Process for making an article of manufacture

Abstract

To provide a process for manufacturing a production article in a consecutive process.SOLUTION: A consecutive process for manufacturing a production article includes: a. a step to provide one or more soluble filament formation materials; b. a step to form an aqueous composition containing one or more soluble filament formation materials; c. a step to generate a filament formation composition by processing the aqueous composition; d. a step to deliver the filament formation composition to one or more dies; e. a step to form a plurality of soluble filaments by spinning the filament formation composition; f. a step to recover the soluble filament on a recovery device and form a fiber structure; and g. a step to convert the fiber structure to a production article.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to processes, e.g., continuous processes, for making articles of manufacture comprising fibrous structures, and more particularly to processes for making articles of manufacture comprising fibrous structures, such as soluble fibrous structures comprising soluble filaments, e.g., water-soluble filaments. [Background technology]

[0002] Processes for making fibrous structures, e.g., soluble fibrous structures, and / or components thereof, such as soluble filaments, are known in the art. Furthermore, fibrous structures and / or components thereof have ultimately been incorporated into consumer products, such as fabric care products, hair care products, dental care products, and other product articles. However, to date, such known processes have been discontinuous. In other words, such known processes have at least two or more discrete (discontinuous) steps or unit operations that interrupt the process of making an article of manufacture, e.g., one or more steps that release and / or make discrete fibrous structures from one or more steps that convert the made fibrous structure into an article of manufacture, e.g., a consumer product. Such a non-continuous / discontinuous process may include one or more of the following steps: 1) a filament-forming composition making step, such as a batch process, to make a filament-forming composition; 2) a spinning step to spin the filament-forming composition to make filaments, e.g., soluble filaments; 3) a mixing (coform) step, optionally, to mix solid additives, e.g., particles, with the filaments; 4) a recovery step to recover the filaments and / or mixed filaments and solid additives to form a fibrous structure, e.g., a soluble fibrous structure; 5) a converting operation (one or more steps to convert the fibrous structure into one or more articles of manufacture, e.g., consumer products (e.g., one or more steps to slit and / or laminate and / or calendar and / or process with minor ingredients such as perfumes, enzymes, bleaches, flavorings, foaming agents, die-cutting, and printing); and 6) a packaging step, optionally, to package the articles of manufacture. Summary of the Invention [Problem to be solved by the invention]

[0003] One problem faced by compounders is how to make such manufactured articles comprising fibrous structures, such as soluble fibrous structures, in a continuous or more continuous manner than known discontinuous processes. In other words, one problem faced by compounders is how to combine multiple process steps from above into a continuous process so that they are not discrete, discontinuous process steps.

[0004] Therefore, there is a need for a process for making articles of manufacture, eg, consumer products, that include fibrous structures, eg, soluble fibrous structures, in a continuous or at least partially continuous process. [Means for solving the problem]

[0005] The present invention meets the above-described needs by providing a continuous process and / or continuous process steps within a process for making an article of manufacture, e.g., a fibrous structure, e.g., an article of manufacture comprising a soluble fibrous structure, e.g., a consumer product.

[0006] One solution to the problems identified above is to provide a process for making articles of manufacture, e.g., consumer products, comprising fibrous structures, e.g., soluble fibrous structures, in a continuous or more continuous process. Such a continuous process includes at least the following steps: 1) a filament-forming composition making step to make a filament-forming composition; 2) a spinning step to spin the filament-forming composition to make filaments, e.g., soluble filaments; 3) a mixing (coform) step to optionally mix solid additives, e.g., particles, with the filaments; and 4) a recovery step to recover the filaments and / or mixed filaments and solid additives to form a fibrous structure, e.g., a soluble fibrous structure, where, if present, steps (1-4) are carried out in a continuous manner, sequentially, without any interruption, stop, or disruption in the process from making the filament-forming composition, to spinning the filament-forming composition into filaments (optionally mixing solid additives with the filaments), to recovering the filaments (and / or mixed filaments and solid additives) in a recovery device, to forming a fibrous structure, which can then be converted into an article of manufacture and ultimately packaged, e.g., in a consumer package. The continuous process may further include 5) a converting operation (one or more steps for converting the fibrous structure into one or more articles of manufacture, e.g., consumer products (e.g., slitting and / or laminating and / or calendaring and / or processing with minor ingredients such as perfumes, enzymes, bleaches, flavorings, foaming agents, die-cutting, and printing)); and 6) optionally, a packaging step for packaging the articles of manufacture.

[0007] The present invention provides a continuous process for making fibrous structures and ultimately articles of manufacture.

[0008] In one embodiment of the present invention, there is provided a process for making a fibrous structure, comprising the steps of: a. providing one or more soluble filament-forming materials; b. forming an aqueous composition comprising one or more soluble filament-forming materials; c. processing the aqueous composition to form a filament-forming composition; d. delivering a filament-forming composition to one or more dies; e. spinning the filament-forming composition to form a plurality of soluble filaments; and f. collecting the soluble filaments on a collection device to form a fibrous structure. In one embodiment, in at least one of steps b, c, and d, one or more active agents may be added to the process. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a schematic diagram of an embodiment of a process according to the present invention; [Figure 2] 1 is a schematic diagram of an example of a process according to the present invention. [Figure 3] 1 is a schematic diagram of an embodiment of an extruder screw suitable for use in the process of the present invention. [Figure 4] 1 is a schematic diagram of an embodiment of a process according to the present invention; [Figure 5] FIG. 1 is a top plan view of a die suitable for use in a process according to the present invention. [Figure 6] 1 is a schematic diagram of an embodiment of a process according to the present invention; [Figure 7] 1 is a schematic diagram of an embodiment of a recovery zone on a recovery apparatus suitable for use in a process according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0010] definition As used herein, "fibrous structure" refers to a structure comprising one or more filaments and, optionally, one or more particles. In one embodiment, a fibrous structure according to the present invention refers to an association of filaments and, optionally, particles that together form a structure, such as a monolithic structure, capable of performing a function.

[0011] The fibrous structures of the present invention may be single-layer or multi-layer. If multi-layer, the fibrous structure may include one or more composite structures having at least two, and / or at least three, and / or at least four, and / or at least five, and / or at least six layers, e.g., one or more filament layers, one or more particle layers, and / or one or more mixed layers of filaments and particles. A layer may include a particle layer within the fibrous structure or between filament layers within the fibrous structure. A layer containing filaments may sometimes be referred to as a ply. A ply may be a fibrous structure that can be single-layer or multi-layer, as described herein. In one example, a layer may be formed by a single spinning die and / or particle delivery source, or, if a composite structure layer, by a single spinning die and particle delivery source.

[0012] In one embodiment, the fibrous structure of the present invention may comprise single or multiple layers, at least one of which must comprise fibers. The layers may also comprise additives (e.g., pastes or sprays) applied to the fibers and / or particles co-mixed with the fibers in the composite structure.

[0013] In one embodiment, a single-ply fibrous structure according to the present invention, or a multi-ply fibrous structure comprising one or more fibrous structure plies according to the present invention, has a basis weight of 5000 g / m 2 or more, when measured according to the basis weight test method described herein. 2 In one embodiment, the single-ply or multi-ply fibrous structure of the present invention may exhibit a basis weight of less than 10 g / m when measured according to the Basis Weight Test Method. 2 Super~approx. 5000g / m 2 , and / or 10 g / m 2 Super ~ about 3000g / m 2 , and / or 10 g / m 2 Super ~ about 2000g / m 2 , and / or 10 g / m 2 Super ~ about 1000g / m 2 , and / or 20 g / m 2 Super ~ about 800g / m 2 , and / or 30 g / m 2 Super ~ about 600g / m2 , and / or 50g / m 2 Super~approx. 500g / m 2 , and / or 300 g / m 2 Super ~ about 3000g / m 2 , and / or 500g / m 2 Super ~ about 2000g / m 2 It may have a basis weight of

[0014] In one embodiment, a single ply comprising a multilayer fibrous structure includes a first layer, such as a scrim layer, comprising a plurality of filaments present in a basis weight of about 10 to about 200 gsm, and / or about 30 to about 100 gsm, and / or about 50 to about 75 gsm, and a second layer, for example, a layer comprising a plurality of filaments, either alone or as a composite structure layer comprising filaments and solid additives, e.g., particles, present in a basis weight of about 400 to about 3000 gsm, and / or about 600 to about 1500 gsm, and / or about 800 to about 1200 gsm.

[0015] In one embodiment, the fibrous structure of the present invention is a "monolithic fibrous structure."

[0016] As used herein, a "monolithic fibrous structure" is an arrangement comprising two or more and / or three or more filaments that are entangled or otherwise bonded to one another to form a fibrous structure and / or fibrous structure ply. The monolithic fibrous structure of the present invention can be one or more plies within a multi-ply fibrous structure. In one embodiment, the monolithic fibrous structure of the present invention can comprise three or more different filaments. In another embodiment, the monolithic fibrous structure of the present invention can comprise two or more different filaments.

[0017] As used herein, "article" refers to a consumer unit, a consumer unitary dose unit, a consumer salable unit, a single dose unit, or other form of use that includes a monolithic fibrous structure and / or that includes one or more fibrous structures of the present invention.

[0018] As used herein, "fiber element" means an elongated particle having a length that is significantly greater than its average diameter, i.e., a length to average diameter ratio of at least about 10. A fiber element can be a filament or a fiber. In one embodiment, a fiber element is a single filament, rather than a yarn containing multiple filaments.

[0019] The fiber elements of the present invention can be spun from a fiber element-forming composition, also referred to as a filament-forming composition, via a suitable spinning process operation (e.g., meltblowing, spunbonding, electrospinning, and / or rotary spinning).

[0020] The fiber elements of the present invention can be monocomponent (a single, integral, solid piece rather than two distinct parts such as core / sheath bicomponent) and / or multicomponent. For example, the fiber elements may comprise bicomponent fibers and / or filaments. The bicomponent fibers and / or filaments can be in any configuration, such as side-by-side, sheath-core, islands-in-the-sea, etc.

[0021] As used herein, "filament" means an elongated particle as defined above exhibiting a length of 2 inches or more, and / or 3 inches or more, and / or 4 inches or more, and / or 6 inches or more.

[0022] Filaments are typically considered to be essentially continuous or substantially continuous. Filaments are relatively longer than fibers. Non-limiting examples of filaments include meltblown filaments and / or spunbond filaments. Non-limiting examples of polymers that can be spun into filaments include natural polymers such as starch, starch derivatives, cellulose (e.g., rayon and / or lyocell), cellulose derivatives, hemicellulose, and hemicellulose derivatives, as well as synthetic polymers, including, but not limited to, polyvinyl alcohol, thermoplastic polymer filaments such as polyester, nylon, polyolefins (e.g., polypropylene filaments and polyethylene filaments), and biodegradable thermoplastic fibers such as polylactic acid filaments, polyhydroxyalkanoate filaments, polyesteramide filaments, and polycaprolactone filaments.

[0023] As used herein, "fiber" means an elongated particle as defined above exhibiting a length of less than 2 inches and / or less than 1.5 inches and / or less than 1 inch.

[0024] Typically, fibers are considered discontinuous in nature. Non-limiting examples of fibers include staple fibers made by spinning the filaments or filament tows of the present invention and then chopping the filaments or filament tows into pieces less than 2 inches.

[0025] In one embodiment, one or more fibers can be formed from the filaments of the present invention, such as when the filaments are cut into shorter lengths (e.g., lengths less than 5.08 cm). Thus, in one embodiment, the present invention also includes fibers made from the filaments of the present invention, such as fibers comprising one or more filament-forming materials and one or more fiber additives, such as an active agent. Thus, references herein to filaments of the present invention also include fibers made from such filaments, unless otherwise specified. Fibers are typically considered to be essentially discontinuous, as opposed to filaments, which are considered to be essentially continuous.

[0026] As used herein, "fiber element-forming composition" and / or "filament-forming composition" refer to a composition suitable for making filaments of the present invention, such as by meltblowing and / or spunbonding. A filament-forming composition includes one or more filament-forming materials, which exhibit properties that make them suitable for spinning into filaments. In one example, the filament-forming material includes a polymer. In addition to the one or more filament-forming materials, the filament-forming composition may include one or more fiber additives, such as one or more active agents. Furthermore, the filament-forming composition may include one or more polar solvents, such as water, in which one or more, e.g., all of the filament-forming materials and / or one or more, e.g., all of the active agents, are dissolved and / or dispersed prior to spinning a filament, such as a filament derived from the filament-forming composition.

[0027] In one example, filaments made from the filament-forming composition of the present invention may have one or more fiber additives present within the filament rather than on it, such as a coating composition comprising one or more active agents, which may be the same as or different from the active agents in the filament and / or particle. The total concentration of filament-forming materials and the total concentration of active agents present in the filament-forming composition may be any suitable amount, so long as a filament of the present invention can be produced therefrom.

[0028] In one embodiment, one or more fiber additives, such as an active agent, may be present in the filament, and one or more additional fiber additives, such as an active agent, may be present on the surface of the filament. In other embodiments, the filaments of the present invention may include one or more fiber additives, such as an active agent, that are originally present in the filament as made but bloom to the surface of the filament before and / or upon exposure of the filament to the intended use conditions.

[0029] As used herein, "fiber element-forming material" and / or "filament-forming material" refer to materials such as polymers exhibiting properties suitable for making filaments, or monomers capable of producing such polymers. In one example, the filament-forming material includes one or more substituted polymers, such as anionic, cationic, zwitterionic, and / or nonionic polymers. In another example, the polymer may include hydroxyl polymers such as polyvinyl alcohol ("PVOH"), partially hydrolyzed polyvinyl acetate, and / or polysaccharides such as starch and / or starch derivatives, such as ethoxylated starch and / or acid-thinned starch, carboxymethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, and methyl cellulose. In another example, the polymer may include polyethylene and / or terephthalate. In yet another example, the filament-forming material is a polar solvent-soluble material.

[0030] As used herein, "particle" refers to a solid additive such as a powder, granule, agglomerate, encapsulation, microcapsule, and / or prill. The shape of the particle may be spherical, rod-shaped, dish-shaped, tubular, square, rectangular, disk-shaped, star-shaped, fibrous, or may have a regular or irregular random shape. The particles of the present invention, at least those particles of at least 44 μm, can be measured by the particle size distribution test method described herein. For particles less than 44 μm, a different test method, such as a light scattering method, can be used to determine the particle size of less than 44 μm, for example, perfume microcapsules, typically ranging in size from about 15 μm to about 44 μm and / or about 25 μm.

[0031] In one aspect, the particles may comprise recycled fibrous structural material, specifically, the fibrous material is recycled by grinding the fibers into finely divided solids and reincorporating the finely divided solids into aggregates, granules, or other particulate forms. In another aspect, the particles may comprise recycled fibrous structural material, specifically, the fibrous material is incorporated into a fluid paste, suspension, or solution and then processed to form aggregates, granules, or other particulate forms. In another aspect, the fluid paste, suspension, or solution containing recycled fibrous material may be applied directly to a fibrous layer in the process of making a new fibrous article.

[0032] As used herein, "active agent-containing particles" refers to solid additives, e.g., particles, that contain one or more active agents. In one example, the active agent-containing particles are active agents in particulate form (i.e., the particles contain 100% active agent). The active agent-containing particles may exhibit a particle size of 5000 μm or less, as measured according to the Particle Size Distribution Test Method described herein.

[0033] In one embodiment of the invention, the fibrous structure comprises a plurality of particles, e.g., active agent-containing particles, e.g., at least one active agent-containing particle, and a plurality of filaments in a ratio of 1:100 or more, and / or 1:50 or more, and / or 1:10 or more, and / or 1:3 or more, and / or 1:2 or more, and / or 1:1 or more, and / or 2:1 or more, and / or 3:1 or more, and / or 4:1 or more, and / or 5:1 or more, and / or The particles, e.g., active agent-containing particles to filaments, comprise a weight ratio of 7:1 or greater, and / or 8:1 or greater, and / or 10:1 or greater, and / or from about 10:1 to about 1:100, and / or from about 8:1 to about 1:50, and / or from about 7:1 to about 1:10, and / or from about 7:1 to about 1:3, and / or from about 6:1 to 1:2, and / or from about 5:1 to about 1:1, and / or from about 4:1 to about 1:1, and / or from about 3:1 to about 1.5:1.

[0034] In another embodiment of the present invention, a fibrous structure comprises a plurality of particles, e.g., active agent-containing particles, and a plurality of filaments, in a weight ratio of particles, e.g., active agent-containing particles to filaments, of from about 20:1 to about 1:1, and / or from about 10:1 to about 1:1, and / or from about 10:1 to about 1.5:1, and / or from about 8:1 to about 1.5:1, and / or from about 8:1 to about 2:1, and / or from about 7:1 to about 2:1, and / or from about 7:1 to about 3:1, and / or from about 6:1 to about 2.5:1.

[0035] In yet another embodiment of the present invention, a fibrous structure comprises a plurality of particles, e.g., active agent-containing particles, and a plurality of filaments, in a weight ratio of particles, e.g., active agent-containing particles to filaments, of from about 1:1 to about 1:100, and / or from about 1:15 to about 1:80, and / or from about 1:2 to about 1:60, and / or from about 1:3 to about 1:50, and / or from about 1:3 to about 1:40.

[0036] In another embodiment, the fibrous structure of the present invention has a basis weight of 1 g / m when measured according to the basis weight test method described herein. 2 and / or 10g / m 2 and / or 20 g / m 2 and / or 30 g / m 2 Over 40g / m2 greater than and / or about 1 g / m 2 to approximately 5000 g / m 2 Up to and / or approximately 3500 g / m 2 Up to and / or about 2000 g / m 2 up to and / or about 1 g / m 2 ~About 2000g / m 2 , and / or about 10 g / m 2 ~About 1000g / m 2 , and / or about 10 g / m 2 ~about 500g / m 2 , and / or about 20 g / m 2 ~about 400g / m 2 , and / or about 30 g / m 2 ~about 300g / m 2 , and / or about 40 g / m 2 ~about 200g / m 2 and a plurality of particles, e.g., active agent-containing particles, at a basis weight of 1000 .mu.m.

[0037] In another embodiment, the fibrous structure of the present invention has a basis weight of 1 g / m when measured according to the basis weight test method described herein. 2 and / or 10 g / m 2 and / or 20 g / m 2 and / or 30 g / m 2 and / or 40 g / m 2 More than and / or about 1 g / m 2 ~About 3000g / m 2 , and / or about 10 g / m 2 ~about 5000g / m 2 and / or approximately 3000 g / m 2 and / or approximately 2000 g / m 2 , and / or about 20 g / m 2 ~About 2000g / m 2 , and / or about 30 g / m 2 ~About 1000g / m 2 , and / or about 30 g / m 2 ~about 500g / m 2 , and / or about 30 g / m 2 ~about 300g / m 2 , and / or about 40 g / m 2~about 100g / m 2 , and / or about 40 g / m 2 ~about 80g / m 2 In one embodiment, the fibrous structure comprises two or more layers, and the filaments have a basis weight of about 1 g / m 2 ~about 500g / m 2 is present in at least one of the layers at a basis weight of

[0038] As used herein, "intermixing" and / or "intermixing" refer to a state or form in which particles are intermixed with fiber elements, e.g., filaments. The intermixing of filaments and particles may be throughout the composite structure or within a plane or region of the composite structure. In one example, the intermixed filaments and particles may form at least a surface of the composite structure. In one example, the particles may be uniformly dispersed throughout the composite structure and / or a plane and / or region of the composite structure. In one example, the particles may be uniformly distributed throughout the composite structure, thereby avoiding and / or preventing sagging and / or free movement and / or migration of particles within the composite structure to other regions within the composite structure, thus resulting in zones of higher particle concentration and zones of lower or no particle concentration within the composite structure. In one example, μCT cross-sections of a composite structure can indicate whether particles are uniformly distributed throughout the composite structure.

[0039] As used herein, "fiber additive" refers to any material present in the filaments of the present invention that is not a filament-forming material. In one embodiment, the fiber additive includes an active agent. In another embodiment, the fiber additive includes a processing aid. In yet another embodiment, the fiber additive includes a filler. In one embodiment, the fiber additive includes any material present in the filament, the absence of which does not result in the filament losing its filament structure, in other words, the absence of which does not result in the filament losing its solid form. In another embodiment, the fiber additive, e.g., an active agent, includes a non-polymeric material.

[0040] In another example, the fiber additive may include a plasticizer for filaments. Non-limiting examples of suitable plasticizers for the present invention include polyols, copolyols, polycarboxylic acids, polyesters, and dimethicone copolyols. Examples of useful polyols include, but are not limited to, glycerin, diglycerin, propylene glycol, ethylene glycol, butylene glycol, pentylene glycol, cyclohexanedimethanol, hexanediol, 2,2,4-trimethylpentane-1,3-diol, polyethylene glycol (200-600), pentaerythritol, sugar alcohols such as sorbitol, mannitol, lactitol, and other monohydric and polyhydric low molecular weight alcohols (e.g., C2-C8 alcohols); monosaccharides, disaccharides, and oligosaccharides such as fructose, glucose, sucrose, maltose, lactose, high fructose corn syrup solids, and dextrins; and ascorbic acid.

[0041] In one embodiment, the plasticizer includes glycerin, and / or propylene glycol, and / or glycerol derivatives such as propoxylated glycerol, hi yet another embodiment, the plasticizer is selected from the group consisting of glycerin, ethylene glycol, polyethylene glycol, propylene glycol, glycidol, urea, sorbitol, xylitol, maltitol, sugars, ethylene bisformamide, amino acids, and mixtures thereof.

[0042] In another example, the fiber additive may include a rheology modifier, such as a shear modifier and / or an elongation modifier. Non-limiting examples of rheology modifiers include, but are not limited to, polyacrylamides, polyurethanes, and polyacrylates that may be used in the filaments of the present invention. Non-limiting examples of rheology modifiers are commercially available from Dow Chemical Company (Midland, MI).

[0043] In yet another example, the fiber additive may include one or more colors and / or dyes incorporated into the filaments of the present invention to provide a visual signal when the filaments are exposed to intended use conditions, and / or when an active agent is released from the filaments, and / or when the morphology of the filaments changes.

[0044] In yet another embodiment, the fiber additive may include one or more release agents and / or lubricants. Non-limiting examples of suitable release agents and / or lubricants include fatty acids, fatty acid salts, fatty alcohols, fatty esters, sulfonated fatty acid esters, fatty amine acetates, fatty amides, silicones, aminosilicones, fluoropolymers, and mixtures thereof. In one embodiment, the release agents and / or lubricants may be applied to the filaments, i.e., after the filaments are formed. In one embodiment, one or more release agents / lubricants may be applied to the filaments before collecting the filaments in a collection device to form a fibrous structure. In another embodiment, one or more release agents / lubricants may be applied to a fibrous structure formed from the filaments of the present invention before contacting one or more fibrous structures, such as a fibrous structure laminate. In yet another example, one or more release agents / lubricants may be applied to the filaments and / or fibrous structures of the present invention before the filaments and / or fibrous structures contact a surface, such as a surface of an apparatus used in a processing system, to facilitate removal of the filaments and / or fibrous structures and / or to prevent plies of the filaments and / or fibrous structures of the present invention from adhering to one another or even unintentionally. In one example, the release agent / lubricant comprises particulates.

[0045] In yet another embodiment, the fiber additive may include one or more antiblocking and / or detackifying agents. Non-limiting examples of suitable antiblocking and / or detackifying agents include starch, starch derivatives, crosslinked polyvinylpyrrolidone, crosslinked cellulose, microcrystalline cellulose, silica, metal oxides, calcium carbonate, talc, mica, and mixtures thereof.

[0046] As used herein, "intended use conditions" refers to the temperature, physical, chemical, and / or mechanical conditions to which the filaments and / or particles and / or fibrous structures of the present invention will be exposed when the filaments and / or fibrous structures are used for one or more of their designed purposes. For example, if the filaments and / or particles and / or fibrous structures comprising the filaments are designed to be used in a washing machine for laundry care purposes, the intended use conditions include the temperature, chemical, physical, and / or mechanical conditions present in the washing machine, including any wash water, during the laundry wash operation. In another example, if the filaments and / or particles and / or fibrous structures comprising the filaments are designed to be used by humans as a shampoo for hair care purposes, the intended use conditions include the temperature, chemical, physical, and / or mechanical conditions present in shampooing human hair. Similarly, when a fibrous structure comprising filaments, and / or particles, and / or filaments is designed to be used in a dishwashing operation, either by hand or in a dishwasher, the intended use conditions include the temperature, chemical, physical, and / or mechanical conditions present in the dishwashing water and / or in the dishwasher during the dishwashing operation.

[0047] As used herein, "active agent" refers to a fiber additive that produces an intended effect in the environment external to the filaments, particles, and / or fibrous structures comprising the filaments of the present invention, such as when the filaments, particles, and / or fibrous structures are exposed to the intended conditions of use of the filaments, particles, and / or fibrous structures comprising the filaments. In one example, the active agent includes a fiber additive that treats a surface, such as a hard surface (i.e., kitchen counter, bathtub, toilet, urinal, sink, floor, wall, tooth, car, window, mirror, dish) and / or a soft surface (i.e., fabric, hair, skin, carpet, crops, plants). In another example, the active agent includes an added fiber additive that creates a chemical reaction (i.e., foaming, effervescent, effervescent, coloring, warming, cooling, foaming, disinfecting and / or purifying, and / or chlorinating, e.g., in purified water and / or disinfected water and / or chlorinated water). In yet another example, the active agent comprises a fiber additive that treats the environment (i.e., deodorizes, purifies, or fragrances the air). In one example, the active agent is formed in situ, such as during the formation of the filaments and / or particles that comprise the active agent; for example, the filaments and / or particles may comprise a water-soluble polymer (e.g., starch) and a surfactant (e.g., an anionic surfactant) that can create a polymer complex or coacervate that functions as the active agent used to treat the surface of the fabric.

[0048] "Treating," as used herein with respect to treating a surface, means that an active agent provides a benefit to the surface or environment. Treatment includes regulating and / or rapidly improving the appearance, cleanliness, odor, purity, and / or feel of the surface or environment. In one example, treatment with respect to treating a keratinous tissue (e.g., skin and / or hair) surface refers to regulating and / or rapidly improving the cosmetic appearance and / or feel of the keratinous tissue. For example, "regulating the condition of the skin, hair, or nails (keratinous tissue)" can include thickening of the skin, hair, or nails (e.g., building up of the epidermal and / or dermal and / or subcutaneous (e.g., subcutaneous fat or muscle) layers of the skin, and building up of the stratum corneum of the nail and hair shaft, if applicable), to reduce atrophy of the skin, hair, or nails, increased convolution of the dermal-epidermal junction (also known as the interpapillary ridges), elastosis, sagging, and deformation of the skin or hair. Examples of beneficial effects include preventing loss of skin or hair elasticity (loss, damage, and / or inactivation of functional skin elastin), such as loss of recovery from aging, and preventing melanotic or non-melanotic changes in skin, hair, or nail color, such as dark circles under the eyes, blemishes (e.g., uneven redness due to rosacea, etc.) (hereinafter referred to as "erythema"), paleness (paleness), discoloration caused by telangiectasia or spider veins, and gray hair. Treatments may include providing benefits to fabrics during washing or softening in a washing machine, to hair during shampooing, conditioning, or coloring of hair, or to an environment, such as a toilet bowl, by cleaning or disinfecting.

[0049] In another example, treating refers to removing stains and / or odors from fabric articles (e.g., clothing, towels, linens) and / or hard surfaces (e.g., counters and / or tableware such as pots and pans).

[0050] As used herein, "fabric care active" means an active that, when applied to a fabric, provides a benefit and / or improvement to the fabric. Non-limiting examples of benefits and / or improvements to fabrics include cleaning (e.g., by surfactants), stain removal, stain reduction, wrinkle removal, color recovery, static control, wrinkle resistance, permanent press, abrasion reduction, abrasion resistance, pilling removal, pilling resistance, stain removal, stain resistance (including stain release), shape retention, shrinkage reduction, softness, fragrance, antibacterial, antiviral, odor control, and odor elimination.

[0051] As used herein, "dishwashing active" means an active that, when applied to tableware, glassware, pots, pans, kitchen utensils, and / or cooksheets, provides a benefit and / or improvement to the tableware, glassware, plastic items, pots, pans, and / or cooksheets. Non-limiting examples of benefits and / or improvements to tableware, glassware, plastic items, pots, pans, kitchen utensils, and / or cooksheets include food and / or soil removal, cleaning (e.g., surfactant) stain removal, stain reduction, grease removal, water stain removal and / or water stain prevention, glass and metal care, sanitizing, shine, and polishing.

[0052] As used herein, "hard surface active agent" means an active agent that, when applied to a floor, counter, sink, window, mirror, shower, bath, and / or toilet, provides a benefit and / or improvement to the floor, counter, sink, window, mirror, shower, bath, and / or toilet. Non-limiting examples of benefits and / or improvements to floors, counters, sinks, windows, mirrors, showers, baths, and / or toilets include food and / or soil removal, cleaning (e.g., with surfactants), stain removal, stain reduction, grease removal, water stain removal and / or water stain prevention, soap scum removal, sanitizing, brightening, polishing, and freshening.

[0053] As used herein, "keratinous tissue active agent" means an active agent that may be useful in treating keratinous tissue (e.g., hair, skin, or nail) conditions. In the case of hair care active agents, "treating" or "treatment" or "treat" includes regulating and / or immediately improving the cosmetic appearance and / or feel of keratinous tissue. For example, "regulating the condition of the skin, hair, or nails" includes thickening of the skin, hair, or nails (e.g., building up the epidermal and / or dermal and / or subcutaneous (e.g., subcutaneous fat or muscle) layers of the skin and, if applicable, building up the stratum corneum of the nail and hair shaft) to reduce atrophy of the skin, hair, or nails; preventing loss of elasticity of the skin or hair (loss, damage, and / or inactivation of functional skin elastin), such as increased convolution of the dermal-epidermal junction (also known as interpapillary ridges); elastosis, sagging, loss of recovery from deformation of the skin or hair; preventing melanotic or non-melanotic changes in the color of the skin, hair, or nails, such as dark circles under the eyes, blemishes (e.g., uneven redness due to rosacea, etc.) (hereinafter referred to as "erythema"), paleness (paleness), discoloration caused by telangiectasia or spider veins, and gray hair. Another example of a keratinous tissue active agent may be an active agent used in shampooing, conditioning, or dyeing hair.

[0054] As used herein, "weight ratio" refers to the ratio between two materials on a dry basis. For example, the weight ratio of filament-forming material to active agent in a filament is the ratio of the weight of the filament-forming material in the filament on a dry weight basis (g or %) to the weight of a fiber additive, such as an active agent, in the filament on a dry weight basis (g or % (same units as the weight of the filament-forming material)). In another example, the weight ratio of particles to fiber elements in a fibrous structure is the ratio of the weight of particles in the fibrous structure on a dry weight basis (g or %) to the weight of fiber elements in the fibrous wall material on a dry weight basis (g or % (same units as the weight of the particles)).

[0055] As used herein, "water-soluble material" means a material that is miscible in water, in other words, a material that is capable of forming a stable homogeneous solution (that does not separate for more than 5 minutes after forming the homogeneous solution) with water at ambient conditions.

[0056] As used herein, "ambient conditions" means 23°C ± 1.0°C and 50% ± 2% relative humidity.

[0057] As used herein, "weight average molecular weight," when measured in accordance with the Weight Average Molecular Weight Test Method described herein, means the weight average molecular weight determined using gel permeation chromatography according to the protocol found in Colloids and Surfaces A. Physico Chemical & Engineering Aspects, Vol. 162, 2000, pg. 107-121.

[0058] As used herein with respect to a filament, "length" means the length along the longest axis of the filament from one end to the other. If the filament has any twists, curls, or bends in it, the length is the length along the entire path of the filament from one end to the other.

[0059] As used herein with respect to filaments, "diameter" is measured according to the Diameter Test Method described herein. In one example, the filaments of the present invention exhibit a diameter of less than 100 μm, and / or less than 75 μm, and / or less than 50 μm, and / or less than 25 μm, and / or less than 20 μm, and / or less than 15 μm, and / or less than 10 μm, and / or less than 6 μm, and / or greater than 1 μm, and / or greater than 3 μm.

[0060] As used herein, "triggering condition" refers, in one embodiment, to anything that acts as a stimulus and initiates or causes a change in the fiber filaments, and / or particles, and / or fiber structures of the present invention (e.g., loss or change in the physical structure of the filaments and / or fiber structures and / or release of fiber additives, such as active agents, therefrom). In another embodiment, the triggering condition may be present in an environment, such as water, when the filaments, and / or particles, and / or fiber structures of the present invention are added to the water. In other words, no change occurs in the water apart from the fact that the filaments and / or fiber structures of the present invention are added to the water.

[0061] As used herein with respect to morphological changes of filaments and / or particles, "morphological change" means that the filaments undergo a change in their physical structure. Non-limiting examples of morphological changes of the filaments and / or particles of the present invention include dissolving, melting, expanding, shrinking, shattering, bursting, lengthening, shortening, and combinations thereof. The filaments and / or particles of the present invention may completely or substantially lose their physical structure, or may have an altered morphology, or may retain or substantially retain their physical structure when exposed to the intended conditions of use.

[0062] "Weight on a dry filament basis," and / or "weight on a dry particle basis," and / or "weight on a dry fibrous structure basis" refer to the weight of the filaments, and / or particles, and / or fibrous structure, respectively, measured immediately after the weight of the filaments, and / or particles, and / or fibrous structure, respectively, has been conditioned for two hours in a room conditioned to a temperature of 23° C.±1.0° C. and a relative humidity of 50%±10%. In one embodiment, weight on a dry filament basis, and / or weight on a dry particle basis, and / or weight on a dry fibrous structure means that the filaments, and / or particles, and / or fibrous structure contain less than 20% by weight, and / or less than 15% by weight, and / or less than 10% by weight, and / or less than 7% by weight, and / or less than 5% by weight, and / or less than 3% by weight, and / or 0% by weight, and / or more than 0% by weight of moisture such as water, e.g., free water, when measured by the Moisture Content Test Method described herein, based on the dry weight of the filaments, and / or particles, and / or fibrous structure.

[0063] For example, when used herein with respect to the total concentration of one or more active agents present in a filament, particle, and / or fibrous structure, "total concentration" refers to the sum of all weights or weight percents of the subject material, e.g., active agents. In other words, the filament, particle, and / or fibrous structure may include 25% by weight of anionic surfactant based on the dry filament, particle, and / or dry fibrous structure, 15% by weight of nonionic surfactant based on the dry filament, particle, and / or dry fibrous structure, 10% by weight of chelating agent based on the dry filament, particle, and / or dry fibrous structure, and 5% by weight of perfume based on the dry filament, particle, and / or dry fibrous structure, such that the total concentration of active agents present in the filament, particle, and / or fibrous structure is greater than 50% by weight, i.e., 55% by weight based on the dry filament, particle, and / or dry fibrous structure.

[0064] As used herein, "textile structure product" means a solid form (e.g., a rectangular solid, sometimes referred to as a sheet) comprising one or more active agents (e.g., fabric care actives, dishwashing actives, hard surface actives, and combinations thereof). In one embodiment, the textile structure product of the present invention comprises one or more surfactants, one or more enzymes (such as in the form of granular enzymes and / or liquid enzymes), one or more perfumes, and / or one or more suds suppressors.

[0065] In one embodiment, one or more active agents in particulate or liquid form may be deposited on one or more surfaces of the fibrous structures of the present invention. For example, enzyme suspensions, perfumes, microcapsule slurries, oils, silicones, surfactant pastes (sometimes referred to herein as minor ingredients) may be deposited on one or more surfaces of the fibrous structures during fabrication and / or conversion of the fibrous structures. Such applications may be present on the surface of the fibrous layer or may be substantially embedded in the fibrous structure.

[0066] In another embodiment, the fibrous structure product of the present invention comprises a builder and / or a chelating agent. In another embodiment, the fibrous structure product of the present invention comprises a bleaching agent (e.g., an encapsulated bleaching agent).

[0067] As used herein, "different morphology" or "different" means, with respect to the filament as a whole, and / or the filament-forming material within the filament, and / or a material, such as an active agent within the filament, that one material, such as the filament, and / or the filament-forming material, and / or the active agent, is chemically, physically, and / or structurally different from another material, such as the filament, and / or the filament-forming material, and / or the active agent. For example, a filament-forming material in filament form is different from the same filament-forming material in fiber form. Similarly, a starch polymer is different from a cellulose polymer. However, different molecular weights of the same material, such as different molecular weight starches, are not different materials for purposes of the present invention.

[0068] As used herein, "random mixture of polymers" means two or more different filament-forming materials that are randomly combined to form filaments. Thus, two or more different filament-forming materials that are regularly combined to form filaments, such as sheath-core bicomponent filaments, are not random mixtures of different filament-forming materials for purposes of the present invention.

[0069] As used herein with respect to filaments and / or particles, "associate," "associated," "association," and / or "associating" means combining filaments and / or particles by either direct or indirect contact to form a fibrous structure. In one example, the filaments and / or particles that are bonded together may be adhered together by, for example, adhesive and / or thermal bonding. In another example, the filaments and / or particles may be bonded to one another by being deposited on the same fibrous structure creating a belt and / or patterned belt.

[0070] As used herein, "machine direction" or "MD" means the direction parallel to the direction in which the fibrous structure flows through the fibrous structure manufacturing equipment and / or fibrous structure product making machine.

[0071] As used herein, "cross-machine direction" or "CD" means the direction perpendicular to the machine direction in the plane of a fibrous structure and / or a fibrous structure product comprising the fibrous structure.

[0072] As used herein, "ply" or "multi-ply" refers to an individual fibrous structure optionally arranged in a substantially continuous face-to-face relationship with another ply to form a multi-ply fibrous structure. It is also contemplated that a single fibrous structure can effectively form two "plies" or multiple "plies," for example, by folding over itself. A ply may include layers of filaments, filament / particle blends, and / or particles. In another embodiment, there may be layers of filaments or particles between the plies.

[0073] As used herein, the articles "a" and "an," e.g., "an anionic surfactant" or "a fiber," as used herein, are understood to mean one or more of the material claimed or described.

[0074] All percentages and ratios are calculated by weight unless otherwise specified. All percentages and ratios are calculated based on the total composition unless otherwise specified.

[0075] Unless otherwise specified, all ingredient or composition concentrations refer to the active concentration of that ingredient or composition and are exclusive of impurities, e.g., residual solvents or by-products, that may be present in commercial sources.

[0076] Process for making an article of manufacture In one embodiment of the present invention, as shown in FIG. 1 , a process 10 for making, e.g., continuously making, an article of manufacture 12 comprising a fibrous structure 14, e.g., a soluble fibrous structure, includes at least the following steps: 1) a filament-forming composition making operation 16 including one or more steps for making a filament-forming composition 18, which is subsequently sent, e.g., via a pipe, to a next operation, i.e., a rotating operation 20; 2) a spinning operation 20 including one or more steps for spinning a filament-forming composition, e.g., the filament-forming composition 18 made in the filament-forming composition making operation 16, to make filaments 22, e.g., soluble filaments; 3) a mixing operation 24 including one or more steps for optionally mixing, e.g., coforming, a plurality of solid additives, e.g., particles 26, with the filaments 22; and 4) a mixing operation 24 including one or more steps for mixing, e.g., coforming, a plurality of solid additives, e.g., particles 26, with the filaments 22, e.g., using a conveying mechanism, such as a belt and / or a rotating drum. Any recovery operation 28 includes one or more recovery steps to recover filaments 22 and / or mixed filaments 22 and solid additives, e.g., particles 26, on a recovery device to form a fibrous structure 14, e.g., a soluble fibrous structure, comprising filaments 22 and, optionally, solid additives, e.g., particles 26, and, if present, operations (1-4) are carried out in a continuous manner, sequentially, without any interruption, stop, or interruption in the process from making a filament-forming composition 18 to spinning the filament-forming composition 18 into filaments 22 (optionally mixing solid additives, e.g., particles 26 with the filaments 22), recovering the filaments 22 (and / or mixed filaments 22 and solid additives, e.g., particles 26) on a recovery device, and forming a fibrous structure 14 comprising filaments 22 and, optionally, solid additives, e.g., particles 26.

[0077] Once the fibrous structure 14 is formed, the fibrous structure 14 can then be converted into an article of manufacture 12, which can be a consumable, sellable unit, via a converting operation 30 that includes one or more steps for converting the fibrous structure 14 into the article of manufacture 12, one or more of which can be continuous with the previous operations (1-4) of the process 10. Once the fibrous structure 14 has been converted into an article of manufacture 12 that includes one or more, two or more, three or more, four or more, five or more plies of the fibrous structure 14, the article of manufacture 12 can be packaged into a package 32 that includes an outer packaging material 34, such as a packaging film, a cardboard box, or the like, via a packaging operation 36.

[0078] In one embodiment, the articles of manufacture and / or process steps of the present invention, such as spinning operations, mixing (coform) operations, recovery operations, converting operations, and packaging operations, may independently be carried out at a relative humidity of from about 20% to about 75%, and / or from about 30% to about 65%, and / or from about 35% to about 60%.

[0079] The converting operation 30 may include one or more steps for converting the fibrous structure 14 into one or more articles of manufacture 12, e.g., consumer products (e.g., slitting and / or laminating and / or calendaring and / or treating with optional ingredients such as perfumes, enzymes, bleaches, flavorings, foaming agents, etc. (e.g., adding optional ingredients to the fibrous structure 14, e.g., to the surface of the fibrous structure 14), die-cutting, and printing), and 6) optionally, a packaging operation 36 including one or more steps for packaging the one or more articles of manufacture 12, e.g., consumer products, such as soluble consumer products, into a package 32.

[0080] In one embodiment, the converting operation may include die-cutting into desired shapes, printing, adding optional ingredients (minor ingredients), and rolling up the fibrous structure on a roll as a converting line process, all of which may be performed in a single process or on a single converting line, for example, to maximize the number of manufactured articles produced from the fibrous structure or multiple desired shapes. For example, the process of the present invention may include one or more converting operations and / or steps selected from the group consisting of slitting, laminating, calendering, treating with optional ingredients, die-cutting, printing, packaging, mechanical ply bonding, chemical ply bonding, and / or combinations thereof. In one embodiment, one or more or all of these converting operations and / or steps are performed on a single converting line, which may be directly connected to a fibrous structure production line (e.g., a spinning / mixing / recovery operation) and a filament-forming composition production operation. In one embodiment, the entire process from the filament-forming composition operation to the converting operation and, optionally, the packaging operation to produce an article of manufacture according to the present invention, as discussed herein, may be performed on a single manufacturing line, e.g., a single continuous manufacturing line. The converting operation ultimately results in a saleable unit available for consumer use.

[0081] In one embodiment, the process is such that the fibrous structure, e.g., composite structure, formed in the recovery operation is further converted into a consumer-usable, saleable unit on a single production line, e.g., a single-ply, multi-ply, or any surface of a single-ply or multi-ply article, using converting operations and / or steps selected from slitting, laminating, calendaring, treating with an optional ingredient, die-cutting, printing, packaging, mechanical plying, chemical plying, and / or combinations thereof.

[0082] a. Preparation of filament-forming composition (16) 2, in one example, filament-forming composition 18 is made by providing one or more filament-forming materials 38, e.g., one or more soluble filament-forming materials, e.g., one or more hydroxylic polymers such as polyvinyl alcohol, to which water or another polar solvent is added to yield an aqueous or polar solvent composition comprising the water-soluble filament-forming materials and the water or polar solvent. The aqueous or polar solvent composition is then processed, e.g., polymer processed, in an extruder to form filament-forming composition 18, which is then suitable for delivery to one or more dies for spinning into a plurality of filaments 22 in a spinning operation 20. In one example, the aqueous or polar solvent composition may be processed in a batch tank (not shown).

[0083] In one embodiment, the filament-forming material 38 is thoroughly cooked to form a homogeneous aqueous or polar solvent composition of the filament-forming material 38 .

[0084] In one embodiment, at least about 30% by weight, and / or at least about 40% by weight, and / or about 70% by weight, and / or about 60% by weight of water is added to one or more filament-forming materials 38 during the filament-forming composition making operation 16.

[0085] In one embodiment, the filament-forming material 38 may be added at a solids concentration of greater than 40%, and / or greater than 50%, and / or greater than 60%, and / or between about 60% and about 80%, and / or between about 60% and about 70%.

[0086] In one embodiment, the filament-forming material 38 may be present at a level greater than 5%, and / or greater than 10%, and / or greater than 13%, and / or less than 50%, and / or less than 40%, and / or less than 30%, and / or less than 25%.

[0087] In one embodiment, the filament-forming material 38 may be present in the extruder at a level greater than 10%, and / or greater than 20%, and / or greater than 30%, and / or less than 90%, and / or less than 80%, and / or less than 70%, and / or less than 65%.

[0088] In one example, the filament-forming material 38 may be in a solid form, e.g., a dry solid form 40 such as pellets and / or a powder. In one example, the filament-forming material 38 and water and / or another polar solvent utilized to solubilize the filament-forming material 38 are added to an extruder 42, e.g., a twin-screw extruder, via a hopper 44, and heated, processed, and mixed to solubilize the filament-forming material 38. In one example, entrained air within the aqueous and / or polar solvent solution containing the filament-forming material 18 within the extruder 40 is minimized and / or eliminated. The water and / or polar solvent may be added to the extruder 42 via a pump 46.

[0089] When the filament-forming material 38 is in solid form, the solid filament-forming material, e.g., one or more hydroxyl polymers such as polyvinyl alcohol, is added from a hopper 44, e.g., in a continuous process, to an extruder 42, e.g., a single-screw extruder or a twin-screw extruder, e.g., a Coperion ZSK 26 twin-screw extruder (maximum speed 1200 rpm, maximum torque per screw 106 Nm, screw diameter 25.5 mm, screw length 900 mm, number of barrel sections 9, heating and cooling zones, flight height 4.55 mm, estimated throughput 20-60 kg / hour). In this example, as shown in FIG. 3, the addition of the solid filament-forming material to the extruder 42 occurs in zone 1 of the extruder 42. The purpose of adding the filament-forming material 38 to the extruder 42 is to achieve hydration of the filament-forming material 38 and to solubilize the filament-forming material 38, especially if it is originally in solid form.

[0090] Non-limiting examples of suitable filament-forming materials 38 include polymers such as those selected from the group consisting of pullulan, hydroxypropyl methylcellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, methylcellulose, polyvinylpyrrolidone, carboxymethylcellulose, sodium alginate, xanthan gum, tragacanth gum, guar gum, acacia gum, gum arabic, polyacrylic acid, methyl methacrylate copolymer, carboxyvinyl polymer, dextrin, pectin, chitin, levan, elsinan, collagen, gelatin, zein, gluten, soy protein, casein, polyvinyl alcohol, carboxylated polyvinyl alcohol, sulfonated polyvinyl alcohol, starch, starch derivatives, hemicellulose, hemicellulose derivatives, proteins, chitosan, chitosan derivatives, polyethylene glycol, tetramethylene ether glycol, hydroxymethyl cellulose, polyethylene oxide, and mixtures thereof.

[0091] In one embodiment, filament-forming material 38 is a water-soluble material that produces soluble filaments, eg, water-soluble filaments.

[0092] In one embodiment, the filament-forming material 38 includes polyvinyl alcohol.

[0093] Water and / or another polar solvent is added, for example, in a continuous process, via pump 46 to extruder 42 containing filament-forming material 18 to mix with and solubilize the filament-forming material 18 within extruder 42. Water and / or another polar solvent is added to extruder 42 in zone 3, as shown in FIG.

[0094] The extruder 42 may be operated to exhibit a wet throughput of at least about 5, and / or at least about 10, and / or at least about 15, and / or at least about 20, and / or at least about 40, at least about 80, and / or from about 5 to about 200, and / or from about 80 to about 135 kg / hr, and in one embodiment, from about 100 to about 700 kg / hr, and / or from about 345 to about 575 kg / hr of full filament forming material flow rate; at least about 2, and / or at least about 4, and / or at least about 6, and / or at least about 10, and / or at least about 15, and / or at least about 20, and / or from about 2 to about 120, and / or from about 10 to about 85, and / or from about 20 to about 85 kg / hr, and / or from about 50 to about 85 kg / hr; a rotational speed of less than about 1600 rpm; and / or less than about 1400 rpm. a maximum screw speed of less than about 100 rpm, and / or less than about 1200 rpm, and / or from about 200 to about 1600 rpm, and / or from about 400 to about 1400 rpm, and / or from about 600 to about 1200 rpm, a % solids (filament-forming material 38) of about 20 to about 95%, and / or from about 30 to about 85%, and / or from about 40 to about 70%, an outlet pressure of about 10 to about 80, and / or from about 15 to about 75, and / or from about 20 to about 65 bar set point, the filament-forming composition may exit the extruder at an SME (Base Solids Throughput) of about 0.10 to about 0.50, and / or from about 0.12 to about 0.45, and / or from about 0.14 to about 0.35 kW-h / kg, and the extruder exposes the filament-forming composition to a temperature of at least 49°C, with exemplary barrel temperatures of the extruder run as shown in Table 1 below.

[0095] [Table 1]

[0096] In addition to solubilizing the filament-forming material 38 in the extruder 42 to produce the filament-forming composition 18, one or more active agents 48, e.g., one or more surfactants such as a surfactant blend, e.g., an anionic surfactant, e.g., a blend of two or more different anionic surfactants, may be mixed with the filament-forming composition 18 via one or more static mixers 50, such as an SMX mixer.

[0097] In one embodiment, the surfactant and / or surfactant blend includes one or more anionic surfactants selected from the group consisting of linear alkylbenzene sulfonates (LAS), alkyl sulfates (AS), and mixtures thereof. The surfactants may be blended or co-neutralized with sodium hydroxide to form low water content pastes. In addition, other surfactants such as alkyl ethoxylate sulfates (AES), co-surfactants such as amine oxides, linear alcohol ethoxylates, glucamide surfactants, and branched alkyl chain versions such as MLAS and HSAS may be used.

[0098] In one example, in addition to one or more surfactants, a structuring agent such as polyethylene oxide, such as PEO 100K and / or PEO N60K, and / or polyvinylpyrrolidone may be mixed with the surfactant to provide phase stability. Optionally, other ingredients may also be mixed with the surfactant, such as a salt, e.g., sodium sulfate.

[0099] In one embodiment, the filament-forming composition 18, and therefore at least one filament 22 produced from spinning the filament-forming composition 18, includes one or more active agents 48 in the case of a filament 22 in which one or more active agents 48 are present within the filament 22.

[0100] In one embodiment, the active agent 48 comprises a surfactant selected from the group consisting of anionic surfactants, cationic surfactants, nonionic surfactants, zwitterionic surfactants, amphoteric surfactants, and mixtures thereof.

[0101] In one embodiment, the one or more active agents 48 are selected from the group consisting of fabric care active agents, dishwashing active agents, carpet care active agents, surface care active agents, air care active agents, oral care active agents (e.g., tooth cleansers, tooth whitening agents, tooth care agents, periodontal and gum care agents, mouthwashes, denture cleansers, tongue cleansers, breath fresheners, fluoride agents, mouth rinses, anti-cavity agents, fragrances), hair care active agents (shampoos and / or conditioners), keratinous tissue care agents, toilet bowl cleansers, skin care active agents, and mixtures thereof.

[0102] In one embodiment, at least one of the activators 48 includes one or more foaming agents.

[0103] In one embodiment, one or more hueing agents, colorants, and / or dyes are added to the filament-forming composition during the filament-forming composition making operation.

[0104] Filament-forming materials The filament-forming material is any suitable material, such as a polymer or a monomer from which such a polymer can be made, that exhibits suitable properties for making fiber elements, such as by a spinning process.

[0105] In one embodiment, the filament-forming material may include a polar solvent-soluble material, such as an alcohol-soluble material and / or a water-soluble material.

[0106] In another example, the filament-forming material may include a non-polar solvent soluble material.

[0107] In yet another example, the filament-forming material may include polar solvent-soluble material and may be free of non-polar solvent-soluble material (less than 5% by weight, and / or less than 3% by weight, and / or less than 1% by weight, and / or 0% by weight, based on the dry fibrous element and / or the dry soluble fibrous structure).

[0108] In yet another embodiment, the filament-forming material can be a film-forming material. In yet another embodiment, the filament-forming material can be synthetic or naturally occurring, and the material can be chemically, enzymatically, and / or physically modified.

[0109] In yet another embodiment of the present invention, the filament-forming material may comprise a polymer selected from the group consisting of polymers derived from acrylic monomers such as ethylenically unsaturated carboxylic acid monomers and ethylenically unsaturated monomers, polyvinyl alcohol, polyacrylates, polymethacrylates, copolymers of acrylic acid and methyl acrylate, polyvinylpyrrolidone, polyalkylene oxides, starch and starch derivatives, pullulan, gelatin, hydroxypropyl methylcellulose, methylcellulose, and carboxymethylcellulose.

[0110] In yet another embodiment, the filament-forming material may comprise a polymer selected from the group consisting of polyvinyl alcohol, polyvinyl alcohol derivatives, starch, starch derivatives, cellulose derivatives, hemicellulose, hemicellulose derivatives, proteins, sodium alginate, hydroxypropyl methylcellulose, chitosan, chitosan derivatives, polyethylene glycol, tetramethylene ether glycol, polyvinylpyrrolidone, hydroxymethylcellulose, hydroxyethylcellulose, methylcellulose, and mixtures thereof.

[0111] In another embodiment, the filament-forming material comprises a polymer selected from the group consisting of pullulan, hydroxypropyl methylcellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, methylcellulose, polyvinylpyrrolidone, carboxymethylcellulose, sodium alginate, xanthan gum, tragacanth gum, guar gum, acacia gum, gum arabic, polyacrylic acid, methyl methacrylate copolymer, carboxyvinyl polymer, dextrin, pectin, chitin, levan, elsinan, collagen, gelatin, zein, gluten, soy protein, casein, polyvinyl alcohol, starch, starch derivatives, hemicellulose, hemicellulose derivatives, proteins, chitosan, chitosan derivatives, polyethylene glycol, tetramethylene ether glycol, hydroxymethylcellulose, and mixtures thereof.

[0112] Polar solvent soluble materials Non-limiting examples of polar solvent-soluble materials include polar solvent-soluble polymers, which may be synthetic or natural in origin and may be chemically and / or physically modified. In one embodiment, the polar solvent-soluble polymer exhibits a weight average molecular weight of at least 10,000 g / mol, and / or at least 20,000 g / mol, and / or at least 40,000 g / mol, and / or at least 80,000 g / mol, and / or at least 100,000 g / mol, and / or at least 1,000,000 g / mol, and / or at least 3,000,000 g / mol, and / or at least 10,000,000 g / mol, and / or at least 20,000,000 g / mol, and / or up to about 40,000,000 g / mol and / or up to about 30,000,000 g / mol, when measured according to the Weight Average Molecular Weight Test Method described herein.

[0113] In one example, the polar solvent-soluble polymer is selected from the group consisting of alcohol-soluble polymers, water-soluble polymers, and mixtures thereof. Non-limiting examples of water-soluble polymers include water-soluble hydroxyl polymers, water-soluble thermoplastic polymers, water-soluble biodegradable polymers, water-soluble non-biodegradable polymers, and mixtures thereof. In one example, the water-soluble polymer comprises polyvinyl alcohol. In another example, the water-soluble polymer comprises starch. In yet another example, the water-soluble polymer comprises polyvinyl alcohol and starch.

[0114] a. Water-Soluble Hydroxyl Polymers—Non-limiting examples of water-soluble hydroxyl polymers according to the present invention include polyols, such as polyvinyl alcohol, polyvinyl alcohol derivatives, polyvinyl alcohol copolymers, starch, starch derivatives, starch copolymers, chitosan, chitosan derivatives, chitosan copolymers, cellulose derivatives, such as cellulose ether and ester derivatives, cellulose copolymers, hemicellulose, hemicellulose derivatives, hemicellulose copolymers, gums, arabinans, galactans, proteins, and various other polysaccharides, and mixtures thereof.

[0115] In one embodiment, the water-soluble hydroxyl polymer of the present invention comprises a polysaccharide.

[0116] As used herein, "polysaccharide" refers to natural polysaccharides and polysaccharide derivatives and / or modified polysaccharides. Suitable water-soluble polysaccharides include, but are not limited to, starch, starch derivatives, chitosan, chitosan derivatives, cellulose derivatives, hemicellulose, hemicellulose derivatives, gums, arabinans, galactans, and mixtures thereof. The water-soluble polysaccharides may exhibit a weight average molecular weight, as measured according to the Weight Average Molecular Weight Test Method described herein, of about 10,000 to about 40,000,000 g / mol, and / or greater than 100,000 g / mol, and / or greater than 1,000,000 g / mol, and / or greater than 3,000,000 g / mol, and / or greater than 3,000,000 to about 40,000,000 g / mol.

[0117] The water-soluble polysaccharides may include non-cellulosic and / or non-cellulosic derivative and / or non-cellulosic copolymer water-soluble polysaccharides, which may be selected from the group consisting of starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose, hemicellulose derivatives, gums, arabinans, galactans, and mixtures thereof.

[0118] In another embodiment, the water-soluble hydroxyl polymer of the present invention comprises a non-thermoplastic polymer.

[0119] The water-soluble hydroxyl polymers may have a weight average molecular weight of from about 10,000 g / mol to about 40,000,000 g / mol, and / or greater than 100,000 g / mol, and / or greater than 1,000,000 g / mol, and / or greater than 3,000,000 g / mol, and / or greater than 3,000,000 g / mol to about 40,000,000 g / mol, as measured according to the Weight Average Molecular Weight Test Method described herein. Higher and lower molecular weight water-soluble hydroxyl polymers may be used in combination with hydroxyl polymers having a particular desired weight average molecular weight.

[0120] For example, well-known modifications of water-soluble hydroxyl polymers, such as native starch, include chemical and / or enzymatic modifications. For example, native starch can be acid-thinned, hydroxyethylated, hydroxypropylated, and / or oxidized. Additionally, water-soluble hydroxyl polymers can include dent corn starch.

[0121] Naturally occurring starches are generally mixtures of linear amylose and branched amylopectin polymers of D-glucose units. Amylose is a substantially linear polymer of D-glucose units joined by (1,4)-α-D bonds. Amylopectin is a highly branched polymer of D-glucose units joined at the branch points by (1,4)-α-D and (1,6)-α-D bonds. Naturally occurring starches, such as corn starch (64-80% amylopectin), waxy maize (93-100% amylopectin), rice (83-84% amylopectin), potato (about 78% amylopectin), and wheat (73-83% amylopectin), typically contain relatively high concentrations of amylopectin. While all starches are potentially useful herein, the invention is most commonly practiced with high amylopectin native starches derived from agricultural sources, which offer the advantages of being in abundant supply, easily replenished, and inexpensive.

[0122] As used herein, "starch" includes unmodified starch, modified starch, synthetic starch, and mixtures thereof of any natural origin, as well as mixtures of amylose or amylopectin fractions, and starches may be modified by physical, chemical, or biological processes, or a combination thereof. The choice of unmodified or modified starch for the present invention may depend on the desired end product. In one embodiment of the present invention, the starch or starch mixture useful in the present invention has an amylopectin content of from about 20% to about 100%, more typically from about 40% to about 90%, and even more typically from about 60% to about 85%, by weight of the starch or mixture thereof.

[0123] Suitable naturally occurring starches include, but are not limited to, corn starch, potato starch, sweet potato starch, wheat starch, sago starch, tapioca starch, rice starch, soybean starch, arrowroot starch, amioca starch, bracken starch, lotus starch, waxy corn starch, and high-amylose corn starch. Naturally occurring starches, particularly corn starch and wheat starch, are preferred starch polymers due to their economical and available properties.

[0124] The polyvinyl alcohol herein can be grafted with other monomers to modify its properties. A wide variety of monomers have been successfully grafted onto polyvinyl alcohol. Non-limiting examples of such monomers include vinyl acetate, styrene, acrylamide, acrylic acid, 2-hydroxyethyl methacrylate, acrylonitrile, 1,3-butadiene, methyl methacrylate, methacrylic acid, maleic acid, itaconic acid, sodium vinyl sulfonate, sodium allyl sulfonate, sodium methylallyl sulfonate, sodium phenyl allyl ether sulfonate, sodium phenyl methallyl ether sulfonate, 2-acrylamido-methylpropane sulfonic acid (AMP), vinylidene chloride, vinyl chloride, vinylamine, and various acrylate esters.

[0125] In one embodiment, the water-soluble hydroxyl polymer is selected from the group consisting of polyvinyl alcohol, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl methylcellulose, and mixtures thereof. Non-limiting examples of suitable polyvinyl alcohols include those commercially available under the trade name CELVOL® from Sekisui Specialty Chemicals America, LLC (Dallas, TX). Non-limiting examples of suitable hydroxypropyl methylcelluloses include those commercially available under the trade name METHOCEL® from Dow Chemical Company (Midland, MI), including combinations with the above-mentioned hydroxypropyl methylcelluloses.

[0126] b. Water-Soluble Thermoplastic Polymers—Non-limiting examples of suitable water-soluble thermoplastic polymers include thermoplastic starch and / or starch derivatives, polylactic acid, polyhydroxyalkanoates, polycaprolactones, polyesteramides, and certain polyesters, and mixtures thereof.

[0127] The water-soluble thermoplastic polymers of the present invention may be hydrophilic or hydrophobic. The water-soluble thermoplastic polymers may be surface and / or internally treated to alter the inherent hydrophilicity or hydrophobicity of the thermoplastic polymer.

[0128] The water-soluble thermoplastic polymer may include a biodegradable polymer.

[0129] Any suitable weight average molecular weight for the thermoplastic polymer may be used, for example, the weight average molecular weight of the thermoplastic polymer according to the present invention is greater than about 10,000 g / mol, and / or greater than about 40,000 g / mol, and / or greater than about 50,000 g / mol, and / or less than about 500,000 g / mol, and / or less than about 400,000 g / mol, and / or less than about 200,000 g / mol, when measured according to the weight average molecular weights described herein.

[0130] Non-polar solvent soluble materials Non-limiting examples of non-polar solvent-soluble materials include non-polar solvent-soluble polymers. Non-limiting examples of suitable non-polar solvent-soluble materials include cellulose, chitin, chitin derivatives, polyolefins, polyesters, copolymers thereof, and mixtures thereof. Non-limiting examples of polyolefins include polypropylene, polyethylene, and mixtures thereof. Non-limiting examples of polyesters include polyethylene terephthalate.

[0131] Non-polar solvent soluble materials may include non-biodegradable polymers such as polypropylene, polyethylene, and certain polyesters.

[0132] Any suitable weight average molecular weight for the thermoplastic polymer may be used, for example, the weight average molecular weight of the thermoplastic polymer according to the present invention is greater than about 10,000 g / mol, and / or greater than about 40,000 g / mol, and / or greater than about 50,000 g / mol, and / or less than about 500,000 g / mol, and / or less than about 400,000 g / mol, and / or less than about 200,000 g / mol, when measured according to the weight average molecular weights described herein.

[0133] activator Active agents are a class of fiber additives designed and intended to provide benefits to something other than the fiber elements and / or particles and / or soluble fiber structures themselves, such as providing benefits to the environment external to the fiber elements and / or particles and / or soluble fiber structures. Active agents can be any suitable fiber additive that produces the intended effect under the intended use conditions of the fiber elements. For example, active agents may be selected from the group consisting of: personal cleansing and / or conditioning agents, such as hair care agents (e.g., shampoos and / or hair dyes), hair conditioning agents, skin care agents, sunscreens, and skin conditioning agents; laundry care and / or conditioning agents, such as fabric care agents, fabric conditioning agents, fabric softeners, fabric anti-wrinkle agents, fabric care anti-static ... Stain removers, soil release agents, dispersants, foam suppressors, foam boosters, defoamers, and fabric refreshing agents; liquid and / or powder dishwashing agents (for hand dishwashing and / or automatic dishwashing), hard surface care and / or conditioning and / or abrasive agents; other cleaning and / or conditioning agents, such as antimicrobial agents, antibacterial agents, antifungal agents, fabric colorants, fragrances, bleaching agents (e.g., oxygen bleach, hydrogen peroxide, percarbonate bleach, perborate bleach, salt bleaching agents), bleach activators, chelating agents, builders, lotions, brighteners, air care agents, carpet care agents, dye transfer inhibitors, clay stain removers, anti-redeposition agents, polymeric stain release agents, polymeric dispersants, alkoxylated polyamine polymers, alkoxylated polycarboxylate polymers, amphiphilic graft copolymers, solubilizers, buffer systems, water softeners, water hardeners, pH adjusters, enzymes, flocculants, foaming agents, preservatives, cosmetic agents, makeup removers, foaming agents, deposition aids, coacervate formers, clays, thickeners, latex, silica, desiccants, odor control agents, antiperspirants, cooling agents, warming agents, absorbent gelling agents, anti-inflammatory agents, dyes, pigments, acids and bases; liquid treatment active agents; agricultural active agents; industrial active agents; ingestible active agents, such as pharmaceutical agents, tooth whitening agents, tooth care agents, mouthwashes, periodontal and gum care agents, edible agents, food agents, vitamins, minerals; water treatment agents, such as water clarifiers and / or disinfectants, and mixtures thereof.

[0134] Non-limiting examples of suitable cosmetic, skin care, skin conditioning, and hair care and conditioning agents are described in CTFA Cosmetic Ingredient Handbook, Second Edition, The Cosmetic, Toiletries, and Fragrance Association, Inc. 1988, 1992.

[0135] One or more classes of chemicals can be useful for one or more of the active agents listed above.For example, surfactants can be used for any number of the above active agents.Similarly, bleaching agents can be used for fabric care, hard surface cleaning, dishwashing, and even dental whitening.Therefore, those skilled in the art will understand that active agents are selected based on the desired intended use of fiber elements and / or particles and / or the soluble fiber structures made therefrom.

[0136] For example, when the fiber elements and / or particles and / or soluble fibrous structures made therefrom are used for hair care and / or conditioning, one or more suitable surfactants, e.g., lathering surfactants, can be selected to provide the desired benefit to the consumer when the fiber elements and / or particles and / or soluble fibrous structures in which the fiber elements and / or particles are incorporated are exposed to the intended conditions of use.

[0137] In one example, when the fiber elements and / or particles and / or soluble fibrous structures made therefrom are designed or intended for use in washing clothes in a laundry operation, one or more suitable surfactants, enzymes, builders, perfumes, suds suppressors, and / or bleaches can be selected to provide a desired benefit to the consumer when the fiber elements and / or particles and / or the soluble fibrous structures into which the fiber elements and / or particles are incorporated are exposed to the intended conditions of use. In another example, when the fiber elements and / or particles and / or soluble fibrous structures made therefrom are designed or intended for use in washing clothes in a laundry operation and / or cleaning dishes in a dishwashing operation, the fiber elements and / or particles and / or soluble fibrous structures can comprise a laundry detergent composition or a dishwashing detergent composition or an active agent used in such compositions. In yet another example, when the fibrous elements and / or particles and / or soluble fibrous structures made therefrom are designed for use in cleaning and / or sanitizing toilet bowls, the fibrous elements and / or particles and / or soluble fibrous structures made therefrom may comprise toilet bowl cleaning compositions and / or foaming compositions and / or active agents used in such compositions.

[0138] In one embodiment, the active agent is selected from the group consisting of surfactants, bleaching agents, enzymes, suds suppressors, suds boosters, fabric softeners, denture cleaners, hair cleansers, hair care agents, personal health care agents, tinting agents, and mixtures thereof.

[0139] In one embodiment, at least one of the active agents is selected from the group consisting of skin treatment agents, medications, lotions, fabric care agents, dishwashing agents, carpet care agents, surface care agents, hair care agents, air care agents, and mixtures thereof.

[0140] The filament-forming composition 18 may then be mixed into the spinning operation 20 via a pump 46, such as a pipe and / or a booster pump, and via a static mixer 50, such as an SMX mixer, with or without jacketing and / or a pump. The filament-forming composition 18 produced from the filament-forming composition making operation 16 may be delivered to one or more dies and / or one or more beams of a die via one or more pumps 46. Before being delivered to the spinning operation 20, the rheology of the filament-forming composition 18 may be measured offline or online, for example, using an online rheometer 52, to ensure that the rheology of the filament-forming composition 18 is suitable for spinning into filaments 22 via the spinning operation 20.

[0141] In one example, two or more different filament-forming compositions may be produced and spun during a spinning operation, such as from a split die, such as a 50 / 50 CD width split die, with each half of the die spinning two or more different filament-forming compositions to form two or more different filaments during the spinning operation, ultimately resulting in a fibrous structure comprising two or more different filaments produced from the two or more different filament-forming compositions.

[0142] In another example, two or more different filament-forming compositions may be produced and spun during a spinning operation, such as from two or more parallel dies, e.g., two or more parallel full CD width dies, each die spinning two or more different filament-forming compositions during the spinning operation, ultimately resulting in a fibrous structure comprising two or more different filaments produced from the two or more different filament-forming compositions.

[0143] Successful filament formation and / or attenuation requires a delicate balance of forces. First, the filament-forming composition 18 must form a stable filament 20 as it exits the die. If the viscosity of the filament-forming composition 18 is too high, complete attenuation cannot be achieved. If the viscosity of the filament-forming composition 18 is too low, the filament 20 will break under the attenuation forces. Additionally, after the filament 20 attenuates to a diameter of approximately 20 μm, stabilization follows. The stabilization process can be achieved in several ways, most notably drying and / or crystallization. The rheological properties of the filament 20 as it transitions from a liquid (filament-forming composition 18) to a solid (filament 20) are paramount to successful spinning of the filament. In one embodiment, the filament-forming composition 18 of the present invention exhibits a capillary number greater than 1, and / or greater than 2, and / or greater than 3, and / or greater than 4, and / or greater than 5. In the spinning process of fiber elements, the fiber elements must have initial stability as they exit the spinning die. In one embodiment, the filament-forming composition 18 exhibits a capillary number of at least 1 to about 50, and / or at least 3 to about 50, and / or at least 5 to about 30, such that the filament-forming composition 18 can be effectively polymer-processed (spun) into filaments 22.

[0144] The capillary number is a dimensionless number used to characterize this drop breakup probability. A higher capillary number indicates greater fluid stability upon exiting the die. The capillary number is defined as:

[0145]

number

[0146] The capillary number is defined for the conditions at the die exit. The fluid velocity is the average velocity of the fluid passing through the die holes. The average velocity is defined as:

[0147]

number

[0148] If the die holes are circular holes, the fluid velocity can be defined as:

[0149]

number

[0150] The shear viscosity of the filament-forming composition 18 is 3000 s -1 The elongational viscosity of the filament-forming composition 18 may range from about 0.1 Pa-s to about 50 Pa-s, and / or from about 0.3 Pa-s to about 40 Pa-s, and / or from about 0.5 Pa-s to about 35 Pa-s. The elongational viscosity of the filament-forming composition 18 may range from about 700 s to about 500 s as measured by an e-VROC instrument from RheoSense (San Ramon, CA) or equivalent. -1 The pressure P23 / P14 on the SSEVR should be greater than 0.8, and / or greater than 0.9, and / or greater than 1. The pressure P23 / P14 on the SSEVR should be greater than 0.8, and / or greater than 0.9, and / or greater than 1.

[0151] In one embodiment, the filament-forming composition can comprise at least 20% by weight, and / or at least 30% by weight, and / or at least 40% by weight, and / or at least 45% by weight, and / or at least 50% by weight up to about 90% by weight, and / or up to about 85% by weight, and / or up to about 80% by weight, and / or up to about 75% by weight of one or more filament-forming materials, one or more active agents, and mixtures thereof. The filament-forming composition may also comprise from about 10% by weight to about 80% by weight of a polar solvent, such as water.

[0152] In one embodiment, the nonvolatile components of the filament-forming composition may comprise from about 20%, and / or from about 30%, and / or from 40%, and / or from 45%, and / or from 50% to about 75%, and / or from 80%, and / or from 85%, and / or from 90% by weight, based on the total weight of the filament-forming composition. The nonvolatile components may comprise the filament-forming composition, such as the backbone polymer, the active agent, and combinations thereof. The nonvolatile components of the filament-forming composition may comprise the remaining percentages, and may range from 10% to 80% by weight, based on the total weight of the filament-forming composition.

[0153] Successful fiber spinning of complex mixtures, such as molten aliphatic alcohols or aqueous surfactant solutions, generally requires the addition of a polymeric component called a structurant. The purpose of the structurant is to increase the shear and extensional viscosity to allow fiber formation. Structurants are generally high molecular weight species, usually in the 100,000 to 6,000,000 g / mol range. However, the balance between concentration and molecular weight is often compromised; thus, lower molecular weight species require higher levels to function properly. Similarly, higher molecular weight species may require higher levels to allow fiber spinning. An important aspect of the structurant is its solubility in the spin fluid to allow for the increased viscosity required for fiber formation. The structurants polyvinylpyrrolidone and polyethylene oxide have been found to be two such polymers that meet the solubility criteria in spin fluids and can be produced at high molecular weights.

[0154] b. Spinning operation (20) Filaments 22 of the present invention, comprising one or more filament-forming materials 18 and, optionally, one or more active agents 48 present within the filaments 22, can be made as shown in Figures 4 and 5. As shown in Figures 4 and 5, a spinning operation 20 for making filaments 22 from filament-forming compositions 18 in a continuous process in accordance with the present invention includes: a. providing a filament-forming composition 18 delivered from a filament-forming composition making operation 16 to a spinning operation 20, the filament-forming composition 18 comprising one or more filament-forming materials 38, and optionally one or more activators 48 and / or one or more polar solvents (such as water), and optionally one or more inhibitors; b. spinning the filament-forming composition 18 through one or more dies, e.g., one or more spinning dies 54, e.g., a multi-row capillary spinning die such as a Biax-fiberfilm multi-row capillary die, into one or more filaments 22 comprising one or more filament-forming materials 38, and optionally, one or more activators 48 and one or more inhibitors.

[0155] In one embodiment, the spinning step further includes providing a filament-forming composition including one or more filament-forming materials to one or more dies, such as one or more spinning dies 54.

[0156] When producing filaments 22 from the filament-forming composition 18, the filament-forming composition 18 can be processed (spun) from the spinning die 54 at a temperature of about 20°C to about 100°C, and / or about 30°C to about 90°C, and / or about 35°C to about 70°C, and / or about 40°C to about 60°C.

[0157] The filament-forming composition 18 may be transported from the filament-forming composition making operation 16 to the spinning die 54 via a suitable pipe 56 with or without the use of a pump 46. A pump 46 such as a Zenith® H-9000 manufactured by Colfax Corporation, Zenith Pumps Division (Monroe, NC, USA) and having a capacity of 30 and / or 45 cubic centimeters per revolution (cc / rev) may be used to facilitate the transport of the filament-forming composition 18 to the spinning die 54. The flow of the filament-forming composition 18 from the filament-forming composition making operation 16 to the spinning die 54 may be controlled by adjusting the revolutions per minute (rpm) of the pump 46.

[0158] The filaments 22 spun from the spinning die 54 may be continuously collected, for example, on a collection device 58, such as a belt and / or fabric, e.g., a patterned belt, and / or a rotating drum that operates continuously to move the collected filaments 22, which forms a fibrous structure 14, such as a plurality of entangled filaments, on the collection device 58, thereby further reducing the process to other operations in making the article of manufacture 12 of the present invention.

[0159] In one example, the process may further include spinning a plurality of filaments from a first die, e.g., a first spinning die, and then collecting the first filaments on a collection device before collecting the mixed filaments and solid additives, e.g., particles, onto the first filaments already present on the collection device.

[0160] The total concentration of one or more filament-forming materials present in the fibrous element 10, if an active agent is present therein, may be less than 80% by weight, and / or less than 70% by weight, and / or less than 65% by weight, and / or less than 50% by weight, based on the dry fibrous element and / or the dry soluble fibrous structure, and the total concentration of one or more active agents, if present in the fibrous element, may be greater than 20% by weight, and / or greater than 35% by weight, and / or greater than 50% by weight, greater than 65% by weight, and / or greater than 80% by weight, based on the dry fibrous element and / or the dry soluble fibrous structure.

[0161] As shown in Figures 4 and 5, the spinning die 54 may include multiple filament-forming holes 32 including melt capillaries 34 surrounded by concentric attenuation fluid holes 36 through which a fluid such as air passes as it exits the filament-forming holes 32 to facilitate attenuation of the filament-forming composition 22 into the fiber elements 10.

[0162] In one embodiment, the spinning die 54 shown in FIG. 5 has two or more rows of circular extrusion nozzles (filament-forming holes 60) spaced apart from one another at a pitch P of about 1.524 millimeters (about 0.060 inches). The nozzles have individual inner diameters of about 0.305 millimeters (about 0.012 inches) and individual outer diameters of about 0.813 millimeters (about 0.032 inches). Each individual nozzle includes a melt capillary 62 surrounded by an annular, diverging, flared orifice (concentric attenuating fluid hole 64) for supplying attenuating air to each individual melt capillary 62. The filament-forming composition 18 extruded through the extrusion nozzle (filament-forming holes 60) is surrounded and attenuated by a generally cylindrical stream of moist air supplied through the orifice to produce filaments 22.

[0163] Attenuating air may be provided by heating compressed air from a supply with an electrical resistance heater, such as a heater manufactured by Chromalox, Division of Emerson Electric (Pittsburgh, Pa., USA).

[0164] The initial filaments 22 are dried by a current of drying air having a temperature of about 149°C (about 300°F) to about 315°C (about 600°F) using electrical resistance heaters and / or gas burners (direct or indirect) (not shown), fed through a drying nozzle and directed at an angle of about 90° relative to the overall orientation of the initial filaments 22 being spun. The dried filaments 22 may be collected on a collection device 58, such as a belt or fabric, which in one embodiment can impart a pattern, e.g., a non-random repeating pattern, to a fibrous structure 14, such as a soluble fibrous structure, formed as a result of collecting the filaments 22 on the belt or fabric. The addition of a vacuum source 66 directly below a forming zone 68, which is the region of the collection device 58 where the filaments 22 contact the collection device 58, may be used to assist in the collection of the filaments 22 on the collection device 58. Spinning and collection of the filaments 22 produces a fibrous structure 14, e.g., a soluble fibrous structure, comprising entangled filaments.

[0165] In one embodiment, the spinning enclosure 70 is an at least partially enclosing, and in one embodiment, completely enclosing housing, to the extent that the collector 58 and the fibrous structure 14 carried on the collector 58 are free to move below the spinning enclosure 70 and the filaments 22 are spun from the spinning die 54 to the collector 58. The spinning enclosure 70 at least partially controls the environment to which the filaments 22 are exposed down the spinline from the spinning die 54 to the collector 58.

[0166] In one example, during the spinning process, any volatile solvent, such as water, present in the filament-forming composition 18 is removed, such as by drying, as the filaments 22 are formed. In one example, more than 30%, and / or more than 40%, and / or more than 50% by weight of the volatile solvent, such as water, of the filament-forming composition 18 is removed, such as by drying the filaments 22 produced, during the spinning process.

[0167] In one embodiment, the filaments 22 are spun from one die, for example, one spinning die 54, for example, a multi-row capillary die.

[0168] In one embodiment, two or more different filaments 22 are spun from at least one die, for example, one spinning die 54 (the same spinning die 54).

[0169] In one embodiment, the filaments 22 are spun from two or more dies, for example, two or more spinning dies 54 .

[0170] In one embodiment, the process of the present invention may include two or more spinning operations 20. In one embodiment, a first spinning operation 20 includes spinning filaments 22 from a filament-forming composition 18 including one or more filament-forming materials 38, with or without an active agent 48, and without the inclusion of solid additives, such as particles 26, via a mixing operation 24 to produce a fibrous structure 14 on a collection device 58, which may be the same collection device 58 where the filaments 22 from the second spinning operation 20 are collected. A second spinning operation 20 downstream from the first spinning operation 20 includes spinning filaments 22 from a filament-forming composition 18 including one or more filament-forming materials 38, with or without an active agent 48, and with the inclusion of solid additives, such as particles 26, via a mixing operation 24, to the fibrous structure 14 formed by the first spinning operation 20.

[0171] The filament-forming composition 18 may include any suitable total concentration of filament-forming material 38 and any suitable concentration of active agent 48, so long as the filament 22 produced from the filament-forming composition 18 includes a total concentration of filament-forming material 38 in the filament 22 of about 5% to 100% by weight or less, on a dry filament basis and / or a dry soluble fibrous structure basis, and a total concentration of active agent 48 in the filament 22 of 0% to about 95% by weight, on a dry filament basis and / or a dry soluble fibrous structure basis.

[0172] c. Mixing operation (24) 6, particles 26 may be added to filaments 22 being spun from one die, e.g., spinning die 54, within a spinning enclosure 70. Addition of particles 26 may be accomplished during formation of the filaments 22 and / or after collection of the filaments 22 at a collector 58. Particles 26 may be added to the fibrous structure 14 and / or filaments 22 from a particle source 72. Particles 26 may be added such that the particles 26 are collected on a surface of the collector 58 within the spinning enclosure 70. The collector 58 may be operable within a forming zone 68, which may be inside the spinning enclosure 70. The spinning enclosure 70 may be positioned above the collector 58 and may encompass the forming zone 68 above the collector 58.

[0173] The addition of particles 26 may result in the particles 26 being entrapped and / or entrapped within the filaments 22 and / or fibrous structure 14 collected on the collection device 58 .

[0174] A suitable particle source 72, e.g., a feeder, for supplying the particle stream is positioned directly above the drying area of ​​the fiber elements, as shown in FIG. 6. In this case, a vibratory feeder manufactured by Retsch® (Haan, Germany), for example, is used. To aid in consistent particle distribution in the cross direction, the particles are fed into a tray (not shown) that starts at the width of the particle source 72 and ends as wide as the face of the spinning die 54, ensuring that particles 26 are delivered to all areas of forming filaments 22. The tray is completely enclosed except for the outlet to minimize disruption of the particle feed.

[0175] In one example, a split particle source, or two or more separate particle sources capable of delivering two or more different particles (e.g., different types, compositions, sizes, properties, etc.), can be used as a particle source in a mixing operation such that the resulting fibrous structure can include different zones and / or regions containing different particles, thereby ultimately resulting in a layered fibrous structure having different particles in each layer after the initially formed fibrous structure is slit and stacked.

[0176] While the filaments 22 are being formed, a particle source 72 is operated to introduce particles 26 into the stream of filaments 22. The particles 26 are mixed with the filaments 22 within the spinning enclosure 70. The mixed filaments 22 and particles 26 are collected on the collector 58 as a composite structure (the filaments 22 and particles 26 are mixed together). In one embodiment, collecting the mixed filaments 22 and particles 26 occurs within the spinning enclosure 70, for example, on the collector 58. The composite structure is referred to as a fibrous structure 14.

[0177] Particles 26 can be introduced into the spinning enclosure 70 between the spinning die 54 and the collection device 58 at any angle, so long as at least a portion of the particles 26 contact the filaments 22 in the forming zone 68, as shown in Figures 4 and 6. If the introduction of particles 26 into the stream of filaments 22 is not coordinated, resulting in particles 26 contacting the filaments 22 in the forming zone 68, as shown in Figure 6, the particles may end up downstream of the forming zone 68, as shown by particle trajectory line A in Figure 6 (a point in the process closer to the finished and / or packaged article of manufacture, relative to the reference point, e.g., if the reference point is a spinning or collection operation, downstream refers to a converting and / or packaging operation), and / or upstream of the forming zone 68, as shown by particle trajectory line B in Figure 6 (a point in the process further away from the finished and / or packaged article of manufacture, 32, relative to the reference point, e.g., if the reference point is a spinning or collection operation, upstream refers to a filament-forming composition production operation 16, for example).

[0178] In one embodiment, the solid additive, eg, particles 26, contacts the filaments 22 on the upstream side of the spinning enclosure 70 (the "upstream side of the filaments").

[0179] In another embodiment, the solid additive, eg, particles 26, contacts the filaments 22 downstream of the spinning enclosure 70 (the "downstream side of the filaments").

[0180] In another embodiment, the solid additive, eg, particles 26, contacts the filaments 22 on both the upstream and downstream sides of the spinning enclosure 70 ("upstream and downstream sides of the filaments").

[0181] FIG. 7 shows another schematic example of a mixing operation 24 in which particles 26 land on a collector 58 in a particle landing zone 74 and contact filaments 22 in a forming zone 68 .

[0182] The solid additive, e.g., particles 26, may contact the filaments 22 at a contact angle of about 0° or more but about 90° or less, and / or about 10° or more but about 90° or less, and / or about 20° or more but about 90° or less, and / or about 30° or more but about 90° or less, and / or at least about 40° but less than about 90° (contact angle relative to the flow direction of the filaments flowing in and out of the spinning die 54), and / or at least about 45° but less than about 90°.

[0183] The solid additives, e.g., particles 26, may be dispersed throughout the fibrous structure 14 with an overall MD basis weight variation RSD% of less than 40.0%, and / or less than 30.0%, and / or less than 25.0%, and / or less than 20.0%, and / or less than 15.0%, and / or less than 10.0%, and / or less than 5.0%, and / or about 0%, when measured according to the CD and MD Basis Weight Variation Test Method described herein.

[0184] The solid additives, e.g., particles 26, may be dispersed throughout the fibrous structure 14 with an overall CD basis weight variation RSD% of less than 40.0%, and / or less than 30.0%, and / or less than 25.0%, and / or less than 20.0%, and / or less than 15.0%, and / or less than 10.0%, and / or less than 5.0%, and / or about 0%, when measured according to the CD and MD Basis Weight Variation Test Method described herein.

[0185] The solid additive, e.g., particles 26, may contact the filaments at a velocity greater than 1 m / sec, and / or at least 2 m / sec, and / or at least 2.5 m / sec, and / or less than 10 m / sec, and / or less than 8 m / sec, and / or 6 m / sec or less, and / or between about 1 m / sec and about 20 m / sec.

[0186] The solid additive, e.g., particles 26, may be mixed with the filaments 22 to provide a solid additive inclusion efficiency (e.g., particle inclusion efficiency) of greater than 40%, and / or at least 42%, and / or at least 45%, and / or at least 50%, and / or at least 54%, and / or at least 65%, and / or at least 75%, and / or at least 85%, and / or at least 90%, and / or at least 95%, and / or at least 98%, as measured according to the Inclusion Efficiency Test Method described herein.

[0187] In one embodiment, the mixing step includes introducing a solid additive, e.g., particles 26, to the plurality of filaments 22, e.g., soluble filaments, between at least one of the dies, e.g., spinning die 54, and collector 58. In one embodiment, the solid additive, e.g., particles 26, is introduced more proximal to the at least one die, e.g., spinning die 54, than to collector 58. In another embodiment, the solid additive, e.g., particles 26, is introduced more proximal to the at least one die, e.g., spinning die 54, than to collector 58.

[0188] In one embodiment, the mixing operation (step) includes introducing solid additives, eg, particles 26, into filaments 22, eg, soluble filaments, spun from two different spin dies 54.

[0189] The solid additive, e.g., particles 26, may comprise one or more types or different types of particles 26. In one embodiment, the solid additive, e.g., particles 26, comprises a mixture of particles 26 of different compositions. In another embodiment, the solid additive, e.g., particles 26, comprises a blend of particles of different compositions. In another embodiment, the solid additive, e.g., particles 26, comprises water-soluble and / or water-insoluble particles, which may include water-swellable particles. Furthermore, in one embodiment, the particles 26 may be in the form of an agglomerate, e.g., an agglomerate comprising water-soluble and / or water-insoluble materials.

[0190] In one example, the solid additive, e.g., particle 26, can exhibit a D50 particle size of about 100 μm to about 5000 μm, and / or about 100 μm to about 2000 μm, and / or about 250 μm to about 1200 μm, and / or about 250 μm to about 850 μm, as measured according to the Particle Size Distribution Test Method described herein.

[0191] In one example, the solid additive, eg, particles 26, may exhibit a D10 of 250 μm when measured according to the Particle Size Distribution Test Method described herein.

[0192] In another example, the solid additive, eg, particles 26, may exhibit a D90 of 1200 μm and / or 850 μm, as measured according to the Particle Size Distribution Test Method described herein.

[0193] In one example, the solid additive, e.g., particle 26, may exhibit a D10 greater than 44 μm, and / or greater than 90 μm, and / or greater than 150 μm, and / or greater than 212 μm, and / or greater than 300 μm, as measured according to the particle size distribution test method described herein.

[0194] In one example, the solid additive, e.g., particle 26, may exhibit a D90 of less than 1400 μm, and / or less than 1180 μm, and / or less than 850 μm, and / or less than 600 μm, and / or less than 425 μm, as measured according to the particle size distribution test method described herein.

[0195] In one example, the solid additive, e.g., particle 26, can exhibit any combination of the D10, D50, and / or D90 specified above, so long as the D50, if present, is greater than the D10, if present, and the D90, if present, is greater than both the D10 and the D50, if present.

[0196] In one embodiment, the solid additive, eg, particles 26, can exhibit any combination of the D10 and D90 specified above, so long as the D90 is greater than the D10.

[0197] In one example, the solid additive, eg, particles 26, may exhibit a D10 of greater than 212 μm and a D90 of less than 1180 μm, as measured according to the Particle Size Distribution Test Method described herein.

[0198] In one example, the solid additive, eg, particles 26, may exhibit a D10 of greater than 90 μm and a D90 of less than 425 μm when measured according to the Particle Size Distribution Test Method described herein.

[0199] In one embodiment, spinning operation 20 can include two or more spinning dies 54 positioned adjacent to each other in the machine direction and / or cross-machine direction. In one embodiment, when spinning operation 20 includes two or more dies positioned adjacent to each other in the machine direction, mixing operation 24 can be positioned between two adjacent (machine direction) dies, for example, two adjacent spinning dies 54.

[0200] The particles 26 used in the present invention to mix with the filaments 22 may be active agent-containing particles.

[0201] d. Recovery operation (28) As shown in Figures 1, 4 and 6, the filaments 22 from the spinning operation 20 and, optionally, the solid additives, e.g., particles 26, from the mixing operation 24 are collected on a collection device 58 during a collection operation 28 to form a fibrous structure 14, which may be a composite structure (mixed filaments 22 and particles 26).

[0202] In one embodiment, the collector 58 may be a belt, such as a patterned belt, that imparts a texture, such as a three-dimensional texture, to at least one surface of the fibrous structure 14 and / or the rotating drum. The collector 58 may impart a pattern, e.g., a non-random, repeating pattern, that may be continuous, discontinuous, and / or semi-continuous in nature. The collector 58 may create different regions, e.g., different average densities, within the fibrous structure 14.

[0203] Test Method Unless otherwise specified, all tests described herein, including those described in the Definitions section, and the following test methods, are performed on samples conditioned for a minimum of two hours in a room conditioned to a temperature of 23°C ± 1.0°C and a relative humidity of 50% ± 2% prior to testing. The tested sample is a "usable unit." As used herein, "usable unit" means a sheet, a flat section obtained from roll material, a pre-converted flat section, a sheet, and / or a single-ply or multi-ply product. All tests are performed under the same environmental conditions and in a room so conditioned. Samples with defects such as wrinkles, tears, holes, etc. are not tested. Samples conditioned as described herein are considered dry samples (e.g., "dry filament") for testing purposes. All instruments are calibrated according to manufacturer specifications.

[0204] Basis Weight Test Method Basis weight is the g / m of the sample being tested 2 This is defined as the weight of the sample in g / m², calculated by accurately weighing a known area of ​​the prepared sample using a suitable balance, recording the weight and area of ​​the sample tested, applying the appropriate conversion factor, and finally converting the weight of the sample to g / m². 2 The basis weight is determined by calculating the basis weight of the sheet.

[0205] Basis weight is measured by cutting a sample from a single web, a stack of webs, or other suitable stacked or consumer-saleable unit and weighing the sample using a top-loading analytical balance with a resolution of ±0.001 g. Samples must be equilibrated at a temperature of 73°F ±2°F (23°C ±1°C) and 50% (±2%) relative humidity for a minimum of two hours before cutting the sample. During weighing, the balance is protected from air currents and other disturbances using a draft shield. All samples are prepared using a precision cutting die measuring 1.625 x 1.625 inches (41.275 x 41.275 mm). A usable sample area is selected that is clean and free of holes, tears, wrinkles, and other defects.

[0206] For each sample, use the die cutter described above to cut the sample, weigh the mass of the sample, and record the mass result to the nearest 0.001 g.

[0207] Calculate the basis weight in g / m2 as follows: Basis weight = (mass of sample) / (area of ​​sample).

[0208] Or specifically, Basis weight (g / m²) = (mass of sample (g)) / (0.001704 m²).

[0209] Results are reported to the nearest 0.1 g / m². Sample size can be altered or varied using a precision cutter similar to that described above. If sample size is reduced, several samples should be measured and the average value should be reported as the basis weight.

[0210] Particle size distribution test method Particle size distribution testing is performed to determine the characteristic size of solid additives, e.g., particles, using ASTM D 502-89, "Standard Test Method for Particle Size of Soaps and Other Detergents," approved May 26, 1989, with additional specifications for sieve size and sieve time used in the analysis. According to Section 7, "Procedure using machine-sieving method," clean, dry sieve nests containing American Standard (ASTM E 11) sieves #4 (4.75 mm), #6 (3.35 mm), #8 (2.36 mm), #12 (1.7 mm), #16 (1.18 mm), #20 (850 micrometers), #30 (600 micrometers), #40 (425 micrometers), #50 (300 micrometers), #70 (212 micrometers), #100 (150 micrometers), #170 (90 micrometers), and #325 (44 micrometers) and pans are required to cover the particle size ranges mentioned herein. The prescribed mechanical sieving method is used with the above nested sieves. A suitable sieve shaker is available from WSTyler Company (Ohio, USA). The sieve shake test sample is approximately 100 grams and is shaken for 5 minutes.

[0211] The data are plotted on a semi-logarithmic plot with the micrometer size opening of each sieve plotted on the logarithmic abscissa and the cumulative mass percent finer (CMPF) plotted on the linear ordinate. An example of such data representation is given in Figure A.4 of ISO 92761:1998, "Representation of results of particle size analysis - Part 1: Graphical Representation." The characteristic particle size (Dx, x=10, 50, 90) is defined for the purposes of this invention as the abscissa value at which the cumulative mass percent equals x percent, and is calculated by linear interpolation between the data points immediately above (a) and below (b) the x value using the following formula: Dx=10^[Log(Da)-(Log(Da)-Log(Db))×(Qa-x%) / (Qa-Qb)] where Log is the base 10 logarithm, Qa and Qb are the cumulative mass percentile values ​​of the measurement data just above and just below the x percentile, respectively, and Da and Db are the micrometer sieve size values ​​corresponding to these data.

[0212] Example data and calculations:

[0213] [Table 2]

[0214] For D10 (x=10), the micrometer screen size (Da) directly above the 10% CMPF is 300 micrometers, and the screen (Db) directly below is 212 micrometers. The cumulative mass (Qa) directly above the 10% CMPF is 15.2%, and the screen (Qb) directly below is 6.8%. D10=10^[Log(300)-(Log(300)-Log(212))×(15.2%-10%) / (15.2%-6.8%)]=242 micrometers.

[0215] For D90 (x=90), the micrometer screen size (Da) directly above where the CMPF is 90% is 1180 micrometers, and the screen (Db) directly below is 850 micrometers. The cumulative mass (Qa) directly above 90% is 99.3%, and the screen (Qb) directly below is 89.0%. D90=10^[Log(1180)-(Log(1180)-Log(850))×(99.3%-90%) / (99.3%-89.0%)]=878 micrometers.

[0216] For D50 (x=50), the micrometer screen size (Da) directly above where the CMPF is 50% is 600 micrometers, and the screen (Db) directly below is 425 micrometers. The cumulative mass (Qa) directly above 50% is 60.3%, and the screen (Qb) directly below is 32.4%. D50 = 10^[Log(600) - (Log(600) - Log(425)) x (60.3% - 50%) / (60.3% - 32.4%)] = 528 micrometers.

[0217] CD and MD basis weight variation test method Cross-direction (CD) basis weight variation is measured in this manner by sampling the web in the cross direction at a given fixed machine direction (MD) location, measuring the basis weight of the samples taken at this MD location, and then calculating the relative standard deviation (RSD) % for the sample set. This analysis is performed on as many samples as necessary to sample the entire cross direction of a given web. As one sampling example, if the web is approximately 53 cm wide and the basis weight sample die cutter is 4.1275 cm wide for the basis weight method described herein, then approximately 12 samples may be taken across the web. Web edge samples may not completely fill the sampling die when cutting across the full MD location; for example, the die cutter may extend beyond the edge of the web and should be discarded. Sampling at a given MD location can vary slightly, as long as the entire CD width is reasonably sampled at each MD location. Sampling is completed for a total of 10 fixed MD locations spaced approximately 1 m apart. The CD basis weight variation is recorded for each MD location, and the values ​​at each location are used to obtain the CD basis weight variation RSD% per MD sampling location. The average of the 10 sampled rows or MD locations is reported as the overall CD basis weight variation RSD%.

[0218] Machine direction (MD) basis weight variation is measured in this method by sampling the web in the machine direction at a given fixed cross direction (CD) location, measuring the basis weight of the sample taken at the given CD location, repeating this measurement at other CD locations, and then calculating the overall MD basis weight variation RSD% for the entire sample set.

[0219] The overall CD basis weight variation RSD% and the overall MD basis weight variation RSD% can be averaged to obtain the overall web basis weight variation RSD%.

[0220] Procedure for measuring cross direction variation at a fixed machine direction position A machine direction position on the web for the sample is selected.

[0221] The basis weight of all samples is measured according to the Basis Weight Test Method described herein.

[0222] Cut as many samples as necessary to sample the entire web width at a given MD location.

[0223] As an example, if the web is about 53 cm wide and the sample die cutter is 4.1275 cm wide, about 12 samples may be taken across the web. Sampling at a given MD location can vary slightly, as long as the entire CD width is reasonably sampled at each MD location.

[0224] Any edge samples of the complete web that do not completely fill the sampling die when cut are discarded.

[0225] Calculate the basis weight of each sample taken along a given MD location.

[0226] Calculate the average sample basis weight at this fixed MD location.

[0227] Calculate the standard deviation of the samples at a fixed MD position.

[0228] Calculate the % RSD (relative standard deviation) for the samples at this MD position by dividing the standard deviation by the average sample basis weight and multiplying by 100 to get the % value.

[0229] Repeat the above for a total of 10 rows or 10 MD locations, sampling the web approximately 1 meter apart from the process.

[0230] Average the average RSD for all 10 rows and report it as the Overall CD Basis Weight Variation RSD%. Report this value to the nearest 0.1%.

[0231] Procedure for measuring machine direction variation at a fixed cross direction position The web is sampled at its transverse centerline.

[0232] The basis weight of all samples is measured according to the Basis Weight Test Method described herein.

[0233] Ten samples are cut along the cross-web centerline at approximately 1 m intervals from the process in the MD of the web.

[0234] Calculate the basis weight of each sample.

[0235] Calculate the average sample basis weight at the CD centerline location.

[0236] Calculate the standard deviation for the same sample set.

[0237] Calculate the MD basis weight variation RSD% at the CD centerline location by dividing the standard deviation by the average sample basis weight and multiplying by 100 to get the value %. Report this value to the nearest 0.1%.

[0238] Repeat the above transverse centerline position measurement by taking the same sampling and measurement along the midline on the left half of the CD centerline, then along the midline on the right half of the CD centerline.

[0239] From the above analysis, three values ​​are generated: RSD% relative to CD centerline position RSD% of the midline above the left half of the CD centerline RSD% of the midline above the right half of the CD centerline The RSD% for these three CD locations is averaged and reported as the overall MD basis weight variation RSD%. Report this value to the nearest 0.1%.

[0240] Content Efficiency Test Method Incorporation efficiency is a measure of the percentage of solid additives, e.g., particles, captured and retained in the fibrous structure during the mixing (coform) operation relative to the number of solid additives, e.g., particles, introduced (fed) to the mixing (coform) operation. A higher incorporation efficiency percentage indicates better solid additive, e.g., particles, synchronization achieved by the mixing (coform) operation and / or coform equipment and / or process conditions operable during the mixing (coform) operation.

[0241] In general, the loading efficiency is as follows:

[0242]

number

[0243]

number

[0244] procedure The mixing (coform) operation is carried out under steady state conditions to produce a particle-free base fiber structure (filaments only).

[0245] Measure the basis weight of a cut sample of the base fibrous structure as defined by the Basis Weight Method defined herein.

[0246] Sampling is done from the transverse center of the base fibrous structure or at the CD centerline of the base fibrous structure.

[0247] This is the basis weight of the base fiber structure (g / m 2 ) and record it as

[0248] Create a composite fiber structure (filaments + particles) at the desired dry mass feed rate.

[0249] Measure the basis weight of a cut sample of the composite fibrous structure as defined by the Basis Weight Method defined herein.

[0250] Sampling is performed from the transverse center of the composite fiber structure or at the CD centerline of the composite fiber structure.

[0251] This is the composite fiber structure basis weight (g / m 2 ) and record it as

[0252] The total particle feed rate and the total filament-forming composition feed rate are process parameters. The total particle feed rate is measured by collecting the entire particle feed stream over a 1-minute interval and is reported in g / min in increments of 1 g / min. The total filament-forming composition feed rate is measured using an in-line process flow meter and is reported in g / min in increments of 1 g / min. The solids concentration of the filament-forming composition is the ratio of the mass of the filament-forming composition material remaining after drying to the mass of the starting filament-forming composition. This can be measured using a Mettler Toledo HC103 or equivalent moisture analyzer. The solids concentration of the filament-forming composition is reported as a percentage to the nearest 0.01 or 1%.

[0253] For clarity, an example of calculation of loading efficiency is given below:

[0254] The base fibrous structure (filaments only - no particles) is made from the filament-forming composition at 55% (0.55) solids concentration. The feed rate of the filament-forming composition to the die is 1600 g / min. A sample cut down the centerline of the base fibrous structure has a mass of 264 g / m. 2 The composite fibrous structure (filaments + solid additives, e.g., particles) is then prepared as described above for the base fibrous structure, except that the solid additives, e.g., particles, are added to the filaments at a total particle feed rate of 2350 g / min. Samples cut from the composite fibrous structure exhibit a basis weight of 870 g / m 2 With these values, an exemplary calculation of loading efficiency is as follows:

[0255]

number

[0256] The content efficiency is reported to the nearest 1%.

[0257] Moisture content test method The moisture content (moisture) present in fibrous elements, particles, and / or fibrous structures is measured using the following moisture content test method. Pre-cut fibrous elements, particles, and / or fibrous structures, or portions thereof ("samples"), in the form of pre-cut sheets, are placed in a room conditioned to a temperature of 23°C ± 1.0°C and a relative humidity of 50% ± 2% for at least 24 hours prior to testing. Each fibrous structure sample has an area of ​​at least 4 square inches but is small enough to fit properly on the weighing pan of a balance. Under the above temperature and humidity conditions, using a balance capable of measuring to at least four decimal places, the weight of the sample is recorded every 5 minutes until the weight has changed by less than 0.5% from the previous (measured) weight within 10 minutes. The final weight is recorded as the "equilibrated weight." Within 10 minutes, the sample is placed on foil in a forced air oven at 70°C ± 2°C and a relative humidity of 4% ± 2% for 24 hours to dry. After 24 hours of drying, the sample is removed and its weight is measured within 15 seconds. This weight is called the "dry weight" of the sample.

[0258] Calculate the moisture (water) content of the sample as follows:

[0259]

number

[0260] The % moisture content (moisture) in the sample for the three replicates is averaged and reported as the % moisture content (moisture) in the sample. Results are reported to one decimal place (0.1%).

[0261] Diameter Test Method The diameter of discrete fiber elements or fiber elements within a fiber structure is determined using a scanning electron microscope (SEM) or optical microscope and image analysis software. A magnification of 200x to 10,000x is selected to adequately magnify the fiber elements for measurement. When using an SEM, the sample is sputtered with gold or palladium compounds to prevent charging and vibration of the fiber elements in the electron beam. A manual procedure is used to measure the diameter of fiber elements from images (on a monitor screen) obtained with an SEM or optical microscope. Using the mouse and cursor tools, locate the edge of a randomly selected fiber element and then measure across its width (i.e., perpendicular to the orientation of the fiber element at that point) to the other edge of the fiber element. A calibrated image analysis tool with a scale provides a scale for obtaining actual readings in μm. For fiber elements within a fiber structure, a few fiber elements are randomly selected from the entire fiber structure sample using an SEM or optical microscope. At least two sections of the fiber structure are cut and tested in this manner. A total of at least 100 such measurements are performed and all data is then recorded for statistical analysis, which is used to calculate the mean (average) fiber element diameter, the standard deviation of the fiber element diameter, and the median fiber element diameter.

[0262] Another useful statistic is the calculation of the amount of fiber element population that is smaller than a particular upper limit. To determine this statistic, the software is programmed to count how many of the fiber element diameter results are smaller than the upper limit, and the count (divided by the total number of data points and multiplied by 100%) is recorded as a percentage, i.e., percent smaller than the upper limit (e.g., percent less than 1 micrometer or submicron %). We refer to the measured diameter (in μm) of an individual circular fiber element as di.

[0263] If the fiber element has a non-circular cross section, the diameter measurement of the fiber element is taken as the hydraulic diameter and set equal to the hydraulic diameter, which is the cross-sectional area of ​​the fiber element multiplied by 4 divided by the perimeter of the cross section of the fiber element (or the outer perimeter in the case of hollow fiber elements). The number-average diameter, or mean diameter, is calculated as follows:

[0264]

number

[0265] Weight-average molecular weight test method The weight-average molecular weight (Mw) of a material (e.g., a polymer) is determined by gel permeation chromatography (GPC) using a mixed-bed column. A high-performance liquid chromatograph (HPLC) with the following components is used: a Millenium® Model 600E pump, a system controller and controller software version 3.2, a Model 717 Plus autosampler, and a CHM-009246 column heater (all from Waters Corporation, Milford, MA, USA). The column is a 600 mm long, 7.5 mm internal diameter PL Gel 20 μm mixed-A column (gel molecular weight: 1,000 g / mol to 40,000,000 g / mol). The guard column is a 50 mm long, 7.5 mm internal diameter PL Gel 20 μm. The column temperature is 55°C, and the injection volume is 200 μL. The detector is a DAWN® Enhanced Optical System (EOS) equipped with Astra® software, version 4.73.04 detector software, a laser light scattering detector with a K5 cell, and a 690 nm laser from Wyatt Technology (Santa Barbara, CA, USA). The gain of the odd-numbered detector is set to 101. The gain of the even-numbered detector is set to 20.9. The Wyatt Technology Optilab® differential refractometer is set to 50°C. The gain is set to 10. The mobile phase is HPLC-grade dimethyl sulfoxide containing 0.1% w / v LiBr, and the mobile phase flow rate is 1 mL / min isocratic. The run time is 30 minutes.

[0266] Samples are prepared by dissolving material in mobile phase at a nominal 3 mg of material per mL of mobile phase. The samples are capped and then stirred for approximately 5 minutes using a magnetic stirrer. The samples are then placed in a convection oven at 85°C for 60 minutes. The samples are then allowed to cool to room temperature. The samples are then filtered through a 5 μm nylon membrane (Type: Spartan-25, manufactured by Schleicher & Schuell, Keene, NH, USA) via a 5 mL syringe into a 5 milliliter (mL) autosampler vial.

[0267] For each series of measurement samples (three or more samples of material), the solvent from the blank sample is injected into the column. A check sample is then prepared in the same manner as for the above samples. The check sample contains 2 mg / mL pullulan (Polymer Laboratories) with a weight-average molecular weight of 47,300 g / mol. The check sample is analyzed before each sample set is analyzed. The blank sample, check sample, and material test sample are tested in duplicate. The blank sample is used for the final measurement. The light scattering detector and differential refractometer are used in accordance with the "Dawn EOS Light Scattering Instrument Hardware Manual" and the "Optilab® DSP Interferometric Refractometer Hardware Manual" (both produced by Wyatt Technology Corp. (Santa Barbara, CA, USA) and both incorporated herein by reference).

[0268] The detector software is used to calculate the weight-average molecular weight of the sample. A dn / dc (differential change in refractive index with concentration) value of 0.066 is used. The baselines of the laser light detector and refractive index detector are corrected to remove detector dark current and solvent scattering interference. If the laser light detector signal is saturated or exhibits excessive noise, its value is not used in calculating the molecular mass. The region for molecular weight characterization is selected so that the 90° detector signals for laser light scattering and refractive index are both greater than three times their respective baseline noise levels. Typically, the high molecular weight side of the chromatogram is limited by the refractive index signal, and the low molecular weight side is limited by the laser light signal.

[0269] The weight average molecular weight can be calculated using the "first-order Zimm plot" defined in the detector software. If the weight average molecular weight of the sample is greater than 1,000,000 g / mol, both the first-order and second-order Zimm plots are calculated, and the result with the least error from the regression fit is used to calculate the molecular mass. The weight average molecular weight reported is the average of two runs of the material test sample.

[0270] Dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise indicated, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "approximately 40 mm."

[0271] All documents cited in this application, including all cross-referenced or related patents or patent applications, and any patent application or patent to which this application claims priority or benefit, are incorporated herein by reference in their entirety, unless expressly stated to the contrary. The citation of any document shall not be deemed to be prior art to any invention disclosed or claimed herein, or to teach, suggest, or disclose any such invention(s), either alone or in combination with any other reference(s). Furthermore, to the extent that any meaning or definition of a term in this document conflicts with a meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0272] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. 1. A continuous process for making a plurality of articles of manufacture, comprising: a. providing one or more water soluble filament-forming materials; b. forming an aqueous composition comprising one or more water-soluble filament-forming materials; c. processing the aqueous composition to produce a filament-forming composition; d. delivering a filament-forming composition to one or more dies; e. spinning the filament-forming composition to form a filament stream from said one or more dies comprising a plurality of water-soluble filaments; f. collecting the mixture of water-soluble filaments on a collecting device to form a fibrous structure; g. Converting the fibrous structure into a plurality of articles of manufacture; h. packaging a plurality of the articles of manufacture; wherein steps a. to h. are carried out in a single continuous manufacturing line.

2. The continuous process of claim 1 , wherein the one or more water-soluble filament-forming materials comprise a hydroxyl polymer.

3. 3. The continuous process of claim 2, wherein the hydroxyl polymer comprises polyvinyl alcohol.

4. 10. The continuous process of claim 1, wherein at least one of the one or more water-soluble filament-forming materials is in the form of pellets.

5. 10. The continuous process of claim 1, wherein in step b, at least 30% by weight of water is added to the one or more water-soluble filament-forming materials.

6. 10. The continuous process of claim 1, wherein the step of processing the aqueous composition occurs in an extruder.

7. 7. The continuous process of claim 6, wherein the aqueous composition exiting the extruder exhibits a % solids of 20% to 95%.

8. 7. The continuous process of claim 6, wherein the filament-forming composition exits the extruder at an exit pressure of 10 to 80 bar.

9. 7. The continuous process of claim 6, wherein the extruder exposes the filament-forming composition to a temperature of at least 49°C.

10. 7. The continuous process of claim 6, wherein the filament-forming composition exits the extruder at an SME of 0.10 to 0.50 kW-h / kg based on solids throughput.

11. 10. The continuous process of claim 1, wherein the water-soluble filaments include an active agent present within the water-soluble filaments.

12. 12. The continuous process of claim 11, wherein the activator is added to the continuous process in one of steps b, c, d, or a combination thereof.

13. 10. The continuous process of claim 1, wherein step g. comprises one or more converting operations selected from the group consisting of die-cutting, slitting, laminating, calendaring, optionally converting, printing, and combinations thereof.

14. 14. The continuous process of claim 13, wherein the one or more converting operations are performed in a single converting line.

15. 14. The continuous process of claim 13, wherein the one or more conversion operations provide saleable units available for consumer use.

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