Nonwoven water-dispersible articles for unit dose packaging

Abstract

The present disclosure provides a nonwoven web, the nonwoven web comprising a plurality of fibers comprising a blend of fiber-forming materials, the blend of fiber-forming materials comprising a first polyvinyl alcohol polymer. The blend of fiber-forming materials further comprises a second polyvinyl alcohol polymer, or does not comprise carboxymethyl cellulose, hydroxypropyl methyl cellulose, or starch. The nonwoven web may be water-dispersible, optionally water-soluble, and / or water-flushable. The present disclosure also provides a pouch comprising a nonwoven web comprising a plurality of fibers according to the present disclosure. In some embodiments, the water-dispersible pouch may comprise a laminate comprising a water-soluble film of the present disclosure and a nonwoven web.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Nos. 62 / 838,282, filed April 24, 2019, and 62 / 908,287, filed September 30, 2019, the disclosures of which are incorporated herein by reference in their entireties.

[0002] FIELD OF THE INVENTION The present disclosure relates generally to nonwoven water-dispersible articles. More particularly, the present disclosure relates to nonwoven water-dispersible articles comprising water-soluble fibers and unit dose packages comprising the same. [Background technology]

[0003] background Water-soluble polymer films are commonly used as packaging materials to simplify the dispersing, pouring, dissolving, and dispensing of materials to be delivered. For example, pouches made from water-soluble films are commonly used to package household product compositions such as laundry and dish detergents. Consumers can add the pouched composition directly to a mixing tank, such as a bucket, sink, or washing machine. Advantageously, this eliminates the need for consumers to measure the composition while providing accurate dosing. Pouched compositions can also (i) reduce the hassle that may be associated with dispensing similar compositions from a tank, such as pouring liquid laundry detergent from a bottle; (ii) reduce the waste that may be associated with dispensing similar compositions from a tank, such as pouring liquid laundry detergent from a bottle; and / or (iii) provide a safer dispensing option than may be associated with dispensing chemicals that may be harmful to humans, such as pesticides or undiluted pool cleaning chemicals. In short, dissolvable pre-measured polymer film pouches provide convenience for consumers in a variety of applications.

[0004] Some water-soluble polymer films used to make currently available pouches can interact with pouch components (e.g., detergents) or moisture in the environment, affecting pouch properties; for example, the solubility of the film can decrease over time when in contact with the contents therein, resulting in undesirable residues after washing and / or deterioration of the film's mechanical properties over time. Another type of problem is that water-soluble films prepared from water-soluble polymers can stick to processing equipment and / or other water-soluble films. This problem can arise particularly when the film is formed into a pouch and the pouch is stored together in secondary packaging. Furthermore, some currently available pouches made with water-soluble polymer films have an unpleasant rubbery or plastic-like feel when handled by consumers. Another type of problem is that when a water-soluble pouch is provided in, for example, bulk water, the pouch may release its contents in a manner that provides localized concentrations of the contents rather than providing a more uniform distribution of the contents throughout the bulk solution. Summary of the Invention [Problem to be solved by the invention]

[0005] Thus, there is a need in the art for a water-dispersible package that is comfortable to handle, releases the pouch contents quickly to provide a more uniform distribution, and retains water solubility after storage in contact with the pouch contents while having a reduced tendency to stick to other water-soluble packages. [Means for solving the problem]

[0006] Disclosure Overview One aspect of the present disclosure provides a nonwoven web having a plurality of fibers, wherein the plurality of fibers includes a first fiber comprising a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material and a second polyvinyl alcohol fiber-forming material, or the blend of fiber-forming materials does not include carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), or starch. The polyvinyl alcohol fiber-forming material may include a polyvinyl alcohol homopolymer and / or a polyvinyl alcohol copolymer. In an embodiment, the nonwoven web is water-dispersible. In an embodiment, the nonwoven web is water-soluble. In an embodiment, the nonwoven web is flushable. In an embodiment, the first fiber of the nonwoven web is prepared by a wet-cooled gel spinning process.

[0007] Another aspect of the present disclosure provides a multilayer nonwoven web comprising a first nonwoven web according to the present disclosure. In an embodiment, the multilayer nonwoven web comprises a second nonwoven web according to the present disclosure. In an embodiment, the multilayer nonwoven web comprises the first nonwoven web and the second nonwoven web in the form of a laminate. In an embodiment, the multilayer nonwoven web comprises a film, optionally a water-soluble film, laminated to the first nonwoven web. In an embodiment, the multilayer nonwoven web is water-dispersible. In an embodiment, the multilayer nonwoven web is water-soluble. In an embodiment, the multilayer nonwoven web is flushable.

[0008] Another aspect of the present disclosure provides fibers comprising a blend of fiber-forming materials, wherein the blend of fiber-forming materials comprises a first polyvinyl alcohol polymer and a second polyvinyl alcohol polymer, or the blend of fiber-forming materials does not comprise CMC, HPMC, or starch. The polyvinyl alcohol fiber-forming material may comprise a polyvinyl alcohol homopolymer and / or a polyvinyl alcohol copolymer. In embodiments, the fibers are water-dispersible. In embodiments, the fibers are water-soluble. In embodiments, the fibers are water-flushable.

[0009] Another aspect of the present disclosure provides a nonwoven web comprising a plurality of fibers of the present disclosure. In embodiments, the nonwoven web is water-dispersible. In embodiments, the nonwoven web is water-soluble. In embodiments, the nonwoven web is flushable.

[0010] Another aspect of the present disclosure provides a multi-layer nonwoven web comprising a first layer nonwoven web comprising a plurality of fibers of the present disclosure. In embodiments, the multi-layer nonwoven web is water-dispersible. In embodiments, the multi-layer nonwoven web is water-soluble. In embodiments, the multi-layer nonwoven web is water-flushable.

[0011] Another aspect of the present disclosure provides a pouch comprising a nonwoven web of the present disclosure or a multi-layer nonwoven web of the present disclosure in the form of a pouch. In embodiments, the pouch is water-dispersible. In embodiments, the pouch is water-soluble. In embodiments, the pouch is flushable.

[0012] Another aspect of the present disclosure provides a sealed article comprising the pouch of the present disclosure. In embodiments, the sealed article comprises a composition enclosed in the interior pouch volume.

[0013] Another aspect of the present disclosure provides a method of preparing a sealed article according to the present disclosure, the method comprising forming a nonwoven web of the present disclosure into the shape of a pouch, filling the pouch with a composition to be encapsulated therein, and sealing the pouch to form the sealed article.

[0014] Another aspect of the present disclosure provides a method of preparing a fiber of the present disclosure using a wet chill gel spinning process, the wet chill gel spinning process comprising the steps of: a) dissolving fiber-forming materials in a solution to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle and into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide a fiber.

[0015] Another aspect of the present disclosure provides a method of controlling the hand of a pouch or packet comprising preparing a pouch or packet from a water-dispersible nonwoven web, the water-dispersible nonwoven web comprising a plurality of water-soluble fibers comprising a water-soluble fiber-forming material.

[0016] Other aspects and advantages will become apparent to those skilled in the art upon review of the following detailed description. While the fibers, nonwoven webs, pouches, sealed articles, and methods of making them may be embodied in a variety of forms, the following description includes specific embodiments with the understanding that this disclosure is illustrative and does not limit the invention to the specific embodiments described herein. [Brief explanation of the drawings]

[0017] [Figure 1A] FIG. 1A is a microscope image of Sample 1 of the example.

[0018] [Figure 1B] FIG. 1B is a microscope image of Sample 2 of the example.

[0019] [Figure 1C] FIG. 1C is a microscope image of Example Sample 3.

[0020] [Figure 1D] FIG. 1D is a microscope image of Example Sample 5.

[0021] [Figure 1E] FIG. 1E is a microscope image of Example Sample 6.

[0022] [Figure 1F] FIG. 1F is a microscope image of Example Sample 4.

[0023] [Figure 2] FIG. 2 is a schematic diagram of an exemplary method for preparing the water-soluble fiber of the present disclosure.

[0024] [Figure 3] FIG. 3 is an illustration of a wire frame cage (shown open at the top to better illustrate the water-soluble pouch contained therein) for use in the liquid release tests described herein.

[0025] [Figure 4] FIG. 4 shows an apparatus for conducting liquid release tests, including a beaker resting on a stand, which holds a rod for lowering a cage into the beaker, the rod being securable by a collar with a set screw (not shown).

[0026] [Figure 5A] FIG. 5A is a microscope image of a nonwoven web of the present disclosure having a softness rating of 1.

[0027] [Figure 5B] FIG. 5B is a microscope image of a nonwoven web of the present disclosure having a softness rating of 5. DETAILED DESCRIPTION OF THE INVENTION

[0028] Detailed Description Provided herein is a nonwoven web comprising a plurality of fibers, the plurality of fibers comprising first fibers prepared from a blend of fiber-forming materials. The blend of fiber-forming materials can comprise a) a first polyvinyl alcohol fiber-forming material and a second polyvinyl alcohol fiber-forming material, or b) a first polyvinyl alcohol fiber-forming material and a second fiber-forming material that is not carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), or starch. In some embodiments, the plurality of water-soluble fibers comprises one or more polyvinyl alcohol fiber-forming materials and / or polyvinylpyrrolidone fiber-forming materials. Optionally, the nonwoven web can comprise fibers prepared from a water-insoluble fiber-forming material. Generally, the nonwoven web is water-dispersible. Optionally, the nonwoven web can be water-soluble. Optionally, the nonwoven web can be water-flushable.

[0029] Water-dispersible nonwoven webs and pouches made therefrom can offer one or more advantages over water-soluble films and pouches, such as improved user or consumer feel (e.g., a cloth-like feel rather than a rubbery or plastic-like feel), reduced pouch-to-pouch sticking (e.g., reduced likelihood of pouches sticking together during pouch formation or secondary packaging, resulting in reduced likelihood of pouch rupture after separation), reduced coefficient of friction (e.g., reduced likelihood of sticking to processing equipment and / or improved ability to conform to mold shapes), increased heat or water shrinkage, increased chemical resistance to harsh chemicals packaged within the nonwoven web, improved or retention of mechanical properties after storage in higher moisture and higher temperature environments, and / or improved solubility and dissolution.

[0030] As used herein, unless otherwise indicated, the term "water-soluble" refers to any nonwoven web or film having a dissolution time of 300 seconds or less at a specified temperature as determined according to MSTM-205 as described herein, or any fiber having a complete dissolution time of less than 30 seconds at a specified temperature according to the method for determining single fiber solubility disclosed herein. For example, the solubility parameter can be characterized for a nonwoven web or laminate structure having a thickness of 6 mils (about 152 μm), or a pouch made therefrom. As used herein, a fiber is "insoluble," "water-insoluble," or "insoluble in water" when the fiber has a complete dissolution time of greater than 30 seconds at a specified temperature according to the method for determining single fiber solubility disclosed herein. For example, the dissolution time of the nonwoven web or film can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less, as appropriate, at temperatures of about 100°C, about 90°C, about 80°C, about 70°C, about 60°C, about 50°C, about 40°C, about 20°C, or about 10°C. In embodiments where a dissolution temperature is not specified, the water-soluble nonwoven web or film has a dissolution time of 300 seconds or less at temperatures of about 100°C or less. The fibers can have a complete dissolution time of 30 seconds or less at temperatures of about 100°C, about 90°C, about 80°C, about 70°C, about 60°C, about 50°C, about 40°C, about 20°C, or about 10°C. In embodiments where a complete dissolution temperature is not specified, water-soluble fibers have a complete dissolution time of 30 seconds or less at temperatures of about 100° C. or less, and water-insoluble fibers have a complete dissolution time of more than 30 seconds at temperatures of about 100° C. or less. As used herein, unless otherwise indicated, the term "cold water-soluble" refers to any nonwoven web or film that has a dissolution time of 300 seconds or less at 10° C. as determined according to MSTM-205. For example, the dissolution time can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less at 10° C., as desired.As used herein, unless otherwise indicated, the term "cold water soluble" in reference to a fiber refers to a fiber having a complete dissolution time of 30 seconds or less at 10°C or less according to the method for determining single fiber solubility disclosed herein. In embodiments, a "water soluble film" means that the film is 1.5 mils thick and dissolves in 300 seconds or less at a temperature of 100°C or less. For example, a water soluble film having a thickness of 1.5 mils (about 38 μm) can have a dissolution time of 300 seconds or less, 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less at temperatures of about 70°C, about 60°C, about 50°C, about 40°C, about 30°C, about 20°C, or about 10°C according to MSTM-205.

[0031] As used herein, unless otherwise indicated, the term "water-dispersible" refers to a nonwoven web, laminate structure, or pouch that physically dissociates into smaller constituent pieces after immersion in water at a specified temperature. The smaller pieces may or may not be visible to the naked eye, may or may not remain suspended in water, and may or may not ultimately dissolve. In embodiments where a dispersion temperature is not specified, the nonwoven web or pouch will disintegrate in 300 seconds or less at a temperature of about 100°C or less according to MSTM-205. For example, the disintegration time can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less at temperatures of about 80°C, about 70°C, about 60°C, about 50°C, about 40°C, about 20°C, or about 10°C, as appropriate, according to MSTM-205. For example, such dispersion parameters can be characteristic of a nonwoven web or laminate structure having a thickness of 6 mils (about 152 μm), or a pouch made therefrom.

[0032] As used herein, the term "flushable" refers to an article, such as a nonwoven web, laminate structure, or pouch, that is dispersible in an aqueous environment, e.g., a liquid sludge system, so that disposal of the web(s), laminate(s), or pouch(es) will not result in such article becoming trapped in the pipes of a piping system or accumulating over time to clog such pipes. The INDA / EDANA standard for flushability requires that greater than 95% of the starting material must pass through a 12.5 mm sieve after 60 minutes of a slosh box test using 28 RPM and an 18° inclination angle. The flushability test described herein provides a more stringent flushability test. A commercially available nonwoven web in the form of a flushable wipe, referred to herein as Commercial Wipe A, is certified to be flushable. Thus, as used herein, unless otherwise indicated, the term "flushable" refers to an article such as a nonwoven web, laminate, or pouch that has a percent disintegration that meets or exceeds the percent disintegration of Commercial Wipe A as measured by the Flushability Test described herein. Flushable nonwoven webs, laminate structures, and pouches have the advantage of being more processable in recycling processes, or can be easily flushed down the drain in, for example, septic and municipal wastewater treatment systems, thus eliminating the need to landfill, incinerate, or otherwise dispose of the web, structure, or pouch after use.

[0033] As used herein, unless otherwise indicated, the term "nonwoven web" refers to a web or sheet comprising, consisting of, or consisting essentially of fibers arranged and bonded together (e.g., by a weaving process). Thus, the term nonwoven web can be considered a shorthand for a nonwoven fiber-based web. Furthermore, as used herein, "nonwoven web" includes any structure comprising a nonwoven web or sheet, including, for example, a nonwoven web or sheet having a film laminated thereon. Methods for preparing nonwoven webs from fibers are well known in the art, as described, for example, in "Nonwoven Fabrics Handbook," prepared by Ian Butler, edited by Subhash Batra et al., Printing by Design, 1999, incorporated herein by reference in its entirety. As used herein, unless otherwise indicated, the term "film" refers to a continuous film or sheet prepared, for example, by a casting or extrusion process.

[0034] As used herein, "comprising" refers to various components, ingredients, or steps that can be used in conjunction with one another in practicing the present disclosure. Thus, the term "comprising" encompasses the more restrictive terms "consisting essentially of" and "consisting of." The compositions of the present invention can include, consist essentially of, or consist of any of the required and optional elements disclosed herein. For example, a thermoformable packet can "consist essentially of" a nonwoven web as described herein for use in its thermoforming properties, including a non-thermoformable film or nonwoven web (e.g., a lid portion) and optional markings on the film, e.g., by inkjet printing. The present disclosure, as illustratively disclosed herein, may be practiced in the absence of any element or step not specifically disclosed herein.

[0035] All percentages, parts, and ratios referred to herein are based on the total dry weight of the nonwoven web or film compositions of the present disclosure or the total weight of the packet contents composition, as the case may be, and all measurements made are made at about 25° C. unless otherwise indicated. All weights as they pertain to listed ingredients are based on the active level and therefore do not include carriers or by-products that may be included in commercially available materials, unless otherwise indicated.

[0036] All ranges described herein include all possible subsets of that range and any combination of such subset ranges. By default, ranges include the stated endpoints unless otherwise stated. When a range of values ​​is provided, it is understood that each value between the upper and lower limits of that range, and any other stated or intermediate value in that stated range, is encompassed within the scope of the disclosure. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the scope of the disclosure, subject to any explicit exclusion limits in the stated range. When a stated range includes one or both of the limits, ranges excluding either or both of those included limits are also contemplated as part of the disclosure.

[0037] For example, for any numerical value described herein as a parameter of the described subject or as part of a range related to the described subject, alternatives forming part of this description are expressly contemplated as functionally equivalent ranges surrounding the particular numerical value (e.g., for a dimension disclosed as "40 mm," an alternative embodiment contemplated is "about 40 mm").

[0038] As used herein, the terms packet(s) and pouch(es) should be considered interchangeable. In certain embodiments, the terms packet(s) and pouch(es) are each used to refer to a container made using a nonwoven web and / or film, preferably a fully sealed container with a sealed material inside, such as a metered dose delivery system. Sealed pouches can be made from any suitable method, including processes and features such as heat sealing, solvent welding, and adhesive sealing (e.g., by using a water-soluble adhesive).

[0039] As used herein, unless otherwise indicated, the terms "wt.%" and "wt%" shall refer to the composition of the specified element in "dry" (anhydrous) parts by weight of the whole article or composition, e.g., referring to a nonwoven web or film (if applicable) or a nonwoven web or film including residual moisture in a laminate structure, or parts by weight of the composition enclosed in a pouch (if applicable).

[0040] As used herein, unless otherwise indicated, the term "PHR" ("phr") refers to the composition of the specified element in parts per hundred parts of water-soluble polymer (whether PVOH or other polymer unless otherwise indicated) in a polymer-containing article, which may refer to, for example, a water-soluble film, fiber, or nonwoven web, or a solution used to make a fiber or film.

[0041] The nonwoven webs, pouches, and related methods of making and using are intended to include embodiments including any combination of one or more of the additional optional elements, features, and steps further described below (including those shown in the examples and figures), unless otherwise stated.

[0042] Water-soluble film and fiber forming materials

[0043] Generally, nonwoven webs of the present disclosure can include a plurality of fibers. In embodiments, the nonwoven web can be a water-dispersible or water-soluble nonwoven web and can include a plurality of water-soluble fibers comprising a single-filament-forming material or a blend of fiber-forming materials. In embodiments, the nonwoven web can be a water-dispersible or water-soluble nonwoven web and can include a plurality of water-soluble fibers comprising, for example, a single water-soluble fiber-forming material or a blend of water-soluble fiber-forming materials. In embodiments, the nonwoven web can be a water-dispersible nonwoven web and can include a plurality of water-dispersible fibers comprising water-soluble and / or water-insoluble fiber-forming materials. As used herein, a water-dispersible nonwoven web comprising fibers having a single-filament-forming material means that all of the fibers are prepared from the same fiber-forming material (e.g., polymer(s)).

[0044] The materials forming the water-soluble fibers and water-soluble films can be water-soluble polymers. Water-soluble polymers used in the water-soluble fibers, water-dispersible nonwoven webs, and water-soluble films can include, but are not limited to, polyvinyl alcohol, polyacrylates, water-soluble acrylate copolymers, polyvinylpyrrolidone, polyethyleneimine, pullulan, water-soluble natural polymers including, but not limited to, guar gum, acacia gum, xanthan gum, carrageenan, and starch, water-soluble polymer derivatives including, but not limited to, modified starch, ethoxylated starch, and hydroxypropylated starch, copolymers of the foregoing, and combinations of any of the foregoing. Further water-soluble polymers can include polyalkylene oxides, polyacrylamides, polyacrylic acids and their salts, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and their salts, polyamino acids, polyamides, gelatin, methylcellulose, carboxymethylcellulose and its salts, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, maltodextrin, polymethacrylates, and combinations of any of the foregoing. Such water-soluble polymers, whether PVOH or not, are commercially available from a variety of sources.

[0045] Generally, the fibers and films of the present disclosure can contain polyvinyl alcohol. Polyvinyl alcohol is a synthetic polymer typically prepared by alcoholysis, commonly referred to as hydrolysis or saponification, of polyvinyl acetate. Fully hydrolyzed PVOH is a strongly hydrogen-bonded, highly crystalline polymer in which virtually all acetate groups have been converted to alcohol groups and is soluble only in hot water above about 140°F (about 60°C). If a sufficient number of acetate groups remain after hydrolysis of polyvinyl acetate, i.e., the PVOH polymer is partially hydrolyzed, the polymer is less hydrogen-bonded and less crystalline, and is generally soluble in cold water below about 50°F (about 10°C). Thus, partially hydrolyzed polymers are vinyl alcohol-vinyl acetate copolymers, which are PVOH copolymers, but are generally referred to as PVOH.

[0046] The fibers and / or films described herein can comprise one or more polyvinyl alcohol (PVOH) homopolymers, one or more polyvinyl alcohol copolymers, or a combination thereof. As used herein, the term "homopolymer" generally includes a polymer having a single type of monomer repeat unit (e.g., a polymer chain consisting of or consisting essentially of a single monomer repeat unit). In the specific case of PVOH, the term "homopolymer" (or "PVOH homopolymer") further includes a copolymer consisting of a distribution of vinyl alcohol monomer units and vinyl acetate monomer units depending on the degree of hydrolysis (e.g., a polymer chain consisting of or consisting essentially of vinyl alcohol and vinyl acetate monomer units). In the limit of 100% hydrolysis, a PVOH homopolymer can include a true homopolymer having only vinyl alcohol units. In some embodiments, the fibers and / or films of the present disclosure comprise a polyvinyl alcohol homopolymer. In some embodiments, the fibers and / or films of the present disclosure comprise a hot-water-soluble polyvinyl alcohol homopolymer.

[0047] In some embodiments, the polyvinyl alcohol includes modified polyvinyl alcohol, e.g., copolymers. Modified polyvinyl alcohol can include copolymers or higher polymers (e.g., terpolymers) containing one or more monomers in addition to vinyl acetate / vinyl alcohol groups. Optionally, the modification is neutral, provided by, for example, ethylene, propylene, N-vinylpyrrolidone, or other uncharged monomer species. Optionally, the modification is cationic, provided by, for example, positively charged monomer species. Optionally, the modification is anionic. Thus, in some embodiments, the polyvinyl alcohol includes anionically modified polyvinyl alcohol. Anionically modified polyvinyl alcohol can include partially or fully hydrolyzed PVOH copolymers containing anionic monomer units, vinyl alcohol monomer units, and, optionally, vinyl acetate monomer units (i.e., if not fully hydrolyzed). In some embodiments, the PVOH copolymer can include two or more types of anionic monomer units. Common types of anionic monomer units that can be used in PVOH copolymers include vinyl polymerized units corresponding to vinyl sulfonate monomers and esters thereof, vinyl monocarboxylic acid monomers, esters thereof, and anhydrides thereof, dicarboxylic acid monomers having a polymerizable double bond, esters thereof, and anhydrides thereof, and alkali metal salts of any of the foregoing.Examples of suitable anionic monomer units include vinyl acetic acid, maleic acid, monoalkyl maleate, dialkyl maleate, maleic anhydride, fumaric acid, monoalkyl fumarate, dialkyl fumarate, itaconic acid, monoalkyl itaconate, dialkyl itaconate, citraconic acid, monoalkyl citraconic acid, dialkyl citraconic acid, citraconic anhydride, mesaconic acid, monoalkyl mesaconic acid, dialkyl mesaconic acid, glutaconic acid, monoalkyl glutaconic acid, dialkyl glutaconic acid, glutaconic anhydride, alkyl acrylate, alkyl alkacrylate, vinyl sulfonic acid, allyl sulfonic acid, ethylene The copolymers include vinyl polymerized units corresponding to vinyl anionic monomers, including sulfonic acids, 2-acrylamido-1-methylpropanesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, 2-methylacrylamido-2-methylpropanesulfonic acid, 2-sulfoethyl acrylate, alkali metal salts of the foregoing (e.g., sodium, potassium, or other alkali metal salts), esters of the foregoing (e.g., methyl, ethyl, or other C1-C4 or C6 alkyl esters), and combinations of the foregoing (e.g., numerous types of anionic monomers or equivalent forms thereof). In some embodiments, the PVOH copolymers can include two or more types of monomer units selected from neutral, anionic, and cationic monomer units.

[0048] The level of incorporation / modification of one or more monomer units in the PVOH copolymer is not particularly limited. In embodiments, the one or more monomer units / modifications are present in the PVOH copolymer in an amount ranging from about 1 mol.% or 2 mol.% to about 6 mol.% or 10 mol.% (e.g., at least 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, or 4.0 mol.%, and / or up to about 3.0, 4.0, 4.5, 5.0, 6.0, 8.0, or 10 mol.%) in various embodiments. In embodiments, the modification is anionic, and the anionic monomer units are present in the PVOH copolymer in an amount ranging from about 1 mol.% or 2 mol.% to about 6 mol.% or 10 mol.% (e.g., at least 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, or 4.0 mol.% and / or up to about 3.0, 4.0, 4.5, 5.0, 6.0, 8.0, or 10 mol.%) in various embodiments.

[0049] Polyvinyl alcohol can undergo changes in solubility characteristics. Those skilled in the art know that the acetate groups of co-poly(vinyl acetate vinyl alcohol) polymers (PVOH homopolymers) can be hydrolyzed by either acid or alkaline hydrolysis. As the degree of hydrolysis increases, polymer compositions made from PVOH homopolymers have increased mechanical strength, but their solubility decreases at lower temperatures (e.g., requiring warmer water temperatures for dissolution). Thus, exposure of PVOH homopolymers to an alkaline environment (e.g., obtained from laundry bleaching additives) can convert the polymer from one that quickly and completely dissolves in a given aqueous environment (e.g., cold water medium) to one that dissolves slowly and / or incompletely in the aqueous environment, potentially resulting in undissolved polymer residue at the end of the wash cycle.

[0050] PVOH copolymers with pendant carboxyl groups, such as vinyl alcohol / hydrolyzed methyl acrylate sodium salt polymers, can form lactone rings between adjacent pendant carboxyl and alcohol groups, thereby reducing the aqueous solubility of the PVOH copolymer. In the presence of a strong base, the lactone rings can open over a period of several weeks under relatively warm (ambient) and humid conditions (e.g., via a lactone ring-opening reaction to form corresponding pendant carboxyl and alcohol groups with increased aqueous solubility). Therefore, in contrast to the effects observed with PVOH homopolymers, such PVOH copolymers may become more soluble during storage due to chemical interactions between the polymer and the alkaline composition within the pouch. As a result, over time, packets may be more prone to dissolution more quickly during high-temperature wash cycles (typically 40°C), potentially reducing the efficacy of certain laundry actives due to the presence of bleach and the resulting decrease in pH.

[0051] Certain sulfonic acids and their derivatives with polymerizable vinyl bonds can be copolymerized with vinyl acetate to provide cold-water-soluble PVOH polymers that are stable in the presence of strong base. The base-catalyzed alcoholysis products of these copolymers, used in formulating water-soluble films, are rapidly soluble vinyl alcohol-sulfonate copolymers. The sulfonic acid groups in the PVOH copolymer can revert to sulfonic acid groups in the presence of hydrogen ions, but the sulfonic acid groups still provide the polymer with excellent cold-water solubility. In embodiments, the vinyl alcohol-sulfonate copolymers contain no residual acetate groups (i.e., are fully hydrolyzed) and therefore are not further hydrolyzable by either acid or alkali hydrolysis. Generally, water solubility increases with increasing amounts of modification; therefore, sufficient modification via sulfonate or sulfonic acid groups inhibits hydrogen bonding and crystallinity, allowing dissolution in cold water. In the presence of acidic or basic species, the copolymers are generally unaffected except for the sulfonate or sulfonic acid groups, maintaining excellent cold-water solubility even in the presence of acidic or basic species. Examples of suitable sulfonic acid comonomers (and / or their alkali metal salt derivatives) include vinyl sulfonic acid, allyl sulfonic acid, ethylene sulfonic acid, 2-acrylamido-1-methylpropanesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, 2-methacrylamido-2-methylpropanesulfonic acid, and 2-sulfoethyl acrylate, with the sodium salt of 2-acrylamido-2-methylpropanesulfonic acid (AMPS) being the preferred comonomer.

[0052] Water-soluble polymers can be blended, whether or not they are polyvinyl alcohol polymers. When a polymer blend includes a blend of polyvinyl alcohol polymers, the PVOH polymer blend can include a first PVOH polymer ("first PVOH polymer"), which can include a PVOH homopolymer or a PVOH copolymer containing one or more types of anionic monomer units (e.g., a PVOH ter-(or higher co-)polymer), and a second PVOH polymer ("second PVOH polymer"), which can include a PVOH homopolymer or a PVOH copolymer containing one or more types of anionic monomer units (e.g., a PVOH ter-(or higher co-)polymer). In some embodiments, the PVOH polymer blend includes only the first and second PVOH polymers (e.g., a binary blend of two polymers). Alternatively or additionally, the PVOH polymer blend or a fiber or film made therefrom can be characterized as being free or substantially free of other polymers (e.g., other water-soluble polymers in general, other PVOH-based polymers in particular, or both). As used herein, "substantially free" means that the first and second PVOH polymers constitute at least 95 wt.%, at least 97 wt.%, or at least 99 wt.% of the total amount of water-soluble polymers in the water-soluble fiber or film. In other embodiments, the water-soluble fiber or film can contain one or more additional water-soluble polymers. For example, a PVOH polymer blend can contain a third PVOH polymer, a fourth PVOH polymer, a fifth PVOH polymer, etc. (e.g., one or more additional PVOH homopolymers or PVOH copolymers, with or without anionic monomer units). For example, a water-soluble film can contain at least a third (or fourth, fifth, etc.) water-soluble polymer other than a PVOH polymer (e.g., other than a PVOH homopolymer or PVOH copolymer, with or without anionic monomer units).

[0053] The degree of hydrolysis (DH) of the PVOH homopolymers and PVOH copolymers contained in the water-soluble fibers and films of the present disclosure can range from about 75% to about 99.9% (e.g., about 79% to about 92%, about 80% to about 90%, about 88% to 92%, about 86.5% to about 89%, or about 88%, 90%, or 92%, e.g., for cold water-soluble compositions; about 90% to about 99%, about 92% to about 99%, about 95% to about 99%, about 98% to about 99%, about 98% to about 99.9%, about 96%, about 98%, about 99%, or greater than 99%). As the degree of hydrolysis decreases, fibers or films made from the polymers will have reduced mechanical strength but faster solubility at temperatures below about 20°C. As the degree of hydrolysis increases, fibers or films made from the polymer tend to be mechanically stronger and less thermoformable. The degree of hydrolysis of the PVOH can be selected so that the water solubility of the polymer is temperature-dependent, thus affecting the solubility of films made from the polymer and additional components. In one option, the film is cold water soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., homopolymers not copolymerized with anionic monomers), cold water soluble fibers or films that are soluble in water at temperatures below 10°C can include PVOH with a degree of hydrolysis ranging from about 75% to about 90%, or from about 80% to about 90%, or from about 85% to about 90%. In another option, the fiber or film is warm water soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., homopolymers that are not copolymerized with anionic monomers), hot water soluble fibers or films that are soluble in water at temperatures of at least about 60°C can include PVOH with a degree of hydrolysis of at least about 98%.

[0054] The degree of hydrolysis of the polymer blend is the arithmetically weighted average degree of hydrolysis.

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[0055] The viscosity of PVOH polymers (μ) is determined by measuring freshly made solutions using a Brookfield LV-type viscometer with a UL adapter, as described in British Standard EN ISO 15023-2:2006 Annex E Brookfield test method. It is international convention to refer to the viscosity of a 4% aqueous polyvinyl alcohol solution at 20°C. It should be understood that all viscosities specified herein in centipoise (cP) refer to the viscosity of a 4% aqueous polyvinyl alcohol solution at 20°C, unless otherwise indicated. Similarly, when a polymer is described as having (or not having) a particular viscosity, unless otherwise indicated, the specified viscosity is intended to be the average viscosity for a polymer originally having the corresponding molecular weight distribution, i.e., the weighted natural log-average viscosity described below. The viscosity of a PVOH polymer is determined based on the weighted average molecular weight of the PVOH polymer.

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[0056] In embodiments, the PVOH resin can have a viscosity of about 1.0 to about 50.0 cP, about 1.0 to about 40.0 cP, or about 1.0 to about 30.0 cP, e.g., about 4 cP, 8 cP, 15 cP, 18 cP, 23 cP, or 26 cP. In embodiments, the PVOH homopolymer and / or copolymer can have a viscosity of about 1.0 to about 40.0 cP, or about 5 cP to about 23 cP, e.g., about 1 cP, 1.5 cP, 2 cP, 2.5 cP, 3 cP, 3.5 cP, 4 cP, 4.5 cP, 5 cP, 5.5 cP, 6 cP, 6.5 cP, 7 cP, 7.5 cP, 8 cP, 8.5 cP, 9 cP, 9.5 cP, 10 cP, 11 cP, 12 cP, 13 cP, 14 cP, 15 cP, 17.5 cP, 18 cP, 19 cP, 20 cP, 21 cP, 22 cP, 23 cP, 24 cP, 25 cP, 26 cP, 27 cP, 28 cP, 29 cP, 30 cP, 31 cP, 32 cP, 33 cP, 34 cP, 35 cP, or 40 cP. In embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 21 cP to 26 cP. In embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 5 cP to about 14 cP. In embodiments, the PVOH homopolymer and / or copolymer may have a viscosity of about 5 cP to about 23 cP.

[0057] For reference, in the polymer blend, a first PVOH polymer is designated as having a first 4% solution viscosity (μ) at 20°C, and a second PVOH polymer is designated as having a second 4% solution viscosity (μ) at 20°C. In various embodiments, the first viscosity μ1 can be in the range of about 4 cP to about 70 cP (e.g., at least about 4, 8, 10, 12, or 16 cP, and / or at most about 12, 16, 20, 24, 28, 30, 32, 35, 37, 40, 45, 48, 50, 56, 60, or 70 cP, e.g., about 4 cP to about 70 cP, about 4 cP to about 60 cP, about 4 cP to about 46 cP, about 4 cP to about 24 cP, about 10 cP to about 16 cP, or about 10 cP to about 20 cP, or about 20 cP to about 30 cP). Alternatively, or in addition, the second viscosity μ2 can be in the range of about 4 cP to about 70 cP (e.g., at least about 4, 8, 10, 12, or 16 cP, and / or at most about 12, 16, 20, 24, 28, 30, 32, 35, 37, 40, 45, 48, 50, 56, 60, or 70 cP, e.g., about 12 cP to about 30 cP, about 10 cP to about 16 cP, or about 10 cP to about 20 cP, or about 20 cP to about 30 cP). When the PVOH polymer blend includes three or more PVOH polymers selected from PVOH polymers and PVOH copolymers, the aforementioned viscosity values ​​can apply to each PVOH polymer or PVOH copolymer individually. Thus, the weight average molecular weight of the water-soluble polymers, including the first PVOH copolymer and the second PVOH copolymer, can be, for example, in the range of about 30,000 to about 175,000, or about 30,000 to about 100,000, or about 55,000 to about 80,000. When referring to the average viscosity of a PVOH polymer blend, the weighted natural log average viscosity is used.

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[0058] Water-soluble fiber

[0059] The fibers of the nonwoven web of the present disclosure can include water-soluble fibers. The water-soluble fibers can include any of the water-soluble fiber-forming materials disclosed herein. The water-soluble fibers can include a single water-soluble polymer or a blend of water-soluble polymers. Suitable water-soluble fibers include, but are not limited to, polyvinyl alcohol homopolymers, polyvinyl alcohol copolymers, polyacrylates, water-soluble acrylate copolymers, polyvinylpyrrolidone, polyethyleneimine, pullulan, water-soluble natural polymers including, but not limited to, guar gum, acacia gum, xanthan gum, carrageenan, and starch, water-soluble polymer derivatives including, but not limited to, modified starch, ethoxylated starch, and hydroxypropylated starch, copolymers of the foregoing, and combinations of any of the foregoing. Still other water-soluble fibers can include polyalkylene oxides, polyacrylamides, polyacrylic acids and their salts, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and their salts, polyamino acids, polyamides, gelatin, methylcellulose, carboxymethylcellulose and its salts, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, maltodextrin, polymethacrylates, and combinations of any of the foregoing. In embodiments, the water-soluble fibers can include polyvinyl alcohol fiber-forming materials. In refinements of the foregoing embodiments, the water-soluble fibers can include PVOH homopolymer fiber-forming materials. In another refinement of the foregoing embodiments, the water-soluble fibers can include PVOH copolymer fiber-forming materials. In embodiments, the water-soluble fibers can include blends of polyvinyl alcohol polymer fiber-forming materials. In a refinement of the foregoing embodiment, the water-soluble fibers can include one or more PVOH homopolymers. In another refinement of the foregoing embodiment, the water-soluble fibers can include one or more PVOH copolymers. In yet another refinement of the above embodiment, the water soluble polymer may comprise one or more PVOH homopolymers and one or more PVOH copolymers.In embodiments, the water soluble fibers may include a blend of polyvinyl alcohol fiber-forming materials and non-polyvinyl alcohol based water soluble fiber-forming materials.

[0060] In embodiments in which the water-soluble fiber comprises a blend of a polyvinyl alcohol homopolymer and a polyvinyl alcohol copolymer, the relative amounts of the homopolymer and copolymer are not particularly limited. The polyvinyl alcohol homopolymer can comprise from about 15 wt.% to about 70 wt.% of the total weight of the water-soluble polymer blend, for example, at least about 15 wt.%, at least about 20 wt.%, at least about 25 wt.%, at least about 30 wt.%, at least about 40 wt.%, at least about 50 wt.%, or at least about 60 wt.%, and up to about 70 wt.%, at most about 60 wt.%, at most about 50 wt.%, at most about 40 wt.%, or at most about 30 wt.%, and can be a single homopolymer or a blend of one or more homopolymers (e.g., with differences in viscosity and / or degree of hydrolysis). The remainder of the water-soluble polymer blend can be a water-soluble polyvinyl alcohol copolymer. Without being bound by theory, it is believed that the ability of a blend of polyvinyl alcohol homopolymers and copolymers to form fibers decreases as the amount of homopolymer decreases below about 15 wt.%. The water-soluble polyvinyl alcohol copolymer can comprise about 30 wt.% to about 85 wt.% of the total weight of the water-soluble polymer blend, for example, at least about 30 wt.%, at least about 40 wt.%, at least about 50 wt.%, at least about 60 wt.%, at least about 70 wt.%, at least about 75 wt.%, or at least about 80 wt.%, and up to about 85 wt.%, at most about 80 wt.%, at most about 70 wt.%, at most about 60 wt.%, at most about 50 wt.%, or at most about 40 wt.%, based on the total weight of the water-soluble polymer blend. The blend can be a single copolymer or a blend of one or more copolymers. The blend can consist of a polyvinyl alcohol homopolymer and a polyvinyl alcohol copolymer. The blend may consist of a polyvinyl alcohol homopolymer and multiple polyvinyl alcohol copolymers.The blend may consist of multiple polyvinyl alcohol homopolymers and multiple polyvinyl alcohol copolymers.

[0061] In embodiments, the nonwoven web can include a plurality of fibers, the plurality of fibers including a first fiber comprising a first polyvinyl alcohol fiber-forming material and a blend of fiber-forming materials including (a) a second polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not include carboxymethyl cellulose, hydroxypropyl methylcellulose, or starch. In embodiments, the nonwoven web can be a water-dispersible nonwoven web including a plurality of fibers, the plurality of fibers including a first water-dispersible fiber comprising a first water-soluble polyvinyl alcohol fiber-forming material and a blend of fiber-forming materials including (a) a second polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not include carboxymethyl cellulose, hydroxypropyl methylcellulose, or starch. In embodiments, the nonwoven web can include a plurality of fibers including first fibers and second fibers, wherein the first fibers include a first polyvinyl alcohol and a blend of fiber-forming materials including (a) a second polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not include carboxymethyl cellulose, hydroxypropyl methyl cellulose, or starch, and the first and second fibers have a length to diameter (L / D) ratio, tenacity, shape, stiffness, elasticity, solubility in water, melting point, glass transition temperature (T g ), water-soluble polymer, color, or a combination thereof. In embodiments, the nonwoven web may be a water-dispersible nonwoven web and may include a plurality of fibers including first water-soluble fibers and second fibers, wherein the first water-soluble fibers include a first polyvinyl alcohol and (a) a blend of fiber-forming materials including a second polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not include carboxymethyl cellulose, hydroxypropyl methyl cellulose, or starch, and the first and second fibers may have different length to diameter (L / D) ratios, tenacity, shape, stiffness, elasticity, solubility in water, melting point, glass transition temperature (T g ), water-soluble polymer, color, or a combination thereof.

[0062] Water-insoluble fiber

[0063] The nonwoven web of the present disclosure can also contain water-insoluble fibers. Water-insoluble fibers generally include fibers made of a fiber-forming material that, when provided as the sole fiber in the nonwoven web, does not dissolve in the nonwoven web in 300 seconds or less at a temperature of 80°C or less, as determined by MSTM-205. Generally, the water-insoluble fibers can include a single water-insoluble polymeric fiber-forming material or a blend of water-insoluble polymeric fiber-forming materials. Suitable water-insoluble fiber-forming materials include, but are not limited to, cotton, polyester, copolyester, polyethylene (e.g., high-density polyethylene and low-density polyethylene), polypropylene, wood pulp, fluff pulp, abaca, viscose, insoluble cellulose, insoluble starch, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, Dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polyester, copolyester, polylactide (PLA), polyethylene terephthalate (PET), polypropylene (PP), or combinations thereof. In embodiments, the water-insoluble fiber does not include cotton or rayon. In embodiments, the water-insoluble fiber includes wool, diacetate, triacetate, nylon, PLA, PET, PP, or combinations thereof.

[0064] Nonwoven web

[0065] Nonwoven webs of the present disclosure are generally water-dispersible, optionally water-soluble, and optionally flushable. Nonwoven webs of the present disclosure generally comprise a plurality of water-soluble fibers and optionally water-insoluble fibers. Nonwoven webs generally refer to an arrangement of fibers bonded together, where the fibers are not woven or knitted. Generally, the plurality of fibers can be arranged in any orientation. In embodiments, the plurality of fibers are randomly arranged (i.e., have no orientation). In embodiments, the plurality of fibers are arranged in a unidirectional orientation. In embodiments, the plurality of fibers are arranged in a bidirectional orientation. In some embodiments, the plurality of fibers are multidirectional, with different arrangements in different regions of the nonwoven web.

[0066] Generally, the fibers of any given nonwoven web can comprise any of the fiber-forming materials disclosed herein. The nonwoven web can comprise (1) a monofilament type comprising a monofilament-forming material, (2) a monofilament type comprising a blend of fiber-forming materials, (3) a blend of fiber types, where each fiber type comprises a monofilament-forming material, (4) a blend of fiber types, where each fiber type comprises a blend of fiber-forming materials, or (5) a blend of fiber types, where each fiber type comprises a monofilament-forming material or a blend of fiber-forming materials. In embodiments comprising a blend of fiber types, the different fiber types can be differentiated by their length-to-diameter (L / D) ratio, tenacity, shape, cross-sectional surface area, stiffness, elasticity, solubility, melting point, glass transition temperature (T g), the chemical nature of the fiber-forming materials, color, or a combination thereof. In embodiments, the plurality of fibers comprises a plurality of water-soluble fibers. The plurality of water-soluble fibers may comprise a single type of water-soluble fiber. In embodiments, the plurality of water-soluble fibers may comprise at least two different types of water-soluble fiber. In embodiments, the water-dispersible nonwoven web may further comprise a plurality of water-insoluble fibers. In embodiments, the water-dispersible nonwoven web may comprise a single type of water-soluble fiber and one or more different types of water-insoluble fiber. In embodiments, the water-dispersible nonwoven web may comprise one or more different types of water-soluble fiber and one or more different types of water-insoluble fiber. In embodiments, the water-dispersible nonwoven web may consist of or consist essentially of one or more types of water-soluble fiber. For example, all of the fiber components in the water-dispersible nonwoven web may be water-soluble fiber.

[0067] In an embodiment, the nonwoven web comprises a plurality of fibers, the plurality of fibers comprising a first fiber type comprising a first polyvinyl alcohol fiber-forming material and a blend of fiber-forming materials comprising (a) a second polyvinyl alcohol fiber-forming material, or (b) the blend does not comprise CMC, HPMC, or starch. In an embodiment, the nonwoven web is water-dispersible and comprises a plurality of water-soluble fibers, the plurality of water-soluble fibers comprising a first water-soluble fiber type comprising a first water-soluble polyvinyl alcohol fiber-forming material and a blend of fiber-forming materials comprising (a) a second polyvinyl alcohol fiber-forming material, or (b) the blend does not comprise CMC, HPMC, or starch.

[0068] In some embodiments, the first polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer or a polyvinyl alcohol copolymer. In some embodiments, the second polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer or a polyvinyl alcohol copolymer. In some embodiments, the first and / or second polyvinyl alcohols may comprise a modified polyvinyl alcohol copolymer. In some refinements of the foregoing embodiments, the modified polyvinyl alcohol copolymer may be an anionically modified polyvinyl alcohol copolymer. In some embodiments, the first polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer and the second polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol copolymer, optionally an anionically modified copolymer.

[0069] In embodiments, the first polyvinyl alcohol fiber forming material has a degree of hydrolysis in the range of about 75% to about 99.9%, optionally about 80% to about 90%, optionally about 92% to about 99%, optionally about 98% to about 99%, and optionally about 98% to about 99.9%. In embodiments, the second first polyvinyl alcohol fiber forming material has a degree of hydrolysis in the range of about 75% to about 99.9%, optionally about 80% to about 90%, optionally about 92% to about 99%, optionally about 98% to about 99%, and optionally about 98% to about 99.9%.

[0070] In embodiments, the plurality of fibers comprises a first fiber type and a second fiber type. Optionally, the first fiber type and / or the second fiber type are water-soluble fibers. Generally, the first and second fiber types have characteristics such as length to distance (L / D) ratio, tenacity, shape, cross-sectional area, stiffness, elasticity, solubility in water, melting point, glass transition temperature (T g ), fiber chemistry, color, or a combination thereof. In embodiments, the first and second fiber types have differences in length to distance (L / D) ratio, tenacity, shape, water solubility, glass transition temperature (T g ), fiber chemistry, or a combination of these.

[0071] In embodiments, the plurality of fibers further comprises water-insoluble fibers. In embodiments, the water-insoluble fibers comprise about 20% to about 80% by weight of the total weight of the plurality of fibers. In embodiments, the water-insoluble fibers comprise cotton, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, Dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polyester, copolyester, viscose, polylactide, polyethylene terephthalate, polypropylene, or combinations thereof.

[0072] Flushable nonwoven webs and flushability

[0073] The nonwoven webs, laminate materials, and pouches described herein can be flushable. The flushable nonwoven webs can include a plurality of fibers, and the plurality of fibers can include water-soluble fibers and water-insoluble fibers.

[0074] The water-soluble fibers of the flushable nonwoven web can comprise any of the water-soluble fiber-forming materials disclosed herein. In an embodiment, the water-soluble fibers comprise a polyvinyl alcohol fiber-forming material. In a refinement of the foregoing embodiment, the water-soluble fibers comprise a PVOH homopolymer. In another refinement of the foregoing embodiment, the water-soluble fibers comprise a PVOH copolymer. In an embodiment, the water-soluble fibers comprise a blend of polyvinyl alcohol fiber-forming materials. In a refinement of the foregoing embodiment, the water-soluble fibers comprise one or more PVOH homopolymers. In another refinement of the foregoing embodiment, the water-soluble fibers comprise one or more PVOH copolymers.

[0075] In embodiments, the water-soluble fiber comprises a blend of water-soluble fiber-forming materials. In a refinement of the foregoing embodiment, the blend of water-soluble fiber-forming materials can comprise a polyvinyl alcohol polymer, or a blend of polyvinyl alcohol polymers including a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. In another refinement, the water-soluble fiber can comprise a blend of water-soluble polymers including a polyvinyl alcohol homopolymer and a polyvinyl alcohol copolymer. In yet another refinement of the foregoing embodiment, the water-soluble polymer comprises one or more PVOH homopolymers and one or more PVOH copolymers. In some embodiments, the water-soluble fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material and (a) a second polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not include CMC, HPMC, or starch.

[0076] In embodiments, the water-flushable nonwoven web may comprise a plurality of water-soluble fibers, including a first water-soluble fiber and a second water-soluble fiber, wherein the first and second water-soluble fibers have an L / D ratio, length, tenacity, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g ), fiber chemistry, color, or a combination thereof.

[0077] Suitable water-insoluble fiber-forming materials for the water-flushable fibers, nonwoven webs, laminates, and / or pouches of the present disclosure include, but are not limited to, cotton, polyester, copolyester, polyethylene (e.g., high-density polyethylene and low-density polyethylene), polypropylene, wood pulp, fluff pulp, abaca, viscose, insoluble cellulose, insoluble starch, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, Dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polyester, copolyester, viscose, polylactide, polyethylene terephthalate, polypropylene, and combinations thereof. In embodiments, the water-insoluble fiber-forming material does not include cotton or rayon.

[0078] The amount of water soluble fibers in the waterflushable nonwoven web can range from at least about 20, 25, 30, 40, 50, or 60 wt. % and / or up to about 100, 95, 90, 85, 80, 75, 70, 60, 50, or 40 wt. % based on the total weight of fibers in the waterflushable nonwoven web, e.g., about 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100 wt. % based on the total weight of fibers in the waterflushable nonwoven web, with the remainder of the fibers being water insoluble fibers.

[0079] The amount of water-insoluble fibers in the flushable nonwoven web can range from about 0, 5, 10, 15, 20, 40, 50, or 60 wt. % and / or up to about 75, 70, 60, 50, 40, 30, or 25 wt. % based on the total weight of fibers in the flushable nonwoven web, for example, about 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, or 75 wt. % based on the total weight of fibers in the flushable nonwoven web, with the remainder of the fibers being water-soluble fibers.

[0080] The ratio of water-insoluble fiber to water-soluble fiber in the flushable nonwoven web can range from about 1:18 to about 4:1, from about 1:10 to about 3:1, from about 1:5 to about 2:1, or from about 1:2 to about 2:1, e.g., about 1:18, 1:16, 1:14, 1:12, 1:10, 1:5, 1:3, 1:2, 1:1, 2:1, 3:1, or 4:1.

[0081] Without being bound by theory, for nonwoven webs containing only polyvinyl alcohol fibers, the mechanical stability decreases as the water washability increases (i.e., as the disintegration value increases as determined by the Water Washability Test herein). Accordingly, the inventors have discovered that by incorporating water-insoluble fibers into the nonwoven web, the water washability can be further increased without compromising the mechanical stability of the web.

[0082] In the case of a water-washable nonwoven film containing polyvinyl alcohol, the water-washability increases with increasing water solubility, but water solubility and mechanical stability generally have an inverse relationship.Therefore, the selection of a specific polyvinyl alcohol and any additional water-soluble and / or water-insoluble fibers can be important for maintaining the mechanical integrity of the web while also having suitable water-washability properties.For example, parameters such as the DH and modification percentage of the polyvinyl alcohol homopolymer or copolymer can affect the water-washability and mechanical properties of the fiber.

[0083] adjuvants

[0084] The water soluble fibers, water insoluble fibers, nonwoven webs, laminates, and / or water soluble films may contain other adjuvants and processing agents, such as, but not limited to, plasticizers, plasticizer compatibilizers, surfactants, lubricants, release agents, fillers, extenders, crosslinking agents, antiblocking agents, antioxidants, antiblocking agents, defoaming agents, nanoparticles, such as layered silicate-type nanoclays (e.g., sodium montmorillonite), bleaching agents (e.g., sodium metabisulfite, sodium bisulfite, or others), aversive agents, For example, bittering agents (e.g., denatonium salts, e.g., denatonium benzoate, denatonium saccharide, and denatonium chloride; sucrose octaacetate; quinine; flavonoids, e.g., quercetin and naringenin; and quassinoids, e.g., quassin and brucine), pungent agents (e.g., capsaicin, piperine, allyl isothiocyanate, and resinferratoxin), and other functional ingredients may be included in amounts appropriate for their intended purpose. As used herein, unless otherwise indicated, "adjuvants" includes secondary additives, processing agents, and active agents. Specific such adjuvants and processing agents may be selected from those suitable for use with water-soluble fibers, water-insoluble fibers, nonwoven webs, or water-soluble films.

[0085] In embodiments, the water-soluble fibers, water-insoluble fibers, nonwoven webs, and / or water-soluble films are free of adjuvants. As used herein, unless otherwise indicated, "free of adjuvants" with respect to fibers means that the fibers contain less than about 0.01 wt.%, less than about 0.005 wt.%, or less than about 0.001 wt.% of adjuvants based on the total weight of the fibers. As used herein, unless otherwise indicated, "free of adjuvants" with respect to nonwoven webs means that the nonwoven web contains less than about 0.01 wt.%, less than about 0.005 wt.%, or less than about 0.001 wt.% of adjuvants based on the total weight of the nonwoven web. In embodiments, the water-soluble fibers contain a plasticizer. In embodiments, the water-soluble fibers contain a surfactant. In embodiments, the water-insoluble fibers contain a plasticizer. In embodiments, the water-insoluble fibers contain a surfactant. In embodiments, the nonwoven web contains a plasticizer. In embodiments, the nonwoven web contains a surfactant. In embodiments where the first fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber further comprises a plasticizer, a surfactant, or a combination thereof. In embodiments where the first fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber further comprises a plasticizer. In embodiments where the first fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber further comprises a surfactant.

[0086] Plasticizers are liquid, solid, or semi-solid substances added to materials (usually resins or elastomers) to make them softer, more flexible (by lowering the polymer's glass transition temperature), and easier to process. Alternatively, polymers can be plasticized internally by chemically modifying the polymer or monomer. Alternatively, polymers can be plasticized externally by adding an appropriate plasticizer. Water is recognized as a very efficient plasticizer for PVOH and other polymers, including, but not limited to, water-soluble polymers; however, water's volatility limits its usefulness because polymer films must have at least some resistance (robustness) to a variety of ambient conditions, including low and high relative humidity.

[0087] Plasticizers can include, but are not limited to, glycerin, diglycerin, sorbitol, ethylene glycol, diethylene glycol, triethylene glycol, dipropylene glycol, tetraethylene glycol, propylene glycol, polyethylene glycols up to 400 MW, neopentyl glycol, trimethylolpropane, polyether polyols, sorbitol, 2-methyl-1,3-propanediol (MPDiol®), ethanolamine, and mixtures thereof. The total amount of non-aqueous plasticizer provided to the fibers can range from about 1 wt.% to about 45 wt.%, or from about 5 wt.% to about 45 wt.%, or from about 10 wt.% to about 40 wt.%, or from about 20 wt.% to about 30 wt.%, or from about 1 wt.% to about 4 wt.%, or from about 1.5 wt.% to about 3.5 wt.%, or from about 2.0 wt.% to about 3.0 wt.%, for example, about 1 wt.%, about 2.5 wt.%, about 5 wt.%, about 10 wt.%, about 15 wt.%, about 20 wt.%, about 25 wt.%, about 30 wt.%, about 35 wt.%, or about 40 wt.%, based on the total fiber weight.

[0088] Surfactants for use in fibers are well known in the art. Surfactants for use in films are also well known in the art and may be suitably used in the fibers, films, and / or nonwoven webs of the present disclosure. Optionally, a surfactant may be included to aid in the dispersion of the fibers in the web. Suitable surfactants for the fibers of the present disclosure include, but are not limited to, dialkyl sulfosuccinates, lactylated fatty acid esters of glycerol and propylene glycol, lactic acid esters of fatty acids, sodium alkyl sulfates, polysorbate 20, polysorbate 60, polysorbate 65, polysorbate 80, alkyl polyethylene glycol ethers, lecithin, acetylated fatty acid esters of glycerol and propylene glycol, sodium lauryl sulfate, acetylated esters of fatty acids, myristyl dimethylamine oxide, trimethyl tallow alkyl ammonium chloride, quaternary ammonium compounds, alkali metal salts of higher fatty acids containing from about 8 to 24 carbon atoms, alkyl sulfates, alkyl polyethoxylate sulfates, alkyl benzene sulfonates, monoethanolamine, lauryl alcohol ethoxylate, propylene glycol, diethylene glycol, salts thereof, and combinations of any of the foregoing.

[0089] Suitable surfactants may include nonionic, cationic, anionic, and zwitterionic classes, including, but not limited to, propylene glycol, diethylene glycol, monoethanolamine, polyoxyethylated polyoxypropylene glycol, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylenic glycols and alkanolamides (nonionic), polyoxyethylated amines, quaternary ammonium salts and quaternized polyoxyethylated amines (cationic), alkali metal salts of higher fatty acids containing about 8 to 24 carbon atoms, alkyl sulfates, alkyl polyethoxylate sulfates and alkylbenzene sulfonates (anionic) and amine oxides, N-alkyl betaines and sulfobetaines (zwitterionic). Other suitable surfactants include dioctyl sodium sulfosuccinate, lactylated fatty acid esters of glycerin and propylene glycol, lactic acid esters of fatty acids, sodium alkyl sulfate, polysorbate 20, polysorbate 60, polysorbate 65, polysorbate 80, lecithin, acetylated fatty acid esters of glycerin and propylene glycol, and acetylated esters of fatty acids, and combinations thereof. In various embodiments, the amount of surfactant in the fiber ranges from about 0.01 wt.% to about 2.5 wt.%, from about 0.1 wt.% to about 2.5 wt.%, from about 1.0 wt.% to about 2.0 wt.%, from about 0.01 wt.% to 0.25 wt.%, or from about 0.10 wt.% to 0.20 wt.%.

[0090] In embodiments, the nonwoven web can be tinted, pigmented, and / or dyed to provide improved aesthetic effects over water-soluble films. Suitable colorants can include indicator dyes, such as pH indicators (e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), moisture / water indicators (e.g., hydrochromic inks or leuco dyes), or thermochromic inks, which change color when the temperature increases and / or decreases. Suitable colorants include, but are not limited to, triphenylmethane dyes, azo dyes, anthraquinone dyes, perylene dyes, indigoid dyes, Food, Drug, and Cosmetic (FD&C) colorants, organic pigments, inorganic pigments, or combinations thereof. Examples of colorants include, but are not limited to, FD&C Red #40; Red #3; FD&C Black #3; Black #2; mica-based pearlescent pigments; FD&C Yellow #6; Green #3; Blue #1; Blue #2; titanium dioxide (food grade); brilliant black; and combinations thereof.

[0091] When included in the fiber, the colorant can be provided in an amount of 0.01% to 25% by weight of the water soluble polymer mixture, for example, 0.02%, 0.05%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, and 24% by weight of the water soluble polymer mixture.

[0092] In embodiments, the nonwoven web of the present disclosure can include an active agent. The active agent can be added to the fibers themselves, or to the fiber sieving of the nonwoven web, and / or can be added to the nonwoven web before bonding. An active agent added to the fibers during sieving can be distributed throughout the nonwoven web. An active agent added to the nonwoven web after sieving but before bonding can be selectively added to one or both sides of the nonwoven web. Additionally, the active agent can be added to the surface of a pouch or other article prepared from the nonwoven web. In embodiments, the active agent is provided as part of a plurality of fibers, dispersed within the nonwoven web, provided on one side of the nonwoven web, or a combination thereof.

[0093] Active agents, when present in the nonwoven web in an amount of at least about 1 wt %, or in a range of about 1 wt % to about 99 wt %, provide additional functionality to the nonwoven web. In embodiments, the active agent can include one or more components, including, but not limited to, enzymes, oils, flavors, colorants, odor absorbers, fragrances, pesticides, fertilizers, activators, acid catalysts, metal catalysts, ion scavengers, cleaning agents, disinfectants, surfactants, bleaching agents, bleaching components, fabric softeners, or combinations thereof. In embodiments, the active agent can include a colorant, a surfactant, or combinations thereof. The active agent can take any desired form, including solids (e.g., powders, granules, crystals, flakes, or ribbons), liquids, pellets, pastes, gases, etc., and can be encapsulated, if desired.

[0094] In certain embodiments, the active agent may comprise an enzyme. Suitable enzymes include those classified into one of the six traditional Enzyme Commission (EC) classifications: EC1 oxidoreductases (catalyzing oxidation / reduction reactions), EC2 transferases (transferring functional groups, such as methyl or phosphate groups), EC3 hydrolases (catalyzing the hydrolysis of various bonds), EC4 lyases (cleaving various bonds using methods other than hydrolysis and oxidation), EC5 isomerases (catalyzing intramolecular isomerization changes), and EC6 ligases (covalently joining two molecules). Examples of such enzymes include EC1 dehydrogenases and oxidases, EC2 transaminases and kinases, EC3 lipases, cellulases, amylases, mannanases, and peptidases (also known as proteases or proteolytic enzymes), EC4 decarboxylases, EC5 isomerases and mutases, and EC6 synthetases and synthases. Suitable enzymes from each class are described, for example, in US Pat. No. 9,394,092, the disclosure of which is incorporated herein by reference in its entirety.

[0095] Enzymes used in laundry and dishwashing applications can include one or more of proteases, amylases, lipases, dehydrogenases, transaminases, kinases, cellulases, mannanases, peptidases, decarboxylases, isomerases, mutases, synthetases, synthases, and oxido-reductase enzymes, including oxidoreductase enzymes that catalyze the formation of bleach.

[0096] It is contemplated that the enzymes used herein can be obtained from any suitable source or combination of sources, such as bacterial, fungal, plant, or animal sources.In one type of embodiment, the mixture of two or more enzymes is obtained from at least two different types of sources.For example, the mixture of protease and lipase can be obtained from bacterial (protease) and fungal (lipase) sources.

[0097] Optionally, enzymes used herein, including but not limited to any of the classes or members of enzymes described herein, are enzymes that function at alkaline pH conditions, e.g., at a pH ranging from about 8 to about 11, such as those used in cleaning applications, including, for example, laundry detergents and / or dish detergents. Optionally, enzymes used herein, including but not limited to any of the classes or members of enzymes described herein, are enzymes that function at temperatures ranging from about 5°C to about 45°C.

[0098] Non-fragrance oils may include flavoring agents and colorants.

[0099] In one type of embodiment, the active agent comprises a flavor or combination of flavors. Suitable flavors include, but are not limited to, spearmint oil, cinnamon oil, oil of wintergreen (methyl salicylate), peppermint oil, and synthetic and natural fruit flavors, including citrus oils.

[0100] In some embodiments, the active agent may be a colorant or a combination of colorants. Examples of suitable colorants include food coloring, caramel, paprika, cinnamon, and saffron. Other examples of suitable colorants can be found in U.S. Patent No. 5,002,789, the entire contents of which are incorporated herein by reference.

[0101] Another type of embodiment includes one or more odor absorbers as active agents. Odor absorbers suitable for use as active agents according to the present disclosure include, but are not limited to, zeolites and complex zinc salts of ricinoleic acid. The odor absorber active agent may also include fixatives known in the art as primarily odor-neutralizing fragrances, including, but not limited to, extracts of labdanum, styrax, and derivatives of abietic acid.

[0102] Another type of embodiment includes one or more fragrances as the active agent. As used herein, the term fragrance refers to any applicable material that is sufficiently volatile to produce a scent. Embodiments that include a fragrance as the active agent can include fragrances that are pleasant to humans or unpleasant to humans, animals, and / or insects. Suitable fragrances include, but are not limited to, fruity scents, including but not limited to lemon, apple, cherry, grape, pear, pineapple, orange, strawberry, and raspberry; musk; and floral scents, including but not limited to lavender, rose, iris, and carnation. Optionally, the fragrance is not a flavoring agent. Other fragrances include herbal scents, including but not limited to rosemary, thyme, and sage; and woodland scents derived from pine, spruce, and other forest scents. Fragrances may be derived from a variety of oils, including but not limited to essential oils, or from plant materials, including but not limited to peppermint, spearmint, and the like. Suitable fragrance oils can be found in U.S. Patent No. 6,458,754, which is incorporated herein by reference in its entirety.Suitable fragrance oils include, but are not limited to, 4-(2,2,6-trimethylcyclohex-1-enyl)-2-en-4-one, acetaldehyde phenylethyl propyl acetal, 2,6,10-trimethyl-9-undecenal, hexanoic acid 2-propenyl ester, 1-octen-3-ol, trans-anethole, isobutyl (z)-2-methyl-2-butenoate, anisaldehyde diethyl acetal, 3-methyl-5-propyl-cyclohezen-1-one, 2,4-dimethyl-3-cyclohezen-1-one, 2,6,10-trimethyl-9-undecenal, 2-propenyl ester of hexanoic acid ... 2,6,10-trimethyl-9-undecenal, 2-propenyl ester of hexanoic acid, 1-octen-3-ol, trans-anethole, isobutyl (z)-2-methyl-2-butenoate, 2,4-dimethyl-3-cyclohezen-1-one, 2,6,10-trimethyl-9-undecenal, 2-propenyl ester of hexanoic acid, 1-octen-3-ol, trans-anethole, isobutyl (z)-2-methyl-2-butenoate, 2,6,10-trimethyl-9-undecenal, 2-propenyl ester These include hexene-1-carbaldehyde, trans-4-decenal, decanal, 2-pentylcyclopentanone, ethyl anthranilate, eugenol, 3-(3-isopropylphenyl)butanoal, methyl 2-octynoate, isoeugenol, cis-3-hexenylmethyl carbonate, linalool, methyl 2-nonynonate, benzoic acid 2-hydroxymethyl ester, nonal, octanal, 2-nonenenitrile, 4-nonanolide, 9-decen-1-ol, and 10-undecen-1-al. Applicable fragrances can also be found in U.S. Patent Nos. 4,534,981, 5,112,688, 5,145,842, 6,844,302, and Perfumes Cosmetics and Soaps, Second Edition, edited by W.A. Poucher, 1959, all of which are incorporated herein by reference in their entirety. These fragrances include acacia, cassia, chypre, cyclamen, fern, gardenia, hawthorn, heliotrope, honeysuckle, hyacinth, jasmine, lilac, lily, magnolia, mimosa, daffodil, fresh-cut hay, orange blossom, orchid, mignonette, sweet pea, clover, tuberose, vanilla, violet, wallflower, and the like.

[0103] The fragrance may include a fragrance. The fragrance may include a natural fragrance, an encapsulated fragrance, or a mixture thereof. Preferably, the fragrance includes a natural fragrance. A portion of the fragrance may be encapsulated in a core-shell encapsulation. In another type of embodiment, the fragrance is not encapsulated in a core-shell encapsulation.

[0104] As used herein, the term "perfume" encompasses perfume raw materials (PRMs) and perfume matches. As used herein, the term "perfume raw materials" refers to compounds having a molecular weight of at least about 100 g / mol and useful for imparting an odor, fragrance, essence, or scent, alone or in conjunction with other perfume raw materials. As used herein, the terms "perfume ingredient" and "perfume raw material" are interchangeable. As used herein, the term "match" refers to a mixture of two or more PRMs.

[0105] Typical PRMs include, among others, alcohols, ketones, aldehydes, esters, ethers, nitrites, and alkenes, such as terpenes. Lists of common PRMs can be found in various reference sources, such as "Perfume and Flavor Chemicals," Vols. I and II; Steffen Arctander Allured Pub. Co. (1994) and "Perfumes: Art, Science and Technology," Miller, P.M. and Lamparsky, D., Blackie Academic and Professional (1994). PRMs are characterized by their boiling point (BP), measured at standard pressure (760 mmHg), and their octanol / water partition coefficient (P). Based on these characteristics, PRMSs can be classified as Quadrant I, II, III, or IV fragrances.

[0106] Suitable insect repellent fragrances include one or more of dichlorovos, pyrethrins, allethrins, naled, and / or fenthion pesticides, as disclosed in U.S. Patent No. 4,664,064, the entire contents of which are incorporated herein by reference.Suitable insect repellents include citronellal (3,7-dimethyl-6-octanal), N,N-diethyl-3-methylbenzamide (DEET), vanillin, and volatile oils extracted from turmeric (Curcuma longa), kaffir lime (Citrus hystrix), citronella (Cymbopogon winterianus), and Thai basil (Ocimum americanum).Furthermore, suitable insect repellents can be a mixture of insect repellents.

[0107] In one type of embodiment, the active agent according to the present disclosure can include one or more pesticides. Suitable pesticides can include, but are not limited to, insecticides, herbicides, miticides, fungicides, and larvicides.

[0108] Another type of embodiment includes one or more fertilizers as an active agent. As used herein, the term "fertilizer" refers to any applicable material that releases one or more of nitrogen, phosphorus, potassium, calcium, magnesium, sulfur, boron, chlorine, copper, iron, manganese, molybdenum, or zinc. Suitable fertilizers include, but are not limited to, zeolites. For example, clinoptilolite is a zeolite that releases potassium and can also release nitrogen if ammonium is added in advance.

[0109] One type of embodiment includes an acid catalyst as an activator. As used herein, the term acid catalyst refers to any chemical species that serves as a proton source, thereby facilitating a chemical reaction. In one type of embodiment, the acid catalyst is a non-oxidizing organic acid. A suitable organic acid is para-toluenesulfonic acid. In some embodiments, the acid catalyst activator facilitates reactions including, but not limited to, acetalization, esterification, or transesterification. Additional acid-catalyzed reactions are well known in the art.

[0110] In one type of embodiment, the activator will comprise a metal catalyst. These catalysts mediate reactions including, but not limited to, oxidation or reduction, hydrogenation, carbonylation, C-H bond activation, and bleaching. Metals suitable for use as metal catalysts include, but are not limited to, VIIIA and IB transition metals, such as iron, cobalt, nickel, copper, platinum, rhodium, ruthenium, silver, osmium, gold, and iridium. The metal mediating the catalyst can be in any suitable oxidation state.

[0111] In an alternative embodiment, the active agent may optionally be an ion scavenger. Suitable ion scavengers include, but are not limited to, zeolites. Optionally, zeolites can be added to water-soluble packets containing laundry or dishwashing detergent as a water softener.

[0112] Inorganic and organic bleaching agents are suitable cleaning actives for use herein. Inorganic bleaching agents include perhydrate salts, including but not limited to perborates, percarbonates, perphosphates, persulfates, and persilicates. Inorganic perhydrate salts are typically alkali metal salts. Alkali metal percarbonates, particularly sodium percarbonate, are suitable perhydrates for use herein. Organic bleaching agents can include diacyl and tetraacyl peroxides, particularly organic peracids, including but not limited to diperoxydodecanedioc acid, diperoxytetradecanedioc acid, and diperoxyhexadecanedioic acid. Dibenzoyl peroxide is a suitable organic peroxyacid according to the present disclosure. Other organic bleaching agents include peroxyacids, specific examples of which are alkylperoxyacids and arylperoxyacids.

[0113] In one type of embodiment, the activator can include a bleach activator, including an organic peracid precursor, that enhances bleaching during cleaning at temperatures of 60° C. and below. Bleach activators suitable for use herein include compounds that, under perhydrolysis conditions, provide aliphatic peroxycarboxylic acids and / or optionally substituted perbenzoic acids having 1 to 10 carbon atoms or 2 to 4 carbon atoms. Suitable materials retain O-acyl and / or N-acyl groups of the specified number of carbon atoms, and / or optionally substituted benzoyl groups. Suitable materials also include, but are not limited to, polyacylated alkylenediamines, particularly tetraacetylethylenediamine (TAED), acylated triazine derivatives, particularly 1,5-diacetyl-2,4-dioxohexahydro-1,3,5-triazine (DADHT), acylated glycolurils, particularly tetraacetylglycoluril (TAGU), N-acylimides, particularly N-nonanoylsuccinimide (NOSI), acylated phenolsulfonates, particularly n-nonanoyl- or isononanoyloxybenzenesulfonate (n- or iso-NOBS), carboxylic acid anhydrides, particularly phthalic anhydride, acylated polyhydric alcohols, particularly triacetin, ethylene glycol diacetate, and 2,5-diacetoxy-2,5-dihydrofuran, and triethylacetyl citrate (TEAC).

[0114] In embodiments including a fabric softener as an active agent, various in-wash fabric softeners, particularly the fine-grained smectic clays of U.S. Patent No. 4,062,647, which is incorporated herein by reference in its entirety, as well as other softening clays known in the art, can be used to obtain the benefits of fabric softening while simultaneously cleaning the fabric, if desired. Clay softeners can be used in combination with amines and cationic softeners, such as those disclosed in U.S. Patent Nos. 4,375,416 and 4,291,071, which are incorporated herein by reference in their entireties.

[0115] In embodiments, the active agent may include a disinfectant. Disinfectants suitable for use herein may include, but are not limited to, hydrogen peroxide, inorganic peroxides and their precursors, sodium metabisulfite, quaternary ammonium cation-based compounds, chlorine, activated carbon, and hypochlorite.

[0116] In embodiments, the active agent may comprise a surfactant. Surfactants suitable for use herein include, but are not limited to, propylene glycol, diethylene glycol, monoethanolamine, polyoxyethylated polyoxypropylene glycol, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylenic glycols and alkanolamides (nonionic), polyoxyethylated amines, quaternary ammonium salts and quaternized polyoxyethylated amines (cationic), alkali metal salts of higher fatty acids containing about 8 to 24 carbon atoms, alkyl sulfates, alkylpoly ... alkylsilylsilylsilylsilylsilylsilylsilylsilylsilylsilylsilylsilyl Included may be sylate sulfates, and alkyl benzene sulfonates (anionic), amine oxides, N-alkyl betaines and sulfobetaines (zwitterionic), dioctyl sodium sulfosuccinate, lactylated fatty acid esters of glycerin and propylene glycol, lactic acid esters of fatty acids, sodium alkyl sulfates, polysorbate 20, polysorbate 60, polysorbate 65, polysorbate 80, lecithin, acetylated fatty acid esters of glycerin and propylene glycol, and acetylated esters of fatty acids, and combinations thereof.

[0117] The active agent may be solid or liquid. A solid active agent may have an average particle size (e.g., Dv50) of at least about 0.01 μm, or, for example, a size ranging from about 0.01 μm to about 2 mm. A liquid active agent may be applied directly to the nonwoven web, mixed with a carrier powder, or microencapsulated. In embodiments that include a carrier powder, the average particle size of the carrier powder may be at least about 0.01 μm, or, for example, in a range from about 0.01 μm to about 2 mm.

[0118] In one type of embodiment, the active agent is encapsulated, allowing for controlled release of the active agent.Suitable microcapsules can include or be made from one or more of melamine formaldehyde, polyurethane, urea formaldehyde, chitosan, polymethyl methacrylate, polystyrene, polysulfone, polytetrahydrofuran, gelatin, gum arabic, starch, polyvinylpyrrolidone, carboxymethylcellulose, hydroxyethylcellulose, methylcellulose, arabinogalactan, polyvinyl alcohol, polyacrylic acid, ethylcellulose, polyethylene, polymethacrylate, polyamide, poly(ethylene vinyl acetate), cellulose nitrate, silicone, poly(lactide-co-glycolide), paraffin, carnauba, spermaceti, beeswax, stearic acid, stearyl alcohol, glyceryl stearate, shellac, cellulose acetate phthalate, zein, and combinations thereof. In one type of embodiment, the microcapsules are characterized by an average particle size (e.g., Dv50) of at least about 0.1 micron, or, for example, in the range of about 0.1 micron to about 200 microns. In alternative embodiments, the microcapsules may form agglomerates of individual particles, e.g., the individual particles have an average particle size of at least about 0.1 micron, or in the range of about 0.1 micron to about 200 microns.

[0119] In embodiments in which the activator is applied to one or more surfaces of a nonwoven web or to a packet, the activator can be applied by any suitable means. In one embodiment, one or more stationary powder spray guns are used to direct a stream of activator powder toward the web or packet from one or more directions, while the web or packet is transported through a coating zone using a belt conveyor. In an alternative embodiment, pouches are conveyed through a suspension of activator in air. In yet another alternative embodiment, packets are tumble-mixed with activator powder in a trough-like device. In another embodiment, which can be combined with any other embodiment, electrostatic forces are used to increase the attraction between the activator powder and the packet. This type of process is typically based on negatively charging the powder particles and directing these charged particles toward a grounded packet. In another alternative embodiment, the activator powder is applied to the packet by a secondary transfer tool, including, but not limited to, a rotating brush that contacts the powder, or by a powdered glove that can transfer powder from a container to the packet. In yet another embodiment, the active agent powder is applied by dissolving or suspending the powder in a non-aqueous solvent or carrier, which is then atomized and sprayed onto the packets. In one type of embodiment, the solvent or carrier subsequently evaporates, leaving the active agent powder behind. In one type of embodiment, the active agent powder is applied to the packets in precise doses. This type of embodiment utilizes a closed-system dry-lubricated application machine, such as PekuTECH's Powder Applicator PM 700D. In this process, the active agent powder is fed into the application machine's feed trough, batchwise or continuously as needed. The packets are transferred from the output belt of a standard rotary drum pouch machine onto the conveyor belt of the powder application machine, where a controlled dose of the active agent is applied to the packets. The packets are then transported to an appropriate secondary packaging process.

[0120] The liquid active agent can be applied to the nonwoven web or packet by, for example, spin casting, spraying a solution such as an aerosolized solution, roll coating, flow coating, curtain coating, extrusion, knife coating, and combinations thereof.

[0121] Fiber and Nonwoven Web Formation

[0122] The plurality of fibers can be prepared by any process known in the art, such as wet-cooled gel spinning, meltblowing, spunbonding, electrospinning, rotary spinning, continuous filament producing operations, tow fiber producing operations, and combinations thereof.

[0123] In an embodiment, the plurality of fibers comprises fibers, such as water-soluble fibers, prepared by a wet cryogel spinning process, the wet cryogel spinning process comprising: (a) dissolving a fiber-forming material(s) (e.g., a water-soluble polymer(s)) in a solvent to form a polymer mixture, optionally including an adjuvant; (b) extruding the polymer mixture through a spinning nozzle and into a coagulation bath to form an extruded polymer mixture; (c) passing the extruded polymer mixture through a solvent exchange bath; (d) optionally wet drawing the extruded polymer mixture; and (e) finishing the extruded polymer mixture to provide fibers. Includes:

[0124] The solvent in which the water-soluble polymer is dissolved can be any solvent in which the polymer is soluble. In embodiments in which the polymer is water-soluble, the solvent in which the water-soluble polymer is dissolved comprises a polar aprotic solvent. In embodiments, the solvent in which the water-soluble polymer is dissolved comprises dimethyl sulfoxide (DMSO).

[0125] Typically, the coagulation bath contains a cooled solvent to gel the extruded polymer mixture. The coagulation bath can generally be at any temperature that facilitates solidification of the extruded polymer mixture. Suitable coagulation bath temperatures can be about 15°C or lower, about 10°C or lower, about 5°C or lower, or 0°C or lower, for example, from about 15°C to about -20°C, from about 12°C to about -15°C, from about 10°C to about -10°C, from about 10°C to about 0°C, from about 6°C to about 0°C, from about 6°C to about 2°C, from about 5°C to about 0°C, or from about 5°C to about 2°C. In embodiments, the coagulation bath can have a temperature of about 5°C. The coagulation bath can contain a mixture of a solvent in which the fiber-forming material is soluble and a solvent in which the fiber-forming material is not soluble. The solvent in which the fiber-forming material is not soluble is generally the primary solvent, and the solvent in which the fiber-forming material is not soluble constitutes more than 50% of the mixture. The solvent in which the fiber-forming material is not soluble and the solvent in which the fiber-forming material is soluble can be provided in a volume ratio of about 95:5 to about 55:45, e.g., about 95:5, about 90:10, about 85:15, about 80:20, about 75:25, about 70:30, about 65:45, about 60:40, or about 55:45. In embodiments where the polymer is water-soluble, the solvent in which the water-soluble polymer is not soluble comprises methanol, acetone, mineral spirits, mineral oil, or a combination thereof. In embodiments, the solvent in which the water-soluble polymer is not soluble comprises methanol, acetone, or a combination thereof. In embodiments, the solvent in which the water-soluble polymer is not soluble comprises methanol. In embodiments, the solvent in which the water-soluble polymer is not soluble comprises acetone. In embodiments, the coagulation bath comprises a mixture of methanol and DMSO in a volume ratio of about 80:20.

[0126] After passing through the coagulation bath, the extruded polymer mixture gel can be passed through one or more solvent replacement baths. The solvent replacement baths are provided to replace the solvent in which the fiber-forming material is soluble with a solvent in which the fiber-forming material is not soluble, further coagulating the extruded polymer mixture, and to replace the solvent in which the fiber-forming material is soluble with a solvent that evaporates more easily, thereby reducing drying time. The solvent replacement baths can include a series of solvent replacement baths with a gradient of solvents in which the fiber-forming material is soluble, including a solvent in which the fiber-forming material is not soluble; a series of solvent replacement baths containing only solvents in which the fiber-forming material is not soluble; or a single solvent replacement bath containing only solvents in which the fiber-forming material is not soluble. In embodiments, at least one solvent replacement bath can consist essentially of a solvent in which the fiber-forming material is not soluble. A representative process for preparing water-soluble fibers of the present disclosure is shown in Figure 2.

[0127] The finished fibers may be referred to as stabilized fibers, short-cut fibers, or pulp. In embodiments, finishing includes drying the extruded polymer mixture. In embodiments, finishing includes cutting or crimping the extruded polymer mixture to form individual fibers. Wet drawing of the extruded polymer mixture provides the extruded polymer mixture with a substantially uniform diameter from which fibers are cut. Drawing differs from extrusion, as is known in the art. In particular, extrusion refers to the act of forcing a resin mixture through a spinneret head to create fibers, whereas drawing refers to mechanically pulling the fibers in the machine direction to promote polymer chain orientation and crystallinity, thereby increasing the strength and tenacity of the fibers. As used herein, fiber diameters are "substantially uniform" if the variance in diameter from fiber to fiber is less than 10%, e.g., 8% or less, 5% or less, 2% or less, or 1% or less. Wet drawing of the extruded polymer mixture may be suitably carried out before the extruded polymer mixture passes through the solvent exchange bath, after the extruded polymer mixture passes through the solvent exchange bath, or between the extruded polymer mixture passing through the first and second solvent exchange baths.

[0128] In embodiments in which fibers are prepared from a wet cryogel spinning process, the fiber-forming material can generally be any water-soluble polymer or blend thereof, such as two or more different polymers as generally described herein. In refinements of the foregoing embodiments, the polymer(s) can have any degree of polymerization (DP), for example, in the range of 10 to 10,000,000, such as at least 10, at least 20, at least 50, at least 100, at least 200, at least 300, at least 400, at least 500, at least 750, or at least 1000, and up to 10,000,000, up to 5,000,000, up to 2,500,000, up to 1,000,000, up to 900,000, up to 750,000, up to 500,000, up to 250,000, up to 100,000, up to 90,000, It can have a range of up to 75,000, up to 50,000, up to 25,000, up to 12,000, up to 10,000, up to 5,000, or up to 2,500, for example, 1000 to about 50,000, 1000 to about 25,000, 1000 to about 12,000, 1000 to about 5,000, 1000 to about 2,500, about 50 to about 12,000, about 50 to about 10,000, about 50 to about 5,000, about 50 to about 2,500, about 50 to about 1000, about 50 to about 900, about 100 to about 800, about 150 to about 700, about 200 to about 600, or about 250 to about 500. In embodiments, the DP is at least 1,000. As is known in the art, nonwoven webs can be prepared by spun and bonding staple fibers. Alternatively, nonwoven webs can be prepared from continuous fibers. The adjuvants described above can be added to the fibers themselves or to the nonwoven web during the spun and / or bonding process.

[0129] Methods for preparing staple and continuous fibers are well known in the art. After the staple or continuous fibers are spun, the nonwoven web is bonded. Methods for bonding staple fibers are well known in the art and can include through-air bonding (heat), calendar bonding (heat with pressure), and chemical bonding. The nonwoven web of the present disclosure can be thermally or chemically bonded. Nonwoven webs can generally be porous, with various pore sizes, morphologies, and web nonuniformities, as shown in FIG. 1. The physical properties of the fibers and the type of bonding can affect the porosity of the resulting nonwoven web. Calendar bonding is achieved by applying heat and pressure and typically maintains the pore size, shape, and alignment created by the spun process. The conditions for calendar bonding can be easily determined by one skilled in the art. Generally, if the applied heat and / or pressure is too low, the fibers will not bond sufficiently to form a self-supporting web, and if the heat and / or pressure is too high, the fibers will begin to melt together. The chemical nature of the fiber governs the upper and lower limits of heat and / or pressure for calendar bonding. Without being bound by theory, it is believed that polyvinyl alcohol-based fibers decompose at temperatures above 235°C. Embossing methods for calendar bonding of fibers are known. Embossing can be single-sided or double-sided. Typically, embossing of water-soluble fibers involves a single embossing roll consisting of an ordered circular array and a single-sided embossing using a steel roll with a flat surface. As embossing increases (e.g., as surface features are imparted to the web), the surface area of ​​the web increases. Without being bound by theory, it is expected that as the surface area of ​​the web increases, the solubility of the web increases. Therefore, the solubility characteristics of a nonwoven web can be advantageously tailored by varying the surface area through embossing. As shown in Figures 1A, 1B, 1C, 1D, and 1E, embossing during calendar bonding can impart observable divots to the nonwoven web.

[0130] In contrast to calendar bonding, chemical bonding typically uses a binder solution of waste polymers left over after fiber preparation to coat the surface fibers under pressure, resulting in pores that are smaller and less ordered than the surfaced pores. Generally, the solvent can be any solvent that solubilizes the binder. Typically, the solvent for the chemical bonding solution is water. Without being bound by theory, it is believed that if the polymer solution used in chemical bonding is sufficiently concentrated and / or sufficient pressure is applied, a nonporous, water-dispersible nonwoven web can be formed. The solvent used in chemical bonding induces partial solubilization of existing fibers in the web, fusing and bonding the fibers together. The polyvinyl alcohol binder provided in the solution aids the fusing process, providing a more mechanically robust web. The temperature of the polymer solution is not particularly limited and can be provided at room temperature (approximately 23°C).

[0131] In some embodiments, a second fibrous layer can be used to bond the nonwoven web. Without being bound by theory, it is believed that fibers prepared by a meltblowing process, such as water-soluble fibers, can be used to bond the nonwoven web using an in-line process. In particular, the nonwoven web can be passed through a meltblowing process station so that the meltblown fibers are deposited after melt extrusion. As the meltblown fibers cool and solidify, they bond to each other and to the nonwoven web on which they are deposited. The meltblown fibers can be micro- to nano-scale in length and can be provided on the nonwoven web so that the meltblown fibers constitute about 15%, about 12%, about 10%, about 8%, about 6%, or about 5% by weight of the final nonwoven web, based on the total weight of the fibers in the final nonwoven web. Without being bound by theory, it is believed that including about 5% to about 15% meltblown fibers can increase the mechanical integrity of the nonwoven web without substantially changing the solubility characteristics of the nonwoven web. Generally, when polyvinyl alcohol fiber-forming materials are used to prepare meltblown fibers, the polyvinyl alcohol polymer will be a homopolymer because the meltblowing process requires a polymer with a low viscosity and high melt flow index.

[0132] Pore ​​size can be determined using high magnification and high order surface analysis techniques, including but not limited to Brunauer-Emmett-Teller theory (BET), small angle X-ray scattering (SAXS), and molecular adsorption.

[0133] The nonwoven web of the present disclosure can generally have any thickness. Suitable thicknesses include, but are not limited to, about 5 to about 10,000 μm (1 cm), about 5 to about 5,000 μm, about 5 to about 1,000 μm, about 5 to about 500 μm, about 200 to about 500 μm, about 5 to about 200 μm, about 20 to about 150 μm, about 20 to about 100 μm, about 40 to about 90 μm, about 50 to 80 μm, or about 60 to 65 μm, such as 50 μm, 65 μm, 76 μm, 88 μm, or 152 μm. The nonwoven web of the present disclosure can be characterized as having high loft or low loft. Loft generally refers to the ratio of thickness to mass per unit area (i.e., basis weight). High loft nonwoven webs can be characterized by a high ratio of thickness to mass per unit area. As used herein, "high loft" refers to nonwoven webs of the present disclosure having a basis weight as defined herein and a thickness greater than 200 μm. The thickness of a nonwoven web can be determined in accordance with ASTM D5729-97, ASTM D5736, and ISO 9073-2:1995, and can include, for example, subjecting the nonwoven web to a load of 2N and measuring the thickness. High loft materials can be used according to methods known in the art, for example, by cross-wrapping, in which a cross-wrapper is used to fold an unbonded web onto itself to build loft and basis weight, or by through-air bonding. Without being bound by theory, in contrast to water-soluble films, the solubility of which may depend on the thickness of the film; the solubility of nonwoven webs is not believed to depend on the thickness of the web. In this regard, because individual fibers offer a higher surface area than water-soluble films, it is believed that the parameter that limits water access to the fibers and thereby fiber dissolution, regardless of the thickness of the film and nonwoven web, is basis weight (i.e., fiber density in the nonwoven).

[0134] The solubility of the nonwoven web of the present disclosure is generally a function of the type of fiber(s) used to prepare the web and the basis weight of the water-dispersible web. Without being bound by theory, it is believed that for nonwoven webs containing a single fiber type, including a single fiber-forming material, the solubility profile of the nonwoven web follows the same solubility profile as the fiber(s) used to prepare the nonwoven web, and the solubility profile of the fiber generally follows the same solubility profile as the fiber-forming polymer(s) from which the fibers are formed. For example, for nonwoven webs containing PVOH fibers, the degree of hydrolysis of the PVOH polymer can be selected to affect the water solubility of the nonwoven web. Generally, at a given temperature, as the degree of hydrolysis of the PVOH polymer increases from partial hydrolysis (88% DH) to full hydrolysis (≧98% DH), the water solubility of the polymer generally decreases. Thus, in one option, the nonwoven web can be cold water soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., not copolymerized with anionic monomers), cold water-soluble webs that are soluble in water at temperatures below 10°C can include fibers of PVOH having a degree of hydrolysis ranging from about 75% to about 90%, or from about 80% to about 90%, or from about 85% to about 90%. Alternatively, the nonwoven web can be hot water-soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., not copolymerized with anionic monomers), hot water-soluble webs that are soluble in water at temperatures of at least about 60°C can include fibers of PVOH having a degree of hydrolysis of at least about 98%.

[0135] Modification of PVOH generally increases the solubility of the PVOH polymer. Therefore, at a given temperature, it is expected that the solubility of a water-dispersible nonwoven web made from a PVOH copolymer will be higher than that of a nonwoven web made from a PVOH homopolymer with the same degree of hydrolysis as the PVOH copolymer. Based on these trends, water-dispersible nonwoven webs with specific solubility characteristics can be designed.

[0136] Surprisingly, as demonstrated in Example 8 herein, for nonwoven webs containing a blend of fiber types, each fiber type having a single fiber-forming material, the solubility of the nonwoven web did not follow the rule of mixtures, as might be expected for a blend of fiber types. Rather, for nonwoven webs containing a blend of two fiber types, when the two fiber types were provided in a ratio other than 1:1, the solubility of the nonwoven web tended toward the solubility of the less soluble fiber (i.e., requiring higher temperatures to completely dissolve and dissolving more slowly at temperatures below the complete dissolution temperature). For nonwoven webs containing a 1:1 blend of fibers, the solubility of the nonwoven web was generally lower than that of nonwoven webs containing blends other than the 1:1 blend (i.e., at a given temperature, the nonwoven web containing the 1:1 blend took longer to break, disintegrate, and dissolve than nonwoven webs containing fiber types in ratios of, for example, 3:1 and 1:3). This trend was particularly pronounced at temperatures below the complete dissolution temperature of the less soluble fiber.

[0137] The inclusion of water-insoluble fibers in a water-dispersible nonwoven web can also be used to design the nonwoven web with specific solubility and / or delayed-release characteristics (e.g., when the nonwoven web is included in a water-dispersible pouch). Without being bound by theory, it is believed that as the weight percentage of water-insoluble fibers included in the nonwoven web increases (relative to the total weight of the nonwoven web), the solubility of the nonwoven web generally decreases and the delayed-release characteristics of a pouch including the nonwoven web generally increase. After contact with water at or above the solubility temperature of the water-soluble fiber, a nonwoven web including water-soluble and water-insoluble fibers will begin to thin as the water-soluble fiber dissolves, thereby disrupting the web structure and / or increasing the pore size of the nonwoven web's pores. Generally, the greater the disruption of the web structure or the larger the pore size, the faster water can contact the contents of the pouch and the faster the contents of the pouch will be released. Similarly, delayed release of the contents of a pouch containing a water-dispersible nonwoven web of the present disclosure can be achieved by using a blend of water-soluble fibers having different solubility characteristics and / or different solubility temperatures. Generally, for nonwoven webs containing water-soluble fibers containing polyvinyl alcohol fiber-forming materials, at water temperatures 50% or higher of the complete dissolution temperature of the water-soluble fiber (e.g., 40°C for fibers with a complete dissolution temperature of 70°C), the fibers will undergo swelling and softening of the polymer network, but the overall structure will remain intact. In embodiments where the water-dispersible nonwoven web contains water-soluble and water-insoluble fibers, the ratio of soluble fiber to insoluble fiber is not particularly limited. The water-soluble fiber can comprise about 1% to about 99%, about 20% to about 80%, about 40% to about 90%, about 50% to about 90%, or about 60% to about 90% by weight of the total weight of the fiber, and the water-insoluble fiber can comprise about 1% to about 99%, about 20% to about 80%, about 10% to about 60%, about 10% to about 50%, or about 10% to about 40% by weight of the total weight of the fiber.

[0138] Furthermore, as shown in Example 7, there is more material to dissolve, so the dissolution rate of the web decreases as the basis weight of the web increases, assuming the fiber composition and bonding parameters remain constant. For example, at a given temperature, a web containing PVOH polymer(s) and e.g., 40 g / m 2 A water-soluble web prepared from fibers having a basis weight of, for example, 30 g / m 2 The water-dispersible nonwoven web is expected to dissolve more slowly than an otherwise identical water-soluble web having a basis weight of about 1 g / m. This relationship was particularly pronounced when the temperature of the water for dissolution was lower than the complete dissolution temperature of the fibers comprising the nonwoven web. Thus, basis weight can also be used to modify the solubility characteristics of the water-dispersible nonwoven web. Water-dispersible nonwoven webs generally have a basis weight of about 1 g / m. 2 to approximately 700 g / m 2 , about 1g / m 2 to approximately 600 g / m 2 , about 1g / m 2 to approximately 500 g / m 2 , about 1g / m 2 to approximately 400 g / m 2 , about 1g / m 2 to approximately 300 g / m 2 , about 1g / m 2 to approximately 200 g / m 2 , about 1g / m 2 to about 100 g / m 2 , about 30g / m 2 to about 100 g / m 2 , about 20g / m 2 to about 100 g / m 2 , about 20g / m 2 to approximately 80 g / m 2 , about 25g / m 2 to about 70 g / m 2 , or approximately 30 g / m 2 to about 70 g / m 2 The sheet may have any basis weight in the range of 1000 to 15000 gram.

[0139] Additionally, the calender settings generally have a secondary effect on the solubility profile of the nonwoven webs of the present disclosure. As shown in Example 7, for nonwoven webs with identical fiber chemistry and similar basis weights, at a given calender pressure, the solubility time of the nonwoven web generally increases with increasing calender temperature. This relationship is particularly pronounced when the temperature of the water at dissolution is lower than the complete dissolution temperature of the fibers comprising the nonwoven web.

[0140] Without being bound by theory, it is believed that the solubility (e.g., in terms of time to dissolution by MSTM-205) of a water-soluble nonwoven web is expected to exceed that of a water-soluble film of the same size (L x W) and / or mass prepared from the same PVOH polymer. This is due to the higher surface area found in the nonwoven compared to the film, leading to faster solubilization. As shown in the examples below, a nonwoven web prepared from a PVOH homopolymer with an 88% degree of hydrolysis dissolves in 14 seconds, while a water-soluble film of similar size prepared from the same PVOH homopolymer with an 88% degree of hydrolysis dissolves in approximately 100 seconds.

[0141] The water-soluble and water-insoluble fibers used to prepare the water-dispersible nonwoven webs of the present disclosure can generally have any tenacity. Fiber tenacity correlates with fiber coarseness. As fiber tenacity decreases, fiber coarseness increases. The fibers used to prepare the water-dispersible nonwoven webs of the present disclosure may have a tenacity of from about 1 to about 100 cN / dtex, or from about 1 to about 75 cN / dtex, or from about 1 to about 50 cN / dtex, or from about 1 to about 45 cN / dtex, or from about 1 to about 40 cN / dtex, or from about 1 to about 35 cN / dtex, or from about 1 to about 30 cN / dtex, or from about 1 to about 25 cN / dtex, or from about 1 to about 20 cN / dtex, or from about 1 to about 15 cN / dtex, or from about 1 to about 10 cN / dtex, or from about 3 to about 8 cN / dtex, or from about 4 to about 8 cN / dtex. tex, or from about 6 to about 8 cN / dtex, or from about 4 to about 7 cN / dtex, or from about 10 to about 20, or from about 10 to about 18, or from about 10 to about 16, or about 1 cN / dtex, about 2 cN / dtex, about 3 cN / dtex, about 4 cN / dtex, about 5 cN / dtex, about 6 cN / dtex, about 7 cN / dtex, about 8 cN / dtex, about 9 cN / dtex, about 10 cN / dtex, about 11 cN / dtex, about 12 cN / dtex, about 13 cN / dtex, about 14 cN / dtex, or about 15 cN / dtex. In embodiments including a first fiber having a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber can have a tenacity ranging from about 3 cN / dtex to about 10 cN / dtex, optionally from about 7 cN / dtex to about 10 cN / dtex, optionally from about 4 cN / dtex to about 8 cN / dtex, or optionally from about 6 cN / dtex to about 8 cN / dtex.

[0142] In embodiments in which the water-soluble fibers are prepared from a wet-cooled gel spinning process, the resulting fibers can generally have any tenacity described herein. In refinements of the foregoing embodiments, the fibers can have a tenacity ranging from about 3 to about 15, from about 3 to about 13, from about 3 cN / dtex to about 10 cN / dtex, from about 5 cN / dtex to about 10 cN / dtex, or from about 6 cN / dtex to about 10 cN / dtex, from about 7 cN / dtex to about 10 cN / dtex, from about 4 cN / dtex to about 8 cN / dtex, or from about 6 cN / dtex to about 8 cN / dtex. In embodiments comprising a first fiber having a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, wherein the first fiber is prepared from a wet cooled gel spinning process, the first fiber can have a tenacity ranging from about 3 cN / dtex to about 10 cN / dtex, optionally from about 7 cN / dtex to about 10 cN / dtex, optionally from about 4 cN / dtex to about 8 cN / dtex, or optionally from about 6 cN / dtex to about 8 cN / dtex.

[0143] The tenacity of the nonwoven web can be the same as or different from the tenacity of the fibers used to prepare the web. Without being bound by theory, it is believed that the tenacity of the nonwoven web is related to the strength of the nonwoven web, with higher tenacity imparting higher strength to the nonwoven web. Generally, the tenacity of the nonwoven web can be modified by using fibers with different tenacities. The tenacity of the nonwoven web can also be affected by processing. Generally, the water-dispersible webs of the present disclosure can have a relatively high tenacity, i.e., the water-dispersible nonwoven web is a self-supporting web that can be used as a single material to prepare articles and / or pouches. In contrast, nonwoven webs prepared by meltblowing, electrospinning, and / or rotary spinning processes typically have a low tenacity and may not be self-supporting or can not be used as a single web to form articles or pouches.

[0144] Generally, the ratio of the dynamic coefficient of friction to the static coefficient of friction for nonwoven webs of the present disclosure will be lower than the ratio of the dynamic coefficient of friction to the static coefficient of friction for water-soluble films due to the increased surface roughness of the nonwoven web compared to water-soluble films, resulting in reduced surface contact with the nonwoven web. Advantageously, this surface roughness can provide improved consumer feel (i.e., a cloth-like feel instead of a rubbery feel), improved aesthetics (i.e., less shine than water-soluble films), and / or facilitate processability when preparing thermoformed and / or vertically formed, filled, sealed, and / or multi-chamber packets that require pulling the web along the surface of a processing tool / mold. Thus, the fibers should be sufficiently rough to provide surface roughness in the resulting nonwoven web without being so rough as to create drag.

[0145] The fibers used to prepare the nonwoven webs of the present disclosure can generally have any fineness. Fiber fineness correlates to how many fibers are present in a cross-section of a given yarn thickness. Fiber fineness is the ratio of fiber mass to length. The primary physical unit of fiber fineness is 1 tex, which is equal to 1000 meters of fiber weighing 1 gram. Typically, the unit dtex is used, representing 1 gram per 10,000 meters of fiber. Fiber fineness can be selected to provide a nonwoven web with appropriate stiffness / handle, torsional rigidity, light reflection and interaction, dye and / or other activator / additive absorption, ease of fiber spinning in the manufacturing process, and finished product uniformity. Generally, as fiber fineness increases, the resulting nonwovens demonstrate greater uniformity, improved tensile strength, extensibility, and luster. Furthermore, without being bound by theory, it is believed that finer fibers will result in slower dissolution times compared to larger fibers based on density. Furthermore, without being bound by theory, when a blend of fibers is used, the average fineness of the fibers can be determined using a weighted average of the individual fiber components. Fibers can be characterized as very fine (dtex≦1.22), fine (1.22≦dtex≦1.54), medium (1.54≦dtex≦1.93), slightly coarse (1.93≦dtex≦2.32), and coarse (dtex≧2.32). The nonwoven webs of the present disclosure can include fibers that are very fine, fine, medium, slightly coarse, or combinations thereof.

[0146] The shape of the fibers used to prepare the nonwoven webs of the present disclosure is not particularly limited and can have cross-sectional shapes including, but not limited to, round, oval (also called ribbon), triangular (also called delta), trilobal, and / or other multilobal shapes. It will be understood that the shape of the fibers need not be perfectly geometric, for example, fibers having a round cross-sectional shape need not have a perfect circle in cross-sectional area, and fibers having a triangular cross-sectional shape will generally have rounded corners.

[0147] It will be understood that the diameter of a fiber refers to the cross-sectional diameter of the fiber along its longest cross-sectional axis. When a fiber is described as having (or not having) a particular diameter, unless otherwise indicated, the specified diameter is intended to be the average diameter for the particular fiber type being referenced; i.e., a plurality of fibers prepared from a polyvinyl alcohol fiber-forming material has an arithmetic average fiber diameter across the plurality of fibers. In the case of shapes not typically considered to have a "diameter," such as triangular or multilobal shapes, the diameter refers to the diameter of a circle circumscribing the fiber shape.

[0148] The water-soluble and water-insoluble fibers used to prepare the water-dispersible nonwoven webs of the present disclosure typically have diameters in the range of about 10 microns to 300 microns, e.g., at least 10 microns, at least 25 microns, at least 50 microns, at least 100 microns, or at least 125 microns, and up to about 300 microns, up to about 275 microns, up to about 250 microns, up to about 225 microns, or up to about 200 microns. In embodiments, the water-soluble fibers used to prepare the nonwoven webs of the present disclosure can have diameters from greater than 100 microns to about 300 microns. In embodiments, the fibers of the present disclosure can have diameters in the range of about 10 to about 300 microns, about 25 to about 300 microns, about 50 to about 300 microns, greater than 100 microns to about 300 microns, or about 75 to about 100 microns. In embodiments, the diameter of the water-soluble fibers used to prepare the nonwoven webs of the present disclosure is substantially uniform. Without being bound by theory, it is believed that drawing the water-soluble polymer mixture during the wet cryogel spinning process can be used to control the diameter of the resulting fiber as well as the uniformity of the diameter size of the resulting fiber. In embodiments in which the first fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber has a diameter ranging from about 10 microns to about 300 microns, from about 50 microns to about 300 microns, or from greater than 100 microns to about 300 microns. In embodiments in which the first fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber has a substantially uniform diameter.

[0149] The water-soluble and water-insoluble fibers used to prepare the nonwoven webs of the present disclosure can generally be of any length. In embodiments, the water-soluble fibers can be in the range of about 30 mm to about 100 mm, about 10 mm to about 60 mm, or about 30 mm to about 60 mm, such as at least about 30 mm, at least about 35 mm, at least about 40 mm, at least about 45 mm, or at least about 50 mm, and up to about 100 mm, up to about 95 mm, up to about 90 mm, up to about 80 mm, up to about 70 mm, or up to about 60 mm. In embodiments, the length of the water-soluble fiber can be less than about 30 mm, or in a range of about 0.25 mm to less than about 30 mm, e.g., at least about 0.25 mm, at least about 0.5 mm, at least about 0.75 mm, at least about 1 mm, at least about 2.5 mm, at least about 5 mm, at least about 7.5 mm, or at least about 10 mm, and up to about 29 mm, up to about 28 mm, up to about 27 mm, up to about 26 mm, up to about 25 mm, up to about 20 mm, or up to about 15 mm. In embodiments where the first fiber comprises a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, the first fiber has a length in a range of about 30 mm to about 100 mm, or about 30 mm to about 60 mm, or less than about 30 mm, or in a range of about 0.25 mm to less than 30 mm. Water-soluble fibers can be prepared to any length by cutting and / or crimping the extruded water-soluble polymer mixture prepared using the wet-cooled gel spinning process. In contrast, processes such as spunbonding, meltblowing, electrospinning, and rotary spinning are continuous processes in which continuous filaments are prepared and directly provided in web form. Therefore, such processes do not provide the opportunity to cut the filaments to the desired fiber length.

[0150] The water-soluble and water-insoluble fibers used to prepare the nonwoven webs of the present disclosure can generally have any length-to-diameter (L / D) ratio. Advantageously, the tactility of the nonwoven webs of the present disclosure can be controlled using the fiber L / D ratio and the respective amounts of fibers with various L / D ratios in the nonwoven composition. Generally, as the fiber L / D decreases, stiffness and resistance to bending increase, resulting in a coarser feel. The fibers of the present disclosure generally impart a coarser feel to nonwoven webs containing the fibers when the fibers have a low L / D ratio ranging from about 0.5 to about 15, or from about 0.5 to about 25, or from about 1 to about 5. Such low L / D fibers can be provided in the nonwoven web in an amount ranging from about 0 to about 50 wt.%, for example, from about 0.5 wt.% to about 25 wt.%, or from about 1 wt.% to about 15 wt.%, based on the total weight of fibers in the nonwoven web. If the amount of low L / D fibers in a nonwoven web is unknown, the amount can be estimated by visual inspection of a photomicrograph of the nonwoven web. As shown in Figure 3, a population of fibers can be observed that has a visibly larger diameter and a shorter cut ratio relative to the total fiber population. Figure 5A is a photomicrograph of a nonwoven web having 0% low L / D fibers and a softness rating of 1, while Figure 5B is a photomicrograph of a nonwoven web having 25% low L / D fibers and a softness rating of 5. In embodiments in which the first fibers comprise a blend of fiber-forming materials including a first polyvinyl alcohol fiber-forming material, at least a portion of the first fibers can have an L / D ratio of about 0.5 to about 25, or about 0.5 to about 15, or about 1 to about 5.

[0151] The wet-cooled gel spinning process advantageously provides one or more benefits, such as providing fibers comprising a blend of water-soluble polymers, controlling the fiber diameter, providing relatively large diameter fibers, controlling the fiber length, controlling the fiber tenacity, providing high tenacity fibers, providing fibers from polymers with a high degree of polymerization, providing fibers that can be used to provide free-standing nonwoven webs, and / or providing fibers from a wider range of materials than can be used with traditional thermal extrusion techniques (e.g., meltblowing and spunbonding), for example, using polymers with higher molecular weights and / or higher melting points / melt viscosities than can be used with traditional thermal extrusion techniques. Continuous processes such as spunbonding, meltblowing, electrospinning, and rotary spinning generally do not allow blending of water-soluble polymers (e.g., due to the difficulty of matching the melt index of various polymers), do not allow for the formation of large diameter fibers (e.g., greater than 50 microns), do not allow for fiber length control, do not allow for high tenacity fibers, and do not allow for the use of polymers with a high degree of polymerization. A comparison of the various processes is provided in the following table: [Table 15-1] [Table 15-2]

[0152] In embodiments, nonwoven webs of the present disclosure may comprise a plurality of water-soluble fibers prepared by a wet chill gel spinning process in combination with continuous filaments prepared by a continuous process selected from the group consisting of meltblowing, spunbonding, electrospinning, rotary spinning, continuous filament-producing operations, tow fiber-producing operations, and combinations of one or more of the aforementioned processes. A water-dispersible nonwoven web comprising a plurality of water-soluble fibers prepared by a wet chill gel spinning process and filaments prepared by a continuous process can be formed using an in-line process. For example, a first nonwoven web of fibers can be prepared, and then the prepared web can be advanced to a second station where filaments are prepared by a continuous process and then deposited onto the nonwoven web prepared from the fibers. The first nonwoven web prepared from the fibers can be bonded before or after the filaments are provided on the first nonwoven web. As used herein, "filament" refers to the extruded product of a water-soluble polymer mixture prepared by a continuous process, and this extruded product does not have a defined length range. The use of "filament" in the phrase "fiber" does not convey any information regarding a specific length. For example, fibers can have any length, theoretically up to or greater than the length of filaments prepared from a continuous process. Thus, as used herein, filaments and fibers are intended to distinguish products having a defined length range (i.e., fibers) from products that do not have a defined length range (i.e., filaments).

[0153] Water-dispersible nonwoven webs containing a plurality of water-soluble fibers prepared by a wet chill gel spinning process and filaments / fibers prepared by a continuous process can also be formed using an indirect process. Meltblown fibers prepared at the nano- or micro-scale are prepared and mixed with a plurality of water-soluble fibers prepared by a wet chill gel spinning process, and then combined with the fibers prepared by the wet chill gel spinning process. Such a fiber blend can provide a water-dispersible nonwoven web with improved mechanical strength (relative to a comparable water-dispersible nonwoven web prepared with water-soluble fibers prepared solely by a wet chill gel spinning process) and stability, which can be advantageous for preparing wipes (e.g., cleaning wipes, personal care wipes, and the like). Generally, blends of water-soluble fibers and meltblown fibers prepared by a wet-cooled gel spinning process can include meltblown fibers in an amount of about 50 wt.% or less based on the total weight of all fibers, for example, in a range of about 1 wt.% to about 50 wt.%, about 5 wt.% to about 50 wt.%, about 10 wt.% to about 40 wt.%, about 15 wt.% to about 30 wt.%, about 20 wt.% to about 30 wt.%, for example, about 1 wt.%, about 5 wt.%, about 10 wt.%, about 15 wt.%, about 20 wt.%, about 25 wt.%, about 30 wt.%, about 40 wt.%, or about 50 wt.% based on the total weight of all fibers. The blend of water-soluble fibers and meltblown fibers prepared by the wet-cooled gel spinning process can be bonded using any suitable bonding method known in the art, such as the physical and chemical bonding processes described herein.

[0154] Water-soluble fibers can be characterized by their water-breaking temperature. "Water-breaking temperature" refers to the minimum temperature required for complete dissolution in practical applications, as estimated using the following method: a 100 mm length of water-soluble fiber is placed in an aqueous solution with an initial temperature of 1.5°C under a load of 1 mg / dtex; the temperature of the aqueous solution is systematically increased as a function of time (1.5°C every 2.5 minutes until the breaking temperature is reached); the water temperature is recorded after fiber breakage under a load of 2 mg / dtex and reported as the water-breaking temperature. Water-soluble fibers can also be characterized by their complete dissolution temperature, as described in the Method for Determining Single Fiber Solubility described herein.

[0155] Advantageously, nonwoven webs of the present disclosure can demonstrate preferential shrinkage in the presence of heat and / or water (e.g., humidity). Thus, when formed into packets, the nonwoven webs can be heat and / or water-shrunk. Even more advantageously, nonwoven webs of the present disclosure can demonstrate increased robustness (i.e., mechanical properties) and improved solubility performance after storage in high heat and moisture environments (e.g., 38°C and 80% relative humidity (RH)). Such increased robustness and improved solubility performance are surprising, since predictions based on water-soluble films of similar composition would suggest that robustness and solubility performance would not be affected by storage in high heat and moisture conditions. In particular, after a comparable water-soluble film is removed from the conditioned conditions, the water-soluble film re-equilibrates with the ambient environment, resulting in no long-term or permanent change in the film's performance characteristics.

[0156] The nonwoven webs of the present disclosure can be used as a single layer or can be layered with other nonwoven webs and / or water-soluble films. In some embodiments, the water-dispersible nonwoven web comprises a single layer of a water-dispersible nonwoven web. In some embodiments, the water-dispersible nonwoven web is a multi-layer water-dispersible nonwoven web comprising two or more layers of a water-dispersible nonwoven web. One or more layers can be layered on each other. In refinements of the foregoing embodiments, the two or more layers can be the same (e.g., prepared from the same fibers and basis weight). In refinements of the foregoing embodiments, the two or more layers can be different (e.g., prepared from different types of fibers and / or have different basis weights). In embodiments, the nonwoven web can be layered on a water-soluble film. In refinements of the foregoing embodiments, the nonwoven web and the water-soluble film can be prepared from the same polymer (e.g., a PVOH polymer having the same specific viscosity, degree of hydrolysis, and, in the case of a modified polymer, amount of modification). In refinements of the foregoing embodiments, the nonwoven web and water-soluble film can be prepared from different polymers (e.g., the polymer used to prepare the fibers of the nonwoven web can have a different fiber chemistry (e.g., modification), viscosity, degree of polymerization, degree of hydrolysis, and / or solubility than the polymer comprising the water-soluble film). Advantageously, multilayered nonwoven webs and laminates can be used to tailor the moisture vapor transmission rate (MVTR) of pouches or packets made therefrom. Multilayer materials can be prepared by a variety of processes known in the art, such as melt extrusion, coating (e.g., solvent coating, aqueous coating, or solid coating), spray bonding, material transfer, high-temperature lamination, low-temperature lamination, and combinations thereof.

[0157] In an embodiment, the nonwoven web can be a multilayer nonwoven web including a first nonwoven web including a plurality of fibers, the plurality of fibers including a first fiber including a first polyvinyl alcohol fiber-forming material and a blend of fiber-forming materials including (a) a second polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not include carboxymethylcellulose, hydroxypropylmethylcellulose, or starch. In a refinement of the foregoing embodiment, the multilayer nonwoven web can include a second nonwoven web including a plurality of fibers, the plurality of fibers including a third polyvinyl alcohol fiber-forming material and a second fiber including a blend of fiber-forming materials including (a) a fourth polyvinyl alcohol fiber-forming material, or (b) the blend of fiber-forming materials does not include carboxymethylcellulose, hydroxypropylmethylcellulose, or starch. In a refinement of the foregoing embodiment, the first and second nonwoven webs can include the same fibers and have the same basis weight. In an alternative refinement of the foregoing embodiment, the first and second nonwoven webs can include different fibers and have the same basis weight. In an alternative refinement of the aforementioned embodiment, the first and second nonwoven webs can comprise different fibers and have different basis weights. In a refinement of the aforementioned embodiment, the first and second nonwoven webs can be layered on one another. In a refinement of the aforementioned embodiment, the first nonwoven web can have a water-soluble film laminated thereto. In a refinement of the aforementioned embodiment, the fiber-forming material of the first fibers of the first nonwoven web can be the same material as the film-forming material of the water-soluble film. In an alternative embodiment, the fiber-forming material of the first fibers of the first nonwoven web can be a different material from the film-forming material of the water-soluble film.

[0158] Generally, a multi-layer nonwoven web can have a basis weight that is the sum of the basis weights of the individual layers. Thus, a multi-layer nonwoven web will take longer to dissolve than either of the individual layers provided as a single layer. In embodiments, the multi-layer nonwoven has a basis weight of about 1 g / m 2 to about 100 g / m 2The nonwoven web may have a basis weight in the range of 0.01 to 0.01 mm. Furthermore, without being bound by theory, it is believed that if the pore size and pore arrangement are nonuniform from layer to layer, the pores in each layer will not line up, thereby providing a multi-layer nonwoven web with smaller pores than the individual layers. Thus, a non-porous water-dispersible nonwoven web can be prepared by layering multiple porous water-dispersible nonwoven webs.

[0159] The nonwoven web can also be laminated to a water-soluble film. Laminates can be formed using any method known in the art, including, but not limited to, heat and pressure, chemical bonding, and / or solvent welding. Chemical bonding can include ionically or covalently functionalizing the surface of the nonwoven web and / or the surface of the water-soluble film so that when the surface of the nonwoven web comes into contact with the surface of the water-soluble film, a chemical reaction occurs and covalently bonds the nonwoven web and the water-soluble film together. Multilayer nonwoven webs can include three or more layers. In embodiments, the multilayer nonwoven web can include a first layer comprising a water-soluble film, a second layer comprising a nonwoven web, and a third layer comprising a water-soluble film. In embodiments, the multilayer nonwoven web can include a first layer comprising a nonwoven web, a second layer comprising a water-soluble film, and a third layer comprising a nonwoven web.

[0160] Advantageously, the laminate can be prepared simultaneously with pouch formation, for example, by using heat applied during thermoforming to bond the nonwoven web and water-soluble film layer together. The water-soluble film can have the same solubility and / or chemical compatibility characteristics as the nonwoven web, or the water-soluble film can have a different solubility and / or chemical compatibility characteristics than the nonwoven web. In embodiments, the water-soluble film has the same solubility and / or chemical compatibility characteristics as the nonwoven web. In some embodiments, the water-soluble film has a different solubility and / or chemical compatibility characteristics than the nonwoven web. Advantageously, when the water-soluble film has a different solubility and / or chemical compatibility characteristics than the nonwoven web, the laminate can be used to form a pouch having an inner surface with a first solubility and / or chemical compatibility and an outer surface with a second solubility and / or chemical compatibility.

[0161] The water-soluble film used in the laminate can generally be any water-soluble film, such as those already known in the art. The polymer used to form the water-soluble film can be any water-soluble polymer, or a combination thereof, such as those described herein. The water-soluble film can contain at least about 50 wt.%, 55 wt.%, 60 wt.%, 65 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, or 90 wt.%, and / or up to about 60 wt.%, 70 wt.%, 80 wt.%, 90 wt.%, 95 wt.%, or 99 wt.%, of a water-soluble polymer, such as a PVOH polymer or polymer blend.

[0162] The water-soluble film can contain other auxiliary and processing agents, such as, but not limited to, plasticizers, plasticizer compatibilizers, surfactants, lubricants, release agents, fillers, extenders, crosslinkers, antiblocking agents, antioxidants, anti-blocking agents, anti-foaming agents, nanoparticles such as layered silicate-type nanoclays (e.g., sodium montmorillonite), bleaching agents (e.g., sodium metabisulfite, sodium bisulfite, or others), aversive agents, such as bittering agents (e.g., denatonium salts, e.g., denatonium benzoate, denatonium saccharide, and denatonium chloride; sucrose octaacetate; quinine; flavonoids, e.g., quercetin and naringenin; and quassinoids, e.g., quassin and brucine), and pungent agents (e.g., capsaicin, piperine, allyl isothiocyanate, and resinferratoxin), and other functional ingredients, in amounts appropriate for their intended purpose. Preferred embodiments include plasticizers. The amount of such agents, individually or collectively, can be up to about 50 wt.%, 20 wt.%, 15 wt.%, 10 wt.%, 5 wt.%, 4 wt.%, and / or at least 0.01 wt.%, 0.1 wt.%, 1 wt.%, or 5 wt.% of the film.

[0163] The plasticizer can include any of the plasticizers disclosed herein, including, but not limited to, glycerin, diglycerin, sorbitol, ethylene glycol, diethylene glycol, triethylene glycol, dipropylene glycol, tetraethylene glycol, propylene glycol, polyethylene glycols up to 400 MW, neopentyl glycol, trimethylolpropane, polyether polyols, sorbitol, 2-methyl-1,3-propanediol (MPDiol®), ethanolamine, and mixtures thereof. Preferred plasticizers are glycerin, sorbitol, triethylene glycol, propylene glycol, dipropylene glycol, 2-methyl-1,3-propanediol, trimethylolpropane, or combinations thereof. The total amount of non-aqueous plasticizer can range from about 10 wt.% to about 40 wt.%, or from about 15 wt.% to about 35 wt.%, or from about 20 wt.% to about 30 wt.%, for example about 25 wt.%, based on the total film weight.

[0164] Suitable surfactants can include nonionic, cationic, anionic, and zwitterionic surfactants. Suitable surfactants include any of the surfactants described herein. In various embodiments, the amount of surfactant in the water-soluble film is in the range of about 0.1 wt% to 2.5 wt%, optionally in the range of about 1.0 wt% to 2.0 wt%. In embodiments, the amount of surfactant in the water-soluble film, expressed in parts per 100 parts of total water-soluble polymer in the water-soluble film (phr), is present in the range of about 0.5 phr to about 4 phr, about 0.75 phr to about 3.0 phr, about 1.0 phr to about 2.5 phr, about 1.0 phr to about 2.0 phr, or about 1.5 phr.

[0165] Suitable lubricants / release agents can include, but are not limited to, fatty acids and their salts, fatty alcohols, fatty esters, fatty amines, fatty amine acetates, and fatty amides. Preferred lubricants / release agents are fatty acids, fatty acid salts, and fatty amine acetates. In one type of embodiment, the amount of lubricant / release agent in the water-soluble film ranges from about 0.02 wt% to about 1.5 wt%, optionally from about 0.1 wt% to about 1 wt%.

[0166] Fillers can be included in the water-soluble film and can include bulking agents, extenders, antiblocking agents, antiblocking agents, and combinations thereof. Suitable fillers / bulking agents / extenders / antiblocking agents / antiblocking agents include, but are not limited to, starch, modified starch, crosslinked polyvinylpyrrolidone, crosslinked cellulose, microcrystalline cellulose, silica, metal oxides, calcium carbonate, talc, mica, stearic acid, and metal salts thereof, such as magnesium stearate. Preferred materials are starch, modified starch, and silica. In one type of embodiment, the amount of filler / extender / antiblocking agent / antiblocking agent in the water-soluble film can range, for example, from about 1 wt.% to about 6 wt.%, or from about 1 wt.% to about 4 wt.%, or from about 2 wt.% to about 4 wt.%, or from about 1 phr to about 6 phr, or from about 1 phr to about 4 phr, or from about 2 phr to about 4 phr.

[0167] In some embodiments, the water-soluble film can include 2 phr or more (e.g., 2 phr to 6 phr or 2 phr to 4 phr) of filler. In some embodiments, the film can include 2 phr or more (e.g., 2 phr to 6 phr or 2 phr to 4 phr) of filler, where the filler includes a bulking agent, an antiblocking agent, or a combination thereof. Without being bound by theory, it is believed that including 2 phr or more (e.g., 2 phr to 6 phr or 2 phr to 4 phr) of filler can help prevent the plasticizer from bleeding or migrating out of the film when the plasticizer is present in an amount greater than or equal to 30 phr, for example, in the range of 30 phr to 50 phr.

[0168] The antiblocking agent (e.g., SiO2 and / or stearic acid) can be present in the film in an amount ranging from at least 0.1 PHR, or at least 0.5 PHR, or at least 1 PHR, or from about 0.1 to 5.0 PHR, or from about 0.1 to about 3.0 PHR, or from about 0.4 to 1.0 PHR, or from about 0.5 to about 0.9 PHR, or from about 0.5 to about 2 PHR, or from about 0.5 to about 1.5 PHR, or from 0.1 to 1.2 PHR, or from 0.1 to 2.7 PHR, e.g., 0.5 PHR, 0.6 PHR, 0.7 PHR, 0.8 PHR, or 0.9 PHR.

[0169] Suitable median particle sizes for the antiblocking agent include ranges of about 3 to about 11 microns, or about 4 microns to about 11 microns, or about 4 to about 8 microns, or about 5 to about 6 microns, e.g., a median size (e.g., Dv50) of 5, 6, 7, 8, or 9 microns. Suitable SiO2 is untreated synthetic amorphous silica designed for use in aqueous systems.

[0170] The water-soluble film may further have a residual moisture content of at least 4 wt.%, such as in the range of about 4 to about 10 wt.%, as measured by Karl Fischer titration.

[0171] Water-dispersible nonwoven webs can be made by any suitable method known in the art, including by solvent casting, as described in Nonwoven Fabrics Handbook, prepared by Ian Butler, edited by Subhash Batra et al., Printing by Design, 1999, which is incorporated herein by reference in its entirety. Water-soluble films can be made by any suitable method, including solvent casting. Water-dispersible nonwoven webs and / or laminates can be used to form containers (pouches) by any suitable process, including vertical form, fill, and seal (VFFS) or thermoforming. Water-dispersible nonwoven webs and / or laminates can be sealed by any suitable process, including solvent sealing or heat sealing of the water-dispersible nonwoven web and / or laminate layers, for example, along the perimeter of the container. Pouches can be used, for example, to administer materials delivered in bulk water.

[0172] biodegradable

[0173] Polyvinyl alcohol polymers are generally biodegradable because they degrade under aerobic, anaerobic, soil, and compost conditions (in the presence of water) in the presence of water and enzymes. Generally, as the degree of hydrolysis of a polyvinyl alcohol polymer increases up to about 80%, the biodegradation activity of the polyvinyl alcohol polymer increases. Without being bound by theory, it is believed that increasing the degree of hydrolysis above 80% does not appreciably affect biodegradability. Furthermore, the stereoregularity of the hydroxyl groups in the polyvinyl alcohol polymer significantly affects the level of biodegradation activity; the more isotactic the hydroxyl groups in the polymer sequence, the higher the degradation activity. Without being bound by theory, it is believed that in soil and / or compost biodegradation, nonwoven webs prepared from polyvinyl alcohol fibers will have a higher level of biodegradation activity than water-soluble films prepared from similar polyvinyl alcohol polymers due to the increased polymer surface area provided by the nonwoven web to the film. Furthermore, without being bound by theory, it is believed that while the degree of polymerization of a polyvinyl alcohol polymer has little or no effect on the biodegradability of a film or nonwoven web prepared with that polymer, the polymerization temperature may affect the biodegradability of the film or nonwoven because it can affect the crystallinity and state of aggregation of the polymer. In particular, as the crystallinity decreases, the hydroxyl groups on the polymer chains become less aligned within the polymer structure, and the polymer chains become more disordered, leading to the chains accumulating as amorphous aggregates, thereby reducing the availability of ordered polymer structures and decreasing biodegradation activity in soil and / or compost, as would be expected if the polymer became insoluble.Without being bound by theory, it is believed that because the stereoregularity of the hydroxyl groups of a polyvinyl alcohol polymer has a significant effect on the biodegradability level, substitution with functional groups other than hydroxyl groups (e.g., anionic AMPS functional groups, carboxylate groups, or lactone groups) is expected to reduce the biodegradability level relative to a polyvinyl alcohol homopolymer having the same degree of hydrolysis, unless the functional groups themselves are biodegradable and the substitution does not increase the biodegradability of the polymer. Furthermore, although the biodegradability level of a substituted polyvinyl alcohol can be lower than that of the corresponding homopolymer, it is believed that the substituted polyvinyl alcohol will still exhibit biodegradability.

[0174] Methods for determining biodegradation activity are known in the art, for example, as described in Chiellini et al., Progress in Polymer Science, Volume 28, Issue 6, 2003, pp. 963-1014, which is incorporated herein by reference in its entirety. Other methods and standards can be found in ECHA's Annex XV Restriction Report - Microplastics, Version number 1, January 11, 2019, which is incorporated herein by reference in its entirety. Suitable standards include OECD 301B (ready biodegradation), OECD 301B (enhanced biodegradation), OECD 302B (native biodegradation), OECD 311 (anaerobic), and ASTM D5988 (soil).

[0175] In embodiments, the fibers and nonwoven webs of the present disclosure can be readily biodegradable, enhanced biodegradable, or native biodegradable. As used herein, the term "ready biodegradable" refers to a standard met by a material (e.g., fiber) according to the OECD 301B test set forth in ECHA's Annex XV, where the material reaches 60% biodegradation (mineralization) within 28 days from the start of the test. As used herein, the term "enhanced biodegradable" refers to a standard met by a material (e.g., fiber) according to the OECD 301B test set forth in ECHA's Annex XV, where the material reaches 60% biodegradation within 60 days from the start of the test. In embodiments, the fibers and nonwoven webs of the present disclosure meet the readily biodegradable standard. In embodiments, the fibers and nonwoven webs of the present disclosure meet the readily biodegradable or enhanced biodegradable standard. In embodiments, the fibers and nonwoven webs of the present disclosure meet the native biodegradable standard. In embodiments, the fibers and nonwoven webs of the present disclosure meet the enhanced biodegradable standard. In embodiments, the fibers and nonwoven webs of the present disclosure meet specifications for natural, enhanced, or facile biodegradation. In embodiments, the laminates (nonwovens and films) of the present disclosure meet specifications for facile or enhanced biodegradation.

[0176] Purpose The nonwoven web of the present disclosure is generally suitable for a variety of commercial applications.Suitable commercial applications of the nonwoven web of the present disclosure include, but are not limited to, water-dispersible or flushable pouches and packets; medical uses such as surgical masks, medical packaging, shoe covers, wound dressings and drug delivery; filtration systems for gasoline and oil, mineral treatment, vacuum bags, air filters and allergen membranes or laminates; personal care products such as baby wipes, makeup remover wipes, exfoliating cloths and makeup applicators; office products such as shopping bags or envelopes; and lens cleaning wipes, cleanroom wipes, plant potting materials, antibacterial wipes, agricultural seed strips, fabric softener sheets, clothing / laundry bags, food packaging materials, floor care wipes, pet care wipes, scouring tools, powder removal and hand washing detergents.

[0177] Sealed pouch The present disclosure further provides a pouch comprising a nonwoven web according to the present disclosure. In some embodiments, the pouch can comprise a laminate comprising a water-soluble film and a water-dispersible nonwoven web according to the present disclosure. The pouch can be a water-dispersible pouch, and optionally a water-soluble pouch and / or a flushable pouch. The present disclosure further provides a method for preparing a packet comprising a nonwoven web according to the present disclosure, the method comprising forming the nonwoven web into a pouch, filling the pouch with a composition to be enclosed therein, and sealing the pouch to form a packet. In some embodiments, the sealing comprises heat sealing, solvent welding, adhesive sealing, or a combination thereof.

[0178] The nonwoven webs and laminates disclosed herein are useful for making sealed articles in the form of pouches that define an interior pouch volume containing a composition therein for release to an aqueous environment. In embodiments, a "sealed article" optionally includes a sealed compartment with a vent, for example, if the compartment encloses a solid that outgasssssssssssss, but more commonly will be a completely sealed compartment.

[0179] The pouch may contain a single compartment or multiple compartments. The water-dispersible pouch may be formed from two layers of water-dispersible nonwoven webs or laminates sealed at their borders, or from a single nonwoven web or laminate folded over itself and sealed. The nonwoven web or laminate forms the outer surface of at least one side wall of the pouch, if necessary, and preferably at least one side wall. In another type of embodiment, the nonwoven web or laminate forms the inner wall of the packet, for example, as a dividing wall between the compartments. The nonwoven web or laminate may also be used in combination with a water-soluble film, for example, as the outer wall, inner wall, and / or compartment lid.

[0180] The composition enclosed in the pouch is not particularly limited and may include, for example, any of the various compositions described herein. In embodiments comprising multiple compartments, each compartment may contain the same and / or different compositions. Furthermore, the composition may take any suitable form, including, but not limited to, liquid, solid, gel, paste, mul, compressed solid (tablet), and combinations thereof (e.g., solid suspended in liquid).

[0181] In some embodiments, the pouch includes multiple compartments. The multiple compartments are generally stacked such that the compartments share a dividing wall within the pouch. The compartments of a multi-compartment pouch may be the same or different sizes and / or volumes. The compartments of a multi-compartment pouch of the present invention can be isolated or connected in any suitable manner. In an embodiment, the second and / or third and / or subsequent compartments are stacked on top of the first compartment. In one embodiment, the third compartment may be stacked on top of the second compartment, which is then stacked on top of the first compartment in a sandwich configuration. Alternatively, the second and third compartments may be stacked on top of the first compartment. However, it is equally conceivable that the first, second and / or third and / or subsequent compartments be oriented side-by-side or in a concentric orientation. The compartments may be wrapped with a string, with each compartment individually separable by a perforation line, so that each compartment may be individually torn away from the remainder of the string by an end user. In some embodiments, a first compartment may be surrounded by at least a second compartment, for example, in a tire and rim configuration or in a pouch-in-pouch configuration.

[0182] The geometries of the compartments may be the same or different. In embodiments, if desired, the third and subsequent compartments have different geometries and shapes compared to the first and second compartments, respectively. In these embodiments, if desired, the third and subsequent compartments are arranged in a design on top of the first or second compartment. The design may be decorative, educational, or illustrative, for example, to illustrate a concept or instruction, and / or may be used to indicate the origin of the product.

[0183] How to make a pouch

[0184] Pouches and packets can be made using any suitable equipment and method. For example, single-compartment pouches can be made using vertical-fill, horizontal-fill, or rotary-drum-fill techniques commonly known in the art. Such methods can be either continuous or intermittent. The nonwoven web, layered nonwoven web and film, or laminate structure can be moistened and / or heated to increase its malleability. The method can also include using a vacuum to draw the nonwoven web, layered nonwoven web and film, or laminate structure into a suitable mold. The vacuum that draws the nonwoven web or laminate into the mold can be applied for about 0.2 to about 5 seconds, or about 0.3 to about 3 seconds, or about 0.5 to about 1.5 seconds once the nonwoven web, layered nonwoven web and film, or laminate structure is on the horizontal portion of the surface. This vacuum may for example result in an overpressure in the range of 10 mbar to 1000 mbar, or in the range of 100 mbar to 600 mbar.

[0185] The mold from which the packet can be made can have any shape, length, width and depth depending on the required dimensions of the pouch.The mold can also vary in size and shape if desired.For example, the volume of the final pouch can be about 5ml to about 300ml, or about 10ml to 150ml, or about 20ml to about 100ml, and the size of the mold is adjusted accordingly.

[0186] thermoforming

[0187] A thermoformable nonwoven web or laminate is one that can be formed by the application of heat and force. Thermoforming of nonwoven webs, layered nonwoven webs, and films or laminate structures is a process of heating the nonwoven web, layered nonwoven web and film, or laminate structure, shaping it (e.g., in a mold), and then cooling the resulting nonwoven web or laminate, at which point it retains its shape, e.g., the shape of the mold. Heat may be applied using any suitable means. For example, the nonwoven web or laminate may be heated directly before being fed onto a surface or at some point on the surface, by placing it under a heating element or passing hot air through it. Alternatively, it may be heated indirectly, for example, by heating the surface of the nonwoven web or laminate or by applying a hot item to its surface. In an embodiment, the nonwoven web or laminate is heated using infrared light. The nonwoven web or laminate may be heated to a temperature ranging from about 50° C. to about 200° C., from about 50° C. to about 170° C., from about 50° C. to about 150° C., from about 50° C. to about 120° C., from about 60° C. to about 130° C., from about 70° C. to about 120° C., or from about 60° C. to about 90° C. Thermoforming may be accomplished by any one or more of the following processes: manual draping of the thermally softened nonwoven web or laminate over a mold, or pressure-induced forming (e.g., vacuum forming) of the softened nonwoven web or laminate onto a mold, or automatic high-speed indexing of a fresh extruded sheet having a precise known temperature to forming and trimming stations, or automatic placement, plug forming, and / or pneumatic stretch forming and pressure forming of the nonwoven web or laminate.

[0188] Alternatively, the nonwoven web or laminate can be wetted directly by any suitable means, such as by spraying a wetting agent (including water, a polymeric composition, a plasticizer for the nonwoven web or laminate composition, or any combination of the foregoing) onto the nonwoven web or laminate before or at the surface, or indirectly by wetting the surface of the nonwoven web or laminate or by applying a wetting article to the surface of the nonwoven web or laminate.

[0189] Once heated and / or wetted, the nonwoven web or laminate can be drawn into a suitable mold, preferably using a vacuum. Filling of the formed nonwoven web or laminate can be accomplished by any suitable means. In embodiments, the most preferred method depends on the product configuration and the required filling speed. In embodiments, the formed nonwoven web or laminate is filled by an in-line filling technique. The filled, open packet is then closed with a second nonwoven web or laminate by any suitable method to form a pouch. This can be done in a horizontal position and with a continuous, constant motion. Closing can be accomplished by continuously feeding a second nonwoven web or laminate, preferably a water-soluble nonwoven web or laminate, onto and over the open packet, and then sealing the first and second nonwoven webs or laminates together, preferably in the area between the molds and therefore between the packets.

[0190] Pouch sealing

[0191] Any suitable method for sealing the pouch and / or its individual compartments may be utilized. Non-limiting examples of such means include heat sealing, solvent welding, solvent or wet sealing, or a combination thereof. Typically, only the area that will form the seal is treated with heat or solvent. Heat or solvent can be applied by any method, typically only to the sealing material and typically only to the area that will form the seal. When using solvent or wet sealing or solvent or wet welding, it may be preferable to also apply heat. Preferred wet or solvent sealing / welding methods include selectively applying solvent to areas between molds or on the surface of the closure material, for example, by spraying or printing the solvent on these areas, and then applying pressure to these areas to form the seal. For example, sealing rolls and belts (which also provide heat, if necessary) can be used.

[0192] In embodiments, the inner nonwoven web or laminate is sealed to the outer nonwoven web or laminate by solvent sealing. The sealing solution is typically an aqueous solution. In embodiments, the sealing solution comprises water. In embodiments, the sealing solvent comprises water and further comprises one or more of a polyol, diol, and / or glycol, such as 1,2-ethanediol (ethylene glycol), 1,3-propanediol, 1,2-propanediol, 1,4-butanediol (tetramethylene glycol), 1,5-pentanediol (pentamethylene glycol), 1,6-hexanediol (hexamethylene glycol), 2,3-butanediol, 1,3-butanediol, 2-methyl-1,3-propanediol, various polyethylene glycols (e.g., diethylene glycol, triethylene glycol), and combinations thereof. In embodiments, the sealing solution comprises erythritol, threitol, arabitol, xylitol, ribitol, mannitol, sorbitol, galactitol, fucitol, iditol, inositol, volemitol, isomal, maltitol, lactitol, hi embodiments, the sealing solution comprises a water soluble polymer.

[0193] The sealing solution can be applied to the interface region of the inner nonwoven web or laminate in any suitable amount to bond the inner and outer nonwoven webs or laminates together. As used herein, the term "coating weight" refers to the amount of sealing solution applied to the nonwoven web or laminate in grams of solution per square meter of nonwoven web or laminate. Generally, if the coating weight of the sealing solvent is too low, the nonwoven web or laminate will not adhere sufficiently, increasing the risk of pouch failure at the seam. Furthermore, if the coating weight of the sealing solvent is too high, there is an increased risk of solvent migration from the boundary region and the possibility of etch holes forming in the sides of the pouch. The coating weight window refers to the range of coating weights that can be applied to a given film while maintaining both good adhesion and avoiding etch hole formation. A wider coating weight window is desirable because it results in a robust seal under a wide range of operations. A suitable coating weight window is at least about 3 g / m. 2 , or at least about 4 g / m 2 , or at least about 5 g / m 2 , or at least about 6 g / m 2 is.

[0194] Packet Drop

[0195] The formed packets can be cut by a cutting device. Cutting can be done using any known method. It may also be preferable that cutting is done continuously, preferably at a constant speed, preferably while in a horizontal position. The cutting device can be, for example, a sharp object, or a warm object, or a laser, which, in the latter case, passes through and "burns" the film / sealed area.

[0196] Multi-compartment pouch forming and filling

[0197] The various compartments of the multi-compartment pouch may be fabricated together in a side-by-side or concentric style, in which case the resulting tethered pouch may or may not be separated by cutting. Alternatively, the compartments may be fabricated individually.

[0198] In embodiments, pouches may be made according to a method comprising the steps of: a) forming a first compartment (as described above), b) forming recesses in or all of the closed compartments formed in step (a) to produce second shaped compartments overlying the first compartment, c) filling the second compartment and closing it with a third nonwoven web, laminate or film, d) sealing the first, second and third nonwoven webs, laminates or films, and e) cutting the nonwoven webs or laminates to produce the multi-compartment pouch. The recesses formed in step (b) may be achieved by applying a vacuum to the compartments prepared in step (a).

[0199] In embodiments, the second and / or third compartments may be made in separate steps and then combined with the first compartment, as described in European Patent Application No. 08101442.5, or U.S. Patent Application Publication No. 2013 / 240388A1, or WO2009 / 152031.

[0200] In embodiments, pouches may be made according to a method comprising the steps of: a) forming a first compartment using a first nonwoven web or laminate in a first forming device, optionally using heat and / or vacuum; b) filling the first compartment with a first composition; c) optionally filling the second compartment with a second composition; d) sealing the first and optional second compartments to the first nonwoven web or laminate with a second nonwoven web or laminate; and e) cutting the nonwoven web or laminate to produce the multi-compartment pouch.

[0201] In embodiments, pouches may be made according to a method comprising the steps of: a) forming a first compartment using a first nonwoven web or laminate in a first forming device, optionally using heat and / or vacuum; b) filling the first compartment with a first composition; c) deforming a second nonwoven web or laminate in a second forming device, optionally using heat and vacuum to create a second and optionally third shaped compartment; d) filling the second and optionally third compartment; e) sealing the second and optionally third compartments using a third nonwoven web or laminate; f) placing the sealed second and optionally third compartments onto the first compartment; g) sealing the first, second and optionally third compartments; and h) cutting the nonwoven web or laminate to produce the multi-compartment pouch.

[0202] The first and second forming devices may be selected based on their suitability for carrying out the above-described method. In an embodiment, the first forming device is preferably a horizontal forming device, and the second forming device is preferably a rotary drum forming device, preferably positioned above the first forming device.

[0203] It should be understood that by use of an appropriate feed station, it may be possible to produce multi-compartment pouches incorporating several different or distinct compositions, and / or different or distinct liquid, gel or paste compositions.

[0204] In embodiments, the nonwoven web or laminate and / or pouch is sprayed or dusted with a suitable substance, such as an active agent, a lubricant, a repellent, or a mixture thereof. In embodiments, the nonwoven web or laminate and / or pouch is printed on its surface, for example, with an ink and / or an active agent.

[0205] Vertical Form, Fill and Seal

[0206] In embodiments, the nonwoven web or laminate of the present disclosure can be used to make a sealed article. In embodiments, the sealed article is a vertical form-filled and sealed article. The vertical form, fill, and seal (VFFS) process is a conventional automated process. A VFFS includes an assembly machine or other device that wraps a single piece of nonwoven web or laminate around a longitudinally oriented feed tube. The machine heat seals or otherwise secures opposing edges of the nonwoven web or laminate together to create a side seal of the nonwoven web or laminate and form a hollow tube. The machine then heat seals or otherwise creates a bottom seal, thereby defining an open-top container portion where a top seal will later be formed. The machine introduces a specified amount of flowable product into the container portion through the open top end. Once the container contains the desired amount of product, the machine feeds the nonwoven web or laminate to another heat sealing device, for example, to create a top seal. Finally, the machine feeds the nonwoven web or laminate to a cutter that cuts the film just above the top seal to provide a filled package.

[0207] During operation, assembly equipment feeds the nonwoven web or laminate from the roll to form the package, therefore the nonwoven web or laminate must be able to easily advance through the equipment and not be so fragile that it will stick to the assembly equipment or break during processing.

[0208] Pouch contents In any embodiment, the pouch can contain (enclose) the composition within the defined interior volume of the pouch. The composition can be selected from a liquid, a solid, or a combination thereof. In embodiments in which the composition is liquid, the nonwoven web can be a nonporous nonwoven web or a porous nonwoven web laminated with a water-soluble film, with the water-soluble film forming the interior surface of the pouch. In embodiments in which the composition is solid, the pouch can be a nonporous nonwoven web, a porous nonwoven web, or a porous nonwoven web laminated with a water-soluble film. In embodiments in which the pouch comprises a porous nonwoven web, the particle size of the solid composition is smaller than the pore size of the nonwoven web.

[0209] In embodiments, the sealed article of the present disclosure can enclose within its internal pouch volume a composition comprising a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, a food and nutritional composition, an industrial cleaning composition, a pharmaceutical composition, a disinfecting composition, a pet composition, an office composition, a livestock composition, an industrial composition, a marine composition, a commercial composition, a military composition, a recreational composition, or a combination thereof. In embodiments, the water-dispersible sealed article of the present disclosure can enclose within its internal pouch volume a composition comprising a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, a food and nutritional composition, an industrial cleaning composition, or a combination thereof. In embodiments, the water-dispersible sealed article of the present disclosure can enclose within its internal pouch volume a composition comprising a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, or a combination thereof. In embodiments, the water-dispersible sealed article of the present disclosure can enclose within its internal pouch volume a composition comprising an agricultural composition or a water treatment composition.

[0210] As used herein, "liquid" includes free-flowing liquids, as well as pastes, gels, foams, and mousses. Non-limiting examples of liquids include light-duty and heavy-duty liquid detergent compositions, dish detergents for hand and / or machine washing; hard surface cleaning compositions, fabric enhancers, gel detergents commonly used in laundry, bleaches and laundry additives, shaving creams, skin care, hair care compositions (shampoos and conditioners), and body washes. Such detergent compositions can include surfactants, bleaches, enzymes, fragrances, dyes or colorants, solvents, and combinations thereof. Optionally, the detergent composition is selected from the group consisting of laundry detergents, dish washing detergents, hard surface cleaning compositions, fabric enhancer compositions, shaving creams, skin care, hair care compositions (shampoos and conditioners), and body washes, and combinations thereof.

[0211] Non-limiting examples of liquids include agricultural compositions, automotive compositions, aviation compositions, food and nutrition compositions, industrial compositions, livestock compositions, marine compositions, pharmaceutical compositions, commercial compositions, military and paramilitary compositions, office compositions, recreational and park compositions, pet compositions, and water treatment compositions, including cleaning and detergent compositions applicable to any such use.

[0212] Gas, e.g., suspended bubbles, or solids, e.g., particles, may be contained within the liquid. "Solids," as used herein, include, but are not limited to, powders, agglomerates, and mixtures thereof. Non-limiting examples of solids include granules, microcapsules, beads, noodles, and glaze balls. Solid compositions may provide technical benefits, including, but not limited to, cleaning benefits, pre-treatment benefits, and / or aesthetic effects.

[0213] The composition may be a non-household care composition. For example, the non-household care composition may be selected from agricultural compositions, aviation compositions, food nutrition compositions, industrial compositions, livestock compositions, marine compositions, pharmaceutical compositions, commercial compositions, military and paramilitary compositions, office compositions, recreational and park compositions, pet compositions, and water treatment compositions, including cleaning compositions and detergent compositions applicable to any such use, but excluding fabric and household care compositions.

[0214] In one embodiment, the composition can comprise one or more of agricultural chemicals, such as pesticides, fungicides, herbicides, pesticides, acaricides, repellents, attractants, defoliants, plant growth regulators, fertilizers, bactericides, micronutrients and trace elements.Suitable pesticides and adjuvants are described in U.S. Patent Nos. 6,204,223 and 4,681,228 and EP0989803A1.For example, suitable herbicides include paraquat salts (for example, paraquat dichloride or paraquat bis(methyl sulfate)), diquat salts (for example, diquat dibromide or diquat alginate), and glyphosate or its salts or esters (also known as sulfosates, such as glyphosate isopropylammonium, glyphosate sesquisodium or glyphosate trimesium). Pairs of incompatible crop protection chemicals can be used in separate chambers, as described, for example, in U.S. Patent No. 5,558,228. Pairs of incompatible crop protection chemicals that can be used include, for example, bensulfuron methyl and molinate; 2,4-D and thifensulfuron methyl; 2,4-D and methyl 2-[[[[N-4-methoxy-6-methyl-1,3,5-triazin-2-yl]-N-methylamino]carbonyl]amino]-sulfonyl]benzoate; 2,4-D and metsulfuron methyl; maneb or mancozeb and benomyl; glyphosate and metsulfuron methyl; tralomethrin and any organophosphate (such as monocrotophos or dimethoate). ); bromoxynil and N-[[4,6-dimethoxypyrimidin-2-yl]-amino]carbonyl]-3-(ethylsulfonyl)-2-pyridine-sulfonamide; bromoxynil and methyl 2-[[[[(4-methyl-6-methoxy)-1,3,5-triazin-2-yl)amino]carbonyl]amino]sulfonyl]-benzoate, bromoxynil and methyl 2-[[[[N-(4-methoxy-6-methyl-1,3,5-triazin-2-yl)-N-methylamino]carbonyl]amino]-sulfonyl]benzoate.In another related type of embodiment, the composition can include one or more seeds, optionally together with soil, including, for example, the type of embodiment described in U.S. Pat. No. 8,333,033, and optionally together with one or more additional components selected from mulch, sand, peat moss, water jelly crystals, and fertilizer.

[0215] In another type of embodiment, the composition is a water treatment agent. Such agents may include harsh chemicals, such as aggressive oxidizing chemicals, as described, for example, in U.S. Patent Application Publication No. 2014 / 0110301 and U.S. Patent No. 8,728,593. For example, disinfectants may include hypochlorites, such as sodium hypochlorite, calcium hypochlorite, and lithium hypochlorite, and chlorinated isocyanurates, such as dichloroisocyanuric acid (also known as "dichlor" or dichloro-s-triazinetrione, 1,3-dichloro-1,3,5-triazinane-2,4,6-trione) and trichloroisocyanuric acid (also known as "trichlor" or 1,3,5-trichloro-1,3,5-triazinane-2,4,6-trione). Salts and hydrates of disinfectant compounds are also contemplated. For example, dichloroisocyanuric acid may be provided as sodium dichloroisocyanurate, sodium dichloroisocyanurate dihydrate, among others. Bromine-containing disinfectants, such as 1,3-dibromo-5,5-dimethylhydantoin (DBDMH), 2,2-dibromo-3-nitrilopropionamide (DBNPA), dibromocyanoacetamide, 1-bromo-3-chloro-5,5-dimethylhydantoin, and 2-bromo-2-nitro-1,3-propanediol, among others, may also be suitable for use in unit-dose packaging applications. The oxidizing agent may be, for example, potassium hydrogen peroxymonosulfate, as described in U.S. Patent No. 7,476,325. The composition may be, for example, a pH-adjusting chemical, such as those described in U.S. Patent Application Publication No. 2008 / 0185347, which contains, for example, an acidic and alkaline component to effervescently foam upon contact with water and adjust the pH of the water. Suitable components include sodium bicarbonate, sodium bicarbonate, potassium hydroxide, sulfamic acid, organic carboxylic acids, sulfonic acids, and potassium dihydrogen phosphate. The buffer blend can include, for example, boric acid, sodium carbonate, glycolic acid, and oxone monopersulfate.

[0216] The water treatment agent can be or can include a flocculant, for example, as described in U.S. Patent Application Publication No. 2014 / 0124454. The flocculant can include a polymer flocculant, such as polyacrylamide, polyacrylamide copolymers (such as acrylamide copolymers of diallydimethylammonium chloride (DADMAC), dimethylaminoethyl acrylate (DMAEA), dimethylaminoethyl methacrylate (DMAEM), 3-methylamidopropyltrimethylammonium chloride (MAPTAC)), or acrylic acid; cationic polyacrylamide; anionic polyacrylamide; neutral polyacrylamide; polyamine; polyvinylamine; polyethyleneimine; polydimethyldiallylammonium chloride; polyoxyethylene; polyvinyl alcohol; polyvinylpyrrolidone; polyacrylic acid; polyphosphoric acid; polystyrene sulfonic acid; or any combination thereof. The flocculant can be selected from chitosan acetate, chitosan lactate, chitosan adipate, chitosan glutamate, chitosan succinate, chitosan malate, chitosan citrate, chitosan fumarate, chitosan hydrochloride, and combinations thereof. The water treatment composition can include one or more phosphate-removing substances selected from, for example, zirconium compounds, rare earth lanthanide salts, aluminum compounds, iron compounds, or any combination thereof.

[0217] The composition may be, for example, a limescale removal composition as described in US Patent Application Publication No. 2006 / 0172910, such as citric acid or maleic acid, or their sulfates, or any mixture thereof.

[0218] Various other types of compositions are contemplated for use in the packets described herein, including particulates such as down feathers as described in, for example, US RE29059E; superabsorbent polymers as described in, for example, US Patent Application Publication Nos. 2004 / 0144682 and 2006 / 0173430; pigments and stains as described in, for example, US Patent Application Publication Nos. 3,580,390 and 2011 / 0054111; brazing fluxes (e.g., alkali metal fluoroaluminates, alkali metal fluorosilicates, and alkali metal fluorozincates) as described in, for example, US Patent Application Publication No. 8,163,104; food products (e.g., coffee powder or dried soup) as described in, for example, US Patent Application Publication No. 2007 / 0003719; and wound dressings as described in, for example, US Patent No. 4,466,431.

[0219] In pouches containing laundry, laundry additive and / or softening booster compositions, the compositions may contain any of the following non-limiting list of ingredients: fabric care benefit agents; detersive enzymes; precipitation aids; rheology modifiers; builders; bleach; bleaching agents; bleach precursors; bleach boosters; bleach catalysts; perfumes and / or perfume microencapsulations (see, e.g., U.S. Pat. No. 5,137,646); perfume-filled zeolites; starch encapsulated accords; accord); polyglycerol esters; whitening agents; pearlescent agents; enzyme stabilizing systems; scavenging agents, including anionic dye fixing agents, anionic surfactant complexing agents, and mixtures thereof; optical brighteners or fluorescent agents; polymers, including, but not limited to, soil releasing polymers and / or soil suspending polymers; dispersants; antifoaming agents; non-aqueous solvents; fatty acids; foam suppressors, such as silicone foam suppressors (see U.S. Publication No. 2003 / 0060390 A1, ¶65-77). cationic starch (see US2004 / 0204337A1 and US2007 / 0219111A1); dross dispersants (see US2003 / 0126282A1, ¶89-90); direct dyes; hueing dyes (see US2014 / 0162929A1); colorants; opacifiers; antioxidants; hydrotropes such as toluenesulfonates, cumenesulfonates, and naphthalenesulfonates; color speckles; colored beads, spheres, or extrudates; clay softeners; and antibacterial agents. Any one or more of these ingredients are further described in U.S. Patent Application Publication Nos. 2010 / 305020A1, 2003 / 0139312A1, and 2011 / 0023240A1. Additionally or alternatively, the composition may include a surfactant, a quaternary ammonium compound, and / or a solvent system. The quaternary ammonium compound may be present in a softening booster composition, such as a fabric softener, and may have the structure NR4 + and R is an alkyl or aryl group.

[0220] Dissolution and Disintegration Test (MSTM-205) Nonwoven webs, water-soluble films, or laminate structures can be characterized or tested for dissolution time and disintegration time according to MonoSol Test Method 205 (MSTM205), a method known in the art. See, for example, U.S. Patent No. 7,022,656. The description provided below refers to nonwoven webs, but is equally applicable to water-soluble films or laminate structures. Equipment and materials: 600mL beaker Magnetic stirrer (Labline model number 1250 or equivalent) Magnetic stirring rod (5cm) Thermometer (0 to 100°C ±1°C) Mold, stainless steel (3.8cm x 3.2cm) Timer (0 to 300 seconds, accurate to the nearest second) Polaroid 35mm slide mount (or equivalent) MonoSol 35mm Slide Mount Holder (or equivalent) Distilled water

[0221] For each nonwoven web to be tested, three specimens are cut from the nonwoven web sample resulting in a 3.8 cm x 3.2 cm specimen. The specimens should be cut from areas of the web that are evenly spaced along the cross direction of the web. Each specimen is then analyzed using the following procedure.

[0222] Each specimen is mounted on an individual 35 mm slide mount.

[0223] Fill a beaker with 500 mL of distilled water. Measure the water temperature with a thermometer and, if necessary, heat or cool the water to maintain the temperature at which dissolution will be determined, e.g., 20°C (approximately 68°F).

[0224] Mark the height of the water column. Place a magnetic stirrer in the bottom of the holder. Place the beaker on the magnetic stirrer, add a magnetic stirring rod to the beaker, turn on the stirrer, and adjust the stirring speed until a vortex is created that is approximately one-fifth the height of the water column. Mark the depth of the vortex.

[0225] Secure the 35 mm slide mount in the alligator clamp of the 35 mm slide mount holder so that the long end of the slide mount is parallel to the water surface. The depth adjuster on the holder should be set so that the end of the clamp drops 0.6 cm below the water surface. One of the short sides of the slide mount should be next to the side of the beaker, with the other positioned directly above the center of the stirring rod, so that the surface of the nonwoven web is perpendicular to the water flow.

[0226] In one motion, drop the clamped slide and clamp into the water and start the timer. Rupture occurs when the sample becomes compromised within the slide, e.g., a hole forms. Disintegration occurs when the nonwoven web breaks apart and no sample material remains within the slide. Once all visible nonwoven web is released from the slide mount, lift the slide out of the water while continuing to monitor the solution for undissolved nonwoven web fragments. Dissolution occurs when all nonwoven web fragments are no longer visible and the solution is no longer cloudy. Rupture and dissolution can occur simultaneously in nonwoven samples, in which case the fibers are prepared from low-hydrolysis (e.g., approximately 65-88%) polyvinyl alcohol. If the difference between rupture and dissolution is 5 seconds or longer, the dissolution time is recorded independently of the rupture time.

[0227] Thinning time can also be determined using MSTM-205. Thinning of a nonwoven web occurs when some of the fibers comprising the nonwoven web dissolve while other fibers remain intact. Thinning of the web occurs before the web disintegrates. Thinning is characterized by a decrease in the opacity of the nonwoven web or an increase in its transparency. The change from opaque to gradually transparent can be observed visually. During MSTM-205, the opacity / transparency of the nonwoven web is monitored after the fixed slide and clamp are lowered into water. The time at which no change in opacity / transparency is observed (i.e., the web does not decrease in opacity or increases in transparency) is recorded as the thinning time.

[0228] Results should include the following: complete sample identification; individual and average disintegration and dissolution times; and the water temperature in which the sample was tested.

[0229] Method for determining single fiber solubility Single fiber solubility can be characterized by the water breaking temperature. The fiber breaking temperature can be determined as follows: A load of 2 mg / dtex is placed on a fiber with a fixed length of 100 mm. The water temperature starts at 1.5°C and then increases in 1.5°C increments every 2 minutes until the fiber breaks. The temperature at which the fiber breaks is designated as the water breaking temperature.

[0230] Single fiber solubility can be characterized by the temperature at which dissolution is complete. The temperature at which dissolution is complete can be determined as follows: 0.2 g of fiber with a fixed length of 2 mm is added to 100 mL of water. The water temperature starts at 1.5°C and then increases in 1.5°C increments every 2 minutes until the fiber is completely dissolved. The sample is stirred at each temperature. The temperature at which the fiber is completely dissolved in less than 30 seconds is designated as the complete dissolution temperature.

[0231] Diameter Test Method The diameter of discrete fibers or fibers within a nonwoven web is determined using a scanning electron microscope (SEM) or optical microscope and image analysis software. A magnification of 200 to 10,000x is selected to provide the appropriate magnification for measuring the fibers. When using an SEM, the sample is sputtered with gold or palladium compounds to avoid charging and vibration of the fibers in the electron beam. A manual procedure for determining fiber diameter is used from the image (on the monitor screen) obtained with the SEM or optical microscope. Using the mouse and cursor device, the edge of a randomly selected fiber is located and then measured along its width (i.e., perpendicular to the fiber direction at that point) to the other edge of the fiber. A calibrated image analysis tool with a magnified scale adjusts the scale to provide an actual reading in microns. For fibers within a nonwoven web, several fibers are randomly selected along a sample of the nonwoven web using the SEM or optical microscope. At least two sections of the nonwoven web material are cut and tested in this manner. A total of at least 100 such measurements are made and all data is then recorded for statistical analysis, which is used to calculate the average (mean) fiber value, the standard deviation of the fiber value, and the median fiber diameter.

[0232] Tensile Strength, Modulus and Elongation Tests Nonwoven webs, water-soluble films, or laminate structures characterized or tested for tensile strength according to the Tensile Strength (TS) Test, modulus (or tensile stress) according to the Modulus (MOD) Test, and elongation according to the Elongation Test are analyzed as follows. The description provided below refers to nonwoven webs but is equally applicable to water-soluble films or laminate structures. The procedure involves determining tensile strength and modulus at 10% elongation according to ASTM D882 ("Standard Test Method for Tensile Properties of Thin Plastic Sheeting") or equivalent. An Instron tensile testing device (Model 5544 Tensile Tester or equivalent) is used to collect nonwoven web data. A minimum of three specimens (each cut using a reliable cutting device to ensure dimensional stability and reproducibility) are tested in the machine direction (MD) (as needed) for each measurement. Testing is performed in a standard laboratory atmosphere of 23±2.0°C and 35±5% relative humidity. For tensile strength or modulus determination, a 1-inch (2.54 cm) wide sample of the nonwoven web is prepared. The sample is then transferred to an Instron tensile tester for testing while minimizing exposure to a 35% relative humidity environment. The tensile tester is prepared according to the manufacturer's instructions, equipped with a 500 N load cell, and calibrated. The correct grips and faces are installed (Instron grips with rubber-coated, 25 mm wide faces, model number 2702-032, or equivalent). The sample is mounted in the tensile tester and analyzed to determine the 100% modulus (i.e., the stress required to achieve 100% film elongation), tensile strength (i.e., the stress required to break the film), and % elongation (sample length at break relative to the initial sample length). Generally, the higher the % elongation of the sample, the better the processing characteristics of the nonwoven web (e.g., improved formability into packets or pouches).

[0233] Determining basis weight Basis weight is determined in accordance with ASTM D3776 / D3776M-09a (2017). Briefly, a minimum of 130 cm 2or several smaller die-cut specimens taken from different locations within the sample, each having an area of ​​at least 130 cm 2 The specimen is then cut into die-cut specimens with a total area of ​​1000 psi. The specimen is weighed and mass is determined on a top-loading analytical balance with a resolution of ±0.001 g. The balance is protected from air currents and other obstructions with a draft shield. A fabric specimen may also be weighed. Mass is calculated to three significant figures in ounces per square yard, ounces per linear yard, linear yards per pound, or grams per square meter.

[0234] Determination of water vapor transmission rate Moisture vapor transmission rate (MVTR) is determined in accordance with MSTM-136. MVTR defines how much moisture will migrate through a film sample per day. The description provided below refers to nonwoven webs but is equally applicable to water-soluble films or laminate structures. Equipment and materials: Permatran-W Model 3 / 34 (or equivalent) Compressed gas cylinder of nitrogen (99.7% or higher) T-shaped regulator (part number 027-343) Main Line Supply Regulator HPLC-grade water (or equivalent) 10cc syringe with Luerlok tip (Part Number 800-020) powder-free gloves High Vacuum Grease (Part Number 930-022) (2) Test cell Cutting mold cutting board Razor blade with handle cut resistant gloves

[0235] Prepare the Permatran W-Model 3 / 34: Ensure the nitrogen pressure level is greater than 300 psi, the carrier gas T-regulator pressure is 29 psi (not exceeding 32 psi), and the main line supply regulator pressure is set to 35 psi. Open the instrument panel door, approach the humidifier, and check the water level. If the water level is low, fill a syringe with HPLC-grade water and insert the luer fitting of the syringe into the reservoir's "fill port." Open the "fill valve" by rotating it counterclockwise two to three times, then press on the syringe plunger to force the water into the reservoir. Close the "fill valve" and remove the syringe. Note: The water level should not exceed the line marked adjacent to the reservoir.

[0236] Sample Preparation and Testing: For each nonwoven web to be tested, take the sample web and place it flat on a cutting board. Place a template on top of the web and use a razor blade with a handle to cut the sample. Be sure to wear cut-resistant gloves when cutting the sample. Set the sample aside. Grease the perimeter of the sealing surface of the top piece of the test cell with high vacuum grease. Mount the film sample on top of the top piece of the sample cell. Note: Orientation can be important. For homogeneous materials, orientation is not important. For multilayered and laminated materials, place the multilayered film or laminate with the barrier coating or laminate facing up against the top of the cell. For example, one side of a wax-coated PVOH web should be mounted wax-side up, with the wax facing in the direction of the carrier gas (nitrogen). Place the top piece of the test cell on top of the bottom piece of the test cell. Ensure the test cell is securely clamped together with a good seal. Press the cell load / unload button and open the cell tray. Grasp the test cell by the leading and trailing edges and lower straight down. Close the cell tray completely by gently pushing straight down towards the panel. Press the cell load / unload button to clamp the cell. Note: A click should be heard. Repeat with the second sample.

[0237] After the sample is loaded and the instrument is ready, the test parameters must be set. Note: There are two types of test parameters: cell parameters and instrument parameters. Cell parameters are specific to each cell, while instrument parameters are common to all cells. Touch the "Test Button" on the screen. Under "Auto Test", select "Tab A". Touch the "Cell Tab". Enter the following by touching each bubble: ID, Area (cm'2), Thickness (mils). Note: The mold area is 50cm 2 . Repeat "Tab B". Touch "Instrument Tab". Enter the following by touching each bubble: Cell Temperature (°C) and Test Gas RH (%). Note: Ensure 100% RH is set to Off. Cell Temperature can be set from a minimum of 10°C to a maximum of 40°C. Test Gas RH can be set from a minimum of 5% to a maximum of 90%. If 100% RH is required, a different method is required. Repeat "Tab B". Once the test parameters are set, select "Start Selected" or "Start All" depending on the number of samples. Note: The indicator light for each cell on the front panel is green, indicating that the test has started.

[0238] Surface resistivity measurement The surface resistivity of nonwoven webs and films can be measured according to ASTM D257.

[0239] Flexibility rating The hand feel of the nonwoven web, laminate, or pouch of the present disclosure relates to the sample's softness and can be evaluated using a relative test method. Regardless of the method or technique chosen by the individual, the softness tester used clean hands to feel the sample, and determined softness ratings for the nonwoven webs and articles of the present disclosure compared to a control material including a nonwoven web made of fibers composed of polyvinyl alcohol homopolymer with an 88% degree of hydrolysis and having a 2.2 dtex / 51 mm cut section with a softness rating of 1 (softest), and a control material including a nonwoven web made of fibers composed of 75% polyvinyl alcohol homopolymer with an 88% degree of hydrolysis and having a 2.2 / 51 mm cut section and 25% PET fiber with a 22 dtex / 38 mm cut section with a softness rating of 5 (coarsest / coarsest). The hand panel conducted a blinded study to ensure that the evaluators were not influenced by the sample names. The samples were rated from 1 to 5.

[0240] Flushability Test The ability of nonwoven webs and / or laminates of the present disclosure to be flushed down a septic tank or municipal wastewater treatment system can be determined in accordance with the modified INDA / EDANA-Flushable Product Certification Standards, as set forth below. While the following tests refer to nonwoven web samples, it is understood that the methods can also be used on laminate structures.

[0241] Device: Rocking Digital Platform Shaker Two clear plastic 12 x 5 x 3.9 inch containers 2 sieves (12.5mm gap) Dry nonwoven web samples 100°C oven

[0242] parameter: Set the rocking platform to 18 RPM and 11° tilt period 1L of tap water per container 30-minute test period

[0243] Test procedure: 1. Place two containers on the rocking platform. This method tests two samples at a time. 2. Measure 1 liter of tap water into a beaker and pour it into one plastic container. Repeat with the other container. Before starting the test, ensure the tap water in the container is at 15°C ± 1°C. 3. Record the weight of the initial dry test sample (initial sample mass (g)) and the weight of the sieve (initial sieve mass (g)) and record them separately. 4. Set the appropriate parameters on the digital locking platform. 5. Place each test sample into its corresponding container and immediately begin the agitation process (agitation of the platform). 6. Once the process is complete (after 30 minutes), take each container and pour into its corresponding sieve, pouring to a height of 10 cm above the sieve plate. 7. Rinse the container into the sieve, ensuring that all residual test sample is removed. 8. Place the sieve in a 100°C oven for 45 minutes to ensure all the water has evaporated. 9. Record the weight of the sieve and the remaining test sample together (total final mass (g)). 10. Calculate the total mass of the retained sample (final sample mass (g)): Final sample mass (g) = total final mass (g) - initial sieve mass (g) 10. Calculate the decay rate (%): % disintegration = [1-(final sample mass (g) / initial sample mass (g))] x 100 11. Ensure the sieve is clean, dry and reweighed before starting the next test. 12. Repeat the test until N=3 replicates are completed for each designated test sample.

[0244] If a sample has a disintegration rate equal to or greater than at least 20%, the sample is sufficiently flushable to be disposed of by flushing in a septic tank or municipal wastewater treatment system. In embodiments, the nonwoven webs, laminates, and pouches of the present disclosure can have a disintegration rate of at least 20%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% as measured by the Flushability Test.

[0245] Liquid Release Test FIG. 3 is an illustration of a wire frame cage (shown open at the top to better illustrate the water-soluble pouch contained therein) for use in the liquid release tests described herein.

[0246] FIG. 4 shows an apparatus for conducting liquid release tests, including a beaker resting on a stand, which holds a rod for lowering a cage into the beaker, the rod being securable by a collar with a set screw (not shown).

[0247] Water-soluble films and / or pouches characterized or tested for delayed solubility according to the Liquid Release Test are analyzed as follows using the following materials: 2 L beaker and 1.2 L of deionized (DI) water Water-soluble pouches to be tested; pouches are pre-conditioned for 2 weeks at 38°C; for results to be comparable, all tested films should have the same thickness, e.g., 88 μm or 76 μm. · Thermometer Wire cage · timer

[0248] Before conducting the experiment, ensure that enough DI water is available for five experimental replicates and that the wire cage and beaker are clean and dry.

[0249] The wire frame cage is a plastic-coated wire cage (4" x 3.5" x 2.5") or similar with no sharp edges. The wire gauge should be approximately 1.25 mm, and the wire should have an opening 0.5 inches (1.27 cm) square in size. An example image of a cage 28 containing a test pouch 30 is shown in Figure 3.

[0250] To set up the test, carefully place the water-soluble pouch into the cage, without damaging the pouch on the cage and allowing the pouch to move in free space. Avoid tying the pouch tightly with the wire cage, again ensuring that the pouch is secured and does not come out of the cage. The orientation of the pouch within the cage, if any, should be such that the natural buoyancy of the pouch is allowed for (i.e., the side of the pouch that floats to the top should be placed facing upwards). If the pouch is asymmetrical, the orientation of the pouch is generally not critical.

[0251] Next, fill a 2 L beaker with 1200 mL of 20°C DI water.

[0252] The wire frame cage containing the sealed pouch is then lowered into the water. Ensure the cage is 1 inch (2.54 cm) from the bottom of the beaker. Ensure the pouch is fully submerged on all sides. Ensure the cage is stable and does not move, and start the timer as soon as the pouch is submerged. The position of the cage relative to the water in the beaker can be adjusted and maintained by any suitable means, for example, by using a clamp fixed on the beaker and a rod attached to the top of the cage. The clamp can engage with the rod to fix the cage's position, and tension can be applied to the clamp to submerge the cage. Other means of frictional engagement can be used in place of the clamp, for example, a collar with a setscrew as shown in Figure 4 (setscrew not shown). FIG. 4 shows beaker 30 resting on stand 40, which holds rod 50 for lowering cage 10 (not shown) into beaker 30, and rod 50 can be held in a vertically fixed position by the use of a collar 60 having a set screw (not shown) that engages rod 50, for example, by friction or by engagement with a hole (not shown) in rod 50.

[0253] Release of the liquid contents is defined as the first visual evidence of liquid leaving the pouch submerged.

[0254] The following embodiments are specifically contemplated:

[0255] In some embodiments, the nonwoven web comprises a polymer blend. The polymer blend can comprise a first anionic group-modified polyvinyl alcohol polymer in an amount ranging from about 30 wt% to about 85 wt%, or from about 50 wt% to about 85 wt%, based on the weight of the nonwoven web, and a second polyvinyl alcohol homopolymer in an amount ranging from about 15 wt% to about 70 wt%, or from about 15 wt% to about 50 wt%, based on the weight of the nonwoven web. The basis weight of the nonwoven web comprising the polymer blend can be about 10 g / m 2 to approximately 80 g / m 2, about 20g / m 2 to about 70 g / m 2 , about 30g / m 2 to about 60g / m 2 or approximately 40 g / m 2 to about 50 g / m 2 in the range of, for example, about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75 or 80 g / m 2The coefficient of static friction of the nonwoven web comprising the polymer blend can be less than about 0.90, less than about 0.85, or less than about 0.80, e.g., about 0.10, 0.25, 0.50, 0.60, 0.70, 0.71, 0.72, 0.73, 0.74, 0.75, 0.76, 0.77, 0.78, 0.79, 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, or 0.90. The ratio of the static coefficient of friction to the kinetic coefficient of friction of the nonwoven web comprising the polymer blend can range from about 0.90 to about 1.10 or from about 0.95 to about 1.05, e.g., about 0.90, 0.95, 0.98, 0.99, 1.00, 1.01, 1.02, 1.05, or 1.10. The yellowness index of the nonwoven web comprising the polymer blend, as measured using ASTM E313, can be less than about 5, less than about 4, or less than about 3. For example, the yellowness index of the nonwoven web comprising the polymer blend can be about 2.50, 2.75, 3.00, 3.10, 3.15, 3.20, 3.25, 3.30, 3.40, 3.50, 3.75, 4.00, 4.25, 4.50, 4.75, or 5.00. The whiteness index of the nonwoven web comprising the polymer blend, as measured using ASTM E313, can range from about 40 to about 70, from about 45 to about 65, or from about 50 to about 60. For example, the whiteness index of the nonwoven web comprising the polymer blend can be about 40, 42, 45, 48, 49, 50, 52, 55, 56, 58, 60, 62, 65, 67, or 70. The brightness of the nonwoven web comprising the polymer blend can range from about 40 to about 70, from about 45 to about 65, or from about 50 to about 60, as measured using a TAPPI 452. For example, the brightness of the nonwoven web comprising the polymer blend can be about 40, 42, 45, 47, 49, 50, 52, 54, 55, 56, 58, 60, 62, 65, 67, or 70.

[0256] In some embodiments, the nonwoven web comprises a single polyvinyl alcohol homopolymer. The degree of hydrolysis of the PVOH homopolymer can range from about 85% to about 99%, for example, about 85%, 88%, 90%, 92%, 94%, 96%, 98%, or 99%. The basis weight of the nonwoven web comprising the single PVOH homopolymer is about 10 g / m. 2 to about 60g / m 2 , about 20g / m 2 to about 50 g / m 2 or approximately 30 g / m 2 to about 40 g / m 2 in the range of, for example, about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55 or 60 g / m 2The coefficient of static friction of nonwoven webs comprising a single PVOH homopolymer can be less than about 0.90, less than about 0.70, or less than about 0.40, e.g., about 0.10, 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, or 0.90. The ratio of static to kinetic coefficient of friction of nonwoven webs comprising a single PVOH homopolymer can range from about 0.90 to about 1.10 or from about 0.95 to about 1.05, e.g., about 0.90, 0.95, 0.98, 0.99, 1.00, 1.01, 1.02, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, or 1.10. The yellowness index of nonwoven webs comprising the polymer blends can be less than about 5, less than about 4, or less than about 3, as measured using ASTM E313. For example, the yellowness index of nonwoven webs comprising a single PVOH homopolymer can be about 1.00, 1.25, 1.50, 1.75, 2.00, 2.50, 2.55, 2.60, 2.75, 3.00, 3.25, 3.30, 3.40, 3.50, 3.75, 4.00, 4.25, 4.50, 4.75, or 5.00. The whiteness index of nonwoven webs comprising a single PVOH homopolymer can range from about 40 to about 70, from about 45 to about 65, or from about 50 to about 60, as measured using ASTM E313. For example, the whiteness of nonwoven webs comprising the polymer blends can be about 40, 42, 45, 48, 49, 50, 51, 52, 54, 55, 56, 58, 60, 62, 65, 67, or 70. The brightness of nonwoven webs comprising a single PVOH homopolymer can range from about 40 to about 70, from about 45 to about 65, or from about 50 to about 60, as measured using a TAPPI 452. For example, the brightness of nonwoven webs comprising the polymer blends can be about 40, 42, 45, 47, 49, 50, 52, 54, 55, 56, 58, 59, 60, 62, 65, 67, or 70.

[0257] One or more optional features, which can be used individually or in combination, are described in the following paragraphs. Optionally, the fibers of the present disclosure are comprised of a monofilament-forming material. Optionally, the fibers of the present disclosure are comprised of a polyvinyl alcohol homopolymer. Optionally, the polyvinyl alcohol homopolymer can have a degree of hydrolysis ranging from 85% to 99.9%, e.g., 88%, 96%, 98%, or 99.9%. Optionally, the fibers of the present disclosure can include a blend of fiber-forming materials. Optionally, the blend of fiber-forming materials can include a polyvinyl alcohol homopolymer in combination with a polyvinyl alcohol copolymer or a second polyvinyl alcohol homopolymer. Optionally, the polyvinyl alcohol homopolymer can have a degree of hydrolysis ranging from 85% to 99.9%, e.g., 88%, 96%, 98%, or 99.9%. Optionally, the polyvinyl alcohol copolymer can be an anionically modified polyvinyl alcohol copolymer. Optionally, the anionically modified polyvinyl alcohol copolymer can be an AMPS copolymer having a degree of modification of about 2 mol.% to about 10 mol.%, for example, 2 mol.%. Optionally, fibers containing a blend of fiber-forming materials can include a homopolymer in an amount of 30 wt.% and a copolymer in an amount of 70 wt.%, based on the total weight of the fiber-forming materials. Optionally, fibers containing a blend of polyvinyl alcohol homopolymers can include a first polyvinyl alcohol homopolymer in an amount of about 25 wt.% to 75 wt.%, for example, about 25 wt.%, 50 wt.%, or 75 wt.%, based on the total weight of the fiber-forming materials, and a second polyvinyl alcohol homopolymer in an amount of about 75 wt.% to about 25 wt.%, for example, about 75 wt.%, 50 wt.%, or 25 wt.%, based on the total weight of the fiber-forming materials. Optionally, the fibers can have a complete melt temperature in the range of about 20°C to about 90°C, for example, about 20°C, about 40°C, about 70°C, or about 90°C. Optionally, the nonwoven web can be a multi-layer nonwoven web. Optionally, the multi-layer nonwoven web can include a first nonwoven web including only one fiber type and a second nonwoven web including only one fiber type.Optionally, the multilayer nonwoven web can include a first nonwoven web including a blend of fiber types and a second nonwoven web including only one fiber type. Optionally, the carded web can be calendered. Optionally, the carded web can be needle-perforated prior to calendering.

[0258] Optionally, the nonwoven web can have a dynamic coefficient of friction in the range of about 0.30 to about 0.90, e.g., 0.31, 0.62, 0.77, 0.78, 0.82, or 0.86. Optionally, the nonwoven web can have a static coefficient of friction in the range of about 0.30 to about 0.90, e.g., 0.34, 0.65, 0.78, 0.79, 0.83, or 0.90. Optionally, the nonwoven web can have a ratio of static to kinetic coefficient of friction in the range of about 1.00 to about 1.10, e.g., 1.01, 1.02, 1.04, 1.05, or 1.09. Optionally, the nonwoven web can have a ratio of static to kinetic coefficient of friction in the range of about 1.00 to about 11.2 N / mm in the machine direction. 2 range, for example, about 1.00 N / mm 2 , 1.53N / mm 2 , 1.64N / mm 2 , 5.99N / mm 2 , 7.36N / mm 2 or 11.11N / mm 2 Optionally, the nonwoven web can have a maximum stress of from about 0.20 to about 5.90 N / mm in the cross direction. 2 , for example, about 0.22 N / mm 2 , 0.42N / mm 2 , 0.51N / mm 2 , 2.76N / mm 2 , 4.28N / mm 2 or 5.86N / mm 2Optionally, the nonwoven web can have a ratio of maximum stress in the machine direction to maximum stress in the cross direction of about 1.4 to about 4.7, e.g., 1.40, 1.90, 2.67, 3.02, 3.91, or 4.64. Optionally, the nonwoven web can have a breaking strain in the machine direction of about 6.80 to 359.00%, e.g., 6.83%, 58.19%, 59.91%, 129.73%, 144.39%, and 358.84%. Optionally, the nonwoven web can have a breaking strain in the cross direction of about 130.00 to about 300.00%, e.g., about 130.17%, 163.84%, 173.75%, 195.34%, 250.02%, or 299.42%. Optionally, the nonwoven web can have a breaking strain in the machine direction relative to the breaking strain in the cross direction of about 0.04 to about 1.9, e.g., about 0.04, 0.20, 0.23, 0.79, 1.11, or 1.85. Optionally, the nonwoven web can have a yellowness index value in the range of about 2.5 to about 3.255, e.g., about 2.56, 2.58, 3.2, 3.21, and 3.52. Optionally, the nonwoven web can have a whiteness value in the range of about 42.00 to about 57.00, e.g., about 42.36, 48.90, 51.24, 51.74, 54.41, or 56.90. Optionally, the nonwoven web can have a brightness value ranging from about 47.80 to about 62.4, e.g., about 47.88, 54.67, 56.01, 56.50, 59.42, or 62.35. Optionally, the nonwoven web can have a brightness value ranging from about 1×10 10 From 1×10 12 Ω range, e.g., 1×10 10 Ω, 1×10 11 Ω or 1×10 12 It may have a surface resistivity of Ω.

[0259] Optionally, the nonwoven web can be a single-layer nonwoven web made of a monofilament type of monofilament forming material and have a basis weight in the range of about 15 to about 50 GSM, e.g., 15.5 GSM, 16.8 GSM, 17 GSM, 17.5 GSM, 18.9 GSM, 19.3 GSM, 19.5 GSM, 19.6 GSM, 19.7 GSM, 21.0 GSM, 22.2 GSM, 22.9 GSM, 23.1 GSM, 23.5 GSM, 25.1 GSM, 27.7 GSM, 32.4 GSM, 33.4 GSM, 38.0 GSM, 39.7 GSM, 40.0 GSM, 40.1 GSM, 41.8 GSM, 42.5 GSM, 43.8 GSM, 45.3 GSM, or 44.7 GSM. Optionally, the nonwoven web can be a single-layer nonwoven web made of a monofilament type, the monofilament type being a single polyvinyl alcohol fiber-forming material having a degree of hydrolysis ranging from 88% to 96%, and having a hydrolysis time at 23°C ranging from about 5.00 seconds to about 140.00 seconds, for example, 8.00 seconds, 8.67 seconds, 10.33 seconds, 13.33 seconds, 13.67 seconds, 15.67 seconds, 16.67 seconds, and a single polyvinyl alcohol fiber forming material having a time to rupture of 18.33 seconds, 20.67 seconds, 21.33 seconds, 22.33 seconds, 24.67 seconds, 68.33 seconds, 73.67 seconds, 85.33 seconds, 90.00 seconds, 90.33 seconds, 92.33 seconds, 97.00 seconds, 128.33 seconds, 131.00 seconds, 133.67 seconds, 136.33 seconds, 138.67 seconds, or 140.00 seconds. Optionally, the nonwoven web can be a single-layer nonwoven web made of a monofilament type, the monofilament type being made of a single polyvinyl alcohol fiber-forming material having a degree of hydrolysis ranging from 88% to 96% and having a disintegration time at 23°C ranging from about 19.00 seconds to about 209.00 seconds, e.g., 19.00 seconds, 21.33 seconds, 23.00 seconds, 24.00 seconds, 28.00 seconds, 28.67 seconds, 29.00 seconds, 34.67 seconds, 35.00 seconds, 30.67 seconds, 31.33 seconds, 42.67 seconds, 127.50 seconds, 134.50 seconds, 140.50 seconds, 175.67 seconds, 189.00 seconds, 191.67 seconds, 193.33 seconds, or 209.00 seconds.Optionally, the nonwoven web can be a single-layer nonwoven web comprised of a monofilament type comprising a single polyvinyl alcohol fiber-forming material having a degree of hydrolysis ranging from 88% to 96% and having a time to rupture at 40°C ranging from about 1.30 seconds to about 11.00 seconds, e.g., 1.22 seconds, 1.33 seconds, 2.00 seconds, 2.33 seconds, 2.67 seconds, 3.00 seconds, 3.33 seconds, 4.33 seconds, 5.00 seconds, 5.33 seconds, 5.67 seconds, 6.33 seconds, 6.67 seconds, 8.67 seconds, 9.00 seconds, or 11.00 seconds. Optionally, the nonwoven web can be a single-layer nonwoven web made of a monofilament type, the monofilament type being made of a single polyvinyl alcohol fiber-forming material having a degree of hydrolysis in the range of 88% to 96% and having a disintegration time at 40°C in the range of about 3.00 seconds to about 27.00 seconds, e.g., 3.00 seconds, 3.33 seconds, 3.67 seconds, 4.00 seconds, 4.67 seconds, 5.00 seconds, 5.33 seconds, 6.67 seconds, 7.00 seconds, 7.67 seconds, 8.33 seconds, 9.67 seconds, 10.67 seconds, 13.33 seconds, 14.33 seconds, 15.33 seconds, 15.67 seconds, 16.00 seconds, 20.33 seconds, or 26.67 seconds. Optionally, the nonwoven web can be a single-layer nonwoven web made of a monofilament type, the monofilament type being made of a single polyvinyl alcohol fiber-forming material having a degree of hydrolysis of 98% and having a time to rupture in the range of about 2.00 seconds to about 7.00 seconds, e.g., 2.33 seconds, 2.67 seconds, 3.33 seconds, 4.33 seconds, or 7.00 seconds, at 80° C. Optionally, the nonwoven web can be a single-layer nonwoven web made of a monofilament type, the monofilament type being made of a single polyvinyl alcohol fiber-forming material having a degree of hydrolysis of 98% and having a disintegration time in the range of about 5.00 seconds to about 34.00 seconds, e.g., 5.33 seconds, 7.67 seconds, 9.00 seconds, 10.33 seconds, 15.33 seconds, or 33.67 seconds, at 80° C.Optionally, the nonwoven web can be a single-layer nonwoven web made of a monofilament type, the monofilament type being made of a single polyvinyl alcohol fiber-forming material having a degree of hydrolysis of 99.9% and having a time to rupture in the range of 5.00 seconds to about 90.00 seconds, e.g., 5.33 seconds, 7.67 seconds, 9.33 seconds, or 89.67 seconds, at 90° C. Optionally, the nonwoven web can be a single-layer nonwoven web made of a monofilament type, the monofilament type being made of a single polyvinyl alcohol fiber-forming material having a degree of hydrolysis of 99.9% and having a disintegration time in the range of about 9.5 seconds to about 180.00 seconds, e.g., 9.67 seconds, 15.67 seconds, 36.00 seconds, or 179.5 seconds, at 90° C.

[0260] Optionally, the nonwoven web can be a single-layer nonwoven web comprising a blend of fiber types, including first fibers comprising a PVOH homopolymer having 88% DH and second fibers comprising a PVOH homopolymer having 96% DH, wherein the first fiber type is provided in a range of 25% to 75% by weight of the total fibers, e.g., 25%, 50%, or 75% by weight, and the second fiber type is provided in a range of 75% to 25% by weight of the total fibers, e.g., 25%, 50%, or 75% by weight. Optionally, a nonwoven web comprising a blend of fiber types having first fibers comprising a PVOH homopolymer having 88% DH and second fibers comprising a PVOH homopolymer having 96% DH can have a basis weight ranging from about 32.5 GSM to about 50.0 GSM, e.g., 32.9 GSM, 40.2 GSM, 43.7 GSM, 43.8 GSM, 43.9 GSM, 41.6 GSM, 44.5 GSM, 44.9 GSM, 45.3 GSM, 45.9 GSM or 47.9 GSM. Optionally, a nonwoven web comprising a blend of fiber types having first fibers comprising a PVOH homopolymer having 88% DH and second fibers comprising a PVOH homopolymer having 96% DH can have a time to rupture at 23°C in the range of about 69.00 seconds to about 122.00 seconds, e.g., 69.00 seconds, 76.33 seconds, 78.33 seconds, 87.00 seconds, 93.33 seconds, 93.67 seconds, 99.00 seconds, 101.00 seconds, 102.67 seconds, 107.67 seconds, 108.67 seconds, or 121.33 seconds. Optionally, a nonwoven web comprising a blend of fiber types having first fibers comprising a PVOH homopolymer having 88% DH and second fibers comprising a PVOH homopolymer having 96% DH can have a disintegration time in the range of about 121.00 seconds to about 164.00 seconds, e.g., 121.00 seconds, 122.67 seconds, 134.67 seconds, 145.00 seconds, 146.67 seconds, 154.33 seconds, 156.00 seconds, 161.33 seconds, or 164.00 seconds.Optionally, a nonwoven web comprising a blend of fiber types having first fibers comprising a PVOH homopolymer having 88% DH and second fibers comprising a PVOH homopolymer having 96% DH can have a time to rupture in the range of about 4.00 seconds to about 8.00 seconds, e.g., about 4.33 seconds, 5.00 seconds, 5.33 seconds, 5.67 seconds, 6.00 seconds, 7.00 seconds, or 7.67 seconds, at 43° C. Optionally, a nonwoven web comprising a blend of fiber types having first fibers comprising a PVOH homopolymer having 88% DH and second fibers comprising a PVOH homopolymer having 96% DH can have a disintegration time in the range of about 9.5 seconds to about 19.00 seconds, e.g., about 9.67 seconds, 10.00 seconds, 11.00 seconds, 12.00 seconds, 12.67 seconds, 13.00 seconds, 18.00 seconds, or 19.00 seconds, at 40° C.

[0261] Optionally, the nonwoven web can be a multilayer nonwoven web comprising one or more layers of a nonwoven comprising only fibers whose sole fiber-forming material comprises a PVOH homopolymer having a DH of 88% and one or more layers of a second nonwoven comprising only fibers whose sole fiber-forming material comprises a PVOH homopolymer having a DH of 96% and a basis weight of 40 GSM. Optionally, the multilayer nonwoven comprises two layers of nonwoven comprising only fibers whose sole fiber-forming material comprises a PVOH homopolymer having a DH of 88%. Optionally, the multilayer nonwoven comprises two layers of nonwoven comprising only fibers whose sole fiber-forming material comprises a PVOH homopolymer having a DH of 96%. Optionally, the multilayer nonwoven comprises one layer of nonwoven comprising only fibers whose sole fiber-forming material comprises a PVOH homopolymer having a DH of 88% and one layer of nonwoven comprising only fibers whose sole fiber-forming material comprises a PVOH homopolymer having a DH of 96%. Optionally, a multilayer nonwoven web comprising one or more layers of a nonwoven comprising only fibers whose sole fiber-forming material comprises a PVOH homopolymer having a DH of 88% and one or more layers of a second nonwoven comprising only fibers whose sole fiber-forming material comprises a PVOH homopolymer having a DH of 96% can have a time to rupture at 23° C. ranging from about 18.5 seconds to about 108.5 seconds, e.g., about 18.67 seconds, 23.00 seconds, 94.67 seconds, 101.00 seconds, 103.33 seconds, or 108.33 seconds. Optionally, a multilayer nonwoven web comprising two layers of nonwoven comprising only fibers whose sole fiber-forming material comprises a PVOH homopolymer having a DH of 88% can have a disintegration time at 23° C. ranging from about 38.5 seconds to about 47.00 seconds, e.g., 38.67 seconds or 46.67 seconds.Optionally, a multi-layer nonwoven web comprising one or more layers of a nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% and one or more layers of a second nonwoven comprising only fiber-forming material comprising a PVOH homopolymer having a DH of 96% can have a time to rupture at 40°C of about 2.00 seconds to about 7.5 seconds, e.g., about 2.33 seconds, about 3.33 seconds, about 5.00 seconds, about 5.67 seconds, about 6.33 seconds, or about 7.33 seconds. Optionally, a multi-layer nonwoven web comprising one or more layers of a nonwoven comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% and one or more layers of a second nonwoven comprising only fiber-forming material comprising a PVOH homopolymer having a DH of 96% can have a disintegration time at 40°C of about 4.00 seconds to about 17.00 seconds, e.g., 4.00 seconds, 14.33 seconds, 15.67 seconds, 16.00 seconds, or 17.00 seconds.

[0262] Optionally, the nonwoven web can be a single-layer nonwoven web comprising a blend of fibers having first PVOH fibers comprising a fiber-forming material including a PVOH homopolymer having a DH of 96% and second non-PVOH fibers comprising a fiber-forming material selected from the group consisting of polyethylene terephthalate, polylactide, viscose, cellulose, and cotton, the nonwoven web having a basis weight of 50 GSM. Optionally, the single-layer nonwoven web comprising a blend of fibers comprising the first PVOH fibers and the second non-PVOH fibers can have a time to rupture at 23° C. in the range of about 123.00 seconds to about 158.00 seconds, e.g., 123.33 seconds, 130.67 seconds, 134.33 seconds, 144.67 seconds, or 158.00 seconds. Optionally, a single layer nonwoven web comprising a blend of fibers comprising a first PVOH fiber and a second non-PVOH fiber can have a time to rupture at 40° C. in the range of about 2.00 seconds to about 7.5 seconds, e.g., 2.33 seconds, 3.33 seconds, 5.00 seconds, 5.67 seconds, 6.33 seconds, or 7.33 seconds. Optionally, a single layer nonwoven web comprising a blend of fibers comprising a first PVOH fiber and a second non-PVOH fiber can have a softness value in the range of 2 to 4, e.g., 2, 3, or 4.

[0263] Optionally, the nonwoven web can be a single-layer nonwoven web comprising a blend of two fibers, each fiber comprising only one PVOH homopolymer fiber-forming material having a DH selected from the group consisting of 88%, 96%, 98%, and 99.9%, with at least one fiber having a PVOH homopolymer fiber-forming material with a DH of 98% or 99.9%. Optionally, the single-layer nonwoven web comprising a blend of two fibers, including at least one fiber having a PVOH homopolymer fiber-forming material with a DH of 98% or 99.9%, can have a basis weight of 40 GSM. Optionally, a single layer nonwoven web comprising a blend of two fibers includes at least one fiber having a PVOH homopolymer having a DH of 98% and a second PVOH homopolymer fiber having a DH of 88% or 96%, and the nonwoven web can have a time to rupture at 80°C in the range of about 1.50 seconds to about 10.5 seconds, e.g., 1.67 seconds, 2.00 seconds, 2.33 seconds, 2.67 seconds, 3.00 seconds, 3.33 seconds, 4.33 seconds, 4.67 seconds, 5.00 seconds, or 10.33 seconds. Optionally, a single layer nonwoven web comprising a blend of two fibers includes at least one fiber having a PVOH homopolymer having a DH of 98% and a second PVOH homopolymer fiber having a DH of 88% or 96%, and the nonwoven web can have a disintegration time at 80°C in the range of about 4.00 seconds to about 32.00 seconds, e.g., 4.00 seconds, 4.33 seconds, 5.00 seconds, 5.33 seconds, 6.00 seconds, 6.67 seconds, 7.67 seconds, 9.33 seconds, 10.00 seconds, 13.67 seconds, 21.00 seconds, 21.33 seconds, or 32.00 seconds.Optionally, a single layer nonwoven web comprising a blend of two fibers includes at least one fiber having a PVOH homopolymer having a DH of 99.9% and a second PVOH homopolymer fiber having a DH of 88%, 96%, or 98%, and the nonwoven web can have a time to rupture at 90°C in the range of about 2.00 seconds to about 93.5 seconds, e.g., 2.00 seconds, 3.00 seconds, 3.33 seconds, 4.33 seconds, 5.33 seconds, 6.67 seconds, 7.00 seconds, 7.33 seconds, 7.67 seconds, 8.00 seconds, 11.67 seconds, 13.67 seconds, 15.00 seconds, 16.33 seconds, 17.00 seconds, 18.33 seconds, 23.33 seconds, or 93.33 seconds. Optionally, a single layer nonwoven web comprising a blend of two fibers includes at least one fiber having a PVOH homopolymer having a DH of 99.9% and a second PVOH homopolymer fiber having a DH of 88%, 96%, or 98%, and the nonwoven web can have a disintegration time at 90°C in the range of about 5.00 seconds to about 168.5 seconds, e.g., 5.33 seconds, 6.33 seconds, 6.67 seconds, 7.00 seconds, 8.33 seconds, 9.33 seconds, 10.33 seconds, 13.00 seconds, 13.33 seconds, 16.67 seconds, 18.33 seconds, 21.33 seconds, 21.67 seconds, 39.00 seconds, 41.00 seconds, 42.33 seconds, 19.33 seconds, 54.67 seconds, 64 seconds, 74.00 seconds, or 168.5 seconds.

[0264] Optionally, the nonwoven web can be a monolayer nonwoven web comprising a blend of two fibers, each fiber comprising only one PVOH homopolymer fiber-forming material having a DH selected from the group consisting of 88%, 96%, 98%, and 99.9%, with at least one fiber comprising a PVOH homopolymer fiber-forming material having a DH of 98%. Optionally, the monolayer nonwoven web comprising a blend of two fibers, comprising at least one fiber comprising a PVOH homopolymer fiber-forming material having a DH of 98%, can have a basis weight of 50 GSM. Optionally, the monolayer nonwoven web comprising a blend of two fibers comprises at least one fiber comprising a PVOH homopolymer fiber having a DH of 98%, with the second PVOH homopolymer fiber having a DH of 88% or 96%, and the nonwoven web can have a thinning time at 40° C. ranging from about 5.00 seconds to about 18.5 seconds, e.g., 5.33 seconds, 7.33 seconds, 10.00 seconds, or 18.33 seconds.

[0265] Optionally, the nonwoven web can be a multi-layer nonwoven web comprising two layers of nonwoven web, each layer comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88%, 96%, 98%, or 99.9% and a basis weight of 100 GSM or 60 GSM. Optionally, the multi-layer nonwoven fabric comprises one layer of a nonwoven web comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88%, and one layer comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 96%, 98%, or 99.9%. Optionally, the multi-layer nonwoven fabric comprises one layer of a nonwoven web comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 96%, and one layer comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88%, 98%, or 99.9%. Optionally, the multilayer nonwoven fabric comprises one layer of a nonwoven web comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 98% and one layer comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% or 96%. Optionally, the multilayer nonwoven fabric comprises one layer of a nonwoven web comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 99.9% and one layer comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% or 96%. Optionally, the multilayer nonwoven fabric comprises one layer of a nonwoven web comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 88% and one layer comprising only fibers having a sole fiber-forming material comprising a PVOH homopolymer having a DH of 98%, the multilayer nonwoven fabric having a total basis weight of up to 100 GSM and a thinning time at 40°C in the range of 98.00 seconds to 134.00 seconds, e.g., 98.00 seconds or 133.67 seconds.Optionally, a multi-layer nonwoven web comprising two layers of nonwoven web, each layer containing only fibers having a DH of 88%, 96%, 98%, or 99.9% and having a sole fiber-forming material comprising a PVOH homopolymer having a basis weight of 60 GSM, can have a thinning time at 40°C in the range of about 6.00 seconds to about 140.5 seconds, e.g., 6.00 seconds, 7.00 seconds, 29.67 seconds, 44.33 seconds, 46.33 seconds, 63.33 seconds, 73.67 seconds, 94.67 seconds, 133.67 seconds, or 140.33 seconds.

[0266] Optionally, the nonwoven web can be a single-layer nonwoven having only fibers with a sole fiber-forming material comprising a PVOH homopolymer having a degree of hydrolysis of 99.9%, the nonwoven having a basis weight of 40 GSM and having at least 20% degradation as determined by the flushability test herein. Optionally, the nonwoven web can be (a) a monolayer nonwoven having only fibers whose only fiber-forming material comprises PVOH homopolymer having a degree of hydrolysis of 88%, 96%, or 98% and a basis weight of about 20 to about 40 GSM, or (b) a multilayer nonwoven web having a basis weight in the range of about 30 GSM to about 50 GSM, both layers comprising only fibers whose only fiber-forming material is PVOH homopolymer, the layers having PVOH homopolymer having degrees of hydrolysis of (i) 88% and 96%; (ii) 88% and 98%; (iii) 88% and 99.9%; or (iv) 96% and 98%, wherein the multilayer nonwoven web has at least 40% disintegration as determined by the flushability test herein.

[0267] The following types of embodiments are specifically contemplated: [Table 16]

[0268] Generally, all water-dispersible webs that are water-soluble can be flushable, provided that any additives added to the web are suitable for disposal in a liquid sewer system.The water-dispersible webs of the present disclosure can also be flushable, for example, if the web contains water-soluble fibers in an amount that allows sufficient disintegration of the web compared to any water-insoluble fibers, and / or if the water-insoluble fibers contain a sufficient amount of water-soluble resin in the fibers to allow sufficient disintegration of the web, i.e., at least 20% disintegration, as determined by the flushability test disclosed herein.The following types of embodiments are specifically contemplated: [Table 17-1] [Table 17-2] [Table 17-3] [Table 17-4] [Table 17-5] [Table 17-6] [Table 17-7] [Table 17-8] [Table 17-9] [Table 17-10]

[0269] In the above embodiments involving a blend of water-soluble fiber-forming materials in a water-soluble fiber, the water-soluble fiber-forming materials can include one or more PVOH homopolymers, one or more PVOH copolymers, one or more non-PVOH polymers, or combinations thereof. The following types of refinements of the above-described embodiments are contemplated, where refinements where only one type of polymer is specified are intended to refer to a blend of the specified polymer types: [Table 18-1] [Table 18-2] [Table 18-3] [Table 18-4] [Table 18-5] [Table 18-6] [Table 18-7] [Table 18-8] [Table 18-9]

[0270] In the above embodiments involving blends of fiber-forming materials in water-insoluble fibers, the fiber-forming materials can include one or more water-insoluble polymers and, optionally, one or more water-soluble polymers, where the one or more water-soluble polymers can include one or more PVOH homopolymers, one or more PVOH copolymers, one or more non-PVOH polymers, or combinations thereof. The following types of refinements of the above-described embodiments are contemplated, where refinements where only one type of polymer is specified are intended to refer to a blend of the specified polymer types: [Table 19-1] [Table 19-2] [Table 19-3] [Table 19-4] [Table 19-5] [Table 19-6] [Table 19-7] [Table 19-8] [Table 19-9] [Table 19-10] [Table 19-11]

[0271] Particularly contemplated embodiments of the present disclosure are described herein in the following numbered paragraphs, which are intended to be illustrative and not limiting in nature.

[0272] Paragraph 1. A water-dispersible nonwoven web comprising a plurality of water-soluble fibers.

[0273] Paragraph 2. The water-dispersible nonwoven web of Paragraph 1, wherein the plurality of water-soluble fibers comprises a blend of water-soluble polymers.

[0274] Paragraph 3. The water-dispersible nonwoven web of paragraph 1 or paragraph 2, wherein the plurality of water-soluble fibers comprises fibers comprising a polyvinyl alcohol polymer fiber-forming material.

[0275] Paragraph 4. The water-dispersible nonwoven web of Paragraph 3, wherein the polyvinyl alcohol polymer comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

[0276] Paragraph 5. The water-dispersible nonwoven web of paragraphs 3 or 4, wherein the polyvinyl alcohol copolymer comprises an anionically modified polyvinyl alcohol copolymer.

[0277] Paragraph 6. The water-dispersible nonwoven web of Paragraph 5, wherein the anionically modified polyvinyl alcohol copolymer has a degree of modification ranging from about 1 mol.% to about 10 mol.%.

[0278] Paragraph 7. The water-dispersible nonwoven web of any one of Paragraphs 3 through 6, wherein the polyvinyl alcohol polymer comprises a polyvinyl alcohol homopolymer and a polyvinyl alcohol copolymer.

[0279] Paragraph 8. The water-dispersible nonwoven web of Paragraph 7, wherein the polyvinyl alcohol homopolymer comprises from about 15 wt.% to about 70 wt.%, based on the total weight of the polyvinyl alcohol polymers, and the copolymer comprises from about 30 wt.% to about 85 wt.%, based on the total weight of the polyvinyl alcohol polymers.

[0280] Paragraph 9. The water-dispersible nonwoven web of any one of Paragraphs 3 through 8, wherein the polyvinyl alcohol polymer has a degree of hydrolysis ranging from about 75% to about 99.9%.

[0281] Paragraph 10. The water-dispersible nonwoven web of paragraph 9, wherein the polyvinyl alcohol polymer has a degree of hydrolysis ranging from about 80% to about 90%.

[0282] Paragraph 11. The water-dispersible nonwoven web of Paragraph 9, wherein the polyvinyl alcohol polymer has a degree of hydrolysis ranging from about 92% to about 99%, optionally from about 98% to about 99%, optionally from about 98% to about 99.9%.

[0283] Paragraph 12. Multiple soluble fibers are a first water-soluble fiber; The second soluble fiber wherein the first and second water-soluble fibers have a diameter, length, tenacity, shape, stiffness, elasticity, water solubility, melting point, glass transition temperature (T g 12. The water-dispersible nonwoven web of any one of paragraphs 1 through 11, having differences in fiber chemistry, color, or combinations thereof.

[0284] Paragraph 13. The water-dispersible nonwoven web of any one of Paragraphs 1 through 12, further comprising a plurality of water-insoluble fibers.

[0285] Paragraph 14. The water-dispersible nonwoven web of Paragraph 13, wherein the plurality of water-soluble fibers constitutes from about 20% to about 80% by weight of the total weight of the fibers, and the plurality of water-insoluble fibers constitutes from about 20% to about 80% by weight of the total weight of the fibers.

[0286] Paragraph 15. The water-dispersible nonwoven web of Paragraph 13 or Paragraph 14, wherein the plurality of water-insoluble fibers comprises cotton, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, Dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polylactide, polyethylene terephthalate, or a combination thereof.

[0287] Paragraph 16. The water-dispersible nonwoven web of any one of Paragraphs 1 through 15, wherein the water-dispersible nonwoven web is biodegradable.

[0288] Paragraph 17. The water-dispersible nonwoven web of any one of Paragraphs 1 to 16, wherein the plurality of water-soluble fibers have a tenacity ranging from about 3 cN / dtex to about 10 cN / dtex, optionally from about 7 cN / dtex to about 10 cN / dtex.

[0289] Paragraph 18. The water-dispersible nonwoven web of Paragraph 17, wherein the plurality of water-soluble fibers have a tenacity ranging from about 4 cN / dtex to 8 cN / dtex, optionally from about 6 cN / dtex to about 8 cN / dtex.

[0290] Paragraph 19. The water-dispersible nonwoven web of any one of Paragraphs 1 through 18, wherein the plurality of water-soluble fibers comprises water-soluble fibers that include a plasticizer.

[0291] Paragraph 20. The water-dispersible nonwoven web of any one of Paragraphs 1 to 19, further comprising an active agent.

[0292] Paragraph 21. The water-dispersible nonwoven web of Paragraph 20, wherein the active agent is provided as part of the water-soluble fibers, dispersed within the nonwoven web, provided on a surface of the nonwoven web, or a combination thereof.

[0293] Paragraph 22. The water-dispersible nonwoven web of Paragraph 20 or Paragraph 21, wherein the active agent is selected from an enzyme, an oil, a flavor, a colorant, an odor absorber, a fragrance, a pesticide, a fertilizer, an activator, an acid catalyst, a metal catalyst, an ion scavenger, a cleaning agent, a disinfectant, a surfactant, a bleach, a bleaching component, a fabric softener, or a combination thereof.

[0294] Paragraph 23. The water-dispersible nonwoven web of any one of Paragraphs 1 to 22, wherein the plurality of water-soluble fibers have a diameter ranging from about 10 microns to about 300 microns, optionally from about 50 microns to about 300 microns, optionally from greater than 100 microns to about 300 microns.

[0295] Paragraph 24. The water-dispersible nonwoven web of any one of Paragraphs 1 to 23, wherein the plurality of water-soluble fibers have a substantially uniform diameter.

[0296] Paragraph 25. The water-dispersible nonwoven web of any one of Paragraphs 1 to 24, wherein the plurality of water-soluble fibers have a length ranging from about 30 mm to about 100 mm, or from about 30 mm to about 60 mm.

[0297] Paragraph 26. The water-dispersible nonwoven web of any one of Paragraphs 1 to 24, wherein the plurality of water-soluble fibers have a length less than about 30 mm, or in the range of about 0.25 mm to less than 30 mm.

[0298] Paragraph 27. The water-dispersible nonwoven web of any one of Paragraphs 1 to 26, wherein the nonwoven web is porous.

[0299] Paragraph 26. The water-dispersible nonwoven web of any one of paragraphs 1 through 20, wherein the nonwoven web is nonporous.

[0300] Paragraph 27. The water-dispersible nonwoven web of any one of Paragraphs 1 through 26, wherein the nonwoven web is colored, dyed, pigmented, or a combination thereof.

[0301] Paragraph 28. Nonwoven webs of approximately 1 g / m 2 to about 100 g / m 2 , about 20g / m2 to approximately 80 g / m 2 , about 30g / m 2 to about 100 g / m 2 , or approximately 25 g / m 2 to about 70 g / m 2 28. The nonwoven web of any one of paragraphs 1 through 27, having a basis weight of

[0302] Paragraph 29. The water-dispersible nonwoven web of any one of paragraphs 1 through 28, wherein at a given temperature, the water-dispersible nonwoven web dissolves at least about five times faster than a water-soluble film prepared from the same water-soluble polymer as the water-soluble fibers of the water-dispersible nonwoven web.

[0303] Paragraph 30. The plurality of water-soluble fibers comprises water-soluble fibers prepared by a wet-cooled gel spinning process, the wet-cooled gel spinning process comprising: a) dissolving a polymer in a solution to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide water-soluble fibers. 30. The water-dispersible nonwoven web of any one of paragraphs 1 to 29, comprising:

[0304] Paragraph 31. The water-dispersible nonwoven web of Paragraph 30, wherein finishing comprises cutting or crimping the extruded polymer mixture to provide water-soluble fibers.

[0305] Paragraph 32. The water-dispersible nonwoven web of paragraphs 30 or 31, wherein the coagulation bath comprises a mixture of solvents including a first solvent in which the water-soluble polymer is soluble and a second solvent in which the water-soluble polymer is not soluble.

[0306] Paragraph 33. The water-dispersible nonwoven web of any one of Paragraphs 30 through 32, wherein the solvent exchange bath consists essentially of a solvent in which the water-soluble polymer is not soluble.

[0307] Paragraph 34. The water-dispersible nonwoven web of any one of Paragraphs 30 through 33, wherein the water-soluble polymer comprises a blend of two or more different polymers.

[0308] Paragraph 35. The water-dispersible nonwoven web of any one of Paragraphs 30 through 34, wherein the water-soluble polymer has a degree of polymerization of at least 1,000.

[0309] Paragraph 36. The water-dispersible nonwoven web of any one of Paragraphs 30 to 35, wherein the water-soluble fibers have a fiber diameter in the range of 10 to 300 microns, 25 to 300 microns, 50 to 300 microns, or 75 to 100 microns.

[0310] Paragraph 37. The water-dispersible nonwoven web of any one of Paragraphs 30 to 36, wherein the water-soluble fibers have a tenacity ranging from about 5 cN / dtex to about 10 cN / dtex, or from about 6 cN / dtex to about 10 cN / dtex, or from about 7 cN / dtex to about 10 cN / dtex.

[0311] Paragraph 38. The water-dispersible nonwoven web of any one of Paragraphs 30 through 37, further comprising filaments prepared by a process selected from the group consisting of meltblowing, spunbonding, electrospinning, rotary spinning, continuous filament producing operations, tow fiber producing operations, and combinations thereof.

[0312] Paragraph 39. The water-dispersible nonwoven web of any one of paragraphs 1 to 38, wherein the water-dispersible nonwoven web is water-flushable.

[0313] Paragraph 40. A multi-layer water-dispersible nonwoven web, comprising a first water-dispersible nonwoven web according to any one of Paragraphs 1 to 39.

[0314] Paragraph 41. The multi-layer water-dispersible nonwoven web of Paragraph 40, further comprising the second water-dispersible nonwoven web of any one of Paragraphs 1 through 39.

[0315] Paragraph 42. The multi-layer water-dispersible nonwoven web of Paragraph 41, wherein the first water-dispersible nonwoven web and the second water-dispersible nonwoven web comprise the same fibers and have the same basis weight.

[0316] Paragraph 43. The multi-layer water-dispersible nonwoven web of Paragraph 41, wherein the first water-dispersible nonwoven web and the second water-dispersible nonwoven web comprise different fibers and have the same basis weight.

[0317] Paragraph 44. The multi-layer water-dispersible nonwoven web of Paragraph 41, wherein the first water-dispersible nonwoven web and the second water-dispersible nonwoven web comprise different fibers and have different basis weights.

[0318] Paragraph 45. The multi-layer water-dispersible nonwoven web of any one of Paragraphs 41 to 43, wherein the first water-dispersible nonwoven web and the second water-dispersible nonwoven web are laminated to one another.

[0319] Paragraph 46. The multi-layer water-dispersible nonwoven web of any one of Paragraphs 40 through 45, further comprising a film laminated to the first water-dispersible nonwoven web.

[0320] Paragraph 47. The multi-layer water-dispersible nonwoven web of Paragraph 46, wherein the fibers of the first water-dispersible nonwoven web and the water-soluble film comprise the same water-soluble polymer.

[0321] Paragraph 48. The multi-layer water-dispersible nonwoven web of Paragraph 46, wherein the fibers of the first water-dispersible nonwoven web and the water-soluble film comprise different water-soluble polymers.

[0322] Paragraph 49. The multi-layer water-dispersible nonwoven web has a viscosity of about 1 g / m 2 to about 100 g / m 2 49. The multi-layer water-dispersible nonwoven web of any one of paragraphs 40 to 48, having a basis weight of

[0323] Paragraph 50. The multi-layer water-dispersible nonwoven web of any one of Paragraphs 40 to 48, wherein the first multi-layer water-dispersible nonwoven web is porous.

[0324] Paragraph 51. The multi-layer water-dispersible nonwoven web of any one of Paragraphs 40 to 48, wherein the multi-layer water-dispersible nonwoven web is non-porous.

[0325] Paragraph 52. The multi-layer water-dispersible nonwoven web of any one of Paragraphs 40 to 51, wherein the multi-layer water-dispersible nonwoven web is waterflushable.

[0326] Paragraph 53. A water-dispersible pouch comprising the water-dispersible nonwoven web of any one of Paragraphs 1 to 39 in the form of a pouch defining an interior pouch volume.

[0327] Paragraph 54. A water-dispersible pouch comprising the multi-layer water-dispersible nonwoven web of any one of Paragraphs 40 to 51 in the form of a pouch defining an interior pouch volume.

[0328] Paragraph 55. The water-dispersible pouch of Paragraph 54, wherein the multi-layer water-dispersible nonwoven web comprises a first water-dispersible nonwoven web and a water-soluble film, the water-soluble film forming an interior surface of the pouch.

[0329] Paragraph 56. A water-dispersible sealed article comprising the water-dispersible pouch of any one of Paragraphs 53 to 55.

[0330] Paragraph 57. The water-dispersible sealed article of Paragraph 56, further comprising a composition enclosed in the interior pouch volume.

[0331] Paragraph 58. The water-dispersible sealed article of Paragraph 56, wherein the composition enclosed in the interior pouch volume comprises a solid, a liquid, or a combination thereof.

[0332] Paragraph 59. The water-dispersible sealed article of Paragraph 58, wherein the composition enclosed in the inner pouch volume comprises a liquid.

[0333] Paragraph 60. The water-dispersible sealed article of Paragraph 58, wherein the composition enclosed in the inner pouch volume comprises a solid.

[0334] Paragraph 61. The water-dispersible sealed article of any one of Paragraphs 57 through 60, wherein the composition enclosed in the inner pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, a food nutrition composition, a pharmaceutical composition, an industrial cleaning composition, a disinfecting composition, a pet composition, an office composition, a livestock composition, an industrial composition, a marine composition, a commercial composition, a military composition, a recreational composition, or a combination thereof.

[0335] Paragraph 62. The water-dispersible sealed article of Paragraph 61, wherein the composition enclosed in the interior pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, a food nutrition composition, an industrial cleaning composition, or a combination thereof.

[0336] Paragraph 63. Forming the water-dispersible nonwoven web into the shape of a pouch; Filling the pouch with the composition to be enclosed therein; and sealing the pouch to form a sealed article 63. A method for preparing the water-dispersible sealing article of any one of paragraphs 57 to 62, comprising:

[0337] Paragraph 64. The method of Paragraph 63, wherein sealing the pouch comprises heat sealing, solvent welding, adhesive sealing, or a combination thereof.

[0338] Paragraph 65. The multi-layer water-dispersible nonwoven web of Paragraph 46 or Paragraph 47, wherein the water-soluble fibers of the first water-dispersible nonwoven web comprise a first polyvinyl alcohol homopolymer and the water-soluble film comprises a second polyvinyl alcohol homopolymer, the first and second polyvinyl alcohol homopolymers have the same degree of hydrolysis, the multi-layer water-dispersible nonwoven web has a dissolution time at 10°C similar to or faster than a water-soluble film comprising an anionically modified polyvinyl alcohol copolymer having the same degree of hydrolysis as the first and second polyvinyl alcohol homopolymers, and the water-dispersible nonwoven web has greater biodegradability than a water-soluble film comprising an anionically modified polyvinyl alcohol.

[0339] Paragraph 66. Water-soluble fibers, including blends of water-soluble polymers.

[0340] Paragraph 67. The water-soluble fiber of Paragraph 66, wherein the blend of water-soluble polymers includes a polyvinyl alcohol polymer.

[0341] Paragraph 68. The water-soluble fiber is prepared by a wet-cooled gel spinning process, and the wet-cooled gel spinning process is a) dissolving two or more polymers in a solution to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide water-soluble fibers. Soluble fiber of paragraph 66 or 67, including:

[0342] Paragraph 69. The water-soluble fiber of any one of Paragraphs 67 to 68, wherein the polyvinyl alcohol polymer has a degree of polymerization of at least 1000.

[0343] Paragraph 70. The water-soluble fiber of any one of Paragraphs 66 to 69, wherein the blend of water-soluble polymers comprises a blend of polyvinyl alcohol polymers.

[0344] Paragraph 71. The water-soluble fiber of Paragraph 70, wherein the blend of polyvinyl alcohol polymers comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

[0345] Paragraph 72. The water-soluble fiber of any one of Paragraphs 66 to 71, wherein the water-soluble fiber has a fiber diameter in the range of about 10 to about 300 microns, about 25 to about 300 microns, about 50 to about 300 microns, or at least about 100 to about 300 microns.

[0346] Paragraph 73. The water-soluble fiber of any one of Paragraphs 66 to 71, having a tenacity ranging from about 5 cN / dtex to about 10 cN / dtex, from about 6 cN / dtex to about 10 cN / dtex, or from about 7 cN / dtex to about 10 cN / dtex.

[0347] Paragraph 74. A water-dispersible nonwoven web comprising a plurality of water-soluble fibers of any one of Paragraphs 67 to 73.

[0348] Paragraph 75. A first layer comprising the water-soluble web of Paragraph 74; and (a) a second layer comprising a water-soluble web of paragraph 74; or (b) a second layer comprising a water-soluble film; A multi-layer water-dispersible nonwoven web comprising:

[0349] Paragraph 76. A water-dispersible pouch comprising the water-dispersible nonwoven web of Paragraph 74 in the form of a pouch defining an interior pouch volume.

[0350] Paragraph 77. A water-dispersible pouch comprising the multi-layer water-dispersible nonwoven web of Paragraph 75 in the form of a pouch defining an interior pouch volume.

[0351] Paragraph 78. A water-dispersible sealed article, including a water-dispersible pouch of paragraph 76 or paragraph 77.

[0352] Paragraph 79. The water-dispersible sealed article of Paragraph 78, further comprising a composition enclosed in the interior pouch volume.

[0353] Paragraph 80. The water-dispersible sealed article of Paragraph 79, wherein the composition enclosed in the interior pouch volume comprises a solid, a liquid, or a combination thereof.

[0354] Paragraph 81. The water-dispersible sealed article of Paragraph 79 or Paragraph 80, wherein the composition enclosed in the inner pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a water treatment composition, a personal care composition, a food nutritional composition, a pharmaceutical composition, a pet composition, an office composition, a livestock composition, an industrial composition, a marine composition, a commercial composition, a military composition, a recreational composition, or a combination thereof.

[0355] Paragraph 82. The water-dispersible sealed article of Paragraph 81, wherein the composition enclosed in the interior pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a water treatment composition, a personal care composition, a food nutrition composition, or a combination thereof.

[0356] Paragraph 83. Forming the water-dispersible nonwoven web into the shape of a pouch; Filling the pouch with the composition to be enclosed therein; and sealing the pouch to form a sealed article 82. A method for preparing the water-dispersible sealing article of any one of paragraphs 78 to 81, comprising:

[0357] Paragraph 84. The method of Paragraph 83, wherein sealing the pouch comprises heat sealing, solvent welding, adhesive sealing, or a combination thereof.

[0358] Paragraph 85. A wet chill gel spinning process, comprising: a) dissolving a water-soluble polymer in a solution to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide water-soluble fibers. 74. A method for preparing the water-soluble fiber of any one of paragraphs 66, 67, or 69 through 73, comprising:

[0359] Paragraph 86. The method of Paragraph 85, wherein finishing includes cutting or crimping the extruded polymer mixture to provide water-soluble fibers.

[0360] Paragraph 87. The method of Paragraph 85 or Paragraph 86, wherein the coagulation bath comprises a mixture comprising a first solvent in which the water-soluble polymer is soluble and a second solvent in which the water-soluble polymer is not soluble.

[0361] Paragraph 88. The method of any one of Paragraphs 85 to 87, wherein the solvent exchange bath consists essentially of a solvent in which the water-soluble polymer is not soluble.

[0362] Paragraph 89. A method of controlling the hand of a water-dispersible pouch or packet, comprising preparing a pouch or packet from a water-dispersible nonwoven web, the water-dispersible nonwoven web comprising a plurality of water-soluble fibers comprising a water-soluble polymer.

[0363] While the above embodiments are specifically contemplated, they are not intended to limit the scope of water-dispersible nonwoven webs according to the present disclosure in any way.

[0364] Water-dispersible nonwoven webs according to the present disclosure can be better understood in light of the following examples, which are intended merely to illustrate water-dispersible nonwoven webs and are in no way intended to limit their scope. [Example]

[0365] Example 1: Preparation of a nonwoven web Single-layer nonwoven webs were prepared from various water-soluble fibers as listed in Table 1 below. Briefly, water-soluble staple fibers were carded and then calendered or chemically bonded. Calendering was performed at temperatures between 160°C and 190°C and at a pressure of approximately 2 kg / m. 2This was done using an embossing roll with a pressure of approximately 2 kg / m. Conventional heated calender rolls made from cast iron or steel were used. Chemical bonding was performed as follows: an aqueous polyvinyl alcohol solution was prepared using the same polyvinyl alcohol used to prepare the fibers. Then, a sponge roller coated with the polyvinyl alcohol solution from a dip pan was used to bond the fibers at a pressure of approximately 2 kg / m. 2 The polyvinyl alcohol solution was coated onto the surface of the unbonded nonwoven web using a pressure of 1000 kJ / cm. [Table 1]

[0366] Thus, Example 1 illustrates the formation of a water-dispersible nonwoven web of the present disclosure.

[0367] Example 2: Nonwoven Web Properties The nonwoven web prepared according to Example 1 was tested for various mechanical and physical properties according to the methods described herein. The results are presented in Table 2. Table 2 also includes the mechanical and physical properties for a water-soluble film having a thickness of 3 mils and prepared from a polyvinyl alcohol homopolymer having a degree of hydrolysis of 88. The water-soluble film further contained about 26.5 PHR of plasticizer, about 0.4 PHR of surfactant, and about 0.2 PHR of other adjuvants. [Table 2]

[0368] Thus, Example 2 demonstrates that water-dispersible webs of the present disclosure have lower static CoF and static to dynamic CoF ratios (compare Sample 6 with Film 1, both prepared from a PVOH homopolymer having a degree of hydrolysis of 88), significantly higher slip, enhanced hand, and ease of processing into, for example, pouches, compared to water-soluble films prepared with similar PVOH polymers. Example 2 further demonstrates that there is a general trend toward higher CoF values ​​for nonwoven webs prepared from fibers having lower tenacity (compare Samples 1, 2, 3, and 6 with Samples 4 and 5).

[0369] (Example 3) Color Index The color index of the nonwoven web prepared according to Example 1 was tested according to procedures commonly used in the art: ASTM E313 (yellowness and whiteness) and TAPPI 452 (brightness). [Table 3]

[0370] Thus, Table 3 shows that the nonwoven webs of the present disclosure have suitable Yellowness Index, Whiteness, and Brightness values. Example 3 further demonstrates that using copolymers with higher substituent numbers as fibers results in improved Yellowness values ​​compared to fibers comprising homopolymers, which is expected when the functionality of the substituents on the PVOH backbone is increased.

[0371] (Example 4) Surface resistivity The surface resistivity of the nonwoven webs prepared according to Example 1 was tested as described above. [Table 4]

[0372] Thus, Example 4 shows that nonwoven fabrics according to the present disclosure generally exhibit higher surface resistivity compared to water-soluble films. Example 4 further shows that the use of fibers containing an anionically modified polyvinyl alcohol copolymer can result in nonwoven fabrics with slightly lower surface resistivity compared to nonwoven fabrics made from polyvinyl alcohol homopolymer fibers.

[0373] Example 5: Aging and Conditioning Water-dispersible nonwoven web samples prepared according to Example 1 were exposed for 24 hours to various temperature and humidity environments as described in Table 5. All samples were then conditioned in an ambient environment (i.e., 23°C, 35% RH) for 24 hours before testing. The mechanical properties of the conditioned samples were obtained as described above, and the results are presented in Table 5. [Table 5]

[0374] Table 5 shows that, as expected, Samples 4 and 5, prepared from fibers containing PVOH homopolymers with 98% and 96% hydrolysis, respectively, were not soluble in cold water. In contrast, Sample 6, prepared from fibers containing PVOH homopolymers with 88% hydrolysis, was soluble in cold water even after exposure to high temperature and humidity conditions. Comparison of Samples 5 and 7 demonstrates that mechanical properties, and the effect of humidity and temperature conditioning environments on mechanical properties, can be controlled by simply changing the applied bonding technique. Table 5 further demonstrates that the mechanical properties of water-dispersible nonwoven webs of the present disclosure are maintained and / or positively affected when exposed to high temperature and humidity environments.

[0375] (Example 6) ATR Crystallinity Ratio The crystallinity of water-dispersible nonwoven web samples prepared according to Example 1 was tested using FTIR-ATR, and the results are presented in Table 6. The absorbance of the shoulder / peak at 1141 cm is an indication of crystallinity, and the ratio of the peak height at 1141 cm to the peak height of the reference peak at 1420 provides the relative crystallinity between samples. Polyvinyl alcohol has a peak at 1141 cm as measured by FTIR (including FTIR-ATR). -1 It is well known in the art that crystalline cellulose has a peak at 1420 to 1430 cm, which is related to crystallinity. The ratio of the absorbance of this peak to the absorbance of a reference peak, typically 1420 to 1430 cm, -1 The peak maxima in the range (associated with CH bending absorption that is expected to be present in all polyvinyl alcohol homopolymers) allow for comparison of the relative differences in crystallinity between the various samples. [Table 6]

[0376] Table 6 shows the expected trend of increasing crystallinity with increasing degree of hydrolysis of the PVOH polymer used to prepare the fibers that were subsequently used to prepare the water-dispersible nonwoven webs of the present disclosure. A comparison of Table 6A and Table 6B further demonstrates the improved crystallinity ratio after heat sealing.

[0377] (Example 7) Single-layer nonwoven fabric containing a monofilament type containing a monofilament-forming material Single-layer nonwoven webs were prepared from various water-soluble fibers, as listed in Table 7A below. Briefly, water-soluble staple fibers were carded and then calender bonded. Calender bonding was performed using an embossing roll at a temperature between 120°C and 140°C and a pressure of about 25 to 50 PSI. Conventional heated calender rolls made from cast iron or steel were used. Calender speeds were between about 1 and 5 FPM. Fibers formed from a PVOH homopolymer with an 88% degree of hydrolysis have a complete melt temperature of 20°C, while fibers formed from a PVOH homopolymer with a 96% degree of hydrolysis have a complete melt temperature of 40°C. [Table 7A]

[0378] The solubility of the nonwoven webs was tested at 23° C. and 40° C. In particular, the time to burst and disintegration of the nonwoven webs was determined in accordance with MSTM-205, as described herein. The solubility, reported as time to burst, is presented below in Table 7B. [Table 7B]

[0379] Thus, Example 7 demonstrates that the solubility of nonwoven webs generally follows the same water solubility profile as the PVOH fiber-forming material from which they are constructed. In particular, for PVOH homopolymer fiber-forming materials, as the degree of hydrolysis increases (e.g., from 88% to 96%), the solubility of the fibers and nonwoven webs increases (e.g., requiring higher temperatures or longer times to rupture / disintegrate). Example 7 further demonstrates that for a given calendering temperature and pressure, the dissolution time of a nonwoven web generally improves as the basis weight increases. This relationship is particularly pronounced when the temperature of the dissolving water is lower than the complete dissolution temperature of the fibers comprising the nonwoven web. For example, compare Samples 12 and 18, and 13 and 19, each of which is prepared from a water-soluble fiber having a complete dissolution temperature of 40°C. At 23°C, Samples 12 and 13, with basis weights of 39.7 and 41.8, respectively (90 and 90.33 seconds, respectively), were slower to burst than Samples 18 and 19, with basis weights of 21 and 23.1, respectively (73.67 and 85.33 seconds, respectively). Example 7 further demonstrates that for a given calendering pressure, for nonwoven webs with identical fiber chemistry and similar basis weights, the dissolution time of the nonwoven web generally increases with increasing calendering temperature. This relationship is particularly pronounced when the temperature of the dissolving water is lower than the complete dissolution temperature of the fibers comprising the nonwoven web. For example, compare Samples 11 and 23, and 17 and 53, each of which was prepared from a water-soluble fiber with a complete dissolution temperature of 40°C. At 40°C, samples calendered at 140°C have longer dissolution times than samples calendered at 120°C (11 seconds compared to 6.67 seconds for samples with basis weights of 42.5 and 44.7, respectively; 6.67 seconds compared to 4.33 seconds for samples with basis weights of 19.3 and 19.5, respectively).The same trend was even more pronounced at 23°C, where samples calendered at 140°C had dissolution times of 138.67 seconds and 92.33 seconds (for nonwovens with basis weights of 42.5 and 19.3, respectively) compared to dissolution times of 97 seconds and 68.33 seconds (for nonwovens with basis weights of 44.7 and 19.5, respectively) for nonwovens calendered at 120°C.

[0380] Example 8: Single-layer nonwoven fabric comprising a blend of fiber types, each fiber type comprising a monofilament-forming material Single-layer nonwoven webs were prepared from various blends of water-soluble fibers, as listed in Table 8A below. Briefly, the water-soluble staple fibers were carded and then calender bonded. Calender bonding was performed using an embossing roll at a temperature of 140°C and a pressure of about 40 to 50 PSI. Conventional heated calender rolls made from cast iron or steel were used. Calender speeds were between about 1 and 2 FPM. [Table 8A]

[0381] The nonwoven webs were tested for solubility at 23° C. and 40° C. In particular, the time to burst and disintegration of the nonwoven webs was determined in accordance with MSTM-205, as described herein. The solubility is presented in Table 8B below. [Table 8B]

[0382] Example 8 illustrates a nonwoven web of the present disclosure comprising a blend of fibers, the blend comprising first fibers comprising a first water-soluble fiber-forming material and second fibers comprising a second water-soluble fiber-forming composition. Specifically, Example 8, combined with Samples 20 and 23 from Example 7, demonstrates that when a blend of fibers is used in a nonwoven web, the solubility of the nonwoven web does not follow the rule of mixtures (compare Samples 63-65 with Samples 20 and 23). Example 8 further demonstrates that for samples having similar basis weights and prepared using the same calendering conditions at a temperature below the complete dissolution temperature of the less soluble fiber (e.g., 23°C for a blend containing a fiber with a complete dissolution temperature of 40°C), the burst time of the nonwoven fabric is substantially the same for a blend of two fibers having a 25:75 molar ratio and a blend of two fibers having a 75:25 molar ratio (compare Samples 63 and 65; 55 and 61; and 56 and 62). Unexpectedly, at all temperatures, nonwoven webs having a 50:50 blend of the two fibers demonstrated different burst times than the 25:75 and 75:25 blends, and surprisingly demonstrated longer burst times than the 25:75 and 75:25 blends (compare Sample 64 with Samples 63 and 65; 58 with 55 and 61; and 59 with 56 and 62).

[0383] (Example 9) Multilayer nonwoven fabric Multilayer nonwoven webs were prepared from various water-soluble fibers, as listed in Table 9A below. Specifically, each nonwoven web included a first layer (L1) and a second layer (L2). Each layer included a monofilament type, including monofilament-forming materials. Briefly, the water-soluble staple fibers were carded and then calender bonded. The two carded webs were then placed on top of each other and passed through calender rollers at specified conditions. Optionally, the top-placed nonwoven web was passed through a needlepunch bonding station before passing through the calender rollers. Calender bonding was performed using an embossing roll at a temperature of 140°C and a pressure of approximately 40 PSI. Conventional heated calender rolls made of cast iron or steel were used. The calender speed was approximately 2 FPM. [Table 9A]

[0384] The nonwoven webs were tested for solubility at 23° C. and 40° C. In particular, the burst and disintegration times of the nonwoven webs were determined in accordance with MSTM-205, as described herein. The solubility is presented in Table 9B below. [Table 9B]

[0385] Thus, Example 9 illustrates a multilayer nonwoven web according to the present disclosure. Example 9 further demonstrates that when the multilayer nonwoven web and the single-layer nonwoven web have similar basis weights, the multilayer nonwoven web having two identical nonwoven web layers generally has the same dissolution characteristics as a single nonwoven web of the same material (compare Samples 66 and 67 with Sample 20 of Example 7; Samples 68 and 69 with Sample 23 of Example 7). Example 9 further demonstrates that when the multilayer nonwoven web has two different layers, the solubility characteristics of the multilayer nonwoven web do not follow the rule of mixtures (compare Samples 70 and 71 with Samples 20 and 23 of Example 7). Instead, at temperatures below the complete dissolution temperature of the fibers of the less soluble nonwoven web, the solubility of the multilayer nonwoven web generally behaves more similarly to the dissolution of the less soluble nonwoven web (compare Samples 70, 71, 20, and 23: the less soluble nonwoven sample (23) contains fibers with a complete dissolution temperature of 40°C, and at temperatures below 40°C (e.g., 23°C), multilayer nonwoven webs containing a layer of Sample 23 and a layer of Sample 20 (i.e., Samples 70 and 71) have increased solubility compared to Sample 23, but not to the extent of a weighted average (i.e., do not follow the rule of mixtures)).

[0386] Example 10: Single-layer nonwoven fabric comprising a blend of fiber types, each fiber type comprising a monofilament-forming material Single-layer nonwoven webs were prepared from various blends of water-soluble fibers, as listed in Table 8A below. Briefly, the water-soluble staple fibers were carded and then calender bonded. Calender bonding was performed using an embossing roll at a temperature of 140°C and a pressure of approximately 40 to 50 PSI. Conventional heated calender rolls made from cast iron or steel were used. Calender speeds were between approximately 1 and 2 FPM. The nonwoven webs comprise first fibers comprising a water-soluble polyvinyl alcohol film-forming material and second fibers comprising a non-polyvinyl alcohol water-insoluble fiber-forming material. The water-insoluble fiber-forming material was one of Trevira 298, 1.6 dtex × 38 mm polyethylene terephthalate fiber ("PET"); 6.6 dtex × 60 mm polylactide fiber ("PLA"); 5.5 dtex × 78 mm viscose (rayon) fiber ("Viscose"), 22 dtex × 38 mm PET fiber ("High PET"); and Lenzing Lyocell, 1.65 dtex × 38 mm cellulose fiber ("Cellulose"). [Table 10A]

[0387] The nonwoven webs were tested for solubility and flexibility at 23° C. and 40° C. In particular, the burst and disintegration times of the nonwoven webs were determined in accordance with MSTM-205, as described herein. The solubility is presented in Table 10B below. [Table 10B]

[0388] Thus, Example 10 illustrates a water-dispersible nonwoven fabric of the present disclosure that includes a blend of water-soluble and water-insoluble fibers. Example 10 further demonstrates that fiber selection can advantageously control the feel (e.g., softness) of a nonwoven web. In particular, for a given fiber type, decreasing the L / D ratio results in decreased softness (i.e., a higher softness rating), as can be seen in the cases of Samples 72 and 75. In this case, when the PVOH has an L / D ratio of 23.18 and the PET has an L / D ratio of 23.75, a mixture of PVOH / PET fibers results in a nonwoven web with a softness rating of 2 (Sample 72), and when the PVOH has the same L / D ratio of 23.18 but the PET has a lower L / D ratio of 1.72, a mixture of PVOH / PET fibers results in a nonwoven web with a softness rating of 4 (Sample 75).

[0389] Example 11: Single-layer nonwoven fabric containing a blend of fiber-forming materials Single-layer nonwoven webs were prepared from various blends of water-soluble fibers as listed in Table 11A below. Briefly, the water-soluble staple fibers were carded and then calender bonded using an embossing roll under the conditions listed in Table 11A. [Table 11A-1] [Table 11A-2]

[0390] The nonwoven webs were tested for solubility at temperatures of 23° C., 40° C., and 80° C. In particular, the time to burst and disintegration of the nonwoven webs was determined in accordance with MSTM-205, as described herein.

[0391] According to MSTM-205, no samples burst, disintegrated, or dissolved within 300 seconds at temperatures of 23° C. or 40° C. Samples containing any amount of fiber, including fully hydrolyzed (99.9% DH) PVOH fiber-forming material, did not burst, disintegrate, or dissolve at temperatures at or below 80° C. Solubility data for samples that burst and / or disintegrated at temperatures of 80° C. and 90° C. are presented below in Table 11B. [Table 11B-1] [Table 11B-2]

[0392] Thus, Example 11 illustrates a warm water soluble nonwoven web of the present disclosure comprising a blend of fibers including first fibers comprising a water soluble polyvinyl alcohol fiber forming material and second fibers comprising a water soluble polyvinyl alcohol fiber forming material.

[0393] Example 12: Multi-layer nonwoven web with different fiber chemistries Multilayer nonwoven webs were prepared from various water-soluble fibers as listed in Table 12A below. Specifically, each nonwoven web contained two layers, each layer containing a monofilament type, and the monofilament type contained a monofilament-forming material. Briefly, the water-soluble staple fibers were carded, and the two carded webs were stacked and calendered. Some samples were needle-perforated after stacking the two carded webs and before calendering, as listed in Table 12A. Calendering was performed using an embossing roll under the conditions listed in Table 12A. Samples 156-159 were single-layer nonwoven webs containing a blend of fiber types, with the amounts of each fiber type specified in Table 12A. [Table 12A]

[0394] The multi-layer nonwoven web was tested for solubility at 23° C. and 40° C. The thinning times were determined according to MSTM-205 and are presented below in Table 12B. [Table 12B]

[0395] Thus, Example 12 shows that for multilayer nonwoven webs of the present disclosure having the same fiber chemistry and bonding conditions, the thinning time generally decreases as the total basis weight of the multilayer nonwoven decreases (compare Samples 144 and 146, and Samples 145 and 147). Example 12 further shows that for multilayer nonwoven webs of the present disclosure having the same total basis weight and bonding conditions, the thinning time generally increases as the fiber solubility of one layer decreases (compare Samples 146 and 150, Samples 147 and 151, Samples 148 and 152, and Samples 149 and 153). Example 12 further shows that for single-layer nonwoven webs comprising a blend of fibers and similar basis weights, the thinning time generally increases as the overall fiber solubility decreases (compare Samples 156 and 157, and Samples 158 and 159; also compare Samples 159 and 157 and Samples 158 and 156).

[0396] (Example 13) Possibility of flushing The flushability of various nonwoven webs prepared in the previous examples was tested using the flushability test described herein. Two commercially available flushable nonwoven wipes were also tested in accordance with the flushability test. The commercially available flushable nonwoven wipes meet the INDA / EDANA requirements for flushability. Therefore, the degradation rates of the commercially available flushable wipes using the flushability test are considered the threshold at which nonwoven webs of the present disclosure are considered flushable, because the INDA / EDANA standards are less stringent than the flushability test, and these nonwoven webs would also be expected to meet the INDA / EDANA standards for flushability. Nonwoven webs of the present disclosure that meet or exceed the degradation rates determined for Commercial Wipe A are indicated in Table 13 with a "(+)". Nonwoven webs of the present disclosure that had a degradation rate at least twice that of Commercial Wipe A are designated in Table 13 with a "(++)". [Table 13]

[0397] Thus, Example 13 demonstrates that nonwoven webs of the present disclosure meet or exceed the flushability demonstrated by commercially available flushable wipes. In particular, Example 13 demonstrates that a single-layer nonwoven web of the present disclosure comprising only one fiber type with only one fiber-forming material, a single-layer nonwoven web of the present disclosure comprising a blend of fiber types, each fiber type with a single fiber-forming material, and a multilayer nonwoven web of the present disclosure (each layer comprising only one fiber type with only one fiber-forming material) all meet or exceed the flushability demonstrated by commercially available flushable nonwoven wipes. Example 13 further demonstrates that for most nonwoven webs of the present disclosure, flushability is significantly improved over commercially available options, demonstrating at least double the degradation of the commercially available samples.

[0398] Example 14 Preparation of Pouches and Sealed Articles The pouches and sealed articles were prepared as follows: A four-sided nonwoven web conforming to Sample 21 was folded in half on itself, and the two unfolded sides were heat-sealed at 175°C to form a pouch having an opening and an internal pouch volume. The powder composition was dispensed through the opening into the internal pouch volume. The opening was heat-sealed at 175°C to form a sealed article.

[0399] Two four-sided nonwoven webs conforming to Sample 21 were placed one on top of the other and folded in half, resulting in an article having one folded side and three unfolded sides. Two of the unfolded sides were heat-sealed at 175°C to form a pouch having an opening and an internal pouch volume. A powder composition was dispensed through the opening into the internal pouch volume. The opening was heat-sealed at 175°C to form a sealed article comprising a laminate of two nonwoven webs.

[0400] A four-sided nonwoven web conforming to Sample 21 was placed over a water-soluble film and folded in half, resulting in an article having one folded side and three unfolded sides containing the water-soluble film therein. Two of the unfolded sides were heat-sealed at 175°C to form a pouch having an opening and an internal pouch volume defined by the water-soluble film. A liquid and / or powder composition was dispensed through the opening into the internal pouch volume. The opening was heat-sealed at 175°C to form a sealed article comprising a laminate of the nonwoven web and the water-soluble film.

[0401] The pouches and sealed products containing a laminate of a nonwoven web and a water-soluble film are as follows: The nonwoven web used conformed to Sample 21. Four different pouches were prepared using four different polyvinyl alcohol water-soluble films. The water-soluble film on the pouch walls was the same as that on the top seal. The nonwoven web was placed over a thermoformable cavity, and a water-soluble film was placed over the nonwoven web. A vacuum pressure of 400 mbar and heat of 120°C were applied to draw the nonwoven web and water-soluble film into the cavity. The cavity was then filled with a liquid and / or solid composition. A second water-soluble film was placed over the filled cavity, and a second nonwoven web according to Sample 21 was placed over the water-soluble film. The cavity was then heat-sealed at a temperature of 175°C to form a sealed article comprising a laminate of a nonwoven web and a water-soluble film.

[0402] The release of the contents of the thermoformed sealed articles was determined according to the Liquid Release Test described herein and compared to the release of the same contents from thermoformed pouches prepared with only water-soluble film, and the results are shown in Table 14. [Table 14]

[0403] Thus, Example 14 demonstrates that a nonwoven web of the present disclosure was used to prepare pouches and sealed articles of the present disclosure. Example 14 further demonstrates that a sealed article prepared from a laminate of the present disclosure comprising a nonwoven web and a water-soluble film maintains the contents of the pouch for a longer period of time when immersed in water than a sealed article prepared from only a water-soluble film, and advantageously provides a delayed release profile compared to an article prepared from only a water-soluble film.

[0404] The above description is set forth for clarity of understanding only, and no unnecessary limitations should be understood from the above description, since modifications within the scope of the invention may be apparent to those skilled in the art.

[0405] All patents, publications, and references cited herein are hereby incorporated by reference in their entirety. In the event of a conflict between the present disclosure and the incorporated patents, publications, and references, the present disclosure shall control. The present invention provides, for example, the following items. (Item 1) A nonwoven web comprising a plurality of fibers, the plurality of fibers comprising a first polyvinyl alcohol fiber-forming material and (a) Second polyvinyl alcohol fiber-forming material or (b) the blend of fiber-forming materials does not include carboxymethyl cellulose, hydroxypropyl methyl cellulose, or starch; Nonwoven web. (Item 2) 2. The nonwoven web of claim 1, wherein the first polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer or a polyvinyl alcohol copolymer. (Item 3) 3. The nonwoven web of claim 1 or 2, wherein the second polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer or a polyvinyl alcohol copolymer. (Item 4) Item 4. The nonwoven web of item 2 or item 3, wherein the polyvinyl alcohol copolymer comprises a modified polyvinyl alcohol copolymer. (Item 5) 5. The nonwoven web of claim 4, wherein the modified polyvinyl alcohol copolymer comprises an anionic modified polyvinyl alcohol copolymer. (Item 6) Item 6. The nonwoven web of item 4 or item 5, wherein the modified polyvinyl alcohol copolymer has a degree of modification ranging from about 1 mol.% to about 10 mol.%. (Item 7) 10. The nonwoven web of claim 1, wherein the first fibers comprise the first and second polyvinyl alcohol fiber-forming materials, the first polyvinyl alcohol fiber-forming material comprising a polyvinyl alcohol homopolymer, and the second polyvinyl alcohol fiber-forming material comprising a polyvinyl alcohol copolymer. (Item 8) 8. The nonwoven web of claim 7, wherein the polyvinyl alcohol homopolymer comprises about 15 wt. % to about 70 wt. % of the total weight of the polyvinyl alcohol fiber-forming material, and the copolymer comprises the remainder of the polyvinyl alcohol fiber-forming material. (Item 9) 10. The nonwoven web of claim 1, wherein the first polyvinyl alcohol fiber-forming material has a degree of hydrolysis ranging from about 75% to about 99.9%. (Item 10) 10. The nonwoven web of claim 9, wherein the first polyvinyl alcohol fiber-forming material has a degree of hydrolysis ranging from about 80% to about 90%. (Item 11) 10. The nonwoven web of claim 9, wherein the first polyvinyl alcohol fiber-forming material has a degree of hydrolysis ranging from about 92% to about 99%, optionally from about 98% to about 99%, optionally from about 98% to about 99.9%. (Item 12) 10. The nonwoven web of claim 1, wherein the second polyvinyl alcohol fiber-forming material has a degree of hydrolysis ranging from about 75% to about 99.9%. (Item 13) Item 13. The nonwoven web of item 12, wherein the second polyvinyl alcohol fiber-forming material has a degree of hydrolysis ranging from about 80% to about 90%. (Item 14) 13. The nonwoven web of item 12, wherein the second polyvinyl alcohol fiber-forming material has a degree of hydrolysis ranging from about 92% to about 99%, optionally from about 98% to about 99%, optionally from about 98% to about 99.9%. (Item 15) The plurality of fibers the first fibers; The second fiber wherein the first and second fibers have a length to distance (L / D) ratio, tenacity, shape, stiffness, elasticity, water solubility, melting point, glass transition temperature (T g ), fiber chemistry, color, or a combination thereof. (Item 16) 2. The nonwoven web of claim 1, wherein the plurality of fibers comprises water-insoluble fibers. (Item 17) Item 17. The nonwoven web of item 16, wherein the water-insoluble fibers comprise from about 20% to about 80% by weight of the total weight of the plurality of fibers. (Item 18) 18. The nonwoven web of claim 16 or 17, wherein the plurality of water-insoluble fibers comprises cotton, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polyester, copolyester, viscose, polylactide, polyethylene terephthalate, polypropylene, or a combination thereof. (Item 19) 2. The nonwoven web of any one of the preceding items, which is biodegradable. (Item 20) 2. The nonwoven web of any one of the preceding items, wherein the first fibers have a tenacity ranging from about 3 cN / dtex to about 10 cN / dtex, optionally from about 7 cN / dtex to about 10 cN / dtex. (Item 21) 21. The nonwoven web of item 20, wherein the first fibers have a tenacity ranging from about 4 cN / dtex to about 8 cN / dtex, optionally from about 6 cN / dtex to about 8 cN / dtex. (Item 22) 2. The nonwoven web of claim 1, wherein the first fibers further comprise a plasticizer. (Item 23) 2. The nonwoven web of any preceding claim, further comprising an active agent. (Item 24) 24. The nonwoven web of claim 23, wherein the active agent is provided as part of a plurality of fibers, dispersed within the nonwoven web, provided on a surface of the nonwoven web, or a combination thereof. (Item 25) 25. The nonwoven web of claim 23 or 24, wherein the active agent is selected from an enzyme, oil, flavor, colorant, odor absorber, fragrance, pesticide, fertilizer, activator, acid catalyst, metal catalyst, ion scavenger, detergent, disinfectant, surfactant, bleach, bleaching component, fabric softener, or combinations thereof. (Item 26) 2. The nonwoven web of any preceding item, wherein the first fibers have a diameter ranging from about 10 microns to about 300 microns, optionally from about 50 microns to about 300 microns, and optionally from greater than 100 microns to about 300 microns. (Item 27) 2. The nonwoven web of claim 1, wherein the first fibers have a substantially uniform diameter. (Item 28) 2. The nonwoven web of claim 1, wherein the first fibers have a length ranging from about 30 mm to about 100 mm, or from about 30 mm to about 60 mm. (Item 29) 28. The nonwoven web of any one of the preceding items, wherein the first fibers have a length less than about 30 mm, or in the range of about 0.25 mm to less than 30 mm. (Item 30) 30. The nonwoven web of any one of the preceding items, wherein the first fibers have a length to diameter (L / D) ratio of about 0.5 to 15, about 0.75 to about 10, or about 1 to about 5. (Item 31) 2. The nonwoven web of any one of the preceding items, which is porous. (Item 32) 31. The nonwoven web of any one of items 1 to 30, which is nonporous. (Item 33) Item 10. The nonwoven web of any one of the preceding items, which is pigmented, dyed, pigmented, or a combination thereof. (Item 34) Approximately 1g / m 2 to about 100 g / m 2 , about 20g / m 2 to approximately 80 g / m 2 , about 30g / m 2 to about 100 g / m 2 , or approximately 25 g / m 2 to about 70 g / m 2 2. The nonwoven web of claim 1, having a basis weight of (Item 35) 2. The nonwoven web of any preceding item, which dissolves at a given temperature at least about 5 times faster than a film prepared from the same polymer as the first fibers of the nonwoven web. (Item 36) The first fiber is prepared by a wet cooled gel spinning process, the wet cooled gel spinning process comprising: a) dissolving said fiber-forming material in a solvent to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide the first fibers. 2. The nonwoven web of claim 1, comprising: (Item 37) The second fiber is prepared by a wet chill gel spinning process, the wet chill gel spinning process comprising: a) dissolving said fiber-forming material in a solvent to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide the second fiber. 37. The nonwoven web of any one of items 15 to 36, comprising: (Item 38) 38. The nonwoven web of any one of items 36 or 37, wherein the finishing comprises cutting or crimping the extruded polymer mixture to obtain the first or second fibers. (Item 39) 39. The nonwoven web of any one of items 36 to 38, wherein the coagulation bath comprises a mixture of solvents comprising a first solvent in which the fiber-forming material is soluble and a second solvent in which the fiber-forming material is not soluble. (Item 40) 40. The nonwoven web of any one of items 36 to 39, wherein the solvent exchange bath consists essentially of a solvent in which the fiber-forming material is not soluble. (Item 41) 41. The nonwoven web of any one of items 36 to 40, wherein the degree of polymerization of the fiber-forming material is at least 1000. (Item 42) 42. The nonwoven web of any one of items 36 to 41, wherein the first fibers have a fiber diameter in the range of 10 to 300 microns, 25 to 300 microns, 50 to 300 microns, or 75 to 100 microns. (Item 43) 43. The nonwoven web of any one of items 36 to 42, wherein the first fibers have a tenacity in the range of about 5 cN / dtex to about 10 cN / dtex, or about 6 cN / dtex to about 10 cN / dtex, or about 7 cN / dtex to about 10 cN / dtex. (Item 44) 44. The nonwoven web of any one of items 36 to 43, further comprising filaments prepared by a process selected from the group consisting of meltblowing, spunbonding, electrospinning, rotary spinning, continuous filament producing operations, tow fiber producing operations, and combinations thereof. (Item 45) Item 10. The nonwoven web of any one of the preceding items, which is flushable. (Item 46) 2. The nonwoven web of any preceding claim, which is water-dispersible. (Item 47) 47. A multi-layer nonwoven web comprising the first nonwoven web of any one of items 1 to 46. (Item 48) Item 48. The multilayer nonwoven web of item 47, further comprising a second nonwoven web of any one of items 1 to 47. (Item 49) Item 49. The multi-layer nonwoven web of item 48, wherein the first nonwoven web and the second nonwoven web comprise the same fibers and have the same basis weight. (Item 50) Item 49. The multi-layer nonwoven web of item 48, wherein the first nonwoven web and the second nonwoven web comprise different fibers and have the same basis weight. (Item 51) Item 49. The multi-layer nonwoven web of item 48, wherein the first nonwoven web and the second nonwoven web comprise different fibers and have different basis weights. (Item 52) 52. The multilayer nonwoven web of any one of items 48 to 51, wherein the first nonwoven web and the second nonwoven web are laminated to one another. (Item 53) 53. The multilayer nonwoven web of any one of items 47 to 52, further comprising a film laminated to the first nonwoven web. (Item 54) Item 54. The multi-layer nonwoven web of item 53, wherein the plurality of fibers of the first nonwoven web and the film comprise the same water-soluble polymer. (Item 55) Item 54. The multilayer nonwoven web of item 53, wherein the plurality of fibers of the first nonwoven web and the film comprise different polymers. (Item 56) Approximately 1g / m 2 to about 100 g / m 2 56. The multilayer nonwoven web of any one of items 47 to 55, having a basis weight of (Item 57) 56. The multilayer nonwoven web of any one of items 47 to 55, which is porous. (Item 58) 56. The multilayer nonwoven web of any one of items 47 to 55, which is nonporous. (Item 59) 59. The multilayer nonwoven web of any one of items 47 to 58, which is flushable. (Item 60) 60. The multilayer nonwoven web of any one of items 47 to 59, which is water-dispersible. (Item 61) 47. A pouch comprising the nonwoven web of any one of items 1 to 46 in the form of a pouch defining an interior pouch volume. (Item 62) 61. A pouch comprising the multilayer nonwoven web of any one of items 47 to 60 in the form of a pouch defining an interior pouch volume. (Item 63) Item 63. The pouch of item 62, wherein the multilayer nonwoven web comprises the first nonwoven web and a water-soluble film, the water-soluble film forming the interior surface of the pouch. (Item 64) Item 64. The pouch according to item 62 or item 63, which is flushable. (Item 65) 65. A sealed artic...

Claims

1. A nonwoven web comprising a plurality of fibers, the plurality of fibers including first fibers comprising a blend of a first polyvinyl alcohol fiber-forming material and a second polyvinyl alcohol fiber-forming material as fiber-forming materials; the first polyvinyl alcohol fiber-forming material comprises a copolymer of vinyl alcohol and vinyl acetate, and the second polyvinyl alcohol fiber-forming material comprises an anionically modified copolymer of vinyl alcohol and vinyl acetate; the first polyvinyl alcohol fiber-forming material has a degree of hydrolysis in the range of 85% to 99.9% and the second polyvinyl alcohol fiber-forming material has a degree of hydrolysis in the range of 86.5% to 99.9%; The anionically modified copolymer of vinyl alcohol and vinyl acetate has a degree of anion modification in the range of 1 mol. % to 10 mol. %, the copolymer of vinyl alcohol and vinyl acetate constitutes 15 wt % to 70 wt % of the total weight of the polyvinyl alcohol fiber-forming material, and the anionically modified copolymer of vinyl alcohol and vinyl acetate constitutes the remainder of the polyvinyl alcohol fiber-forming material; Nonwoven web.

2. 10. The nonwoven web of claim 1, wherein the first polyvinyl alcohol fiber-forming material has a degree of hydrolysis ranging from 92% to 99%.

3. 3. The nonwoven web of claim 1 or 2, wherein the second polyvinyl alcohol fiber-forming material has a degree of hydrolysis in the range of 92% to 99%.

4. The plurality of fibers the first fibers; a second fiber; wherein the first and second fibers have a length to distance (L / D) ratio, tenacity, shape, stiffness, elasticity, water solubility, melting point, glass transition temperature (T ｇ 4. The nonwoven web of claim 1, wherein the nonwoven web has differences in fiber chemistry, color, or a combination thereof.

5. The nonwoven web of claim 1 , wherein the plurality of fibers comprises water-insoluble fibers.

6. 6. The nonwoven web of claim 5, wherein the water-insoluble fibers comprise from 20% to 80% by weight of the total weight of the plurality of fibers.

7. 7. The nonwoven web of claim 5 or claim 6, wherein the plurality of water-insoluble fibers comprises cotton, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, Dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polyester, copolyester, viscose, polylactide, polyethylene terephthalate, polypropylene, or combinations thereof.

8. The nonwoven web of any one of claims 1 to 7, which is biodegradable.

9. 9. The nonwoven web of any one of claims 1 to 8, wherein the first fibers have a tenacity in the range of 3 cN / dtex to 10 cN / dtex.

10. 10. The nonwoven web of claim 9, wherein the first fibers have a tenacity in the range of 4 cN / dtex to 8 cN / dtex.

11. The nonwoven web of any one of claims 1 to 10, wherein the first fibers further comprise a plasticizer.

12. The nonwoven web of any one of claims 1 to 11, further comprising an active agent.

13. 13. The nonwoven web of claim 12, wherein the active agent is provided as part of a plurality of fibers, dispersed within the nonwoven web, provided on a surface of the nonwoven web, or a combination thereof.

14. 14. The nonwoven web of claim 12 or claim 13, wherein the active agent is selected from an enzyme, an oil, a flavor, a colorant, an odor absorber, a fragrance, a pesticide, a fertilizer, an activator, an acid catalyst, a metal catalyst, an ion scavenger, a cleaning agent, a disinfectant, a surfactant, a bleach, a bleaching component, a fabric softener, or a combination thereof.

15. 15. The nonwoven web of any one of the preceding claims, wherein the first fibers have a diameter in the range of 10 microns to 300 microns.

16. 16. The nonwoven web of any one of claims 1 to 15, wherein the first fibers have a substantially uniform diameter.

17. 17. The nonwoven web of any one of claims 1 to 16, wherein the first fibers have a length in the range of 30 mm to 100 mm.

18. 17. The nonwoven web of any one of the preceding claims, wherein the first fibers have a length in a range of less than 30 mm.

19. 19. The nonwoven web of any one of the preceding claims, wherein the first fibers have a length to diameter (L / D) ratio of from 0.5 to 15.

20. 20. The nonwoven web of any one of claims 1 to 19, which is porous.

21. 20. The nonwoven web of any one of claims 1 to 19, which is non-porous.

22. 22. The nonwoven web of any one of claims 1 to 21, which is pigmented, dyed, pigmented, or a combination thereof.

23. 1 g / m ２ to 100 g / m ２ 23. The nonwoven web of any one of claims 1 to 22, having a basis weight of

24. The first fiber is prepared by a wet-cooled gel spinning process, the wet-cooled gel spinning process comprising: a) dissolving said fiber-forming material in a solvent to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide the first fibers.

24. A method for producing the nonwoven web of any one of claims 1 to 23, comprising:

25. The second fiber is prepared by a wet chill gel spinning process, the wet chill gel spinning process comprising: a) dissolving said fiber-forming material in a solvent to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide the second fibers.

25. The method of claim 24 when directly or indirectly relying on claim 4, comprising:

26. 26. The method of any one of claims 24 or 25, wherein the finishing comprises cutting or crimping the extruded polymer mixture to obtain the first or second fibers.

27. 27. The method of any one of claims 24 to 26, wherein the coagulation bath comprises a mixture of solvents comprising a first solvent in which the fiber-forming material is soluble and a second solvent in which the fiber-forming material is not soluble.

28. 28. The method of any one of claims 24 to 27, wherein the solvent exchange bath consists essentially of a solvent in which the fiber-forming material is not soluble.

29. 29. The method of any one of claims 24 to 28, wherein the degree of polymerization of the fiber-forming material is at least 1000.

30. 30. The method of any one of claims 24 to 29, wherein the first fibers have a fiber diameter in the range of 10 to 300 microns.

31. 31. The method of any one of claims 24 to 30, wherein the first fibers have a tenacity in the range of 5 cN / dtex to 10 cN / dtex.

32. 32. The method of any one of claims 24 to 31, wherein the nonwoven web further comprises filaments prepared by a process selected from the group consisting of meltblowing, spunbonding, electrospinning, rotary spinning, continuous filament producing operations, tow fiber producing operations, and combinations thereof.

33. 24. The nonwoven web of any one of claims 1 to 23, which is flushable.

34. 34. The nonwoven web of any one of claims 1 to 23 and 33, which is water-dispersible.

35. 35. A multi-layer nonwoven web comprising a first nonwoven web that is the nonwoven web of any one of claims 1-23 and 33-34.

36. 36. The multilayer nonwoven web of claim 35, further comprising a second nonwoven web that is the nonwoven web of any one of claims 1-23 and 33-34.

37. 37. The multi-layer nonwoven web of claim 36, wherein the first nonwoven web and the second nonwoven web comprise the same fibers and have the same basis weight.

38. 37. The multi-layer nonwoven web of claim 36, wherein the first nonwoven web and the second nonwoven web comprise different fibers and have the same basis weight.

39. 37. The multi-layer nonwoven web of claim 36, wherein the first nonwoven web and the second nonwoven web comprise different fibers and have different basis weights.

40. 40. The multi-layer nonwoven web of any one of claims 36 to 39, wherein the first nonwoven web and the second nonwoven web are laminated to one another.

41. 41. The multilayer nonwoven web of any one of claims 35 to 40, further comprising a film laminated to the first nonwoven web.

42. 42. The multi-layer nonwoven web of claim 41, wherein the plurality of fibers of the first nonwoven web and the film comprise the same water-soluble polymer.

43. 42. The multi-layer nonwoven web of claim 41, wherein the plurality of fibers of the first nonwoven web and the film comprise different polymers.

44. 1 g / m ２ to 100 g / m ２ 44. The multi-layer nonwoven web of any one of claims 35 to 43, having a basis weight of

45. 44. The multilayer nonwoven web of any one of claims 35 to 43, which is porous.

46. 44. The multilayer nonwoven web of any one of claims 35 to 43, which is non-porous.

47. 35. A pouch comprising the nonwoven web of any one of claims 1-23 and 33-34 in the form of a pouch defining an interior pouch volume.

48. 47. A pouch comprising the multi-layer nonwoven web of any one of claims 35 to 46 in the form of a pouch defining an interior pouch volume.

49. 49. The pouch of claim 48, when directly or indirectly reliant on any one of claims 41 to 43, wherein the multilayer nonwoven web comprises the first nonwoven web and the film, and the film forms the inner surface of the pouch.

50. 50. A sealed article comprising a pouch according to any one of claims 47 to 49.

51. 51. The sealed article of claim 50, further comprising a composition enclosed within the interior pouch volume.

52. 52. The sealed article of claim 51, wherein the composition enclosed in the internal pouch volume comprises a solid, a liquid, or a combination thereof.

53. 53. The sealed article of claim 52, wherein the composition enclosed in the internal pouch volume comprises a liquid.

54. 54. The sealed article of claim 52 or claim 53, wherein the composition enclosed in the internal pouch volume comprises a solid.

55. 55. The sealed article of any one of claims 51 to 54, wherein the composition enclosed in the internal pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, a food nutritional composition, a pharmaceutical composition, an industrial cleaning composition, a disinfecting composition, a pet composition, an office composition, a livestock composition, an industrial composition, a marine composition, a commercial composition, a military composition, a recreational composition, or a combination thereof.

56. 56. The sealed article of claim 55, wherein the composition enclosed in the internal pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a household cleaning composition, a water treatment composition, a personal care composition, a food nutrition composition, an industrial cleaning composition, or a combination thereof.

57. forming the nonwoven web into a pouch; filling the pouch with a composition to be enclosed therein; and sealing the pouch to form a sealed article.

56. A method for preparing the sealed article of any one of claims 50 to 55, comprising:

58. 58. The method of claim 57, wherein sealing the pouch comprises heat sealing, solvent welding, adhesive sealing, or a combination thereof.

59. 43. The multilayer nonwoven web of claim 41 or 42, wherein the plurality of fibers of the first nonwoven web comprise a first polyvinyl alcohol homopolymer and the film comprises a second polyvinyl alcohol homopolymer, the first and second polyvinyl alcohol homopolymers having the same degree of hydrolysis, the multilayer nonwoven web has a faster 10°C dissolution time as determined by MSTM-205 than a film comprising an anionically modified polyvinyl alcohol copolymer having the same degree of hydrolysis as the first and second polyvinyl alcohol homopolymers, and the first nonwoven web has greater biodegradability than the film comprising the anionically modified polyvinyl alcohol.

60. 1. A fiber comprising a blend of a first polyvinyl alcohol polymer and a second polyvinyl alcohol polymer as a fiber-forming material, the first polyvinyl alcohol polymer is a copolymer of vinyl alcohol and vinyl acetate, and the second polyvinyl alcohol polymer is an anionically modified copolymer of vinyl alcohol and vinyl acetate; the first polyvinyl alcohol polymer has a degree of hydrolysis in the range of 85% to 99.9% and the second polyvinyl alcohol polymer has a degree of hydrolysis in the range of 86.5% to 99.9%; The anionically modified copolymer of vinyl alcohol and vinyl acetate has a degree of anion modification in the range of 1 mol. % to 10 mol. %, A fiber wherein the copolymer of vinyl alcohol and vinyl acetate constitutes 15 wt % to 70 wt % of the total weight of the fiber-forming material, and the anionically modified copolymer of vinyl alcohol and vinyl acetate constitutes the remainder of the fiber-forming material.

61. The fibers are prepared by a wet chill gel spinning process, the wet chill gel spinning process comprising: a) dissolving two or more fiber-forming materials in a solution to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle and into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide the fibers.

61. A method for producing the fiber of claim 60, comprising:

62. 61. The fiber of claim 60, wherein the first polyvinyl alcohol polymer has a degree of polymerization of at least 1000.

63. 63. The fiber of claim 60 or 62, having a fiber diameter in the range of 10 to 300 microns.

64. 64. The fiber of any one of claims 60 and 62-63, having a tenacity in the range of 5 cN / dtex to 10 cN / dtex.

65. 65. The fiber of any one of claims 60 and 62-64, which is biodegradable.

66. 66. The fiber of any one of claims 60 and 62-65, which is water soluble.

67. 66. A nonwoven web comprising a plurality of fibers according to any one of claims 60 and 62-65.

68. a first layer comprising the nonwoven web of claim 67; and A second layer comprising the nonwoven web of claim 67.

1. A multi-layer nonwoven web comprising:

69. a first layer comprising the nonwoven web of claim 67; and A second layer comprising a water-soluble film 1. A multi-layer nonwoven web comprising:

70. 68. A pouch comprising the nonwoven web of claim 67 in the form of a pouch defining an interior pouch volume.

71. 70. A pouch comprising the multi-layer nonwoven web of claim 68 or 69 in the form of a pouch defining an interior pouch volume.

72. 72. A sealed article comprising the pouch of claim 70 or 71.

73. 73. The sealed article of claim 72, further comprising a composition enclosed within the interior pouch volume.

74. 74. The sealed article of claim 73, wherein the composition enclosed in the internal pouch volume comprises a solid, a liquid, or a combination thereof.

75. 75. The sealed article of any one of claims 73-74, wherein the composition enclosed in the internal pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a water treatment composition, a personal care composition, a food nutritional composition, a pharmaceutical composition, a pet composition, an office composition, a livestock composition, an industrial composition, a marine composition, a commercial composition, a military composition, a recreational composition, or a combination thereof.

76. 76. The sealed article of claim 75, wherein the composition enclosed in the internal pouch volume comprises a liquid laundry detergent, an agricultural composition, an automatic dishwashing composition, a water treatment composition, a personal care composition, a food nutritional composition, or a combination thereof.

77. forming the multi-layer nonwoven web into the shape of a pouch; filling the pouch with a composition to be enclosed therein; and sealing the pouch to form a sealed article.

77. A method for preparing the sealed article of any one of claims 72 to 76, comprising:

78. 78. The method of claim 77, wherein sealing the pouch comprises heat sealing, solvent welding, adhesive sealing, or a combination thereof.

79. a wet cooled gel spinning process, the wet cooled gel spinning process comprising: a) dissolving said fiber-forming material in a solution to form a polymer mixture; b) extruding the polymer mixture through a spinning nozzle and into a coagulation bath to form an extruded polymer mixture; c) passing the extruded polymer mixture through a solvent exchange bath; d) wet drawing the extruded polymer mixture; and e) finishing the extruded polymer mixture to provide fibers.

65. A method for preparing the fiber of any one of claims 60 and 62-64, comprising:

80. 80. The method of claim 79, wherein said finishing comprises cutting or crimping said extruded polymer mixture to provide said fibers.

81. 81. The method of claim 79 or 80, wherein the coagulation bath comprises a mixture comprising a first solvent in which the fiber-forming material is soluble and a second solvent in which the fiber-forming material is not soluble.

82. 82. The method of any one of claims 79 to 81, wherein the solvent exchange bath consists essentially of a solvent in which the fibers are not soluble.

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