, these methods have several drawbacks. When incorporating particles into a substrate during substrate fabrication, the particles can interfere with the entrapment and entanglement process of substrate fabrication. This can lead to insufficient or uncontrolled dissolution of the substrate and / or the actual inability to form a substrate. These issues significantly limit the types and properties of particles that can be added in this type of process. These potentially limiting particle properties can include particle size, particle size distribution, chemical composition, particle surface properties (such as adhesiveness and cohesiveness), particle stability within the substrate fabrication process, and difficulty in separating incompatible particles. This addition method can also add cost to the manufacturing process because it may require solubilization of solid components to add them to the substrate. Another drawback is that it is difficult to control where the particles are applied to the substrate, which can create problems with sealing when the particles reach areas of the substrate that are to be sealed.

[0012] Despite the challenges associated with known manufacturing methods, it remains desirable to be able to load larger quantities of particles, different particle types, control where particles are located within a water-soluble product, and manufacture in an economically viable manner. This would allow for greater product flexibility. A review of possible solutions in the industry for unit dose applicators did not identify an intermittent particle applicator that could meet the basic requirements of dose frequency, individual dose mass (mass flow rate), dosing footprint, and manufacturing flexibility within practical limits. For example, auger-type intermittent particle load applications are typically limited to an operating frequency of 3.33 doses / second (nearly half the target start rate of 6 doses / second). Utilizing such technology requires substantial capital investment to "number" units in succession in an attempt to achieve a target start rate of 6 doses / second.

[0013] Another challenge with adding particles to water-soluble products is in the production of the water-soluble products. For example, one way to make water-soluble products is to use a continuous substrate. However, this continuous substrate is used to make individual products. This means that even though the substrate is continuous, particles must be applied intermittently to create individual products. To create individual products on a continuous substrate, the particles must be delivered to the substrate so that they remain primarily within a defined area, i.e., a target area. Other particle delivery devices, such as rotary feeders, are generally designed for bulk flow control and are not designed to create uniform, discrete doses. Without controlled particle delivery, this can lead to variations in the amount of particles per product or the inability to form individual products due to particles being located within the area required for sealing.

[0014] An additional challenge in controlling particle delivery to a substrate occurs where the substrate is moving. This requires coordination between the delivery of particles to the substrate and the positioning of the substrate by the delivery mechanism. In unit dose applications, the dosing interruptions are phased with the position of uncut substrate product locations on the substrate to form individual units. Therefore, the timing of particle dose delivery and substrate movement must be coordinated to allow for the formation of individual units.

[0015] Furthermore, movement of the substrate during and after particle application can exacerbate attempts to deliver particles to the desired portion of the substrate, as the particles may roll and / or fly off as they land on the moving substrate or continue to move with the substrate to complete the manufacturing process. Additionally, failure to control the footprint of the particles deposited on the substrate can result in some of the particles flowing into the area used to seal the substrate and create the water-soluble product. While a small amount of particles in this area may be acceptable, too many particles in this area can interfere with sealing and cause product defects or poor product formation. Ideally, these issues are controlled through manufacturing conditions that do not require additional corrective steps, such as vacuuming to remove loose particles, to enable more cost-effective and rapid manufacturing of products.

[0016] In searching for a solution, the inventors were interested in finding something that could be utilized for intermittent particle delivery, with the ability to precisely control particle deposition onto targeted areas of the substrate. One possible solution was the use of a gravure applicator, but gravure applicators are most commonly known for gravure printing, which involves liquids rather than particles. In the gravure printing process, an image is recessed into the surface of a metal cylinder. These recesses are very small microcavities that contain ink. The ink is most often contained in an ink tray that is contacted by the cylinder to pick up the ink, and the ink is then transferred to the substrate by pressing the cylinder against the substrate. The cavity dimensions and the contact between the inked gravure cylinder and the substrate are designed so that the dominant forces governing mass transfer are surface tension, capillary forces, and compression forces. In addition, gravure printing is highly dependent on ink viscosity, substrate speed, and the pressure applied between the gravure applicator and the substrate to facilitate the gravure printing process. In this application, the particles could not be applied in the same manner, so a gravure type applicator could not be directly applied, and the conventional gravure process required significant adaptations to be able to achieve the desired production.

[0017] First, the scale is adapted to accommodate particle delivery from a gravure applicator. Microcavities are eliminated, and larger pockets are included on the applicator (i.e., discretization unit). The use of larger pockets allows for the accommodation of both smaller and larger particles at the desired level for addition to the fibrous substrate. In addition, it is desirable to have the flexibility to dynamically change the amount of material dispensed using fixed pockets on the discretization unit. Unlike conventional gravure rotors, which are almost always locked to the desired image to be printed, the use of oversized pockets on the discretization unit allows for the use of inserts to adjust the particle dosage as desired without having to replace the entire discretization unit. The oversized pockets also allow for undesirable voids in printing applications.

[0018] Additionally, physical contact between the gravure applicator and the target substrate needs to be eliminated, as contact between the discretization unit and the substrate can damage the substrate. In the absence of physical contact between the discretization unit and the substrate, a process for particle transfer to the substrate is required that is different from that used in conventional gravure processes. The primary means for particle transfer from the discretization unit and the substrate can be gravity with appropriate settings.

[0019] A stationary part such as a stator can be utilized to facilitate the use of gravity for the compressive force to deposit the particles from the discretization unit onto the substrate. While a stator is not required in a conventional gravure process, the stator can be useful in many ways. For example, the stator can be utilized to help direct the entry and exit of particles into and from the discretization unit. Additionally, the location of the stator inlet can be optimized to help minimize the amount of particles entering the annular space between the stator and the discretization unit. Furthermore, the location of the stator outlet can affect how the particles are deposited onto the substrate and their footprint on the substrate. The use of a stator is a significant departure from a conventional gravure printing process.

[0020] As can be seen from the above description, while generally utilizing the concepts of the gravure process, the inventors have made significant modifications to accommodate such a system for use in a non-contact environment with particles.

[0021] Manufacturing Process As described above, the process for producing a substrate having particles can have two main elements: a discretization unit 200 and a stator 300. The discretization unit 200 can serve to take a flow of particles and convert it into discrete units of particles. An example of a discretization unit 200 is shown in FIG. 1. The discretization unit 200 can then deliver these discretized particle units to the substrate. This function can be achieved, for example, by including pockets 210 on the discretization unit 200 for receiving the particles.

[0022] The discretization unit 200 can have one or more pockets 210. The pockets can be fixed relative to the discretization unit, i.e., the pockets do not move away from the discretization unit. The number of pockets 210 can be optimized based on the desired and / or operable size of the discretization unit 200. They can also be optimized based on the desired delivery of particles onto the substrate. For example, the pockets can be side-by-side or top-to-bottom to allow for simultaneous delivery of multiple particle loads. These particle loads can be the same or different. The discretization unit can include, for example, about 1 to about 20 pockets, about 2 to about 20 pockets, about 3 to about 20 pockets, about 5 to about 18 pockets, about 6 to about 16 pockets, about 8 to about 16 pockets, about 8 to about 12 pockets, or any combination thereof.

[0023] The locations of the pockets 210 on the discretization unit 200 can be, for example, equidistant around the circumference of the discretization unit. Equidistant pocket locations on the discretization unit are preferred because, when operating at a fixed speed, non-equidistant pocket locations can result in periodic and / or non-constant motion profiles for the discretization unit that can be difficult to control and regulate at high operating speeds. They can also cause timing issues for particle entry and / or release from the pockets.

[0024] The pockets 210 on the discretization unit 200 can be sized as needed for the desired dose. This can include cross, machine, and depth dimensions. The cross direction is aligned with the axis of rotation of the discretization unit. With respect to the cross direction, this can contribute to the width of the particle footprint when the particles are placed on the substrate. A wider pocket in the cross direction results in a larger particle footprint on the substrate. The cross dimension can also affect particle entry and release from the pocket. A larger cross dimension can allow for more rapid release of particles onto the substrate and entry of particles into the pocket. These can be important parameters to consider when assembling a particle delivery system. The desired cross dimension of the pocket can be, for example, about 1 mm to about 100 mm, about 3 mm to about 95 mm, about 10 mm to about 90 mm, about 20 mm to about 50 mm, about 25 mm to about 40 mm, or any combination thereof.

[0025] The machine direction is perpendicular to the cross direction. The dimensions of the pocket in the machine direction can also contribute to the particle footprint on the substrate. The longer the machine direction dimension, the longer the particle's potential footprint on the substrate. Therefore, the machine direction dimension can be limited based on the desired particle footprint. The machine direction dimension can also affect particle entry into and release from the pocket. The desired machine direction dimension of the pocket can be, for example, about 1 mm to about 100 mm, about 3 mm to about 95 mm, about 10 mm to about 90 mm, about 20 mm to about 50 mm, about 25 mm to about 40 mm, about 10 mm to about 15 mm, about 8 mm to about 12 mm, or any combination thereof.

[0026] There is an additional consideration regarding the machine direction dimension. The machine direction dimension in combination with the stator inlet size helps define the exposure time of the pockets to particle infeed. For a given discretization unit rotation speed, an increase in the machine direction dimension allows the pockets "more time to fill" with particles. So, it is a balance between a machine direction dimension that is long enough to adequately fill with particles and a machine direction dimension that is small enough so as not to contribute to unnecessarily long dosing times.

[0027] The pocket also has a depth. The depth can be optimized to allow for particle ingress and egress. The pocket depth can also be optimized to allow for particle ingress and air egress from the pocket. A minimum depth is preferred to allow particles to fit into the pocket and minimize particle sealing on the stator. For example, the pocket can have a depth of about 1 to about 25 mm, preferably about 2 to about 15 mm, or about 3 to about 10 mm. Particle sealing can cause hygiene issues in the system and can lead to malfunction over time.

[0028] The pockets can also have a certain shape. The shape can be any that meets the needs of the desired particle delivery. For example, the pockets can be rectangular prisms, cubes, cones, pyramids, concave "v" shapes, divots, or cylinders, and can have triangular or rectangular cross sections, or any combination thereof. For example, a grid of depressions can be a repeating pattern on the circumference of a discretized unit. In this pattern, for example, a 5x5 grid can be a unit dose, replacing a single pocket per unit dose. When the pockets are depressions, the number of pockets can be much greater than the number mentioned above, for example, about hundreds to thousands of depressions. For elongated particles such as prills, a preferred shape can be a concave "v" shape. In addition, the interior of the pockets can be textured.

[0029] The discretization unit 200 can also function as a metering device. In this configuration, the pocket 210 or collection of pockets used together to create a unit dose on the discretization unit 200 is the exact volume of the target dose of particles. If the discretization unit 200 is not also metering, the pocket 210 will likely be oversized for the target dose, and a separate metering device, such as a weight loss feeder, can be used to meter the flow of particles into the pocket 210 of the discretization unit 200. The target dose of the discretization unit pocket can be by weight or by volume. Using particles can be more accurate since particle density can vary from particle to particle. A target dose in weight can be, for example, about 0.1 g to about 15 g, about 0.2 g to about 15 g, about 0.3 g to about 10 g, about 0.4 g to about 8 g, or about 0.1 g to about 4.0 g. A target dose in volume can be, for example, about 0.1 cm. 3 ~about 8cm 3 , about 0.1cm 3 ~about 7cm 3 , about 0.1cm 3 ~approx. 6cm 3 , about 0.1cm 3 ~about 5cm 3 , and approximately 0.1 cm 3 ~Approx. 4.0cm 3 , or any combination thereof.

[0030] The discretization unit is movable and preferably rotates. The discretization unit may rotate, for example, at a speed of about 10 rpm to about 100 rpm. The discretization unit 200 may be a rotor. A rotor can generally be described as a rotating assembly. It is generally a driven element controlled by a motor. The rotor can be rotated at a desired speed. The speed may be uniform or variable. The speed contributes to the residence time of the pockets while the particles are entering the pockets. When utilizing a non-uniform speed, the discretization unit may be decelerated to allow the particles to enter the pockets through the stator inlet and then accelerated to pass through a portion of the discretization unit without pockets. Similarly, the discretization unit may be accelerated to capture fewer particles at the stator inlet and then decelerated to pass through a portion of the discretization unit without pockets. The same applies to the exit from the pockets of the discretization unit. The discretization unit may be accelerated or decelerated at the point of particle exit to accommodate a desired particle footprint on the substrate or to aid in coordinating the timing of the dose on the substrate.

[0031] The rotor can be uniform or non-uniform, depending on the desired configuration. The advantage of a highly uniform rotor is that it allows the process to operate at a set speed to achieve the desired units per minute target. It also allows for better control of the annular space between the discretization unit and the stator. Rotors with varying pocket spacing can also be utilized, including motion profiles versus rotational speed.

[0032] The next element for the particle delivery system can include a stator 300. An example of a stator can be seen in FIG. 2, and an exploded view of the stator 300 and discretization unit 200 can be seen in FIG. 3. The stator 300 can include one or more particle inlets 310. The stator 300 can control the flow of particles into the pockets 210 of the discretization unit 200. This can be done, for example, through the design of the particle inlets 310. The size, shape, and location of the inlets 310 around the circumference of the stator 300 can affect the efficiency with which the discretization unit pockets 210 fill with particles. For example, as discussed above, increasing the stator inlet opening increases the ability to fill the pockets at higher rotational speeds. For example, by changing the stator inlet opening from a length (in the direction of rotation) of 6 mm to approximately 17 mm, the maximum rate of administration of all pocket doses increased from approximately 2 doses / second to 8 doses / second without any other changes.

[0033] The stator 300 may be a housing for the discretization unit 200 and may be positioned around the discretization unit 200 (see FIGS. 3 and 4). The location of the stator relative to the discretization unit also contributes to another parameter—the annular space between the discretization unit and the stator. The specifications and tolerances of this component can ensure minimal particle migration into this annular space, which in turn may contribute to particle shearing / breakage, surface fouling, and / or clogging. Additional mechanisms may be added to help prevent or minimize particle ingress into the annular space, for example, mechanical seals or blades may be utilized to prevent particles from entering the gap between the discretization unit and the stator.

[0034] The annular space between the discretization unit and the stator can be adjusted as needed, depending on, for example, the size of the particles to be deposited on the substrate, machining constraints, cost, and assembly feasibility. The annular space can be, for example, about 10 μm to about 125 μm, about 20 μm to about 100 μm, about 20 μm to about 90 μm, about 30 μm to about 80 μm, about 40 μm to about 80 μm, about 50 μm to about 75 μm, or any combination thereof.

[0035] Another way to minimize particles entering the annular space is to minimize contact between the particles and the annular space. This can be done by positioning the stator inlet so that it delivers particles from the pinch point to the discretization unit downhill. The location of the pinch point is determined by the stator inlet wall and the direction of rotation of the discretization unit. A visualization of this concept can be seen in Figure 8, which shows the pinch point on the left-hand representation and how moving the stator inlet to a downhill position minimizes particle impingement on the pinch point (i.e., the annular space). This minimization helps keep particle integrity intact, which is especially important for particles that generate benefits upon rupture, such as fragrance microcapsules. Minimization also helps prevent the generation of fines through shear processes that alter the particle size distribution of particles being deposited on the substrate.

[0036] Additional features of the stator 300 can include the size and location of the outlet 320 along the stator circumference. The outlet design, combined with the pocket geometry of the discretization unit, can primarily contribute to particle laydown on the substrate. For example, slight modifications to the stator outlet design can dramatically increase or decrease particle ejection time from a gravure process, which, when combined with a moving substrate, directly translates to modifying the particle laydown footprint on the substrate. In particular, a stator opening approximately 45 degrees from horizontal provides the optimal minimum ejection time for most particles, as can be seen in Figure 7. It is also beneficial to design the stator outlet so that the final portion of particles exiting the stator outlet have a trajectory that is primarily in the machine direction of the substrate, rather than primarily downward. The net effect is that it reduces the overall particle footprint, speeding up the process and providing the economic benefit of having a better footprint on the substrate.

[0037] The discretization unit and stator can be incorporated into a process for making a fibrous water-soluble product, as described below.

[0038] Method for making a fibrous water-soluble product having particles The process for making a fibrous water-soluble product can include first making a fibrous water-soluble substrate.The substrate can be continuous or discontinuous.A description of the process for making a water-soluble fibrous substrate can be found, for example, in U.S. Patent No. 10,683,618, which is incorporated herein by reference.

[0039] Once the substrate is formed, it can be provided to a process. A single substrate can be provided, or multiple substrates, or even a parent substrate can be provided that is cut into multiple substrates during the manufacturing process. An example of a single substrate being formed into multiple substrates can be seen in FIG. 5. In FIG. 5, a parent continuous substrate 59 can be formed on a die block assembly 40 and then cut in the machine direction MD by a knife 70, such as a rotary cutting knife that cuts in the machine direction MD, to form a first continuous substrate 60 and a second continuous substrate 65. Cutting a second substrate from the parent continuous ply substrate 59 can be practical to provide better manufacturing quality control.

[0040] Whether starting with two substrates, a single substrate, or a parent substrate that will be separated into multiple individual substrates, particles can be added to the substrate utilizing the discretization unit 200 and stator 300. The particles are fed into a hopper 400, which feeds into the stator 300. At least a portion of the particles pass through a stator inlet 310 and into the discretization unit pocket 210. The discretization unit pocket 210 can be fully or partially filled with particles. The discretization unit pocket can be sized to meter a dose. In this implementation, the discretization unit pocket dimensions determine the dose volume. This dose volume can be changed, for example, by modifying the discretization unit to one with a different sized pocket or, for example, by adding a pocket insert to adjust to a desired volume. The dose can also be metered upstream of the discretization unit, for example, by a metering device. In this implementation, the discretization unit pocket can be oversized and then filled to the target dose as controlled by the metering device.

[0041] The substrate can have a target area for particle application and / or laydown. The target area is the portion of the substrate where particle application is desired. The configuration of the gravure device can affect the ability of the delivered particles to be applied to and remain within the target area. The gravure process can allow about 75% or more, about 80% or more, about 85% or more, about 90% or more, about 95% or more, or most preferably about 97% or more of the particle deposits delivered from the pockets to remain within the target area after exiting the discretization unit, e.g., the pocket opening, or until the substrate containing the particles is covered and / or sealed. Multiple pockets can deliver particles to the same target area of ​​the substrate.

[0042] As can be seen in FIG. 9, the discretization unit rotates to bring the particles to the stator outlet. The discretization unit can rotate either in the same direction as the substrate (preferred) or in the opposite direction to the substrate. The particles exit the discretization unit pocket, pass through the stator outlet, and are deposited onto the substrate. The substrate can be stationary or moving during the deposition process. For example, the substrate can be moving at a speed of about 15 meters per minute or more, about 20 meters per minute or more, about 25 meters per minute or more, or about 30 meters per minute or more, or preferably about 30 m / min to about 60 m / min. Gravity can help the particles exit the discretization unit pocket and deposit onto the substrate located below the discretization unit.

[0043] The substrate can be any reasonable distance from the stator outlet. Generally, this distance is minimized to reduce particle velocity and, therefore, particle rebound upon contact with the substrate. The distance from the stator outlet to the substrate should not be too close, otherwise it may scrape the substrate. In one example, a target distance of approximately 1 cm from the stator outlet to the substrate surface is used. Additionally, airflow through the substrate, a vacuum through the substrate, or an air curtain can be utilized to help contain particle rebound or movement upon contact with the substrate. Furthermore, the substrate can be at least partially coated with a material to help the particles adhere to the substrate and / or minimize particle rebound upon application to the substrate. This can include any material that makes the substrate itself sticky, such as water or any material that partially wets the particles and makes them sticky. These materials can be other liquid actives, such as fragrances, silicones (e.g., antifoam agents), etc. The substrate can also be, for example, an adhesive. Suitable adhesives can be found in "Viscoelastic Windows of Pressure-Sensitive Adhesives," EPChang, J. Adhesion 34 (1991) 189-200. These materials can be applied to the substrate, for example, by spraying. This can be in a pattern or randomly.

[0044] Once the particles are positioned on the substrate, a second portion of the substrate or a second substrate is positioned on top of the first substrate on which the particles are deposited. Once one or more substrates are positioned as desired, they can be bonded to one another, for example, by thermal bonding. Thermal bonding can be practical when one or more of the layers contain a thermoplastic powder, optionally a water-soluble thermoplastic material. Thermal bonding can also be practical when the fibers comprising one or more of the substrates are thermoplastic. The substrates can optionally be calendar bonded, point bonded, ultrasonic bonded, infrared bonded, air bonded, needle punched, hydroentangled, fusion bonded, adhesive bonded, or any other known technical method for bonding layers of material.

[0045] The water-soluble products 5 may be separated from one another by a die cutter 160, optionally a rotary die cutter 160. The rotary die cutter 160 comprises a die roll and an anvil roll, which rotate in opposite directions.

[0046] Substrates can be bonded together and die-cut in a single step using a reciprocating bonding and die-cutting device or a single rotary bonding and die-cutting device. In a rotary bonding and die-cutting device that combines bonding and die-cutting, the die is shaped to provide die cuts that pinch the material to be cut between the knife edge of the die and the smooth surface of the anvil. Additionally, the die is shaped to compress portions of the product or continuous substrate and layers thereof together to bond them together. The die can be a patterned die that provides cutting and bonding patterns in plies, continuous ply substrates, and layers thereof. Optionally, the die can be heated, which can be practical for thermal bonding.

[0047] To be economically viable, the manufacturing process can have a target minimum number of fibrous water-soluble product doses per second. This can be, for example, about 6 water-soluble product doses per second. The manufacturing process can have a target of about 100 to about 1000 doses per minute per lane.

[0048] Fibrous water-soluble products The substrate can be a fibrous water-soluble substrate, as described above. The fibrous water-soluble substrate can be continuous or discrete, as shown in Figures 1 and 2. The fibrous water-soluble substrate can be utilized in the formation of fibrous water-soluble products, which are discussed in more detail below.

[0049] The fibrous water-soluble product can include one or more layers. These layers may be stacked on top of each other. The layers may be placed directly on top of each other, may have particles between them, or a combination thereof. For example, as can be seen in FIG. 5, one substrate layer 500 is at the bottom, particles 510 are on top of it, a second substrate layer 520 is on top of the particles 510, a second set of particles 530 is on top of the second layer 520, and a third substrate layer 540 is stacked on top of the second set of particles 530 and the second layer 520 to form the fibrous water-soluble product. The edges of the layers appear sandwiched in FIG. 5 because they are pressed together and sealed to hold the particles inside.

[0050] The fibrous water soluble unit dose article may comprise 50% or more bio-based material, for example, 50% to 95% bio-based material. Some of the individual components of the fibrous water soluble unit dose article may be entirely bio-based to create an article with a total bio-based content of greater than 50%.

[0051] These fibrous water-soluble unit dose articles are capable of dissolving under a variety of washing conditions, such as low temperatures, low water volumes and / or short wash cycles or cycles where the consumer overloads the washing machine, especially with items having high water absorption capacity, while delivering sufficient active agent to exert the intended effect on the targeted consumer substrate (with performance similar to today's liquid products).

[0052] The surface of the fibrous water-soluble unit dose article may include a printed area. The printed area may cover from about 10% to about 100% of the surface of the article. The printed area may include ink, pigment, dye, bluing agent, or a mixture thereof. The printed area may be opaque, translucent, or transparent. The printed area may include a single color or multiple colors. The printed area may be present on two or more sides of the article and may include explanatory text, graphics, etc. The surface of the water-soluble unit dose article may include an aversive agent, such as a bittering agent. Suitable bittering agents include, but are not limited to, naringin, sucrose octaacetate, quinine hydrochloride, denatonium benzoate, or mixtures thereof. Any suitable concentration of the aversive agent may be used. Suitable concentrations include, but are not limited to, 1 to 5000 ppm, or even 100 to 2500 ppm, or even 250 to 2000 ppm.

[0053] The fibrous water-soluble unit dose article may, for example, exhibit a thickness of greater than 0.01 mm, and / or greater than 0.05 mm, and / or greater than 0.1 mm, and / or not greater than about 100 mm, and / or not greater than about 50 mm, and / or not greater than about 20 mm, and / or not greater than about 10 mm, and / or not greater than about 5 mm, and / or not greater than about 2 mm, and / or not greater than about 0.5 mm, and / or not greater than about 0.3 mm.

[0054] The fibrous water-soluble unit dose article has a density of about 500 grams / m 2 ~approximately 5,000 grams / m 2 , or about 1,000 grams / m 2 ~approximately 4,000 grams / m 2 , or about 1,500 grams / m 2 ~approximately 3,500g / m 2 , or about 2,000 grams / m 2 ~approximately 3,000 grams / m 2 , or any combination thereof.

[0055] The fibrous water soluble unit dose article may exhibit different regions, for example, regions of different basis weight, density, caliper, and / or wetting characteristics. The fibrous water soluble unit dose article may be compressed at the end sealing points. The fibrous water soluble unit dose article may include a texture on one or more of its surfaces. The surface of the fibrous water soluble unit dose article may include a pattern, such as a non-random repeating pattern. The fibrous water soluble unit dose article may include openings. The fibrous water soluble unit dose article may include a fibrous structure having discrete regions of fibrous elements that are distinct from other regions of fibrous elements in the structure. The fibrous water soluble unit dose article may be used as is or may be coated with one or more active agents.

[0056] The fibrous water-soluble unit dose article may include one or more plies. The fibrous water-soluble unit dose article may include at least two, and / or at least three, and / or at least four, and / or at least five plies. The fibrous plies may be fibrous structures. Each ply may include one or more layers, such as one or more fibrous element layers, one or more particle layers, and / or one or more fibrous element / particle mixture layers. The layers may be sealed. In particular, the particle layer and the fibrous element / particle mixture layer may be sealed to prevent particle leakage. The water-soluble unit dose article may include multiple plies, each including two layers, one fibrous element layer and one fibrous element / particle mixture layer, and the multiple plies are sealed together (e.g., at the edges). In addition to preventing particle leakage, the sealing may help the unit dose article maintain its original structure. However, when the water-soluble unit dose article is added to water, the unit dose article dissolves, releasing particles into the wash solution.

[0057] The fibrous water-soluble unit dose can be in the form of any three-dimensional structure. The fibrous water-soluble unit dose article can be perforated. The article can also be cut or shaped into various sizes for different uses. For example, the water-soluble unit dose can be in the form of a square, a rolled square, a kite, a rectangle, a triangle, a circle, an oval, and mixtures thereof.

[0058] A fibrous water soluble unit dose may contain fewer than 10 components. A water soluble unit dose may contain, for example, 3 to 9 components, such as 4 components, 5 components, 6 components, 7 components, or 8 components.

[0059] The fibrous water-soluble unit dose articles disclosed herein include a water-soluble fibrous structure and one or more particles. The fibrous water-soluble fibrous structure may include a plurality of fibrous elements, e.g., a plurality of filaments. One or more particles, e.g., one or more active agent-containing particles, may be distributed throughout the structure. The fibrous water-soluble unit dose article may include a plurality of two or more and / or three or more fibrous elements that are intertwined or otherwise associated with one another to form the fibrous structure, and one or more particles that may be distributed throughout the fibrous structure.

[0060] The fibrous water-soluble unit dose article may include a water-soluble fibrous structure. The water-soluble fibrous structure may include two or more different fibrous elements. Non-limiting examples of differences between the fibrous elements include physical differences such as differences in diameter, length, texture, shape, stiffness, and elasticity; chemical differences such as crosslinking level, solubility, melting point, Tg, active agent, filament-forming material, color, active agent concentration, basis weight, filament-forming material concentration, the presence of any coating on the fibrous elements, biodegradability, hydrophobicity, and contact angle; differences in whether the fibrous elements lose their physical structure when exposed to the intended use conditions; differences in whether the morphology of the fibrous elements changes when exposed to the intended use conditions; and differences in the rate at which the fibrous elements release one or more of their active agents when exposed to the intended use conditions. Two or more fibrous elements within the fibrous structure may contain different active agents. This may be the case when different active agents, such as an anionic surfactant and a cationic polymer, are incompatible with each other. When different fibrous elements are used, the resulting structures may exhibit different wetting, water absorption, and solubility characteristics.

[0061] Fibrous Structure The fibrous structure includes one or more fibrous elements. The fibrous elements can be associated with one another to form a structure. The fibrous structure can include particles within and / or on the structure. The fibrous structure can be homogeneous, layered, single, zoned, or otherwise as desired, with different active agents defining various of the aforementioned portions.

[0062] The fibrous structure may include one or more layers, which together form a ply.

[0063] Fibrous elements The fibrous elements can be water-soluble. The fibrous elements can include one or more filament-forming materials and / or one or more active agents, such as surfactants. The one or more active agents can be releasable from the fibrous elements, such as when the fibrous elements and / or a fibrous structure including the fibrous elements are exposed to intended use conditions.

[0064] Fibrous elements may be spun from the filament-forming composition, also referred to as the fibrous element-forming composition, by any suitable spinning process operation, such as meltblowing, spunbonding, electrospinning, and / or rotary spinning.

[0065] As used herein, "filament-forming composition" and / or "fibrous element-forming composition" refer to a composition suitable for producing fibrous elements, such as by meltblowing and / or spunbonding. The filament-forming composition includes one or more filament-forming materials that exhibit properties that make the material suitable for spinning into fibrous elements. The filament-forming material may include a polymer. In addition to the one or more filament-forming materials, the filament-forming composition may include one or more active agents, such as surfactants. Additionally, the filament-forming composition may include one or more polar solvents, such as water, in which one or more, e.g., all, of the filament-forming materials and / or one or more, e.g., all, of the active agents are dissolved and / or dispersed prior to spinning fibrous elements, such as filaments, derived from the filament-forming composition.

[0066] The filament-forming composition may include two or more different filament-forming materials. Thus, the fibrous elements may be monocomponent (one type of filament-forming material) and / or multicomponent, such as bicomponent. Two or more different filament-forming materials may be randomly combined to form the fibrous elements. Two or more different filament-forming materials may be regularly combined to form the fibrous elements, such as sheath-core bicomponent fibrous elements, which, for purposes of this disclosure, are not considered to be random mixtures of different filament-forming materials. Bicomponent fibrous elements may be in any configuration, such as side-by-side, sheath-core, islands-in-the-sea, etc.

[0067] The fibrous elements may be substantially free of alkyl alkoxylated sulfate. Each fibrous element may contain, based on the dry fibrous element, about 0%, about 0.1%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40% to about 0.2%, about 1%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, or about 50% by weight of alkyl alkoxylated sulfate. The amount of alkyl alkoxylated sulfate in each fibrous element is small enough so as not to affect its processing stability and film solubility. When alkyl alkoxylated sulfates are dissolved in water, they can undergo a highly viscous hexagonal phase at certain concentrations, e.g., 30-60% by weight, resulting in a gel-like substance. Therefore, when incorporated into fibrous elements in significant amounts, alkyl alkoxylated sulfates can significantly slow the dissolution of water-soluble unit dose articles in water, or even worse, leave undissolved solids behind. Accordingly, most such surfactants are formulated into particles.

[0068] Each fibrous element may contain at least one filament-forming material and an active agent, preferably a surfactant. The surfactant may have relatively low hydrophilicity because it is less likely to form a viscous, gel-like hexagonal phase when diluted. The use of such surfactants in the formation of filaments can effectively reduce gel formation during washing, which in turn can result in faster dissolution and less or no residue in washing. The surfactant may be, for example, a non-alkoxylated C6-C 20 Linear or branched alkyl sulfate (AS), C6-C 20 The surfactant may be selected from the group consisting of C6-C7 alkyl benzene sulfonates (LAS), and combinations thereof. 20 The surfactant may be a linear alkylbenzene sulfonate (LAS). LAS surfactants are well known in the art and can be readily obtained by sulfonating commercially available linear alkylbenzenes. Exemplary C6-C8 surfactants that can be used include: 20 Linear alkylbenzene sulfonates include C6 to C 20 Alkali metal, alkaline earth metal, or ammonium salts of linear alkylbenzenesulfonic acid, such as C 11 ~C 18 or C 11 ~C 14 Examples include sodium, potassium, magnesium, and / or ammonium salts of linear alkylbenzene sulfonic acid. 12 Sodium or potassium salts of linear alkylbenzene sulfonic acid, e.g., C 12 The sodium salt of linear alkylbenzene sulfonic acid, i.e., sodium dodecylbenzene sulfonate, can be used as the first surfactant.

[0069] the fibrous elements comprise at least about 5% by weight, and / or at least about 10% by weight, and / or at least about 15% by weight, and / or at least about 20% by weight, and / or less than about 80% by weight, and / or less than about 75% by weight, and / or less than about 65% by weight, and / or less than about 60% by weight, and / or less than about 55% by weight, and / or less than about 50% by weight, and / or less than about 45% by weight, and / or less than about 40% by weight, and / or less than about 35% by weight, and / or less than about 30% by weight, and / or less than about 25% by weight of filament-forming material; The fibrous elements may comprise more than about 20% by weight, and / or at least about 35% by weight, and / or at least about 40% by weight, and / or at least about 45% by weight, and / or at least about 50% by weight, and / or at least about 55% by weight, and / or at least about 60% by weight, and / or at least about 65% by weight, and / or at least about 70% by weight, and / or less than about 95% by weight, and / or less than about 90% by weight, and / or less than about 85% by weight, and / or less than about 80% by weight, and / or less than about 75% by weight of an active agent, preferably a surfactant, based on the dry fibrous elements and / or the dry fibrous structure. The fibrous elements may comprise more than about 80% by weight of surfactant based on the dry fibrous elements and / or the dry fibrous structure.

[0070] Preferably, each fibrous element can be characterized by a sufficiently high total surfactant content, for example, at least about 30% by weight, or at least about 40% by weight, or at least about 50% by weight, or at least about 60% by weight, or at least about 70% by weight of the first surfactant, based on the dry fibrous element and / or dry fibrous structure.

[0071] The total concentration of filament-forming material present in the fibrous elements can be from about 5% to less than about 80% by weight based on the dry fibrous elements and / or dry fibrous structure, and the total concentration of surfactant present in the fibrous elements can be from more than about 20% to about 95% by weight based on the dry fibrous elements and / or dry fibrous structure.

[0072] One or more of the fibrous elements may comprise at least one additional surfactant selected from the group consisting of other anionic surfactants (i.e., other than AS and LAS), nonionic surfactants, zwitterionic surfactants, amphoteric surfactants, cationic surfactants, and combinations thereof.

[0073] Other suitable anionic surfactants include C6-C 20 Linear or branched alkyl sulfonates, C6-C 20 Linear or branched alkyl carboxylates, C6-C 20 Linear or branched alkyl phosphates, C6-C 20 Linear or branched alkyl phosphonates, C6-C 20 Alkyl N-methyl glucose amide, C6-C 20 methyl ester sulfonate (MES), and combinations thereof.

[0074] Suitable nonionic surfactants include alkoxylated fatty alcohols. Nonionic surfactants have the formula R(OC2H4) n OH ethoxylated alcohols and ethoxylated alkylphenols, where R is selected from the group consisting of aliphatic hydrocarbon radicals containing from about 8 to about 15 carbon atoms and alkylphenyl radicals where the alkyl group contains from about 8 to about 12 carbon atoms, and the average value of n is from about 5 to about 15. Non-limiting examples of nonionic surfactants useful herein include C8-C 18 Alkyl ethoxylates, such as NEODOL® nonionic surfactants from Shell, where the alkoxylate units can be ethyleneoxy units, propyleneoxy units, or mixtures thereof, C6-C 12 Alkylphenol alkoxylate, C 12 ~C 18 C6-C with alcohol and ethylene oxide / propylene oxide block polymer 12 Alkylphenol condensates (such as Pluronic® manufactured by BASF); C14 ~C 22 Medium-chain branched alcohols, BA, C 14 ~C 22 Medium-chain branched alkyl alkoxylate (BAE) x (wherein x is 1 to 30); alkyl polysaccharides; specifically alkyl polyglycosides; polyhydroxy fatty acid amides, and ether-end-capped poly(oxyalkylated) alcohol surfactants. Suitable nonionic detersive surfactants also include alkyl polyglucosides and alkyl alkoxylated alcohols. Suitable nonionic surfactants also include those sold by BASF under the trade name Lutensol®.

[0075] Non-limiting examples of cationic surfactants include quaternary ammonium surfactants, which may have up to 26 carbon atoms, such as alkoxylate quaternary ammonium (AQA) surfactants, dimethylhydroxyethyl quaternary ammonium, dimethylhydroxyethyl lauryl ammonium chloride, polyamine cationic surfactants, cationic ester surfactants, and amino surfactants, such as amidopropyldimethyl amine (APA). Suitable cationic detersive surfactants also include alkylpyridinium compounds, alkylquaternary ammonium compounds, alkylquaternary phosphonium compounds, alkyl tertiary sulfonium compounds, and mixtures thereof.

[0076] Suitable cationic detersive surfactants are quaternary ammonium compounds having the general formula: (R)(R1)(R2)(R3)N + X - wherein R is a linear or branched, substituted or unsubstituted C 6~18R1 and R2 are independently selected from methyl or ethyl moieties, R3 is a hydroxyl, hydroxymethyl or hydroxyethyl moiety, and X is an anion that provides charge neutrality, suitable anions include halides such as chloride, sulfates, and sulfonates. Suitable cationic detersive surfactants include mono-C 6~18 Alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride. A highly suitable cationic detersive surfactant is mono-C 8~10 Alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride, mono-C 10~12 Alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride, and mono-C 10 Alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride.

[0077] Suitable examples of zwitterionic surfactants include derivatives of secondary and tertiary amines, including derivatives of heterocyclic secondary and tertiary amines; derivatives of quaternary ammonium, quaternary phosphonium, or tertiary sulfonium compounds; betaines, including alkyl dimethyl betaines, cocodimethylamidopropyl betaines, and sulfo and hydroxy betaines; C8-C 18 (For example, C 12 ~C 18 ) amine oxide; N-Alkyl-N,N-dimethylamino-1-propanesulfonate (alkyl group is C8-C 18 (It may be possible that

[0078] Suitable amphoteric surfactants include aliphatic derivatives of secondary or tertiary amines, or aliphatic derivatives of heterocyclic secondary and tertiary amines, wherein the aliphatic group can be linear or branched, one of the aliphatic substituents contains at least about 8 carbon atoms or about 8 to about 18 carbon atoms, and at least one of the aliphatic substituents contains an anionic water-solubilizing group, such as carboxy, sulfonate, or sulfate.Suitable amphoteric surfactants also include sarcosinates, glycinates, taurinates, and mixtures thereof.

[0079] The fibrous elements may comprise surfactant systems containing only anionic surfactants, for example, either a single anionic surfactant or a combination of two or more different anionic surfactants. Alternatively, the fibrous elements may comprise composite surfactant systems containing, for example, a combination of one or more anionic surfactants with one or more nonionic surfactants, or a combination of one or more anionic surfactants with one or more zwitterionic surfactants, or a combination of one or more anionic surfactants with one or more amphoteric surfactants, or a combination of one or more anionic surfactants with one or more cationic surfactants, or a combination of all of the above types of surfactants (i.e., anionic, nonionic, amphoteric, and cationic).

[0080] Generally, fibrous elements are elongated, slender particles whose length greatly exceeds their average diameter, e.g., having a length to average diameter ratio of at least about 10. Fibrous elements can be filaments or fibers. Filaments are relatively longer than fibers. Filaments can have lengths of about 2 inches or more, and / or about 3 inches or more, and / or about 4 inches or more, and / or about 6 inches or more. Fibers can have lengths less than about 2 inches, and / or less than about 1.5 inches, and / or less than about 1 inch.

[0081] The one or more filament-forming materials and active agents may be present in the fibrous elements in a weight ratio of the total concentration of filament-forming materials to active agent of about 2.0 or less, and / or about 1.85 or less, and / or less than about 1.7, and / or less than about 1.6, and / or less than about 1.5, and / or less than about 1.3, and / or less than about 1.2, and / or less than about 1, and / or less than about 0.7, and / or less than about 0.5, and / or less than about 0.4, and / or less than about 0.3, and / or greater than about 0.1, and / or greater than about 0.15, and / or greater than about 0.2. The one or more filament-forming materials and active agents may be present in the fibrous elements in a weight ratio of the total concentration of filament-forming materials to active agent of about 0.2 to about 0.7.

[0082] The fibrous elements may comprise from about 10% to less than about 80% by weight of a filament-forming material, such as a polyvinyl alcohol polymer, a starch polymer, and / or a carboxymethyl cellulose polymer, based on the dry fibrous elements and / or the dry fibrous structure, and from about 20% to about 90% by weight of an active agent, such as a surfactant, based on the dry fibrous elements and / or the dry fibrous structure. The fibrous elements may further comprise a plasticizer (e.g., glycerin) and / or an additional pH adjuster (e.g., citric acid). The fibrous elements may have a weight ratio of filament-forming material to active agent of about 2.0 or less. The filament-forming material may be selected from the group consisting of polyvinyl alcohol, starch, carboxymethyl cellulose, polyethylene oxide, and other suitable polymers, particularly hydroxyl-containing polymers and their derivatives. The filament-forming material may have a weight average molecular weight ranging from about 100,000 g / mol to about 3,000,000 g / mol. In this range, it is believed that the filament-forming material may provide an extensional rheology that is not so elastic that fiber attenuation is inhibited during the fiber making process.

[0083] The one or more active agents may be releasable and / or may be released when the fibrous elements and / or fibrous structures comprising the fibrous elements are exposed to intended use conditions. The one or more active agents in the fibrous elements may be selected from the group consisting of surfactants, organic polymeric compounds, and mixtures thereof.

[0084] The fibrous elements may exhibit diameters of less than about 300 μm, and / or less than about 75 μm, and / or less than about 50 μm, and / or less than about 25 μm, and / or less than about 10 μm, and / or less than about 5 μm, and / or less than about 1 μm. The fibrous elements may exhibit diameters greater than about 1 μm. The diameter of the fibrous elements can be used to control the release rate of one or more active agents present in the fibrous elements and / or the rate of degradation and / or change in the physical structure of the fibrous elements.

[0085] particle The particles may be incorporated into the above-described fibrous water-soluble products at a level of, for example, about 0.1 g to about 30 g. The type of particles utilized may be any that is compatible with the manufacturing system. One parameter that may contribute to the success of particle deposition by this method is particle flowability. Particle flowability (f p ) can be defined as the ratio of the consolidation stress (cs) to the unconfined yield strength (ys). p The larger the f, the better the particle flow. p <1 is not liquidity, f p >1 but less than 2 is very cohesive, f p is considered to be cohesive when f is between 2 and 4. p is considered to be free-flowing when f is between 4 and 10. p An f of 10 or greater is considered free-flowing. In the process described above, an f of about 4 or greater is considered free-flowing. pParticles having a value of 0.01 to 0.000 are preferred. The level of fluidity can be determined by the fluidity methods listed below. The fluidity of the particles can be, for example, about 1 or more, about 2 or more, about 3 or more, about 4 or more, about 5 or more, about 5 or more, about 6 or more, about 7 or more, about 8 or more, about 9 or more, about 10 or more, or up to about 1000.

[0086] The particles may be powders, granules, agglomerates, inclusions, microcapsules, and / or small spheres. The particles may be produced using many methods well known in the art, such as spray drying, agglomeration, extrusion, granulation, encapsulation, tableting, and combinations thereof. The shape of the particles may be in the form of a sphere, rod, dish, tube, square, rectangle, disk, star, fiber, or may have a regular or irregular random shape. The particles may have a D50 particle size of about 100 μm to about 1600 μm.

[0087] The particles may comprise a mixture of chemically different particles such as: surfactant particles, including surfactant aggregates, surfactant extrudates, surfactant needles, surfactant noodles, surfactant flakes; phosphate particles; zeolite particles; silicate particles, especially sodium silicate particles; carbonate particles, especially sodium carbonate particles; polymer particles, such as carboxylate polymer particles, cellulose-based polymer particles, starch particles, polyester particles, polyamine particles, terephthalate polymer particles, polyethylene glycol particles; aesthetic particles, such as colored noodles, needles, lamellar particles and ring particles; enzyme particles, such as protease granules, amylase granules, lipase granules, cellulase granules, mannanase granules, pectate lyase granules, xyloglucanase granules, bleaching enzyme granules, and co-granules of any of these enzymes (these enzyme granules may contain sodium sulfate); bleach particles, such as percarbonate particles, especially carbonate, sulfate, ketone, etc. coated percarbonate particles, such as percarbonates coated with boronate salts, borosilicate salts, or any combination thereof; perborate particles; bleach activator particles, such as tetraacetylethylenediamine particles and / or alkyloxybenzenesulfonate particles; bleach catalyst particles, such as transition metal catalyst particles and / or isoquinolinium bleach catalyst particles; preformed peracid particles, particularly coated preformed peracid particles; filler particles, such as sulfate particles and chloride particles; clay particles, such as montmorillonite particles and clay and silicone particles; flocculating agent particles, such as polyethylene oxide particles; wax particles, such as wax aggregates; silicone particles, whitening agent particles; dye transfer inhibitor particles; dye fixative particles; perfume particles, such as perfume microcapsules and starch-encapsulated perfume accord particles, or pro-perfume particles, such as Schiff base reaction product particles; hue dye particles; chelating agent particles, such as chelating agent aggregates; and any combination thereof.

[0088] combination 1. A method for producing a fibrous water-soluble product comprising particles, the method comprising: a) providing a first continuous water-soluble fibrous substrate having a first side and moving in a first direction; b) providing a discretization unit having one or more pockets with openings; c) providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket openings to at least partially fill at least one of the one or more pockets; d) delivering the first particles from the pockets through the openings onto a portion of the first side of the first continuous water-soluble fibrous substrate; and e) at least partially covering the first side of the first continuous water-soluble fibrous substrate.

[0089] 2. A method for producing a fibrous water-soluble product comprising particles, the method comprising: a) providing a first continuous water-soluble fibrous substrate having a first side and moving in a first direction; b) providing a discretization unit having one or more pockets with openings; c) providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket openings; d) intermittently delivering the first particles from the pocket openings onto a portion of the first side of the first continuous water-soluble fibrous substrate; e) metering the first particles to a target dose; and f) at least partially covering the first side of the first continuous water-soluble fibrous substrate.

[0090] 3. The method of 1 or 2, further comprising sealing the first continuous water-soluble fibrous substrate and a covering, the covering enclosing at least a portion of the first particles between the first water-soluble substrate and the covering, the covering comprising a second fibrous water-soluble substrate.

[0091] 4. The method of 3, wherein enclosing the first continuous, water-soluble fibrous substrate in a second continuous, water-soluble fibrous substrate that entraps at least a portion of the particles forms a unit dose.

[0092] 5. The method of any one of 1-4, wherein the first particles are delivered to a target area on a first side of the first continuous water-soluble substrate, and at least 75%, about 80% or more, about 85% or more, about 90% or more, about 95% or more, or most preferably about 97% or more of the first particles remain on the target area upon exiting the discretization unit.

[0093] 6. The method according to any one of 1 to 5, wherein the discretization unit comprises a rotor.

[0094] 7. The method of 6, wherein the rotor comprises one or more pockets, and the particles are contained within at least one of the one or more pockets of the rotor before being delivered onto a portion of the first side of the first continuous substrate.

[0095] 8. The method of any one of 1-7, wherein the size of the pocket measures the amount of first particles delivered to a portion of the first side of the first continuous substrate.

[0096] 9. The method of any one of 1 to 8, wherein the first continuous water-soluble fibrous substrate is moving in the first direction at a speed of about 5 m / min to about 100 m / min.

[0097] 10. The method of any one of 1 to 9, wherein the first particles are delivered intermittently from one or more pockets of the discretization unit.

[0098] 11. The method according to any one of 1 to 10, wherein the particles have a fluidity of about 4 or more, preferably from about 4 to about 1000.

[0099] 12. The particles are separated from the discretization unit by approximately 20 mm of the first continuous substrate. 2 ~approx. 6000mm 2 12. The method of any one of 1-11, wherein the first continuous substrate is delivered to an area of ​​1000 nm to form a unit dose, and one or more unit doses may be formed on the first continuous substrate.

[0100] 13. The method of any one of 1 to 12, wherein the discretization unit discretizes the continuous stream of first particles into one or more individual doses.

[0101] 14. The method of any one of 1-13, further comprising: a) providing a third continuous water-soluble fibrous substrate moving in a first direction and having a first side and a second side; b) providing a supply of second particles to a second discretization unit; c) delivering the second particles from the discretization unit onto a portion of the second side of the second continuous water-soluble substrate; and d) positioning the first side of the third continuous substrate over the second particles.

[0102] 15. The method of any one of 1 to 14, further comprising providing a supply of second particles to the discretization unit, wherein the first particles and the second particles are the same or different.

[0103] 16. The method according to any one of 1 to 15, wherein the discretization unit moves at a constant speed.

[0104] 17. The method of any one of 1 to 16, wherein the discretization unit moves at a variable speed.

[0105] 18. The method of any one of 1 to 17, wherein at least one pocket of the discretization unit advances synchronously with the first continuous water-soluble fibrous substrate during deposition of particles onto the first continuous water-soluble fibrous substrate.

[0106] 19. The method of any one of 1-18, wherein the particles comprise powders, granules, agglomerates, encapsulates, microcapsules, prills, or combinations thereof.

[0107] 20. The method of any one of 1 to 19, wherein the first particles have a fluidity of about 4 or greater.

[0108] 21. A particle applicator device comprising: a stator having an inlet and an outlet; a rotating discretization unit for receiving and delivering particles comprising one or more pockets, depressions, or combinations thereof; A particle applicator device, wherein a stator and a rotary discretization unit are operatively connected.

[0109] 22. The particle applicator apparatus of claim 21, wherein the rotary discretization unit rotates at a variable speed.

[0110] 23. A particle applicator device according to 21 or 22, wherein the rotary discretisation unit comprises pockets, preferably equally spaced pockets.

[0111] 24. A particle applicator device according to any one of 21 to 23, wherein the rotary discretization unit comprises about 1 to about 20 pockets, about 2 to about 20 pockets, about 3 to about 20 pockets, about 5 to about 18 pockets, about 6 to about 16 pockets, about 8 to about 16 pockets, or about 8 to about 12 pockets.

[0112] 25. A particle applicator device according to any one of 21 to 24, wherein the rotary discretization unit comprises pockets having transverse dimensions of about 1 mm to about 100 mm, about 3 mm to about 95 mm, about 10 mm to about 90 mm, about 20 mm to about 50 mm, or about 25 mm to about 40 mm.

[0113] 26. A particle applicator device according to any one of 21 to 25, wherein the rotary discretization unit comprises pockets having machine direction dimensions of about 1 mm to about 100 mm, about 3 mm to about 95 mm, about 10 mm to about 90 mm, about 20 mm to about 50 mm, about 25 mm to about 40 mm, about 10 mm to about 15 mm, or about 8 mm to about 12 mm.

[0114] 27. A particle applicator device according to any one of 21 to 26, wherein the rotary discretization unit comprises pockets having a depth of about 1 mm to about 100 mm, about 3 mm to about 95 mm, about 10 mm to about 90 mm, about 20 mm to about 50 mm, about 25 mm to about 40 mm, about 10 mm to about 15 mm, or about 8 mm to about 12 mm.

[0115] 28. A particle applicator device according to any one of 21 to 27, wherein the rotating discretization unit comprises pockets having the shape of a rectangular prism, a cube, a cone, a pyramid, a concave "v", a divot, a cylinder, any shape with a triangular cross section, any shape with a rectangular cross section, or any combination thereof.

[0116] 29. A particle applicator device according to any one of 21 to 28, wherein the discretization unit meters a target dose of particles.

[0117] 30. A particle applicator device according to any one of 21 to 29, wherein the rotary discretization unit comprises a pocket, the pocket being the volume of a target dose of particles.

[0118] 31. The particle applicator device according to any one of 21 to 30, wherein the target dose of particles for the rotary discretization unit is about 0.1 g to about 15 g, about 0.2 g to about 15 g, about 0.3 g to about 10 g, about 0.4 g to about 8 g, or about 0.1 g to about 4.0 g. The target dose in terms of volume is, for example, about 0.1 cm 3 ~about 8cm 3 , about 0.1cm 3 ~about 7cm 3 , about 0.1cm 3 ~approx. 6cm 3 , about 0.1cm 3 ~about 5cm 3 , and approximately 0.1 cm 3 ~about 4.0cm 3 , or any combination thereof.

[0119] 32. A particle applicator device according to any one of claims 21 to 31, wherein the rotary discretization unit comprises a rotor.

[0120] 33. The particle applicator device of any one of 21 to 32, wherein the stator comprises a housing.

[0121] 34. The particle applicator apparatus of 33, wherein the rotating discretization unit is located at least partially inside the stator housing.

[0122] 35. The particle applicator device of 34, wherein an annular space exists between the stator housing and the rotary discretization unit.

[0123] 36. The particle applicator device of 35, wherein the annular space is about 10 μm to about 125 μm, about 20 μm to about 100 μm, about 20 μm to about 90 μm, about 30 μm to about 80 μm, about 40 μm to about 80 μm, about 50 μm to about 75 μm, or any combination thereof.

[0124] 37. A particle applicator described in any one of 21 to 36, wherein the stator inlet is positioned so that the rotating discretization unit receives particles when the particle-receiving portion of the rotating discretization unit advances in a downward trajectory.

[0125] 38. A particle applicator according to any one of 21 to 37, wherein the stator outlet is positioned at approximately 45° from horizontal.

[0126] 39. A particle applicator according to any one of 21 to 38, wherein the particle applicator applies particles to a fibrous substrate.

[0127] liquidity method The following comparative tests are performed to demonstrate particle flowability at ambient temperature and humidity.

[0128] The device adapted for this test is a commercially available flowability testing system, FloDex™ (Teledyne Hanson Research, Chatsworth, Calif., USA), which includes a flat-bottomed cylindrical hopper with a removable bottom and a set of interchangeable bottom disks containing different sized orifices therein. Additionally, additional bottom disks with smaller sized orifices (having diameters below 4 mm) are fabricated to provide a more complete range of orifice diameters, including 3 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 12 mm, 14 mm, 16 mm, 18 mm, and up to 34 mm.

[0129] The FloDex™ instrument includes a funnel for loading a particulate test sample into a stainless steel, flat-bottomed, cylindrical hopper having a diameter of approximately 5.7 cm. The hopper has a removable bottom defined by a removal bottom disk having a specific sized orifice therein. As described above, multiple removal bottom disks having different sized orifices are provided, which can be interchangeably attached to the bottom of the hopper in place of the disk to define different sized bottom orifices. A discharge gate is positioned directly below the orifice and above the receiver. When a flowability measurement is initiated, the discharge gate is moved to expose the bottom orifice, allowing the particulate test sample to flow from the hopper through the bottom orifice and into the receiver.

[0130] To test the flowability of a particular test sample, the following steps are followed. Fill the hopper by pouring approximately 75 ml of test sample through the funnel, which corresponds to approximately a 1 inch (25 mm) layer of powder in the cylindrical hopper. b. After the sample has settled for 30 seconds, the spring-loaded discharge gate is opened, allowing the sample to flow through the orifice into the receiver. c. Steps (a) and (b) are repeated for the same test sample using different bottom disks with orifices of gradually increasing orifice size. When a bottom disk with a relatively small orifice is used initially, the flow of the test sample typically stops at some point due to clogging, i.e., the test sample is unable to pass through the orifice due to the small orifice size. Once the test sample flow stops, a clogging is declared, and the particular bottom disk that caused the clogging is removed and replaced with another bottom disk with a slightly larger orifice for another repetition of steps (a) and (b). When the test sample can flow completely through a particular size orifice three consecutive times without clogging, such orifice size is recorded as the FloDex™ blockage parameter, where B refers to the diameter of the orifice in the flow disk used in the test. The smaller the FloDex™ blockage parameter, the better the test sample's flow properties (i.e., it can flow through a smaller orifice without clogging).

[0131] Liquidity is calculated according to the following equation:

[0132]

number

[0133]

number

[0134] The dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

[0135] All documents cited herein, including any cross-referenced or related patents or patent applications, and any patent applications or patents to which this application claims priority or benefit, are incorporated herein by reference in their entirety, unless expressly stated to the contrary. The citation of any document shall not be deemed to be prior art to any invention disclosed or claimed herein, or to teach, suggest, or disclose any such invention, either alone or in combination with any other reference or references. Furthermore, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall control.

[0136] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. 1. A method for producing a fibrous water-soluble product comprising particles, comprising: a) providing a first continuous water-soluble fibrous substrate having a first side and moving in a first direction; b) providing a discretization unit comprising one or more pockets with openings; c) providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket opening to at least partially fill the at least one of the one or more pockets; d) delivering the first particles from the pocket through the opening onto a portion of the first side of the first continuous water-soluble fibrous substrate; e) at least partially covering said first side of said first continuous water-soluble fibrous substrate.

2. 10. The method of claim 1, further comprising sealing the first continuous water-soluble fibrous substrate and a covering, the covering trapping at least a portion of the first particles between the first water-soluble substrate and the covering, the covering comprising a second fibrous water-soluble substrate.

3. 3. The method of claim 1 or 2, wherein the first particles are delivered to a target area on the first side of the first continuous water-soluble fibrous substrate, and at least 75%, preferably 80% or more, more preferably 85% or more, even more preferably 90% or more, even more preferably 95% or more, or most preferably 97% or more of the first particles remain on the target area upon exiting the discretization unit.

4. The method according to any one of claims 1 to 3, wherein the discretization unit comprises a rotor.

5. 5. The method of claim 4, wherein the rotor comprises the one or more pockets, and the particles are contained in at least one of the one or more pockets of the rotor before being delivered onto a portion of the first side of the first continuous water-soluble fibrous substrate.

6. The method of any one of claims 1 to 5, wherein the size of the pocket meters the amount of the first particles delivered to the portion of the first side of the first continuous substrate.

7. The method of any one of claims 1 to 6, wherein the discretization unit discretizes the continuous stream of first particles into one or more individual doses.

8. The method of any one of claims 1 to 7, wherein the first particles are delivered intermittently from the one or more pockets of the discretization unit.

9. The method according to any one of claims 1 to 8, wherein the particles have a fluidity of about 4 or greater, preferably measured according to the Flowability Method.

10. The particles are removed from the discretization unit to remove about 20 mm of the first continuous water-soluble fibrous substrate. ２ ~ Approximately 6000 mm ２ to form a unit dose, and one or more unit doses are formed on the first continuous water-soluble fibrous substrate.

11. 11. The method of any one of claims 1 to 10, wherein at least one pocket of the discretization unit advances synchronously with the first continuous, water-soluble fibrous substrate during deposition of the particles onto the first continuous, water-soluble fibrous substrate.

12. The method according to any one of claims 1 to 11, wherein the discretization unit moves at a constant speed.

13. The method according to any one of claims 1 to 11, wherein the discretization unit moves at a variable speed.

14. 14. The method of any one of claims 1 to 13, further comprising providing a supply of second particles to the discretization unit, wherein the first particles and the second particles are the same or different.

15. a) providing a third continuous water-soluble fibrous substrate having a first side and a second side, the third continuous water-soluble fibrous substrate moving in said first direction; b) providing a second supply of particles to a second discretization unit; c) delivering the second particles from the discretization unit onto a portion of a second side of a second continuous water-soluble fibrous substrate; 14. The method of any one of claims 1 to 13, further comprising: d) disposing the first side of the third continuous water-soluble fibrous substrate over the second particles.

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