Laundry detergents and supplies

Abstract

This disclosure provides cleaning supplies. The supplies can be formed from two outer layers separated by an intermediate layer which may contain one or more independent, isolated compositions. The outer layers can be formed from a solid foam and, in particular, can be configured to allow access to the intermediate layer composition from the surrounding environment. The outer layers can provide rapid penetration of water to facilitate the diffusion of the intermediate layer composition through the outer layers, as well as the dissolution of the outer layers and intermediate layers.

Description

[Technical Field]

[0001] This disclosure relates to detergent formulations and supplies for providing unit doses of detergent formulations having improved solubility, particularly for automatic washing machines. The supplies may include detergent formulations contained within porous sheet materials, such as sheets formed from water-soluble materials. [Background technology]

[0002] The use of water-soluble film carriers for delivering unit-dose laundry products is known, and detergents and bleaches have been sold in this form for many years. Known unit-dose detergent products may suffer from insufficient dissolution of the carrier material, which can worsen the poor solubility of the detergent held by the carrier. This can result in wash cycles where substantially undissolved carrier remains during the wash load, or wash cycles where residue exists due to detergent released from the product but not completely dissolved. There remains a demand and need for laundry detergent compositions in unit-dose form. There is also a demand and need for unit-dose laundry compositions and products that achieve improved solubility in the washing machine while maintaining the efficacy expected by consumers of current liquid laundry detergents and sachets. Furthermore, there is a demand for visually distinguishing differentiated product types (i.e., sub-brands and / or targeted effects such as odor control, stain prevention, softening, etc.) in a way that still optimizes complete solubility during washing. [Overview of the project] [Means for solving the problem]

[0003] Summary of Disclosure This disclosure relates to laundry detergent products. The laundry detergent products described herein can be provided as unit-dose articles, in that each individual unit is intended to provide a sufficient amount of detergent to perform a typical load of laundry in a standard washing machine. The products include detergent, at least partially contained within a water-soluble sheet material to provide a unit dose. More specifically, the unit-dose laundry detergent products according to this disclosure can be defined by at least two outer sheets and at least one intermediate layer positioned between the two outer sheets. Each sheet can be particularly composed of a solid foam, a water-soluble material. The sheet material includes pores that improve water penetration for diffusing the retained detergent material through the sheet material and for dissolving the sheet material itself. Each detergent material can form part of an outer sheet and / or be present within at least one intermediate layer. Alternatively, one or more detergent materials can be combined to form a detergent composition provided as at least one intermediate layer. In some embodiments, multiple different detergent compositions can be deposited as multiple separate fillers defining a single intermediate layer or multiple intermediate layers. A separate filler (i.e., a separate detergent composition) may exhibit a visually distinguishable color such as blue, green, pink, purple, white, or a combination thereof, and may demonstrate cleaning function. The composition of the laundry detergent products of this disclosure can offer several advantages, such as improving detergent diffusion and beneficially providing additional cleaning efficacy.

[0004] Compositions defining one or more intermediate layers or fillers can be formulated to exhibit high solubility in water so that the detergent material can quickly disperse in the wash water and provide a cleaning function to the article being washed. Such compositions can also be provided in a form that imparts stability so that the composition remains in a solid or semi-solid state and thus avoids outflow or leaching from the boundaries defined by the outer sheet. This combination of high solubility and high stability can be difficult to achieve, and the present disclosure can relate to specific formulations that impart this combination of properties. In certain embodiments, this can include, in particular, formulations in which the detergent composition is combined with a polymer additive to form a stable foam structure.

[0005] In one or more embodiments, the cleaning article according to the present disclosure can include a first outer layer that is porous and contains a water-soluble polymer, a second outer layer that is porous and contains a water-soluble polymer, and an intermediate layer disposed between the first outer layer and the second outer layer. The intermediate layer can include at least a first segment and a second segment. The first segment is formed from a first composition having at least one cleaning component, and the second segment is formed from a second composition having at least one cleaning component. The second composition is different from the first cleaning composition. At least the first segment and the second segment are disposed in one or both of the longitudinal and transverse directions of the cleaning article. In further embodiments, the cleaning article can be defined in relation to one or more of the following descriptions, and these descriptions can be combined in any number and / or order.

[0006] One or both of the first outer layer and the second outer layer can include a cleaning component.

[0007] One or both of the first outer layer and the second outer layer can be configured as a solid foam sheet.

[0008] One or both of the first outer layer and the second outer layer can be configured as a fabric.

[0009] The first outer layer and the second outer layer can each be configured as a sheet having a porosity measured as the pore void volume divided by the total sheet volume, and the porosity is from about 10% to about 90%.

[0010] At least one of the first composition and the second composition can be configured as a foam containing a water-soluble polymer having a melting point in the range of about 40°C to about 80°C mixed with at least one cleaning component.

[0011] The water-soluble polymer can be a polyethylene glycol (PEG) polymer.

[0012] The PEG polymer can have a molecular weight from about 1,000 Da to about 300,000 Da.

[0013] The water-soluble polymer can constitute from about 10% to about 50% by weight of the foam structure.

[0014] At least one of the first cleaning composition and the second cleaning composition can be configured as a semi-solid.

[0015] The semi-solid can have a complex elastic modulus (G*) of 5,000 Pa or more at ambient temperature.

[0016] The semi-solid can be a paste.

[0017] The semi-solid can contain one or both of a water-soluble solid and a water-insoluble solid at about 10% by weight or more.

[0018] The semi-solid can contain a water-soluble solid in an amount from about 30% to about 80% by weight based on the total weight of the cleaning composition.

[0019] The semi-solid can contain an alkali metal salt.

[0020] The semi-solid can be anhydrous.

[0021] The semi-solid may contain at least one base and at least one acid that are effective in reacting with water to form carbon dioxide gas.

[0022] The cleaning products may be substantially completely water-soluble at temperatures of approximately 15°C to 30°C for approximately 0.5 to 10 minutes.

[0023] At least one cleaning component may be selected from the group consisting of surfactants, enzymes, stabilizers, dyes, fluorescent whitening agents, anti-redeposition agents, fluorescent whitening agents, fragrances, chelating agents, foam regulators, corrosion inhibitors, color transfer inhibitors, fabric softeners, fragrances, pH control and buffering agents, antioxidants, viscosity enhancers, formulation aids, bittering agents, thickeners, defoamers, pH adjusters, bleaches, fabric softeners, pearlescent agents, preservatives, and laundry boosters.

[0024] The first and second compositions may, individually, include one of the following: a cleaning composition, an odor removal composition, a softening composition, a bleaching composition, an enzyme composition, and a booster composition.

[0025] The first composition may have a first color, and the second composition may have a second color that is visually distinct from the first color.

[0026] The first color of the first composition can correspond to a first cleaning function, and the second color of the second composition can correspond to a second cleaning function that is different from the first cleaning function.

[0027] At least the first and second segments can be arranged as a colored pattern visible through either or both of the first and second outer layers.

[0028] The coloring pattern may be an alternating pattern of straight and curved strips, or both.

[0029] One or both of the first and second outer layers can have a transparency of approximately 5% to approximately 50%.

[0030] The brightness of each of the first and second colors may be greater in the cross-sectional view of the cleaning product than when the intermediate layer is seen through one or both of the first and second outer layers.

[0031] At least one of the first and second colors can be defined by one of the following: blue, defined by L*a*b* values ​​of approximately 64, approximately -14, and approximately -20; green, defined by L*a*b* values ​​of approximately 75, approximately -10, and approximately 8; and purple, defined by L*a*b* values ​​of approximately 75, approximately 5, and approximately -7.

[0032] The first color may have a first set of L*a*b* values ​​when measured at the edge of the cleaning product where the intermediate layer is not obstructed by the first or second outer layer, and may have a second different set of L*a*b* values ​​when measured through the first and second outer layers.

[0033] The L* value of the first color may be higher when measured through either the first or second outer layer.

[0034] The a* value and / or the b* value may be smaller when measured through one of the first and second outer layers.

[0035] The cleaning material may have a length measured along the longitudinal axis, a width measured along the transverse axis, and a thickness measured in directions perpendicular to the longitudinal and transverse axes, and one of the following may apply: the cleaning material may be composed of a length-to-width ratio (L:W) of about 1:1 to about 10:1; the cleaning material may be composed of a length-to-thickness ratio (L:T) of about 10:1 to about 200:1; the first outer layer, the second outer layer, and the intermediate layer may each have individual thicknesses; the ratio of the individual thickness of either the first or second outer layer to the individual thickness of the intermediate layer may be about 0.05:1 to about 2:1.

[0036] The first outer layer may have a first outer layer surface having a first surface area, and the second outer layer may have a second outer layer surface having a second surface area, the sum of the first and second surface areas may be the total surface area of ​​the cleaning product, the intermediate layer may define an edge along one or more sides of the cleaning product, the intermediate layer is not covered by the first or second outer layer, the edge has a total edge surface area, and the cleaning product may consist of an edge-to-face area ratio (EFAR) of less than 0.5, defined as the ratio of the total edge surface area to the total surface area.

[0037] EFAR can range from approximately 0.01 to approximately 0.5.

[0038] In one or more embodiments, the Disclosure includes a method for preparing a cleaning product, comprising combining a first composition having at least one cleaning component and a second composition having at least one cleaning component with a first outer layer and a second outer layer to form an intermediate layer between the first outer layer and the second outer layer, wherein the first composition defines a first segment of the intermediate layer and the second composition defines a second segment of the intermediate layer, and the combination is performed such that the first segment and the second segment are positioned longitudinally and transversely or both within the cleaning product between the first outer layer and the second outer layer. The Disclosure further encompasses cleaning products prepared according to the Method. In further embodiments, a cleaning product may be defined in relation to one or more of the following descriptions, and these descriptions may be combined in any number and / or order.

[0039] The first outer layer and the second outer layer may each be porous and may contain a water-soluble polymer.

[0040] The cleaning products may be substantially completely water-soluble at temperatures of approximately 15°C to 30°C for approximately 0.5 to 10 minutes.

[0041] At least one cleaning component may be selected from the group consisting of surfactants, enzymes, stabilizers, dyes, fluorescent whitening agents, anti-redeposition agents, fluorescent whitening agents, fragrances, chelating agents, foam regulators, corrosion inhibitors, color transfer inhibitors, fabric softeners, fragrances, pH control and buffering agents, antioxidants, viscosity enhancers, formulation aids, bittering agents, thickeners, defoamers, pH adjusters, bleaches, fabric softeners, pearlescent agents, preservatives, and laundry boosters.

[0042] In one or more embodiments, the cleaning product according to the Disclosure may comprise a cleaning agent composition and a water-soluble polymer having a melting point in the range of about 40°C to about 80°C, wherein the cleaning agent composition and the water-soluble polymer are mixed to define a foam structure. In further embodiments, the cleaning product may be defined in relation to one or more of the following descriptions, which may be combined in any number and / or order. The foam structure may be substantially non-flowing at temperatures below 40°C and ambient pressure when not in contact with an aqueous liquid. The cleaning product may be substantially completely water-soluble in a time of about 0.5 minutes to about 10 minutes at temperatures of about 15°C to about 30°C. The detergent composition may contain one or more materials selected from the group consisting of surfactants, enzymes, stabilizers, dyes, fluorescent whitening agents, anti-redeposition agents, fluorescent whitening agents, fragrances, chelating agents, foam regulators, corrosion inhibitors, color transfer inhibitors, fabric softeners, fragrances, pH control and buffering agents, antioxidants, viscosity enhancers, formulation aids, bittering agents, thickeners, defoamers, pH adjusters, bleaching agents, fabric softeners, pearlescent agents, preservatives, laundry boosters, and combinations thereof. The water-soluble polymer may be polyethylene glycol (PEG) polymer. PEG polymers can have a molecular weight of about 8,000 Da to about 20,000 Da. Water-soluble polymers can constitute about 2% to about 75% by weight of the foam structure. Water-soluble polymers can constitute about 10% to about 50% by weight of the foam structure. The foam structure can be arranged between a first outer layer and a second outer layer, each independently being solid and porous, and formed from the same or different second water-soluble polymer as the water-soluble polymer mixed with the detergent composition to define the foam structure. One or both of the first and second outer layers can contain a cleaning component held within the layer. The cleaning component held within one or both of the first and second outer layers may be a surfactant.The first and second outer layers can each be constructed as sheets having a porosity measured as the volume of pores divided by the total sheet volume, with a porosity of approximately 10% to 90%. The first and second outer layers can each contain polyvinyl alcohol material.

[0043] In one or more embodiments, the Disclosure may provide a cleaning product comprising a first outer layer, a second layer, and an intermediate layer. The first and second layers may be solid, porous, and formed from a water-soluble polymer. The intermediate layer may include a plurality of individual filler compositions positioned between the first and second outer layers so that the cleaning product is configured as a sheet. In particular, at least one of the plurality of individual filler compositions may be defined as a cleaning product comprising a cleaning agent composition and a water-soluble polymer having a melting point in the range of about 40°C to about 80°C, wherein the cleaning agent composition and the water-soluble polymer are mixed to define a foam structure. Each of the plurality of individual filler compositions contains one or more cleaning components and exhibits a visually distinguishable color resulting in an intermediate layer having a color pattern. The intermediate layer is configured to have thickness, each having a length and width that is individually greater than the thickness of the sheet. This arrangement allows the color pattern of the intermediate layer to be visible through one or both of the first and second outer layers. In further embodiments, the cleaning product may be defined in relation to one or more of the following descriptions, and these descriptions may be combined in any number and / or order. One or both of the first and second outer layers may contain cleaning components held within the layers. The cleaning components held within one or both of the first and second outer layers may be surfactants. The water-soluble polymer forming one or both of the first and second outer layers may include polyvinyl alcohol (PVOH). Polyvinyl alcohol can be partially hydrolyzed and may have a molecular weight of about 25 kg / mol to about 100 kg / mol. One or both of the first and second outer layers may be constructed as a solid foam.One or more cleaning components in each of the multiple individual filling compositions may be selected from the group consisting of surfactants, enzymes, stabilizers, dyes, fluorescent whitening agents, anti-redeposition agents, fluorescent whitening agents, fragrances, chelating agents, foam regulators, corrosion inhibitors, color transfer inhibitors, softeners, fragrances, pH control and buffering agents, antioxidants, viscosity enhancers, formulation aids, bittering agents, thickeners, defoamers, pH adjusters, bleaches, fabric softeners, pearlescent agents, preservatives, laundry boosters, and combinations thereof. The visually distinguishable colors of each of the multiple individual filling compositions may correspond to their cleaning functions. The visually distinguishable color brightness of each of the multiple individual filler compositions can be greater in a cross-sectional view of the cleaning product than when viewed through one or both of the first and second outer layers. At least one of the visually distinguishable colors may be blue, defined by L*a*b* values ​​of about 64, about -14, and about -20, respectively. At least one of the visually distinguishable colors may be green, defined by L*a*b* values ​​of about 75, about -10, and about 8, respectively. At least one of the visually distinguishable colors may be purple, defined by L*a*b* values ​​of about 75, about 5, and about -7, respectively. The cleaning product can be constructed with a length-to-width ratio (L:W) of about 1:1 to about 10:1. The cleaning product can be constructed with a length-to-thickness ratio (L:T) of about 10:1 to about 200:1. The cleaning product can be constructed with a length-to-thickness ratio (L:T) of about 1:1 to about 20:1. The first outer layer, the second outer layer, and the intermediate layer each have individual thicknesses, and the ratio of the individual thickness of either the first or second outer layer to the individual thickness of the intermediate layer may be about 0.05:1 to about 2:1. The coloring pattern may be an alternating stripe pattern. One or both of the first and second outer layers may have a transparency of about 5% to about 50%. The intermediate layer may be constructed as a semi-solid with some fluidity. The semi-solid may have a complex modulus (G*) of 5,000 Pa or more.The first and second outer layers can be configured to be substantially completely water-soluble at approximately 15°C and 30°C, respectively, in a time of approximately 0.5 to 10 minutes. The first and second outer layers can each be configured as a sheet having a porosity measured as the volume of pores divided by the total sheet volume, with a porosity of approximately 10% to 90%. The multiple individual filling compositions forming the intermediate layer may include at least two of the following: a cleaning composition, an odor removal composition, a softening composition, a bleaching composition, an enzyme composition, and a booster composition. The product may include two intermediate layers separated by a divided layer, providing an overall structure from top to bottom: the first outer layer, the first intermediate layer, the divided layer, the second intermediate layer, and the second outer layer.

[0044] In one or more embodiments, the Disclosure may provide a method for preparing cleaning products. In non-limiting examples, such a method may include combining a cleaning agent composition with a water-soluble polymer having a melting point in the range of about 40°C to about 80°C; heating the cleaning agent composition combined with the water-soluble polymer above the melting point of the water-soluble polymer to form a fluid cleaning agent / polymer mixture; aerating the fluid cleaning agent / polymer mixture to form a fluid foam; and cooling the fluid foam to form a substantially solid foam structure. In further embodiments, the method may be defined in relation to one or more of the following descriptions, which may be combined in any number and / or order. Mixing and / or heating may be carried out simultaneously. The fluid cleaning agent / polymer mixture may be about 0.2 g / cm³ 3 ~about 0.5g / cm 3It can have a density of . Aeration may include mixing by a high-speed mixer. Aeration may include blowing gas into the fluid detergent / polymer mixture. A substantially solid foam structure may be substantially non-flowing at temperatures below 40°C and ambient pressure when not in contact with an aqueous liquid. The method may further include casting a fluid foam such that a substantially solid foam structure exhibits a defined shape of defined dimensions. The method may further include combining the fluid foam with at least one sheet which is solid and porous and formed from the same or different second water-soluble polymer as the water-soluble polymer in the fluid foam. The substantially solid foam structure and at least one sheet may have substantially the same length and substantially the same width. In addition to the above, the disclosure may provide cleaning products prepared according to the above method or other methods discussed herein. In particular, cleaning products prepared by the method may exhibit any properties shown by the cleaning products described herein, such as being substantially completely water-soluble at temperatures of about 15°C and about 30°C in a time of about 0.5 minutes to about 10 minutes. [Brief explanation of the drawing]

[0045] While the aspects of this disclosure have been described using the general terminology described above, refer here to the attached drawings, which are not necessarily drawn to a consistent scale. The drawings are illustrative and should not be construed as limiting this disclosure. [Figure 1] Figure 1 shows an example of a unit-dose laundry detergent product configured as a multilayer sheet according to an embodiment of the present disclosure. [Figure 2] Figure 2 is a graph showing the force corresponding to the complex modulus according to the embodiment of this disclosure. [Figure 3] Figure 3 is a photograph showing a water-soluble sheet material sandwiching a detergent formulation according to an embodiment of the present disclosure. [Figure 4] Figure 4 shows another example of a unit-dose laundry detergent product according to an embodiment of the present disclosure. [Figure 5]Figure 5 shows a method for manufacturing a unit-dose laundry detergent product according to an embodiment of the present disclosure. [Figure 6] Figure 6 illustrates another method for manufacturing unit-dose laundry detergent products according to an embodiment of the present disclosure. [Figure 7] Figure 7 illustrates a method for changing the size parameter of a sheet material according to an embodiment of the present disclosure. [Figure 8] Figure 8 is a graph showing the dissolution percentage as a function of the weight fraction of one component of a composition according to an example embodiment of the present disclosure. [Figure 9] Figure 9 is a graph showing the pH change as a function of time for a composition according to an example embodiment of the present disclosure. [Figure 10] Figure 10 is a graph showing the dissolution percentage as a function of the weight fraction of one component for a composition according to an example embodiment of the present disclosure. [Figure 11] Figure 11 is a graph showing the pH change as a function of time for a composition according to an example embodiment of the present disclosure. [Figure 12] Figure 12 is a graph showing the change in the complex modulus of elasticity as a function of applied shear stress for a slurry composition according to an example of an embodiment of the present disclosure. [Figure 13] Figure 13 is a graph showing the dissolution time of cleaning products prepared using a solid foam structure formed from a mixture of a detergent concentrate and two different water-soluble polymers. [Modes for carrying out the invention]

[0046] Herein, this disclosure is described more fully below with reference to the accompanying drawings. This disclosure may be embodied in many different forms and should not be construed as being limited to the embodiments described herein, but rather these embodiments are provided so as to satisfy the applicable legal requirements. Throughout, similar numbers refer to similar elements. Where used herein and in the claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly indicates otherwise.

[0047] In one or more embodiments, the Disclosure provides cleaning products, for example, laundry detergents. The cleaning products may be provided as substantially solid articles so that consumers can handle them directly and substantially maintain their shape through such handling. The cleaning products according to the Disclosure may be defined as a single object, which may be a single mass of a substantially homogeneous composition. Alternatively, the cleaning products may be defined as a single object, which may be a combination of several separate masses, compositions, layers, sections, pieces, etc. In certain embodiments, the cleaning products according to the Disclosure may be molded to be substantially sheet-like, and thus may be defined by a single sheet, or may include several separate layers, one or more of which are in sheet-like form. In various embodiments, one, two, three, four, or more outer layers may be utilized and thus referred to as a first outer layer, a second outer layer, a third outer layer, etc. Any one or more outer layers used in the product may be referred to as “sheets,” “outer sheets,” or “retaining sheets,” taking into account one functional aspect of a sheet that holds filler material between them.

[0048] In some embodiments, the cleaning products according to the present disclosure may include, in addition to a plurality of outer layers, at least one “intermediate layer,” which may also be referred to as a “filler layer,” a “filling layer,” or simply “filling.” The term “intermediate” in this use indicates the positioning of the layer relative to the outer layers or retaining sheets. The intermediate layer / filling may include a plurality of separate filling compositions. In some embodiments, the first and second outer layers may be two separate, distinct layers, but the first and second outer layers may be defined by a single folded retaining sheet such that, in some embodiments, the intermediate layer is located between a portion of a single sheet defining the first outer layer and a portion of a single sheet defining the second outer layer. In some embodiments, the intermediate layer filling composition may be referred to as “sandwiched” between at least the first outer layer or retaining sheet and the second outer layer or retaining sheet.

[0049] In another embodiment, three or more retaining sheets can be used. For example, a cleaning product may be configured such that a first retaining sheet and a second retaining sheet are arranged as outer layers, and at least a third retaining sheet is arranged as a dividing layer, where the term dividing layer in this use refers to the positioning of the dividing layer relative to at least two intermediate or filling layers. In such embodiments, the first intermediate layer or filling can be placed between the first outer layer and the dividing layer, and the second intermediate layer or filling can be placed between the second outer layer and the dividing layer. Each of the first and second intermediate layers may contain a plurality of distinct filling compositions, and each of the first and second intermediate layers may have different overall compositions and / or combinations of compositions. In some embodiments, each intermediate layer contains the same filling composition, but each intermediate layer may, in some embodiments, have alternating or different compositions. In some embodiments, the intermediate layer composition can be referred to as “sandwiched” between the first and second outer layers, “sandwiched” between the outer layer and the dividing layer, or “sandwiched” between the two dividing layers. In some embodiments, a divided layer can be referred to as being "sandwiched" between a first intermediate layer and a second intermediate layer. In an unrestricted example, a cleaning product may include, from top to bottom, a first outer layer, an intermediate layer, and a second outer layer. In another unrestricted example, a cleaning product may include, from top to bottom, a first outer layer, a first intermediate layer, a divided layer, a second intermediate layer, and a second outer layer. In yet another unrestricted example, a cleaning product may include, from top to bottom, a first outer layer, a first intermediate layer, a first divided layer, a second intermediate layer, a second divided layer, a third intermediate layer, and a second outer layer. In each of the foregoing, any of the intermediate layers may comprise a single composition or a plurality of distinct compositions arranged apart to form an intermediate layer. Similarly, in each of the foregoing, any of the first outer layer, the second outer layer, the first divided layer, and the second divided layer may have the same composition or different compositions.

[0050] Figure 1 shows an example of an embodiment of a cleaning product according to the present disclosure. Specifically, the product comprises two retaining sheets which can be characterized as a first outer layer and a second outer layer, and an intermediate layer which can be characterized as a filler or packing agent. The product can be configured such that the packing agent is in direct contact with (or generally held by) the outer layers. The products of the present disclosure are configured such that the outer layers dissolve rapidly in water or other aqueous liquids suitable for use with the cleaning product. Rapid dissolution also advantageously promotes the diffusion and / or dissolution of the packing agent in water.

[0051] The cleaning products of this disclosure can be characterized as being in the form of a sheet or a multilayer sheet when each of the individual layers is combined. Thus, each cleaning product sheet may be a composite of several separate sheets and a filling layer. The layered structure is beneficial for positioning specific cleaning agent components to limit contact with the user and can limit contact between components. This arrangement is further beneficial because the retaining sheet defining the outer layer and any divided layers may be in a substantially solid form, while at least one intermediate layer is less structured and rather a semi-solid with some fluidity. As will be further discussed herein, the degree of fluidity is preferably limited to be measured and defined by having at least a minimum complex modulus (G*) value. In some embodiments, the semi-solid may be configured as a gel, slurry, or paste. Thus, the retaining sheet is in direct contact with one or more compositions defining at least one intermediate layer and is effective in maintaining the entire product as a solid, compact article that is easily handled by the consumer. When the cleaning product comes into contact with an aqueous medium, such as a laundry detergent, the retaining sheet defining the outer layer is exposed to the aqueous medium and dissolves, completely releasing the cleaning composition present in at least one intermediate layer that is in direct contact with the outer layer. In other embodiments, the filler or intermediate layer may be configured to be substantially solid, such as in the form of a substantially solid foam structure. By providing the filler or intermediate layer as a solid foam structure, the stability of the cleaning product can be improved while still allowing a suitable dissolution time in the cleaning water.

[0052] In embodiments comprising at least two intermediate layers and one or more segmented layers, the segmented layers can exhibit delayed release of any cleaning material held therein relative to the outer layer. In particular, as the intermediate layers dissolve in the aqueous medium, the segmented layers are exposed to and dissolve in the aqueous medium.

[0053] The retaining sheet defining the outer layer is configured to have substantially high porosity so that water can diffuse in and out of the outer layer and begin dissolving the composition in at least one intermediate layer before the outer layer itself is completely dissolved. Similarly, any existing segmented layers may exhibit similar porosity and water diffusion capacity. Furthermore, one or more detergents may be incorporated into the structure of the retaining sheet, and such detergents may be rapidly released as water penetrates the retaining sheet through its many pores.

[0054] The intermediate layer(s) used in the cleaning supplies are specifically configured to exhibit a high degree of water solubility while having a storage-stable physical structure, meaning that the composition used in the intermediate layer does not bleed out of the supplies or leak out in any other way (e.g., rise or bleed outward from between the outer layers and / or seep through pores in the outer layers). As further described herein, this can be achieved in various ways depending on the desired physical structure of the intermediate layer composition. In some embodiments, the intermediate layer composition may be in a semi-solid form such as a gel, slurry, paste, or dough, exhibiting a structure sufficient to avoid bleed or leak as described above. In other embodiments, the intermediate layer composition may be in the form of a substantially solid foam structure that similarly avoids bleed or leak from the cleaning supplies. In one or more embodiments, certain states may be explicitly excluded. For example, the composition for the intermediate layer does not have to be in the form of a gel, nor in the form of a slurry, nor in the form of a paste, nor in the form of a foam. The cleaning supplies can further retain their original chemical and physical properties as described herein over a relatively wide temperature range that may be encountered during storage. Furthermore, the retaining sheet (or outer layer) may be configured to allow the semi-solid composition forming at least one intermediate layer to diffuse through it when in contact with an aqueous medium. Nevertheless, the retaining sheet is configured such that a significant amount of the intermediate layer composition does not escape or leak out from the cleaning supplies or through the outer layer before use. Similarly, the outer layer may be configured to allow water to diffuse through it (e.g., via a network of interconnected pores) to facilitate the dissolution of the intermediate layer(s).

[0055] The structural arrangement of some components of the cleaning products of this disclosure can, for example, enhance the efficiency of the cleaning products as laundry detergents. For example, a high surface area of ​​the cleaning product, when arranged in sheet form, can increase the diffusion rate of the intermediate layer composition through the outer layer. Similarly, a retaining sheet can be configured to facilitate the diffusion of the intermediate layer composition in an aqueous medium, while also limiting the exposure of consumers to components of the intermediate layer composition when handling the cleaning product, and limiting the mixing of any separated components through the retaining sheet before use. For example, certain components, such as enzymes or basic substances, may be irritating to the skin, and the cleaning product may still contain such substances in the intermediate layer, while the outer layer has a composition that is substantially non-irritating. The dissolution rates of the intermediate layer composition and the outer layer directly affect the efficiency and performance of the cleaning product. For example, providing a faster release of the components of the cleaning product into the cleaning solution can increase the possibility that substantially the entirety of the cleaning product components is dispersed during the washing cycle to provide their individual cleaning functions. Furthermore, a faster dissolution rate means a shorter washing cycle, which is more environmentally friendly and leads to a reduction in water and electricity consumption during washing. In some embodiments, the porosity of the retaining sheet may form a gradient, with the exposed outer surface of the retaining sheet being more porous than the inner surface that is in direct contact with the intermediate layer. Reducing the porosity of the inner surface that is in direct contact with the intermediate layer increases the retention of the intermediate layer composition, while increasing the porosity of the outer surface increases water permeability and accelerates the dissolution rate. Therefore, one or both of the pore size and porosity (or pore percentage) may increase from the inner surface to the outer surface along the thickness of the retaining sheet.

[0056] The cleaning supplies described herein can be provided in a variety of shapes and sizes, which can be determined at least in part by the overall shape of the retaining sheet. For example, the outer layer, as viewed from the top or bottom, and therefore the entire cleaning supply, may be substantially square, rectangular, parallelogram, triangular, circular, or other shapes, but may conveniently have a rectangular or square shape when viewed perpendicular to the plane of its two longest dimensions. Rectangular or square cleaning supplies can be manufactured more easily than other configurations when using conventional packaging equipment.

[0057] The cleaning products disclosed may be offered in different sizes and weights (e.g., small, medium, large) to meet different consumer needs. The size may correspond to the recommended detergent dosage for a load or level of soiling of laundry fabrics. Furthermore, the retaining sheet may independently have a thickness that is thinner, thicker, or equal to at least one intermediate layer composition. The weight and dimensions of the cleaning products may be balanced to ensure the rapid and complete dissolution of the products in the cleaning water. In various embodiments, the cleaning products described herein may have a length defined by an upper limit of 30 cm and a lower limit of 5 cm, which includes all possible ranges bounded by the upper and lower limits (e.g., 5 cm to 30 cm, 10 cm to 25 cm, etc.), and therefore all integers (or fractions thereof) from 5 to 30 are expressly included in this disclosure to define the upper and lower limits of the included range. Similarly, the length may be "at least" one of the values ​​within the above range, or "less than" one of the values ​​within the above range. In various embodiments, the cleaning product may have a width defined by an upper width of 20 cm and a lower width of 3 cm, which includes all possible ranges limited by the upper and lower widths (e.g., 3 cm to 20 cm, 5 cm to 15 cm, etc.). Similarly, the width may be "at least" one of the values ​​within the above range, or "less than" one of the values ​​within the above range. In various embodiments, the cleaning product may have a thickness defined by an upper thickness of 20 mm and a lower thickness of 2 mm, which includes all possible ranges bounded by the upper and lower thicknesses (e.g., 2 mm to 20 mm, 5 mm to 15 mm, etc.), and therefore all integers (or fractions thereof) from 2 to 20 are expressly included in this disclosure to define the upper and lower boundaries of the included range. Similarly, the thickness may be "at least" one of the values ​​within the above range, or "less than" one of the values ​​within the above range. In some embodiments, for example, if multiple individual intermediate layers are separated by one or more segmented layers, the overall thickness of the cleaning product can be increased by multiplying it by a multiple of the number of intermediate and segmented layers.Therefore, the cleaning supplies may take the form of a cube or cuboid, cylinder, pentagonal prism, hexagonal prism, or any other three-dimensional shape. For example, a cleaning supply having the length and width within the range already described above may have a total thickness of approximately 100 mm, 80 mm, 50 mm, or 30 mm. In an example of a larger thickness embodiment of the cleaning supply, the cleaning supply may have a thickness defined by an upper limit of 100 mm and a lower limit of 10 mm, which includes all possible ranges bounded by the upper and lower limits (e.g., 10 mm to 100 mm, 20 mm to 80 mm, etc.), and therefore all integers (or fractions thereof) from 10 to 100 are expressly included in this disclosure to define the upper and lower limits of the included range.

[0058] The disclosed retaining sheets can also be offered in different sizes and weights (e.g., small, medium, large) to meet different consumer needs. The size may correspond to the recommended detergent dosage for a load or level of soiling of laundry fabrics. Furthermore, the retaining sheets may have a thickness that is thinner, thicker, or equal to that of the intermediate layer composition. The weight and dimensions of the retaining sheets can be balanced to ensure rapid and complete dissolution of the layers in wash water while limiting gel flow or creep of at least one intermediate layer through the retaining sheet during packaging, shipping, handling, etc.

[0059] In various embodiments, each retaining sheet described herein may individually have a length and width substantially the same as the length and width of the entire cleaning product. In various embodiments, each retaining sheet may have a thickness defined by an upper limit thickness of 15 mm and a lower limit thickness of 0.5 mm, which includes all possible ranges bounded by the upper and lower limit thicknesses (e.g., 0.5 mm to 15 mm, 0.5 mm to 10 mm, 1 mm to 5 mm, etc.), and therefore all integers (or fractions thereof) from 0.5 to 20 are expressly included in this disclosure to define the upper and lower limits of the included range. Similarly, the thickness may be "at least" any of the values ​​within the above range, or "less than" any of the values ​​within the above range. In certain embodiments where at least one segmented layer is present, at least one segmented layer may have a size and / or weight equal to the size and / or weight of each of the outer layers. At least one segmented layer may have the same length, width, and thickness as each outer layer, but in some embodiments, at least one segmented layer may have a different length, width, and thickness from each of the outer layers, or a combination thereof.

[0060] In various embodiments, the intermediate layers described herein may have a length and / or width less than or equal to the length and / or width of the outer layer. By providing individual intermediate layers having a length and / or width smaller than the length and / or width of the retaining sheet, extra space can be provided for the intermediate layer (especially if it is in the form of a semi-solid material) to flow out during packaging, shipping, handling, or use, providing extra space for gel flow or creep and preventing the intermediate layer from creeping beyond the outer boundary or edge of the retaining sheet.

[0061] Each intermediate layer may have a thickness range based on its weight, specific gravity, and viscosity, as well as the amount of cleaning composition required to achieve optimal cleaning results. In some embodiments, each intermediate layer may have a thickness defined by an upper limit of 15 mm and a lower limit of 0.5 mm, which includes all possible ranges bounded by the upper and lower limits (e.g., 0.5 mm to 15 mm, 0.5 mm to 10 mm, 1 mm to 5 mm, etc.), and therefore all integers (or fractions thereof) from 0.5 to 20 are expressly included in this disclosure to define the upper and lower limits of the included range. Similarly, the thickness may be "at least" one of the values ​​within the above range, or "less than" one of the values ​​within the above range. Cleaning products can be further characterized with respect to the length-to-width and / or length-to-thickness ratio. In some embodiments, the cleaning product may have a length-to-width ratio (i.e., L:W) of about 1:1 to about 10:1, about 1:1 to about 5:1, or about 1: to about 3:1. In some embodiments, the cleaning product may have a length-to-thickness ratio (L:T) of about 10:1 to about 200:1, about 15:1 to about 100:1, or about 20:1 to about 80:1. However, as described above, thicker embodiments are also encompassed by this disclosure, and the L:T ratio in such embodiments may be about 1:1 to about 20:1, about 2:1 to about 15:1, or about 3:1 to about 12:1. The width-to-thickness ratio (W:T) may be within the same range as the L:T ratio, and the W:T ratio may be less than or equal to the L:T ratio. The ratio (Tr:Tf) of the thickness of an individual retaining sheet (e.g., an outer layer or segmented layer) to the thickness of an individual intermediate layer (e.g., an individual filler layer formed from multiple different compositions) can be about 0.05:1 to about 2:1, about 0.1:1 to about 2:1, about 0.5:1 to about 1.5:1, or about 0.8:1 to about 1.2:1.

[0062] The entire cleaning product can be provided in dimensions that can provide improved dissolution and diffusion of the various components of the cleaning product resulting from the combination of the outer layer and intermediate layer composition. Examples of non-limiting embodiments include a length of about 130 cm, a width of about 100 cm, and a thickness of about 1 to 10 mm; a length of about 15 cm, a width of about 10 cm, and a thickness of about 0.5 to 5 mm; a length of about 11 cm, a width of about 7 cm, and a thickness of about 0.5 to 5 mm; a length of about 10 cm, a width of about 6.5 cm, and a thickness of about 0.5 to 5 mm; a length of about 6.5 cm, a width of about 5 cm, and a thickness of about 0.5 to 5 mm.

[0063] The aforementioned dimensions and ratios can be specifically selected to provide improved dissolution and diffusion of various components of the cleaning product resulting from the combination of the retaining sheet and the intermediate layer composition. Similarly, the dimensions can be balanced with the weight of the intermediate layer composition in a manner not achievable with products known in the industry or disclosed in the art, in order to provide rapid and complete dissolution of the cleaning product.

[0064] In one or more embodiments, dissolution may relate to the surface area of ​​various layers for interaction with the wash water. Referring to Figure 1, a laundry product according to this disclosure, comprising at least one outer layer and at least one intermediate layer, can be defined in relation to the outer surface of the product. Each outer layer (retaining sheet) present defines a surface area having an area that can be calculated as the product of the length and width of the outer layer. The intermediate layer is covered on both its top and bottom by the outer layer, but the intermediate layer is not covered or obstructed by one or more outer layers at the edges of the product. A single intermediate layer edge has an area that can be calculated as the product of the length of the edge and the average thickness of the intermediate layer at that edge. In the embodiment of Figure 1, the product is substantially configured as a rectangle having two long edges of substantially equal length and two short edges of substantially equal length. Thus, the total edge area of ​​the intermediate layer is the sum of the areas of each individual edge.

[0065] The ratio of the surface area of ​​the laundry item to the surface area of ​​the laundry item can be determined based on competing interests. Since rapid and substantially complete dissolution of the laundry item is beneficial in maximizing its cleaning effectiveness, it may be useful for the laundry item to have a relatively large edge surface area for contact with the wash water. On the other hand, since the intermediate layer composition takes various non-solid forms, leakage or creep of the intermediate layer through the open edge should be minimized or avoided. The presence of an outer layer retaining sheet can be configured to help immobilize the intermediate layer and prevent creep, and this immobilization effect can be enhanced by providing the outer layer(s) as a porous sheet without excessively restricting the dissolution rate of the intermediate layer composition in the wash water.

[0066] In light of the foregoing, in one or more embodiments, a laundry product may be constructed with a specified edge-to-face area ratio ("EFAR"), where the edge is the edge of the intermediate layer on all sides of the product that are open and not obstructed by an outer layer(s), and the face encompasses the face of each outer layer present within the product. For example, a single face may be defined by a single outer layer folded with an intermediate layer in between, and two faces may be defined by two outer layers positioned on either side of an intermediate layer (as in Figure 1). The EFAR of a laundry product according to this disclosure may be configured to be less than 0.5, less than 0.4, less than 0.2, or less than 0.1, and may have a lower limit boundary of at least 0.01. In one or more embodiments, the EFAR may be in the range of about 0.01 to about 0.5, about 0.02 to about 0.4, or about 0.03 to about 0.2. In one or more embodiments, EFAR may be in the range of about 0.01 to about 0.2, about 0.015 to about 0.15, about 0.02 to about 0.1, or about 0.025 to about 0.09.

[0067] Each retaining sheet is porous and can be configured as a solid sheet or pad formed from a water-soluble material. In various embodiments, the retaining sheets of this disclosure are not configured as films. A film configuration indicates that the material is a continuous or uninterrupted sheet of material. A film configuration also indicates a very thin material, less than 0.2 mm or less than 0.1 mm. The configurations of the retaining sheets of this disclosure rather indicate a thicker material (as already described above), where the material contains multiple voids, pores, or other discontinuities formed therein, and as a result, when the intermediate layer is sandwiched between retaining sheets, the intermediate layer composition communicates directly with the surrounding atmosphere through the discontinuities in the retaining sheets. This allows for simultaneous dissolution of the outer layer and diffusion of the intermediate layer composition through the discontinuities in the outer layer when exposed to water.

[0068] The retaining sheet can be prepared from any material suitable for providing an outer layer having desired physical properties (e.g., solubility, porosity, and structure) and, if present, a segmented layer. In certain embodiments, the retaining sheet can be made from a water-soluble compound or a water-soluble polymer. In various embodiments, the structural material of the retaining sheet is substantially water-soluble or completely water-soluble. Solubility can be characterized as an index measured in minutes, for example, by stirring or agitating at a specific water temperature. Materials useful for water-soluble materials described herein may be partially, substantially completely, or completely water-soluble under both cold water (e.g., 15°C) and hot water (e.g., 30°C) conditions (as well as intermediate temperatures). Completely water-soluble is understood to mean that at least 99.9% by weight of the polymer is solubilized in water, and substantially completely water-soluble is understood to mean that at least 98%, at least 98.5%, at least 99%, or at least 99.5% is solubilized in water.

[0069] The time it takes for a retaining sheet to become completely or substantially completely solubilized in water, or the dissolution time, is an indicator of product performance. For example, retaining sheets that take longer to dissolve reduce the time the washed material is exposed to the cleaning components during the washing cycle. The materials useful for retaining sheets described herein are preferably completely or substantially completely water-soluble by moderate stirring in both cold and hot water for a period of about 0.5 to about 10 minutes, as defined above.

[0070] The dissolution time of the retaining sheet is directly affected by the permeability, porosity (and corresponding air permeability), thickness, and / or other parameters of the water-soluble material. By configuring an outer layer with high permeability, faster dissolution of the material forming the outer layer and faster penetration of water can be provided, thereby promoting the dissolution of the intermediate layer composition. In various embodiments, the retaining sheets described herein may have permeability that ensures liquid from the washing water permeates through the outer layer and provides a desirable rate of simultaneous dissolution of the retaining sheet and the intermediate layer composition. Since permeability can be defined with respect to pore size, consideration must be given to optimizing permeability while maintaining retention of the intermediate layer composition before use. In various embodiments, the retaining sheet may have a pore size such that a significant portion of the intermediate layer composition held between the retaining sheets does not escape before use. In some embodiments, the porosity may be configured to limit consumer exposure to the intermediate layer during handling, while achieving the desired dissolution characteristics of the retaining sheet and the intermediate layer composition through the pores in the retaining sheet. In practice, the advantage of this configuration is that it reduces or eliminates the consumer's exposure to potential irritants such as enzymes, corrosive agents, acidifying agents, fragrances, or disinfectants in the intermediate layer composition during handling.

[0071] Porosity can be qualitatively determined by visual inspection of the pore size of the retaining sheet. In some embodiments, porosity can be defined in relation to the average size of the pores in each retaining sheet. In various embodiments, the retaining sheet may have an average pore size of about 10 to 300 micrometers or about 50 to 250 micrometers. This can be evaluated using microscopy for pore counting, such as SEM. However, more generally, porosity is measured instead by sheet density (mass per unit volume), which also provides higher accuracy. In the disclosed retaining sheet, porosity can be defined as the proportion of void space in the material, where voids include air. Specifically, porosity can be determined by dividing the volume of voids in the retaining sheet by the total volume of the retaining sheet. In one or more embodiments, the porosity (mass per unit volume) may range from about 0.3 to about 1.5, depending on the components and load. In some embodiments, the porosity of each retaining sheet can be defined by the percentage of the volume of the retaining sheet occupied by pores (i.e., porosity = pore void volume / total sheet volume), with an upper limit of 0.9 (90%) and a lower limit of 0.1 (10%), and the percentage of porosity includes all possible ranges bounded by the upper and lower limits (e.g., 10% to 90%, 20% to 80%, 30% to 70%, etc.), and therefore all integers from 10 to 90 are expressly included in this disclosure to define the upper and lower limits of the range that is included. Similarly, the percentage of porosity can be "at least" one of the values ​​within the above range, or "less than" one of the values ​​within the above range.

[0072] The retaining sheet may be provided in any configuration having the porosity as already described. In one or more embodiments, the retaining sheet may be configured as a foam. In one or more embodiments, the retaining sheet may be configured as a woven fabric. In one or more embodiments, the retaining sheet may be configured as a nonwoven fabric.

[0073] In various embodiments, the retaining sheets described herein provide a means of retaining the intermediate layer and structural base of the cleaning products disclosed herein while providing a desirable rate of simultaneous dissolution of the retaining sheet and the intermediate layer composition. Since the type of solubility and structural stability of materials are often inversely proportional, the material of the retaining sheet must be considered in terms of its effect on dissolution. In some embodiments, the material of the retaining sheet may include polyvinyl alcohol, polyethylene oxide, methylcellulose, cellulose or silica reinforcing agents, or structural polymers of mixtures thereof. Among polyvinyl alcohols, partially hydrolyzed grades, particularly those hydrolyzed to a range of 87-89%, are preferred. The molecular weight can be in the range of about 25 kg / mol to about 100 kg / mol, with a molecular weight of about 30 kg / mol to about 50 kg / mol being preferred. The molecular weight may be measured as a number average (Mn) or a weight average (Mw). Unless otherwise specified, the molecular weights described herein are based on the weight average. Other polymers include starch, poly(vinylpyrrolidone), poly(vinylpyrrolidone-co-vinyl acetate), polyacrylic acid and related copolymers, alginates, carrageenan, and gums such as xanthan gum and locust bean.

[0074] The structural polymer may be intentionally separated from the intermediate layer composition, such as a detergent or caustic solubilizer, to protect the stability of the disclosed cleaning product during its manufacture at high temperatures (typically 90-100°C). In certain formulation embodiments, the retaining sheet material is processed in an aqueous fluid scenario, and this aqueous portion is maintained at an acidic pH (pH 5-6) at a drying temperature of 90-100°C to prevent the polyvinyl alcohol structural grid from coexisting with the high pH (pH 8.0-11.0) of the caustic detergent phase. Enabling the pre-formation and drying of the low pH retaining sheet material helps protect the physical integrity of the dried polyvinyl alcohol grid from the caustic pH of the intermediate layer composition added by the post-drying process of the retaining sheet material, thus maintaining both the acidic nature of the retaining sheet material and the caustic nature of the intermediate layer composition. This helps, at least in part, ensure a stable retaining sheet material and a stable intermediate layer composition for low-temperature processing or manufacture in an aqueous environment. Both the retaining sheet material and the intermediate layer composition remain integral and stable until the cleaning supplies are finally placed in the aqueous environment of the washing machine, where the retaining sheet and intermediate layer dissolve through the dissolution of polyvinyl alcohol aided by the presence of the washing water.

[0075] In one or more embodiments, the retaining sheets described herein may be configured to include, in addition to the water-soluble material itself, one or more components typically useful in detergent formulations. Useful formulations may include one or more of the following components (each of which may exist alone or as multiple different members of the group described): surfactants, chelating agents, builders, alkalizing agents, thickeners, bicarbonates, enzymes, enzyme stabilizers, dyes, fluorescent whitening agents, anti-redeposition polymers, fluorescent whitening agents, fragrances, bittering agents, defoaming agents, pH adjusters, bleaches, pearlescent luminescent agents, preservatives, and laundry boosters such as fabric softeners, fabric conditioning agents, and disintegrants such as sodium starch glycolate. In this embodiment, any embedded component does not introduce undesirable effects on clothing or other fabric articles being washed with the disclosed product, dissolves as described above under washing conditions, and preferably has a low melting point to facilitate combination with other components of the water-soluble material disclosed herein. In practice, the embedded component may provide additional cleaning properties.

[0076] The cleaning products according to this disclosure comprise one or more fillers or filling layers (i.e., intermediate layer compositions) held between retaining sheets. Because the retaining sheets are porous, the intermediate layer compositions can be provided in various forms, such as solid or substantially solid forms, including semi-solid forms (e.g., gels, slurries, pastes, or doughs) and / or foam forms (e.g., substantially solid foam structures). Similarly, where divided layers are present, such divided layers may be substantially solid forms, such as porous sheets similar to or identical to the outer layer sheets, as otherwise described herein. The intermediate layer compositions may be particularly configured to begin diffusing through the retaining sheets almost immediately upon contact with water, due to the rapid penetration of water through the pores of the retaining sheets. The intermediate layer compositions may also be configured to achieve rapid dissolution during use while still being held between the porous materials.

[0077] The intermediate layer compositions (i.e., fillers or filler compositions) used in the cleaning products according to this disclosure may contain any number of cleaning components that are typically useful in a cleaning product composition. Each intermediate layer composition may be characterized as containing one or more cleaning components, and the term “cleaning component” is understood to mean that it is a component that is useful in a laundry detergent composition. Some components of a typical laundry detergent (e.g., dyes, fragrances, defoamers, etc.) are not provided for cleaning in the sense of removing dirt or odor from laundry, but such components are still considered cleaning components according to this disclosure in that they may be present in a composition that is contained in the entire cleaning product. The following are some of the components useful for laundry detergent compositions, and therefore for laundry detergent formulations according to this disclosure (each of these may exist alone or as a different member of the group described): surfactants, chelating agents, builders, alkalizing agents, thickeners, bicarbonates, enzymes, enzyme stabilizers, dyes, fluorescent whitening agents, re-adhesion polymers, fluorescent whitening agents, fragrances, bittering agents, defoaming agents, pH adjusters, bleaches, pearlescent agents, preservatives, and laundry boosters such as fabric softeners, fabric conditioning agents, and disintegrants such as sodium starch glycolate. Any of the above components, as well as other components typically found in such products, may be used in any composition or formulation described, regardless of form or intended use. In other words, each intermediate layer composition used in the cleaning products of this disclosure may contain one, two, three, four, five, six, seven, eight, nine, or more components from the group of cleaning components listed above, within the range of one, two, three, four, five, six, seven, eight, nine, or more. Furthermore, any other components described herein that are not otherwise defined as necessary may be expressly excluded from embodiments of the intermediate layer composition. Any of the aforementioned materials may be present in one or more intermediate layer compositions in amounts of 0% to about 20% by weight, about 0.01% to about 15% by weight, about 0.02% to about 10% by weight, or about 0.05% to about 5.0% by weight, based on the total weight of the intermediate layer composition.In other embodiments, any of the aforementioned materials may be present in the intermediate layer composition in amounts of 0% to about 4.0% by weight, about 0.01% to about 3.0% by weight, about 0.02% to about 2.0% by weight, or about 0.05% to about 1.0% by weight, based on the total weight of the intermediate layer composition.

[0078] In one or more embodiments, an intermediate layer composition, configured as a semi-solid gel, slurry, paste, or dough, may exhibit specific rheological properties, such as a particular complex modulus or a range of complex moduli. Measuring the complex modulus can be useful in indicating whether the semi-solid intermediate layer composition exhibits sufficient physical properties to prevent it from flowing through any discontinuities or pores in the outer layer of the cleaning product, while also showing a sufficiently short time for partial dissolution and a sufficiently short time for complete dissolution. Preferably, the time for complete dissolution is at least within the time frame of a typical cleaning cycle (e.g., about 10 minutes). With respect to the complex modulus, G* (a measure of the total resistance to material flow) can be measured with a commercially available rheometer, such as the Anton Parr model MCR702e used in the tests described in the appended examples. To evaluate the complex modulus, a sample of the semi-solid material for use in the intermediate layer according to this disclosure can be placed between two circular plates with a diameter of 40 mm, spaced 1-2 mm apart. Next, the upper plate is vibrated back and forth at a constant frequency of 1.0 Hz (6.28 radians / second) while a stress gradient from 0.5 to approximately 700 Pa is applied. The complex modulus at the applied stress of 10 Pa (in the plateau region of the curve) is a useful parameter for characterizing the structural integrity of the semi-solid intermediate layer composition. An example of the values ​​obtained as a result of performing such an evaluation method is shown in Figure 2. In some embodiments, the composition used for the intermediate layer of the cleaning product, which is configured as a gel, slurry, or paste, is preferably 10 6 The upper limit of the complex modulus of elasticity (G*) in Pa and 10 2 The lower bound of the complex modulus of Pa (G*) can be defined by the lower bound of the complex modulus of Pa (G*), which is the entire possible range bounded by the upper and lower bounds of G* (e.g., 10 2 Pa~10 6 Pa, 102 Pa to 10 4 including Pa, etc., and thus, 10 2 to 10 6 All integers between are explicitly included in the present disclosure to define the upper and lower boundaries of the included range. Further, in some embodiments, the gel, slurry, or paste composition used for the intermediate layer can be defined by a minimum complex modulus of 5,000 Pa or more, 10,000 Pa or more, or 15,000 Pa or more. A high complex modulus can be useful to prevent the intermediate layer composition from flowing out from the edges of the cleaning product (i.e., between the two outer layers) and also to prevent the exudation of the intermediate layer composition through the porous outer layer. The magnitude of the complex modulus may also affect the dissolution time of the entire cleaning product, and staying below a specific range may be beneficial to avoid incomplete dissolution. In some embodiments, the gel, slurry, or paste composition used for the intermediate layer can preferably be defined by a complex modulus in the range of about 5,000 Pa to about 30,000 Pa, about 6,000 Pa to about 25,000 Pa, about 7,000 Pa to about 23,000 Pa, or about 8,000 Pa to about 20,000 Pa.

[0079] In one or more embodiments, the intermediate layer composition may contain one or more rheological modifiers to assist in the suspension of cleaning components that traditionally exhibit low solubility and / or low stability. In certain embodiments, the intermediate layer composition may be in the form of a slurry containing one or more suspended components. For example, a bicarbonate slurry may be used to suspend enzymes, fluorescent whitening agents, etc., and to enhance the stability of these components. In some embodiments, the slurry may contain a nonionic surfactant liquid containing a high percentage (e.g., at least 65%) of an alkali builder such as potassium carbonate. Furthermore, the structure may be provided by containing one or both of a water-soluble solid (such as sodium bicarbonate or potassium carbonate) and a water-insoluble solid (such as fumed silica such as Aerosil® R974 (Evonik)). In some embodiments, the semi-solid intermediate layer composition may contain one or more agents configured to impart sufficient rheological properties to the composition, thereby preventing leakage through exposed ends or exposed sides of cleaning supplies. Surfactants with higher melting points can be used, which may be advantageous due to their ability to function as cleaning agents while retaining their polymeric properties that can add the necessary structure to the composition. Alternatively, the composition may further contain one or more water-soluble rheological modifiers, such as gel-forming agents, gums, etc., which immobilize the formulation (i.e., prevent leakage) but are readily soluble in cold water.

[0080] In one or more embodiments, the intermediate layer composition can be formed in particular as a solid foam structure. Thus, a cleaning product according to the Disclosure may include at least one outer layer sheet and at least one intermediate layer configured as a solid foam. For example, a single outer layer sheet may be folded with at least one intermediate layer positioned between them. In some embodiments, a cleaning product according to the Disclosure may comprise a first outer layer sheet, a second outer layer sheet, and at least one intermediate layer configured as a solid foam and positioned between the first and second outer layer sheets. The intermediate layer may comprise multiple compositions, and the solid foam may be one or more of the multiple compositions. If multiple intermediate compositions exist, the multiple intermediate compositions may be selected from one or more of solid foams, gels, slurries, pastes, or doughs.

[0081] The term "solid foam" refers to a structure characterized by the presence of pores, which may be separate or interconnected pores, achieved by specifically incorporating a gas (e.g., air) into the composition such that pores remain when the composition solidifies into a solid or non-flowing state while it is in a liquid or fluid state. Solid foams may be rigid. Solid foams may be flexible. Solid foams may be compressible. In any state, a solid foam is a foam that does not dissipate or shrink to a non-foaming state after achieving a solid state.

[0082] In one or more embodiments, a solid foam structure useful as an intermediate layer may include a cleaning component and a water-soluble polymer that are mixed and treated to obtain a foam. Such treatment may include aeration of a non-foaming, viscous liquid, gel, slurry, or paste to incorporate air. The treatment may further include drying the composition so that the incorporated or trapped air forms pores, as described herein.

[0083] The cleaning component useful in the intermediate layer of the solid foam structure may include any one or more materials useful for cleaning agents, as described separately herein. In particular, the cleaning component may include multiple materials and is preferably in a substantially concentrated form. As used herein, “concentrated” means that the cleaning agent composition is not diluted with a non-cleaning substance such as water, or is diluted only minimally. A concentrated cleaning composition may contain, in particular, less than 10% by weight, less than 5% by weight, less than 2% by weight, or less than 1% by weight of non-cleaning material. The non-cleaning material is any material that is not typically included in the cleaning agent composition for the purpose of providing cleaning or cleaning power. As a non-limiting example, a concentrated detergent or detergent composition may be a composition in which at least 90% by weight, at least 95% by weight, at least 98% by weight, or at least 99% by weight of the composition consists solely of components selected in any number from the following list: surfactants, enzymes, stabilizers, fluorescent whitening agents, redeposition agents, fluorescent whitening agents, chelating agents, viscosity enhancers, bleaching agents, and pearlescent agents. In some embodiments, a useful detergent composition is substantially in solid form before being combined with a water-soluble polymer. Thus, a concentrated detergent composition may be solid at room temperature (e.g., about 25°C) (or contain only solid components).

[0084] Water-soluble polymers useful in foam structures may be of the same type as those useful in forming the outer layer or sheet as described above. However, in some embodiments, different water-soluble polymers may be used to form the outer layer separately and to form the foam structure for the intermediate layer. In various embodiments, the water-soluble polymer may contain about 2% to about 75% by weight, about 10% to about 50% by weight, or about 15% to about 40% by weight of the foam structure.

[0085] A suitable water-soluble polymer may be specifically defined in relation to the melting point of the polymer. As described below, a solid foam structure can be prepared by mixing a detergent composition with a water-soluble polymer, melting the polymer to form a fluid mixture that can be aerated to form a fluid foam, and then cooling under aerated conditions to reach a solid foam structure. The polymer preferably has a melting point that is low enough to accommodate ease of manufacture, but high enough to ensure that the solid foam structure maintains structural integrity in hotter climates, especially when exposed to storage conditions. In some embodiments, the water-soluble polymer may be a polymer having a melting point in the range of about 40°C to about 80°C, about 45°C to about 70°C, or about 50°C to about 65°C. In some embodiments, the preferred range may be about 40°C to about 60°C or about 45°C to about 55°C.

[0086] The selection of the cleaning composition and the water-soluble polymer can similarly be based on the processability of the combined materials. When the materials are mixed at a temperature above the melting point of the polymer, the resulting fluid cleaning agent / polymer mixture can preferably be mixed and aerated to form a fluid foam with a suitable low density. Preferably, the resulting fluid foam has a density of about 0.2 g / cm³. 3 ~about 0.5g / cm 3 , about 0.25g / cm 3 ~Approx. 0.45g / cm 3 , or approximately 0.3 g / cm³ 3 ~Approximately 0.4g / cm³ 3 It has a density in the range of [value]. Furthermore, the combined material hardens when cooled below the melting point of the water-soluble polymer, while retaining its foamed structure. This results in a solid intermediate layer composition with high porosity, which gives the solid foamed structure a high surface area that promotes rapid water solubility and layer collapse.

[0087] As a non-limiting example, polyethylene glycol (PEG) polymers may be particularly useful as water-soluble polymers in the intermediate layers of solid foam structures. In some embodiments, PEG polymers may be defined in relation to their molecular weight. For example, particularly useful PEG polymers may have molecular weights in the range of about 1,000 Da to about 600,000 Da, about 1,500 Da to about 200,000, about 1,800 Da to about 80,000 Da, about 2,000 Da to about 20,000 Da, about 4,000 Da to about 16,000 Da, or about 6,000 Da to about 14,000 Da. In certain embodiments, useful PEG polymers may have molecular weights in the range of about 2,000 Da to about 4,000 Da, about 4,000 Da to about 6,000 Da, about 6,000 Da to about 8,000 Da, or about 6,000 Da to about 10,000 Da. Non-limiting examples of PEG polymers suitable for use in the foam structure of the present invention include those marketed under the names Carbowax® and Pluriol®. Other polymers that may be useful in the foam structure include ethylene oxide (EO) propylene oxide (PO) copolymers. Such materials may include (but are not limited to) EO-PO-EO type copolymers, such as those marketed under the trade name Pluronic®, which may be called poloxamers. Another example of a suitable polymer embodiment is a pyrrolidone acetate copolymer such as poly(vinylpyrrolidone-co-vinyl acetate) [PVAc-PVP] copolymer. Similarly, PO-EO-PO copolymers may be used in the same way as tetrafunctionally modified ethylenediamines with PO-EO block groups, available under the trade name Tetronic®.

[0088] The foam structure useful as an intermediate layer is preferably substantially non-flowing at temperatures below 40°C and ambient pressure when not in contact with an aqueous liquid. In some embodiments, it remains substantially non-flowing up to temperatures of about 45°C, about 50°C, or about 55°C. The foam structure also exhibits solubility in water, as separately described herein. For example, the foam structure is substantially completely water-soluble at temperatures of about 15°C to about 30°C in a time of about 0.5 minutes to about 10 minutes.

[0089] A foam structure useful as an intermediate layer can be prepared by combining the cleaning composition described herein with the above-mentioned water-soluble polymer, particularly a water-soluble polymer having a melting point in the range of about 40°C to about 80°C. The combination of the cleaning composition and the water-soluble polymer can then be heated above the melting point of the water-soluble polymer to form a fluid detergent / polymer mixture. Heating can be carried out by any suitable method, such as a hot plate, water bath, heating oven, hot water, or a mixing vessel with a steam jacket. The composition can also be configured for spontaneous heat generation in an amount sufficient to at least partially melt the water-soluble polymer. For example, the composition can be configured to contain a component that reacts exothermically when combined. Certain surfactants may exhibit an exothermic reaction when combined, or the mixing of certain surfactants with other composition components may exhibit an exothermic reaction. Heating is preferably carried out for a sufficient time to substantially completely melt the water-soluble polymer and form a fluid detergent / polymer mixture. The detergent / polymer melt can be mixed before, during, and / or after heating. The degree of mixing can vary and may be sufficient to achieve a substantially homogeneous mixture of components so that the detergent composition is substantially homogeneously dispersed throughout the molten polymer in the fluid detergent / polymer mixture.

[0090] The method may further include aerating a fluid detergent / polymer mixture to form a fluid foam. Aeration can be achieved using any suitable method. In some embodiments, sufficient aeration may be achieved by using a high-speed mixer. In some embodiments, it may be useful to introduce gas into the detergent / polymer mixture to accelerate the dispersion of gas pockets through the mixture. Air or other inert gases may be used for such purposes. In non-limiting examples, sufficient aeration can be incorporated using arrangements such as a mixer with a whisk attachment, a reverse sweep, a screw agitator, or an integrated airflow induction system. Suitable brands of mixers include Hobart mixers, Tri-Mix® Turbo-Shear® mixing systems from Lee Industries, high-shear mixers available from Charles Ross & Son company, or Kitchen Aid mixers. In particular, aeration is preferably performed sufficiently to achieve a relatively low-density foam that is fluid at high temperatures. Preferably, heating can be continued during aeration to ensure that the detergent / polymer mixture remains sufficiently fluid for processing. Once the desired foaming is achieved, the fluid foam can be cooled to form a substantially solid foam structure. Cooling can be performed, in particular, when the fluid foam is deposited into a desired final form for use in cleaning supplies. For example, in some embodiments, the foam structure may be suitable for use as a standalone cleaning supply. In such cases, the fluid foam may be cast or molded into a defined shape of defined dimensions. Even when combined with other structures such as an outer layer as described herein, the foam structure may be pre-cast or pre-molded into a desired shape and size to be combined with the outer layer or other structure. In some embodiments, the fluid foam may be combined with at least one sheet that is solid, porous, and formed from a water-soluble polymer. Such a water-soluble polymer may be characterized as a second water-soluble polymer that is the same as or different from the water-soluble polymer in the fluid foam.The fluid foam may be cooled to below the melting point of its water-soluble polymer during and / or immediately after deposition onto the sheet to form a solid foam structure in combination with at least one sheet. When the foam structure is positioned between two sheets, it may be preferable that the foam remain fluid until both outer layer sheets have been applied with the foam structure between them, at which point the fluid foam can solidify into a non-fluid, substantially solid foam structure forming an intermediate layer. In some embodiments, the substantially solid foam structure and at least one sheet may have substantially the same length and substantially the same width. This can be achieved by combining the fluid foam with at least one sheet, or by applying further processing to achieve the desired dimensions (e.g., trimming or cutting off excess sheet material and / or intermediate layer material of the solid foam). In various embodiments, this disclosure particularly includes cleaning supplies prepared according to the methods described above.

[0091] In one or more embodiments, the intermediate layer composition can be formed in particular as a gel. Thus, a cleaning product according to the Disclosure may include at least one outer layer sheet and at least one intermediate layer configured as a gel. For example, a single outer layer sheet may be folded with at least one intermediate layer positioned between them. In some embodiments, a cleaning product according to the Disclosure may comprise a first outer layer sheet, a second outer layer sheet, and at least one intermediate layer configured as a gel and positioned between the first and second outer layer sheets. The intermediate layer may comprise multiple compositions, and the gel may comprise one or more of the multiple compositions. If multiple intermediate compositions exist, the multiple intermediate compositions may be selected from one or more solid foams, gels, slurries, pastes, or doughs.

[0092] The intermediate layer composition, configured as a gel, may be readily water-soluble. The intermediate layer composition may be configured to immobilize at least partially when applied to at least one of the retaining sheets. For example, a formulation containing a surfactant with a higher melting point and a readily water-soluble rheological modifier may immobilize the formulation while remaining soluble in cold water. Immobilization refers to the ability to resist runoff from the edges of the cleaning product, and the sufficiency of immobilization may, in some embodiments, be characterized in relation to the complex modulus of the formulation, as already described above. Such gel formulations may contain longer-chain ethoxylated alcohols, higher molecular weight polyethylene glycol, gelatin, or combinations thereof.

[0093] In one or more embodiments, the intermediate layer composition can be formed in particular as a slurry. Thus, a cleaning product according to the Disclosure may include at least one outer layer sheet and at least one intermediate layer configured as a slurry. For example, a single outer layer sheet may be folded with at least one intermediate layer positioned between them. In some embodiments, a cleaning product according to the Disclosure may comprise a first outer layer sheet, a second outer layer sheet, and at least one intermediate layer configured as a slurry and positioned between the first and second outer layer sheets. The intermediate layer may comprise multiple compositions, and the slurry may comprise one or more of these multiple compositions. If multiple intermediate compositions exist, the multiple intermediate compositions may be selected from one or more solid foams, gels, slurries, pastes, or doughs.

[0094] A slurry composition suitable for use as an intermediate layer may be configured to have rheological properties, as otherwise described herein, such that the slurry is configured as a semi-solid material that resists or avoids creep. In other words, the slurry may be configured such that, when placed as an intermediate layer between one or more outer retaining sheets, the slurry is situally stable, does not become significantly flattened, does not leak through the porous outer layer sheets, or does not expand outward between the outer layer sheets.

[0095] In the examples of the embodiments, the semi-solid intermediate layer composition may be configured as a slurry of one or more alkali metal salts in an aqueous medium (i.e., containing at least water). Such a slurry can readily suspend additional cleaning components, such as enzymes, whitening agents, and other components typically available in particulate form. Such a slurry may be a particularly advantageous approach for containing components that may be unstable and / or have low solubility when contained in known compositions, such as bulk liquid and bulk solid cleaning agents. The slurry may be prepared with a sufficiently high solids content to avoid leakage of the composition through exposed ends or exposed sides of the cleaning supplies.

[0096] In the embodiments, the polymer matrix-forming material may be used to form a semi-solid intermediate layer composition having the ability to resist leakage. In non-limiting examples, useful polymer materials as matrix-forming materials include ethylene oxide (EO)-propylene oxide (PO) copolymers. Such materials include (but are not limited to) EO-PO-EO type copolymers, which have been found useful as polymer surfactants that increase stability, compatibility, wettability, and lubricity, and therefore cleaning power, in cleaning compositions. Suitable EO-PO-EO block copolymers are commercially available under the trade name Pluronic® and are sometimes referred to as poloxamers. Another example of a suitable matrix-forming material is a pyrrolidone acetate copolymer, such as poly(vinylpyrrolidone-co-vinyl acetate) [PVAc-PVP] copolymer. The matrix-forming material can preferably provide one or more (preferably all) of the following functionalities: providing a vehicle for separating sensitive materials from other cleaning components; controlling the release of components embedded in the matrix; and adding cleaning power to cleaning products through surface activity present on the matrix-forming material. Examples of “sensitive” materials include oxidizing agents, enzymes, fragrances, and buffers used as bleaches. Such materials may decompose, be chemically modified, or otherwise lose some or all of their intended functionality upon contact with various materials of which they are sensitive. The matrix-forming material preferably provides an intermediate layer composition with sufficient complex modulus and is used at high temperatures, e.g., 50°C, or in amounts suitable for maintaining the complex modulus, as described herein. In non-limiting examples, PO-EO-PO copolymers may be used similarly to tetrafunctionally modified ethylenediamines with PO-EO block groups, available under the trade name Tetronic®. These types of polymer materials may similarly be suitable for use as water-soluble polymers in solid foam structures that can be utilized as intermediate layers in some embodiments.

[0097] In the examples of embodiments, one or more suitable rheological modifiers may be used to form a semi-solid intermediate layer composition having the ability to resist leakage. The rheological modifiers are intended to include materials that, when added to a liquid, reduce the fluidity of the liquid. Non-limiting examples include, but are not limited to, one or more hydrophilic colloids, including gelatin, pectin, agar, alginates, carrageenan, cellulose derivatives (e.g., MCC, HPMC, HPC, CMC), exudative gums (e.g., gum arabic, tragacanth gum, karaya gum), gellan gum, konjac gum, modified starch, seed gums (e.g., locust bean gum, guar gum, and tara gum), and xanthan gum. The hydrophilic colloids are preferably used in an amount suitable for providing a semi-solid intermediate layer composition having a sufficient complex modulus, as separately described herein. Rheological modifiers may be particularly useful in intermediate layer compositions formed as gels or slurries, but they can also be used in compositions formed as pastes or doughs.

[0098] In one or more embodiments, the intermediate layer composition can be formed in particular as a paste. Thus, a cleaning product according to the present disclosure may include at least one outer layer sheet and at least one intermediate layer configured as a paste. For example, a single outer layer sheet may be folded with at least one intermediate layer positioned between them. In some embodiments, a cleaning product according to the present disclosure may comprise a first outer layer sheet, a second outer layer sheet, and at least one intermediate layer configured as a paste and positioned between the first and second outer layer sheets. The intermediate layer may comprise multiple compositions, and the paste may comprise one or more of the multiple compositions. If multiple intermediate compositions exist, the multiple intermediate compositions may be selected from one or more solid foams, gels, slurries, pastes, or doughs.

[0099] The paste composition may include a liquid component that allows all components to be mixed to form a paste structure. The liquid component may be an aqueous material. The liquid component may be a molten water-soluble polymer. For example, PEG polymers, such as those described herein in relation to the formation of solid foams, can be used as the liquid component for forming the paste. The polymer may be substantially solid at room temperature but may be molten in a relatively low temperature range, such as about 40°C to about 80°C. The solid polymer can be mixed with the remaining components, and the mixture can be heated to melt the polymer and form a paste. The paste may then be aerated to form a foam, as already described above. The remaining solid components may be, for example, solid surfactants and alkali metal salts, such as soda ash and sodium bicarbonate.

[0100] Paste compositions formed from water-soluble, soluble polymers do not necessarily need to be foamed for use. Rather, because components that are typically solid at room temperature are present in substantially high concentrations, the water-soluble, soluble polymers can be mixed as a paste at high temperatures where they are in a fluid liquid form. However, upon cooling, the paste substantially hardens, so the resulting intermediate layer composition is substantially non-flowing. In this case as well, the solid may be in the form of detergent salts such as alkali metal salts, and / or surfactants that are solid at normal storage and handling temperatures, such as in the range of about 35°C or below. Examples of surfactants available in such solid forms include sodium dodecylbenzenesulfonate and various alcohol ethoxylates. However, such compositions are not limited to solid surfactants. Rather, relatively small amounts of liquid surfactants or other laundry detergent components can be used, for example, in amounts of about 20% by weight or less, about 15% by weight or less, or about 10% by weight or less.

[0101] In some embodiments, the paste composition may be formed without using water-soluble and soluble polymers. Rather, the paste may achieve appropriate thickness and stability against flow or creep solely due to a significantly high solid content. The solid may be solely water-soluble, solely water-insoluble, or a mixture of water-soluble and water-insoluble solids. Again, surfactants and other laundry detergent components that are solid at room temperature may be used in the paste composition, but components that are liquid at room temperature may also be included, which may be useful in producing the miscibility and cohesiveness required for the paste.

[0102] The paste composition may be configured to foam when added to washing water. The foaming paste may contain a substantial amount of alkali metal salts, based on the total weight of the composition, in the range of about 30% to about 80% by weight, about 35% to about 75% by weight, or about 40% to about 70% by weight. Examples of alkali metal salts include sodium carbonate or potassium and sodium bicarbonate. Such a paste composition may also contain an acidic component. Such formulations are preferably prepared in a non-aqueous mixture to prevent premature reactions between the acidic and basic components. Specifically, the composition may contain less than 10% by weight, less than 5% by weight, less than 2% by weight, or less than 1% by weight of water, based on the total weight of the composition. The acidic component may be an organic acid, such as citric acid or malic acid. Any acid available in anhydrous solid form may be used. In one or more embodiments, preferred acids may have a pKa of about 2.5 to about 8.0. Acidic components(s) may be present in the composition in a total amount of approximately 2% to 25% by weight, approximately 5% to 22% by weight, or approximately 10% to 20% by weight, based on the total weight of the composition. When added to wash water, laundry products having an intermediate layer of foaming paste foam up due to a water-induced reaction between the acidic and basic components of the intermediate layer. This causes the formation of CO2, and the generation of gas accompanied by foaming further promotes the decomposition and dissolution of the laundry products in the wash water.

[0103] Paste compositions suitable for formation without requiring high temperatures, such as those necessary to melt water-soluble binder polymers, may be particularly suitable for suspending cleaning components such as enzymes, whitening agents, and other components typically available in particulate form. Thus, they can provide a vehicle for separating sensitive materials from other cleaning components. Examples of “sensitive” materials include oxidizing agents, enzymes, fragrances, and buffers used in bleaches. Such materials may decompose, be chemically modified, or otherwise lose some or all of their intended functionality upon contact with various materials of which they are sensitive. The use of solid components (e.g., solid surfactants, cleaning builders, etc.) that are also cleaning agents also provides cleaning properties to cleaning products and therefore provides the structure required for intermediate compositions while still functioning as active laundry detergent components.

[0104] The semi-solid paste compositions according to this disclosure may contain about 10% by weight or more, about 20% by weight or more, about 30% by weight or more, about 40% by weight or more, about 50% by weight or more, or about 60% by weight or more of water-soluble solids. In one or more embodiments, the semi-solid paste may contain about 10% to about 85% by weight, about 25% to about 80% by weight, about 30% to about 75% by weight, or about 40% to about 70% by weight of water-soluble solids. In one or more embodiments, the semi-solid paste may contain more than 50% by weight of water-soluble solids, such as water-soluble solids in the range of about 51% to about 90% by weight, about 55% to about 85% by weight, or about 60% to about 80% by weight.

[0105] The semi-solid paste compositions according to this disclosure may contain about 5% by weight or more, about 10% by weight or more, about 15% by weight or more, or about 20% by weight or more of water-insoluble solids. In one or more embodiments, the semi-solid paste may contain about 5% to about 50% by weight, about 10% to about 45% by weight, or about 20% to about 40% by weight of water-insoluble solids.

[0106] The semi-solid paste composition may contain only water-soluble solids while excluding water-insoluble solids. The semi-solid paste composition may contain both water-soluble and water-insoluble solids. The semi-solid paste composition may contain only water-insoluble solids while excluding water-soluble solids.

[0107] In one or more embodiments, the above solid range may be applied to a semi-solid gel composition. In one or more embodiments, the above solid range may be applied to a semi-solid slurry composition. In one or more embodiments, the above solid range may be applied to a semi-solid dough composition. In one or more embodiments, the above solid range may be applied to a composition configured to cure to form a solid intermediate layer.

[0108] In one or more embodiments, the intermediate layer composition can be formed in particular as a dough. Thus, a cleaning product according to the present disclosure may include at least one outer layer sheet and at least one intermediate layer configured as a dough. For example, a single outer layer sheet may be folded with at least one intermediate layer positioned between them. In some embodiments, a cleaning product according to the present disclosure may comprise a first outer layer sheet, a second outer layer sheet, and at least one intermediate layer configured as a dough and positioned between the first and second outer layer sheets. The intermediate layer may comprise multiple compositions, and the slurry may comprise one or more of these multiple compositions. If multiple intermediate compositions exist, the multiple intermediate compositions may be selected from one or more solid foams, gels, slurries, pastes, or doughs.

[0109] A composition formed as dough is soft but thickened to maintain its shape and resist flow or creep. The dough may be a particularly thick paste. The dough can be formed from any materials used to form a paste and may be mixed in particular to achieve a dough-like consistency.

[0110] In some embodiments, the need for rheological modifiers can be partially or completely eliminated by utilizing paste or dough formulations. This can be achieved because pastes and doughs can have significantly higher solid concentrations, providing more structure to the composition, and thus reducing or eliminating the possibility of paste or dough creeping or leaking from cleaning supplies when used as an intermediate layer.

[0111] The intermediate layer of the cleaning product of the present invention may include at least one composition that is effective as a cleaning agent and / or may be known to be used to achieve a particular cleaning function. The intermediate layer may contain one or more compositions or fillers, preferably two or more compositions or fillers. Multiple compositions may be mixed at their adjacent edges, but may remain separate compositions. The number of compositions or fillers may be indicated visually, and each composition or filler may be clearly visible through the outer layer. The number of separate compositions used in the intermediate may be any integer from 2 to 10. Each of the separate compositions or fillers may have the same formulation, a different formulation, or a combination thereof. In particular, one composition may be present in a single application of a specified volume, or the same composition may be repeated in multiple applications of a specified volume. Similarly, some compositions may be present alone in the intermediate, while others may be present in multiple applications (i.e., repetitions).

[0112] Each intermediate layer composition can be positioned between retaining sheets to improve the performance of the cleaning supplies. In some embodiments, as shown in Figure 3, each intermediate layer or filler composition is deposited perpendicular to the stack of supplies. Thus, like each retaining sheet, the intermediate layer composition preferably has a length or width greater than or equal to the thickness of the intermediate layer composition when applied to the retaining sheet. The advantage of the disclosed orientation is that it increases the surface area of ​​each cleaning agent composition in contact with the ambient air, thus increasing the diffusion rate of the intermediate layer composition, which in turn directly increases the dissolution rate of the composition in the cleaning water. The intermediate layer compositions can be positioned between the outer layer sheets adjacent to each other and not substantially overlapping. In other words, the intermediate layer compositions may be positioned on the same horizontal plane, or not on the same vertical plane between one or more outer retaining layers. If multiple intermediate layer compositions are used, all intermediate layer compositions may be positioned on the same horizontal plane.

[0113] Accordingly, in one or more embodiments, the cleaning product may include a first outer layer, a second outer layer, and an intermediate layer disposed between the first and second outer layers. Each of the outer layers may be porous, contain a water-soluble polymer, or have a configuration otherwise provided herein. The intermediate layer may include at least a first segment and a second segment, the first segment being formed from a first cleaning composition, and the second segment being formed from a second cleaning composition different from the first cleaning composition. The intermediate layer may include any number of segments disposed in the cleaning product in either the longitudinal or transverse direction, or both.

[0114] Cleaning supplies, and therefore their layers, can have various shapes, but can typically be characterized in relation to sheet-like dimensions. The outer layer(s), intermediate layer(s), and the entire supply can have longitudinal dimensions measurable along the longitudinal axis (the direction with the longest length), and therefore have a longitudinal axis length. The longitudinal axis may be referred to as the "x" axis, having the x-axis length. The layers can also have transverse dimensions measurable along an axis perpendicular to the longitudinal axis, in the same plane as the longitudinal axis, having a length shorter than the longitudinal axis length, and therefore the transverse axis length. The transverse axis may be referred to as the "y" axis, having the y-axis length. The longitudinal and transverse axes are interchangeable when the longitudinal and transverse axes are the same length (e.g., square or circular configuration). The layers and supplies can further have thickness dimensions measurable along orthogonal axes perpendicular to both the longitudinal and transverse axes. The orthogonal axes may be referred to as the "z" axis, having the z-axis length. In an elongated embodiment of the product and its layer, the product may have a length along the x-axis, a width across the y-axis, and a thickness across the z-axis.

[0115] Segments arranged longitudinally and / or transversely in the product or intermediate layer are understood to be arranged such that the segments are adjacent to or next to each other without substantially overlapping each other. This means that there is no measurable overlap of segments, or any overlapping portion of individual segments is less than or equal to about 10%, 5%, 4%, 3%, 2%, or 1% of the width of the individual segments. Thus, all segments are arranged substantially or completely in the same plane. Arranged longitudinally in the product or intermediate layer means that lines extending parallel to the longitudinal axis or x-axis may cross multiple segments, but lines extending parallel to the transverse axis or y-axis or parallel to the orthogonal axis or z-axis may not cross multiple segments. Arranged transversely in the product or intermediate layer means that lines extending parallel to the transverse axis may cross multiple segments, but lines extending parallel to the longitudinal axis or parallel to the orthogonal axis may not cross multiple segments. The arrangement of components or intermediate layers in both longitudinal and transverse directions indicates that lines extending parallel to the longitudinal axis and lines extending parallel to the transverse axis can cross multiple segments, but lines extending parallel to the orthogonal axes cannot cross multiple segments. Therefore, the arrangement of segments can be referred to as a longitudinal array, a transverse array, or both a longitudinal and a transverse array.

[0116] As shown in Figure 3, the cleaning supplies have an intermediate layer containing seven segments arranged transversely to the cleaning supplies. As an example of longitudinal arrangement, the segments or stripes of the supplies in Figure 3 may be arranged perpendicular to the illustrated arrangement. The supplies in Figure 3 include perforations, which may separate the supplies into two separate, smaller sheets. When the supplies in Figure 3 are separated into two smaller sheets, each segment of the smaller sheets is arranged longitudinally to the supplies due to the dimensional change of the smaller sheets relative to the larger starting sheet.

[0117] Products having multiple segments arranged both transversely and longitudinally may be configured such that the segments are arranged diagonally. As a further example, segments of a checkerboard pattern may be considered to be arranged both transversely and longitudinally on the product. Similarly, concentric circles form a pattern that is considered to be arranged both transversely and longitudinally on the product. In each embodiment, lines extending parallel to the longitudinal axis and lines extending parallel to the transverse axis can cross multiple segments. Furthermore, segments are not limited to the shape shown in Figure 3 (i.e., substantially linear strips). Rather, segments may be linear or curved, define a regular or irregular pattern of one or more shapes, or have any other arrangement that is not a stacked arrangement along the thickness of the product. Individual intermediate layers may exclude a stacked arrangement, but it is understood that other arrangements discussed herein may be used, such as having multiple intermediate layers separated by one or more further retaining layers.

[0118] In various embodiments, each of the intermediate layer compositions used in the separated segments may be configured to have separate and independent cleaning properties, or to have overlapping cleaning properties in terms of cleaning functionality. The compositions may have various functional properties that affect the laundry purpose, such as being specifically configured for cleaning or stain removal, softening, odor removal, bleaching, or a combination thereof. The intermediate layer compositions may also have various physical properties such as color, form (i.e., gel, slurry, paste, dough, foam), diffusion rate, and complex modulus.

[0119] The outer layers described herein provide cleaning supplies with a distinctive appearance and at least partially provide visibility of the intermediate layer composition held between the outer layers. In various embodiments, the thickness of the outer layers, the presence of pores within the outer layers, the color of the outer layers, or a combination thereof, enhances the visibility of the intermediate layer. In some embodiments, the material of the outer layers may be transparent or translucent. In certain embodiments, the outer layers are made of a white translucent material or a blue translucent material. In one or more embodiments, the intermediate layer is substantially the same length and width as the outer layers and thereby extends to the side edges of the disclosed cleaning supplies, providing visibility of the intermediate layer color at the edges of the sheet. This configuration allows the color of the intermediate layer composition to be easily seen when the sheet is viewed from an edge view. In some embodiments, the retaining sheet defining the outer layer may have a transparency level defined by an upper limit of 80% and a lower limit of 5% (e.g., 5% to 80%, 5% to 50%, 5% to 25%, 8% to 12%), and therefore all integers from 5 to 80 (e.g., 10%) are expressly included in this disclosure to define the upper and lower boundaries of the range to be included. Similarly, the transparency level may be at least one of the values ​​within the above range, or less than any of the values ​​within the above range. Transparency can be measured using any known method, such as using a transparency meter or clarity meter. Transparency can be calculated in relation to the total transmittance of light passing through an object, excluding any light that is absorbed or reflected, and such measurement can be calculated as total transmittance (%) = incident light (100%) - (% absorbed + % reflected). Transparency using a clarity meter may conform to ASTM standard D1746.

[0120] In some embodiments, one or more physical properties of the intermediate composition may indicate a functional property of the intermediate composition. Consumers often select cleaning products based on the specific functionality offered, and therefore may desire a visual cue indicating that a particular functionality exists in the selected cleaning product. Bulk cleaners (e.g., solid or liquid cleaning agents packaged in large quantities for consumer use) typically have a single, uniform color that does little to indicate what functionality is offered. Some unit-dose products sold as pouches or pods may have two or three individual chambers filled with different compositions, but as already mentioned above, such pouches or pods have various drawbacks. The cleaning products of the present disclosure can be provided in a whole form that is easy to use, dissolves in cleaning water as needed, and provides consumers with easily identifiable visual cues of cleaning functionality.

[0121] In some embodiments, each of several individual intermediate compositions may exhibit a visually distinguishable color. As described above, a particular color may be identifiable by a particular cleaning function, and the cleaning products of the present invention may provide intermediate composition in individual colors for quick identification by consumers. Colors may be defined in general terms (e.g., blue, green, purple, white, etc.). Colors may also be explicitly located within a defined CIELAB color space chosen as a unique identifier of functionality, which is defined by a given L*a*b* value. Under this standard, L* represents perceived lightness, with a value of 0 defining black and a value of 100 defining white. The a* and b* values ​​represent chromaticity without specific numerical limitations. Specifically, a* defines colors in the range from green to red, with negative a* values ​​corresponding to green and positive a* values ​​corresponding to red. Similarly, b* defines colors in the range from blue to yellow, with negative b* values ​​corresponding to blue and positive b* values ​​corresponding to yellow.

[0122] In some embodiments, the intermediate composition may be configured to exhibit a blue or green color. Such a color may be used to indicate that the intermediate composition is configured to provide general cleaning efficacy or is a detergent booster. A preferred blue color can be defined, for example, by L*, a*, and b* values ​​of 64 (+ / -5), -14 (+ / -5), and -20 (+ / -5). A preferred green color can be defined, for example, by L*, a*, and b* values ​​of 75 (+ / -5), -10 (+ / -5), and 8 (+ / -5). In some embodiments, the intermediate composition may be configured to exhibit a pink color. Such a color may be used to indicate that the intermediate composition is configured to provide softening. A preferred lighter pink color can be defined, for example, by L*, a*, and b* values ​​of 45 (+ / -5), 69 (+ / -5), and -17 (+ / -5). A preferred darker pink color can be defined, for example, by L*, a*, and b* values ​​of 75 (+ / -5), 37 (+ / -5), and 4 (+ / -5). In some embodiments, the intermediate layer composition may be configured to exhibit a purple color. Such a color may be used to indicate that the intermediate layer composition is configured to provide odor removal. A preferred purple color can be defined, for example, by L*, a*, and b* values ​​of 75 (+ / -5), 5 (+ / -5), and -7 (+ / -5). In some embodiments, the intermediate layer composition may be configured to exhibit a white color. Such a color may be used to indicate that the intermediate layer composition is configured to provide bleaching. A preferred white color can be defined, for example, by an L* value in the range of 95 to 100, an a* value of 0 (+ / -5), and a b* value of 0 (+ / -5). It should be understood that the disclosed colors, purposes, and correlations are not limiting, and individual intermediate layer compositions may have additional or different functionalities than those described above.

[0123] In some embodiments, the intermediate layer composition is configured to be visible through one or both of the outer layers. This typically provides a distinctive appearance that gives consumers a visual cue of the product's function when viewed through the surface of the outer layer sheet, typically at its maximum dimensions. To achieve the desired visual cue when the intermediate layer and its segments are viewed through the outer layers, the compositions forming the intermediate layer segments must have color values ​​different from the desired final values. As described above, the colors used in the compositions forming the intermediate layer segments can be defined by their L*a*b* values. Thus, the individual compositions forming the individual segments of the intermediate layer may be visible at the edges of the cleaning product and may have a first L* value, a first a* value, and a first b* value, and may have one or more second L* values, second a* values, and second b* values ​​different from the first values ​​when viewed through one of the outer layers.

[0124] In one or more embodiments, the intermediate layer segment may have a first color defined by a first set of L*a*b* values ​​when measured at the edge of the cleaning product where the intermediate layer is not obstructed by the first or second outer layer, and may have a second different set of L*a*b* values ​​when measured through one of the first and second outer layers. For example, the L* value of the first color may be greater when measured through one of the first and second outer layers. For example, one or both of the a* and b* values ​​may be smaller when measured through one of the first and second outer layers.

[0125] In one or more embodiments, the color of the intermediate layer segment may have a first L* value when viewed from the edge of the cleaning product not covered by the outer layer, and a second L* value when viewed through the outer layer of the cleaning product, the second L* value being greater than the first L* value. The second L* value may be greater than the first L* value by at least an integer of 2, at least an integer of 3, at least an integer of 4, at least an integer of 5, at least an integer of 10, or at least an integer of 15, up to a maximum L* value of 100. In some embodiments, the second L* value may be about 5% to about 90%, about 10% to about 80%, about 15% to about 70%, or about 20% to about 60% greater than the first L* value. For example, as described above, a preferred blue color may be defined by L*, a*, and b* values ​​of 64 (+ / -5), -14 (+ / -5), and -20 (+ / -5). Therefore, the first L* value of the segment (when viewed at the unobstructed edge of the product) may be 64, and the second L* value (when viewed through the upper outer layer sheet) may be greater than 64 by the aforementioned numerical range.

[0126] In one or more embodiments, the color of the intermediate layer segment may have a first a* value when viewed from the edge of the cleaning product not covered by the outer layer, and a second a* value when viewed through the outer layer of the cleaning product, the second a* value being smaller than the first a* value. The second a* value may be smaller than the first a* value by at least two integer absolute values, at least three integer absolute values, at least four integer absolute values, at least five integer absolute values, at least ten integer absolute values, or at least fifteen integer absolute values, for example, up to the positive and negative boundaries outside the a* value. In some embodiments, the second a* value may be about 5% to about 90%, about 10% to about 80%, about 15% to about 70%, or about 20% to about 60% smaller than the first a* value. For example, as mentioned above, a preferred blue color can be defined by L*, a*, and b* values ​​of 64 (+ / -5), -14 (+ / -5), and -20 (+ / -5). Thus, the first a* value of the segment (when viewed at the unobstructed edge of the product) may be -14, and the second a* value (when viewed through the overlay sheet) may be less than -14 within the aforementioned numerical range.

[0127] In one or more embodiments, the color of the intermediate layer segment may have a first b* value when viewed from the edge of the cleaning product not covered by the outer layer, and a second b* value when viewed through the outer layer of the cleaning product, the second b* value being smaller than the first b* value. The second b* value may be smaller than the first b* value by at least an integer absolute value of 2, at least an integer absolute value of 3, at least an integer absolute value of 4, at least an integer absolute value of 5, at least an integer absolute value of 10, or at least an integer absolute value of 15, for example, up to the outer boundaries of the positive and negative b* values. In some embodiments, the second b* value may be smaller than the first b* value by about 5% to about 90%, about 10% to about 80%, about 15% to about 70%, or about 20% to about 60%. For example, as mentioned above, a preferred blue color can be defined by L*, a*, and b* values ​​of 64 (+ / -5), -14 (+ / -5), and -20 (+ / -5). Thus, the first b* value of the segment (when viewed at the unobstructed edge of the product) may be -20, and the second b* value (when viewed through the overlay sheet) may be less than -20 within the aforementioned numerical range.

[0128] In some embodiments, multiple individual filling compositions of the intermediate layer are deposited to form a pattern visible through one or both of the outer layers. While the pattern design is not limited, in some embodiments, the pattern may be stripes, as shown in Figure 3. The striping may be a repeating arrangement (e.g., the stripes in Figure 3) or a non-repeating pattern. In some embodiments, the pattern may be non-repeating (e.g., striping, waves, spirals, marble patterns, artistic designs, or other arrangements representing a company logo, trademark, etc.). In some embodiments, a stripe pattern may be defined such that no stripe of a given color is directly adjacent to another stripe of the same given color. Similarly, a stripe pattern may be defined such that any two stripes of the same given color are separated by at least one stripe of a different given color. Compositions of different colors may similarly exist as multiple squares, circles, triangles, or other shapes filling part or all of the area of ​​the retaining sheet to form an intermediate layer between the two outer layers. The stripes may be substantially linear. The stripes may be substantially non-linear. The nonlinear stripes may be curved to define a wave structure that is either a uniform wave with uniformly spaced peaks and troughs, or a non-uniform wave with unevenly spaced peaks and troughs.

[0129] Individual intermediate compositions may be labeled in relation to the desired functionality. Therefore, individual intermediate compositions may be referred to separately as, for example, intermediate cleaning compositions, intermediate odor removal compositions, intermediate softening compositions, intermediate bleaching compositions, intermediate enzyme compositions, intermediate booster compositions, etc. While such terms may define the primary function of each individual composition, it is understood that each composition may still contain other cleaning components disclosed separately herein.

[0130] The intermediate layers may individually have the same or different dissolution rates. For example, it may be desirable for the intermediate layer cleaning composition to be available early in the wash cycle so that the components of the cleaning composition can act on the items being washed over a longer period of the wash cycle. On the other hand, it may be desirable for the intermediate layer softening composition to be available later in the wash cycle, or even in the rinse cycle of an automatic washing machine, so that the washed items achieve and retain maximum softness later in the wash cycle. Therefore, the cleaning products according to this disclosure can be configured such that the intermediate layer cleaning composition dissolves from the cleaning product faster than the intermediate layer softening composition. Similarly, one or more of the individual intermediate layers may be configured with individualized different dissolution rates.

[0131] In one or more embodiments, the intermediate layer composition may be present in a sheet-like arrangement between the outer layers. In other words, the intermediate layer may include two or more layers arranged side-by-side between a first outer layer and a second outer layer, each of which is configured to provide a different cleaning function. Such orientation of the intermediate layer composition may be effective in providing controlled release of specific components of the intermediate layer composition. Each intermediate layer composition may have substantially the same thickness.

[0132] As described above, the cleaning products of this disclosure comprise two outer layers (i.e., retaining sheets), one or more intermediate layers, each formed from a plurality of intermediate layer compositions (i.e., filler compositions), and optionally, one or more segmented layers or sheets. This arrangement is advantageous because, in order to provide a multitude of benefits, it provides multiple positions for providing a multitude of cleaning components (e.g., any components commonly found in laundry care compositions) in a multitude of variations. The outer layers may consist only of carriers and do not have to contain components having intentional cleaning functionality. However, beneficially, one or both of the first and second outer layers may be configured to contain one or more cleaning components embedded therein. Since the outer layers are configured to be handled by consumers, any cleaning components present in or on the outer layers preferably have little to no skin irritation associated with their handling. For example, one or both of the outer layers may contain one or more surfactants useful for removing dirt, stains, etc., from fabrics. The outer layers preferably contain “mild” surfactants that provide cleaning efficacy but are not strong enough to irritate skin upon contact. Alkaline agents, enzymes, and other substances that may irritate the skin are safely isolated from contact with the consumer within the intermediate layer composition. Other cleansing components described herein may be included in the outer layer as substitutes for or in addition to one or more surfactants.

[0133] In some embodiments, the outer layer component may be prepared using a typical polymer composition manufacturing method, particularly one that involves forming a molten composition, which is then cast, molded, extruded, etc., into a desired final form. Alternatively, the outer layer sheet may be defined as a fabric formed from polymer fibers that are substantially melt-extruded and laid in a nonwoven form, or gathered and used to form a woven sheet. The intermediate layer composition can be prepared by an alternative method that does not involve significant heating, which could damage sensitive materials (e.g., enzymes) in the cleaning composition (e.g., a simple mixing to form a paste or slurry or gel). Given that several different filling compositions can be used for the intermediate layer, this provides the ability to prepare a number of different cleaning products having desired combinations of cleaning components.

[0134] In one or more embodiments, the disclosure also includes a method for producing laundry detergent products having improved properties, as disclosed herein. The method can begin with forming a water-soluble material. In one or more embodiments, the water-soluble material, such as PVOH, is provided in slurry form. The slurry can be placed in a pan under a rotating drum, the drum brushing the surface of the pan, and forming a thin layer of slurry on the drum surface. The rotating drum is then heated from the inside to expel moisture from the thin layer of slurry and dry the layer. This layer is then removed from the surface with a scraping knife and operated with idler rollers to form a foamed sheet, which is then rolled for further processing. In one or more embodiments, a double rotating drum is provided, as shown in Figure 5, each rotating inward to form a sheet of water-soluble material. This is a commercially obvious and preferred orientation for making layered products, but ultimately produces inferior products, as will be discussed later. In one or more embodiments, a double rotating drum is provided, as shown in Figure 6, each rotating outward to form a sheet of water-soluble material. As will be discussed later, the choice of drum rotation can affect one or more characteristics of the formed product, and using a drum that rotates outward can result in a superior product with desirable characteristics and functionality not seen when prepared with an inward rotation. The direction of rotation (i.e., inward in Figure 5, outward in Figure 6) can affect, for example, the appearance and texture of each sheet. As moisture is pushed out of the slurry layer, it moves outward in the direction of the drum, forming bubbles or pores within the layer as it dries. In an embodiment like that of Figure 5, for example, inward rotation of the drum results in a sheet with pores that move from the outer surface to the inner surface. As a result, the outer surface of the sheet may have a smoother texture and glossier appearance than the inner surface, and the inner surface of the sheet may have a higher porosity than the outer surface. Conversely, in an embodiment like that of Figure 6, for example, outward rotation of the drum results in a sheet with pores that move from the inner surface to the outer surface. As a result, the inner surface of the sheet may have a smoother texture and a more glossy appearance than the outer surface of the sheet, and the outer surface of the sheet may have a higher porosity than the inner surface of the sheet.Various studies have shown that consumers prefer handling the laundry detergent products disclosed herein with a porous outer layer rather than a smooth outer layer. In particular, the increased grip provided by the porous surface was considered desirable. In addition, the porous outer layer further accentuates the midlayer, which communicates to consumers that the product dissolves rapidly.

[0135] In one or more embodiments, as shown in Figure 7, a slitting device may be provided after the layer of dry slurry has been removed from the rotating drum with a scraper knife. The sheets of water-soluble material may be cut and sliced ​​to desired dimensions before being filled.

[0136] In one or more embodiments, a sheet is rolled and oriented to form a first side and a second side of a laundry detergent product. A detergent formulation is deposited and filled between the first and second sides. In various embodiments, as shown in Figure 5, the detergent formulation comprises multiple compositions. Each composition may be deposited separately and simultaneously between the rolled sheets. In some embodiments, the detergent compositions are cooled and pressed to form a detergent formulation, which is then deposited between the rolled sheets. The sheets and the filled detergent formulation may then be pressed to adhere the first and second sides to the detergent formulation, forming a laundry detergent product. In various embodiments, the laundry detergent product is further processed by embossing, printing, slitting, and / or die-cutting.

[0137] As described above, the cleaning components used in the cleaning products of this disclosure can include a wide variety of materials useful for washing fabrics, and more specifically, clothing. Surfactants and builders are commonly used in laundry detergents and may also be used in the present composition.

[0138] A wide variety of anionic surfactants and / or nonionic surfactants may be used in accordance with this disclosure. In various embodiments, suitable anionic surfactants may include one or more salts of anionic sulfates, sulfonates, carboxylates, and sarcosinates (e.g., sodium salts, potassium salts, ammonium salts, and substituted ammonium salts, e.g., mono-, di-, and triethanolamine salts). Exemplary anionic sulfates include linear and / or branched primary and secondary alkyl sulfates, alkylethoxysulfates, fatty oleoyl glycerol sulfates, alkylphenol ethylene oxide ether sulfates, and C5-C 17 Examples include acyl-N-(C1-C4 alkyl) and -N-(C1-C2 hydroxyalkyl) glucamine sulfates, as well as alkyl polysaccharide sulfates, such as alkyl polyglucoside sulfates. Exemplary alkyl sulfates include linear and branched primary C12 sulfates. 10 ~C 18 Alkyl sulfates can be cited as examples. Exemplary alkylethoxysulfate surfactants include C134, which is ethoxylated with 0.5 to 20 moles of ethylene oxide per molecule. 10 ~C 18 Alkyl sulfates can be cited as examples. Exemplary anionic sulfonate surfactants include C5-C 20 Linear alkylbenzene sulfonates, alkyl ester sulfonates, C6~C 22 Primary or secondary alkanesulfonates, C6-C 24Examples of anionic surfactants include olefin sulfonates, sulfonated polycarboxylic acids, alkylglycerol sulfonates, fatty acid acylglycerol sulfonates, salts of fatty acid oleylglycerol sulfonates, and any combination thereof. Examples of anionic carboxylates include alkylethoxycarboxylates and alkyl polyethoxypolycarboxylates. In some embodiments, preferred anionic surfactants include various sulfates (e.g., alkyl ether sulfates, e.g., laureth sulfate salts), alkyl ester sulfonates, and alkylbenzene sulfonates (e.g., C5-C5). 20 or C 10 ~C 16 Examples of anionic surfactants that may be used herein include sodium laureth sulfate (SLES), sodium lauryl sulfate (SLS), methyl ester sulfonate (MES), and C 10~16 Examples include sodium alkylbenzene sulfonate (LAS). In certain embodiments, ethoxylated anionic surfactants may be used and may contain a limited number of ethylene oxide groups. For example, alkyl ether sulfate anionic surfactants may contain less than 5 moles or less than 4 moles of ethylene oxide groups, for example, 1 to 4 or 2 to 3 ethylene oxide groups.

[0139] In various embodiments, suitable nonionic surfactants include alkyl ethoxylate condensation products of an aliphatic alcohol and 1 to 25 moles of ethylene oxide, where the alkyl chain of the aliphatic alcohol can be linear or branched, primary or secondary, and generally contains 6 to 22 carbon atoms. Even more suitable nonionic surfactants are water-soluble ethoxylated C6-C6 18 Fatty alcohols and C6-C 18 Examples include mixed ethoxylated / propoxylated fatty alcohols. For example, ethoxylated fatty alcohols have a degree of ethoxylation of 3 to 20 C 10 ~C 18The mixture may be an ethoxylated fatty alcohol. In some embodiments, the mixed ethoxylated / propoxylated fatty alcohol may have an alkyl chain length of 10 to 18 carbon atoms, a degree of ethoxylation of 3 to 30, and a degree of propoxylation of 1 to 10. In further embodiments, a suitable nonionic surfactant may be one formed from the condensation of a hydrophobic base formed by the condensation of propylene oxide and propylene glycol with ethylene oxide. An example of this type of compound is certain commercially available Pluronic® surfactants sold by BASF. Furthermore, a suitable nonionic surfactant may be one formed from the condensation of ethylene oxide with a product obtained from the reaction of propylene oxide and ethylenediamine. An example of this type of nonionic surfactant is a commercially available Tetronic® compound sold by BASF. In certain embodiments, the suitable nonionic surfactant may be selected from, for example, a variety of alcohol ethoxylates. In some embodiments, nonionic surfactants can be defined in relation to the alcohol chain length and / or the number of ethoxylate groups present in the molecule. For example, nonionic surfactants may include alcohol ethoxylates formed from alcohols having carbon chain lengths of 3 to 20 carbon atoms, 5 to 20 carbon atoms, 7 to 19 carbon atoms, 9 to 18 carbon atoms, 10 to 17 carbon atoms, or 12 to 15 carbon atoms. Further examples include alcohol ethoxylates having 2 to 10, 4 to 9, or 6 to 8 moles of ethylene oxide per mole of alcohol. Non-limiting examples of nonionic surfactants that may be used herein include ethoxylated alcohols (AEs) (especially C 12-15 Examples include alcohols, such as those available under the trade name NEODOL®, lauryl or myristyl glucoside (APG), and polyoxyethylene alkyl ethers (2°AE).

[0140] Suitable builders include materials effective as alkalizing agents. For example, various alkali carbonates and / or other inorganic alkalizing agents may be used to increase the pH of the laundry detergent composition while simultaneously increasing its viscosity to a desired level. Preferably, sodium salts and / or potassium salts (e.g., K2CO3 and / or Na2CO3) may be used. For example, soda ash can be used. In some embodiments, one or more components may be used for the formation of carbonates in situ. For example, a combination of bicarbonate and hydroxide may be effective for the formation of carbonates in situ. In exemplary embodiments, sodium bicarbonate and sodium hydroxide may be used for this purpose, and other forms of bicarbonate and hydroxide may be used as well.

[0141] The cleaning products of this disclosure may also include any number of additional ingredients that are recognized as useful in cleaning products such as laundry detergents. As a non-limiting example, one or more of the following materials may be included in any of the various compositions of this disclosure: betaine and aminooxide surfactants, enzymes, enzyme stabilizers, dyes, fluorescent whitening agents, readhesion polymers, fluorescent whitening agents, fragrances, bittering agents, thickeners, defoamers, pH adjusters, salts, bleaches, fabric softeners, pearlescent agents, preservatives, laundry boosters, formulation aids (e.g., alcohols, polyols, sugars), etc.

[0142] In one or more embodiments, the intermediate composition according to this disclosure may contain one or more of the following components in any combination: Pluronic® F127 (polyol surfactant); propylene glycol; Neodol® 25-7 (alcohol ethoxylate); Laponite RDS; PVAc-PVP copolymer; sodium dodecyl sulfate; glycerin; Kelzan® AP-AS (xanthan gum); Acusol® 445N (acrylic acid homopolymer); Trilon® M; MgCl2; Neodol® 25-9; Brij 56 (C16E10 nonionic); Steol® 25-3S / 70FC[C] 12-15 (EO)3-Sulfate Na salt 70% aqueous solution; Mirataine® O-30 (30% oleamidopropyl betaine); Pluronic P123; Na4EDTA; MEA (monoethanolamine); BIOSOFT® S-118 (linear alkylbenzene (11.8) sulfonic acid); STEOL® OS-370 Plus (linear fatty alcohol ether sulfate); TRILON® C (pentasodium diethylenetriaminepentaacetate); PKFA (palm kernel fatty acid); ACTICIDE® MBS; sodium bicarbonate; citric acid; malic acid; Nacconol® 90G (dodecylbenzenesulfonic acid, sodium salt); Stepanol® ME-DRY (sodium lauryl sulfate powder); Carbowax PEG 600; Pluronic® F-77 (nonionic block copolymer surfactant); Bioterge® AS-90 (anionic C14-16 olefin sulfonate); sodium starch glycolate; Carbowax PEG 8000; PEG 600; Aerosil® R 816 (fumed silica post-treated with hexadecylsilane); Aerosil® 150 (150m 2 Fumed silica having a specific surface area of ​​ / g; and Aerosil® 300 (300m 2 (Fume-deposited silica with a specific surface area of ​​ / g) [Examples]

[0143] experiment Example 1 A series of samples were formulated using ethylene oxide (EO) propylene oxide (PO) copolymers, specifically the EO-PO-EO type. These polymers exhibit unique properties because, in addition to their polymeric properties, they also exhibit surfactant behavior. These EO-PO-EO block copolymers are commercially available from BASF under the trade name Pluronic® and are collectively called poloxamer surfactants. Laponite RDS, a layered silicate, was also used. The three sample compositions are shown in Table 1 below.

[0144] [Table 1]

[0145] Furthermore, compositions were prepared using poly(vinylpyrrolidone-co-vinyl acetate) [PVAc-PVP] copolymer (MW = 50,000 g / mol and VAc / VP ratio of 1.3). The four sample compositions are shown in Table 2 below.

[0146] [Table 2]

[0147] The sample was prepared by applying approximately 1 g of packing material between two PVOH sheets measuring 125 mm (length) x 50 mm (width) x 0.8 mm (thickness). The aggregate was then passed through a nip roller to distribute the packing material between the outer sheets.

[0148] The assemblies were left at room temperature for up to one week, and bleeding of the packing material through the outer sheet was observed. Table 3 below shows the observation results for each assembly using different packing materials, along with the G* values ​​measured for each.

[0149] [Table 3]

[0150] The data indicates that a minimum complex modulus in the range of approximately 5,000 to 15,000 Pa is preferable for preventing the filler from flowing out and / or seeping through the outer sheet.

[0151] The composition was further evaluated for its dissolution time. 4 g of the sample (sheet + packing) was added to 1 L of water (in a 2 L beaker) and stirred with a 2-inch diameter impeller rotating at 700 rpm. The water temperature was 10°C. The observations are shown in Table 4 below. The data suggest that while the size of G* may have some effect on dissolution time, it may not be the sole factor driving dissolution.

[0152] [Table 4]

[0153] Example 2 Compositions using polysaccharides such as xanthan gum can also be used as fillers. The following examples of compositions are presented, as shown in Table 5. Observations regarding filling stability and dissolution time are also recorded. Note that leakage may be reduced by decreasing the water content, which may reduce the level of interaction with the sheet.

[0154] [Table 5]

[0155] Example 3 Compositions using various fillers placed between two PVOH sheets were assembled and tested for cleaning efficacy in a cleaning study. Flags containing various test stains and dirt were washed in a top-load washing machine (capacity = 70L) under conditions of water hardness of 120 ppm (as CaCO3) and a temperature of 86°F. Percent stain removal (%SR) values ​​were evaluated by measuring the L*, a*, and b* parameters in the CIE L*a*b* color space using imaging techniques. The ΔE value (root mean square color difference between the sample and the unstained standard sample) was calculated for unwashed and washed samples according to the following:

[0156] Before cleaning: ΔE u = [(L u - L o ) 2 + (a u - a o ) 2 + (b u - b o ) 2 ] 1 / 2 [1]

[0157] After washing: ΔE w = [(L w - L o ) 2 + (a w - a o ) 2 + (b w - b o ) 2 ] 1 / 2 [2]

[0158] (In the formula, u, w, and o correspond to the values ​​for the unwashed sample, the washed sample, and the unstained sample, respectively.) Next, the stain removal rate (%SR) was calculated as follows:

[0159] %SR = [(ΔE u - ΔE w ) / ΔE u ] X 100 [3]

[0160] In the cleaning test, the efficacy of samples using the compositions described in Examples 1 and 2, as well as the following compositions shown in Table 6, was evaluated.

[0161] [Table 6]

[0162] PVOH sheet filling assemblies were constructed using PVOH-based laundry sheets (referred to as sheet "A" in Table 7) commercially available under the trademark name Breezeo®. The sheets were cut to a size of 2.5g each, and 1g of the filling composition was placed between two 2.5g sheets to form test articles. A control set of "A" sheets (totaling approximately 5g) was also performed. The washing results are provided in Table 7 below, which provides washing efficacy in terms of the total percentage (%SR) of stain / dirt removal. Various samples were tested on fabrics made of cotton or polyester / cotton 65 / 35 woven fabrics stained with various substances including blood, olive oil, chocolate ice cream, dirty motor oil, blueberries, meat juice, dust, sebum, grape juice, mustard, wine, spaghetti sauce, tea, coffee, coffee with milk, grass, cosmetics, clay, chocolate syrup, beef tallow, meat juice, burnt butter, and blue ballpoint pen ink. The cleaning data indicates that the experimental samples generally performed better than the sheets alone.

[0163] [Table 7]

[0164] Example 4 A second washing test was conducted. The evaluated formulations are shown in Table 8 below. Formulations 128-3 and 128-4 from Example 2 were also included.

[0165] [Table 8]

[0166] Laundry supplies were prepared using commercially available sheets as described in Example 3. Before applying composition 128-1, composition 128-2, composition 128-3, or composition 128-4 to the sheets, 0.2% by weight of mannanase enzyme and 0.8% by weight of protease enzyme were added to the filling composition. Various samples were tested on cotton or polyester / cotton 65 / 35 woven fabrics soiled with various substances including blood, olive oil, chocolate ice cream, dirty motor oil, blueberries, meat juice, dust, sebum, grape juice, mustard, wine, spaghetti sauce, tea, coffee, coffee with milk, grass, cosmetics, clay, chocolate syrup, beef tallow, meat juice, burnt butter, and blue ballpoint pen ink. The washing results are reported in Table 9 below.

[0167] [Table 9]

[0168] The results show that adding filler components improves cleaning performance compared to the sheet alone. We can also see how changing the structured polymer (and in these examples, the surfactant) from F127 to P123 improved the overall cleaning power. Table 10 below compares the surfactant properties of each polymer.

[0169] [Table 10]

[0170] The weight percentage of hydrophilic material in the structuring is preferably over 30%. In the xanthan gum-based fillers (128-3 and 128-4), it was observed that the performance improved by using Brij (nonionic) surfactants rather than betaine surfactants, but it should be noted that 128-4 had a higher surfactant level compared to 128-3 (12.1% in 128-4 compared to 5.8% in 128-3).

[0171] Example 5 This example shows that the solubility of the Pluronic / K2CO3 layer is determined by the type of Pluronic used. Mixtures of K2CO3 and Pluronic were prepared by varying the ratio of the two Pluronics, as shown in Table 11 below.

[0172] [Table 11]

[0173] The composition was prepared by placing both Pluronics in a beaker, heating them in a microwave oven to approximately 70°C, and then adding K2CO3 while stirring. The molten slurry was then poured into a silicone mold to form a solid approximately 2.5 cm × 3.7 cm × 0.3 cm in size.

[0174] Dissolution was investigated by placing one Pluronic / K2CO3 bar into 1.0 L of water in a 1.5 L beaker. The water was agitated with a 3-inch diameter radial impeller rotating at 250 rpm. The sample was weighed before and after the 10-minute dissolution test. The measured dissolution percentages plotted against the weight fraction of P123 (based on Pluronic only) are shown below. The resulting data are reproduced in Figure 8. These results indicate that solubility increased with increasing levels of P123.

[0175] In the dissolution study, pH versus time was also evaluated. The resulting data is reproduced in Figure 9. The data shows that increasing the proportion of P123 not only increased the initial pH and pH throughout most of the experiment, but also that the incorporation of K2CO3 into the Pluronic matrix enabled controlled release of the buffer. Such a controlled release mechanism can be applied to other active substances such as oxidizing agents (bleaching agents), enzymes, greening agents, and fragrances.

[0176] Example 6 In this example, data demonstrating the effect of varying the K2CO3 level are presented. The following compositions shown in Table 12 were prepared. It should be noted that the weight fraction of P123 was maintained at 0.81.

[0177] [Table 12]

[0178] The sample was prepared as described above. The solubility data, plotted against the level of K2CO3 in the sample, is reproduced in Figure 10. It is particularly interesting that the optimal point may exist at approximately 73.5% K2CO3. The reason for this is currently unknown, but it may be because the optimal level of the component exists to provide a structure that has sufficient soluble salt but is dispersed well enough that the salt is not compressible on its own. The pH data of the sample is reproduced in Figure 11, with the pH value plotted against time. As these results show, increasing the level of K2CO3 generally increased the pH throughout the experiment.

[0179] Example 7 Several slurry compositions were prepared and their rheological properties were evaluated. The compositions are shown in Table 13. The rheological data for each slurry is shown in Figure 12, which illustrates how the addition of Aerosil R974 fumed silica can increase the slurry modulus. Among these compositions, those with an Aerosil level of 0.2% or higher are most preferred for the intermediate layer.

[0180] [Table 13]

[0181] Example 8 Various combinations of water-soluble polymers and concentrated detergent compositions were evaluated for their usefulness in forming a substantially solid foam structure that can be used in cleaning supplies, particularly as an intermediate layer placed between one or more outer sheets. Tests were conducted to determine the suitability of mixtures for forming foams that exhibit reduced leakage from cleaning supplies while still providing the desired dissolution time.

[0182] The same concentrated detergent base was used in each mixture. The detergent base formulations are shown in Table 14. These detergents were mixed with PEGs of different levels and grades, as further described below.

[0183] [Table 14]

[0184] The base detergent was mixed with PEG1000, PEG4000, PEG6000, and PEG8000 in several weight ratios (PEG:detergent at 10:90, 20:80, and 30:70). The mass of each component was weighed and placed in a beaker, covered with aluminum foil, and placed in a laboratory oven at 70°C to melt the PEG. Once the PEG had melted sufficiently to form a fluid detergent / PEG mixture, the beaker was removed from the oven and placed in a 70°C water bath, where it was mixed using an overhead mixer with sufficient aeration to obtain a foamed fluid detergent / PEG mixture within the desired density range. To maintain fluidity, the fluid detergent / PEG mixture was kept at approximately the same high temperature. After foaming the formulation into a fluid foam, samples were taken and their density was measured. The densities of the detergent mixtures with PEG4000 and PEG8000 are shown in Table 15 below. At 70°C, formulations containing 10% PEG tended to be more viscous, more difficult to aerate, and resulted in a denser foam than formulations containing 20-30% PEG.

[0185] [Table 15]

[0186] Cleaning supplies were prepared using a PVOH outer layer sheet, and a multilayer "sandwich" structure was created by rapidly spreading a PEG detergent-flowable foam onto a laundry sheet sample using a spatula. A second (upper) laundry sheet was added, and gentle pressure was applied to adhere the flowable foam to the upper and lower sheets. The composite sheet was then left to cool, allowing the flowable foam to solidify into a substantially solid foam structure. The samples were evaluated for processability (e.g., suitable density for the flowable foam), short-term stability (e.g., whether the flowable foam solidifies to an acceptable degree to produce a stable solid foam structure), and accelerated aging (e.g., to evaluate the ability of the solid foam structure to maintain a substantially non-flowable state in solid form).

[0187] The detergent / PEG1000 formulation was found to be too fluid at room temperature, resulting in composite sheet products that were unacceptably prone to leakage. Structures prepared using PEG4000 or higher were solid at room temperature. The detergent / PEG4000 sample was not stable under accelerated aging tests (50°C laboratory oven) and rapidly liquefied, resulting in a non-acceptable product. PEG6000 (which has a higher melting point than PEG4000) moved much better under these conditions (50°C), but began to move slowly into the PVOH (upper and lower) washing sheet. The PEG8000 sample remained almost unchanged in appearance after one week at 50°C.

[0188] PEG6000 and PEG8000 composite sheets were tested for dissolution in cold water (10°C). A 1g sample of the composite sheet was placed in a beaker containing 250mL of DI (deionized) water at 10°C. The sample was stirred with an overhead stirrer (150rpm), and the time it took for the sample to completely dissolve was recorded three times. For samples that took longer than 10 minutes to dissolve, the experiment was stopped. The dissolution times are shown in Figure 13.

[0189] Formulations containing 10% PEG did not completely dissolve in 10 minutes (600 seconds). Formulations containing 20% ​​PEG4000 took 9–9.5 minutes to dissolve, while a PEG8000 version with the same composition took over 10 minutes to completely dissolve. At a 30% PEG concentration, both PEG4000 and PEG8000 dissolved in 3–5 minutes. These results demonstrate that high levels of water-soluble polymers (e.g., approximately 30% or more) may aid in the dissolution of solid foam structures. The tests were repeated using samples of PEG / cleaning agent formulations that were not foamed and existed as a solid layer in a composite sheet structure. These samples generally had dissolution times longer than 10 minutes, demonstrating that porous foam structures are essential for efficient dissolution in water. Thus, the tests confirmed that mixtures of cleaning agents and water-soluble polymers can form solid water-soluble structures usable in multi-layer laundry sheets or other unit-dose cleaning products.

[0190] Example 9 Various detergent compositions were prepared to evaluate the order of component addition and its usefulness in forming a substantially solid structure that can be used in cleaning products, particularly as an intermediate layer placed between one or more outer sheets, in relation to the physical properties of the composition. The tests showed that the order of operations in forming the composition and the alkali source used to neutralize the acidic surfactant component significantly affected the physical state of the composition. In particular, these factors were found to be related to maintaining a substantially solid state, such as a powder, dough, or paste, while avoiding the formation of a semi-solid state, such as a gel.

[0191] A composition suitable for use as an intermediate layer in cleaning products according to this disclosure was prepared by forming a mixture of PEG, an alkali source, a surfactant, a builder, and a cleaning agent auxiliary, which was ultimately neutralized to a desired pH by adding an acidic surfactant (Biosoft® S-118a dodecylbenzenesulfonic acid - "DBSA"). Test formulations are shown in Table 16.

[0192] [Table 16]

[0193] Table 16 lists the order of addition of each component of the formulation from top to bottom, and the physical appearance of each formulation after the addition of each component. Sample 5671-106-1 is essentially the same formulation as Example 8, but the order of addition of the components in forming the composition was changed. In the addition order shown in Table 16, Sample 5671-106-1 was initially in powder form, and as the raw materials were added until the acidic Biosoft® surfactant was added, it became a thick, opaque paste, at which point the formulation became a dilute, opaque liquid. For Samples 5671-106-2 and 5671-106-3, the addition of powdered alkali (soda ash or sodium bicarbonate) maintained the formulation in a powder or dough-like state until the addition of dodecylbenzenesulfonic acid (Biosoft® S-118), at which point the heat of neutralization melted the PEG and converted the formulation into a viscous paste. Upon final neutralization, the paste was sufficiently fluid to be mechanically aerated to form a foam with a density of approximately 0.4–0.5 g / mL. The foam was laminated between two outer sheets (commercially available Arm&Hammer Power Sheets®), cooled, and solidified to form the final multi-layer laundry product.

[0194] In sample 5671-106-1, the heat released by the neutralization reaction between monoethanolamine and Biosoft® S-118 was sufficient to completely melt PEG8000, yielding a low-viscosity slurry that was easily mechanically aerated before cooling. The addition of soda ash in sample 5671-106-2 and sodium bicarbonate in sample 5671-106-3 reduced the heat generation, and additional heating at approximately 70°C was used to sufficiently reduce the viscosity to facilitate aeration. The neutralization reaction in sample 5671-106-3 produced CO2 gas as a byproduct, which contributed to aeration. In addition, mechanical aeration was still required. The final pH was measured by dissolving 1 g of the final formulation in 100 g of deionized water. Foam density was measured immediately after aeration mixing using a density cup of known volume.

[0195] Example 10 Various detergent compositions were prepared to evaluate foaming as a factor in the dissolution properties of substantially solid structures that can be used in cleaning products, particularly as intermediate layers placed between one or more outer sheets. The prepared formulations used combinations of acid and sodium bicarbonate that react to form bubbles when wetted in a cleaning solution. It was observed that foaming disrupts the structure of the solid layer, resulting in faster dissolution. The compositions tested in this regard are shown in Table 17. It was found that providing powder components as fine particles promotes homogeneous mixing in paste-like filling compositions.

[0196] [Table 17]

[0197] The intermediate layer composition used in the multilayer laundry products of this disclosure is useful to be substantially anhydrous to promote stability. However, the absence of water in the composition slows down the acid-base reaction that generates CO2 gas and promotes dissolution. Samples 5671-103-2, 5671-103-3, and 5671-103-4 mainly used powdered DBSA (Nacconol® 90G) as the surfactant, while sample 5671-105-2 used a 50 / 50 mixture of powdered Nacconol® 90G and Neodol® 25-7. Compositions with a higher proportion of Neodol® are not stable at high temperatures (e.g., above about 50°C) because Neodol migrates from the intermediate layer to the outer layer sheet, giving the laundry products a greasy texture. This can be improved by using an effective component to immobilize the Neodol® surfactant within the physical structure of the composition. For example, the addition of one or more of a coagulant, gelling agent, or powder absorbent may be effective in reducing or eliminating the migration of Neodol® from the intermediate layer composition. The particles in the composition bound together with several liquid components, such as glycerin and liquid surfactants, to form a paste. In some of these compositions, Neodol® 25-7 was found to add cleaning power as well as function as a binder. Low molecular weight polyethylene glycol (PEG), such as Carbowax 600 (melting point about 15°C to about 25°C), was also found to help bind the particles together. Finally, Pluronic F-77 (melting point about 48°C) was found to bind and harden the paste, and thus help stabilize the intermediate layer against leakage. All effervescent formulations dissolved completely, leaving no measurable residue. Tests showed that various organic acids can be used alone or in combination as acidity sources used to initiate the effervescence effect of sodium bicarbonate when in contact with water. The tested sample compositions could be processed at approximately room temperature (e.g., about 15°C to 30°C). This "low-temperature" processing allows for the addition of heat-sensitive materials such as enzymes and fragrances, as well as oxygen bleaching agents such as sodium percarbonate, to the final product.

[0198] Example 11 Various cleaning agent compositions were prepared to evaluate the use of powdered surfactants in combination with meltable binders to form substantially solid structures that can be used in cleaning products, particularly as intermediate layers placed between one or more outer sheets. PEG was specifically used to bind the powdered surfactants to form the intermediate layer composition. Thus, the compositions existed in powder form until the addition of a binder that, upon melting, converted the composition into a paste. Mixing was carried out at high temperatures (e.g., above about 50°C) to keep the binder in a liquid state and prevent the paste from solidifying prematurely. The hot paste was layered between two outer sheets (commercially available Arm & Hammer Power Sheets®) to form a sandwich structure once the filler cooled and hardened. The compositions tested are shown in Table 18.

[0199] [Table 18]

[0200] Sample 5671-99-1 was a simple mixture of three powdered surfactants mixed together, then introduced into liquid PEG8000 to form a slurry. The slurry was rapidly spread onto a PVOH laundry sheet and covered with a second PVOH laundry sheet to form a water-soluble multilayer sandwich structure. Sample 5671-105-1 demonstrated that liquid components (Trilon® C, Acusol® 445, and glycerin) could be successfully added to the detergent powder. Sample 5671-107-1 incorporated powdered and liquid surfactants and a disintegrant (sodium starch glycolate) to improve the disintegration and dissolution of the packed bed when exposed to water.

[0201] Example 12 Various detergent compositions were prepared to evaluate the use of soluble and insoluble particle fillers to curate surfactant mixtures and reduce their fluidity, making them suitable for use in cleaning supplies, particularly as intermediate layers placed between one or more outer sheets. The particles were found to not only increase paste viscosity but also provide performance advantages and were effective in minimizing leakage of the intermediate layer composition during storage and handling. The tested samples are shown in Table 19.

[0202] [Table 19]

[0203] Sample 5671-103-1 was formed using a high level of water-soluble sodium bicarbonate, providing higher alkalinity during washing while also providing a high level of rigidity to the detergent paste. Sample 5770-17-2 was formed using a significantly lower level of sodium bicarbonate compared to sample 5671-103-1, and therefore the surfactant concentration was increased. It was found that the rigid particles did not necessarily need to be water-soluble as long as they were water-dispersible in the washing solution and the residue remaining on the fabric after washing was minimal or nonexistent. Samples 5770-17-3, 5770-17-4, and 5770-17-5 were prepared using fumed amorphous silica particles (Aerosil) to increase the rigidity of the composition. Sample 5671-103-1, containing a high concentration of soluble particles, showed the best solubility compared to the remaining four samples, as indicated by the minimal residue remaining after dissolution. Other particulate materials (such as starch and other water-soluble salts) can similarly provide the same benefits as those shown in particular in sample 5671-103-1. These compositions do not require high temperatures for processing and are therefore suitable for use with heat-sensitive materials.

[0204] The dissolution tests for each of the aforementioned Examples 9-12 were evaluated by gravimetric measurement under harsh conditions of cold water and relatively short dissolution test times. In each case, laundry supplies were prepared by using the sample composition prepared according to Examples 9-12 as an intermediate layer in a sandwich configuration between two outer sheets (commercially available Arm & Hammer Power Sheets®). 1 g of the sample for each laundry supply was placed in 1 L of stirred cold deionized water (10.0°C ± 0.5°C, 49.1°F ~ 50.9°F). The water was stirred at 250 rpm using a 70 mm stirring rod in a 2 L beaker. The sample was allowed to dissolve for 5 minutes, and the solution was filtered through a stainless steel mesh filter on a Buchner funnel vacuum filtration system. The metal mesh (including undissolved residue) was dried, and the mass of the residue was measured. The results were expressed as a percentage of the original sample mass. It should be noted that when tested under these conditions, the outer layer sheet typically has 0% residue, meaning that most of the residue from the sandwich sample is related to the undissolved intermediate layer composition.

[0205] Example 13 The cleaning efficacy of samples from Examples 9-12 was tested using a Terg-o-tometer laboratory-scale washing machine. The machine parameters were as follows: load size 1L; wash temperature 86°C ± 0.5°F; wash time 10 minutes; rinse temperature ambient temperature; rinse time 5 minutes; water hardness 120 ppm CaCO3 equivalent; and impeller speed 95-100 rpm. The stains used were a limited selection from ASTM Test Method D4265-21 and included: grass stains on cotton cloth; blueberry stains on cotton cloth; dirty motor oil stains on cotton cloth; cosmetics on polycotton cloth; and dust / sebum on polycotton cloth. Two samples of each stain were included in a single detergent treatment, and each detergent treatment was performed in double cycles, resulting in four sample sizes for each stain. The color value of each sample was measured before and after washing using an imaging colorimeter (MACH5+, available from ColourConsult BV (Netherlands)). The stain removal index (SRI) was calculated according to section 10 of ASTM D4265-21. The SRI values ​​were averaged and compared to the control detergent using the least significant difference (LSD) statistic. Dosing was performed assuming an 11-gallon (42 L) top-load HE machine wash water volume scaled to a 1 L volume used in a terg-o-tometer. Arm & Hammer Clean Burst ("AHCB") liquid laundry detergent was used as the control wash treatment. The formulation was completely dissolved before adding the stain sample and initiating the wash procedure. AHCB was administered at 0.73 g / L. For each test sample, the outer sheet layer was present at a dose of 0.1 g / L and the intermediate layer composition was present at a dose of 0.24 g / L.

[0206] Tables 20-22 show the cleaning performance data for samples selected from Examples 9-12. The %SRI score is the average of the four samples tested. The total %SRI (sum of all five stains) is listed below, providing a rough indicator of the total cleaning effectiveness for all stain / fabric types.

[0207] [Table 20]

[0208] [Table 21]

[0209] [Table 22]

[0210] The total %SRI scores ranged from 213.9 to 232.1, compared to 221.6 for the control group. These were all very close, with the mean score being 99.9 ± 2.4% of the control score. Greater nuances in the data are observed regarding statistical differences in treatment at the stain level.

[0211] As used herein, the terms “about,” “substantially,” and “generally” may indicate that a particular enumerated value or condition is intended to be interpreted as encompassing not only the explicitly enumerated value or condition, but also values ​​relatively close to it or conditions perceived as relatively close to it. For example, unless otherwise indicated herein, “about” a particular number or “substantially” or “generally” a particular value or result may indicate a particular number, value, or result, as well as numbers, values, or results that vary from there by only (+ or -) 2% or less, or 1% or less. Similarly, unless otherwise indicated herein, “substantially existing” may indicate that the condition is exactly as described or claimed, or within typical manufacturing tolerances, or, even if not fully meeting the required condition, appears to meet the required condition upon casual observation. In some embodiments, a value or condition may be defined as explicit, and thus the terms “about” or “substantially” (and therefore the variances mentioned) may be excluded from such explicit values. When multiple possible lower and upper limits are provided for a particular parameter, it is understood that all possible combinations of values, including either the lower limit or either the upper limit, are included to describe the parameter.

[0212] Many modifications and other embodiments of this disclosure will be conceivable to those skilled in the art in which this disclosure relates, who are of interest in the teachings presented in the foregoing description; and it will be apparent to those skilled in the art that modifications and alterations of this disclosure can be made without departing from the scope or spirit of this disclosure. Therefore, it should be understood that this disclosure is not limited to the specific embodiments disclosed, and modifications and other embodiments are intended to be included within the scope of the appended claims. Certain terms are used herein, but they are used only in a general and descriptive sense and not for limiting purposes.

Claims

1. It is porous and has a first outer layer containing a water-soluble polymer, It is porous and has a second outer layer containing a water-soluble polymer, A cleaning product comprising an intermediate layer disposed between a first outer layer and a second outer layer, wherein the intermediate layer comprises at least a first segment and a second segment, the first segment being formed from a first composition having at least one cleaning component, and the second segment being formed from a second composition having at least one cleaning component, the second composition being different from the first cleaning composition, and the at least first segment and the second segment being disposed in the cleaning product in either the longitudinal or transverse direction or both.

2. The cleaning product according to claim 1, wherein one or both of the first outer layer and the second outer layer contain a cleaning component.

3. The cleaning product according to claim 1, wherein one or both of the first outer layer and the second outer layer are configured as a solid foam sheet.

4. The cleaning product according to claim 1, wherein one or both of the first outer layer and the second outer layer are made of fabric.

5. The cleaning product according to claim 1, wherein the first outer layer and the second outer layer are each composed of a sheet having a porosity measured as the volume of pores divided by the total sheet volume, and the porosity is approximately 10% to approximately 90%.

6. The cleaning product according to any one of claims 1 to 5, wherein at least one of the first composition and the second composition is configured as a foam containing a water-soluble polymer having a melting point in the range of about 40°C to about 80°C, mixed with the at least one cleaning component.

7. The cleaning product according to claim 6, wherein the water-soluble polymer is polyethylene glycol (PEG) polymer.

8. The cleaning product according to claim 7, wherein the PEG polymer has a molecular weight of about 8,000 Da to about 20,000 Da.

9. The cleaning product according to claim 6, wherein the water-soluble polymer constitutes about 10% to about 50% by weight of the foam structure.

10. The cleaning product according to any one of claims 1 to 5, wherein at least one of the first cleaning composition and the second cleaning composition is configured as a semi-solid.

11. The cleaning product according to claim 10, wherein the semi-solid has a complex modulus of elasticity (G*) of 5,000 Pa or more at ambient temperature.

12. The cleaning product according to claim 10, wherein the semi-solid is a paste.

13. The cleaning product according to claim 10, wherein the semi-solid comprises about 10% by weight or more of either a water-soluble solid or a water-insoluble solid, or both.

14. The cleaning product according to claim 13, wherein the semi-solid comprises a water-soluble solid in an amount of about 30% to about 80% by weight based on the total weight of the cleaning composition.

15. The cleaning product according to claim 10, wherein the semi-solid contains an alkali metal salt.

16. The cleaning product according to claim 10, wherein the semi-solid is anhydrous.

17. The cleaning product according to claim 16, wherein the semi-solid comprises at least one base and at least one acid that are effective in reacting with water to form carbon dioxide gas.

18. The cleaning product according to any one of claims 1 to 17, wherein the cleaning product is substantially completely water-soluble at a temperature of about 15°C to about 30°C for a time of about 0.5 minutes to about 10 minutes.

19. The cleaning product according to any one of claims 1 to 18, wherein the at least one cleaning component is selected from the group consisting of surfactants, enzymes, stabilizers, dyes, fluorescent whitening agents, anti-redeposition agents, fluorescent whitening agents, fragrances, chelating agents, foam regulators, corrosion inhibitors, color transfer inhibitors, softeners, fragrances, pH control and buffering agents, antioxidants, viscosity enhancers, formulation aids, bittering agents, thickeners, defoaming agents, pH adjusters, bleaches, fabric softeners, pearlescent agents, preservatives, and laundry boosters.

20. The cleaning product according to any one of claims 1 to 18, wherein the first composition and the second composition each comprise one of a cleaning composition, an odor removal composition, a softening composition, a bleaching composition, an enzyme composition, and a booster composition, respectively.

21. The cleaning product according to any one of claims 1 to 20, wherein the first composition has a first color, and the second composition has a second color that is visually distinguishable from the first color.

22. The cleaning product according to claim 21, wherein the first color of the first composition corresponds to a first cleaning function, and the second color of the second composition corresponds to a second cleaning function different from the first cleaning function.

23. The cleaning product according to claim 21, wherein at least the first segment and the second segment are arranged as a colored pattern visible through one or both of the first and second outer layers.

24. The cleaning product according to claim 23, wherein the coloring pattern is an alternating pattern of straight strips and curved strips, or both.

25. The cleaning product according to claim 23, wherein one or both of the first outer layer and the second outer layer have a transparency of about 5% to about 50%.

26. The cleaning product according to claim 23, wherein the brightness of each of the first and second colors is greater in the cross-sectional view of the cleaning product than when the intermediate layer is seen through one or both of the first and second outer layers.

27. At least one of the first color and the second color is The blue color is defined by L*a*b* values ​​of approximately 64, approximately -14, and approximately -20, respectively. Green, defined by L*a*b* values ​​of approximately 75, -10, and 8 respectively. Purple is defined by L*a*b* values ​​of approximately 75, 5, and -7, respectively. A cleaning product according to claim 21, defined by one of the following.

28. The cleaning product according to claim 21, wherein the first color has a first set of L*a*b* values ​​when measured at the edge of the cleaning product where the intermediate layer is not obstructed by the first outer layer or the second outer layer, and has a second different set of L*a*b* values ​​when measured through one of the first outer layer and the second outer layer.

29. The cleaning product according to claim 28, wherein the L* value of the first color is greater when measured through one of the first outer layer and the second outer layer.

30. The cleaning product according to claim 28, wherein one or both of the a* value and the b* value are smaller when measured through one of the first outer layer and the second outer layer.

31. The cleaning product has a length measured along the longitudinal axis, a width measured along the transverse axis, and a thickness measured perpendicular to the longitudinal axis and the transverse axis, and the following: The cleaning supplies are composed of materials with a length-to-width ratio (L:W) of approximately 1:1 to approximately 10:1; The cleaning supplies are composed of materials with a length-to-thickness ratio (L:T) of approximately 10:1 to approximately 200:1; The first outer layer, the second outer layer, and the intermediate layer each have their own individual thicknesses, and the ratio of the individual thickness of either the first or second outer layer to the individual thickness of the intermediate layer is approximately 0.05:1 to approximately 2:1; A cleaning product according to any one of claims 1 to 30, wherein one of the above applies.

32. The first outer layer has a first outer layer surface having a first surface area, and the second outer layer has a second outer layer surface having a second surface area, and the sum of the first surface area and the second surface area is the total surface area of ​​the cleaning product. The intermediate layer defines an edge along one or more sides of the cleaning product that are not covered by the first outer layer or the second outer layer, and the edge has a total edge surface area, and The cleaning product according to any one of claims 1 to 30, wherein the cleaning product is configured such that the edge-to-face surface area ratio (EFAR), defined as the ratio of the total edge surface area to the total surface area, is less than 0.

5.

33. The cleaning product according to claim 32, wherein the EFAR is approximately 0.01 to approximately 0.

5.

34. A method for preparing cleaning supplies, A first composition having at least one cleaning component and a second composition having at least one cleaning component are combined with a first outer layer and a second outer layer to form an intermediate layer between the first outer layer and the second outer layer. The first composition defines the first segment of the intermediate layer, and the second composition defines the second segment of the intermediate layer, and The combining is carried out such that the first segment and the second segment are positioned longitudinally and transversely, or both, on the cleaning product between the first outer layer and the second outer layer.

35. A cleaning product prepared according to the method of claim 34.

36. The cleaning product according to claim 35, wherein the first outer layer and the second outer layer are each porous and contain a water-soluble polymer.

37. The cleaning product according to claim 35, wherein the cleaning product is substantially completely water-soluble at a temperature of about 15°C to about 30°C for a period of about 0.5 minutes to about 10 minutes.

38. The cleaning product according to any one of claims 35 to 37, wherein the at least one cleaning component is selected from the group consisting of surfactants, enzymes, stabilizers, dyes, fluorescent whitening agents, anti-redeposition agents, fluorescent whitening agents, fragrances, chelating agents, foam regulators, corrosion inhibitors, color transfer inhibitors, softeners, fragrances, pH control and buffering agents, antioxidants, viscosity enhancers, formulation aids, bittering agents, thickeners, defoaming agents, pH adjusters, bleaches, fabric softeners, pearlescent agents, preservatives, and laundry boosters.

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