Flexible solid unit dose article

Abstract

The present invention relates to a flexible solid article comprising a water-soluble polymer, particularly a flexible solid article in the form of a sheet which provides improved dissolution. The present inventors have found that when a flexible solid unit dose article comprises an anionic surfactant system including specific amounts of an alkyl taurate surfactant it provides for accelerated dissolution of the article comprising a water-soluble polymer while maintaining structural integrity during storage and handling. It was also found that the flexible solid unit dose article was storage stable and provided improved cleaning performance.

Description

[0001] P0001459 CPL

[0002] 1

[0003] FLEXIBLE SOLID UNIT DOSE ARTICLE

[0004] Field of the Invention

[0005] 5 The present invention relates to a flexible solid article comprising a water-soluble polymer, particularly a flexible solid article in the form of a sheet which provides improved dissolution.

[0006] Background of the Invention

[0007] Laundry products particularly cleaning composition have traditionally been marketed in a variety of forms such as powders, liquids, bars, and unit dose capsules.

[0008] Flexible solid unit dose article such as a laundry sheet is one of the emerging product formats which offers the convenience of accurate dosing and reduced wastage. These flexible, solid unit dose sheets are particularly used for delivering surfactant and / or other active ingredients upon

[0009] 15 dissolution in water. Typically, a laundry sheet has detergent ingredients such as surfactants and other active ingredients supported in a water-soluble polymeric carrier or matrix.

[0010] Water-soluble sheets are widely used in laundry applications to deliver detergents, softeners, and other cleaning agents in a convenient, pre-measured format.

[0011] 20

[0012] These sheets are typically composed of hydrophilic polymers such as polyvinyl alcohol (P A), which dissolve upon contact with water during the wash cycle. The dissolution of the sheet is critical to the timely and effective release of the active ingredients.

[0013] 25 Despite their widespread use, a persistent challenge in the field is achieving rapid and complete dissolution, particularly under cold water conditions, low agitation, or hard water environments. Incomplete or delayed dissolution can result in residue on fabrics, inefficient cleaning, and consumer dissatisfaction.

[0014] Many attempts have been reported in the patent literature to improve upon the properties of water-soluble polymers. These efforts have included for example, modifying polymer composition to enhance hydrophilicity, incorporating plasticizers to improve film flexibility and water permeability and blending of different types of water soluble polymers.

[0015] 35 However, these approaches often involve trade-offs between film stability during storage and dissolution performance during use. For example, increasing hydrophilicity may lead to P0001459 CPL

[0016] 2 premature degradation under humid conditions, while excessive plasticizer content can compromise mechanical integrity.

[0017] However, none of these efforts have been entirely satisfactory in providing water soluble sheets

[0018] 5 which are sufficiently stable against degradation of physical properties when stored under relatively different storage conditions and which provides fast dissolution under wash conditions.

[0019] Thus, it is an object of the present invention to provide water-soluble flexible solid unit dose article which provides accelerated dissolution under laundry wash conditions.

[0020] It is yet another object of the present invention to provide flexible solid unit dose article which is maintains structural integrity during storage and handling.

[0021] 15 It is yet another object of the present invention to provide a flexible unit dose article which is single-layered or multi-layered which provides accelerated dissolution.

[0022] Summary of the Invention

[0023] The present inventors have found that when a flexible solid unit dose article comprises an

[0024] 20 anionic surfactant system including specific amounts of an alkyl taurate surfactant it provides for accelerated dissolution of the article comprising a water-soluble polymer while maintaining structural integrity during storage and handling. It was also found that the flexible solid unit dose article was storage stable and provided improved cleaning performance.

[0025] 25 According to a first aspect of the present invention provided is a flexible solid unit dose article comprising: i. a water-soluble polymer; and, ii. an anionic surfactant system; wherein the anionic surfactant system comprises an alkyl taurate surfactant, and wherein the alkyl taurate surfactant is present in an amount ranging from 2.5 parts to 60 parts by weight of the anionic surfactant system.

[0026] Detailed Description of the Invention

[0027] According to the first aspect of the present invention provided is a flexible solid unit dose article.

[0028] 35 P0001459 CPL

[0029] 3

[0030] The term “sheet” as used herein relates to a specific form of a solid laundry composition that is characterised by its 3-dimensional shape with a thickness, a length and a width in that its thickness is small compared to its length and breadth. The sheet as used herein is a non- fibrous structure and has a length to thickness aspect ratio at least 5:1 and a width to thickness

[0031] 5 aspect ratio at least 5:1 and a length to width aspect ratio at least 1 :1. Preferably the length to width aspect ratio is at least 1.2:1 and most preferably 1.618:1.

[0032] Preferably the flexible solid unit dose article comprises a single layered flexible sheet. Also, preferably the flexible solid unit dose article comprises two or more flexible sheets to form a multi-layered three dimensional structure.

[0033] Preferably the flexible solid unit dose article when single layered has a thickness ranging from 0.5 to 5 mm, still preferably from 0.5 to 1 mm. Preferably when the flexible solid unit dose article which includes two or more flexible, sheets, each sheet is characterized by a thickness ranging

[0034] 15 from 0.5 mm to 5 mm, preferably from 0.6 mm to 3.5 mm, more preferably from 0.7 mm to 3 mm, still more preferably from 0.8 mm to 2 mm, most preferably from 0.9 mm to 1 .5 mm, more preferably from 0.9 to 1 .2 mm.

[0035] The flexible solid unit dose article of the present invention may include from 2 to 50,

[0036] 20 preferably from 3 to 40, more preferably from 3 to 30, flexible sheets.

[0037] Preferably the flexible sheet is porous. Preferably the flexible sheet dissolves completely in sufficient amount of deionised water at 20°C and under atmospheric pressure within 1 hour without any stirring, still preferably within 30 minutes, still preferably within 15 minutes leaving

[0038] 25 less than 5 wt.% undissolved residues without any stirring.

[0039] The term “solid” refers to an article which retains its shape at 20°C under atmospheric pressure when no external force is applied thereto.

[0040] The term "flexible" as used herein refers to the ability of an article to withstand stress without breakage or significant fracture when it is bent at 90° along a centre line perpendicular to its longitudinal direction.

[0041] The flexible solid unit dose article can be of any shape known to the person skilled in the art.

[0042] 35 The shape of the article may be regular or irregular. Non-limiting examples of the shape of the article include spherical, disc, rectangular, square, polygonal, oblong, sheet, flower shaped, leaf P0001459 CPL

[0043] 4 shaped, star shaped, sheet-shaped. More preferably the flexible solid unit dose article may take any shape which is tessellated.

[0044] Preferably the flexible solid unit dose article may include through-holes, preferably the through

[0045] 5 holes has a width or diameter ranging from 0.2 to 0.8 mm. Preferably, the sum of the volumes of said one or more holes is from 0.1% to 20%, preferably from 0.5% to 15%. more preferably from 1% to 10%, most preferably from 2% to 5%, by total volume of said article. The through holes may extend through the entire thickness of the article or partially.

[0046] Preferably the flexible solid unit dose article is porous structure. As used herein, the term porous structure refers to a matrix formed from a water-soluble film-forming polymer, wherein the matrix comprises a network of voids or interstitial spaces that are occupied by a gas, typically air. The porous configuration is characterized by its ability to remain stable throughout the drying process, such that the foam-like architecture does not collapse. This structural

[0047] 15 stability contributes to the physical strength, flexibility, and cohesiveness of the resulting solid unit dose article.

[0048] Preferably the flexible solid unit dose article comprises at least one line of frangibility. Preferably the line of frangibility are formed by indentation or perforation. Preferably the line of frangibility

[0049] 20 comprises of holes, preferably circular in shape and having a diameter of 1 mm or less, preferably 0.2 mm to less than 1 mm. Lines of frangibility may be of other forms which are known to a person skilled in the art and which provide, in effect, lines of weakness along which a user may readily separate the flexible solid unit dose into smaller sections. The separated smaller sections may be of same size or different sizes, may be of same shape or different

[0050] 25 shapes. The smaller sections formed may have same active ingredients or different active ingredients.

[0051] Preferably the flexible solid unit dose article may be present in the form of a multilayer structure comprising two or more flexible sheets. Preferably the flexible sheets are self-adhering.

[0052] Preferably the contacting surfaces of two adjacent flexible sheet may be adhered using an adhesive. Also, preferably the contacting surfaces of two adjacent flexible sheet may be adhered without using an adhesive. By the term “adhesive” it is meant to refer to a component which when applied to the formed flexible sheet, adheres two surfaces preferably at room temperature with little or no pressure, or at elevated temperature under pressure and / or in

[0053] 35 presence of moisture. Non-limiting examples of the adhesive includes gums, polysaccharides and resins. P0001459 CPL

[0054] 5

[0055] Preferably the flexible solid unit dose article is a multilayered structure comprising 2 or more flexible sheet which are adhered by a cut-seal. Preferably the multilayered structure is prepared by first providing two or more flexible sheets, and next arranging said two or more flexible, sheets together to form a stack; and followed by cut-sealing said stack of sheets to form the

[0056] 5 flexible solid unit dose article. Preferably the contacting surfaces of said at least two adjacent sheets are essentially free of adhesives. Further preferably the flexible solid unit dose article may be edge-sealed at least along a portion of the peripheral of the article.

[0057] Preferably the flexible solid unit dose article is non-fibrous. Preferably the flexible solid unit dose article has a structure which is free or substantially free of fibre elements, where the fibrous elements refers to structure which are elongate where the length is greatly exceeding its average diameter, preferably where the length to average diameter aspect ratio is at least 10:1 , and an average diameter of no more than 1 mm.

[0058] 15 Preferably the article has two or more flexible sheets. Preferably the two or flexible sheets are porous sheet. Preferably the contacting surfaces or said at least two adjacent sheets are essentially free of adhesive. The article may comprise certain functional ingredients that are sensitive to processing steps, like temperature. In such case, the process may involve a step of preparing two or more continuous sheets, preferably free of the sensitive functional ingredient

[0059] 20 and then superimposing two or more of said continuous sheet while including said sensitive ingredients between the sheets as an aqueous solution or dispersion of the sensitive ingredients, may be applied on at least one of the opposite surfaces of said two or more continuous flexible sheet. Coupling the two or more continuous sheet into a single multilayer sheet structure. Preferably the solid laundry sheet is cut into desired sizes. Optionally the cut

[0060] 25 unit dose article is packaged.

[0061] The article according to the present invention may be of any three-dimensional shapes, including but not limited to spherical, cubic, rectangular, polygonal, oblong, cylindrical, rod, sheet, flower-shaped, fan-shaped, star-shaped, disc-shaped, and the like. Preferably, the article may be characterized by an aspect ratio ranging from 1 to 20, preferably from 1 .4 to 18, preferably from 1 .5 to 16, more preferably from 2 to 12, where the aspect ratio refers to the ratio of a longest side D of such solid article over the shortest side that may be substantially perpendicular each other. The article in three-dimensional shape may also be achieved by moulding or extrusion. P0001459 CPL

[0062] 6

[0063] The article may comprise individual sheet of different colours, which are visible from an external surface of such article. The colours are aesthetically pleasing to the consumers. Two or more different colours preferably provides visual cues indicative of different benefit agents present in the individual sheet. Preferably the article may comprise a first sheet that has a first colour and

[0064] 5 includes a first benefit agent and a second sheet that has a second colour and includes a second benefit, where the first colour provides a visual cue indicative of the first benefit agent, and where the second colour provides a visual cue indicative of the second benefit agent.

[0065] Preferably the article may include two or more sheets having different dissolution rate, such that there is a first sheet with a first dissolution rate and a second sheet with a second dissolution rate. The “dissolution rate” as used herein refers to the time (in seconds) required to completely dissolve 0.5 g of a sheet made of water-soluble polymer in accordance with the present invention in 300 mL of water.

[0066] In some scenarios, one or more functional ingredients may be sandwiched between the

[0067] 15 individual sheets of the article. The functional ingredient may be added by spraying, sprinkling, dusting, coating, spreading, dipping, injecting, or even vapor deposition. Preferably the functional ingredients are located within a central region between two adjacent sheets.

[0068] Functional ingredients may include perfumes, softening agents, polymers, enzymes, bleaches, colorants, builders, pH modifiers and mixtures thereof.

[0069] 20

[0070] According to the first aspect of the present invention provided is a flexible unit dose article which comprises a water-soluble polymer and an anionic surfactant system.

[0071] Water soluble polymer

[0072] 25 According to the first aspect of the present invention provided, there is a flexible solid unit dose article which includes a water-soluble polymer. As used herein, the term “water-soluble polymer” refers to a polymer which is water-soluble or water-dispersible polymer with a solubility in water when measured at 25°C of at least 0.1 gram / litre, more preferably of at least 0.1 gram / litre to 500 grams / litre (g / L), still preferably from 25 grams / litre to 100 grams / litre.

[0073] The water-soluble polymers for use in the present invention may be either synthetic or natural in origin and may be chemically mid / or physically modified.

[0074] Preferably the water-soluble polymer is a film forming polymer. P0001459 CPL

[0075] 7

[0076] Preferably the water-soluble polymer has a weight average molecular weight ranging from 20,000 to 1 ,00,000 Daltons, preferably 50,000 to 400,000 Daltons, still preferably from 60,000 to 300,000 Daltons, further preferably from 70,000 to 200,000 Daltons and still more preferably from 80,000 to 150,000 Daltons. The weight average molecular weight is calculated by adding

[0077] 5 the average molecular weights of each polymer raw material multiplied by their respective relative weight percentages by weight of the total weight of polymers present within the flexible solid unit dose article.

[0078] Suitable examples of the water-soluble polymers include polyalkylene glycols, polyvinyl alcohol, polysaccharide (which includes starch, modified starch, pullulan, xanthan gum, guar gum, and carrageenan), polyvinylpyrrolidones, copolymers of polyvinylpyrrolidone and vinyl acetate, proteins, polypeptides or hydrolyzed products thereof (such as collagen and gelatin) and combinations thereof.

[0079] 15 Preferably the water-soluble polymers of the present invention may be include gums, protein isolated, extract of good, carrageenan, alginates, agar, pectins, pullulan, xanthan and combinations thereof.

[0080] More preferably the water-soluble polymer is selected from the group consisting of polyalkylene

[0081] 20 glycol (also known as polyalkylene oxide or polyoxyalkylenes), polyvinyl alcohol, starch, modified starch, pullulan, dextrin, gelatin, polyvinylpyrrolidone and combinations thereof.

[0082] Preferably the water-soluble polymer is a polyalkylene glycol. More preferably the water soluble polymer is polyethylene glycol (PEG), more preferably the PEG may be selected from

[0083] 25 polyethylene glycol) homopolymers and poly (ethylene glycol) copolymers having a weight average molecular weight of between about 2,000 and about 100,000 g / mol, preferably between about 4,000 and about 90,000 g / mol, and more preferably between about 6,000 and about 8,000 g / mol. Suitable polyethylene glycol) copolymers preferably contain at least about 50 wt percent of PEG and may be selected from the group consisting of poly(lactide-block- ethylene glycol), poly(glycolide-block-ethylene glycol), poly(lactide-co-caprolactone)-block- poly(ethylene glycol), polyethylene glycol-co-lactic acid), poly(ethylene glycol-co-glycolic acid), poly(ethylene glycol-co-poly(lactic acid-co-glycolic acid), poly(ethylene glycol-co-propylene glycol), poly(ethylene oxide-block-propylene oxide-block-ethylene oxide), poly(propylene oxide- block-ethylene glycol-block-propylene glycol), and poly(ethylene glycol-co-caprolactone). A

[0084] 35 particularly preferred PEG is a poly(ethylene glycol) homopolymer having a weight average molecular weight of between about 6,000 and about 80,000 g / mol. P0001459 CPL

[0085] 8

[0086] Preferably the water-soluble polymer is polyvinyl alcohol (PVA) or a copolymer thereof. Preferably the polyvinyl alcohol may be unmodified or modified. Preferably polyvinyl alcohol may be carboxylated or sulphonated. Preferably, the PVA is partially or fully alcoholised or hydrolysed. For example, it may be from 40% to 100%, preferably 70 to 92 %, more preferably

[0087] 5 88% to 92%, alcoholised or hydrolysed.

[0088] Preferably the polyvinyl alcohol or a copolymer thereof has a weight average molecular weight ranging from about 10,000 to about 500,000 Daltons, preferably from about 15,000 to about 200,000 Daltons, more preferably from about 20,000 to about 100,000 Daltons, still more preferably 50,000 to 300,000 Daltons.

[0089] Further, it is preferred that the polyvinyl alcohol or a copolymer thereof has a degree of polymerization ranging from about 200 to about 12,000, preferably from about 300 to about 5,000, more preferably from about 400 to about 2000, still more preferably 400 to 1000

[0090] 15 repeating units. Preferably the polyvinyl alcohol or a derivative thereof can be selected from either a PVA homopolymer or a PVA copolymer, including copolymers of vinyl alcohol and maleic acid. An example of preferred PVA is ethoxylated PVA.

[0091] Preferably the polyvinyl alcohol has a degree of hydrolysis of at least 80%, 84%, or 85% and

[0092] 20 more preferably the degree of hydrolysis ranges from 80% to 92%, more preferably from 84% to 90%. The term degree of hydrolysis is expressed as a percentage of vinyl acetate units converted to vinyl alcohol units.

[0093] Also preferred are blends of two or more different polyvinyl alcohol polymers. Preferably the

[0094] 25 blend includes a first polyvinyl alcohol and a second polyvinyl alcohol different from the first polyvinyl alcohol. Preferably the first polyvinyl alcohol has a molecular weight ranging from 50,000 Daltons to 300,000 Daltons, preferably from 60,000 to 150,000 Daltons. Preferably the second polyvinyl alcohol has a molecular weight ranging from 60,000 to 300,000 Daltons, more preferably 80,000 to 250,000 Daltons.

[0095] Preferably the water-soluble polymer is present in an amount ranging from 10 wt.% to 50 wt.%, more preferably 10 wt.% to 40 wt.%, further preferably from 15 wt.% to 40 wt.% also preferably from 15 wt.% to 50 wt.% by total weight of the unit dose article. Preferably the water-soluble polymer is polyvinyl alcohol or a copolymer thereof.

[0096] 35 P0001459 CPL

[0097] 9

[0098] Anionic surfactant system

[0099] According to a first aspect of the present invention provided, a flexible solid unit dose article comprising an anionic surfactant system.

[0100] 5 Preferably the flexible solid unit dose article comprises from 10 wt.% to 80 wt.% anionic surfactant system. More preferably the flexible solid unit dose article includes from 20 wt.% to 70 wt.% anionic surfactant system, still preferably from 50 wt.% to 70 wt.% anionic surfactant system. Preferably the amount of the anionic surfactant system is at least 12 wt.%, preferably at least 20 wt.%, still preferably at least 30 wt.%, still more preferably at least 35 wt.%, but typically the amount of the anionic surfactant system is not more than 80 wt.%, still preferably not more than 75 wt.%, still further preferably not more than 70 wt.%, still more preferably not more than 60 wt.%, most preferably not more than 55 wt.% by total weight of the flexible solid unit dose article.

[0101] 15 N-alkyl acyl taurate surfactant

[0102] According to the first aspect of the present invention the anionic surfactant system comprises a 2.5 parts to 60 parts N-alkyl acyl taurate.

[0103] Preferably the N-alkyl acyl taurate has a general formula (I)

[0104] 20 wherein R1 is an alkyl group with 5 to 23 carbon atoms, still preferably 7 to 21 , still more preferably 7 to 17, more preferably 7 to 15, 7 to 13, 11 to 17, 11 to 15 and most preferably 11 to 13 carbon atoms, R2is an alkyl group having 1 to 4 carbon atoms and X is a suitable counterion which is selected from the group consisting of potassium, magnesium, ammonium or triethanolamine, more preferably sodium.

[0105] Preferably the alkyl acyl taurate surfactant is alkyl taurate amide.

[0106] 30

[0107] Preferably the N-alkyl acyl taurate surfactant is selected from the group consisting of methyl substituted acyl taurates, ethyl substituted acyl taurates, propyl substituted acyl taurates, butyl substituted acyl taurates, salts of these and combinations thereof, preferably from the group P0001459 CPL

[0108] 10 consisting of methyl capric ester taurate, methyl cocoyl taurate, methyl lauroyl taurate, methyl myristoyl taurate, methyl caproyl taurate, methyl oleoyl taurate, methyl capryloyl taurate, methyl palmitoyl taurate, methyl stearoyl taurate, methyl linoleoyl taurate, salts of these and combinations thereof.

[0109] 5

[0110] Some non-limiting examples of N-alkyl acyl taurate includes methyl capric ester taurate, methyl cocoyl taurate, methyl lauroyl taurate, methyl myristoyl taurate, methyl caproyl taurate, methyl oleoyl taurate, methyl capryloyl taurate, methyl palmitoyl taurate, methyl stearoyl taurate, methyl linoleoyl taurate, salts of these and combinations thereof.

[0111] Preferably the alkyl taurate surfactant is a sodium methyl alkyl taurate.

[0112] The N-alkyl taurate surfactant described herein is typically not a single compound, as suggested by their general formula (I), but rather a mixture of several homologs having varied

[0113] 15 chain lengths and molecular weights. Additionally, the alkyl acyl taurate surfactant herein may be either saturated or unsaturated.

[0114] Preferably the alkyl taurate comprises an alkyl group having 7 to 17 carbon atoms. More preferably the alkyl taurate is sodium methyl cocoyl taurate.

[0115] 20

[0116] The alkyl taurate comprises from 2.5 parts to 60 parts by weight of the total anionic surfactant system. More preferably the alkyl taurate comprises from 5 parts to 60 parts by weight of the total anionic surfactant system, still more preferably from 5 parts to 50 parts by weight of the total anionic surfactant system. Preferably the anionic surfactant system according to the

[0117] 25 present invention comprises at least 3 parts, still preferably at least 4 parts, still more preferably at least 5 parts, further preferably at least 8 parts, still more preferably at least 10 parts alkyl taurate by weight of the anionic surfactant system present in the flexible solid unit dose article. Typically, the anionic surfactant system according to the present invention comprises not more than 55 parts, still preferably not more than 50 parts, still more preferably not more than 40 parts, further preferably not more than 30 parts, still more preferably not more than 25 parts alkyl taurate by weight of the anionic surfactant system present in the flexible solid unit dose article.

[0118] Alkyl sulphonate surfactant

[0119] 35 According to the first aspect of the present invention the anionic surfactant system comprises an alkyl sulphonate surfactant. Preferably the alkyl group comprises from 6 to 22, more P0001459 CPL

[0120] 11 preferably 8 to 22 carbon atoms. Preferably the alkyl group is linear or branched, preferably linear.

[0121] Preferably the alkyl sulphonate surfactant is an alkyl aryl sulphonate surfactant. Preferably the

[0122] 5 alkyl group comprises from 8 to 22 carbon atoms, more preferably from 10 to 18 carbon atoms. Preferably the alkyl group is linear or branched, preferably linear. Preferably the aryl group is a phenyl group, still more preferably a benzene group. Preferably the alkyl aryl sulphonate surfactant is alkyl benzene sulphonate surfactant.

[0123] Preferably the alkyl aryl sulphonate surfactant is C6-C2o linear alkylbenzene sulfonate (LAS), more preferably C10-C20 linear alkylbenzene sulfonate (LAS). LAS anionic surfactants are well known in the art and can be readily obtained by sulfonating commercially available linear alkylbenzenes. Exemplary C6-C2o linear alkylbenzene sulfonates that can be used in the present invention include alkali metal, alkaline earth metal or ammonium salts of C6-C20linear

[0124] 15 alkylbenzene sulfonic acids, and preferably the sodium, potassium, magnesium and / or ammonium salts of CH-CIS or C11-C14 linear alkylbenzene sulfonic acids. More preferred are the sodium or potassium salts of C12 linear alkylbenzene sulfonic acids, and most preferred is the sodium salt of C12 linear alkylbenzene sulfonic acid, i.e., sodium dodecylbenzene sulfonate. Commercial LAS is a mixture of closely related isomers and homologues alkyl chain

[0125] 20 homologues, each containing an aromatic ring sulfonated at the “para” position and attached to a linear alkyl chain at any position except the terminal carbons. Preferably the linear alkyl chain typically has a chain length of from 11 to 15 carbon atoms, with the predominant materials having a chain length of about C12. Preferably each alkyl chain homologue consists of a mixture of all the possible sulpho-phenyl isomers except for the 1 -phenyl isomer. Preferably

[0126] 25 LAS is normally formulated into compositions in acid (i.e., HLAS) form and then at least partially neutralized in-situ. Preferably the counterion for anionic surfactant is generally an alkali metal such as sodium or potassium; or an ammoniacal counterion. Mixtures of such counterions may also be employed. Sodium and potassium are preferred. Most preferably the anionic surfactant comprises an alkyl benzene sulphonate which has sodium as the counter ion.

[0127] Preferably the anionic surfactant system comprises alkyl benzene sulphonate surfactant in an amount ranging from 20 parts to 90 parts by weight of the total anionic surfactant system. Preferably the article may comprise further anionic surfactants in addition to the alkyl benzene sulphonate surfactant and alkyl taurate.

[0128] 35 P0001459 CPL

[0129] 12

[0130] Preferably the further anionic surfactant is selected from the group consisting of alkyl sulphate, alkyl ether sulphate, and combinations thereof.

[0131] Preferably the alkyl sulphate surfactant has the general formula ROSO3M wherein R is alkyl or

[0132] 5 alkenyl having 8 to 18 carbon atoms.

[0133] Preferably the anionic surfactant system may preferably include an alkyl ether sulphate surfactant. Preferably the alkyl ether sulphate surfactant has the general formula RO(C2H4)XSO3M wherein R is alkyl or alkenyl having 8 to 18 carbon atoms, x is an integer having a value of from 1 to 10 and M is a cation such as ammonium, alkanolamines, such as triethanolamine, monovalent metals, such as sodium and potassium and polyvalent metal cations, such as magnesium and calcium.

[0134] Non-limiting examples of alkyl sulphate anionic surfactant include salts of organic sulphates

[0135] 15 having alkyl radicals containing from about 8 to about 22 carbon atoms, the term “alkyl” being used to include the alkyl portion of higher acyl radicals. The alkyl radicals preferably contain from 10 to 18 carbon atoms and may be unsaturated. Preferably the alkyl ether sulphate surfactant may contain from one to ten ethylene oxide or propylene oxide units per molecule, and preferably contain one to three ethylene oxide units per molecule. Preferably the suitable

[0136] 20 further anionic surfactant includes non-ethoxylated primary and secondary alkyl sulphates with an alkyl chain length of from 10 to 18.

[0137] Preferably the article may contain alkyl ether sulphates having a straight or branched chain alkyl group having 10 to 18, more preferably 12 to 14 carbon atoms and containing an average of 1

[0138] 25 to 3 ethylene oxide (EO) units per molecule. A preferred example is sodium lauryl ether sulphate (SLES) in which the predominantly C12 lauryl alkyl group has been ethoxylated with an average of 3EO units per molecule. The alkyl ether sulphates may be used alone or in combination with any other further anionic surfactant.

[0139] The article according to the present invention may further comprise additional surfactants which may be selected from nonionic surfactant, amphoteric surfactant and combinations thereof. Preferably the additional surfactant comprises a mixture non-ionic surfactant and an amphoteric surfactant. The additional surfactant is preferably present in the article in addition to the anionic surfactant according to the first aspect of the present invention.

[0140] 35 P0001459 CPL

[0141] 13

[0142] Suitable non-ionic surfactants include water soluble aliphatic ethoxylated non-ionic surfactants including the primary aliphatic alcohol ethoxylates and secondary aliphatic alcohol ethoxylates. This includes the condensation products of a higher alcohol (e.g., an alkanol containing about 8 to 16 carbon atoms in a straight or branched chain configuration) condensed with about 4 to

[0143] 5 20 moles of ethylene oxide, for example, lauryl or myristyl alcohol condensed with about 10 moles of ethylene oxide (EO), tridecanol condensed with about 6 to 15 moles of EO, myristyl alcohol condensed with about 10 moles of EO per mole of myristyl alcohol, the condensation product of EO with a cut of coconut fatty alcohol containing a mixture of fatty alcohols with alkyl chains varying from 10 to about 14 carbon atoms in length and wherein the condensate contains either about 6 moles of EO per mole of total alcohol or about 9 moles of EO per mole of alcohol and tallow alcohol ethoxylates containing 6 EO to 11 EO per mole of alcohol.

[0144] Examples of the foregoing non-ionic surfactants include, but are not limited to, the Neodol (trade mark, ex Shell), which are higher aliphatic, primary alcohol containing about 9 to 15

[0145] 15 carbon atoms, such as C9 to C11 alkanol condensed with 4 to 10 moles of ethylene oxide (Neodol 91-8 or Neodol 91-5), C12 to C13 alkanol condensed with 6.5 moles ethylene oxide (Neodol 23-6.5), C12 to C15 alkanol condensed with 12 moles ethylene oxide (Neodol 25-12), C14 to C15 alkanol condensed with 13 moles ethylene oxide (Neodol 45-13), and the like. Such ethoxamers have an HLB (hydrophobic lipophilic balance) value of about 8 to 15 and give good

[0146] 20 O / W emulsification, whereas ethoxamers with HLB values below 7 contain less than 4 ethylene oxide groups and tend to be poor emulsifiers and poor detergents.

[0147] Another group of suitable non-ionic surfactants are alkylpolyglycoside (APG) which are sugar derivatives of fatty alcohol. Examples of such surfactants are decyl glucoside, lauryl glucoside, myristyl glucoside.

[0148] The article may comprise an additional amphoteric surfactant in addition to anionic and / or non- ionic surfactant. Suitable amphoteric surfactants include derivatives of aliphatic quaternary ammonium, sulphonium and phosphonium compounds having an aliphatic radical of from 8 to

[0149] 30 18 carbon atoms and an aliphatic radical substituted by an anionic water-solubilising group, for instance 3-(N-N-dimethyl-N-hexadecylammonium) propane-1 -sulphonate betaine, 3- (dodecylmethyl sulphonium) propane-1 -sulphonate betaine and 3- (cetylmethylphosphonium) ethane sulphonate betaine. P0001459 CPL

[0150] 14

[0151] Examples of additional amphoteric surfactants suitable for the present invention include cocoamidopropyl betaine (CAPB), cocoamidopropyl amine oxide (CAPAO), cocodiethanol amide (CDEA) and cocomonoethanol amide (CMEA).

[0152] 5 Preferably the article comprises 0 to 30% by weight, more preferably 1 to 25% by weight, even more preferably 2 to 20% by weight and most preferably 3 to 20% by weight of the additional amphoteric surfactant.

[0153] Optional ingredients

[0154] In additional to the water-soluble polymer and the anionic surfactant system the flexible solid unit dose article may include one or more optional ingredients selected from the group consisting of plasticizers, additional surfactant, enzymes, polymers, fragrance, disintegrants, slip additives, enzyme stabilizers.

[0155] 15 Plasticizers:

[0156] Preferably the flexible solid unit dose article includes a plasticizer. Suitable plasticizers can be selected from the group consisting of polyols, copolyols, polycarboxylic acids, polyesters, and dimethicone copolyols. For example, pentaerythritols (such as depentaerythritol), sugar alcohols (such as sorbitol and mannitol), glycols (such as glycerol, ethylene glycol, and

[0157] 20 propylene glycol) and polyethylene glycols with molecular weight ranging from 200 to 600 can be readily used as plasticizers in the flexible solid unit dose article. Most preferred plasticizers include glycerol and propylene glycol. Still more preferably glycerol. Plasticizers are generally used in an amount of up to 35 wt percent, for example from 1 to 35 wt percent, preferably from 3 to 20 wt percent, more preferably from 5 to 15 wt percent by total weight of the flexible solid

[0158] 25 unit dose article.

[0159] Swellable disintegrant:

[0160] The flexible unit dose article according to the first aspect of the present invention may preferably comprises a swellable disintegrant, more preferably the swellable disintegrant is selected from the group consisting of microcrystalline cellulose, sodium starch glycolate and combination thereof.

[0161] Preferably the swellable disintegrant has a water absorption ratio greater than 1 when measured using ASTM D570 method. Swellable disintegrant herein refers to the components

[0162] 35 which swell in contact with water and there by accelerates dissolution of the article. Particularly, P0001459 CPL

[0163] 15 in the present invention swellable disintegrant are referring to one which has a water absorption ratio (WAR) of greater than 1 .

[0164] Water Absorption Ratio (WAR) is a measure as to how much water a material absorbs under

[0165] 5 controlled and defined conditions. The process described in ASTM D570 is used in this application.

[0166] The swellable disintegrant is preferably selected from the group consisting of microcrystalline cellulose, sodium starch glycolate and mixtures thereof. Most preferred swellable disintegrant is microcrystalline cellulose. Microcrystalline cellulose absorbs water and swells, it has a WAR value more than 5.

[0167] The flexible unit dose article may preferably comprises from 1 to 10% by weight swellable disintegrant. More preferably the article comprises from 1 to 5% by weight, even more

[0168] 15 preferably 1 to 3% by weight of the swellable disintegrant.

[0169] The article may further comprise a non-swellable disintegrant. Non-swellable disintegrant herein refer to those which have water absorption ratio (WAR) less than 1 . Examples of the non- swellable disintegrate include polyvinyl pyrrolidone, calcium silicate, starch, magnesium

[0170] 20 stearate and mixtures thereof. The non-swellable disintegrant may preferably be present from 1 to 20% by weight, more preferably from 1 .5 to 15% by weight, even more preferably from 2 to 10% by weight and most preferably from 3 to 8% by weight, of the article.

[0171] Slip additive:

[0172] 25 The flexible unit dose article may preferably comprise 0.1 to 10% by weight of a slip additive. Slip additive is known in the context for reducing coefficient of friction and thereby reduces stickiness between two adjacent flexible unit dose article. Preferably the slip additive is selected from the group consisting of stearamide, erucamide and oleamide and mixture thereof. Most preferred slip additive is erucamide and / or oleamide.

[0173] Preferably the flexible unit dose article may comprises 0.2% to 8% by weight, more preferably 0.5 to 7% by weight, even more preferably 1 .0% to 6% by weight, furthermore preferably 1 .0 to 5% by weight, yet more preferably 1 .0 to 4% by weight and most preferably 1 .0 to 3% slip additive by weight of the flexible unit dose article.

[0174] 35 P0001459 CPL

[0175] 16

[0176] Water:

[0177] The article according to the present invention is in dry format. It may not contain significant amount of water, particularly free water. ‘Free water’ herein refers to water added or visually perceivable on the product. However, the process of making the article may comprises a step of

[0178] 5 preparing a solution of ingredients in a water and casting on a surface. Thus, it may contain water residue in it. Preferably the article comprises less than 25% by weight, more preferably less than 20% by weight and most preferably less than 15% by weight water. Preferably the article comprises 5 to 25% by weight more preferably 5 to 20% by weight, even more preferably 8 to 15% by weight, most preferably 10 to 15% by weight of water and the water is bound to the article. Water content may be measured by thermogravimetrically, such as, moisture balance or thermogravimetric analyser.

[0179] The article may comprise detergent adjunct or additional cleaning ingredients to deliver improve cleaning or sensory. The term “detergent adjunct” herein refers to ingredients included in a

[0180] 15 flexible unit dose article for improving cleaning efficacy or sensory, they often present in addition to surfactant or detersive actives. Examples of detergent adjuncts include sequestrants, soil release polymer, anti-redeposition polymer, antifoaming agent, enzyme, shading dye and combinations thereof.

[0181] 20 Sequestrant :

[0182] The article may preferably comprise a sequestrant. Preferably the sequestrant is selected from organic detergent builders or sequestrant materials. Examples of such sequestrants include the alkali metal, citrates, succinates, malonates, carboxymethyl succinates, carboxylates, polycarboxylates and polyacetyl carboxylates. Specific examples include sodium, potassium

[0183] 25 and lithium salts of oxydisuccinic acid, mellitic acid, benzene polycarboxylic acids, and citric acid. Other examples are DEQUEST™, organic phosphonate type sequestering agents sold by Monsanto and alkanehydroxy phosphonates.

[0184] Other suitable organic builders / sequestrants include the higher molecular weight polymers and copolymers known to have builder properties. For example, such materials include appropriate polyacrylic acid, polymaleic acid, and polyacrylic / polymaleic acid copolymers and their salts, for example those sold by BASF under the name SOKALAN™. A preferred sequestrant is Dequest® 2066 (Diethylenetriamine penta(methylene phosphonic acid) or Heptasodium DTPMP). Other suitable sequestrant is HEDP (1 -Hydroxyethylidene -1 ,1 , -diphosphonic acid),

[0185] 35 for example sold as Dequest 2010. P0001459 CPL

[0186] 17

[0187] Preferably the sequestrant is selected from amino-phosphonic acid, phosphonic acid, amino carboxylic acid, and salts thereof. Preferably the sequestrant is selected from Diethylenetriamine penta (methylene phosphonic acid- hepta sodium salt (DTPMPA), 1- Hydroxyethylidene 1 ,1-diphosphonic acid (HEDP), Trisodium salt of Methyl glycine di-acetic

[0188] 5 acid (MGDA), N, N Di-carboxymethyl glutamic acid tetrasodium salt (GLDA) Ethylenediamine- N,N'-disuccinic acid (EDDS)and combinations thereof. Most preferred sequestrant is diethylenetriamine penta (methylene phosphonic acid- hepta sodium salt (DTPMPA) and / or 1- hydroxyethylidene 1 ,1-diphosphonic acid (HEDP).

[0189] The amount of the sequestrant in the article preferably is in the range 0.1 to 10% by weight, more preferably 0.2 to 9% by weight, even more preferably 0.3 to 8% by weight and most preferably 0.4 to 7 % by weight.

[0190] Antifoaming agent:

[0191] 15 The article may preferably comprise an anti-foaming agent as the detergent adjunct, preferably in consideration with machine wash scenario.

[0192] Anti-foam materials are well known in the art and include silicones and fatty acid. Suitable fatty acids in the context of the present invention include aliphatic carboxylic acids of formula

[0193] 20 RCOOH, where R is a linear or branched alkyl or alkenyl chain containing from 6 to 24, more preferably 10 to 22, most preferably from 12 to 18 carbon atoms and 0 or 1 double bond. Preferred examples of such materials include saturated C12-18 fatty acids such as lauric acid, myristic acid, palmitic acid or stearic acid; and fatty acid mixtures in which 50 to 100% (by weight based on the total weight of the mixture) consists of saturated C12-18 fatty acids. Such

[0194] 25 mixtures may typically be derived from natural fats and / or optionally hydrogenated natural oils (such as coconut oil, palm kernel oil or tallow). The fatty acids may be present in the form of their sodium, potassium or ammonium salts and / or in the form of soluble salts of organic bases, such as mono-, di- or triethanolamine. Mixtures of any of the above-described materials may also be used. For formula accounting purposes, in the formulation, fatty acids and / or their salts (as defined above) are not included in the level of surfactant or in the level of builder.

[0195] Preferably, the anti-foaming agent is present at from 0.1 to 5% by weight, more preferably 0.1 to 3 by weight, even more preferably 0.1 to 2% by weight and most preferably 0.1 to 1% by weight of the article.

[0196] 35 P0001459 CPL

[0197] 18

[0198] Soil release polymer:

[0199] The flexible solid unit dose article may preferably include a soil release polymer, preferably considering laundry application. Soil release polymers improve cleaning efficacy by means of detaching of soils from fabric by modifying the fabric surface during washing. The adsorption of

[0200] 5 a soil release polymer over the fabric surface is promoted by an affinity between the chemical structure of the soil release polymer and the target fibre.

[0201] Soil release polymers for use in the present invention may include a variety of charged (e.g., anionic) as well as non-charged monomer units and structures may be linear, branched or starshaped etc. The soil release polymer structure may also include capping groups to control molecular weight or to alter polymer properties such as surface activity. The weight average molecular weight (Mw) of the SRP may suitably range from about 1000 to about 20,000 and preferably ranges from about 1500 to about 10,000.

[0202] 15 Examples of the soil release polymer include co-polyesters of dicarboxylic acids (e.g., adipic acid, phthalic acid or terephthalic acid), diols (e.g., ethylene glycol or propylene glycol) and poly diols (e.g., polyethylene glycol or polypropylene glycol). The co-polyester may also include monomeric units substituted with anionic groups, such as for example sulfonated iso-phthaloyl units. Examples of such materials include oligomeric esters produced by transesterification /

[0203] 20 oligomerization of polyethylene glycol) methyl ether, dimethyl terephthalate (“DMT”), propylene glycol (“PG”) and polyethylene glycol) (“PEG”); partly- and fully-anionic-end-capped oligomeric esters such as oligomers from ethylene glycol (“EG”), PG, DMT and Na-3,6-dioxa-8- hydroxyoctanesulfonate; non-ionic-capped block polyester oligomeric compounds such as those produced from DMT, Me-capped PEG and EG and / or PG, or a combination of DMT, EG

[0204] 25 and / or PG, Me-capped PEG and Na-dimethyl-5-sulfoisophthalate, and copolymeric blocks of ethylene terephthalate or propylene terephthalate with polyethylene oxide or polypropylene oxide terephthalate.

[0205] Other types of soil release polymer suitable for the present invention include cellulosic derivatives such as hydroxy ether cellulosic polymers, C1-C4 alkyl celluloses and C4 hydroxyalkyl celluloses; polymers with poly(vinyl ester) hydrophobic segments such as graft copolymers of poly(vinyl ester), for example C1-C6 vinyl esters (such as poly(vinyl acetate)) grafted onto poly alkylene oxide backbones; poly(vinyl caprolactam) and related co-polymers with monomers such as vinyl pyrrolidone and / or dimethyl aminoethyl methacrylate; and

[0206] 35 polyester-polyamide polymers prepared by condensing adipic acid, caprolactam, and polyethylene glycol. P0001459 CPL

[0207] Preferred soil release polymer includes co-polyesters formed by condensation of terephthalic acid ester and diol, preferably 1 ,2 propanediol, and further comprising an end cap formed from repeat units of alkylene oxide capped with an alkyl group. Examples of such materials have a structure corresponding to general formula (I):

[0208] 5 in which R1and R2independently of one another are X-(OC2H4)n-(OC3H6)m; in which X is C1 to C4 alkyl and preferably methyl; n is a number from 12 to 120, preferably from 40 to 50; m is a number from 1 to 10, preferably from 1 to 7; and a is a number from 4 to 9.

[0209] Because they are averages, m, n and a are not necessarily whole numbers for the polymer in bulk. Combinations of any of the above-mentioned materials may also be used. Suitable soil release polymers are also described in greater detail in U. S. Patent Nos. 5,574,179; 4,956,447;

[0210] 15 4,861 ,512; 4,702,857, WO 2007 / 079850 and WO2016 / 005271 .

[0211] The article comprises preferably 0.1 to 15% by weight, more preferably 0.2 to 12% by weight and even more preferably 0.5 to 10% by weight and most preferably 1 to 8 % by weight of the soil release polymer.

[0212] 20

[0213] Anti redeposition polymer:

[0214] The flexible unit dose article may preferably include an anti-redeposition polymer. Antiredeposition polymers often considered in detergent products, preferably in laundry detergents, for prevention of redeposition by stabilising soil in the wash solution.

[0215] Suitable soil release polymers for use in the invention include alkoxylated polyethyleneimines. Polyethyleneimines are materials composed of ethylene imine units -CH2CH2NH- and, where branched, the hydrogen on the nitrogen is replaced by another chain of ethylene imine units. Preferred alkoxylated polyethyleneimines for use in the invention have a polyethyleneimine

[0216] 30 backbone of about 300 to about 10000 weight average molecular weight (Mw). The polyethyleneimine backbone may be linear or branched. It may be branched to the extent that it is a dendrimer. The alkoxylation may typically be ethoxylation or pro-poxylation, or a mixture of both. Where a nitrogen atom is alkoxylated, a preferred average degree of alkoxylation is from P0001459 CPL

[0217] 20

[0218] 10 to 30, preferably from 15 to 25 alkoxy groups per modification. A preferred material is ethoxylated polyethyleneimine, with an average degree of ethoxylation being from 10 to 30, preferably from 15 to 25 ethoxy groups per ethoxylated nitrogen atom in the polyethyleneimine backbone. Combinations of any of the above-described ingredients may also be used. Most

[0219] 5 preferred anti-redeposition polymer is alkoxylated polyethyleneimines.

[0220] The article comprises preferably 0.1 to 15% by weight, more preferably 0.2 to 12% by weight and even more preferably 0.5 to 10% by weight and most preferably 1 to 8 % by weight of the anti-redeposition polymers.

[0221] Shading dye:

[0222] The flexible unit dose article may preferably include a shading dye, preferably when the article is formulated for laundry application. Shading dyes are preferably used to improve the performance of the compositions. Preferred dyes are violet or blue. It is believed that the

[0223] 15 deposition on fabrics of a low level of a dye of these shades, masks yellowing of fabrics. A further advantage of shading dyes is that they can be used to mask any yellow tint in the composition itself.

[0224] Shading dyes are well known in the art of laundry products. Suitable and preferred classes of dyes include direct dyes, acid dyes, hydrophobic dyes, basic dyes, reactive dyes and dye conjugates.

[0225] Preferred examples are Disperse Violet 28, Acid Violet 50, anthraquinone dyes covalently bound to ethoxylate or propoxylated polyethylene imine as described in WO2011 / 047987 and

[0226] 25 WO 2012 / 119859, alkoxylated mono-azo thiophenes, dye with CAS-No 72749-80-5, acid blue 59, and the phenazine dye selected from: P0001459 CPL

[0227] 21 wherein: X3is selected from: -H; -F; -CH3; -C2H5; -OCH3; and, -OC2H5; X4 is selected from: -H; - CH3; -C2H5; -OCH3; and, -OC2H5; Y2is selected from: -OH; -OCH2CH2OH; -CH(OH)CH2OH; - OC(O)CH3; and, C(O)OCH3.

[0228] 5 Alkoxylated thiophene dyes are discussed in WO2013 / 142495 and W02008 / 087497.

[0229] The shading dye when present, may be in the range 0.1 to 2% by weight, more preferably 0.1 to 1% by weight, even more preferably 0.1 to 0.8 by weight and most preferably 0.1 to 0.5 by weight of the article.

[0230] Enzymes:

[0231] The flexible unit dose article may preferably include one or more enzyme as the detergent adjunct. The article may comprise an effective amount of one or more enzyme preferably selected from the group comprising, hemicellulases, peroxidases, proteases, cellulases,

[0232] 15 hemicellulases, xylanases, xantanase, lipases, phospholipases, esterases, cutinases, pectinases, carrageenases, mannanases, pectate lyases, keratinases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases, tannases, pentosanases, malanases, P-glucanases, arabinosidases, hyaluronidase, chondroitinase, laccase, tannases, amylases, nucleases (such as deoxyribonuclease and / or ribonuclease), phosphodiesterases, or mixtures

[0233] 20 thereof. Particularly preferred are mixtures of protease, amylase, lipase, cellulase, phosphodiesterase, and / or pectate lyase.

[0234] Preferably the protease enzyme is present in the greatest weight fraction. Preferably the protease is present a levels that are greater than 3 times any other single enzyme.

[0235] 25

[0236] Examples of preferred enzymes are sold under the following trade names Purafect Prime®, Purafect®, Preferenz® (DuPont), Savinase®, Pectawash®, Mannaway®, Lipex ®, Lipoclean ®, Whitzyme ® Stainzyme®, Stainzyme Plus®, Natalase ®, Mannaway ®, Amplify ® Xpect ®, Celluclean ® (Novozymes), Biotouch (AB Enzymes), Lavergy ® (BASF)

[0237] Detergent enzymes are discussed in W02020 / 186028(Procter and Gamble), W02020 / 200600 (Henkel), W02020 / 070249 (Novozymes), W02021 / 001244 (BASF) and WO2020 / 259949 (Unilever).

[0238] A nuclease enzyme is an enzyme capable of cleaving the phosphodiester bonds between the

[0239] 35 nucleotide sub-units of nucleic acids and is preferably a deoxyribonuclease or ribonuclease enzyme. Preferably the nuclease enzyme is a deoxyribonuclease, preferably selected from any P0001459 CPL

[0240] 22 of the classes E.C. 3.1.21.x, where x=l, 2, 3, 4, 5, 6, 7, 8 or 9, E.C. 3.1 ,22.y where y=l, 2, 4 or 5, E.C. 3.1 .30. Z where z= 1 or 2, E.C. 3.1 .31 .1 and mixtures thereof.

[0241] Preferably the enzyme may be added to the premix before drying. Alternately the enzyme may

[0242] 5 be added to the formed flexible unit dose article after removal of water.

[0243] Perfume:

[0244] The flexible unit dose article may preferably include a perfume. Preferably the perfume is present in the form of free perfume. By free perfume herein refers to perfume that is not encapsulated as part of a delayed or controlled release mechanism. Preferably the free perfume comprises ester perfume component having the structure where R1 and R2 are independently selected from Ci to C3o linear or branched, cyclic or non-cyclic, aromatic, or nonaromatic, saturated or unsaturated, substituted, or unsubstituted alkyl group. It is also preferred that the free perfume is selected from those having a functional group selected from aldehyde,

[0245] 15 carboxylic acid, and mixtures thereof. The aldehyde may be aliphatic, cycloaliphatic, aromatic, araliphatic and mixtures thereof. The term aldehyde in the context of the free perfume also includes the corresponding acetals, ester, and lactones. The esters include the aliphatic carboxylic acid esters, esters of cyclic alcohols, esters of cycloaliphatic carboxylic acids, aromatic and araliphatic carboxylic acid esters.

[0246] 20

[0247] Preferably, the perfume comprises a component selected from the group consisting of ethyl-2- methyl valerate (manzanate), limonene, (4Z)-cyclopentadec-4-en-1-one, dihyromyrcenol, dimethyl benzyl carbonate acetate, benzyl acetate, spiro[1 ,3-dioxolane-2,5'-(4',4',8',8'- tetramethyl-hexahydro-3',9'-methanonaphthalene)], benzyl acetate, Rose Oxide, geraniol,

[0248] 25 methyl nonyl acetaldehyde, decanal, octanal, undecanal, verdyl acetate, tert- butyl cyclo hexyl acetate, cyclamal, beta ionone, hexyl salicylate, tonalid, phenafleur, octahydrotetramethyl acetophenone (OTNE), the benzene, toluene, xylene (BTX) feedstock class such as 2-phenyl ethanol, phenoxanol and mixtures thereof, the cyclododecanone feedstock class, such as habolonolide, the phenolics feedstock class such as hexyl salicylate, the C5 blocks or oxygen containing heterocycle moiety feedstock class such as gamma decalactone, methyl dihydrojasmonate and mixtures thereof, the terpenes feedstock class such as dihydromycernol, linalool, terpinolene, camphor, citronellol and mixtures thereof, the alkyl alcohols feedstock class such as ethyl-2-methylbutyrate, the diacids feedstock class such as ethylene brassylate, and mixtures of these components.

[0249] 35 P0001459 CPL

[0250] 23

[0251] Preferably the perfume is selected from the group consisting of geraniol, phenafleur, cyclamal, betaionone, verdyl acetate dimethylbenzyl carbinol acetate, dihydromrycenol, limonene, oxazolidine compound, silicic acid ester and diricinoleates or combinations thereof. The perfume may present as such or may be adsorbed into the halloysite particle and incorporated

[0252] 5 in the article.

[0253] Preferably, the perfume is present in the article in an amount ranging from 0.0001 to 2% by weight, more preferably 0.001 to 1% by weight and most preferably 0.001 to 0.5% by weight of the article.

[0254] Preferably the perfume may be in the form of perfume oil, encapsulated perfume, and microencapsulated perfume.

[0255] Preservative:

[0256] 15 The flexible unit dose article may preferably comprises a preservative. The article may be dissolved in water and store in a container for later use. In such scenario, preservatives could be helpful by inhibiting microbial growth. For example, preservatives may optionally be included in various embodiments as a way to further boost microbial protection for gross bacteria, virus and / or fungi contamination introduced e.g., by a consumer, through a contaminated ingredient,

[0257] 20 contaminated storage container, equipment, processing step or other source. Any conventional preservative known in the art may be used. Some illustrative preservatives include: potassium sorbate, sodium benzoate, benzoic acid, phenoxyethanol, benzyl alcohol, dehydoxyacetic acid, sodium borate, boric acid, usinic acid, phenols, quaternary ammonia compounds, glycols, isothiazolinones (methyl, benzyl, chloro), DMDM hydantoin, hexidine, ethanol, IPBC,

[0258] 25 polyaminopropyl biguanide, phenylphenol, imidazolidinyl urea, parabens, formaldehyde, salicylic acid or salts, caprylyl glycol, D-glucono-1 ,5 lactone, sodium erythorbate, sodium hydroxymethylglycinate, peroxides, sodium sulphite, bisulphite, glucose oxidase, lacto peroxidase, and other preservatives compatible with the cleaning ingredients. Some other natural materials might also be considered like cinnamon, fruit acids, essential oils like thyme and rosemary, willow bark, aspen bark, tocopherol, curry, citrus extracts, honeysuckle, and amino acid-based preservatives. Especially preferred preservatives that do not compete with the cleaning ingredients and do not have reported health or environmental issues. Some of the more preferred preservatives are: phenoxyethanol, benzoic acid / potassium sorbate, enzymes, borates, isothiazolinones such as MIT, BIT and CIT, and the natural solutions above. Further

[0259] 35 preferred preservatives include itaconic acid and phenoxyethanol. P0001459 CPL

[0260] The preservative may present in an amount less than about 5% by weight of the article. Preferably the preservative is present in an amount from 0.1 to 2% by weight and most preferably 0.1 to 1 % by weight of the article. Preferably the amount of the preservative in a cleaning composition formed on dilution of the article is in the range 0.01 to 0.2% by weight.

[0261] 5 Preferably when the article comprises IT-based preservative, such as BIT and / or MIT, the amount is judged to be in the range 300 to 550 ppm in a liquid cleaning composition obtained buy dissolving the article. Such adjustment may be obtained by the dilution ratio of the article to water, and it is part of common general knowledge and known to the skilled person. The perfume may present as such or may be adsorbed into the halloysite particle and incorporated in the article.

[0262] Most preferably, the article may comprise benzoate salt as preservative. Preferably the benzoate salt is present at from 0.1 to 5% by weight more preferably 0.2 to 4% by weight, most preferably 0.5 to 3% by weight of the article.

[0263] 15

[0264] Fluorescer:

[0265] The article may preferably include a fluorescer. Examples of the fluorescer suitable for the present invention are described below.

[0266] 20 Sulphonated di-styryl biphenyl fluorescers are discussed in Chapter 7 of Industrial Dyes (K. Hunger ed, Wiley VCH 2003), also disclosed in US5145991 A1 (Ciba Geigy). One of the preferred fluorescer is 4,4’- distyrylbiphenyl are preferred. Preferably the fluorescer contains 2 SO3- groups. Most preferably the fluorescer is of the structure:

[0267] Where X is suitable counter ion, preferably selected from metal ions, ammonium ions, or amine salt ions, more preferably alkali metal ions, ammonium ions or amine salt ions, most preferably Na or K. The perfume may present as such or may be adsorbed into the halloysite particle and

[0268] 30 incorporated in the article. P0001459 CPL

[0269] 25

[0270] Preferably the fluorescer is present at levels of 0.1 to 5% by weight, more preferably 0.2 to 4% by weight and most preferably 0.5 to 3% by weight of the article.

[0271] The article may further contain other auxiliary agents and processing agents, such as, but not

[0272] 5 limited to, plasticizers, plasticizer compatibilizers, surfactants, lubricants, release agents, fillers, extenders, cross-linking agents, anti-blocking agents, antioxidants, detackifying agents, antifoams, nanoparticles such as layered silicate-type nanoclays (e.g., sodium montmorillonite), bleaching agents (e.g., sodium metabisulphite, sodium bisulphite or others), aversive agents such as bitterants (e.g., denatonium salts such as denatonium benzoate, denatonium saccharide, and denatonium chloride; sucrose octaacetate; quinine; flavonoids such as quercetin and naringen; and quassinoids such as quassin and brucine) and pungents (e.g., capsaicin, piperine, allyl isothiocyanate, and resinferatoxin), and other functional ingredients, in amounts suitable for their intended purposes.

[0273] 15 Preferably the flexible solid unit dose article includes one or more additional surfactant other than the anionic surfactant system described herein above. The additional surfactant include but not limited to nonionic surfactant, cationic surfactant, zwitterionic surfactant, amphoteric surfactant and combinations thereof.

[0274] 20 Preferably the additional surfactants include additional anionic surfactant which includes alkyl sulphate, alkyl ether sulphate, sulphated monoglycerides, sulphonated olefins, alkyl sulphosuccinates, acyl isethionates, alkyl glyceryl ether sulphonate, sulphonated methyl esters, sulphonated fatty acids, alkyl phosphates, acyl glutamates, acyl sarcosinates, alkyl sulphoacetates, acylated peptides, alkyl ether carboxylates, acyl lactylates,

[0275] 25 anionic fluoro surfactants, sodium lauroyl glutamate, and combinations thereof.

[0276] Process

[0277] According to a second aspect of the present invention provided is a process for preparing the flexible solid unit dose article according to the first aspect of the present invention.

[0278] The flexible solid unit dose article can be made by any suitable film-forming method, such as casting, molding, pressing, extrusion / extrusion-coating, calendar rolling, solution deposition, skiving, and lamination.

[0279] 35 Preferably the flexible unit dose article is formed by first (i) providing a slurry including the water soluble polymer and anionic surfactant system dissolved or dispersed in water, and then (ii) P0001459 CPL

[0280] 26 shaping the slurry into a sheet-like form. Drying the shaped slurry is carried out either simultaneously with the shaping step, or it can be carried out subsequently, to remove water and form a finished sheet.

[0281] 5 Preferably the flexible solid unit dose article is formed in a cylindrical sheet forming system such as a rotary drier.

[0282] The process for preparing the flexible solid unit dose article comprises the steps of:

[0283] (i) preparing a slurry comprising a water-soluble polymer and an anionic surfactant system and having a viscosity ranging from 25,000 to 1 ,00,000 cps, when measured at 40°C and 1s-1;

[0284] (ii) aerating said slurry to form an aerated wet mix;

[0285] (iii) forming said aerated wet mix into a sheet having opposing first and second surface; and,

[0286] (iv) drying said formed sheet for a drying time of from 1 minute to 60 minutes.

[0287] 15

[0288] Preparing a slurry:

[0289] The process for preparing the flexible solid unit dose article according to the first aspect of the present invention involves a first step of preparing a slurry. The wet slurry comprises water soluble polymer and the anionic surfactant system dissolved or dispersed in water or a suitable

[0290] 20 solvent. Preferably the mixing is carried out in a mechanical mixer. Preferably the slurry may include other ingredients including but not limited to disintegrant, slip additive, plasticizer, enzymes, perfume and combinations thereof. The wet slurry has a viscosity ranging from 25,000 to 1 ,00,000 cps, when measured at 40°C and 1s1. Preferably the viscosity of the slurry is adjusted to 25,000 to 1 ,00,000 cps.

[0291] 25

[0292] Aerating the slurry:

[0293] The next step in preparing the flexible solid unit dose article involves a step of aerating the slurry. The aeration step may be done by introducing a gas into the slurry to form the wet aerated mix. Preferably the wet aerated mix has a density ranging from 0.05 to 0.5 g / mL, preferably from 0.08 to 0.5 g / mL, more preferably from 0.1 to 0.35 g / mL, still more preferably from 0.15 to about 0.5 g / mL, most preferably from 0.2 to 0.25 g / mL.

[0294] Preferably the slurry may be heated immediately prior to and / or during the aeration process at above ambient temperature but below any temperature that would cause degradation of the

[0295] 35 components. P0001459 CPL

[0296] 27

[0297] Aeration may be by either physical or chemical means. Preferably aeration is carried by introducing a gas into the slurry through mechanical agitation, preferably but not limited to by using a rotor stator mixer, a planetary mixer, a pressurized mixer, a non-pressurized mixer, a batch mixer, a continuous mixer, a semi-continuous mixer, a high shear mixer, a low shear

[0298] 5 mixer, a submerged sparger, or any combinations thereof.

[0299] Aeration of the slurry can be achieved by using the spinning bar that is a part of the rotary drum dryer, more specifically a component of the feeding trough where the slurry is stored before it is coated onto the heated outer surface of the drum dryer and dried. The spinning bar is typically used for stirring the slurry to preventing phase separation or sedimentation in the feeding trough during the waiting time before it is coated onto the heated rotary drum of the drum dryer. In the present invention, it is possible to operate such spinning bar at a rotating speed ranging from less than 150 rpm, also preferably at a rotating speed of 150 to 500 rpm, preferably from 200 to 400 rpm, more preferably from 250 to 350 rpm, to mix the slurry at the air interface and provide

[0300] 15 sufficient mechanical agitation needed for achieving the desired aeration of the slurry.

[0301] Forming a sheet:

[0302] After the aeration step, the aerated wet mix is formed into a sheet having opposing first surface and a second surface. The sheet-forming step can be conducted in any suitable manners, e.g.,

[0303] 20 by extrusion, casting, molding, vacuum-forming, pressing, printing, coating, and the like. More specifically, the aerated wet mix can be formed into a sheet by: (i) casting it into shallow cavities or trays or specially designed sheet moulds; (ii) extruding it onto a continuous belt or screen of a dryer; (iii) coating it onto the outer surface of a rotary drum dryer. Preferably, the supporting surface upon which the sheet is formed is formed by or coated with materials that are anti¬

[0304] 25 corrosion, non-interacting and / or non-sticking, such as metal (e.g., steel, chromium, and the like), TEFLON , polycarbonate, NEOPRENE , HDPE, LDPE, rubber, glass and the like.

[0305] Preferably, the formed sheet of aerated wet mix has a thickness ranging from 0.5 mm to 4 mm, preferably from 0.6 mm to 3.5 mm, more preferably from 0.7 mm to 3 mm, still more preferably from 0.8 mm to 2 mm, most preferably from 0.9 mm to 1 .5 mm.

[0306] Drying to form the flexible unit dose article

[0307] Preferably the drying is carried out for 2 minutes to 30 minutes, more preferably from 2 minutes

[0308] 35 to about IS minutes, still more preferably from about 2 minutes to about 10 minutes, most preferably from about 2 minutes to about 5 minutes, at a drying temperature of from 70°C to P0001459 CPL

[0309] 28

[0310] 200°C, preferably from 80°C to 170°C, preferably from 90°C to 150°C, more preferably from 100°C to 140°C.

[0311] Preferably the drying is carried out in a conveyor belt or a rotary drum drier. Preferably the

[0312] 5 hearting direction is such that a temperature gradient is formed between the first surface and a second surface. More preferably the heating direction is substantially along the gravitational direction, alternately the heating direction is substantially opposite to the gravitational direction for more than half of the drying time, preferably for more than 55%, still more preferably for more than 60%, more preferably for more than 75% of the drying time.

[0313] Examples

[0314] Evaluation of the effect of the amount of alkyl taurate on the dissolution rate of different flexible unit dose articles comprising PVOH as the water soluble polymer.

[0315] 15 Different flexible sheets were prepared having the formulation as shown in table 1 , by a process which involved first mixing the PVOH along with anionic surfactant system comprising alkyl taurate and alkyl benzene sulphonate surfactant to form a slurry, the remaining ingredients were added into the slurry and the slurry was aerated and then formed into a sheet followed by drying at 70 to 90°C for 2 hours. The formed flexible solid unit dose article in the form of single layered sheet was collected.

[0316] The sheets were evaluated to determine their formability of the sheet and the dissolution speed. Dissolution test: 1 gram sample of the sheet was taken in a beaker with 1000 mL water at room temperature (25°C) and stirred continuously using a magnetic stirrer at 300 rpm until a clear

[0317] 25 solution was obtained. The time taken to reach the clear solution stage was recorded and provided in table below. The dissolution of the sheet is considered to be quick when the time taken to achieve the clear solution is less than 2 minutes.

[0318] P0001459 CPL

[0319] 29

[0320] Table 1

[0321] The PVOH polymer has a molecular weight of 22,000 to 95,000 Daltons, degree of

[0322] 5 polymerization of around 500 to 600 repeating units and degree of hydrolysis of 85 to 89 mol%. The data in table 1 clearly shows that when the levels of the alkyl taurate are within the claimed ranges it provides for quick dissolution.

Claims

P0001459 CPL30CLAIMS1 . A flexible solid unit dose article comprising: i. a water-soluble polymer; and, ii. an anionic surfactant system; wherein the anionic surfactant system comprises an alkyl taurate surfactant, and wherein the alkyl taurate surfactant is present in an amount ranging from 2.5 parts to 60 parts by weight of the anionic surfactant system.

2. A flexible solid unit dose article according to claim 1 wherein the anionic surfactant system comprises an alkyl sulphonate surfactant.

3. A flexible solid unit dose article according to claim 1 or 2 wherein the alkyl sulphonate surfactant comprises a C6to C2o linear alkyl benzene sulphonate, more preferably C10 to C2o linear alkyl benzene sulphonate.

4. A flexible solid unit dose article according to any one of the preceding claims wherein the alkyl taurate surfactant is an N-alkyl acyl taurate having a general formula (I)wherein R1 is an alkyl group with 5 to 23 carbon atoms, still preferably 7 to 21 , still more preferably 7 to 17, more preferably 7 to 15, 7 to 13, 11 to 17, 11 to 15 and most preferably 11 to 13 carbon atoms, R2is an alkyl group having 1 to 4 carbon atoms and X is a suitable counterion which is selected from the group consisting of potassium, magnesium, ammonium or triethanolamine, more preferably sodium.

5. A flexible solid unit dose article according to claim 4 wherein the N-alkyl acyl taurate is selected from the group consisting of methyl capric ester taurate, methyl cocoyl taurate, methyl lauroyl taurate, methyl myristoyl taurate, methyl caproyl taurate, methyl oleoyl taurate, methyl capryloyl taurate, methyl palmitoyl taurate, methyl stearoyl taurate, methyl linoleoyl taurate, salts of these and combinations thereof, more preferably the N-alkyl acyl taurate is a sodium salt of methyl cocoyl taurate.P0001459 CPL316. A flexible solid unit dose article according to any one of the preceding claims wherein the water-soluble polymer is selected from the group consisting of polyethylene glycol polyvinyl alcohol or a copolymer thereof, gums, protein isolated, extract of good, carrageenan, alginates, agar, pectins, pullulan, xanthan and combinations thereof.

7. A flexible solid unit dose article according to any one of the preceding claims wherein the water soluble polymer is a polyvinyl alcohol or a copolymer thereof.

8. A flexible solid unit dose article according to any one of the preceding claims wherein the anionic surfactant system is present in an amount ranging from 10 wt.% to 80 wt.% by weight of the flexible solid unit dose article.

9. A flexible solid unit dose article according to any one of the preceding claims wherein the water -soluble polymer is present in an amount ranging from 15 wt.% to 50 wt.% by weight of the solid unit dose article.

10. A flexible solid unit dose article according to any one of the preceding comprises a fragrance.

11. A flexible solid unit dose article according to any one of the preceding claims wherein the article comprises an enzyme, more preferably the enzyme is selected from the group consisting of protease, amylase, mannanase, lipase, cellulase and combinations thereof.

12. A flexible solid unit dose article according to any one of the preceding claims wherein the article comprises a cleaning ingredient selected from sequestrant, soil release polymer, antiredeposition polymer, builder and mixtures thereof, preferably the sequestrant is selected from the group consisting of diethylenetriamine penta (methylene phosphonic acid- heptasodium salt (DTPMPA), 1-hydroxyethylidene 1 ,1-diphosphonic acid (HEDP), trisodium salt of methylglycinediacetic acid (MGDA), N, N-dicarboxymethyl glutamic acid tetrasodium salt (GLDA), Ethylenediamine-N,N'-disuccinic acid (EDDS) and combinations thereof.

13. An article as claimed in any one of claims 1 to 12 wherein the article is in the form of a single detergent sheet.P0001459 CPL3214. An article as claimed in any one of the preceding claims wherein the article comprises two or more flexible sheet to form a multilayered detergent sheet based article.

15. A process for preparing a flexible solid unit dose article according to any one of the preceding claims, comprising the steps of: i. preparing a slurry comprising a water-soluble polymer and an anionic surfactant system and having a viscosity ranging from 25,000 to 1 ,00,000 cps, when measured at 40°C and 1 s1; ii. aerating said slurry to form an aerated wet mix;Hi. forming said aerated wet mix into a sheet having opposing first and second surface; and, iv. drying said formed sheet for a drying time of from 1 minute to 60 minutes, wherein the anionic surfactant system comprises an alkyl taurate surfactant, and wherein the alkyl taurate surfactant is present in an amount ranging from 2.5 parts to 60 parts by weight of the anionic surfactant system.

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