Water-soluble multi-compartment unit dosage article

Abstract

The present invention provides a compressible, water-soluble unit-dose article in which multiple compartments are arranged in an overlapping configuration with high sealing quality. [Solution] A water-soluble multi-compartment unit-dose article is provided, comprising at least two overlapping compartments, wherein the compartments are formed by sealing a water-soluble film to contain a liquid detergent composition. The water-soluble film comprises a polyvinyl alcohol polymer comprising a polyvinyl alcohol resin, and the polyvinyl alcohol resin comprises a homopolymer. The total volume of the liquid detergent composition is 10 mL to 20 mL.

Description

Technical Field

[0001] A water-soluble multi-compartment unit-dose article comprising individual compartments in a stacked configuration.

Background Art

[0002] Water-soluble unit-dose articles are preferred by consumers because they are convenient and efficient to use. Such water-soluble unit-dose articles often include laundry detergent compositions. Each unit-dose article is generally designed to provide a laundry detergent composition sufficient to wash one load of laundry.

[0003] Such water-soluble unit-dose articles are commercially available in a variety of designs, including designs having multiple compartments. The multiple compartments can be arranged in a parallel configuration, a stacked configuration, or a mixed configuration in which multiple compartments arranged in a parallel configuration are superimposed on one or more other compartments. An example of such a mixed configuration is the Tide or Ariel Pods products marketed by The Procter & Gamble Company.

[0004] Specific challenges related to creating a pouch configuration with overlapping or parallel / overlapping mixing relate to ensuring seal strength, and considering that more than two films must be sealed together, the risk of seal failure increases. Such seal failures can result in leakage of the detergent product from the water-soluble unit-dose article.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Therefore, there is a need for a compressed water-soluble unit-dose article in which multiple compartments are arranged in a stacked configuration with high seal quality.

[0006] Surprisingly, it has been found that a multi-compartment water-soluble unit-dose article comprising a water-soluble film according to the present invention overcomes this problem.

Means for Solving the Problems

[0007] The present invention relates to a unit-dose article comprising a water-soluble film and at least one liquid detergent composition, wherein each liquid detergent composition is enclosed within a compartment formed by the water-soluble film. The unit-dose article comprises at least a first compartment and at least a second compartment, the second compartment superimposed on the first compartment, and each compartment is formed by a seal surrounding the compartment to contain the liquid detergent composition. The water-soluble film comprises a polyvinyl alcohol resin, and the polyvinyl alcohol resin is made of a homopolymer. The total volume of the liquid detergent composition is 10 mL to 20 mL. [Brief explanation of the drawing]

[0008] [Figure 1] This is a water-soluble unit-quantity article according to the present invention. [Figure 2A] Figure 1 is a cross-sectional view of a unit dose of an article. [Figure 2B] This is an enlarged view of the seal area in Figure 2A. [Modes for carrying out the invention]

[0009] Water-soluble multi-compartment pouch The present invention is a water-soluble multi-compartment unit-dose article comprising a water-soluble film and a laundry detergent composition according to the present invention.

[0010] In this specification, a multi-compartment unit-dose article, also referred to as a multi-compartment article, includes two or more compartments.

[0011] The superimposed multiple-compartment unit-dose article includes at least a first compartment that contacts the horizontal plane when placed in a stable equilibrium state on a horizontal plane, and at least a second compartment positioned above the first compartment and separated from the horizontal plane.

[0012] At least one compartment contains the laundry detergent composition, but the laundry detergent composition may be contained in at least two or even three compartments. The water-soluble film is sealed to prevent the laundry detergent composition from leaking out of the compartments during storage. However, when a water-soluble unit quantity of the article is added to water, the water-soluble film dissolves, releasing the contents of the internal compartments into the washing solution.

[0013] Each compartment should be understood to mean a sealed internal space within a unit-dose article that holds the laundry detergent composition. The unit-dose article is manufactured such that a water-soluble film completely surrounds the laundry detergent composition, thereby defining the compartment containing the laundry detergent composition. The film is described in more detail below.

[0014] A unit dose article comprises at least two compartments, or more precisely, at least three compartments, or more precisely, at least two compartments are in an overlapping position, i.e., one is placed on top of the other. A unit dose article may further include compartments arranged in adjacent orientations, i.e., one oriented next to the other, or may be oriented in a “tire and rim” arrangement, i.e., the first compartment is placed next to the second compartment, but the first compartment at least partially surrounds the second compartment, although it does not have to completely surround the second compartment, or one compartment may be completely enclosed within another compartment.

[0015] One of the compartments may be smaller than the others. If the unit dose article contains at least three compartments, two of the compartments may be smaller than the third compartment, preferably with the smaller compartments overlapping the larger ones. If the unit dose article contains at least four compartments, three of the compartments may be smaller than the fourth compartment, preferably with the smaller compartments overlapping the larger ones. The overlapping compartments are preferably oriented adjacent to each other.

[0016] In the orientation of multiple compartments, the laundry detergent composition according to the present invention may be contained in at least one of the compartments. For example, the laundry detergent composition may be contained in only one compartment, or in two compartments, or even three compartments, or even in all of the compartments present.

[0017] Each section may contain the same composition or different compositions. The different compositions may all be in the same form, or they may be in different forms, for example, liquid or powder.

[0018] Preferably, the water-soluble unit-dose article comprises one larger compartment and at least one, preferably at least two, or even more than three smaller compartments superimposed thereon. Preferably, the larger bottom compartment contains the liquid detergent composition, and more preferably, at least one of the larger bottom and the superimposed smaller compartments contains the liquid detergent composition. Most preferably, all compartments contain the liquid detergent composition. The water-soluble unit-dose article contains 10 g to 22 g, preferably 12 g to 20 g, of laundry detergent, preferably all of the liquid laundry detergent. Most preferably, the water-soluble unit-dose article contains, preferably consists of, 10 mL to 20 mL, preferably 12 mL to 18 mL, of liquid laundry detergent. Preferably, more than 60 volume%, more more than 65 volume%, and most preferably 70 volume% to 75 volume%, of the laundry detergent is contained in the larger bottom compartment.

[0019] The outer contour seal region includes, or preferably consists of, a flange region. The flange region is positioned around the perimeter of a water-soluble multi-compartment unit-dose article, and the flange includes a sealed film from at least two, three, or more water-soluble films. In other words, the flange region protrudes from the water-soluble unit-dose article and includes a sealed film. "Seal region" as used herein means both the inner seal region, which is defined as the region of films sealed together to define individual compartments where no flange exists, and the outer seal region that defines the flange of the water-soluble unit-dose article. Here, the flange excludes the inner seal region. Preferably, the flange includes a sealed film from at least a first water-soluble film, a second water-soluble film, and a third water-soluble film. The inner seal region may be created by sealing two water-soluble films together to create physically separated individual compartments, or by sealing at least three films together to create physically separated individual compartments. Preferably, the inner seal is created by sealing only two water-soluble films together.

[0020] Preferably, the water-soluble multi-compartment unit dose article excluding the flange has a length and a width, each of the length and the width being, independently, less than 50 mm, preferably 30 mm to 48 mm, more preferably 35 mm to 45 mm, and preferably the ratio of the width to the length is 0.5 to 1.5, preferably 0.75 to 1.25, even more preferably 0.85 to 1.15, and most preferably 0.9 to 1.1. The water-soluble unit dose article preferably includes a flange, and the flange has a width of 1 mm to 10 mm, preferably 4 mm to 8 mm. More preferably, the water-soluble multi-compartment unit dose article further has a maximum height, and the maximum height is less than 29 mm, preferably 15 mm to 27 mm, more preferably 20 mm to 26 mm, and each of the ratio of the width to the height and the ratio of the length to the height (the width and the height include the flange) is, independently, 1.25 to 3.5, preferably 1.5 to 2.5. Preferably, each of the ratio of the width to the height and the ratio of the length to the height excluding the flange is, independently, 1 to 3, preferably 1.25 to 2.

[0021] Figure 1 shows a water-soluble unit dose article 1 according to the present invention. The water-soluble unit dose article 1 includes a first water-soluble film 2, a second water-soluble film (not shown, separating the upper compartment from the bottom compartment), and a third water-soluble film 3, which are sealed together. The unit dose article 1 also includes a flange 4. The laundry detergent composition 5 is contained within the water-soluble soluble unit dose article 1. <L

[0022] Figures 2A and 2B show cross-sectional views of the water-soluble unit dose article 1. The cross-sectional views disclose a first water-soluble film 2, a second water-soluble film 3, and a third water-soluble film 6. The water-soluble unit dose article 1 includes a first compartment 7, a second compartment 8, and a third compartment 9. The water-soluble unit dose article 1 includes an inner seal region 11 and a seal region 10 including the flange 4. The second water-soluble film 3 and the third water-soluble film 6 are sealed together to define the second compartment 8 and the third compartment 9.

[0023] Multi-compartment water-soluble unit dose articles have become more common in the laundry detergent market, and the multi-compartment elements provide formulators with the flexibility to co-formulate essentially immiscible materials together within the same product. Multi-compartment water-soluble unit dose articles, when designed in a stacked configuration, are thought to require more layers of sealed film and thus have a higher risk of seal failure. Thus, when greater stress is exerted on the seal area, this can potentially cause tearing or opening of the sealed film and thus leakage of the water-soluble unit dose article. Surprisingly, it has been found that composite compression of the entire detergent, in combination with an appropriate selection of water-soluble resin chemistries, helps to improve seal quality and relieve the applied stress, thus reducing seal failure.

[0024] Water-soluble film The film of the present invention is water-soluble or water-dispersible. The water-soluble film preferably has a pre-deformation thickness of 20 to 150 micrometers, preferably 35 to 125 micrometers, even more preferably 50 to 110 micrometers, and most preferably about 76 micrometers.

[0025] Preferably, after use of a glass filter with a maximum pore size of 20 micrometers, when measured by the method described herein, the water solubility of the film is at least 50%, preferably at least 75%, or even at least 95%. Add 5 grams ± 0.1 grams of film material to a pre-weighed 3 L beaker and add 2 L ± 5 mL of distilled water. Stir this vigorously for 30 minutes at 30 °C with a magnetic stirrer (Labline model number 1250) or equivalent set at 600 rpm and a 5 cm magnetic stirrer. Next, filter the mixture through a pleated qualitative sintered glass filter with the pore size (maximum 20 micrometers) defined above. Dry the water from the recovered filtrate by any conventional method and determine the weight of the remaining material (this is the dissolved or dispersed fraction). Next, the percentage of solubility or dispersibility can be calculated.

[0026] A preferred film material is preferably a polymer material. The film material can be obtained by methods well known in the art, such as casting, blow molding, extrusion, or blow extrusion of polymer materials.

[0027] The water-soluble film contains a polyvinyl alcohol polymer, which consists of a polyvinyl alcohol homopolymer or a blend thereof. The polyvinyl alcohol polymer may be present in the water-soluble film at an amount of 50% to 95% by weight, preferably 55% to 90% by weight, and more preferably 60% to 80% by weight. While we do not wish to be bound by theory, the term "homopolymer" generally includes polymers having one type of monomer repeating unit (e.g., polymer chains containing or consisting of a single monomer repeating unit). In the case of polyvinyl alcohol in particular, the term "homopolymer" further includes copolymers having a certain distribution of vinyl alcohol monomer units and optionally vinyl acetate monomer units (e.g., polymer chains containing or consisting of vinyl alcohol monomer units and vinyl acetate monomer units), depending on the degree of hydrolysis. If hydrolysis is 100%, the polyvinyl alcohol homopolymer may contain only vinyl alcohol units. While we do not wish to be bound by theory, the term “copolymer” generally includes polymers having two or more types of monomer repeating units (e.g., polymer chains containing or consisting of two or more different monomer repeating units, whether random copolymers, block copolymers, etc.). In particular, in the case of polyvinyl alcohol, the term “copolymer” (or “polyvinyl alcohol copolymer”) further includes, depending on the degree of hydrolysis, a copolymer having a certain distribution of vinyl alcohol monomer units and vinyl acetate monomer units, and at least one other type of monomer repeating unit (e.g., a polymer chain containing or consisting of vinyl alcohol monomer units, vinyl acetate monomer units, and one or more other monomer units, e.g., anionic monomer units). If hydrolysis is 100%, a polyvinyl alcohol copolymer may contain a copolymer having vinyl alcohol units and one or more other monomer units, but not vinyl acetate units. While we do not wish to be bound by theory, the term “anionic copolymer” includes copolymers having anionic monomer units containing anionic moieties.

[0028] Preferably, in the case of polyvinyl alcohol and / or polyvinyl alcohol blends, the individual polyvinyl alcohol polymers and / or composite polyvinyl alcohol polymers have an average viscosity (μ1) in the range of 4 mPa.s to 30 mPa.s, preferably 10 mPa.s to 25 mPa.s, when measured as a 4% polyvinyl alcohol polymer solution in desalinated water at 20°C. The viscosity of the polyvinyl alcohol polymer is determined by measuring a freshly prepared solution using a Brookfield LV viscometer with a UL adapter, as described in British Standard EN ISO15023-2:2006 Annex E Brookfield Test method. It is international practice to specify the viscosity of a 4% polyvinyl alcohol aqueous solution at 20°C. It is well known in the art that the viscosity of an aqueous solution of a water-soluble polymer (polyvinyl alcohol or others) correlates with the weight-average molecular weight of the same polymer, and that viscosity is often used as a substitute for weight-average molecular weight. Therefore, the weight-average molecular weight of polyvinyl alcohol may be in the range of 30,000 to 175,000, or 30,000 to 100,000, or 55,000 to 80,000. Preferably, in the case of polyvinyl alcohol and / or polyvinyl alcohol blends, the individual polyvinyl alcohol polymers have an average degree of hydrolysis in the range of 75% to 99%, preferably 80% to 95%, and most preferably 85% to 95%. A suitable test method for measuring the degree of hydrolysis is in accordance with the standard method JIS K6726.

[0029] Preferably, the water-soluble film contains a non-aqueous plasticizer. Preferably, the non-aqueous plasticizer is selected from polyols, sugar alcohols, and mixtures thereof. Suitable polyols include polyols selected from the group consisting of glycerol, diglycerin, ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol with a molecular weight of 400 or less, neopentyl glycol, 1,2-propylene glycol, 1,3-propanediol, dipropylene glycol, polypropylene glycol, 2-methyl-1,3-propanediol, trimethylolpropane, and polyether polyols, or mixtures thereof. Suitable sugar alcohols include sugar alcohols selected from the group consisting of isomalt, maltitol, sorbitol, xylitol, erythritol, adonitol, dulcitol, pentaerythritol, and mannitol, or mixtures thereof. More preferably, the non-aqueous plasticizer is selected from glycerol, 1,2-propanediol, dipropylene glycol, 2-methyl-1,3-propanediol, trimethylolpropane, triethylene glycol, polyethylene glycol, sorbitol, or mixtures thereof, and most preferably selected from glycerol, sorbitol, trimethylolpropane, dipropylene glycol, and mixtures thereof. One particularly preferred plasticizer system comprises a blend of glycerol, sorbitol, and trimethylolpropane. Another particularly preferred plasticizer system comprises a blend of glycerin, dipropylene glycol, and sorbitol. Preferably, the film contains 5% to 50% by weight, preferably 10% to 40% by weight, more preferably 20% to 30% by weight of the non-aqueous plasticizer.

[0030] Preferably, the water-soluble film contains a surfactant. Preferably, the water-soluble film contains 0.1% to 2.5% by weight, preferably 1% to 2% by weight, of the surfactant. Suitable surfactants include nonionic, cationic, anionic, and bipolar types. Suitable surfactants include, but are not limited to, polyoxyethylene-modified polyoxypropylene glycol, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylene glycols and alkanolamides (nonionic substances), polyoxyethylene-modified amines, quaternary ammonium salts and quaternized polyoxyethylene-modified amines (cationic substances), and amine oxides, N-alkyl betaines and sulfobetaines (bipolar substances). Other suitable surfactants include sodium dioctyl sulfosuccinate, lactyl fatty acid esters of glycerol and propylene glycol, lactyl esters of fatty acids, sodium alkyl sulfate, polysorbate 20, polysorbate 60, polysorbate 65, polysorbate 80, lecithin, acetylated fatty acid esters of glycerol and propylene glycol, acetylated esters of fatty acids, and combinations thereof.

[0031] Preferably, the water-soluble film according to the present invention contains a lubricant / release agent. Suitable lubricants / release agents include, but are not limited to, fatty acids and their salts, aliphatic alcohols, fatty acid esters, aliphatic amines, aliphatic amine acetates, and fatty acid amides. Preferred lubricants / release agents are fatty acids, fatty acid salts, and aliphatic amine acetates. Preferably, the amount of lubricant / release agent in the water-soluble film is in the range of 0.02% to 1.5% by weight of the water-soluble film, preferably 0.1% to 1% by weight.

[0032] Preferably, the water-soluble film contains a filler, a spreader, an anti-tack agent, a detack agent, or a mixture thereof. Suitable fillers, spreaders, anti-tack agents, detack agents, or mixtures thereof include, but are not limited to, starch, modified starch, cross-linked polyvinylpyrrolidone, cross-linked cellulose, microcrystalline cellulose, silica, metal oxides, calcium carbonate, talc, and mica. Preferred materials are starch, modified starch, and silica. Preferably, the amount of filler, spreader, anti-tack agent, detack agent, or mixture thereof in the water-soluble film is in the range of 0.1% to 25% by weight of the water-soluble film, preferably 1% to 10% by weight, more preferably 2% to 8% by weight, and most preferably 3% to 5% by weight. In the absence of starch, one preferred range of suitable fillers, spreaders, anti-tacks, detacks, or mixtures thereof is 0.1% to 1% by weight, preferably 4% by weight, more preferably 6% by weight, even more preferably 1% to 4% by weight, and most preferably 1% to 2.5% by weight of the water-soluble film.

[0033] Preferably, the water-soluble film according to the present invention has a residual water content in the range of at least 4% by weight, more preferably 4% to 15% by weight, and even more preferably 5% to 10% by weight, when measured by Karl Fischer titration.

[0034] A preferred film is one that exhibits good solubility in cold water, i.e., unheated distilled water. Preferably, such a film exhibits good solubility at a temperature of 24°C, and more preferably at 10°C. Good solubility means that the film exhibits water solubility of at least 50%, preferably at least 75%, or even more preferably at least 95%, when measured by the method described herein after using the glass filter with a maximum pore size of 20 micrometers as described above.

[0035] The film may be opaque, transparent, or translucent. The film may include printed areas.

[0036] The printable area can be obtained using standard techniques such as flexographic printing or inkjet printing.

[0037] The film may contain 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 in the film. Suitable concentrations include, but are not limited to, 1 to 5000 ppm, or even 100 to 2500 ppm, or even 250 to 2000 rpm.

[0038] The water-soluble film or water-soluble unit-dose article, or both, may be further coated with a lubricant, preferably selected from talc, zinc oxide, silica, siloxane, zeolite, silicic acid, alumina, sodium sulfate, potassium sulfate, calcium carbonate, magnesium carbonate, sodium citrate, sodium tripolyphosphate, potassium citrate, potassium tripolyphosphate, calcium stearate, zinc stearate, magnesium stearate, starch, modified starch, clay, kaolin, gypsum, cyclodextrin, or mixtures thereof.

[0039] Preferably, the water-soluble film and each of its individual components independently contain 0 ppm to 20 ppm, preferably 0 ppm to 15 ppm, more preferably 0 ppm to 10 ppm, even more preferably 0 ppm to 5 ppm, even more preferably 0 ppm to 1 ppm, even more preferably 0 ppb to 100 ppb, and most preferably 0 ppb of dioxane. Those skilled in the art will recognize known methods and techniques for determining the dioxane levels in the water-soluble film and its components.

[0040] Liquid laundry detergent composition The laundry detergent composition may be a powder, a liquid, or a mixture thereof, preferably a liquid.

[0041] The term "liquid laundry detergent composition" refers to, but is not limited to, any laundry detergent composition containing a liquid capable of wetting and treating fabrics, including liquids, gels, pastes, and dispersions. Liquid compositions may contain preferably subdivided forms of solids or gases, but liquid compositions exclude forms that are non-flowing as a whole, such as tablets or granules.

[0042] In this specification, "powder" means that a laundry detergent composition may contain solid particles or may be a single homogeneous solid. Preferably, the powder laundry detergent composition contains particles. This means that the powder laundry detergent composition contains individual solid particles, as opposed to a single homogeneous solid. The particles may be free-flowing or compressed, and are preferably free-flowing.

[0043] The laundry detergent composition may be used for hand washing of fabrics or for washing fabrics in an automatic washing machine.

[0044] Preferably, the laundry detergent composition contains a non-soap surfactant. The non-soap surfactant is preferably selected from a non-soap anionic surfactant, a nonionic surfactant, or a mixture thereof. Preferably, the laundry detergent composition contains 10% to 60% by weight, more preferably 20% to 55% by weight, of the non-soap surfactant. Exemplary weight ratios of non-soap anionic surfactant to nonionic surfactant are 1:1 to 20:1, 1.5:1 to 17.5:1, 2:1 to 15:1, or 2.5:1 to 13:1.

[0045] Preferably, the anionic non-soap surfactant includes a linear alkylbenzene sulfonate, an alkyl sulfate, an alkoxylated alkyl sulfate, or a mixture thereof. Preferably, the alkoxylated alkyl sulfate is an ethoxylated alkyl sulfate.

[0046] Preferably, the laundry detergent composition contains 5% to 60% by weight, preferably 15% to 55% by weight, more preferably 25% to 50% by weight, and most preferably 30% to 45% by weight of a non-soap anionic surfactant.

[0047] Preferably, the non-soap anionic surfactant comprises a linear alkylbenzene sulfonate and an alkoxylated alkyl sulfate, wherein the ratio of linear alkylbenzene sulfonate to alkoxylated alkyl sulfate, preferably the weight ratio of linear alkylbenzene sulfonate to ethoxylated alkyl sulfate, is 1:2 to 9:1, preferably 1:1 to 7:1, more preferably 1:1 to 5:1, and even more preferably 1:1 to 4:1. The alkoxylated alkyl sulfate can be derived from synthetic alcohols or natural alcohols, or blends thereof, between desired mean alkyl carbon chain length and mean branching degree. Preferably, synthetic alcohols are produced by the Ziegler process, oxo process, modified oxo process, Fischer-Tropsch process, Guerbet process, or a mixture thereof. Preferably, naturally derived alcohols are derived from natural oils, preferably coconut oil, palm kernel oil, or mixtures thereof.

[0048] Preferably, the laundry detergent composition contains 1% to 25% by weight, preferably 2% to 20% by weight, and most preferably 3% to 15% by weight of a nonionic surfactant. The nonionic surfactant is preferably selected from alcohol alkoxylates, Ziegler synthetic alcohol alkoxylates, oxo synthetic alcohol alkoxylates, Guerbet alcohol alkoxylates, alkylphenol alcohol alkoxylates, or mixtures thereof.

[0049] Preferably, the laundry detergent composition, preferably a liquid laundry detergent composition, contains 1.5% to 20% by weight, more preferably 2% to 15% by weight, even more preferably 3% to 10% by weight, and most preferably 4% to 8% by weight of soap, preferably a fatty acid salt, more preferably an amine-neutralized fatty acid salt, wherein the amine is preferably an alkanolamine selected from monoethanolamine, diethanolamine, triethanolamine, or a mixture thereof, and more preferably monoethanolamine.

[0050] Preferably, the laundry detergent composition contains a non-aqueous solvent, preferably selected from 1,2-propanediol, dipropylene glycol, tripropylene glycol, glycerol, sorbitol, polyethyleneglycerol, polypropylene glycol, or a mixture thereof, preferably polypropylene glycol having a molecular weight of 400. Preferably, the liquid laundry detergent composition contains 10% to 40% by weight, preferably 15% to 30% by weight, of the non-aqueous solvent. While we do not wish to be bound by theory, the non-aqueous solvent ensures that the film is neither too brittle nor too "soft" so as to achieve an appropriate level of film plasticization. While we do not wish to be bound by theory, having the correct degree of plasticization also facilitates the dissolution of the film when exposed to water during the washing process.

[0051] Preferably, the liquid laundry detergent composition contains 0.5% to 15% by weight, preferably 5% to 13% by weight, of water.

[0052] Preferably, the laundry detergent composition contains components selected from the list including cationic polymers, polyester terephthalate, amphiphilic graft copolymers, carboxymethylcellulose, enzymes, fragrances, encapsulated fragrances, bleaches, or mixtures thereof.

[0053] The laundry detergent composition may contain auxiliary components, which are selected from ethanol, color dyes, aesthetic dyes, enzymes, builders, preferably citric acid, chelating agents, cleaning polymers, dispersants, color transfer inhibitor polymers, fluorescent whitening agents, opacifying agents, defoaming agents, preservatives, antioxidants, or mixtures thereof. Preferably, the chelating agent is selected from aminocarboxylate chelating agents, aminophosphonate chelating agents, or mixtures thereof.

[0054] Preferably, the laundry detergent composition has a pH of 6 to 10, more preferably 6.5 to 8.9, and most preferably 7 to 8, and the pH of the laundry detergent composition is measured as a 10% dilution in desalinated water at 20°C.

[0055] Liquid laundry detergent compositions may be Newtonian or non-Newtonian. Preferably, liquid laundry detergent compositions are non-Newtonian. While we do not wish to be bound by theory, non-Newtonian liquids have different properties from Newtonian liquids; more specifically, the viscosity of non-Newtonian liquids depends on the shear rate, whereas Newtonian liquids have a constant viscosity regardless of the shear rate applied. The decrease in viscosity of non-Newtonian liquids when shear is applied is thought to further promote the dissolution of the liquid detergent. The liquid laundry detergent compositions described herein may have any preferred viscosity depending on factors such as the components blended and the purpose of the composition. In the case of Newtonian compositions, according to the methods described herein, the compositions may have viscosity values ​​of 100 to 3,000 cP, or 200 to 2,000 cP, or 300 to 1,000 cP at a shear rate of 20 s⁻¹ and a temperature of 20°C. In the non-Newtonian case, the composition may have high shear viscosity values ​​of 100-3,000 cP, or 300-2,000 cP, or 500-1,000 cP at a shear rate of 20 s⁻¹ and a temperature of 20°C, and low shear viscosity values ​​of 500-100,000 cP, or 1,000-10,000 cP, or 1,300-5,000 cP at a shear rate of 1 s⁻¹ and a temperature of 20°C. Methods for measuring viscosity are known in the art. According to this disclosure, viscosity measurement is performed using a rotational rheometer, for example, TA Instrument's AR550. This instrument includes a 40 mm 2° or 1° cone fixture with a gap of about 50-60 μιη for isotropic liquids, or a 40 mm flat steel plate with a gap of 1,000 μιη for liquid-containing particles. This measurement is performed using a flow procedure that includes a tune-up step, peak hold, and continuous sloping step. The tune-up step includes a 10-second pre-shear at a shear rate of 10 s1, and a 60-second equilibrium at the selected temperature, with the measurement temperature set at 20°C. Peak hold involves sampling every 10 s and applying a shear rate of 0.05 s1 at 20°C for 3 minutes. The continuous sloping step is performed at shear rates from 0.1 to 1200 s1 at 20°C for 3 minutes to obtain the full flow profile.

[0056] use One aspect of the present invention is the use of a water-soluble unit-dose article according to the present invention to reduce instances of seal failure.

[0057] Cleaning method A further aspect of the present invention is a washing method comprising the steps of: adding a water-soluble unit-dose article according to the present invention to a sufficient amount of water to dilute the laundry detergent composition by at least 200 times, preferably 250 to 3000 times, more preferably 250 to 1500 times, and most preferably 500 to 1500 times to produce a washing solution; and bringing a fabric to be washed into contact with the washing solution.

[0058] When a water-soluble unit dose of the product is added to water, the water-soluble film dissolves, releasing the laundry detergent composition inside into the water. The laundry detergent composition disperses in the water, creating a cleaning solution.

[0059] Preferably, the washing solution may contain 10 L to 75 L of water, preferably 20 L to 70 L, and more preferably 30 L to 65 L.

[0060] Preferably, the washing solution is at a temperature of about 5°C to about 90°C, preferably about 10°C to about 60°C, more preferably about 12°C to about 45°C, and most preferably about 15°C to about 40°C.

[0061] Preferably, the washing of the fabric in the washing solution takes 5 to 50 minutes, preferably 5 to 40 minutes, more preferably 5 to 30 minutes, even more preferably 5 to 20 minutes, and most preferably 6 to 18 minutes to complete.

[0062] Preferably, the cleaning solution contains 1 kg to 20 kg, preferably 5 kg to 20 kg, and most preferably 10 to 20 kg of fabric.

[0063] The cleaning solution may preferably contain water of any hardness ranging from 0 gpg to 40 gpg.

[0064] Manufacturing method Those skilled in the art will understand, using known techniques in the art, how to prepare the water-soluble unit-dose articles and laundry detergent compositions according to the present invention.

[0065] More specifically, the process for producing the water-soluble unit-dose article according to the present invention is: a. A step of moving the first water-soluble film in a first direction; b. A step of deforming a first portion of the first water-soluble film to create a first open section; c. A step of filling the first open compartment with the treatment composition; d. A step of moving the second water-soluble film in a second direction, bringing the first film into contact with the second film to close the open compartment and create a first closed compartment; e. The process of sealing the first film and the second film; f. A step of moving the third water-soluble film in a third direction and deforming a portion of the third water-soluble film to create a second open compartment; g. A step of filling the second open compartment with the treatment composition; h. The process of closing the second open section with the first closed section by bringing the second film into contact with the third film; i. The process may include the step of sealing a third film onto the sealed first and second films to produce a closed superimposed water-soluble unit-dose article, The process may be performed sequentially for each of steps a to i, or simultaneously for steps f and b, and simultaneously for steps c and g, or for step f to be performed before step b, and for step g to be performed before step c, or a combination of these.

[0066] The above process produces a superimposed water-soluble unit-dose article containing three water-soluble films.

[0067] An alternative process can be used to produce a superimposed water-soluble unit-dose article containing four water-soluble films. Therefore, the process for producing a water-soluble unit-dose article according to the present invention is: a. A step of moving the first water-soluble film in a first direction; b. A step of deforming a first portion of the first water-soluble film to create a first open section; c. A step of filling the first open compartment with the treatment composition; d. A step of moving the second water-soluble film in a second direction to close the first open compartment and create a first closed compartment; e. The process of sealing the first film and the second film together; f. A step of moving the third water-soluble film in a third direction and deforming a portion of the third water-soluble film to create a second open compartment; g. A step of filling the second open compartment with the treatment composition; h. A step of moving the fourth water-soluble film in the fourth direction to close the second open compartment and create a second closed compartment; i. The process of sealing the third film and the fourth film together; j. The step of arranging the first and second closed compartments by bringing the second film and the fourth film into contact so that the first and second closed compartments are oriented in an overlapping manner; k. The process may include the step of sealing sealed third and fourth films onto sealed first and second films to produce a superimposed water-soluble unit-dose article, Steps a to k can be performed sequentially, or steps b to e and f to i may be performed simultaneously with each other, or steps f to i may be performed before steps b to e, or a combination thereof.

[0068] Preferably, a first closed compartment is created on a rotating drum, and preferably, a second open and closed compartment is created on a horizontal conveyor belt. The sealing process can be selected from a solvent sealing process, a heat sealing process, or a combination thereof, preferably a solvent sealing process, most preferably the sealing solvent containing water, and preferably essentially made of water. The sealing solvent can be applied according to a direct contact approach, such as by using a felt roll, or a non-direct contact approach, such as by using a spray sealing approach. The film deformation process can be selected from thermoforming, vacuum forming, or a combination thereof. Preferably, a web of superimposed water-soluble unit-dose articles is created through the above process, resulting in individual water-soluble unit-dose articles which are then transported on a transfer belt to a packaging unit and placed into a packaging container, preferably selected from boxes, tabs, or bags. [Examples]

[0069] Using the process described above, a water-soluble unit-dose article was prepared in a pilot plant-scale single-lane converter operating at a line speed of 7.2 m / min. A first cavity with a footprint of 41 mm × 43 mm and a volume of either 12.3 mL (according to the present invention) or 17.3 mL (comparative example) was prepared. A smaller superimposed cavity with a total volume of 4.7 mL was prepared on a rotating drum located at the top of the converter. The total volume of liquid was either 17 mL (according to the present invention) or 22 mL (comparative example). Sealing water was applied at a coating weight of 17.3 gsm.

[0070] Each cavity contained the following detergent composition:

[0071] [Table 1] * The nuclease enzyme is as claimed in concurrently pending European Patent Application No. 19219568.3. ** Lutensol FP620 - Ethoxylated Polyethyleneimine (PEI600 EO20) manufactured by BASF *** A polyethylene glycol graft polymer comprising a polyethylene glycol backbone (Pluriol E6000) and hydrophobic vinyl acetate side chains, wherein the polymer system comprises 40% by weight of the polyethylene glycol backbone polymer and 60% by weight of the grafted vinyl acetate side chains. **** Lutensit Z96 (a zwitterionic polyamine manufactured by BASF - a zwitterionic hexamethylenediamine with the following formula: 100% quaternized, and approximately 40% of the polyethoxy (EO24) groups are sulfonated).

[0072] [ka] ***** Clariant Texcare SRA300

[0073] Water-soluble film 1: Polyvinyl alcohol homopolymer: Polyvinyl alcohol consisting of a polyvinyl alcohol homopolymer blend, obtained as is from MonoSol, used as an intermediate film in Ariel All-in-1 Pods, and commercially available in the UK since October 2022.

[0074] Water-soluble film 2: Anionic polyvinyl alcohol copolymer: Polyvinyl alcohol containing a polyvinyl alcohol homopolymer / anionic polyvinyl alcohol copolymer blend, obtained as is from MonoSol, used as the outer film in Ariel All-in-1 Pods, and commercially available in the UK since October 2022.

[0075] Test method The test method for determining the seal failure rate % uses a Mark-10 test instrument ESM750SLCE (jjbos bv, Marconistraat 1, NL-2809 PH Gouda, The Nederlands) equipped with a load cell with a maximum of 100 kN (kilonewtons). Under the action of an external compressive force, the water-soluble unit-dose article deforms, and stress accumulates in both the film and the seal area. The internal pressure of the pouch depends on the externally applied force across the entire surface area of ​​the water-soluble unit-dose article. Pouch strength (Newtons) is defined as the maximum compressive force required by two parallel plates to raise the internal pressure of the water-soluble unit-dose article to the rupture point. Articles that rupture in the seal area are reported as "seal failure" and used to calculate the seal failure rate % (seal failure = 1, no seal failure = 0) over 18 repeated tests.

[0076] Water-soluble unit-dose samples were stored under ambient conditions for 7 days, pre-conditioned at 23°C / 50%RH for 16-24 hours, and then the seal failure rate (%) was measured. This method is performed in an indoor environment with 40-50% relative humidity (RH) and 22-24°C. Samples are tested within 1 hour of removal from pre-conditioning.

[0077] result

[0078] [Table 2]

[0079] The dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​listed. Instead, unless otherwise indicated, each such dimension is intended to mean both the listed value and the functionally equivalent range encompassing that value. For example, a dimension disclosed as "40 mm" is intended to mean "approximately 40 mm."

Claims

1. A unit-dose article comprising a water-soluble film and at least one liquid detergent composition, wherein each liquid detergent composition is enclosed within a compartment formed by the water-soluble film. The unit dose article comprises at least a first compartment and at least a second compartment, the second compartment superimposed on the first compartment, and each compartment is formed by a seal surrounding the compartment for containing the liquid detergent composition. The water-soluble film contains a polyvinyl alcohol resin, and the polyvinyl alcohol resin is made of a polyvinyl alcohol homopolymer. A unit dose article wherein the total volume of the liquid detergent composition is 10 mL to 20 mL.

2. The unit dose article according to claim 1, wherein the laundry detergent composition contains 5% to 60% by weight of a non-soap anionic surfactant in the detergent composition.

3. The unit-dose article according to claim 1 or 2, wherein the laundry detergent composition contains 1% to 25% by weight of a nonionic surfactant in the laundry detergent composition.

4. The unit-dose article according to any one of claims 1 to 3, wherein the laundry detergent composition contains 0.5% to 15% water in the liquid laundry detergent composition.

5. The unit dose article according to any one of claims 1 to 4, wherein the total volume of the liquid detergent composition is 12 mL to 18 mL.

Images